JPH0871345A - Air filter substrate - Google Patents

Abstract

PURPOSE: To provide an air filter substrate with which a removing function for materials to be filtered can be heightened while pressure loss being suppressed to low. CONSTITUTION: An air filter substrate 1 is composed by flocking a large number of fibers 5 in the inside face of each air passing route 3 of a diaphragm body 4 partitioned by diaphragms 2 and having a plurality of air passing routes 3. Air 6 enters the filter through an air proceeding inlet IN, passes the air passing routes 3, and is discharged through an air discharging outlet OUT. When the air 6 passes the air passing routes 3, the air weaves its way through the fibers 5 flocked in the inside faces of the air passing routes 3 and at that time, materials to be filtered which are contained in the air 6 are captured by the fibers 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION The present invention relates to, for example, dust and odor,
Alternatively, the present invention relates to an air filter base material used in an air cleaner or the like for removing harmful substances such as ozone.

[0002]

2. Description of the Related Art As a conventional air filter substrate of this type, for example, JP-A-4-71609 and JP-A-62-298417 are known.
There is one disclosed in the publication.

The air filter substrate (first conventional example) disclosed in Japanese Patent Laid-Open No. 4-71609 is composed of a honeycomb structure made of a non-woven fabric sheet having a plurality of air passages.

Further, the air filter base material (second conventional example) disclosed in Japanese Patent Laid-Open No. 62-298417 is a honeycomb structure in which granular activated carbon is enclosed in each air passage.

[0005]

However, the conventional example having such a structure has the following problems. That is, since the air filter substrate of the first conventional example simply allows air to pass through the air passage, it has a problem of low removal performance of the substance to be filtered.

The air filter base material of the second conventional example is
Since the granular activated carbon is enclosed in each air passage, the removal performance of the substance to be filtered is improved to some extent, but there is another problem that the pressure loss is increased.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide an air filter base material capable of enhancing the ability to remove substances to be filtered while suppressing pressure loss to a low level. And

[0008]

The present invention has the following constitution in order to achieve such an object. That is, the invention according to claim 1 is an air filter substrate including a partition having a plurality of air passages, wherein a large number of fibers are planted on the inner surface of the air passage. .

The invention according to claim 2 is the air filter substrate according to claim 1, wherein the partition walls are formed of a honeycomb structure having a substantially hexagonal cross section of the air passage. .

The invention according to claim 3 is the air filter substrate according to claim 1 or 2, wherein the fibers to be flocked are electret fibers.

Further, the invention according to claim 4 is the air filter substrate according to claim 1 or 2, wherein the fibers to be transplanted are composed of fibrous activated carbon.

According to a fifth aspect of the present invention, in the air filter substrate according to the first or second aspect, the fibers to be transplanted are composed of fibrous ion exchangers.

The invention according to claim 6 is the air filter substrate according to any one of claims 1 to 5, wherein a prefilter for removing a coarse object to be filtered is introduced into the partition wall. In addition to being provided on the mouth side, an end filter for removing an object to be filtered which is finer than the prefilter is provided on the air outlet side of the partition wall.

[0014]

According to the first aspect of the invention, the air that has entered the air passage from the air inlet of the partition wall passes through the air passage so as to sew the fibers that have been bristled on the inner surface of the air passage. At this time, the substance to be filtered in the air is captured by the fibers and discharged from the air discharge port of the partition body.

Further, according to the second aspect of the invention, since the partition wall is made of a honeycomb structure having an air passage cross section of a substantially hexagonal shape, the partition wall is easy to manufacture and the structure is stable.

According to the third aspect of the invention, the air containing the substance to be filtered passes through the electret fiber having an electrostatic adsorption function.

According to the fourth aspect of the invention, the air containing the substance to be filtered passes through the fibrous activated carbon having a higher adsorption performance (removal property of the substance to be filtered) than the granular activated carbon.

