JPH0910535A - Flat sheet-like filter element - Google Patents

Abstract

PURPOSE: To make no tight contact of adjoining filter material even without providing a spacer and to obtain a filter with folding three dimensionally a sheet-like filter material by periodical repeating of a projecting part and a recessed part and forming a filter raw material. CONSTITUTION: A three dimensional folded line structure of periodical repeating of a projecting part and a recessed part is formed into a flat sheet shape with a thickness (W), a length (in the direction L) and a width (in the direction J) each with a fixed dimension. In addition, on both ends of the length (in the direction L) of a filter raw material 1, a projecting ridge 8 and a recessed ridge 9 are formed. The projecting ridge 8 corresponds to the end part of the projecting part 4 and the recessed ridge 9 corresponds to the end part of the recessed part 5. The ridge line formed by folding along the folded line, namely, the projecting parts 4 and 6 and the recessed part 5 can be fixed either only by folding processing or by thermoforming depending on the kind of the sheet- like filter material to be used. This filter element can be obtd. by supporting the periphery of the flat sheet-like folding processing filter raw material 1 thus obtd. with a filter frame.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

FIELD OF THE INVENTION The present invention relates to a flat plate filter element.

[0002]

2. Description of the Related Art In a filter that collects dust contained in a fluid to be treated such as gas or liquid to purify the fluid, the larger the surface area of the filter material in contact with the fluid to be treated, the more the ventilation resistance increases. Can be lowered. This is because the larger the surface area of the filter medium, the smaller the amount of fluid to be treated per unit area of the filter medium. Conventionally, in flat plate filters, in order to increase the surface area of the filter medium,
For example, as shown in FIG. 1, a pleated filter 20 in which a sheet-shaped filter medium 21 is pleated is known.
The pleated filter 20 has a structure in which parallel linear peaks 22 and valleys 23 are alternately repeated when viewed in the passage direction (arrow a) of the fluid to be processed. In the pleated filter 20 of this type, in order to increase the filter medium surface area in contact with a certain amount of the fluid to be processed within a certain volume without increasing the thickness w of the flat plate-shaped filter, the above-mentioned peaks 22 and valleys are required. It is necessary to increase the folding density of the portion 23.

[0003]

However, the pleat-processed filter has a drawback that the folded filter medium surfaces adhere to each other during the use of the filter, and the tendency becomes remarkable as the folding density increases. . Since the area of the filter medium sheet that comes into contact with the fluid to be treated decreases when the adjacent filter medium surfaces are in close contact, it was necessary to provide a spacer between the folding filter media to prevent the close contact. For this reason, the pleating process has a limit in the foldable density, and it has not always been possible to obtain a sufficient filter medium density. Furthermore,
When dust is clogged, the parts with low ventilation resistance will adhere due to pressure loss, and the filter characteristics will deteriorate without being fully utilized, and the life will be shortened. There was also. An object of the present invention is to provide a filter having a long service life by increasing the folding amount of a filter medium sheet within a certain volume and preventing the adjacent filter medium surfaces from adhering to each other without providing a spacer.

[0004]

According to the present invention, a flat plate-shaped folded filter material obtained by bending a sheet-like filter medium three-dimensionally by periodically repeating peaks and valleys and a flat plate thereof are provided. A filter element including a filter frame that supports a bent filter material around the filter material, wherein a ridge line forming a three-dimensional bent shape of the filter material is a fold line on a plan development view of the filter material. (1) a plurality of parallel straight lines, or a plurality of zigzag lines that are bent in zigzag at a substantially constant predetermined angle and are parallel to each other, and (2) a substantially constant intersection point between the parallel straight lines. It is bent at a predetermined angle, or is bent at a substantially constant predetermined angle at the intersection of the parallel zigzag lines at the bending point, and is composed of a plurality of zigzag lines parallel to each other, and (a)
In each of the parallel straight lines or the parallel zigzag lines (1), the mountain fold line and the valley fold line are periodically repeated every time the zigzag line (2) is crossed, and (b) the adjacent zigzag lines. Also in each parallel straight line or parallel zigzag line (1) between (2), the peak fold line and the valley fold line repeat periodically, and (c) each zigzag line (2) is
Either the mountain fold line or the valley fold line as a whole, and the zigzag line (2) of the mountain fold line and the zigzag line (2) of the valley fold line are alternately and periodically repeated. Can be achieved by a filter element.

