JPH11221412A - Filter and its production - Google Patents
Filter and its productionInfo
- Publication number
- JPH11221412A JPH11221412A JP2629498A JP2629498A JPH11221412A JP H11221412 A JPH11221412 A JP H11221412A JP 2629498 A JP2629498 A JP 2629498A JP 2629498 A JP2629498 A JP 2629498A JP H11221412 A JPH11221412 A JP H11221412A
- Authority
- JP
- Japan
- Prior art keywords
- sheet
- filter
- base material
- upstream
- downstream
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、塵埃の捕集性能に
加え、悪臭や有害なガス等をも吸着し得るフィルタ及び
その製造方法に関する。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filter capable of adsorbing foul odors and harmful gases in addition to dust collecting performance, and a method of manufacturing the same.
【０００２】[0002]
【従来の技術】近年、例えば一般家庭やビルおよび自動
車の室内等を浄化する空調関連のフィルタに対して、塵
埃の捕集性能に加え、悪臭や有害なガス等（以下、悪臭
等と呼ぶ）を脱臭，吸着する性能も必要とされてきてい
る。そこで、悪臭等を吸着する活性炭等の粒状の吸着剤
を、ネットや不織布のような基材に結着剤を介して接着
させたフィルタが、従来から提案されている。2. Description of the Related Art In recent years, for example, air-conditioning-related filters that purify general households, buildings, and automobile interiors, in addition to dust collection performance, have a bad odor or harmful gas (hereinafter, referred to as bad odor). The ability to deodorize and adsorb is also required. Therefore, a filter in which a granular adsorbent such as activated carbon that adsorbs an odor or the like is bonded to a base material such as a net or a nonwoven fabric via a binder has been conventionally proposed.
【０００３】[0003]
【発明が解決しようとする課題】ところで、上記のよう
に吸着剤を固着させた基材の上流側表面や下流側表面
に、不織布等からなる薄肉状のシートをそれぞれ重合さ
せると、フィルタ自体の強度が向上するとともに、吸着
剤の脱落を低減する効果を期待できる。By the way, when a thin sheet made of a non-woven fabric or the like is polymerized on the upstream surface or the downstream surface of the base material to which the adsorbent is fixed as described above, the filter itself is formed. The effect of improving the strength and reducing the falling off of the adsorbent can be expected.
【０００４】しかしながら、この場合でも、フィルタ周
縁部のフィルタ端面では基材の端面が直接外部に露出す
るため、外部からの衝撃やこすれ等に起因して、フィル
タ端面から吸着剤が脱落してしまう。このため、フィル
タ端面を何らかのシール部材で塞ぐ必要があり、シール
部材の追加により部品点数が増加するとともに作業工数
が増加し、その構造が複雑化するとともに製造コストが
上昇してしまう。However, even in this case, since the end face of the base material is directly exposed to the outside at the filter end face at the periphery of the filter, the adsorbent falls off the end face of the filter due to an external impact or rubbing. . For this reason, it is necessary to close the filter end surface with some kind of sealing member, and the number of parts increases and the number of man-hours increases due to the addition of the sealing member, which complicates the structure and increases the manufacturing cost.
【０００５】本発明は、フィルタ端面からの吸着剤の脱
落を有効に阻止し得る新規なフィルタ及びその製造方法
を提供することを目的としている。An object of the present invention is to provide a novel filter which can effectively prevent the adsorbent from falling off from the end face of the filter, and a method for manufacturing the same.
【０００６】[0006]
【課題を解決するための手段】そこで、本発明では、吸
着材を保持する基材と上流側，下流側シートとを第１の
熱プレス処理により融着する構成とし、これら基材又は
上流側，下流側シートの熱可塑性を利用して、基材の端
面が露出するフィルタ端面の近傍に、第２の熱プレス処
理を行うことによって、別途シール部材等を用いること
のない簡素な構造で、フィルタ端面を実質的に塞いで、
フィルタ端面からの吸着剤の脱落を有効に阻止するよう
にした。Therefore, in the present invention, the base material holding the adsorbent and the upstream and downstream sheets are fused by a first hot pressing process, and the base material or the upstream side sheet is fused. By using the thermoplastic property of the downstream sheet and performing a second hot pressing process in the vicinity of the filter end surface where the end surface of the base material is exposed, a simple structure without using a separate sealing member or the like is achieved. By substantially blocking the filter end face,
The adsorbent is effectively prevented from falling off from the end face of the filter.
【０００７】すなわち、請求項１の発明は、内部に粒状
の吸着剤が厚さ方向に分散した状態で保持された熱可塑
性を有する基材の上流側表面並びに下流側表面に、それ
ぞれ上流側シート並びに下流側シートが第１の熱プレス
処理によって予め融着されたフィルタであって、上記基
材の端面が露出するフィルタ端面の近傍に、上記基材を
実質的に押し潰すように、第２の熱プレス処理がなされ
ていることを特徴としている。That is, according to the first aspect of the present invention, the upstream sheet and the downstream surface of the thermoplastic base material in which the granular adsorbent is dispersed in the thickness direction are provided on the upstream sheet and the downstream sheet, respectively. And a second sheet in which the downstream sheet is pre-fused by the first hot press treatment, and the second sheet is substantially crushed near the filter end face where the end face of the base material is exposed. Characterized by being subjected to a hot press treatment.
