JPH1085539A - Element and air cleaner for storing and retaining this element - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an element which is capable of fixing a prefilter without lowering its dependable filtering performance, when a highly pliable and bulky filter medium with high voids is used as the prefilter, and also an air cleaner which stores and retains the element. SOLUTION: This element 1 consists of a pleated main filer 2, a prefilter 3 which is arranged on the upstream side of the main filter 2 and is formed of unwoven fabric with high voids and a resin frame 4 which keeps the main filter 2 pleated and at the same time, has a protrusion 6 for engagement, jutting out to the upstream side to install the prefilter 3, on end faces 540, 560 opposite to the prefilter 3. The protrusion for engagement 6 has a shaft part 60 which passes through the prefilter 3 and a tip part 6 with an enlarged diameter, which is formed on the tip side of the shaft part 60 and positioned on the upstream side of the prefilter 3 to fix the prefilter 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an element having a pre-filter holding mechanism disposed upstream of a main filter and an air cleaner having the element as a component.

[0002]

2. Description of the Related Art Japanese Patent Laying-Open No. 3-114568 discloses an air cleaner having a pre-filter holding mechanism disposed upstream of a main filter. This air cleaner is composed of a filter element (hereinafter referred to as a main filter) folded in a zigzag shape, a main filter element for fine dust removal constituted by a cylindrical element frame for fixing an outer peripheral portion thereof inside, and a continuous filter element for coarse dust removal. A sub-filter element (hereinafter, referred to as a pre-filter) made of a flexible film made of a foam is inserted into a cleaner case in order, and the main filter element and the pre-filter are pressed against a cleaner case by a case lid. Fix the filter,
As a means for positioning, a pre-filter is inserted and held using four rod-shaped positioning and locking members projecting higher than the ridges of the main filter from the inner bottom of the element frame.

[0003]

According to the above-mentioned conventional fixing means, a pre-filter made of a foam material having a good shape-retaining property and having an elastic restoring force as a material is pressed by a case lid on the upstream side of the main filter element, and Although it can be fixed by a relative action with the elastic return force, for example, when a material that is easily deformed by an external force such as a nonwoven fabric having a large porosity is used, the shape retention is extremely low, and the prefilter itself is fixed. Therefore, an appropriate elastic return force required for the above cannot be obtained.

Further, for example, depending on the type of the air cleaner, a large space must be provided between the pre-filter and the lid due to the necessity of providing a silencing function, or when the air cleaner is disposed on the upstream side of the main filter, the ventilation may not be provided. In the case where it is necessary to adopt a non-woven fabric pre-filter with a large porosity to increase the amount of dust that can be captured while minimizing the increase in resistance and achieve excellent filtration performance,
It is necessary to fix the pre-filter by fixing means other than the conventional fixing means.

According to the present invention, there is provided an element capable of fixing a prefilter without deteriorating the excellent filtration performance when a filter medium having a high flexibility and a bulky and high porosity is used as a prefilter. An object of the present invention is to provide an air cleaner for housing and holding.

[0006]

According to an aspect of the present invention, there is provided an element comprising: a foldable main filter; a pre-filter, which is disposed upstream of the main filter and is made of a non-woven fabric having a large porosity; A resin frame that retains the shape and is provided on the end face facing the pre-filter and that protrudes toward the upstream side and is provided with a locking projection for attaching the pre-filter. It has a shaft portion penetrating the pre-filter, and a large-diameter portion formed at the front end side of the shaft portion, located upstream of the pre-filter, and fixing the pre-filter.

According to a second aspect of the invention, in the element according to the first aspect, the element is made of a material having a melting point higher than the melting point of the resin constituting the resin frame. An annular member having a larger outer diameter and an inner diameter larger than the outer diameter of the shaft of the locking projection is disposed between the upstream side surface of the pre-filter and the large-diameter tip portion.

According to a third aspect of the present invention, there is provided an element having a folded main filter, a pre-filter made of a non-woven fabric having a large porosity disposed upstream of the main filter, and having the folded fold shape of the main filter. A resin frame provided on an end face facing the pre-filter and protruding toward the upstream side and provided with a locking projection for mounting the pre-filter, wherein the locking projection is a shaft penetrating the pre-filter. And a tip bent holding portion formed on the tip end side of the shaft portion and located on the upstream side of the pre-filter and fixing the pre-filter.

According to a fourth aspect of the present invention, there is provided an element having a foldable main filter, a pre-filter made of a non-woven fabric having a high porosity disposed upstream of the main filter, and having the fold-fold shape of the main filter. A resin frame having a locking hole for fixing the pre-filter on an end surface facing the pre-filter, an insertion portion and an insertion removably inserted into the locking hole of the resin frame via the pre-filter; And a stopper having an umbrella-shaped grip portion formed on the other end side of the portion and located on the upstream side surface of the pre-filter and fixing the pre-filter.

