KR20040053088A - The manufacturing method of polyurethane frame air cleaning filter using non-fabric filter material and air cleaning filter manufactured - Google Patents

Abstract

PURPOSE: Provided are a method for preparing a polyurethane frame air cleaning filter by using a non-woven fabric filter media having a good dust holding capacity and an air cleaning filter prepared thereby. CONSTITUTION: The method comprises steps of (a) after cutting a filter media made of a non-woven fabric in a certain width and at a certain interval by using a cutter, bending it with a bending machine; (b) adhesion-hardening by applying a hot melt resin on both sides border of the bent filter media by using an edge or adhesion-hardening only by a hot melt resin to stabilize the bent filter media; and (c) molding the stabilized non-woven fabric filter media into a polyurethane-based frame by using a molding frame.

Description

The manufacturing method of polyurethane frame air cleaning filter using non-woven filter media and the air cleaning filter manufactured by the method of manufacturing the present invention The manufacturing method of polyurethane frame air cleaning filter using non-fabric filter material and air cleaning filter manufactured}

According to the present invention, a filter medium made of a nonwoven fabric having excellent dust collecting capacity (DHC) is bent at a predetermined interval using a filter medium made of a nonwoven fabric, and bent using edge banding and resin at both edges of the bent filter medium. After stabilizing the gap between the acid in the filter media and stabilizing it regularly, it is manufactured by the manufacturing method of automobile air purifying filter and foamed polyurethane foam which can greatly improve the productivity of air purifying filter. The present invention relates to a car air purifying filter.

Looking at the prior art related to the present invention, the filter element for automobile air cleaning is mainly used elements made of non-woven filter media and paper filter media, 0.38 ㎡ for non-woven filter media, 0.70 ㎡ for paper filter media The paper filter media takes 1.8 times more, but in contrast to the ability to capture dust, the nonwoven filter media is 250 g / element and the paper filter media is 70 g / element. The nonwoven filter media is 3.6 times more capable of collecting dust. Big. That is, the filter media made of nonwoven fabric is 3.6 times longer than the filter media made of paper. Dust collection is caused by the structural difference of filter media, and nonwoven filter media is much more advantageous than paper filter media.

Conventional productivity of automobile air purification filter produced using the above two kinds of materials is about 700 to 800 hours per hour in the case of air filter which is bent paper filter media and molded into urethane frame In the case of an air cleaning filter molded from an insert injection frame (using a thermoplastic plastic material) using a filter medium made of a nonwoven fabric, approximately 100 to 110 filter media made of paper are more productive than a filter medium made of a nonwoven fabric. This is much higher.

In other words, the conventional technology has a problem in that the production cost is high while the productivity is very low due to the large amount of time and expense required to mold the insert injection frame when using the non-woven filter medium having high dust collection capability. In this case, the productivity is high by molding the frame with urethane, but there is a problem that the dust collecting ability is very low due to the characteristics of the paper filter. The above problems are because the non-woven filter media made of synthetic fiber (VR, PE, PP) -based material has a thicker and larger elasticity than the paper filter media made of pulp material, so that the filter media made of non-woven fabric is bent at regular intervals, and between acid and acid. This can be achieved by introducing a relatively expensive insert injection frame in order to be able to keep the spacing constant.

The technical problem to be achieved by the present invention is to recognize the problems of the prior art as described above by using a non-woven filter medium having a large dust collection capacity, low production cost, polyurethane-based material that can greatly improve productivity Introduce the process of bending the filter media consisting of non-woven fabric at regular intervals to form a frame with a desired interval, and applying the adhesive cured by applying hot-melt resin to the non-woven fabric or fabric on both edges (ends) of the bent filter media. The process of applying hot-melt resin to the hardening process to maintain the gap between the acid and acid in the bent filter media to stabilize the bent filter media, and then the frame is made of polyurethane-based material which is relatively inexpensive and simple to process. Excellent dust collection capacity and production Constitute a method for producing a significantly improved automotive air filter for the manufacture of a filter prepared by the method it is an object.