【０００８】また、請求項２の発明は、内部に粒状の吸
着剤が厚さ方向に分散した状態で保持された熱可塑性を
有する基材の上流側表面並びに下流側表面に、それぞれ
上流側シート並びに下流側シートを第１の熱プレス処理
により予め融着したフィルタの製造方法であって、上記
基材の端面が露出するフィルタ端面の近傍に、上記基材
を実質的に押し潰すように、第２の熱プレス処理を行う
ことを特徴としている。[0008] Further, the invention according to claim 2 is characterized in that the upstream side sheet and the downstream side surface of the thermoplastic base material in which the particulate adsorbent is dispersed in the thickness direction are respectively provided on the upstream side sheet. And a method for manufacturing a filter in which the downstream sheet is pre-fused by a first hot press treatment, wherein the base material is substantially crushed in the vicinity of the filter end surface where the end surface of the base material is exposed, It is characterized in that a second heat press process is performed.
【０００９】請求項３の発明は、内部に粒状の吸着剤が
厚さ方向に分散した状態で保持された基材の上流側表面
並びに下流側表面に、熱可塑性を有する上流側シート並
びに下流側シートがそれぞれ第１の熱プレス処理によっ
て予め融着されたフィルタであって、上記上流側シート
または下流側シートの一方のシートが、他方のシート並
びに上記基材の端面よりも延在しており、この延在部分
が、上記端面を覆うように、他方のシートの表面に第２
の熱プレス処理によって融着されていることを特徴とし
ている。According to a third aspect of the present invention, there is provided an upstream sheet and a downstream sheet having thermoplasticity on an upstream surface and a downstream surface of a base material in which a particulate adsorbent is dispersed in a thickness direction. Each of the sheets is a filter pre-fused by a first hot pressing process, wherein one of the upstream sheet and the downstream sheet extends beyond the other sheet and the end face of the base material. , So that the extended portion covers the end face on the surface of the other sheet.
Is characterized by being fused by hot pressing.
【００１０】請求項４の発明は、内部に粒状の吸着剤が
厚さ方向に分散した状態で保持された基材の上流側表面
並びに下流側表面に、熱可塑性を有する上流側シート並
びに下流側シートをそれぞれ第１の熱プレス処理によっ
て予め融着したフィルタの製造方法であって、上記上流
側シートまたは下流側シートの一方のシートが、他方の
シート並びに上記基材の端面よりも延在しており、この
延在部分が上記端面を覆うように、上記延在部分を他方
のシートの表面に第２の熱プレス処理により融着したこ
とを特徴としている。According to a fourth aspect of the present invention, there is provided an upstream sheet and a downstream sheet having thermoplasticity on an upstream surface and a downstream surface of a base material in which a particulate adsorbent is dispersed in a thickness direction. A method for manufacturing a filter, in which sheets are each pre-fused by a first hot pressing process, wherein one of the upstream sheet and the downstream sheet extends from the other sheet and the end face of the base material. The extended portion is fused to the surface of the other sheet by a second hot pressing process so that the extended portion covers the end face.
【００１１】更に、請求項１又は３に係る請求項５の発
明は、フィルタ長手方向にプリーツ加工がなされ、か
つ、フィルタ幅方向端面に、それぞれ形状保持プレート
が接着されているとともに、フィルタ長手方向端面に、
上記第２の熱プレス処理がなされていることを特徴とし
ている。Further, according to the invention of claim 1 or 3, the pleating process is performed in the longitudinal direction of the filter, and the shape holding plates are bonded to the end faces in the filter width direction, respectively. On the end face,
The second heat press processing is performed.
【００１２】本発明に係わる基材や上流側，下流側シー
トに用いられる繊維としては、例えば、ポリクラール繊
維、ビニリデン繊維、ポリ塩化ビニル繊維、ポリエステ
ル繊維、ポリアミド繊維、アクリル繊維、ポリビニルア
ルコール繊維、ポリプロピレン織維、ポリエチレン繊
維、或いは複数の樹脂成分からなる複合繊維などの合成
繊維、この合成繊維に芳香剤，抗菌剤，抗かび剤等を混
入した繊維、レーヨン，ビスコース等の再生繊維、アセ
テート等の半合成繊維、炭素繊維，ガラス繊維等の無機
繊維、等が挙げられる。これらの中でも、ポリクラール
繊維、ビニリデン繊維、ポリ塩化ビニル繊維は、難燃性
に優れており、またポリエステル繊維は、耐薬品性、耐
熱性に優れているため、好適に使用できる。なお、繊維
の平均繊維径は、圧力損失や強度を考慮して２０〜３５
μｍが好ましい。The fibers used in the base material and the upstream and downstream sheets according to the present invention include, for example, polychloral fiber, vinylidene fiber, polyvinyl chloride fiber, polyester fiber, polyamide fiber, acrylic fiber, polyvinyl alcohol fiber, and polypropylene. Synthetic fibers such as textiles, polyethylene fibers, or composite fibers composed of multiple resin components, fibers mixed with aromatics, antibacterial agents, and antifungal agents, regenerated fibers such as rayon and viscose, and acetate. And inorganic fibers such as carbon fibers and glass fibers. Among these, polychloral fiber, vinylidene fiber, and polyvinyl chloride fiber are excellent in flame retardancy, and polyester fiber is excellent in chemical resistance and heat resistance, and thus can be suitably used. The average fiber diameter of the fiber is 20 to 35 in consideration of pressure loss and strength.
