WO2003049838A1

WO2003049838A1 - Air filter and method of manufacturing the air filter

Info

Publication number: WO2003049838A1
Application number: PCT/JP2002/012952
Authority: WO
Inventors: Kousaku Takaki
Original assignee: Kodaka Sangyo Kaisha, Ltd.
Priority date: 2001-12-13
Filing date: 2002-12-11
Publication date: 2003-06-19

Abstract

An air filter and a method of manufacturing the air filter, the air filter characterized in that a filter medium (10) is formed in continuous corrugated shape by bending the band-like filter medium (10) formed of nonwoven fabric along crease lines (11) alternately in projected and recessed shapes and the sides (13) of the filter medium (10) are connected to each other so as to hold rear side crease lines (11d), whereby, since a side plate must not be formed on the filter medium (10), the processing of the filter medium (10) can be facilitated; the method comprising a connection step for the filter medium (10) wherein workability is improved.

Description

Description Air filter and method for manufacturing the same

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an air filter for trapping dust in air by allowing air to pass through, and a method for manufacturing the same. Background art

Conventionally, in order to remove dust contained in the air, various air filters have been incorporated into an air cleaner and a suction line of an automobile or a clean room.

Among the above-mentioned air filters, there is a non-woven fabric formed by folding a non-woven fabric. This air filter is provided with a frame of, for example, resin or metal around the air filter, and is incorporated in each of the above devices.

As a method for manufacturing the above air filter, there is a method disclosed in Japanese Patent Application Laid-Open No. H11-222417. First, as shown in FIG. 19 (A), a filter medium 100 having substantially triangular side plates 102a and 102b integrally formed on both sides of a corrugated plate 101 provided continuously in one direction, respectively. By bending along the dotted line shown in FIG. 19 (A) to form a wavy shape, and by bending the side plates 102a and 102b according to the arrows shown in FIG. 19 (A), FIG. ), And the contact portion is joined by means such as ultrasonic joining to complete the air filter.

However, in the above-described manufacturing method, it is necessary to process the filter medium 100 in advance into the shape shown in FIG. 19 (A), and the joining work of the side plates 102a and 102b requires the side plates 102a and 102b. The two steps of contacting b and joining Since it required work, it was troublesome.

When this joining operation is performed by ultrasonic welding, in the present manufacturing method, it is necessary to arrange ultrasonic horns for generating ultrasonic waves on both sides of the filter medium 100, and the width dimension of the filter medium 100 is required. However, the width of the equipment became larger than that of the conventional equipment, and there was a problem of taking up space.

In view of the above problems, in the present invention, it is not necessary to form a side plate or the like on the filter medium as in the related art, so that the processing of the filter medium can be simplified, and the workability of the filter medium joining process can be improved. It is an object to provide a good air filter.

It is another object of the present invention to provide an air filter which can fold the filter medium three-dimensionally and can enlarge the bag-like space of the air filter.

It is another object of the present invention to provide an air filter that can locally bond only a minimum required portion and that can prevent deformation and damage due to high temperature over a wide range generated by a method using a conventional heater or the like.

Also, there is no need to form a side plate or the like on a filter medium as in the past, so that it is possible to simplify the processing of the filter medium, and to provide a method of manufacturing an air filter which has good workability in a joining process of the filter medium. As an issue. Disclosure of the invention