According to the fifth aspect of the present invention, the air containing the substance to be filtered passes through the fibrous ion exchanger having adsorption performance for ionic gas and the like.

According to the sixth aspect of the invention, the air from which the coarse object to be filtered is removed by the pre-filter passes through the air passage of the partition wall, and the fine object to be filtered is removed by the end filter. It

[0020]

An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a diagram showing a schematic configuration of an air filter base material according to an embodiment of the present invention. Note that FIG. 1 illustrates a part of the partition wall, and the same structure is developed in the vertical and horizontal directions.

The air filter substrate 1 according to the present invention is constructed by partitioning a large number of fibers 5 on the inner surface of each air passage 3 of a partition body 4 having a plurality of air passages 3 partitioned by the partition walls 2. ing. In FIG. 1, the partition wall 4 is formed of a honeycomb structure having an air passage 3 whose cross section is substantially hexagonal.

According to the air filter substrate 1, as shown by the arrow in FIG. 1, the air 6 enters from the air inlet IN, passes through the air passage 3 and is discharged from the air outlet OUT. When the air 6 passes through the inside of the air passage 3, the air 6 passes through the fibers 5 planted on the inner surface of the air passage 3 in a sewing manner.
At this time, the substance to be filtered contained in the air 6 is captured by the fiber 5.

Since a large number of fibers 5 are planted on the inner surface of the air passage 3 as described above, the removal performance of the substances contained in the air 6 is improved as compared with the first conventional example. Also, air 6
Since a large number of fibers 5 that have been flocked pass through like sewing, the pressure loss can be suppressed to a low level as compared with the case of enclosing granular activated carbon in the air passage 3 as in the second conventional example. Therefore, a suitable air filter substrate 1 can be realized.

By the way, in order to improve the removal performance of the substance to be filtered as compared with the first conventional example and to suppress the pressure loss as compared with the second conventional example, for example, the fiber is made into cotton and enclosed in the air passage 3. It is also possible. However, in the case of such a configuration, the cotton-like fibers are easily gathered on the air outlet OUT side by being pressed by the flow of the air 6, and the trapped substances are clogged in the cotton-like fibers. Therefore, the pressure loss increases rapidly with the passage of time. On the other hand, as in the present invention, the positions of the fibers 5 are fixed by implanting the fibers 5, so that the above-mentioned inconvenience does not occur.

Next, a preferred embodiment of the air filter substrate 1 will be described. The material of the partition wall body 4 is not particularly limited, and non-woven fabric, paper (Japanese paper, foreign paper), metal such as aluminum, woven fabric, film, plastic, rubber, ceramic, etc. can be used, but it is not permeable to non-woven fabric such as non-woven fabric. By constructing the partition wall body 4 with a high material, the air 6 passes through the partition wall 2, so that the substance to be filtered contained in the air 6 is also removed by the partition wall 2 and the removal performance of the substance to be filtered is improved.
Since the air permeability is high, the pressure loss can also be reduced. Therefore, it is preferable that the partition body 4 is made of a material having high air permeability.

Further, it is preferable that the size of the cross section of each air passage 3 (distance between the partition walls 2) D is set within the range of about 1 to 15 mm. When the distance D between the partition walls 2 is smaller than about 1 mm, the resistance of the air 6 passing through the air passage 3 cannot be ignored and the fibers 5 are densely formed in the space. Becomes
Air resistance is further increased and pressure loss is increased, which is not preferable.