μm is preferred.
【００１３】また、上記基材や上流側，下流側シートと
して利用可能な不織布は、繊維ウェブを全面または部分
的に接合処理して得ることができ、具体的には、シート
状に集積した繊維をバインダ等で化学的に結合させるラ
テックスボンド法、あるいは熱により繊維同士を圧着さ
せるサーマルボンド法、または機械的に繊維同士を絡ま
せるニードルパンチ法や水流絡合法等の方法により得る
ことができる。また、繊維をシート状に集積する方法と
しては、繊維の元の原料自体から直に繊維を紡糸するス
パンボンド法，メルトブロー法，フラッシュスピニング
法、または繊維を紡績に似たカードで機械的に並べてつ
くるカード法、あるいは紙を漉す方法と同様にして漉し
上げる湿式法等が挙げられる。The non-woven fabric usable as the base material and the upstream and downstream sheets can be obtained by joining a fiber web entirely or partially. Can be obtained by a latex bonding method in which the fibers are chemically bonded with a binder or the like, a thermal bonding method in which the fibers are press-bonded by heat, a needle punch method in which the fibers are mechanically entangled, or a hydroentanglement method. In addition, as a method of accumulating the fibers in a sheet shape, a spun bond method, a melt blow method, a flash spinning method in which the fibers are directly spun from the original raw material of the fibers, or a method in which the fibers are mechanically arranged with a card similar to spinning. A carding method and a wet method in which the paper is strained in the same manner as in the method of straining the paper may be used.
【００１４】本発明に用いられる上流側，下流側シート
としては、粒状の吸着剤のこぼれを極力なくすため、吸
着剤よりも目の小さい空隙を有し、かつ、圧力損失低減
の観点から厚さの薄いものが好ましく、具体的には目付
け量が１０〜１００ｇｒ／ｍ2で、厚さが０．１〜１．
０ｍｍ程度が好適である。なお、吸着剤の粒径よりも目
の粗い不織布を数枚重ねて目を細かくしてもよい。The upstream and downstream sheets used in the present invention have voids smaller than the adsorbent in order to minimize spillage of the particulate adsorbent, and have a thickness from the viewpoint of reducing pressure loss. Is preferable. Specifically, the basis weight is 10 to 100 gr / m 2 , and the thickness is 0.1 to 1.
About 0 mm is preferable. It should be noted that several nonwoven fabrics having a coarser particle size than the particle size of the adsorbent may be overlapped to make the fineness.
【００１５】なお、上流側，下流側シートは、互いに同
じものを使用することもできるが、上流側シートが下流
側シートよりも目が粗くなるようにすれば、上流側から
下流側へ向けて目が密となり、流入する塵埃が上流側シ
ートで目詰まりし難くなってフィルタの寿命が向上する
とともに、下流側シートで小さな塵埃を確実に捕捉し得
るようになり、濾過性能が向上する。The same sheet can be used for the upstream sheet and the downstream sheet. However, if the upstream sheet is made coarser than the downstream sheet, the upstream sheet and the downstream sheet are moved from the upstream to the downstream. The eyes become denser, and the inflowing dust is less likely to be clogged by the upstream sheet, so that the life of the filter is improved. In addition, small dust can be reliably captured by the downstream sheet, and the filtering performance is improved.
【００１６】中間層となる基材は、粒状吸着剤を厚さ方
向に分散して立体的に配置し得るように、吸着剤の粒子
の大きさよりもやや目が粗く、適度な厚さをもった低密
度な不織布等が好ましく、例えば目付け量が２０〜１０
０ｇ／ｍ2で厚さが０．５〜１０ｍｍ程度が好適であ
る。ここで、散布された吸着剤が下流側に向かうにした
がって密となるように、粒状吸着剤の大きさと基材の目
の大きさとを調整すれば、フィルタの耐久性や濾過性能
が更に向上する。The substrate serving as the intermediate layer has a coarser grain than the size of the particles of the adsorbent and has an appropriate thickness so that the particulate adsorbent can be dispersed and arranged three-dimensionally in the thickness direction. Low-density nonwoven fabric or the like is preferable.
It is preferable that the thickness is about 0.5 to 10 mm at 0 g / m 2 . Here, if the size of the particulate adsorbent and the size of the base material are adjusted so that the dispersed adsorbent becomes denser toward the downstream side, the durability and filtration performance of the filter are further improved. .
【００１７】上記悪臭等を吸着する粒状の吸着剤として
は、例えば、鉄、マンガン、銅、アルミニウム、マグネ
シウム、亜鉛、ニッケル、コバルト、白金、パラジウ
ム、金、ルテニウム、ロジウムなどの金属単体、これら
の金属酸化物または金属塩化物、ゼオライト、カオリ
ン、セピオライト、シリカゲル、活性炭等を単独で、或
いは混合して使用することができる。吸着剤の平均大き
さは、あまり大きいとフィルタが厚くなってプリーツ加
工が困難となり、あまり小さいと吸着性能が低下するた
め、１０〜２００メッシュ（０．１５〜１．７ｍｍ）程
度が好ましい。Examples of the granular adsorbent for adsorbing the above-mentioned odors include simple metals such as iron, manganese, copper, aluminum, magnesium, zinc, nickel, cobalt, platinum, palladium, gold, ruthenium and rhodium. Metal oxides or metal chlorides, zeolite, kaolin, sepiolite, silica gel, activated carbon and the like can be used alone or as a mixture. If the average size of the adsorbent is too large, the filter becomes thick and pleating becomes difficult, and if the average size is too small, the adsorbing performance deteriorates. Therefore, the average size of the adsorbent is preferably about 10 to 200 mesh (0.15 to 1.7 mm).