In order to solve the above-mentioned problem, the first invention of the present application is directed to a belt-shaped filter medium 10, a direction perpendicular to the side 13, between both sides 13 parallel to the longitudinal direction of the filter medium 10. In addition, the fold line 11 is formed at regular intervals, and in the air fill formed by alternately bending the fold line 11 above the valley, the fold line obtained by the mountain fold becomes the front side fold 11 c. The fold line at the valley fold becomes the back fold line 11d, and this filter medium 10 is divided into the first surface 10a and the second surface 1Ob through each fold line 11 and By alternately arranging the first surface 10a and the second surface 10b, the filter medium 10 is formed in a continuous wave shape, and the side surface 13 of the first surface 10a and the second surface 1a are formed. Side 1 and 3 of O b are folded back 1 1d is sandwiched, so that an opening 12a is formed between adjacent front side folds 1 1c, and a back side fold 1 1d and the first side 10a And an air filter characterized in that a bag-shaped space 12 surrounded by the first surface 10 and the second surface 10 is formed. '' In the second invention of the present application, in the first invention, the fold line 11 is a straight main fold line 11 a formed between both sides 13 and a portion near the both sides 13. And a sub-fold line 11b formed on both sides of the main fold line 11a, whereby the bag-shaped space 12 can be formed wide. An air filter characterized by the above is provided. In the third invention of the present application, the fold line 11 is constant in the direction orthogonal to the side 13 between the side 13 parallel to the longitudinal direction of the filter 10 with respect to the strip-shaped filter 10. In the air filter formed by folding the above-mentioned fold lines 11 alternately at the peaks and valleys, at least one of the above-mentioned fold lines 11 is located at the center of the filter medium 10 in the lateral direction. The present invention provides an air filter characterized in that, in a portion thereof, the air filter is formed as a plurality of widened crease lines 11e. In the fourth invention of the present application, in the third invention, the filter medium 10 is divided into a first surface 10a and a second surface 10b via each fold line 11; By alternately arranging the 0a and the second surface 10b, the filter medium 10 is formed in a continuous wave shape, and the fold line 11 of the mountain-folded side is a front-side fold 1 1c, a valley fold The folded line 1 1 becomes the backside fold 1 1d, and the side 13 of the first surface 10a and the side 13 of the second surface 1Ob The opening 11 2a is formed between the adjacent front side folds 1 1c, and the back side fold 1 1d, the first side 10 a and the second side And a bag-shaped space 1 2 surrounded by 10 b and the above-mentioned wide crease line 1 1 e is formed at the position of the backside fold 11d, which allows the center portion of the bag-shaped space 12 to be formed wider. provide. A fifth invention of the present application provides the air filter according to the first or fourth invention, wherein the joining is performed by ultrasonic welding. According to a sixth aspect of the present invention, in the fourth aspect, the front fold line 11 c of the fold line 11 is a linear main fold line 11 a formed between both side edges 13, and a filter medium. At both ends in the short direction of 10, there are sub-fold lines 11 b formed on both sides of the main fold line 11 a, and the back fold lid is A linear main fold line 11a formed at both ends in the transverse direction, sub-fold lines 11b formed on both sides of the main fold line 11a, and a short filter medium 10 An air filter characterized by having at a central portion in the hand direction two fold-out fold lines 1 le branching off from a main fold line 11 a. In the seventh invention of the present application, the strip-shaped filter medium 10 continuously supplied in the longitudinal direction is orthogonal to the side 13 parallel to the longitudinal direction of the filter 10, and both sides 13 The fold line 11 is formed at regular intervals, and a fold line forming step 2 is performed, and the fold line 11 is bent alternately between the valley and the valley. The folded fold line becomes the back side fold line 11d, and the strip-shaped filter medium 10 is divided into the first surface 10a and the second surface 10b through each fold line 11 and these first fold lines are formed. The folding step 3 in which the surface 10 a and the second surface 10 b are alternately arranged, and the side 13 of the first surface 10 a and the side 13 of the second surface 10 b The joining is performed through the backside fold 11d and, at the same time, an unnecessary portion is cut. The joining step 4 includes the first side 10a and the second side. 1 Direction where O b comes into close contact Made by applying a force And a method for manufacturing an air filter. In the eighth invention of the present application, the strip-shaped filter medium 10 which is continuously supplied in the longitudinal direction is orthogonal to the side 13 parallel to the longitudinal direction of the filter 10 and both side 13 A fold line 11 is formed at regular intervals, and a fold line forming step 2 is performed, and the fold line 11 is bent alternately between the valley and the valley. The folded fold line becomes the back side fold 1 Id, and this band-shaped filter medium 10 is divided into the first surface 10 a and the second surface 1 Ob through each fold line 11, and these Folding step 3, in which the first surface 10a and the second surface 10b are alternately arranged, the side 13 of the first surface 10a and the side 13 of the second surface 1Ob Are joined through the backside fold 1 1d, and unnecessary portions are cut at the same time. The joining process 4 consists of the above fold line 11 and the backside fold 1 1d. Is a filter medium of 10 short In the central part of the direction, to provide a production method of an air filter, characterized in that the width Deori Looking 1 1 e of the multiple is formed. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view showing an appearance of an air filter according to an example of an embodiment of the present invention.

FIG. 2 is an explanatory view showing a series of apparatuses for manufacturing the air filter of the present embodiment. FIG. 3 is an explanatory view showing a series of apparatuses for manufacturing the air filter of the present embodiment, which are related to a fold line forming process. FIG.

FIG. 4 is an explanatory diagram showing another example of a series of devices for manufacturing an air filter.

FIG. 5 is an explanatory diagram illustrating an example of a mold used in the fold line forming step.

FIG. 6 is an explanatory view showing an example of the mold. T JP02 / 12952

FIG. 7 is a plan view showing a state in which a fold line is formed in the filter medium in this example. FIG. 8 is a plan view showing a state in which a fold line is formed in the filter medium in the present example (second example).