Figure 1: Life bending process

Figure 2: Edge Banding Process

Figure 3: Rotary Bending Process

Figure 4: Embossing process (rotary bending rolls)

<Explanation of symbols for the main parts of the drawings>

11; Nonwoven filter media 12; Width cutting knife

13; Preheater 14; Bending knife

15; Electric heater (main heater) 16; Bended Nonwoven Filter Media

21; Hot melt applicators 22; edge

23; Hot melt nozzle 24; Bended Filter Media

25; Hot Melt Resin Bonded Edge

31; Filter media 32; Preheater

33; Bending knife 34; Rotary bending rolls

35; Adhesive to prevent air leak

36; Bending nonwoven filter media

37; Hot Melt Glue with Rib

41; Filter media 42; Rotary bending rolls

43; Engineered bend line 44; Pieces formed on rolls for embossing

45; Embossed filter media 46; Bending emboss processed by bending mountain

The present invention is bent at a predetermined interval by a predetermined width using a filter medium made of a non-woven fabric having excellent performance of collecting dust to achieve the above object, and bent by using edge banding and resin on both edges of the bent filter media After the stabilization and stabilization of the gap between the acid in the filter medium to stabilize the production of the air purifying filter for automobiles formed by foaming polyurethane that can greatly improve the productivity of the air purification filter and the manufacturing method The present invention relates to a car air purifying filter.

Looking at the use and role of the air cleaning filter manufactured according to the present invention, the air filter for automobiles manufactured in accordance with the present invention in the case of engines using automobiles and internal combustion engines by properly mixing the outside air and fuel into the cylinder The injected and injected air is mixed with fuel, and the mixing of air and fuel has a great influence on the performance of the engine. Especially, when impurities or foreign substances are introduced into the engine without filtration, the engine is lethal defects. It can be used to clean the air flowing into the engine because it is installed at the part where external air enters. The structure of the air purifying filter for automobiles is characterized by bending the filter media portion where actual dust collection occurs and bending the filter media at regular intervals, and maintaining the shape of the filter media bent to maintain excellent filter performance for a long time. It is composed of a frame part that prevents the air flow from leaking. In the present invention, a polyurethane fiber (VR, PE, PP) -based nonwoven fabric having excellent ability to trap dust as a method for solving the problems of the prior art as described above is relatively simple and inexpensive, and the time required for manufacturing polyurethane is short. By introducing a process of forming a frame with a series of materials, a method of manufacturing an air purifying filter for automobiles formed of a polyurethane frame using a nonwoven fabric having excellent dust collecting performance and a reduction in production cost and a greatly improved productivity is achieved. It is to provide an automobile air purification filter manufactured by the method. Looking specifically at the constituent means according to the present invention, a process for manufacturing a car air filter using a filter medium made of a non-woven fabric is largely composed of a bending process and a frame manufacturing process. The bending machine used in the bending process uses a knife pleating machine and a rotary pleating machine to bend the nonwoven fabric or paper. The knife bending machine is composed of an unwinder, a width cutter, a pre heater, a bending knife and a main heater or oven. In the bending process using a knife bending machine, the filter media made of non-woven fabric is cut to a desired width with a cutter and then passed through a pre-heater to soften the filter media and then bent with a knife to stabilize the filter media bent in the main heater or oven. It consists of a process.