【００１８】このような吸着剤は、基材内部で厚さ方向
に三次元的に分散した状態で保持される。吸着剤の密度
は、あまり小さいと吸着機能が低下し、あまり大きいと
通気性を阻害するため、例えば不織布基材に対して５０
〜５００ｇ／ｍ2、特に２００〜３５０ｇ／ｍ2程度が好
適である。Such an adsorbent is held in a state dispersed three-dimensionally in the thickness direction inside the base material. If the density of the adsorbent is too small, the adsorption function is reduced, and if it is too large, the air permeability is impaired.
５００500 g / m 2 , particularly preferably 200-350 g / m 2 .
【００１９】なお、吸着剤とともにホットメルト系の結
着剤を用いると、吸着剤がより確実に基材内に融着され
るとともに、基材と上流側，下流側シートとがより確実
に融着される。このようなホットメルト結着剤として、
例えばポリエステル系、ポリアミド系、ウレタン系、ポ
リオレフィン系、エチレン、塩化ビニル（ＥＶＡ）系の
ものを使用できる。これらの中でも塩化ビニル系樹脂は
難燃性に優れているため、特に好適である。When a hot-melt binder is used together with the adsorbent, the adsorbent is more reliably fused into the base material, and the base material and the upstream and downstream sheets are more reliably fused. Be worn. As such a hot melt binder,
For example, polyesters, polyamides, urethanes, polyolefins, ethylene, and vinyl chloride (EVA) can be used. Of these, vinyl chloride resins are particularly suitable because of their excellent flame retardancy.
【００２０】また、フィルタに抗菌性や抗かび性を付与
するために、例えば基材や上流側，下流側シートの表面
に予め抗菌層や抗かび層を予め形成しても良い。また、
フィルタの表面に帯電性を付与しておくと、タバコの煙
や自動車の排気ガスのような通常捕獲し得ない小さな粉
塵をも捕獲することができ、捕集性能が更に向上する。In order to impart antibacterial and antifungal properties to the filter, for example, an antibacterial layer and an antifungal layer may be formed in advance on the surface of the base material and the upstream and downstream sheets. Also,
When the surface of the filter is charged, small dust that cannot be normally trapped, such as cigarette smoke and automobile exhaust gas, can be trapped, further improving the trapping performance.
【００２１】[0021]
【発明の効果】本発明によれば、基材の内部に粒状の吸
着材が厚さ方向に分散して保持され、かつ、基材の上流
側表面並びに下流側表面に上流側，下流側シートが融着
されたフィルタ及びその製造方法において、別途シール
部材等を用いることなく、基材の端面が露出するフィル
タ端面を実質的に塞いで、フィルタ端面から吸着剤が脱
落することを有効に阻止できる。According to the present invention, the granular adsorbent is dispersed and held in the thickness direction inside the base material, and the upstream and downstream sheets are provided on the upstream surface and the downstream surface of the base material. In the filter and the manufacturing method thereof, the end face of the base material is substantially closed without using a sealing member or the like, and the adsorbent is effectively prevented from dropping from the filter end face. it can.
【００２２】更に、請求項５の発明によれば、上記の効
果に加え、プリーツ加工により折り曲げられたフィルタ
幅方向端面に形状保持プレートが接着されているから、
幅方向端面からの吸着剤の脱落が防止されることに加
え、フィルタ自体の強度が更に向上する。この結果、フ
ィルタ単体でその形状を保持できるようになり、製品に
ケーシング等を付加する必要がないから、製品単価を低
減できる。Further, according to the fifth aspect of the present invention, in addition to the above effects, the shape holding plate is bonded to the end face in the filter width direction bent by pleating.
In addition to preventing the adsorbent from falling off from the width direction end face, the strength of the filter itself is further improved. As a result, the shape of the filter can be maintained by itself, and it is not necessary to add a casing or the like to the product, so that the unit price of the product can be reduced.
【００２３】[0023]
【発明の実施の形態】先ず、図１，２を参照して、本発
明に係わるフィルタ及びその製造方法の一例を製造順に
説明する。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, referring to FIGS. 1 and 2, an example of a filter and a method of manufacturing the same according to the present invention will be described in the order of manufacture.
【００２４】先ず、第１ローラ１１から熱可塑性不織布
からなる下流側シート４が供給され、この下流側シート
４上に第２ローラ１２から一定速度で供給される基材２
が載置される。基材２は、比較的目の粗い熱可塑性不織
布が用いられる。一方、第２ローラ１２の下流側に配置
されたホッパー１３内には、活性炭等の粒状の吸着剤５
とホットメルト系の結着剤６とが所定の割合で充填され
ており、このホッパー１３の開口する下端部より、粒状
吸着剤５とホットメルト結着剤６とが基材２上に散布さ
れる。First, a downstream sheet 4 made of a thermoplastic nonwoven fabric is supplied from a first roller 11, and a base material 2 supplied from a second roller 12 onto the downstream sheet 4 at a constant speed.
Is placed. The base material 2 is made of a relatively non-woven thermoplastic nonwoven fabric. On the other hand, inside the hopper 13 arranged on the downstream side of the second roller 12, a granular adsorbent 5 such as activated carbon is placed.