On the other hand, when the distance D between the partition walls 2 is larger than about 15 mm, the removal performance of the substance to be filtered is lowered as described below, which is not preferable. That is, the partition wall 2
If the fiber 5 is too short with respect to the distance D, the central portion of the air passage 3 becomes scattered and the removal performance of the substance to be filtered cannot be improved. Therefore, it is desirable that the fibers 5 having a length corresponding to the distance D between the partition walls 2 are planted in the partition walls 2, and the length of the fibers 5 is preferably increased in proportion to the size of the distance D between the partition walls 2. However, if the fiber 5 becomes too long, the air 6 will pass through the fiber 5, and the central portion of the air passage 3 will end up in a scatter state, and the removal performance of the substance to be filtered cannot be improved. Generally, a fiber length of about 7 to 8 mm results in poor fiber 5. Therefore, it is preferable to implant fibers having a fiber length of about 7 to 8 mm or less. Also, fiber 5
As shown in FIG. 1, bristles are planted on each partition wall 2 from the partition wall 2 toward the central portion of the air passage 3. Therefore, the distance D between the partition walls 2 is about twice the fiber length of the fiber 5, and
The interval D between the partition walls 2 when the fiber length of about 8 mm is planted is 1
It will be about 5 mm. Therefore, in order to eliminate the strain of the fibers 5 and maintain the removal performance of the substance to be filtered, the distance D between the partition walls 2
Is preferably smaller than about 15 mm.

The flock density, length (fiber length), and thickness (diameter) of the fibers 5 to be flocked depend on the removal performance of the object to be filtered.
It greatly affects the pressure loss.

For example, if the flocked density is too low, the flocked fibers 5 become too coarse, and the removal performance of the substance to be filtered cannot be improved. On the other hand, if the flocked density is too high, the flocked fibers 5 become dense. And the pressure loss becomes high. Considering these, as the hair transplant density, 5000 to 5000
About 0 / cm ² is preferable.

The upper limit of the fiber length is, as described above,
It is preferably about 7 to 8 mm or less, and particularly preferably about 5 mm or less. On the other hand, the lower limit is determined by the relationship with the distance D between the partition walls 2 as described above, and is preferably about 0.5 mm or more (the distance D between the partition walls 2 is about 1 mm or more).

Further, the range of the diameter of the fiber is determined by the relationship with the above-mentioned flock density and the fiber length. That is, if the diameter of the fiber is too large (too thick), the optimum flock density cannot be obtained. Further, when the diameter of the fiber is small (thin) and the fiber length is long, the fibers are easily entangled with each other and it becomes difficult to align them. Therefore, it is expected that the pressure loss is high and the removal performance of the substance to be filtered is deteriorated, which is not preferable. . Therefore, the fiber diameter is selected according to the optimum fiber length with respect to the interval D of the partition wall 2 so that the fibers are not entangled with each other and a desired hair transplant density is obtained.

The intervals D of the partition walls 2, the flock density, the fiber length and the diameter of the fibers 5 were tested under the conditions that the removal performance of the substance to be filtered and the pressure loss are suitable according to the use of the air filter substrate 1. You can ask for it.

The fibers 5 to be flocked are not particularly limited, but are preferably composed of, for example, electret fibers, fibrous activated carbon, or fibers such as fibrous ion exchangers. These electret fibers, fibrous activated carbon, and fibrous ion exchangers have a high adsorption performance for the substance to be filtered, in other words, the adsorption performance (removal performance) of the substance to be filtered is mechanical when using ordinary fibers. It is possible to obtain a performance higher than simple filtration.

For example, the electret fiber has an electrostatic adsorption function, and the electric force also adsorbs micro dust and cigarette smoke. Therefore, it is suitable for the air filter substrate 1 when adsorbing and removing these substances to be filtered.

Further, the adsorption performance of the fibrous activated carbon is capable of removing harmful substances such as ozone, and the adsorption performance of the substance to be filtered is higher than that of the granular activated carbon. Therefore, as compared with the second conventional example, it is possible to further improve the removal performance of the substance to be filtered while suppressing the pressure loss to be low.

The adsorption performance of the fibrous ion exchanger is
It is also possible to adsorb ionic gases (ammonia, amine-based gases, acidic gases, etc.) and harmful gases in cigarette smoke (nitrosamines, etc.), etc. An air filter for adsorbing and removing these substances to be filtered. It is suitable for the substrate 1.