[0010] In the element according to the fourth aspect, the stopper may have a wide portion that is widened toward the front end of the insertion portion, a slit or a hole formed at the center of the wide portion, or the front end thereof. May have a plurality of ribs whose width decreases toward. In the element according to the fourth aspect, a ring member may be interposed between the end surface of the resin frame near the locking hole and the downstream side surface of the prefilter. In addition, this ring member
It is desirable to form a plurality of small projections on the surface that contacts the downstream side surface of the prefilter.

According to a fifth aspect of the present invention, the foldable main filter, a pre-filter made of a non-woven fabric having a large porosity disposed upstream of the main filter, and a fold-fold shape of the main filter are maintained. An end face facing the pre-filter is formed of a resin frame having a locking hole for mounting the pre-filter, and the pre-filter has a portion facing the locking hole of the resin frame hardened in a convex shape. The pre-filter is fixed to a resin frame by having a connecting projection, and detachably inserting the connecting projection into the locking hole.

[0012] In particular, in the element according to claim 4 or 5, the locking hole of the resin frame extends in a direction perpendicular to the ridge line of the ridge of the main filter, and has both ends of the frame-shaped portion. It is desirable that the reinforcing rib is provided on the end face on the upstream side of the reinforcing rib connected to the outer frame. The air cleaner according to claim 6 is the air cleaner according to claim 1, claim 2,
The element according to claim 3, 4, or 5, wherein the case body forming a housing portion opened to one end side and the opening of the housing portion are attached to the case body so as to be openable and closable. And a housing configured by a cap, and housed and held in the housing portion of the housing.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION A prefilter is made of a nonwoven fabric having a high porosity, which is arranged upstream of a folded main filter. Polyester, nylon, acryl, rayon, cotton, and the like can be used as the types of fibers constituting the nonwoven fabric. The basis weight of the pre-filter is 100-
600 g / m ² and the porosity can be 94 to 99. The thickness of the pre-filter can be between 10 and 30 mm. By setting the basis weight, the porosity, and the thickness of the pre-filter within the above ranges, the pre-filter is attached to the resin frame, and when air including dust is passed and filtered while being arranged on the upstream side of the main filter. Can be made smaller than a conventional pre-filter formed of a foam or the like.

Further, after the pre-filter of the present invention has been used for a predetermined period of time (after the ventilation resistance has increased due to the capture of dust), the dust can be removed by air blow without removing the pre-filter from the resin frame. The regenerative ability (the ability to recover the dust capturing function to almost the same level as the initial value) is large, and therefore, it can be used repeatedly by air blowing.

The locking projection has a shaft portion penetrating the pre-filter, and a large-diameter portion formed at the front end of the shaft portion, located upstream of the pre-filter, and fixing the pre-filter. As the material of the locking projection, the melting point is 150 to
Polypropylene having a temperature of 180 ° C. can be used. Further, it is desirable that at least the shaft portion of the locking projection is integrally formed of the same material as the resin frame.

The diameter of the shaft can be variously set according to the inner diameter of the through-hole of the prefilter, has a certain strength, and is softened by heating for a short time (about 2 minutes). (Melting), and it is desirable that the pressure is within a range in which plastic deformation is possible by applying pressure to a large-diameter portion having a larger end diameter than the inner diameter of the through-hole of the prefilter. As the material of the annular member, nylon or the like having a melting point in the range of about 200 to 240 ° C. can be used.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the element of the present invention will be described with reference to Embodiments 1 to 6, and the air cleaner of the present invention will be described with reference to Embodiment 7. (Embodiment 1) The element 1 of Embodiment 1 shown in FIG. 1 includes a main filter 2, a pre-filter 3, and a resin frame 4.

The main filter 2 has a fold 20 formed by folding a non-woven fabric made of polyester, and has a substantially rectangular parallelepiped appearance. The prefilter 3 is made of a flat nonwoven fabric made of polyester and has a basis weight of 300 g / m ² ,
The porosity is as large as 96%, the thickness t is 20 mm, and it has a substantially rectangular appearance. The pre-filter 3 has four holes 30 with an inner diameter of 4 mm penetrating in the thickness direction (from the one surface 31 side to the other surface 32 side) at four corners.

The resin frame 4 is molded using polypropylene containing 20% talc (melting point: 167 ° C.). The resin frame 4 forms a substantially rectangular parallelepiped storage space S at a predetermined depth inside, and
Are formed at positions that are parallel to the short-side frame parts 51 and 52 and that maintain a predetermined distance therebetween, and that both ends of the long-side frame parts 50 and 53 and the short-side frame parts 51 and 52 surround the long-side frame parts 50 and 53. A frame portion 5 having three partition frame portions (reinforcement ribs) 54, 55, 56 connected to 53;
One end surface 540 of the partition frame portion 54 and one end surface 560 of the frame portion 56 are provided.
0, projecting from one end face 560,
And four locking projections 6 formed at positions facing the three holes 30.