The filter medium having completed the bending is carried out to manufacture a polyurethane frame in order to be able to be employed as a vehicle air purification filter. Frame work using polyurethane is a method of manufacturing a frame by bending the edge (Edge) on both edges of the filter medium bent by the knife bending machine. Edges on both edges of the filter media may be in the form of nonwovens, fabrics, paper or other flat plates. The width of the edge is cut 1mm to 3mm larger than the acid height of the bent filter media and wound around the roll to fix the edge of the bent filter media easily accessible. Resin is applied to the edge and bonded to the edge of the bent filter media, the bent filter media is sandwiched in a jig (Jig) to maintain a constant acid spacing. Then, hot melt resin melted in a hot melt applicator as shown in FIG. 2 is sprayed through the hot melt nozzle and evenly applied to the edges, and the hot melt resin is applied to the jig before the resin is cured. Adhere to both ends of the filter medium. The edge bonded to both ends of the filter media is pressed by using a small roll or other device capable of applying pressure to uniformly bond. After the edge bonding is completed, the filter is cooled in the air for a predetermined time and cured while the hot melt resin cools down to stabilize the adhesion by the edge, thereby completing the edge banding process. Here, when the width of the filter medium is 50 mm or more, a rib is inserted to prevent the filter medium from lying down due to the force of air, or a hot melt resin is applied to the middle of the filter medium using a nozzle to use the filter medium. Prevent dead space from occurring. The method of inserting the rib is made of plastic material, hard paper or iron (SUS) and manufactured according to the shape (height, spacing) of the acid. Let's do it. Dead air is pushed by the force of the air when the air passes through the filter while the filter medium is bent to the side, and adjacently connected to the bent filter medium affects the filter medium is laid down due to the phenomenon of dominoes overlapping the filter medium It means the space that is caused by not collecting dust. In this way, the dead space filter has a poor dust collection capacity, and the pressure loss is high, which greatly reduces the performance of the filter. When the bonding of the edge banding of the bent filter media is completed, the urethane foaming operation, which is the final step of manufacturing the air purification filter frame, is performed. The filter media fixed by bending at fixed intervals after the edge banding operation is completed is made of polyurethane by using a mold frame to play a role of preventing air leakage. Mold the frame. In manufacturing a frame, a mold (mould) capable of molding by foaming a liquid polyurethane is required. The molding frame is composed of two top and bottom to prevent the deformation of the filter medium bent in the molding process to the maximum to have a good filter performance. In the manufacturing process, after the polyurethane is poured into the groove of the mold by using a urethane shooting machine in the lower mold formed into a desired shape, the bending portion of the filter media with bending the edge with the hot melt resin is directed downward. Put it in the mold and cover the mold on the upper side to prevent the deformation of the filter media bent during foaming. After the polyurethane foaming is completed, the upper and lower mold molds are removed to complete the air filter for automobiles. Foaming of the polyurethane may be foamed at room temperature, but it is advantageous to use an oven to increase the foaming speed, it is appropriate to maintain the temperature in the oven between 50 ° ~ 100 °. The reason for using polyurethane or elastic materials in the manufacture of the frame is that the use of such a material does not require a separate packing material to prevent the leakage of air, which can reduce the manufacturing process cost and speed up the production speed. have. The distance between the acid and the acid of the bent filter medium is comprised within 2 mm to 5 mm.

The following is a rotary bending method, the rotary bending machine is composed of a pre-heater, a bending roll, the main heater, the process is to enhance the bending workability by softening the product in the pre-heater filter media, the bending roll is composed of two upper and lower have. The upper and lower rolls are embossed and embossed at the desired height to bend at the intersection. When the filter media passes, marks are made in the embossed or embossed at the set height of the mountain. The bending is performed by the embossed and the intaglio formed in the heater, and the bending is stabilized by the heat of the heater. The advantage of rotary bending is that the speed is high, while the wide width has the disadvantage of being difficult to bend.

Rotary type bending machine configuration is composed of an unwinder, a pre heater, a bending roll, and a hot melt applicator, as shown in FIG. Rotary bending process includes a) smoothing the filter media through a pre heater, and b) passing the filter media through the preheater through a bending roll engraved with a bend line and various patterns. Forming a pattern on the filter media at a predetermined acid height by the embossing, and c) the filter media is bent according to the pressed marks while passing through the bending roll, and ethylene vinyl acetate (EVA) on both edges of the bent filter media. ), By applying hot melt resin made by melting thermoplastic resins such as polyester and polyamide, so that both edges of the filter medium are completely adhered by the hot melt resin applied, and the bending of the filter medium without air leakage is completed at both edges. do. The bending roll is composed of two top and bottom. Since the resin applied to the edge of the bent filter media is relatively narrow within 4 mm, the bonded filter media is bonded while maintaining a constant gap between the acid and the acid at the edge of the bent filter media, thereby adhering both edges of the filter media. It serves to prevent the leakage of unfiltered air.