Next, a method for implanting the fibers 5 will be described. This flocking is performed using an electro-planting technique. The outline will be described below.

First, as a pretreatment, the surface of the substrate (the object on which the fibers are to be planted) is cleaned. This is performed in order to prevent the adhesive strength of the adhesive, which will be described later, from being reduced due to the surface contamination of the base material, and to prevent defects in the product due to the inclusion of foreign matter. This surface cleaning is performed, for example, by wiping with alcohol. The surface cleaning process may be omitted when the substrate and the process are sufficiently controlled and there is no risk of contamination of the substrate surface.

Next, primer treatment and masking are performed. These treatments are for applying an adhesive to the fiber-implanted area on the surface of the base material (in this embodiment, the inner surface of each air passage 3), and are conventionally performed according to the adhesive application method described later. Done in the same way as it is done.

Next, an adhesive is applied to the flocked region on the surface of the base material. This adhesive application is performed by a spray method or a dip method. For example, when the distance D between the partition walls 2 is small and the adhesive application is performed by the dip method, the air passage 3 may be clogged. In some cases, spraying is preferred.

Next, fibers are implanted into the fiber-implanted region on the surface of the base material. As this method, up method, down method,
The side method and the like have been conventionally known. In this flocking, fibers that are difficult to be charged, such as carbon fibers and metal fibers, are subjected to surface treatment to increase the resistance value.

Next, the adhesive is dried to increase the adhesive strength. Then, at the time of the above-mentioned flocking, the play hair not flocked on the surface of the base material is removed. This hair removal is performed by blowing off with air blown from a nozzle, or by rubbing the surface of the base material with a brush and then blowing off with air.

The air filter base material 1 may be manufactured by forming the partition walls 4 and the fibers 5 may be planted on the partition walls 4, or the fibers 5 may be planted (for example, the fibers 5 may be formed on both sides). The partition wall body 4 may be manufactured by using a non-woven fabric sheet having flocked.

By the way, in the above embodiment, the air passage 3
The partition body 4 is a honeycomb structure having a substantially hexagonal cross section.
However, the partition body 4 according to the present invention may have another structure. For example, as shown in FIG. 2A, the air passage 3 may have a rectangular sectional shape (square or rectangular), or as shown in FIG. 2B, a substantially triangular sectional shape. May be Although not shown, the cross-sectional shape of the air passage 3 may be another polygonal shape or a circular shape. Further, the present invention can be similarly applied to the air filter substrate 1 having the structure as shown in FIGS. 2C and 2D in which the partition wall 4 having the structure shown in FIG. 2B is wound. The structure of these partition walls 4 may be appropriately selected according to the application of the air filter substrate 1. In addition,
In FIGS. 2A and 2B, a part of the partition wall body 4 is drawn, and a similar structure is developed vertically and horizontally.

The air passage 3 may be parallel to the flow of the air 6 shown by the arrow as shown in FIG. 3 (a), or the air 6 as shown in FIG. 3 (b). May be inclined with respect to the flow.

Further, the pre-filter 11 may be provided on the side of the air inlet IN of the partition 4 and the end filter 12 may be provided on the side of the air outlet OUT of the partition 4 as described above. The pre-filter 11 contains a few μ including dust and the like.
A filter made of, for example, a non-woven fabric or a woven fabric for filtering a coarse object to be filtered having a size of m to 10 μm or more, and being 30% or more by a gravimetric method (a method for measuring the efficiency of collecting the object to be filtered). Is preferred. In addition, the end filter 12
Is a filter, which is finer than the pre-filter 11 and for filtering an object to be filtered having a thickness of about 0.1 μm to several μm, and is made of, for example, a non-woven fabric or a glass filter paper.