9A is a plan view showing the air filter of the present example, and FIG. 9B is a front view of the same.

FIG. 10A is a plan view showing the air filter of the present example (second embodiment), and FIG. 10B is a front view thereof.

FIG. 11 is an explanatory diagram showing an apparatus related to a folding step in a series of apparatuses for manufacturing the air filter of the present example.

FIG. 12 is an explanatory diagram showing an apparatus related to a joining step in a series of apparatuses for manufacturing the air filter of the present example.

FIG. 13 is an enlarged explanatory view of a main part showing a device related to a joining step in a series of devices for manufacturing the air filter of the present example.

FIG. 14 is an enlarged explanatory view of a main part showing an apparatus related to a joining step in a series of apparatuses for manufacturing the air filter of the present example.

FIG. 15A is an explanatory view showing an example of a jig used in the joining step, and FIG. 15B is a sectional view taken along line AA of FIG.

FIG. 16 is a perspective view showing an example of how to assemble the air filter.

FIGS. 17A and 17B are perspective views showing an example of a method of assembling the air filter, and FIG. 17B is an explanatory view showing a cross section of another example of the method of assembling the air filter.

FIG. 18 is an explanatory view showing still another example of how to assemble the air filter. FIG. 19 is a diagram showing a conventional air filter, where (A) is a development view and (B) is a perspective view. BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, an example of an embodiment of the present invention will be described with reference to the drawings. Figure 1 Is a sword 4 view showing the appearance of the air filter of this example. FIG. 2 is an explanatory view showing an apparatus for manufacturing the air filter.

For the sake of explanation, the side of the filter medium 10 where the fold line 11 is formed is referred to as the front side, and the opposite side is referred to as the back side.

As shown in FIG. 1, the air filter 1 is formed by folding a band-shaped filter medium 10.

The process of manufacturing this air filter 1 can be roughly divided into three steps: a fold line forming step 2, a folding step 3, and a joining step 4. In this example, an apparatus constituting each step 2 to 4 However, as shown in Fig. 2, they are arranged so that a series of operations are performed continuously. The arrangement of each of the steps 2 to 4 is not limited to this, and may be arranged separately or only two of the three steps may be arranged continuously. It is possible.

First, the filter medium 10 is supplied to a fold line forming step 2 including an apparatus as shown in FIG. As shown in FIG. 2, this filter medium 10 is set in a rolled state before the fold line forming step 2 and is supplied to the fold line forming step 2.

Returning to FIG. 3, the explanation will be continued. In this example, the filter medium 10 supplied to the fold line forming step 2 continuously in the longitudinal direction by the drive roller 21 is arranged above the mold 22, and the filter medium 10 is sandwiched therebetween. The ultrasonic horn 23, which is arranged to be able to move up and down, presses the filter medium 10, thereby forming a fold line 11 in the filter medium 10. The fold line 11 is a groove formed in the filter medium 10 as described above. In the subsequent folding step 3, the part of the fold line 11 is bent, so that the filter medium 10 becomes wavy. Is folded.

Here, as shown in FIG. 8, in a case where the fold lines 11 having different shapes are alternately formed on the filter medium 10 (hereinafter, referred to as a second embodiment), different shapes are provided on the mold base 2a. 2 molds 2 2 are provided in parallel, and this mold stand 2 a The filter media 10 alternately by moving them back and forth

One can form one.

Also, in the case of the second embodiment, as shown in FIG.

It may be composed of one step 2a and a second step 2b, and may be formed by passing through these two steps.

The ultrasonic horn 23 is for processing the filter medium 10 by heat generated by ultrasonic vibration. By pressing the ultrasonic horn 23 against the filter medium 10, the main fold line 1 is formed on the filter medium 10 at a position corresponding to the projection formed on the mold 22, as shown in FIG. 1 a, 1 lb minor fold line is formed. Further, in the second embodiment, as shown in FIG. 8, a main fold line 11a, a sub fold line 11b, and a wide fold line 11e are formed.

The ultrasonic horn 23 is attached to the lower end of a hydraulically driven press device 24, and moves up and down in accordance with the operation of the press device 24. Therefore, the ultrasonic horn 23 first descends with respect to the filter medium 10 and is pressed to form a fold line 11 on the filter medium 10. Thereafter, once the ultrasonic horn 23 is once raised, the filter medium 10 is simultaneously sent in the longitudinal direction so as to be shifted by one step. And again, the ultrasonic horn 23 descends. By repeating this, fold lines 11 are formed at equal intervals with respect to the filter medium 10.