The locking projections 6 extend in parallel with each other across the ridge direction of the fold 20 at a predetermined interval.
Of the two partition frame portions 54, 55, 56, which are provided at positions closer to both sides.
6, and the long side frame portions 50, 5
3 are provided one by one in the vicinity of the connecting portion with 3, and a total of four are formed.

As shown in FIG. 2, each of the locking projections 6 is formed by thermally deforming a shaft portion 60 having a diameter of about 3 mm and a distal end side of the shaft portion 60, and has a substantially semicircular cross section and a diameter. About 6m
It is composed of a large end diameter portion 61 of m. Note that the numerical value of the shaft portion 60 and the cross-sectional shape of the large-diameter portion 61 are not limited. For example, the diameter of the shaft portion 60 can be variously set in accordance with the size of the inner diameter of the hole 30 of the prefilter 3, and the shaft portion 60 does not break as much as touched by another substance, and has a short time (about 2 minutes). It is preferable that the large-diameter portion 61 having a shape larger than the inner diameter of the hole 30 of the prefilter 3 be plastically deformed by softening (melting) by heating and pressurizing.

The main filter 2 is accommodated in the accommodation space S of the resin frame 4. Then, the top (fold ridge) 200 of the fold fold 20 of the main filter 2 is
One end face 540 which is the top of the partition frame portions 54 and 56 of the frame portion 5 forming the housing space S of the resin frame 4;
The position is slightly lower than 560. Next, each hole 30 of the pre-filter 3 is inserted into each shaft portion 60 of the resin frame 4. Then, the pre-filter 3 has the other surface 32 facing the top 200 of the fold 20 of the main filter 2 and a part of the other surface 32 as shown in FIG. 540 and 560.

Further, a washer 7 is inserted into each locking projection 6 of the resin frame 4 and the washer 7 is seated on one surface 31 of the pre-filter 3. The washer 7
Is made of nylon having a melting point of 220 ° C. and has an outer diameter of about 15 m.
m, inner diameter about 3 mm, thickness about 2 mm. In this state, the portion protruding from the washer 7 for each shaft portion 60 is approximately 190
C. and then pressurized to form a large tip diameter portion 61 having a diameter of about 5 mm, which was deformed into a semicircular cross section, and washer 7.
Formed in contact with the

At this time, the washer 7 is made of nylon and has a melting point (167) of polypropylene forming the shaft portion 60.
° C), which acts as a thermal shield for the pre-filter 3 and thermally deforms the tip of the shaft 60 to form the large-diameter portion 61 in the process of forming the large-diameter tip 61. It does not cause thermal damage. In addition, as a material of the washer 7, iron, alumina, a bake material, etc. other than the above-mentioned nylon can be used.

As described above, the shaft portion 60 is formed with the large-diameter portion 61 at the front end thereof for pressing the one surface 31 of the pre-filter 3 with the washer 7 interposed therebetween. For this reason, the other side 32 side of the pre-filter 3 contacts the long side frame parts 50, 53, the short side frame parts 51, 52, and the partition frame parts 54, 55, 56 in the frame part 5 of the resin frame 4. , The main filter 2 faces the one surface 21 with a slight gap therebetween, and the partition frame portion 54,
It can be fixedly held by an area sandwiched between the end faces 540, 560 of 56 and the washer 7.

That is, when the element 1 is housed in, for example, an air cleaner 1F shown in FIG. 20 as a reference, the pre-filter 3 has a large porosity and is bulky. Many can be fully utilized for the filtering action, and the increase in the air flow resistance is small, the retention amount of the captured dust can be improved, and after being used for a predetermined period, the element 1 is taken out from the air cleaner 1F, and The blow cleaning of the main filter 2 and the pre-filter 3 fixed to the resin frame 4 can be easily performed, and the air filtering function can be repeatedly restored.

The air flow resistance of the entire element 1 is 70 mmA when a conventional pre-filter made of foam is used.
Since it is 60 mmAg (at 6.5 m ³ / min) with respect to g, pressure loss during filtration can be reduced. Note that the locking projections 6 formed to protrude from one end surfaces 540 and 560 of the frame portions 54 and 56 of the frame portion 5.
And the number of holes 30 of the pre-filter 3 is not limited to four, but can be increased or decreased.

(Embodiment 2) The element 1A of Embodiment 2 shown in FIGS. 3 and 4 is different from the element 1 of Embodiment 1 in that the locking projection 6 and the washer 7 are used instead of the shaft portion 60a having a diameter of about 3 mm. Formed by thermally deforming the distal end side of the shaft portion 60a, and having a substantially semicircular cross section and a diameter of about 10
The configuration is the same as that of the element 1 of the embodiment, except that a locking projection 6a composed of a large-diameter tip portion 61a of mm is provided and the washer 7 is not required.