The present invention will be described in detail below with reference to the accompanying drawings. FIG. 2 shows one embodiment of a flat plate-shaped folded filter material that can be used in the filter element according to the present invention. The flat plate-shaped bending filter material 1 can be manufactured by folding the plane development view (partial development view) shown in FIG. 3 (combination of parallel straight lines and zigzag lines) or FIG. 4 (combination of zigzag lines). . That is, in the case of a combination of parallel straight lines and zigzag lines, as shown in FIG. 3, a crease line is formed on the sheet-shaped filter medium 10. The fold line is (1) a plurality of parallel straight lines 11 and (2) a plurality of zigzag lines which are bent in zigzag at a substantially constant predetermined angle θ ₁ at intersections 12 of the parallel straight lines 11 and are parallel to each other. It consists of 13. In the case of a combination of zigzag lines, a crease line is formed on the sheet-shaped filter medium 10 as shown in FIG. The fold line is (1 ′) a plurality of parallel zigzag lines 11 ′ that are bent in a zigzag at a substantially constant predetermined angle θ ₂ and (2 ′) an intersection of the parallel zigzag lines 11 ′ at a bending point. At 12, a plurality of zigzag lines 13 are bent in zigzag at a substantially constant predetermined angle θ ₃ and are parallel to each other.

Further, the above-mentioned fold line is (a) in each parallel straight line 11 or parallel zigzag line 11 ′, every time it intersects with the above-mentioned zigzag line 13, a mountain fold line 14 and a valley fold line 15 And (b) each parallel straight line 11 between adjacent zigzag lines 13 or parallel zigzag lines 1
Also in 1 ′, the mountain fold line 14 and the valley fold line 15 are periodically repeated, and (c) each zigzag line 13
Is either the mountain fold line 16 or the valley fold line 17 as a whole, and the zigzag line 1 of the mountain fold line 16 is
3 and the zigzag line 13 of the valley fold line 17 are alternately and periodically repeated.

When the fold lines are formed according to the above conditions (1) and (2) and the conditions (a) to (c), a parallel straight line 11 and a zigzag line 13 are respectively formed on the plan development view. Various parallelograms having different side lengths and inner angle sizes are formed, but there are two kinds of combinations of the angles of two adjacent inner angles among the four inner angles of each parallelogram. . Further, in particular, when the intervals of the parallel straight lines 11 and the intervals of the zigzag lines 13 are made equal, as shown in FIG. 3, the parallel straight lines 11 and the zigzag lines 1 are shown on the plan development view.
3 and 2 form a plurality of substantially congruent parallelograms 18a and 18b (18a and 18b are line-symmetrical).

When fold lines are formed according to the conditions (1 ') and (2') and the conditions (a) to (c), parallel zigzag lines 11 'are formed on the plan development view. The zigzag line 13 forms various parallelograms having different side lengths and inner angles, and the combination of the angles of two adjacent interior angles among the four interior angles of each parallelogram. There are 4 types. Further, if the intervals between the parallel zigzag lines 11 ′ and the zigzag lines 13 are equal, as shown in FIG. 4, a plurality of parallel zigzag lines 11 ′ and parallel zigzag lines 13 are provided on the plan development view. Of four substantially parallelograms 19a, 19 of
b, 19c and 19d are formed. Further, the sum of one interior angle α of a certain parallelogram 19a and one interior angle δ of another parallelogram 19d that only contacts the parallelogram 19a at the intersection becomes 180 °, and the other one Parallelogram 19
When the sum of one interior angle β of b and one interior angle γ of another parallelogram 19c that is in contact with the parallelogram 19b only at the intersection is 180 °, two types of parallelograms are congruent. Since (19a = 19d, 19b = 19c), a plurality of substantially congruent two types of parallelograms are formed on the plan development view.