Here, in the case of the second embodiment, the mold 22 shown in FIG. 5 and the mold 22 shown in FIG. 6 are mounted on the mold stand 22 a one by one. Then, the ultrasonic horns 23 are alternately pressed against the filter medium 10 against the molds 22 to form the fold lines 11.

The mold 22 is as shown in FIG. 5, and has a flat crimping surface 22a formed on the upper surface. The crimping surface 22a has streaky projections 22b, 22c. Are formed. Examples of the shapes of the projections 22b and 22c include those shown in FIGS. 5A to 5C. These are a straight main fold at the center in the short direction of the crimping surface 22a. A protrusion 22b is provided, and a sub-fold protrusion 22c is provided at a predetermined distance of both end portions of the crimping surface 22a so as to be separated from the main fold protrusion 22b on both sides. is there.

The one shown in Fig. 5 (A) shows that the secondary fold projections 22 are parallel to the main fold projections 2 2b from the both ends of the crimping surface 22a to the center. Then, it bends and goes diagonally toward the direction of the main fold projection 22b, where it merges. The one shown in FIG. 5 (B) has sub-fold projections 22 c extending obliquely from both ends of the crimping surface 22 a toward the main fold projections 22 b. The one shown in Fig. 5 (C) has a sub-fold protrusion 22 formed parallel to the main fold protrusion 22b, but the one shown in Figs. 5 (A) and (B) Is different from the main fold projection 2 2 b.

The shapes of the projections 22b and 22c are not limited to the above-mentioned shapes, but can be variously modified and implemented. In this example, two sub-fold line projections 2 2c are formed for one main fold line projection 2 2b, but the present invention is not limited to this. A large number of c may be formed.

In the case of the second embodiment, the mold shown in FIG. 6 is used at the same time. The die 22 shown in FIG. 6 also has a crimping surface 22 a similar to the die shown in FIG. 5 on the upper surface, and the crimping surface 22 a has streaky projections 22 b , 22 c and 22 d are formed.

This mold 22 is different from the mold 22 shown in FIGS. 5A to 5C in that the main fold projection 2 2 b provided at the center in the short direction of the crimping surface 22 a is formed by a mold. 22 are provided only at both ends in the longitudinal direction. In the central portion in the longitudinal direction, width-opening fold projections 22 d are formed so as to be located on both sides of the virtual extension line of the main fold projection 22 b. In this example, the fold projection 22d for widening is formed so that the main fold projection 22b branches into two branches. Although not shown, three or more ridges 2d for widening are also formed, or curved or curved. It may be a dotted line, and can be implemented in various forms.

The sub-fold projections 22c are provided in the same manner as shown in FIGS. 5A to 5C. The combination of the shape with 22 d is not particularly limited.

As described above, the main fold projections 2 2b, the sub fold projections 2 2c, and, in the case of the second embodiment, in addition to these, the wide fold projections 2 2d are formed on the mold 22. As a result, a main fold line 11a, a sub fold line 1lb, and a wide fold line 11e are formed as shown in Fig. 7 and Fig. 8 so as to correspond to each of the filter media 10. be able to. As a result, the filter medium 10 can be folded three-dimensionally as compared with the case where only the linear main fold line 11a is formed.

Among the above, the sub-fold line l ib exerts an effect on the front-side fold 11 c formed in the subsequent folding step 3. If the filter media 10 is folded only at the main fold line 1 1a, the filter media 10 is folded in a flat shape, so that the filter media 10 is formed in a form facing each fold line 11 The bag-shaped space 1 2 is narrow. On the other hand, in the portion near both sides 13 of the filter medium 10, the sub-fold line 11b is also folded, so that the interval between the main fold lines 11a can be increased, and as shown in FIG. Thus, the bag-shaped space 12 can be widened.

In addition, the widened crease line 11 e formed in the second embodiment is effective for the back crease 11 d. With only the formation of the sub-fold line 1 lb described above, the central portion of the bag-shaped space 12 does not spread much. Therefore, in this central portion, by forming the widened crease line 11 e in the filter medium 10, as shown in FIG. 10, the bag-shaped space 12 is formed at least with the wide crease line 11 e. It can be held at the set interval, and can be broadened as a whole in conjunction with the operation of the sub-fold line 11b. By forming the bag-shaped space 12 wide as described above, the air flow in the bag-shaped space 12 becomes better when the air fill 1 is actually used, and the pressure loss is relatively low. Phil evening can be offered. Also, in this mold 22, the number of main fold projections 2 2 b, sub fold projections 2 2 c, and widening fold projections 2 2 d is not limited to the above example. And can be changed in various ways. Thereby, the size of the bag-shaped space 12 can be appropriately changed, and the air filter 1 adapted to various purposes can be formed. The filter medium 10 is sent to the folding step 3 after the folding line forming step 2 described above.