The element 1A of the second embodiment has substantially the same effect as that of the first embodiment. In addition, the element 1A does not use the washer 7 and has a large tip diameter having a maximum diameter substantially equal to the outer diameter of the washer 7. The pre-filter 3 can be fixed by 61a. Therefore, the number of components of the element 1A can be reduced compared to the number of components of the element 1 of the first embodiment. According to the element 1A of the second embodiment, a thermal stress is applied to the pre-filter 3 near the large-diameter end portion 61a of the locking projection 6a as compared with the first embodiment, but the filtering performance as a whole is reduced. There is no significant drop.

Instead of thermally deforming the distal end of the locking projection 6a, another member for retaining the distal end may be joined or welded to the distal end. (Embodiment 3) The element 1B of Embodiment 3 shown in FIG. 5 and FIG.
Instead of using the washer 7 and the shaft portion 60b, the shaft portion 60b is inserted into the hole 30 of the pre-filter 3 and then thermally deformed into a substantially rectangular shape.
Except for using a locking projection 6b formed with a tip bending holding portion 61b that abuts on one surface 31 of the prefilter 3,
It has the same configuration as the element 1 of the embodiment.

The element 1B of the third embodiment has substantially the same effect as that of the first embodiment. In addition, the pre-filter 3 can be fixed by the bent front end holding portion 61b without using the washer 7. Therefore, the number of components of the element 1B can be reduced as compared with the number of components of the element 1 of the first embodiment. According to the element 1B of the third embodiment, the shaft 6
By heating only the bent portion 62b of FIG. 0b, the tip bending pressing portion 61b can be formed, so that the area to be heated is one surface 31 of the pre-filter 3 as compared with the large tip diameter portion 61b of the locking projection 6b of the second embodiment. Since the pre-filter 3 is further separated, the thermal stress applied to the pre-filter 3 can be reduced. Further, in this embodiment, since only a part of the shaft portion 60b is bent, the manufacturing is easy, and no separate parts such as washers are required, so that the productivity is excellent.

(Embodiment 4) An element 1C of Embodiment 4 shown in FIGS. 7 and 10 is a resin frame having a locking projection 6 for fixing the main filter 2 and the pre-filter 3 in the element 1 of the embodiment. 4 is substantially the same as the configuration of the element 1 of the embodiment except that a resin frame 4c having a locking hole 6c for attaching a fixing member 8 for fixing the main filter 2c and the pre-filter 3 is used. is there.

The resin frame 4c is connected to the main filter 2
The two long-side frame portions 50c and 53c and the short-side frame portions 51c and 52c surrounding the accommodation space S that accommodates the
Are formed at positions that are parallel to the long side frame portions 50c and 53c and that maintain a predetermined interval, and have both ends at the short side frame portions 51c and 53c.
c, two partition frame portions 54c connected to 52c,
A frame-shaped portion 5c having an upper surface 56c;
c on one end surface 540c and one end surface 560c of the partition frame portion 56c, and four locking holes 6c formed at positions facing the four holes 30 of the pre-filter 3.
With

The locking hole 6c has an inner diameter of 3 mm and a depth of about 15 mm.
It is a straight shape set to mm. The fixture 8 is made of nylon and has a shaft portion 80 having an outer diameter of 5 mm.
And a large-diameter holding portion 81 formed on the upper end side of the shaft portion 80.
And a knob portion 82 vertically protruded from the large-diameter holding portion 81.
And an insertion portion 8 formed on the lower end side of the shaft portion 80 and detachable from the locking holes 6c of the partition frame portions 54c and 56c.
Has three.

The shaft portion 80 is provided with the hole 30 of the pre-filter 3.
The outer diameter is set slightly larger than the inner diameter of. The large-diameter holding portion 81 is similar to the washer 7 of the first embodiment, the large-diameter portion 61a of the locking projection 6a of the second embodiment, the tip pressing portion 61b of the locking projection 6b of the third embodiment, and the like. It abuts on one surface 31 of the pre-filter 3 and fixes it. Knob 82
The operator grips the fixing device 8 to fix the resin frame 4
This is to make it easy to operate detachably on c. The insertion portion 83 has a slit 830 at substantially the center in the vertical direction, and has a width w wider than the locking hole 6c and becomes narrower toward the front end O. The insertion portion 83 is reduced and reduced in the width w direction by the slit 830. It is set to a shape that is expandable from the state, that is, a so-called elastically deformable shape, and can be inserted into and pulled out of the locking hole 6c.

According to the element 1C of the fourth embodiment, when the pre-filter 3 mounted on the frame portion 5c is fixed in a state where the main filter 2c is accommodated in the accommodation space S of the resin frame 4c, the fixture is used. 8, the insertion portion 83 is inserted through the hole 30 of the pre-filter 3 into the locking hole 6c of each of the partition frame portions 54c and 56c. Then, the fixture 8 is inserted into the locking hole 6c having a width smaller than the width w while elastically deforming the insertion portion 83, and the shaft portion 80 is inserted.
The lower end 800 is one end face 540 of the partition frame portion 54c.
c and the partition frame 56c until it reaches a position where it comes into contact with one end face 560c. At this time, the insertion portion 83
Is locked in the locking hole 6c by a reaction force accompanying elastic deformation. The large-diameter holding portion 81 of the fixture 8 abuts on the one surface 31 side of the pre-filter 3 and fixes it.

