JPS5849417A - Production of air filter for air conditioner - Google Patents

Abstract

PURPOSE:To improve the injection moldability of frame members markedly and to prevent the failure in melt sticking and the slackening of filter members by molding the frames of the same material as that of filters into separate bodies, and forming the same into one body by ultrasonic welding. CONSTITUTION:A filter member 5 which is molded of a PP resin or the like into the form of yarn and is woven to a corrugating shape and a frame member 6 which consists of the same material as that of the filter member and has a mol.wt. lower than the mol. weight of the filter member are molded into separate bodies. The member 6 is set to a horn receiver 8 in such a way that the opposite surface of the member 6 provided with ribs 6a contacts the receiver 8. After the member 5 is pinned 6a tentatively thereto, ultrasonic waves are applied to the members by means of a horn 7 for melt sticking, then the ribs 6b of the member 6 having a lower mol.wt. melt first by the friction of the joined surfaces then the member 5 melts to be joined in one body to the member 6.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing an air filter for an air conditioner.

The first manufacturing method for conventional air filters for air conditioners
This will be explained with reference to the figure and FIG. 1 is the air filter,
It consists of a filter member 2 and a frame member 3. The filter member 2 is formed by molding a hard vinyl chloride resin or the like into a thread shape and woven into a corrugated shape so as to have a good dust removal effect φ; and to reduce ventilation resistance. The frame member 3 is molded from AB8 resin, styrene resin, or the like. Thus, the air filter L 1 is manufactured by injection molding the frame member 6 with the filter member 2 sandwiched between a mold (not shown) for molding the frame member 6, and the mold being clamped. The filter member 2 and the frame member 3 are integrally formed.

According to this method of manufacturing the air filter 1, when molding the frame member 3, the filter member becomes an obstacle to the flow of resin, resulting in very poor injection moldability, and even though the amount of resin in the frame member 6 is small, First, it requires a large injection molding machine, making it relatively expensive. Moreover, it is extremely difficult to reduce the thickness of the frame member 2.

In addition, in order to cut the filter member 2 protruding from the end face of the frame member 5 during mold clamping, the mold for forming the frame member 6 must be a blade type, which results in a short mold life and Maintenance and ensuring flatness were difficult. Furthermore, since the filter member 2 is clamped and clamped during injection molding, the mold contact portions located on both sides of the frame member 5 (section A in Fig. 2)
In this case, the filter member 2 is crushed and becomes flat, which increases ventilation resistance and causes a decrease in performance such as a decrease in air volume.If the clamping pattern is too strong, the filter member 2 may break at the end face of the frame member 3. If the mold clamping is too weak, a part of the mold member 6 will flow out, causing flakes, which will make the filter member 2 more likely to break and at the same time increase the ventilation resistance. Therefore, mold clamping management and mold maintenance are extremely troublesome.A Also, since the filter member 2 and the frame member 3 are made of different materials, the filter member 2 may become loose due to molding shrinkage of the frame member 5. In order to correct this problem, it is necessary to correct the problem using hot air, etc., and it is not possible to recycle defective products.

This Aoi Akira was made in order to eliminate the above-mentioned defects. That is, after separately molding a frame made of the filter material B, these are integrally formed by ultrasonic welding.

The details of the present invention will be explained below with reference to an embodiment shown in FIGS. 3 to 5. 4 is an air filter, which is made up of a filter member 5 and a frame member 6.

The filter member 5 is made by molding polypropylene resin or the like into a thread shape and weaving it into a corrugated shape. The frame member 6 is made of the same material as the filter member 5 and is molded separately from the filter member 5. Also, the frame member 6 has a molecular weight lower than that of the filter member 5.

The frame member 6 has a rib 6a, the end face of the rib 6a is at an acute angle, and two ELs are provided on the filter welding surface all around the circumference. In the middle thereof, a plurality of bottles 6b with acute-angled tips are provided higher than the ribs 6a6.Furthermore, the end surface of the filter welding surface of the frame member 6 is formed into an arc shape, and the opposite surface of the filter welding surface is formed into an arc shape. Make it flat.

7 is a welding horn whose contact surface with the filter member 5 is flat, and an escape hole 7a is provided at a position relative to the bottle 6, and the depth B of the escape hole 7a is smaller than the bottle height C. . 8
is a horn receiver with a flat contact surface.

Therefore, in order to integrate the filter member 5 and the frame member 6,
Set the opposite side of the frame member 6 on which the ribs 6a are provided to the horn receiver 8, and after temporarily fixing the filter member 5 to the bottle 6a, apply ultrasonic waves using the welding horn 7 to bond the joint surface. Due to friction, the ribs 6b provided on the frame member 6 are first melted, and then the filter member 5 is melted and integrated with the frame member 6.

1, the end face of the filter member 5 is located inside the outer circumferential surface of the frame member 6, and the width of the welding horn 7 is set on the frame side 6.
It is arranged so that the width is larger than the width E of .

According to this method of manufacturing an air filter for an air conditioner, the filter member 5 and the frame member 6 made of the same material are separately molded and then integrally formed by ultrasonic welding.
The injection moldability of the frame member 6 is greatly improved compared to the conventional method. Therefore, a small molding machine and a minimum number of molds are sufficient.
Therefore, it is inexpensive, and the frame member 6 can be thinned and formed at high speed.

Furthermore, there is no welding failure due to a difference in melting point, and there is no loosening of the filter member 5 due to molding shrinkage of the frame member 6, and recycling is possible. In addition, since the molecular weight of the frame member 6 is lower than the molecular weight of the filter member 50, the frame member 6 melts first and then the filter member 5 when melting, and the filter member 5 is not overheated and its strength does not decrease. Therefore, the filter member 5 is not cut at the end face of the frame member B. Furthermore, the filter welding surface of the frame member 6 has a rib 6 with an acute angle end face extending over almost the entire circumference.
af is provided, and a bottle 6b with an acute-angled tip is provided in the middle of the rib 6a, so that the frame member 6 is melted more reliably at the beginning, and the filter member 5 is positioned and temporarily fixed by the bottle 6b. And there is a riveting effect after welding. In addition, since the surface opposite to the filter welding surface of the frame member B and the contact surface of the welding horn 7 are made flat, it is easy to ensure flatness and a uniform welding and appearance can be achieved over the entire surface, making it easy to attach and detach from the decorative cover, etc. Good operability. Furthermore, since the filter member 5 does not collapse in any part other than the frame member 6, ventilation resistance does not increase. In addition, since the end face of the filter member 5 is located inside the outer circumferential end face of the frame member 6, there is no risk of damage even if the filter member 5 is touched, and the width of the welding horn 7 can be made larger than the width of the frame member B. Therefore, it is possible to obtain many effects such as there is no need to worry about poor welding even if the position is slightly shifted during setting.

[Brief explanation of the drawing]

Fig. 1 is a front view of a conventional air filter, Fig. 2 is a partially enlarged cross-sectional view taken along II-II in Fig. 1, Fig. 6 is a back view of the air filter of the present invention before welding, and Fig. 4 is a welded one. Figure 5 is an enlarged partial cross-sectional view at the time of welding, and Figure 6 is ■-■ after welding.
It is a partially enlarged equivalent view of a cross section. 4... Air filter, 5... Filter part,
6... Frame member, 7... Horn for welding, 8... Horn holder is semi-four factor/ha

Claims (1)

[Claims] 1. A filter member (5) made by weaving and molding polypropylene resin etc. into a thread shape and a frame member made of the same material (
6) A method for producing an air filter for an air conditioner, characterized in that after separately molding, these are integrally formed by ultrasonic welding.