This folding step 3 is performed by the apparatus shown in FIG. 11, and the two folding plates 31 a and 3 lb moving up and down move the folding line 1 as shown in FIGS. The filter medium 10 on which 1 is formed is folded. Each of the folding plates 3 1 a and 3 1 b includes an upper blade 31 a formed downward and a lower blade 31 b formed upward. b can move back and forth in the longitudinal direction of the filter medium in addition to vertical movement. Although the operation of the folding plates 3 la and 3 1 b will not be described in detail, the upper blade 31 a and the lower blade 31 b alternately sandwich the filter medium 10 vertically and longitudinally. Due to the movement, the filter medium 10 is folded in a wave shape. In this step 3, the position where the filter medium 10 is folded is adjusted in advance so as to match the position of the fold line 11, and the mountain fold and the valley fold are alternately performed.

Here, in the case of the second embodiment, the fold line 11 on the side where the widening fold line 11e was formed in the present process 3 is a valley fold when viewed from the front side. Yes, and the other fold line 11 is a mountain fold.

In the present step 3, the filter medium 10 folded as described above is heated by a flat electric heater 32 so that the filter medium 10 is folded. As a result, the filter medium 10 is supplied to the next joining step 4 in the folded state.

After the above-mentioned folding step 3, the filter medium 10 is sent to the joining step 4.

This joining step 4 is performed by the apparatus shown in FIG. 12, and the filter medium 10 which has been folded through the folding step 3 is opposed to each other. By joining the side edges 13, the bag-shaped spaces 12 are formed so as to be parallel in the longitudinal direction.

When the filter medium 10 in this state is viewed from the front side, of the fold lines 11, a mountain-folded one is a front-side fold 11c, and a valley-folded one is a back-side fold 11d. In each of the steps 2 to 4 in this example, the front fold 11c is located on the lower side, and the back fold lid is located on the upper side.

Here, the surfaces of the filter medium 10 divided by the respective fold lines 11 are referred to as a first surface 10a and a second surface 10b, and the first surface 10a and the second surface 10 sandwiching the back side fold 11d. The following description is given by naming one set of the unit wave body 10 e for convenience. The first surface 10a and the second surface 10b are alternately positioned with respect to each fold line 11. In addition, each fold 11 c, lid and each surface 10 a, 1

The positional relationship of Ob is as shown in FIG.

In this example, as shown in FIG. 13, the filter medium 10 is folded once in the longitudinal direction in the present process 4, and at the folded portion 4a, which is the portion, the unit medium 10e The side 13 of the first surface 10a and the second surface 1 Ob is joined.

In this example, as shown in FIGS. 13 and 14, FIG. 13 shows a rotary feeder 41 that holds the side 13 of the filter medium 10 and a unit wave body 10 e immediately before entering the folded portion 4 a. In this way, the unit holder body 10 e overlaps the folded part 4 a, and the first surface 10 a and the second surface 1 Ob are vertically overlapped by the work holder 42 that can be moved in the front-rear direction. It is arranged in a state, that is, a state of lying down. The transfer device 41 is rotatable, and the work holder 42 is movable in the front-rear direction as shown by a solid line and a two-dot chain line in FIG.

Then, a positioning head 43 is inserted between the first surface 10a and the second surface 10 of the unit wave body 10e in the above state, and the positioning of the unit wave body 10e at the turnback portion 4a is performed. Is made. The positioning head 43 is also shown in FIG. It is movable in the front-rear direction as indicated by the line and the two-dot chain line.

Next, a metal fitting jig 44 is arranged below the side 13 of the unit wave body 10e in a state where the positioning head 43 is inserted. At the same time or thereafter, the ultrasonic horn 45 descends from above the metal fitting jig 44 and presses the side 13 of the unit wave body 10e. Thus, the side 13 of the first surface 10a and the second surface 10b is sandwiched between the metal jig 44 and the ultrasonic horn 45. The first surface 10a and the second surface 10b of the sandwiched portion are heated by the ultrasonic horn 45, and are welded and integrated.

At the same time, as shown in FIG. 15, unnecessary portions outside the welding surface formed on the side 13 of the filter medium 10 are formed by the cutting edge portion 4 4 b formed on the metal fitting jig 44. Is cut off. As a result, the sides 13 of the first surface 10a and the second surface 10b are joined to each other with the backside fold 11d therebetween, and a bag-like space 12 having an opening 12a is formed. It is formed.