The element 1C of the fourth embodiment provides substantially the same effects as those of the first embodiment, and furthermore, the locking projections 6 of the first embodiment, the locking projections 6a of the second embodiment, and the elements of the third embodiment. Since the pre-filter 3 is fixed using the detachable fixing tool 8 instead of thermally deforming the stopping projection 6b, the step of thermally deforming is not required. Operations such as removal and fixing can be repeated.

Note that the locking hole 6c into which the insertion portion 83 of the fixing tool 8 can be attached and detached is not limited to a straight hole, and for example, as shown in FIG. Is smaller than the inner diameter of the inside 6c2, it is also possible to make the insertion portion 83 difficult to come off. Fifth Embodiment An element 1D of a fifth embodiment shown in FIGS. 12 to 18 has a planar shape instead of using the locking holes 6c and the fixtures 8 of the frame portions 54c and 56c in the element 1C of the fourth embodiment. Cross-shaped locking hole 6d (FIG. 1)
6), the shaft portion 8 having the annular groove 801 formed therein.
0d (see FIG. 14) and an insertion portion 83d (see FIG.
5), and a lower end holding plate 9 (see FIG. 13) attached to the annular groove 801 and abutting against the other end 32 of the prefilter 3 is used. The configuration is the same as that of the element 1C of Example 4.

The locking holes 6d are formed in the frame portions 54c and 56c as shown in FIGS. 12 and 18, and have a cross shape with a groove width a of 1 m as shown in FIG.
m, the large diameter b in the groove is set to 4 mm, and the small diameter c in the groove is set to 2.5 mm. The outer diameter C of the shaft portion 80d of the fixture 8d is 4m.
m, the annular groove 801 is formed on the outer periphery of the shaft portion 80d at a position closer to the tip end side by 2 mm from the lower end surface of the large-diameter holding portion 81, the groove width is 2 mm, the groove depth is 1 mm, and the diameter (the annular groove 8
The diameter D of the 01 part is 3 mm.

The insertion portion 83d of the fixture 8d is shown in FIGS.
As shown in FIG. 5, it is composed of four projecting portions (ribs) 832 having a cross-shaped cross section, and four escape portions 833 formed between the projecting portions 832. The protruding portion 832 has a width A of about 1 mm and two protruding portions 832 on a straight line.
Has a length B of 3.5 mm. The values of the locking hole 6d and the fixing tool 8d are not limited to the above values, but can be variously set in the range of the following relationship.

That is, the relationship between the size of the locking hole 6d and the insertion portion 83d is as follows: width A <groove width a, length B <groove large diameter b, outer diameter C> groove small diameter c, diameter ( The diameter of the annular groove 801) D <the small diameter c in the groove is set. The lower end holding plate 9 is a disk-shaped nylon plate having a thickness of 2 mm, an outer diameter of 15 mm, and an inner diameter of 3.
It has a hole 90 of 2 mm and a large number of substantially triangular pyramid-shaped protrusions 92 arranged on the one surface 91 side in the circumferential direction at predetermined intervals.

According to the element 1D of the fifth embodiment, when the pre-filter 3 mounted on the frame portion 5c is fixed with the main filter 2c housed in the housing space S of the resin frame 4c (see FIG. 7). First, the pre-filter 3 arranged in the positional relationship shown in FIG.
And the lower end side holding plate 9 are assembled. That is, the grip portion 82 of the fixture 8d is gripped, and the insertion portion 83d is inserted through the hole 30 from the one surface 31 side to the other surface 32 side of the pre-filter 3, so that the shaft portion 80d is positioned in the hole 30. The insertion portion 83d protrudes from the other surface 32 of the pre-filter 3. The insertion portion 83d is pushed into the center hole 90 of the lower end side holding plate 9 in a state where one end 91 side faces the other surface 32 side of the pre-filter 3, and the center hole 90 is
It is attached to the annular groove 801 of the shaft 80d (see FIG. 18).

At this time, the projections 92 (see FIG. 17) formed on the one end surface 91 of the lower end pressing plate 9 bite into the other surface 32 of the pre-filter 3 so as not to be displaced from each other. Next, the fixing tool 8d, to which the pre-filter 3 and the lower end side holding plate 9 are integrally attached, is inserted into the insertion portion 83d in the direction of the arrow shown in FIG. 18 in each of the locking holes of the frame portions 54d, 56d of the resin frame 4c. 6d and attached as shown in FIG.

Here, the insertion portion 83d of the fixture 8d inserted into each of the locking holes 6d has a cross-sectional shape of a cross, and the width of the four projections becomes narrower as it approaches the tip O. 832 and four escape portions 833 are formed so as to be structurally easily elastically deformed. For this reason, the insertion portion 83d of the fixing tool 8d is easily inserted into each locking hole 6d, and hardly comes off.