And the hot-melt binder 6 are filled in a predetermined ratio, and the granular adsorbent 5 and the hot-melt binder 6 are sprayed on the base material 2 from the lower end of the hopper 13 opening. You.
【００２５】次いで、基材２の上流側の表面に、第３ロ
ーラ１４から一定速度で供給される上流側シート３が載
置される。この上流側シート３は、濾過性能を向上する
目的で、下流側シート２より目の荒い熱可塑性不織布が
用いられる。この後、加熱プレス機１５によって、上流
側，下流側シート３，４が加熱されながら厚さ方向に加
圧（第１の熱プレス処理）される。これにより、基材２
やホットメルト結着剤６等が溶融し、吸着剤５が基材２
の繊維２ａに融着されるとともに、上流側，下流側シー
ト３，４と基材２とが融着される。次いで、加熱プレス
機１５から供給されたフィルタ本体１は、帯電機１６に
よって適宜に帯電性を付与された後、帯電機１６の後方
に配置された第４ローラ１７によって回収される。Next, the upstream sheet 3 supplied at a constant speed from the third roller 14 is placed on the upstream surface of the substrate 2. For the purpose of improving the filtration performance, the upstream sheet 3 is made of a thermoplastic nonwoven fabric which is coarser than the downstream sheet 2. After that, the heating press machine 15 presses the upstream and downstream sheets 3 and 4 in the thickness direction while heating (first hot pressing). Thereby, the base material 2
And the hot melt binder 6 are melted, and the adsorbent 5 is
And the upstream and downstream sheets 3 and 4 and the base material 2 are fused together. Next, the filter body 1 supplied from the heating press machine 15 is appropriately charged by the charging machine 16 and then collected by the fourth roller 17 disposed behind the charging machine 16.
【００２６】このようにして得られる帯状のフィルタ本
体１においては、図２に示すように、粒状吸着剤５が基
材２内部の繊維２ａ間に絡まるように融着し、厚さ方向
に適宜に分散した三次元的な配列状態で保持されるた
め、吸着性及び通気性に優れたものとなっている。In the band-shaped filter body 1 thus obtained, as shown in FIG. 2, the particulate adsorbent 5 is fused so as to be entangled between the fibers 2a inside the base material 2, and is appropriately moved in the thickness direction. Since it is held in a three-dimensional array state dispersed in the air, it has excellent adsorbability and air permeability.
【００２７】また、比較的目が粗く厚肉な基材２が上流
側，下流側シート３，４間に挟まれた積層構造となって
いるため、これら上流側，下流側シート３，４によっ
て、基材２の上流側，下流側表面が製造中や使用中の摩
擦から守られるとともに、適度な強度が与えられて、後
述する折り加工も行い易くなる。加えて、上流側シート
３と下流側シート４とは粒状吸着剤５よりも小さい空隙
を有し、つまり比較的薄肉で目が細かいため、製造時や
使用中に吸着剤５が基材２の上流側，下流側表面から脱
落することはない。Since the relatively coarse and thick base material 2 has a laminated structure sandwiched between the upstream and downstream sheets 3 and 4, the upstream and downstream sheets 3 and 4 In addition, the upstream and downstream surfaces of the base material 2 are protected from friction during manufacturing and use, and a moderate strength is given, so that the later-described folding process can be easily performed. In addition, since the upstream sheet 3 and the downstream sheet 4 have voids smaller than the granular adsorbent 5, that is, they are relatively thin and fine, so that the adsorbent 5 It does not fall off the upstream and downstream surfaces.
【００２８】更に、一度の熱プレス処理によって、吸着
剤５が基材２の繊維２ａに融着して分散，保持されると
ともに、上流側，下流側シート３，４と基材２とが融着
されるから、別途接着剤等を用いて上流側，下流側シー
ト３，４と基材２とを接着する必要がなく、製造工程が
著しく簡素化される。Further, the adsorbent 5 is fused and dispersed and held by the fiber 2a of the base material 2 by one heat press treatment, and the upstream and downstream sheets 3 and 4 and the base material 2 are fused. Since it is attached, there is no need to separately bond the upstream and downstream sheets 3, 4 and the base material 2 using an adhesive or the like, and the manufacturing process is significantly simplified.
【００２９】なお、上流側，下流側シート３，４や基材
２の表面に、予め抗菌層や抗かび層を形成したり、ある
いは吸着剤５と一緒に抗菌剤や抗かび剤を散布すること
によって、フィルタに抗菌性や抗かび性を付与すること
も可能である。An antibacterial layer or an antifungal layer is previously formed on the surfaces of the upstream and downstream sheets 3 and 4 and the substrate 2, or an antibacterial agent and an antifungal agent are sprayed together with the adsorbent 5. Thereby, it is also possible to impart antibacterial property and antifungal property to the filter.
【００３０】図３，４は、本発明の第１実施例に係わる
フィルタを示している。製造行程順に説明すると、先
ず、上記のように製造されたフィルタ本体１を、図外の
周知のレシプロ織り機を用いて長手方向に折り畳み加
工、いわゆるプリーツ加工し、次いで、所定の織り数毎
に裁断する。この状態のフィルタ本体１は、切断面とな
った長手方向端面２０並びに幅方向端面２２で、基材２
の端面が外部に露出し、内部に保持されている吸着剤５
が脱落し易い状態にある。FIGS. 3 and 4 show a filter according to the first embodiment of the present invention. Explaining in the order of the manufacturing process, first, the filter main body 1 manufactured as described above is folded in the longitudinal direction using a well-known reciprocating weaving machine (not shown), so-called pleating, and then, at every predetermined number of weaves. To cut. In this state, the filter body 1 has a base material 2 formed by the longitudinal end face 20 and the width end face 22 that have been cut.