As described above, each time one unit wave body 10 e is joined, the work holder 42 and the positioning head 43 are moved backward, as shown by a two-dot chain line in FIG. 13. The bracket jig 44 moves once to the diagonally lower position shown by the two-dot chain line in FIG. 14, and in that state, the rotary feeder 41 is formed around it. By rotating one of the filter medium holding branches 41a, the unit wave body 10e to be processed next is arranged in the folded portion 4a. Then, the above procedure is repeated again, and the filter media 10 are joined one after another.

The configuration of this part is not limited to the one described above, and can be implemented with various changes. For example, in addition to the work holder 42, a stopper for holding the filter medium 10 before processing may be separately provided. Instead of using the positioning head 43, a similar effect may be obtained by pinching and pulling the filter medium 10 from the outside.

The metal fitting jig 44 used in the joining step 4 is shown in a plan view in FIG. Fig. 15 (A) is a cross-sectional view taken along the line A-A in Fig. 15 (A), which is shown in Fig. 15 (B). It is arranged symmetrically left and right to come to the position. On the upper surface of the metal fitting jig 44, a crimping part 44a and a cutting blade part 44b are formed.

In this example, a hatched groove is formed in the crimping portion 44a. For this reason, when the filter medium 10 is joined by the ultrasonic horn 45, this hatched pattern is formed on the side 13 of the filter medium 10. As a result, as compared with the case where the crimping portion 44a is a smooth flat surface, the ultrasonic horn 45 generates heat more quickly, so that the filter medium 10 is hardly deteriorated by heat, and the process itself is performed. Can be performed promptly. The shape of the crimping portion 44a is not limited to the shape described above, and may be implemented in various forms. The cutting edge 44b can be divided into an ear cutting edge 44c, a side cutting edge 44d, and a bottom cutting edge 44e. In this example, as shown in Fig. 15 (A), they are in a right-angled positional relationship and are continuous through the radius, but their shapes are There is no limitation, and there may be no connection and the connection may be straight. Further, the ear cutting edge 44c and the bottom cutting edge 44e may be omitted depending on the shape. Also, the cutting edges 44 a to 44 c need not be at right angles. For example, the side edges 13 b formed on the filter medium 10 after cutting are perpendicular to the fold line 11. The side cutting edge 44 d may be formed obliquely so as to have an angle other than that described above, and implementation is possible by variously changing the form.

By pressing the ultrasonic horn 45 as shown in FIG. 14 onto the unit wave body 10 e on the fitting jig 44 formed as described above, the unit wave body 10 e is formed. The side edge 13 corresponds to the edge cutting edge 4 4c of the cutting edge portion 4 4b, and the edge side edge 13a corresponds to the side cutting edge 4 4d. b forms a bottom side edge 13c with respect to the bottom cutting edge 44e. As a result, a lug 14 is formed at the end of the front side fold 1 lc, and this portion becomes a portion that is hooked to each device or mounting frame after the air filter 1 is completed.

Four Further, as described above, the metal fitting jig 44 is movable in order to avoid interference when transmitting the unitary wave body 10a in the folded portion 4a. The moving direction of the metal fitting jig 44 may be set in various directions depending on the design of the device. In this example, as shown by a solid line and a two-dot chain line in FIG. 14, it is possible to move diagonally.

In the method of joining and cutting the filter medium 10 described above, according to the conventional method using a heater, etc., it is necessary to perform joining by heating and cutting of the joined portion in separate steps. There was a problem that it was difficult to position the filter medium 10 for cutting. On the other hand, in the method according to the present invention, since these can be performed at the same time, the joining position and the cutting position necessarily coincide. For this reason, the above positioning problem is solved.

Similarly to the ultrasonic horn 23 in the fold line forming step 2, the ultrasonic horn 45 is attached to the distal end of the hydraulically driven press device 46, and corresponds to the metal jig 44. There are two.

In this example, the ultrasonic horn 45 is disposed so as to descend from the upper side with respect to the unit wave body 10 e which is in the folded state at the folded portion 4 a, so that the conventional There is no need to press the sonic horn against the filter medium 10 from the lateral direction, so that the device is relatively compact and workability is improved. Of course, depending on the design conditions of the device, it may be arranged so that the filter media is pressed from the lateral direction as before.

In this example, the ultrasonic horns 23 and 45 are used in the fold line forming step 2 and the joining step 4. These are to form a fold line 11 or join the filter medium 10 using heat generated by ultrasonic vibration, specifically, frictional heat. By using these ultrasonic horns 23 and 45, only the necessary points can be locally heated, so that the deformation caused by high heat over a wide area caused by the conventional method using a heater etc. It is excellent in that it can prevent is there.