The filter medium, which is completed by the rotary bending machine, manufactures a frame using polyurethane and a mold. Frame manufacturing method is the same as the method used for bending the knife and the effect of the frame produced by the same method is the same.

Example 1

Types of filter media use non-woven filter media, non-woven filter media using a weight of 50g / ㎡ ~ 500g / ㎡, thickness 0.5 ~ 7.0mm, air permeability 20 ~ 300cc / ㎠ / sec. Bending of the nonwoven filter media may use either a rotary bending method or a knife bending method. In Example 1, bending is performed by selecting a knife bending method. In the bending process, the non-woven filter media selected to the unwinder is applied with a small tension to slowly loosen the filter media and then the filter media is cut to a desired width using a cutter. The width of the desired filter media is determined by fixing the position of the cutter using a ruler or other measuring tool installed at the place where the cutter is located, and then cutting while passing through the filter media. It is preferable to use a circular shape as shown in FIG. 1, and the cutting is not a full cutting but a partial dotted cutting to prevent each width from being disturbed in the bending process. The cutting filter medium is completed is bent with a knife pre-installed according to the height of the mountain to be bent through the preheater. After the bending is completed, the filter medium is heat-treated so that the bending is not disturbed by passing through the main heater to complete the bending. Next, the frame is manufactured to make it possible to employ the filter medium in which the bending is completed as an air purifying filter for automobiles. Frame work using polyurethane is a method of manufacturing a frame after bending the edge (Edge) on both edges of the filter medium bent by the knife bending machine. Edges bonded to both edges of the filter media may be non-woven, woven, paper or other flat forms. The width of the edge is cut 1 mm to 3 mm larger than the acid height of the bent filter media and wound around the roll to fix the edge of the bent filter media easily to both sides of the bent filter media as shown in FIG. . The bent filter media is fixed to the jig (Jig) in order to maintain a constant interval between the bent filter media before applying the resin to the edge and banding the edge of the filter media. As shown in FIG. 2, the hot melt resin melted in a hot melt applicator is sprayed through the hot melt nozzle and evenly applied to the edges. Glue to the edges on both sides. The edge bonded to both ends of the filter media is pressed by using a small roll or other device capable of applying pressure to uniformly bond. After the adhesion is completed, the filter is cooled in the air for a predetermined time, the hot melt resin is cured as it cools down, and the adhesion by the edge is stabilized to complete the edge banding process. In this case, when the width of the filter medium is 50 mm or more, a rib is inserted so that the filter medium does not lie down due to the force of air, or a hot melt resin is applied to the middle of the filter medium using a nozzle to use the filter medium. Prevents the creation of poor spaces. The method of inserting the rib is made of plastic material, hard paper or iron (SUS), and its size and shape are made different according to the shape of the acid (height, spacing) and fixed by urethane foam in the middle of the bent filter media. Let's do it. When the edge banding process of the bent filter media is completed, polyurethane foaming, which is the final step of the frame work of the air purification filter, is performed. The edge filter is completed and bent at fixed intervals, and the filter medium fixed to the frame is formed of polyurethane that serves to prevent the leakage of air into the deformation and deformation of the bent filter medium. In manufacturing the frame, a mold mold capable of molding by molding a liquid polyurethane is required. The molding frame is composed of two top and bottom to prevent the deformation of the filter medium bent in the molding process to the maximum to have a good filter performance. In the manufacturing process, the polyurethane is poured into the groove of the mold by using a urethane shooting machine on the lower mold molded into a desired shape, and then the bending portion of the filter media with bending is turned downward with the hot melt resin facing down. Place the mold in the top and cover the upper mold to prevent maximum deformation of the bent filter media. After foaming is completely finished, the upper and lower molds are removed to complete the air filter for automobiles. Polyurethane foam may be foamed at room temperature, but it is advantageous to use an oven to increase the foaming speed, and it is appropriate to maintain the temperature inside the oven between 50 ° and 100 °. The reason why the polyurethane or elastic material is used in the frame manufacture is that there is no need for a separate packing material to prevent the leakage of air, and thus the manufacturing process cost can be reduced and the production speed is high. The distance between the acid and the acid of the bent filter medium is comprised within 2 mm to 5 mm.