Adsorbent 5 whose end face is exposed to the outside and held inside
Are in a state of being easily dropped.
【００３１】そこで、本実施例では、長手方向端面２０
近傍の上流側，下流側シート３，４に対し、加熱プレス
機２４を用いて熱プレス処理（第２の熱プレス処理）が
施されている。これにより、長手方向端面２０の近傍で
は、ホットメルト結着剤６や基材２等が再び溶融し、基
材２が厚さ方向に実質的に押し潰された状態で再度融着
される。この結果、長手方向端面２０が実質的に塞がれ
た状態となり、長手方向端面２０からの吸着剤５の脱落
が確実に防止される。Therefore, in this embodiment, the longitudinal end face 20
The adjacent upstream and downstream sheets 3 and 4 are subjected to hot press processing (second hot press processing) using a heating press machine 24. Thus, in the vicinity of the longitudinal end face 20, the hot melt binder 6, the substrate 2, and the like are melted again, and the substrate 2 is fused again in a state of being substantially crushed in the thickness direction. As a result, the longitudinal end face 20 is substantially closed, so that the adsorbent 5 from the longitudinal end face 20 is reliably prevented from falling off.
【００３２】なお、加熱プレス機２４によるプレス荷重
は、フィルタ内部のホットメルト結着剤６や基材２等が
十分溶融した時点で解放して問題ないが、フィルタ本体
１が厚い場合等、フィルタ本体１の反発力が強い場合に
は、熱プレス後にプレス荷重を維持したままの状態で、
長手方向端面２０の近傍を冷却固化させれば良い。The pressing load from the heating press 24 can be released when the hot-melt binder 6, the base material 2 and the like inside the filter are sufficiently melted. When the repulsive force of the main body 1 is strong, with the press load maintained after the hot pressing,
The vicinity of the longitudinal end surface 20 may be cooled and solidified.
【００３３】一方、幅方向端面２２に対しては、それぞ
れ矩形の形状保持シート２６が幅方向端面２２を完全に
覆うように融着されている。この形状保持シート２６
は、例えば比較的硬く薄肉な不織布を用いることがで
き、その接合面には、熱可塑性を有する接着剤層が予め
形成されている。これら形状保持シート２６により、幅
方向端面２２からの吸着剤５の脱落が確実に防止される
とともに、フィルタ本体１が長手方向に変形することが
抑制され、フィルタ自体の剛性が向上する。On the other hand, a rectangular shape holding sheet 26 is fused to the width direction end face 22 so as to completely cover the width direction end face 22. This shape holding sheet 26
For example, a relatively hard and thin nonwoven fabric can be used, and a thermoplastic adhesive layer is previously formed on the joint surface. The shape maintaining sheet 26 reliably prevents the adsorbent 5 from dropping off from the width direction end face 22, suppresses the filter body 1 from being deformed in the longitudinal direction, and improves the rigidity of the filter itself.
【００３４】このようにして製造されたフィルタは、内
部の吸着剤５が脱落することはなく、かつ、単体でも十
分に形状を保持し得る強度を持っているから、別途ケー
シング等で保持する必要がなく、製品コストを低く抑え
ることが可能である。The filter manufactured in this manner has a strength such that the adsorbent 5 therein does not fall off and has a sufficient strength to maintain its shape even by itself, so it is necessary to hold the filter separately in a casing or the like. Therefore, it is possible to keep product costs low.
【００３５】図５，６は、本発明の第２実施例に係わる
フィルタを示し、上記第１実施例と同じ部分には同一参
照符号を付している。先ず、第１実施例と同様、フィル
タ本体１を長手方向にプリーツ加工し、かつ、所定の織
り数毎に裁断する。FIGS. 5 and 6 show a filter according to a second embodiment of the present invention. The same parts as those in the first embodiment are denoted by the same reference numerals. First, as in the first embodiment, the filter main body 1 is pleated in the longitudinal direction and cut every predetermined number of weaves.
【００３６】そして、この実施例では、図５（ａ）に示
すように、熱可塑性不織布からなる上流側，下流側シー
ト３，４の一方のシート（この実施例では下流側シート
４）を、他方の上流側シート３並びに基材２の長手方向
端面２８よりも延在させている。具体的には、下流側シ
ート４のみを残して上流側シート３及び基材２の一部３
０を切除しておく。そして図５（ｂ）に示すように、下
流側シート４の延在部分３２を基材２及び上流側シート
３の端面２８を覆うように上流側シート３の表面に重ね
た上で、適当な加熱プレス機３４を用いて厚さ方向に熱
プレス処理（第２の熱プレス処理）を行う。このときの
加熱温度は、少なくとも下流側シート４の融点よりも高
く設定されている。この結果、上流側シート３と下流側
シート４とが融着して、長手方向端面２８が閉塞され、
長手方向端面２８からの吸着剤５の脱落が確実に防止さ
れる。一方、幅方向端面２２に対しては、上記第１実施
例と同様、矩形の形状保持シート２６がそれぞれ融着さ
れる。In this embodiment, as shown in FIG. 5 (a), one of the upstream and downstream sheets 3 and 4 (downstream sheet 4 in this embodiment) made of a thermoplastic nonwoven fabric is used. The other upstream sheet 3 and the base material 2 extend beyond the longitudinal end surface 28. Specifically, the upstream sheet 3 and a part 3 of the base material 2 are left, leaving only the downstream sheet 4.