In the present specification, the zigzag straight lines are parallel to each other in the above plan development view.
This means that if a certain zigzag line is translated, the zigzag line overlaps with another zigzag line, and it becomes substantially one zigzag line. However, in the present invention, the parallel straight lines and the parallel zigzag lines only have to be substantially parallel, and some errors are allowed within a range in which the predetermined effect of the present invention can be obtained.

3 and 4, the peak fold lines 14 and 16 are shown by solid lines, and the valley fold lines 15 and 17 are shown by broken lines. The sheet-shaped filter medium 10 in which the fold lines are created according to the plan development view shown in FIG.
4 and 16 and the valley fold lines 15 and 17, the three-dimensional folded structure of the filter material 1 shown in FIG. 2 can be formed. In addition, the sheet-shaped filter medium 10 in which a fold line is formed according to the plane development view shown in FIG.
Is folded along the mountain fold lines 14 and 16 and the valley fold lines 15 and 17, a three-dimensional bent structure of the filter material 1 similar to that shown in FIG. 2 can be formed.

FIG. 5 illustrates the structure of the peaks 4 and 6 and the valleys 5 and 7 (only shown in FIG. 5) of the filter material 1 shown in FIG. Unfold and widen, and ridges 4 and 6 (respectively crease line 14
FIG. 17 is a reference diagram showing the structures of valleys 5 and 7 (corresponding to valley fold lines 15 and 17, respectively). 2 and 5, L represents the direction in which the parallel straight line 11 extends, and J represents the direction in which the zigzag line 13 extends.
In the present specification, the “ridges” (that is, convex portions) and the “valleys” (that is, concave portions) that correspond to the ridgelines of the filter material are viewed from the inflow direction (arrow A in FIG. 2) of the fluid to be processed. The unevenness is reversed when viewed from the outflow direction side of the fluid to be processed.

In the fold lines shown in the plan development views of FIGS. 3 and 4, the intervals between the parallel straight lines 11 or the parallel zigzag lines 11 ', the intervals between the zigzag lines 13 and the ratio of the intervals, and the parallel straight lines 11 or the parallel zigzag lines. Line 11 'and zigzag line 1
The bending angles θ ₁ , θ ₂ and θ ₃ with respect to ₃ are not particularly limited and can be appropriately selected depending on the type and thickness of the material of the sheet-like filter material to be used, and further the use of the filter element. . In the present specification, the “substantially constant predetermined angle” means about 1 from a specific predetermined angle.
It means within a margin of error. The interval between the zigzag lines 13 is mainly defined by the thickness (W) of the filter element to be manufactured. Further, it is desirable that the interval between the parallel straight lines 11 or the parallel zigzag lines 11 ′ is as narrow as possible in order to increase the surface area of the filter element. Therefore, it should be selected in consideration of the use of the element. It should be noted that it is preferable that the intervals of all the lines are substantially equal, because the folding process is easier and a stable filter element can be manufactured. Here, “substantially equal intervals” means about 1 from a specific predetermined interval.
It means within a margin of error.

The bending angles θ ₁ , θ ₂ and θ ₃ are the same or different angles independently of each other, and it is desirable that they are close to 180 ° in order to increase the folding amount and increase the surface area. On the contrary, in order to prevent the filter medium from adhering to each other, it is desirable to separate it from 180 °, and it should be selected in consideration of the type and thickness of the sheet-shaped filter medium, the use of the element and the like. In the case of the parallel straight line 11, θ ₁ is 180
Shall not be °. When θ ₁ becomes 180 °, the folding structure of the present invention as shown in FIG. 3 cannot be obtained. Further, θ ₃ can be 180 °, but in this case, the zigzag line 11 ′ shown in FIG. 4 becomes the straight line 11. Furthermore, θ ₂ is also 1
It shall not be 80 °. When θ ₂ becomes 180 °, the folding structure of the present invention as shown in FIG. 4 cannot be obtained.