The element 1D of the fifth embodiment has substantially the same effect as that of the fourth embodiment. In addition, the projection 92 formed on the one end surface 91 of the holding plate 9 is provided on the other surface 32 of the pre-filter 3. The effect of preventing the bites from being displaced from each other is obtained. (Embodiment 6) Element 1E of Embodiment 6 shown in FIG.
Instead of using the fixing tool 8 in the element 1C of Example 4, a pre-filter 3e formed in advance by mixing heat fusion fibers or chemical fibers is moved from its surface 31e side to the other surface 32e side by a hot press or the like. An insertion portion 83e formed of a hollow protrusion having a size large enough to be thermoformed in a convex shape and integrated with the pre-filter 3e and insertable into the locking hole 6c.
Form as

According to the element 1E of the sixth embodiment, the number of parts can be reduced as compared with the configurations of the first to fifth embodiments.
This is advantageous in cost. (Embodiment 7) The air cleaner 1F of the embodiment 7 shown in FIG.
Are a case 10 constituting a housing, a lid 11 detachably attached to the case 10, an element 1 of the first embodiment, an element 1A of the second embodiment, and a third embodiment housed in the case 10. Element 1B, element 1C of Example 4, element 1D of Example 5, and Example 6
(Hereinafter, referred to as element 1 for explanation).

The case 10 is in the form of a bottomed container made of polypropylene reinforced with glass fiber or talc. The case 10 houses the element 1 in a detachable manner and forms a dusty space. A cylindrical air introduction portion (inlet) 101 for communicating the air to be filtered from the outside into the housing portion 100, and a cover for swingably engaging and holding the cover 11 with the outside. A joint 102 is formed. Case 1
A clamp member 103 is formed on an outer peripheral portion of the first member 103 so as to pivotally support one end 103a at a position spaced apart from the engaging portion 102 by a predetermined distance, and form a second hook portion 103b that swings around the one end 103a. Installed.

The lid 11 is a bottomed container made of polypropylene reinforced with glass fiber or talc. The cover 110 forms a clean side space, and the air after purification by filtering the element 1 is omitted. A cylindrical air outlet (outlet) 111 for supplying to an intake manifold fed to the engine side, and an engaging portion 102 of the case 10
, The hinge 12 is constituted by the engaging portion 102, and an engaging shaft 112 serving as a swing center is formed. The outer peripheral portion of the lid 11 is provided with the engaging shaft 11.
A hook protrusion 113 for locking the other hook portion 103b of the other end of the clamp member 103 of the case 10 is formed at a position separated from the hook 2 by a predetermined distance.

The case 1 in which the lid 11 is open
After the element 1 is accommodated in the accommodating portion 100, the lid 11 is closed around the hinge 12. This closed state is maintained by engaging the clamp member 103 of the case 10 with the hooking projection 113 of the lid 11,
The air containing dust that is used as the air cleaner 1F and flows from the air introduction portion (inlet) 101 into the housing portion 100 that forms the dusty space of the case 10 in this state is purified by the element 1 and the cover 11 is cleaned. After being led out to the accommodating part 110 forming the side space, it is supplied from the air lead-out part (outlet) 111 to the intake manifold fed to the engine side.

Therefore, according to the air cleaner 1F of the seventh embodiment, the housing portion 100 of the case 10 and the housing portion 110 of the lid 11 are provided with the element 1 of the first embodiment, the element 1A of the second embodiment, and the third embodiment. Element 1B of Example 4, Example 4
, The element 1D of the fifth embodiment, and the element 1E of the sixth embodiment. After use for a predetermined period, the element 1
1E is taken out and blow-cleaned, and the air filtering function is functioned. Then, it is stored again in the storage portion 100 of the case 10 and the storage portion 110 of the lid 11, and is reused. . These operations can be performed repeatedly.

[0051]

【effect】

(1) According to the element of the first aspect, the pre-filter made of a nonwoven fabric having a large porosity, which is arranged on the upstream side of the main filter housed in the resin frame, is formed on the tip side of the shaft portion of the locking projection. It can be fixed by a region sandwiched between the large-diameter portion of the tip and the one end surface of the partition frame portion.

For this reason, when the element is housed in an air cleaner and used, this pre-filter has a large porosity and is bulky, so that a relatively large amount of the space inside the air cleaner is used for air filtration. Therefore, the volume of the filter body can be set large, so that the amount of retained dust can be improved. Further, since the pre-filter has a large porosity and can form a thick ventilation flow path inside the pre-filter, the increase in air ventilation resistance is small, and when the main filter needs to be blow-cleaned, a resin frame is formed. The main filter can be easily blow-cleaned while being fixed without being removed, and the air filtering function of the main filter and the pre-filter can be repeatedly restored. (2) According to the element of the second aspect, the pre-filter made of a non-woven fabric having a large porosity arranged on the upstream side of the main filter housed in the resin frame has a large tip diameter portion formed on the locking projection. And it can be fixed by the area | region clamped by the annular member formed from the raw material which has a melting point higher than the melting point of the resin which comprises a resin-made frame, and one end surface of a partition frame part.