The air filter 1 is completed by cutting the filter medium 10 formed in each of the above steps 2 to 4 by counting the number of peaks formed by the fold line 11 for each required length in the longitudinal direction. Let it.

When the air filter 1 is actually attached to each device and used, as shown in FIG. 16, the air filter 1 is made of resin, metal, cardboard, and the same material as the filter medium 10. A filter unit is formed by attaching the filter unit to a base material 51 made of a material or the like, or a resin unit is welded to the air filter 1 to form an integrated filter unit. In the latter case, for example, the air filter 1 is arranged in the mold of the injection molding machine, and the thermoplastic resin is placed in the space between the entire outer peripheral side surface of the air filter 1 and the inner surface of the mold in the mold. The material is heated and melted and injected, so that the frame is formed integrally with the air filter 1. As the thermoplastic resin for forming the frame, a material obtained by kneading a powder frame of waste paper may be used. As a result, the used filter unit can be incinerated and disposed of, and the filter unit can be manufactured at a low cost and light weight.

In the actual use state of the air filter 1, the air filter 1 is arranged so that the air flow passes from the back side to the front side.

The filter unit molded as described above is incorporated into each device for use. It is also possible to directly attach the air filter 1 without forming a frame as described above.

When attaching the air filter 1 to the above-mentioned frame, etc., the air filter 1 may be simply aligned with the front and back, but a part of the side 13 of the air filter 1 that is not joined is made. However, this part may be folded back and assembled as shown in FIG. 17 (A), inserted into a separately formed casing, and used as a filter unit. This may be formed by repeating folding as shown in FIG. 17 (B). Further, as shown in FIG. 18, the air filter 1 may be combined in a V-shape to form a filter unit. In this example, the air filter 1 is formed on the base material 51 so that the openings 12a face each other so as to form a V-shape when viewed from the side, thereby forming a V-shaped space. Are closed with closing plates 52 on both sides. The base material 51 and the closing plate 52 may be made of a material having no air permeability or a material having the same air permeability as the filter material 10.

By forming the filter unit by each of the above methods, even when the area of the mounting unit of the filter unit is limited, a large number of air filters 1 can be arranged, and the dust collection efficiency can be improved. . The invention of the present application has the following effects because it is configured as described above. In the first invention of the present application, since it is not necessary to form a side plate or the like on the filter medium as in the related art, the processing of the filter medium can be simplified. Also, the workability of the filter material joining process is good.

Further, in the second invention of the present application, in addition to the effects of the first invention, by forming the fold line from the main fold line and the sub fold line, the filter medium can be folded three-dimensionally. The bag-shaped space can be widened.

In the third or fourth invention of the present application, by forming a wide crease line in the filter medium, a bag-like space of the air filter can be formed wider, air can be easily introduced into the bag-like space, and the pressure can be increased. A filter with relatively low loss can be provided.

Also, in the fifth invention of the present application, in addition to the effects of the first or fourth invention, since the filter medium is joined by utilizing heat generated by ultrasonic vibration, only the minimum necessary parts are locally Since it is possible to form a joint, it is possible to prevent deformation and damage due to a wide range of high heat generated by a conventional method using a heater or the like.

In the sixth invention of the present application, in addition to the effect of the fourth invention, in the front fold, a sub fold line is formed at both ends of the filter medium with the main fold line interposed therebetween, and the back fold line is formed. Eye In this case, the bag-shaped space can be formed wider by forming two width-folding fold lines in the center of the filter medium.

Further, in the seventh invention of the present application, since it is not necessary to form a side plate or the like on the filter medium as in the related art, the processing of the filter medium can be simplified. Also, the workability is good in the joining process of the filter media.

Further, since the joining by heating and the cutting on the joined portion can be performed simultaneously, the joining position and the cutting position necessarily coincide with each other, so that there is no problem in positioning.

Also, in the eighth invention of the present application, by forming a fold crease line in the filter medium, the bag-like space of the air filter can be formed wider, and air is introduced into the bag-like space, and the pressure loss is reduced. Can provide a method of manufacturing a filter having a relatively low noise.

Claims

The scope of the claims

1. For the belt-shaped filter media (10),

A fold line (11) is formed at regular intervals in a direction orthogonal to the side (13) between both sides (13) parallel to the longitudinal direction of the filter medium (10),

In an air filter formed by alternately folding the fold line (11) above,

The mountain-folded fold line becomes the front-side fold (11c), the valley-folded fold line becomes the back-side fold (11d),

The filter medium (10) is divided into a first surface (10a) and a second surface (1 Ob) through each fold line (11), and the first surface (10a) and the second surface (1 Ob) are divided. By alternately coordinating with 10b), the filter medium (10) is formed in a continuous wave shape,

The side surface (13) of the first surface (10a) and the side surface (13) of the second surface (1 Ob) are joined with the back side fold (lid) therebetween.