By providing the pre-filter 11 in this way, since the coarse filter object is filtered by the pre-filter 11, there is no inconvenience that the coarse filter object is clogged in the air passage 3. Further, by providing the end filter 12, since the fine material to be filtered is also removed by the end filter 12, the removal performance of the material to be filtered is further improved,
Even if the fibers 5 that have been flocked are removed, the end filters 1
It can also be controlled by 2.

[0048]

As is apparent from the above description, according to the invention described in claim 1, since many fibers are planted on the inner surface of the air passage of the partition wall, the air containing the substance to be filtered is When passing through the ventilation passage, the substance to be filtered is captured by the fibers, and the removal performance of the substance to be filtered is improved. Moreover, since the air passing through the air passage passes through the fibers in a stitched manner, the pressure loss can be suppressed to a low level. Moreover, since the fibers are fixed on the flock, the fibers do not move to the air discharge side and are not densely packed with the lapse of use time, and the pressure loss does not increase due to the structural change.

According to the second aspect of the present invention, since the partition wall body is formed of a honeycomb structure having an air passage cross section of a substantially hexagonal shape, the partition wall body is easy to manufacture and the structure is stable.

According to the third aspect of the invention, since the fibers to be flocked are composed of electret fibers, in addition to mechanical filtration, the electrostatic adsorption function can improve the removal performance of the substance to be filtered in the air. It can be further improved.

According to the invention as set forth in claim 4, since the fibers to be flocked are made of fibrous activated carbon, in addition to the mechanical filtration, the function of adsorbing the substance to be filtered is high, and the substance to be filtered in the air is high. The removal performance of the substance can be further improved. Moreover, since this adsorption performance is higher than that of granular activated carbon,
As compared with the conventional example, it is possible to realize an air filter base material that further improves the performance of removing the substance to be filtered while suppressing the pressure loss.

According to the invention described in claim 5, the fibers to be transplanted are composed of ion exchangers on the fibers. Therefore, in addition to the mechanical filtration, the adsorbing ability for ionic gas and the like can reduce the harmful substances. It is also possible to remove the substance to be filtered containing.

According to the sixth aspect of the invention, since the coarse object to be filtered is filtered by the prefilter, there is no inconvenience such as the coarse object to be filtered being clogged in the air passage. Since the fine object to be filtered is also removed, the removal performance of the object to be filtered is further improved. Further, there is an advantage that even if the fibers that have been transplanted are dehaired, they are controlled by the end filter.

[Brief description of drawings]

FIG. 1 is a diagram showing a schematic configuration of an air filter substrate according to an embodiment of the present invention.

FIG. 2 is a front view showing a schematic configuration of a modified example of the embodiment apparatus.

FIG. 3 is a side sectional view showing a schematic configuration of a modified example of the embodiment apparatus.

FIG. 4 is a side sectional view showing a schematic configuration of a modified example in which a prefilter and an end filter are provided in the apparatus of the embodiment.

[Explanation of symbols]

 1 ... Air filter base material 2 ... Partition wall 3 ... Air passage 4 ... Partition body 5 ... Fiber 6 ... Air 11 ... Pre-filter 12 ... End filter IN ... Air inlet OUT ... Air carry-out port

Claims (6)

[Claims] 1. An air filter substrate comprising a partition having a plurality of air passages, wherein a large number of fibers are planted on the inner surface of the air passage. 2. The air filter base material according to claim 1, wherein the partition wall body is formed of a honeycomb structure having a substantially hexagonal cross section of the air passage. 3. The air filter base material according to claim 1 or 2, wherein the fibers to be transplanted are electret fibers. 4. The air filter base material according to claim 1, wherein the fibers to be transplanted are made of fibrous activated carbon. 5. The air filter base material according to claim 1, wherein the fibers to be transplanted are made of a fibrous ion exchanger. 6. The air filter substrate according to any one of claims 1 to 5, wherein a prefilter for removing a coarse object to be filtered is provided on the air inlet side of the partition wall, An air filter substrate, characterized in that an end filter for removing fine matter to be filtered is provided on the air outlet side of the partition wall.