Therefore, the element of claim 2 acts as a thermal shield for the pre-filter because the melting point of the annular member is higher than the melting point of the locking projection, in addition to the effect of the element of claim 1. In the process of forming the large-diameter portion by thermally deforming the distal end portion of the locking projection, the pre-filter is not thermally damaged. (3) According to the element of claim 3, the pre-filter made of non-woven fabric having a large porosity, which is arranged on the upstream side of the main filter housed in the resin frame, has a bent front end holding portion formed on the locking projection. And the area sandwiched by the one end face of the partition frame portion.

For this reason, in the element of the third aspect, in addition to the effect of the element of the first aspect, since only a part between both ends of the locking projection can be heated and bent to form a bent-end holding portion. In addition, since the heating target region is separated from the tip bending pressing portion and one surface of the pre-filter, the application of thermal stress to the pre-filter can be reduced. In addition, since only a part of the locking projection needs to be bent, the structure is simple and the productivity is excellent. (4) According to the element of the fourth aspect, the pre-filter made of a non-woven fabric having a large porosity, which is arranged on the upstream side of the main filter housed in the resin frame, is provided with a locking hole at one end surface of the partition frame portion. The insertion portion can be fixed by the region held between the umbrella-shaped grip portion of the inserted stopper and one end surface of the frame portion.

For this reason, the element according to the fourth aspect, in addition to the effect of the element according to the first aspect, fixes the pre-filter using a detachable stopper, so that the step of thermally deforming is required. In addition, operations such as removing and fixing the pre-filter can be repeatedly performed as necessary. Accordingly, individual serviceability such as cleaning of only the pre-filter or only the main filter is improved, and separate replacement is also possible. (5) In the element according to the fourth aspect, the insertion portion of the stopper is formed with a wide portion that becomes wider on the way to the tip thereof, and a slit or hole formed at the center of the wide portion. Alternatively, by forming a plurality of ribs in the insertion portion, the width of which becomes narrower toward the tip, the air inside the locking hole smoothly escapes when the stopper is pressed into the locking hole. The trapped air acts as a repulsion spring, so that a large insertion load is not required when the stopper is pressed. (6) In the element according to the above (4), after the pre-filter is previously sandwiched between the large-diameter holding portion of the stopper of the element and the plate attached to the shaft portion, the insertion portion is connected to the partition frame. The pre-filter can be fixed to the resin frame by inserting the pre-filter into the locking hole on one end surface of the portion.

In such a configuration, the stopper and the pre-filter can be integrated before the pre-filter is fixed, and the fixing operation is easy. (7) Further, in the element according to the fourth aspect, a plurality of small protrusions may be formed on a surface of the ring member on a side abutting on the downstream side surface of the pre-filter. At this time, the plurality of small projections of the ring member bite into the other surface side of the pre-filter, and the ring member can be attached without causing positional displacement. (8) According to the element of the fifth aspect, a pre-filter made of a non-woven fabric having a large porosity, which is arranged on the upstream side of the main filter housed in the resin frame and formed by curing a part of the pre-filter. The pre-filter can be fixed by inserting the convex portion into the locking hole.

Therefore, the element of claim 5 can reduce the number of parts. (9) The locking hole of the resin frame of the element according to claim 4 or 5 extends in a direction perpendicular to the ridge line of the ridge of the main filter, and both ends of the frame-like portion are formed. When provided on the upstream end surface of the reinforcing ribs connected to the outer frame, the reinforcing ribs are joined to the resin frame at a position slightly closer to the center from the end of the plate-shaped pre-filter. Is maintained to some extent, and the joining of the pre-filter can be assured as a whole. (10) According to the air cleaner of (6), one of the elements according to (1), (2), (3), (4) or (5) is housed in the housing portion of the housing. , And used in a held state.

After use for a predetermined period, if necessary, the element is taken out of the housing portion of the housing and blow-cleaned, and the air filtering function is restored.
It is housed in the housing part of the housing and reused. This operation can be performed repeatedly.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an element of a first embodiment.

FIG. 2 is a cross-sectional view showing a state in which the pre-filter is fixed to one surface side of the pre-filter via a washer by a large-diameter portion formed on a locking projection that protrudes from one end surface of the partition frame in FIG.

FIG. 3 is a perspective view showing an element according to a second embodiment.

FIG. 4 is a cross-sectional view showing a state in which a pre-filter is fixed by a large-diameter portion formed on a locking projection protruding from one end surface of a partition frame in FIG. 3;

FIG. 5 is a perspective view showing an element of a third embodiment.

FIG. 6 is a cross-sectional view showing a state in which a pre-filter is fixed by a tip bending holding portion formed on a locking projection protruding from one end surface of the partition frame in FIG. 5;

FIG. 7 is a perspective view showing an element of a fourth embodiment.