As a result, an opening (12a) is formed between the adjacent front side folds (11c), and is formed by the back side fold (11d), the first surface (10a), and the second surface (10b). An air filter characterized by forming an enclosed bag-shaped space (12).

2. The above fold line (11) is a linear main fold line (11a) formed between both sides (13),

The part near the both sides (13) is composed of sub-fold lines (1 lb) formed on both sides of the main fold line (11a),

2. The air filter according to claim 1, wherein the bag-shaped space (12) can be formed wider by this.

3. For the belt-shaped filter media (10), A fold line (11) is formed at regular intervals in a direction orthogonal to the side (13) between both sides (13) parallel to the longitudinal direction of the filter medium (10),

In an air filter formed by alternately folding the fold line (11) above,

· It is characterized in that at least one of the fold lines (11) is formed as a plurality of wide fold lines (lie) at the center in the short direction of the filter medium (10). Airfill evening.

4. The filter medium (10) is divided into a first surface (10a) and a second surface (10b) through each fold line (11), and these first surface (10a) and second surface (10 b) are alternately coordinated with each other, so that the filter medium (10) is formed in a continuous wave shape,

The fold line (11) for the mountain fold is the front fold (11c), and the fold line for the valley fold (11) is the back fold (lid),

The side (13) of the first surface (10a) and the side (13) of the second surface (1 Ob) are joined with the back side fold (lid) therebetween.

As a result, an opening (12a) is formed between adjacent front side folds (11c), and is surrounded by the back side fold (lid), the first surface (10a), and the second surface (10b). And a bag-shaped space (12) is formed,

The above width crease line (l i e) is formed at the position of the back side crease (l i d).

4. The air filter according to claim 3, wherein a central portion of the bag-shaped space (12) can be formed wider by this.

5. The air filter according to claim 1, wherein the joining is performed by ultrasonic welding.

6. Regarding the above fold line (11), the front fold line (11c) is a straight main fold line (11a) formed between both sides (13) and the short side direction of the filter medium (10). And a sub-fold line (11b) formed at both sides of the main fold line (11a) at both end portions of the

The back fold (1 Id) is located on both sides of the straight main fold line (11a) formed at both ends in the short direction of the filter medium (10) and the main fold line (11a). The sub-fold line (lib) formed at the center of the filter medium (10) in the short direction, and the two width-fold lines (11 e) branching off from the main fold line (11a) The air filter according to claim 4, wherein the air filter has the following.

7. For the strip-shaped filter media (10) that is continuously supplied in the longitudinal direction,

Forming a fold line (11) at right angles to the side (13) parallel to the longitudinal direction of the filter medium (10) and forming a fold line (11) between the both sides (13) at a certain interval; By folding the above fold line (11) alternately between the valley and the valley, the fold line at the mountain fold becomes the front fold (11c), and the fold line at the valley fold becomes the back fold (lid). (10) is divided into a first surface (10a) and a second surface (10b) via each fold line (11), and these first surface (10a) and second surface (10b) ) And the folding step (3),

The side (13) of the first side (10a) and the side (13) of the second side (10b) are joined via the back side fold (lid), and It consists of the cutting process and the joining process (4),

A method for manufacturing an air filter, wherein the joining and the cutting are performed by applying a force in a direction in which the first surface (10a) and the second surface (10b) are in close contact with each other.

8. For the strip-shaped filter media (10) continuously supplied in the longitudinal direction, Forming a fold line (11) at right angles to the side (13) parallel to the longitudinal direction of the filter medium (10) and forming a fold line (11) between the both sides (13) at a certain interval; By folding the above fold line (11) alternately between the valley and the valley, the fold line at the mountain fold becomes the front fold (11c) and the fold line at the valley becomes the back fold (id). The filter medium (10) is divided into a first surface (10a) and a second surface (1 Ob) through each fold line (11), and these first surface (10a) and second surface (10b) And the folding process (3) are alternately arranged.

The side (13) of the first side (10a) and the side (13) of the second side (1 Ob) are joined via the back side fold (lid), It consists of the cutting process and the joining process (4),

Regarding the above-mentioned fold line (11), it is understood that, in the back fold (1 Id), a plurality of wide fold lines (lie) are formed at the central portion in the short direction of the filter medium (10). A characteristic method for manufacturing air filters.