Example 2

Example 2 is a method for manufacturing an air purifying filter with a polyurethane frame that can greatly improve the productivity of the air purifying filter using a filter medium made of a nonwoven fabric having a high performance of collecting dust using a rotary bending machine. It relates to a urethane frame air purification filter produced by. This method is manufactured by cutting the filter medium made of non-woven fabric to the width desired, and unlike the knife bending process of Example 1, it does not cut in the bending process. The most important thing for bending is the bending roll. The bending roll is composed of two rolls up and down, and the bending roll is carved into an embossed and intaglio. This piece plays two roles. The first role is to sculpt the mountain at regular intervals on the roll to allow bending at the height of the mountain to be bent. The pieces are engraved on one roll in the form of a straight line throughout the roll, and may be engraved on the opposite roll with no engraving. have. It may be formed in an engraved form on one roll of the piece and in an embossed form on the other roll. In the same manner as described above, the surface of the roll is repeatedly carved at regular intervals while being turned into pieces. Passing the filter medium having a predetermined width between the acid and the acid of the carved roll is formed embossed embossed and engraved on the surface of the filter medium. In order to more easily form wrinkles or bends, an embossment is formed on one roll in the center part between embosses, and an intaglio is formed on the opposite roll so that the gap between the acid is constant after the bending of the filter media by the bending roll. Keep it. The filter media is a filter media made of a nonwoven fabric as in Example 1, and the filter media are transferred from an unwinder to soften the filter media through a preheater and then pass through a bending roll. At this time, the filter media is formed according to the shape engraved on the bending roll and the embossed to maintain the pattern and the acid spacing is formed, the hot melt resin is applied to both edges of the filter media. Components of the applied hot melt resin is composed of ethylene vinyl acetate (EVA), polyamide (Polyamide), polyester (Polyester) and the like. The filter medium is bent at regular intervals according to the bending pattern by lowering the advancing speed of the filter medium to which the hot melt resin is applied, and the bent filter medium is bonded to both edges of the filter medium where the hot melt resin applied to both edges is cured and bonded. It prevents air from leaking and maintains the bent shape at regular intervals. Since the width between the acid and the acid of the bent filter media is relatively narrow within 4 mm, it is possible to prevent air leaking to the edge of the bent filter media by adhesion of the resin applied to both edges of the bent filter media. When the width of the bent filter media is more than 50 mm, hot melt resin is applied to the center of the bent filter media to uniformly fix the gap between the acid of the bent filter media, which may occur when the air filter is actually used. Prevent dead spaces. Another method for preventing the dead space is a method of forming and fixing a polyurethane frame by inserting a rib in the same manner as in Example 1. The manufacturing process of the frame from polyurethane consists of the same process as in Example 1.

The present invention bends the filter media made of non-woven fabric to the desired interval using a non-woven filter media having a large dust collection capacity, and a polyurethane-based material that can significantly improve productivity while having low production costs. By introducing hot melt resin on both sides of the bent filter media by applying hot melt resin to the non-woven fabric or fabric or by applying hot melt resin on both edges to harden the gap between the acid and acid of the bent filter media After forming the frame by using a polyurethane-based material, which is relatively inexpensive and simple to process, the air filter is manufactured for automobiles.The effect of collecting dust is excellent and productivity is greatly improved. There is a saving effect.