Remove 0. Then, as shown in FIG. 5B, the extending portion 32 of the downstream sheet 4 is overlapped on the surface of the upstream sheet 3 so as to cover the base material 2 and the end surface 28 of the upstream sheet 3, and A hot press process (second hot press process) is performed in the thickness direction using the heating press machine 34. The heating temperature at this time is set at least higher than the melting point of the downstream sheet 4. As a result, the upstream sheet 3 and the downstream sheet 4 are fused and the longitudinal end face 28 is closed,
The falling off of the adsorbent 5 from the longitudinal end face 28 is reliably prevented. On the other hand, rectangular shape holding sheets 26 are respectively fused to the width direction end surfaces 22 as in the first embodiment.
【００３７】このような第２実施例においても、上記第
１実施例と同様、基材２内部に保持された吸着剤５の脱
落が確実に阻止され、かつ、フィルタ単体で十分に形状
を保持し得る強度を有するため、別途ケーシング等の必
要がなく、製品コストを低く抑えることが可能である。In the second embodiment as well, like the first embodiment, the adsorbent 5 held inside the base material 2 is reliably prevented from falling off, and the shape of the filter alone is sufficiently maintained. Since it has sufficient strength, there is no need for a separate casing or the like, so that product cost can be reduced.
【００３８】なお、本発明は上記実施例に限定されるも
のではなく、例えば上記第２の加熱処理では、上記の加
熱プレス機２４，３４を用いる方法に代えて、超音波溶
着法等を用いることもできる。また、基材２や上流側，
下流側シート３，４は、上記の不織布に限定されるもの
ではなく、例えば熱可塑性を有する樹脂ネット等を基材
として使用することもできる。The present invention is not limited to the above embodiment. For example, in the second heat treatment, an ultrasonic welding method or the like is used in place of the method using the heating press machines 24 and 34 described above. You can also. In addition, the base material 2 and the upstream side,
The downstream sheets 3 and 4 are not limited to the nonwoven fabric described above. For example, a thermoplastic resin net or the like can be used as a base material.
【図１】本発明に係わるフィルタ本体の製造行程説明
図。FIG. 1 is an explanatory diagram of a manufacturing process of a filter main body according to the present invention.
【図２】本発明に係わるフィルタ本体を簡素化して示す
断面対応図。FIG. 2 is a cross-sectional view schematically showing a filter body according to the present invention.
【図３】本発明の第１実施例に係わるフィルタの製造工
程を示す断面対応図。FIG. 3 is a cross-sectional view showing a process of manufacturing a filter according to the first embodiment of the present invention.
【図４】第１実施例に係わるフィルタの斜視図。FIG. 4 is a perspective view of a filter according to the first embodiment.
【図５】本発明の第２実施例に係わるフィルタの製造工
程を示す断面対応図。FIG. 5 is a cross-sectional view showing a process of manufacturing a filter according to a second embodiment of the present invention.
【図６】第２実施例に係わるフィルタの斜視図。FIG. 6 is a perspective view of a filter according to a second embodiment.
１…フィルタ本体 ２…基材 ３…上流側シート ４…下流側シート ５…吸着剤 ２０…長手方向端面 ２２…幅方向端面 ２６…形状保持シート ３２…延在部分 １５，２４，３４…加熱プレス機 DESCRIPTION OF SYMBOLS 1 ... Filter main body 2 ... Base material 3 ... Upstream sheet 4 ... Downstream sheet 5 ... Adsorbent 20 ... Longitudinal end face 22 ... Width end face 26 ... Shape retention sheet 32 ... Extension part 15, 24, 34 ... Heat press Machine
Claims (5)
た状態で保持された熱可塑性を有する基材の上流側表面
並びに下流側表面に、それぞれ上流側シート並びに下流
側シートが第１の熱プレス処理によって予め融着された
フィルタであって、 上記基材の端面が露出するフィルタ端面の近傍に、上記
基材を実質的に押し潰すように、第２の熱プレス処理が
なされていることを特徴とするフィルタ。An upstream sheet and a downstream sheet are provided on an upstream surface and a downstream surface of a thermoplastic base material in which a particulate adsorbent is dispersed in a thickness direction. A filter previously fused by the hot pressing process, wherein a second hot pressing process is performed near the filter end surface where the end surface of the base material is exposed so as to substantially crush the base material. A filter characterized by the following.
た状態で保持された熱可塑性を有する基材の上流側表面
並びに下流側表面に、それぞれ上流側シート並びに下流
側シートを第１の熱プレス処理により予め融着したフィ
ルタの製造方法であって、 上記基材の端面が露出するフィルタ端面の近傍に、上記
基材を実質的に押し潰すように、第２の熱プレス処理を
行うことを特徴とするフィルタの製造方法。2. An upstream sheet and a downstream sheet are respectively provided on the upstream surface and the downstream surface of a thermoplastic base material in which a particulate adsorbent is dispersed in the thickness direction. A method of manufacturing a filter which has been previously fused by hot press processing, wherein a second heat press processing is performed near the filter end face where the end face of the base material is exposed, so as to substantially crush the base material. A method of manufacturing a filter.