8 is a cross-sectional view showing a state in which the pre-filter is fixed to a locking hole on one end surface of the partition frame in FIG. 7 by a large-diameter holding portion of a stopper having an insertion portion inserted therein.

9 is a perspective view of the stopper shown in FIG. 7 when viewed from the side of the large-diameter holding portion.

FIG. 10 is a perspective view of the stopper in FIG. 7 as viewed from the insertion portion side.

FIG. 11 is a cross-sectional view showing a modification of the locking hole on one end surface of the partition frame in FIG. 7;

FIG. 12 is a diagram showing a pre-filter sandwiched between a large-diameter holding portion of a stopper and a plate attached to a shaft in the element of the fifth embodiment. Sectional drawing which shows the state which fixes a pre-filter by inserting in a hole for use.

FIG. 13 is a partial cross-sectional view showing a stage before assembling a stopper, a prefilter, and a plate in the element of Embodiment 5.

14 is a perspective view of the stopper shown in FIG. 13 as viewed from an insertion portion side.

FIG. 15 is a sectional view taken along the line AA in FIG. 14;

FIG. 16 is a plan view showing a locking hole as viewed from one end surface side of the partition frame portion in FIG. 12;

FIG. 17 is a perspective view of the pre-filter in FIG. 13 viewed from a side facing the other surface of the pre-filter.

FIG. 18 is a perspective view showing a state in which a pre-filter is sandwiched between a large-diameter holding portion of a stopper and a plate attached to a shaft in the element of the fifth embodiment, and the insertion portion is engaged with one end surface of a partition frame portion. Sectional drawing which shows the state which made it face the hole for use.

FIG. 19 shows the element of Example 6, and shows a state where the pre-filter is fixed by inserting an insertion portion formed by partially deforming the pre-filter into a locking hole on one end surface of the partition frame portion. FIG.

FIG. 20 is a side view showing the air cleaner of the seventh embodiment.

[Explanation of symbols]

 1, 1A, 1B, 1C, 1D, 1E: Element 1F: Air cleaner

 ──────────────────────────────────────────────────続 き Continued on the front page (72) Inventor Hiroaki Fujii 1-1-1 Toyota-cho, Kariya-shi, Aichi Prefecture Inside Toyota Boshoku Corporation

Claims (6)

[Claims] 1. A foldable main filter, a prefilter made of a non-woven fabric having a high porosity disposed upstream of the main filter, and a foldable shape of the main filter is maintained and opposed to the prefilter. A resin frame provided on an end surface thereof with a locking projection protruding toward the upstream side for mounting the pre-filter, wherein the locking projection includes a shaft portion penetrating the pre-filter, and a shaft. An element formed on the distal end side of the portion and having a large distal end portion that is located upstream of the prefilter and fixes the prefilter. 2. An outer diameter which is formed of a material having a melting point higher than the melting point of the resin constituting the resin frame, is larger than the outer diameter of the large-diameter tip end of the locking projection, and the outer diameter of the shaft of the locking projection. 2. The element according to claim 1, wherein an annular member having a larger inner diameter is arranged between the upstream side surface of the pre-filter and the larger tip diameter portion. 3. A foldable main filter, a pre-filter made of a non-woven fabric having a high porosity disposed upstream of the main filter, and a fold-fold shape of the main filter is maintained and opposed to the pre-filter. A resin frame provided on an end surface thereof with a locking projection protruding toward the upstream side for mounting the pre-filter, wherein the locking projection includes a shaft portion penetrating the pre-filter, and a shaft. An element formed on the distal end side of the portion and having a distal bending holding portion that is located upstream of the prefilter and fixes the prefilter. 4. A foldable main filter, a prefilter made of a non-woven fabric having a high porosity disposed upstream of the main filter, and opposing the prefilter while maintaining the fold shape of the main filter. A resin frame having a locking hole for fixing the pre-filter on the end face, an insertion portion removably inserted into the locking hole of the resin frame via the pre-filter, and the other end of the insertion portion; And a stopper having an umbrella-shaped grip for fixing the pre-filter and located on the upstream side of the pre-filter. 5. A fold-folded main filter, a pre-filter made of a non-woven fabric having a high porosity and arranged upstream of the main filter, and a fold-fold shape of the main filter is maintained and opposed to the pre-filter. The end face is made of a resin frame having a locking hole for mounting the pre-filter, and the pre-filter has a coupling convex portion in which a portion facing the locking hole of the resin frame is hardened in a convex shape. An element, wherein the coupling protrusion is removably inserted into the locking hole to fix the pre-filter to a resin frame. 6. A housing comprising a case main body forming a housing portion opened at one end side, a cap mounted on the case main body so as to open and close the opening of the housing portion, and the housing portion of the housing. An air cleaner comprising: the element according to claim 1, claim 2, claim 3, claim 4, or claim 5, which is housed and held in the air cleaner.