Claims (14)

In the manufacturing method of the air purifying filter for automobiles by using a filter medium made of a non-woven fabric to form a frame from polyurethane, Using a cutter and a bending machine to cut the filter media made of non-woven fabric at a constant width and spacing, and then Stabilizing the bent filter media by applying cured adhesive by hot melt resin using edges at both edges of the bent filter media or by attaching and curing only with hot melt resin; A method of manufacturing an air purifying filter for automobiles, comprising forming a frame from a polyurethane-based material using a desired mold frame by applying the resin to attach, harden, or stabilize the edge by attaching the resin. The method according to claim 1, The bending machine is a method of manufacturing an air purifying filter for a vehicle comprising a step of bending the nonwoven filter media using a rotary knife that can engrave a knife or an emboss. The method according to claim 1, The nonwoven filter medium has a weight of 50g / ㎡ ~ 500g / ㎡, the thickness is 0.5mm ~ 7.0mm, the air permeability of the manufacturing method of the air purifying filter for automobiles manufactured by having a 20cc ~ 300cc / ㎠ / sec. The method according to any one of claims 1 to 3, The hot melt resin is a manufacturing method of an air purifying filter for a vehicle manufactured by using a thermoplastic resin, such as ethylene vinyl acetate, polyamide, polyester selectively as needed. The method according to claim 4, The material of the edge is a non-woven fabric, fabric or paper, etc. and the manufacturing method of the air purifying filter for automobiles composed of a shape cut 1mm to 3mm larger than the acid height of the bent filter media. The method according to any one of claims 1 to 3, The height and spacing of the acid with a plastic material, hard paper, aluminum or iron (SUS), etc., so that the bent filter media does not lie down by air force before the step of attaching and curing the hot melt resin is completed and the frame is formed of polyurethane. According to the manufacturing method of the air filter for automobile further comprising the step of inserting in the middle of the filter medium bent by varying the size and shape. The method according to claim 6, The hot melt resin is applied to the middle portion of the bent filter media instead of inserting ribs so that the bent filter media does not lie down by air force before the step of attaching and curing the hot melt resin is completed and forming the frame with polyurethane. Method of manufacturing an air purification filter for a vehicle further comprising the step of curing. In the air purifying filter for automobiles manufactured by molding a frame from polyurethane using a filter medium made of a nonwoven fabric, Means for cutting the filter medium made of nonwoven fabric using a cutter and a bending machine to a predetermined width, and then bending at regular intervals; Means for stabilizing the bent filter media by applying a hot melt resin to the edges on both sides of the filter media bent by the means by applying hot melt resin or by hardening only by hot melt resin; An air purifying filter for automobile manufactured by means of forming a frame from a polyurethane-based material using a desired mold frame by applying the resin to harden an edge or attach a hot melt resin to stabilize the bent filter media. The method according to claim 8, The bending machine is a vehicle air purifying filter manufactured by means of bending the nonwoven filter media by using a rotary bending machine that can engrave a knife or an embosser. The method according to claim 8, The non-woven filter medium has a weight of 50g / ㎡ ~ 500g / ㎡, the thickness is 0.5mm ~ 7.0mm, the air permeability of the automobile air filter produced by having a 20cc ~ 300cc / ㎠ / sec. The method according to any one of claims 8 to 10, The hot melt resin is an automobile air purifying filter manufactured by using a thermoplastic resin, such as ethylene vinyl acetate, polyamide, polyester selectively as needed. The method according to claim 11, The edge material may be a non-woven fabric, a fabric or paper, etc., and the air filter for automobiles manufactured by forming a shape cut 1mm to 3mm larger than the acid height of the bent filter media. The method according to any one of claims 8 to 10, After the means for attaching and curing the hot melt resin is completed, the bent filter media is made of plastic material, hard paper, aluminum or iron (SUS), etc. in size and shape depending on the height and spacing of the acid so as not to lie down by air force. Air filter for automobile further comprising a means for sandwiching the middle of the filter medium bent by. The method according to claim 13, Further comprising a means for applying the hot melt resin to the middle portion of the bent filter media instead of fitting the rib so that the filter medium bent by the force of air after the means for attaching and curing the hot melt resin is completed Air Purification Filter.