た状態で保持された基材の上流側表面並びに下流側表面
に、熱可塑性を有する上流側シート並びに下流側シート
がそれぞれ第１の熱プレス処理によって予め融着された
フィルタであって、 上記上流側シートまたは下流側シートの一方のシート
が、他方のシート並びに上記基材の端面よりも延在して
おり、この延在部分が、上記端面を覆うように、他方の
シートの表面に第２の熱プレス処理によって融着されて
いることを特徴とするフィルタ。3. An upstream sheet and a downstream sheet having thermoplasticity are respectively provided on an upstream surface and a downstream surface of a base material in which a particulate adsorbent is dispersed in a thickness direction. Wherein one of the upstream sheet and the downstream sheet extends beyond the other sheet and the end face of the base material, and the extended portion Is fused to the surface of the other sheet by a second hot pressing process so as to cover the end face.
た状態で保持された基材の上流側表面並びに下流側表面
に、熱可塑性を有する上流側シート並びに下流側シート
をそれぞれ第１の熱プレス処理によって予め融着したフ
ィルタの製造方法であって、 上記上流側シートまたは下流側シートの一方のシート
が、他方のシート並びに上記基材の端面よりも延在して
おり、この延在部分が上記端面を覆うように、上記延在
部分を他方のシートの表面に第２の熱プレス処理により
融着したことを特徴とするフィルタの製造方法。4. An upstream sheet and a downstream sheet having thermoplasticity are respectively provided on an upstream surface and a downstream surface of a base material in which a granular adsorbent is dispersed in a thickness direction. A method of manufacturing a filter which has been fused in advance by hot press processing, wherein one of the upstream sheet and the downstream sheet extends from the other sheet and the end face of the base material. A method for manufacturing a filter, characterized in that the extended portion is fused to the surface of the other sheet by a second hot pressing process so that the existing portion covers the end face.
れ、かつ、フィルタ幅方向端面に、それぞれ形状保持プ
レートが接着されているとともに、フィルタ長手方向端
面に、上記第２の熱プレス処理がなされていることを特
徴とする請求項１又は３に記載のフィルタ。5. A pleating process is performed in the longitudinal direction of the filter, a shape retaining plate is bonded to each end face in the filter width direction, and the second hot pressing is performed on the longitudinal end face of the filter. 4. The filter according to claim 1, wherein:
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP02629498A JP3884158B2 (en) | 1998-02-09 | 1998-02-09 | filter |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP02629498A JP3884158B2 (en) | 1998-02-09 | 1998-02-09 | filter |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH11221412A true JPH11221412A (en) | 1999-08-17 |
| JP3884158B2 JP3884158B2 (en) | 2007-02-21 |
Family
ID=12189312
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP02629498A Expired - Fee Related JP3884158B2 (en) | 1998-02-09 | 1998-02-09 | filter |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3884158B2 (en) |
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| JP2002058923A (en) * | 2000-08-23 | 2002-02-26 | Asahi Techno Plus Kk | Method for cutting filter sheet |
| JP2003519568A (en) * | 1999-12-23 | 2003-06-24 | スリーエム イノベイティブ プロパティズ カンパニー | Microtiter plate with insertion filter and related manufacturing methods |
| FR2852861A1 (en) * | 2003-03-27 | 2004-10-01 | Valeo Materiaux Friction | Air filter containing a filter with a layer of granular material held between two synthetic sheets and formed using an ultrasonic cutter |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2003519568A (en) * | 1999-12-23 | 2003-06-24 | スリーエム イノベイティブ プロパティズ カンパニー | Microtiter plate with insertion filter and related manufacturing methods |
| JP2002058923A (en) * | 2000-08-23 | 2002-02-26 | Asahi Techno Plus Kk | Method for cutting filter sheet |
| JP4585098B2 (en) * | 2000-08-23 | 2010-11-24 | 旭化成テクノプラス株式会社 | Filter sheet cutting method |
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| EP2127723A1 (en) * | 2008-05-20 | 2009-12-02 | Mann+Hummel Gmbh | Filter element and method for manufacturing same |
| JP2013511376A (en) * | 2009-11-20 | 2013-04-04 | ハイダック フィルターテヒニク ゲゼルシャフト ミット ベシュレンクテル ハフツング | Formation method of filter mat |
| JP2013230446A (en) * | 2012-05-01 | 2013-11-14 | Yuho:Kk | Filter unit and manufacturing method thereof, and air filter |
| JP2014193426A (en) * | 2013-03-28 | 2014-10-09 | Toyota Boshoku Corp | Filter medium manufacturing method and filter medium manufacturing apparatus |
| WO2014196564A1 (en) * | 2013-06-07 | 2014-12-11 | 東洋紡株式会社 | Filtering medium for deodorizing filter |
| US10076718B2 (en) | 2013-06-07 | 2018-09-18 | Toyobo Co., Ltd. | Filtering medium for deodorizing filter |
| JP2015073954A (en) * | 2013-10-10 | 2015-04-20 | 株式会社コーワ | Filter, and drying furnace |
| WO2021107134A1 (en) * | 2019-11-29 | 2021-06-03 | エステー株式会社 | Fiber-made interior product interpolation sheet, manufacturing method therefor, and fiber-made interior product including same |
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