Compared to the case of forming the fold lines of the parallel straight lines 11 in FIG. 3, the case of forming the fold lines of the parallel zigzag lines 11 'in FIG. Obtainable. On the other hand, in order to perform folding processing based on the crease line, it is necessary to perform more complicated processing in FIG. 4 than in FIG. 3, so that the filter material can be obtained more easily in FIG. For example, the thickness is about 750 μm
In the case of manufacturing a filter element for an automobile cabin from the non-woven fabric filter material, the distance between the parallel straight lines 11 or the parallel zigzag lines 11 'is 2 to 5 cm, and the distance between the zigzag lines 13 is 1.
The bending angles θ ₁ , θ ₂ , and θ ₃ may be 100 ° or more and less than 180 °, and more preferably 160 ° or more and less than 180. Also, for example, the thickness is about 150μ.
When producing a filter element for an air cleaner from a non-woven fabric filter material of m, the parallel straight lines 11 or the parallel zigzag lines 1 are used.
The interval of 1'is 0.5 to 2 cm, the interval of the zigzag line 13 is 1 to 5 cm, and the bending angles θ ₁ , θ ₂ , and θ ₃ are 80 ° or more and less than 180 °, more preferably 140 ° or more and less than 180. Can be

The filter medium for the filter material is any conventionally known filter medium material, for example, fibrous material (for example, knitted fabric, woven fabric, non-woven fabric, paper, or composite thereof), net, perforated film, Alternatively, a membrane filter or the like can be used. In particular, when used in a filter element for gas (for example, for an air cleaner), a non-woven filter material (for example, melt blown non-woven fabric, binder-bonded non-woven fabric, fiber-bonded non-woven fabric, hydroentangled non-woven fabric, wet non-woven fabric, or laminated body thereof) Is particularly preferable, and a charged (electretized) meltblown nonwoven fabric or a laminate of a charged meltblown nonwoven fabric and another nonwoven fabric is particularly preferable. When used for a liquid (for example, water or oil) filter element, it is particularly preferable to use a non-woven filter material or an oil-resistant filter paper.

As shown in FIG. 2, the filter material 1 described above is used.
Includes a three-dimensional bent structure in which peaks and valleys are periodically repeated, and as a whole, a thickness (W) of a constant dimension and a vertical (L
It is formed in a flat plate shape in the direction) and the horizontal direction (J direction). Also,
A projecting ridge 8 and a concave ridge 9 are formed at both ends of the filter material 1 in the vertical direction (L direction). The protruding ridge 8 corresponds to the end of the crest 4, and the recessed ridge 9 corresponds to the end of the trough 4.
The ridgelines formed by folding along the fold lines, that is, the ridges 4, 6 and the valleys 5, 7 may be fixed simply by folding, depending on the type of the sheet-like filter medium used,
Alternatively, it can be formed by thermoforming. Generally, most of the filter media are only folded and the peaks 4, 6 and valleys 5,
7 can be formed, but in the case of a filter medium containing a heat-fusible fiber or a filter medium having a multilayer structure, it may be formed by heat molding.

The filter element according to the present invention can be obtained by supporting the periphery of the plate-shaped bent filter material thus obtained with a filter frame. The circumference of the filter material supported by the filter frame is preferably the entire circumference, but may be a part of the circumference. As the filter frame, it is possible to use the filter frame used in the same kind of conventionally known filter element as it is, but as described above, the protruding ridges 8 are provided on the pair of two opposite sides of the filter material used in the present invention. And the ridged ridges 9 exist, the shape of at least the inside of the filter frame is made uniform to the shape corresponding to the ridged edges 8 and the ridged edges 9, or the ridged edges 8 and the ridged edges 9 of the filter material are formed into a flat plate shape. It is necessary to cut it. For example, in a normal rectangular filter frame, a spacer member capable of filling the space occupied by the recessed ridge 9 is provided inside a pair of opposing two sides, or a pair of opposing two sides of the filter frame are provided. The recesses formed on the outside of the filter frame by aligning the shapes with the shapes corresponding to the protruding ridges 8 and the recessed ridges 9 can be filled in the filter device in which the filter element of the present invention is installed.
Note that the filter frame may be formed by adhering or fusing the filter material itself. For example, in the case of the filter material of FIG. 2, vertical (L direction) adjacent filter medium pieces are brought into contact with a heating body or the like. It may be replaced with a filter frame by forming a sealed surface by heat fusion and the like.

The filter element according to the invention can generally be used in gas filters and liquid filters. Examples of gas filters include filters for air purifiers and filters for automobile cabins, and examples of liquid filters include, for example, semiconductors, foods, paints, for treating water used in manufacturing pharmaceuticals, etc. There are filters and oil filters.

[0019]

The filter material constituting the filter element according to the present invention has a structure in which the adjacent filter medium surfaces do not adhere to each other at least in the extending direction of the parallel straight lines by the special bending process according to the present invention. Further, in the extending direction of the zigzag line, if the thickness of the sheet-shaped filter medium itself is not taken into consideration, in theory, adhesion between adjacent filter medium surfaces occurs, but since the sheet-shaped filter medium actually used has a certain thickness, Virtually no such adhesion occurs. In addition, since the bent flat plate filter material according to the present invention has a specific bent structure, the amount of the filter material that can be stored in a certain volume is dramatically increased. For example, comparing the amount of the filter material that can be folded up to a practically usable limit as a filter material for a filter element for an automobile cabin between the present invention and a conventional pleated filter (see FIG. 1), 22
6,500 to 7,300c for the pleated filter material within the flat area of cm × 30 cm × 3 cm.
^On the other hand, it is 2,500 to 11,000 cm ² in the folded flat plate filter material of the present invention, which is about 1.3 to 1.5 times as large as m ² .

[Brief description of the drawings]

FIG. 1 is a perspective view of a prior art pleated filter.

FIG. 2 is a perspective view of a plate-shaped folded filter material that can be used in the filter element according to the present invention.

FIG. 3 is a partial view of a developed plan view of the filter material of FIG.

FIG. 4 is a partial view of an exploded plan view of another filter material.

FIG. 5 is an explanatory view showing respective structures of a peak portion and a valley portion by releasing and unfolding a part of the folded structure of the filter material shown in FIG.

[Explanation of symbols]

1 ... Plate-shaped bent filter material; 4, 6 ... Crests; 5, 7 ... Valleys; 8 ... Projected ridges; 9 ... Recessed ridges; 10 ... Sheet-shaped Filter material; 11 ... Parallel straight line; 1
2 ... Intersection; 11 ', 13 ... Zigzag line; 14,
16 ... Mountain fold line; 15, 17 ... Valley fold line;
18 ... Parallelogram; 20 ... Pleated filter; 21 ... Sheet-shaped filter material; 22 ... Mountain portion; 23.
..Tanibe.

Claims (1)

[Claims] 1. A flat plate-shaped bent filter material obtained by three-dimensionally bending a sheet-shaped filter medium by periodically repeating peaks and valleys, and a filter supporting the flat-plate bent filter material around it. A filter element including a frame, wherein a ridge line forming a three-dimensional bent shape of the filter material is a fold line on a plan development view of the filter material as follows: (1) a plurality of parallel straight lines or substantially A plurality of zigzag lines parallel to each other at a predetermined constant angle, and a plurality of zigzag lines parallel to each other (2) Bent at a substantially constant predetermined angle at the intersection of the parallel straight lines or the parallel zigzag lines. Is bent at a substantially constant predetermined angle at the intersection of the bending points, and is composed of a plurality of zigzag lines parallel to each other, and (a)
In each of the parallel straight lines or the parallel zigzag lines (1), the mountain fold line and the valley fold line are periodically repeated every time the zigzag line (2) is crossed, and (b) the adjacent zigzag lines. Also in each parallel straight line or parallel zigzag line (1) between (2), the peak fold line and the valley fold line repeat periodically, and (c) each zigzag line (2) is
Either the mountain fold line or the valley fold line as a whole, and the zigzag line (2) of the mountain fold line and the zigzag line (2) of the valley fold line are alternately and periodically repeated. A filter element characterized by.