JP3770838B2 - Single stage corrugated dust filter - Google Patents

Description

【００３２】
２−１．粉塵保持容量の評価
参考例１〜３、実施例１、比較例１〜５を試験用ダスト１１種を用いて下記の手順にてフィルターの除塵効率を測定した。評価したサンプルは１００ｍｍ×１００ｍｍ角。
手順
( １ )ウレタン部分が風上になるように評価用フィルター設置する。
( ２ )風速２ｍ／ｓｅｃで試験用ダスト１１種１ｇ、評価用フィルターへ送り込む。
( ３ )評価フィルターの初期の圧力損失の２倍になるまで、の操作を繰り返す。
( ４ )評価フィルターの初期の圧力損失の２倍になった時点、ダスト捕捉量を求めて粉塵保 持容量とする。
【００３３】
２−２.評価結果
評価結果を以下の表２に示す。
【００３４】
【表２】

【００３５】
３−１．水洗性能の評価
実施例１、比較例１，２，４を２００ｍｍ×２００ｍｍのサイズにカットして評価した。約１０分間水に浸積後、軽く押し洗いをする。その後、軽く水を切った後、雑巾を絞るように水を切り、陰干しする。
【００３６】
３−２．評価結果
評価結果を以下の表３に示す。
【００３７】
【表３】

【００３８】
４−１．水洗耐久性の評価
参考例３、実施例１を２００ｍｍ×２００ｍｍのサイズにカットして評価した。約１０分間水に浸積後、軽く押し洗いをする。その後、軽く水を切った後、雑巾を絞るように水を切り、陰干しする。この操作を２０回行った。
【００３９】
４−２．評価結果
評価結果を以下の表４に示す。
【００４０】
【表４】

【００４１】
【発明の効果】
除塵フィルターの評価により、単段コルゲート除塵フィルターは、除塵効率が高く、粉塵をたくさん保持できることが分かった。また、水洗可能な単段コルゲート除塵フィルターは手揉み洗いしても、元の形に戻り、何回も洗浄して使用できるフィルターであることがわかった。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a dust filter.
[0002]
[Prior art]
In recent years, due to changes in the living environment and an increase in health-consciousness, the use of air purification devices has been promoted in homes and workplaces. This device removes dust and dust such as cigarette smoke, pollen, and mite bodies, and further deodorizes odors such as cigarette odors and pet odors. As a method, in a domestic air purifier, a dust removing function is realized by a HEPA filter or an electret filter, an electric dust collection method, and a deodorizing function is realized by an activated carbon filter, ozone, a photocatalytic filter, and the like, and is widely spread.
[0003]
As part of this, the number of cases where air purifiers are added to air conditioners such as air conditioners is increasing. For room air conditioners, HEPA filters and electret filters are used for dust removal, and photocatalytic filters and catechins are used for deodorization. It has been adopted.
[0004]
Among them, the above-described HEPA filter, electret filter, and electrostatic dust collection method are mainly used as a dust removal function. The purpose of these dust removal methods is mainly to remove fine dust. Air conditioners, vacuum cleaners, etc. need to have an air purifier function in a narrow space. For this reason, the filter becomes smaller and the dust holding capacity is reduced, so that the filter is clogged immediately and the use of the filter is not sufficient. Further, a single-plate dust filter is usually used in such a narrow place, and these are mainly for coarse dust. The dust removal filter that removes fine dust is clogged immediately and the pressure loss increases, so the current situation is that it is not used.
[0005]
Furthermore, the filter etc. are basically disposable, which is contrary to the recent direction of waste reduction. It is very useful if such a dust removal filter can be used again by washing with water. Normally, dust filters that are folded into pleats are fixed to a frame, and using special equipment such as an ultrasonic cleaner can remove accumulated dust, but such a cleaning method is not available at home. The current situation is possible. The method of washing the dust removal filter at home is push washing or scouring, and the filter fixed to the frame as described above cannot perform such washing.
[0006]
[Problems to be solved by the invention]
The present invention solves the above-described problems, and an object thereof is to provide a dust removal filter capable of holding a large amount of dust. Furthermore, the present invention provides a filter having a structure that makes it easy to remove dust accumulated by washing the dust filter with water.
[0007]
[Means for Solving the Problems]
As a result of intensive studies to solve the above-mentioned problems, the present inventor has produced a single-stage corrugated dust removal filter in which the liner part is an ether-based breathable urethane foam having a cell size of 30 cells / inch and the corrugation part is a dust removal filter. It has been found that the adhesive used for this purpose is a water-resistant adhesive, and the problem can be solved by a single-stage corrugated dust filter that makes the filter washable . Thereby , it is possible to provide a single-stage corrugated dust filter that can not only hold a lot of dust but can be washed with water.
[0008]
In the present invention, the corrugated portion can be controlled at a peak height of 5 mm or less. Usually, a pleated filter or the like is limited by a manufacturing machine, and it has been difficult to fold it to a height of 5 mm. In addition, it is necessary to fix the folded pleats with a ribbon or a filter frame. As a practical matter, it is impossible to manufacture a pleated filter having a thickness of 5 mm or less. However, since the present invention is a single-stage corrugated, the height of the mountain can be 5 mm or less, and the dust removal filter can be installed in a narrow installation space, particularly in an installation place in a thin thickness direction.
[0009]
Furthermore, in the present invention, it is possible to provide a dust removing filter having a structure in which dust is held in the liner part of the single-stage corrugated dust removing filter, and further, the corrugated part firmly receives the dust, and the dust easily drops by washing. It was.
[0010]
In the present invention, since the liner portion is an ether-based air-permeable urethane foam, a flexible dust removal filter can be provided, and a filter that can be perfectly attached to a product having a curved surface such as a vacuum cleaner can be provided. Usually, since a pleated filter is always fixed with a filter frame, it is usually difficult to use a flexible filter. In addition, due to the stretchability of urethane foam, it can be installed in a place slightly narrower than the thickness of the filter, and there is flexibility in dimensions. Thus, it has become possible to provide a filter that can be mounted along the mounting portion in a narrow place.
[0011]
In the present invention, since the adhesive for producing a single-stage corrugate is a water-resistant adhesive, it has become possible to provide a single-stage dust removal filter that can be washed by washing or manually. In this case, it is essential to use an ether-based air-permeable urethane foam having flexibility and shape self-restoring in the liner portion. By using this material, the corrugated shape of the corrugated portion is destroyed by washing by pressing or by hand-washing, but the original corrugated shape can be restored together with the self-restoring property of the liner portion.
[0012]
Usually, when a nonwoven fabric is used for the liner portion, a large and small number of wrinkles enter and cannot be self-recovered by hand-washing, and the corrugated portion formed thereon cannot be used as a filter because the shape of the corrugated portion collapses.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
A single-stage corrugated dust filter characterized in that the liner part is an ether-based breathable urethane foam having a cell size of 30 cells / inch or more, and the corrugated part is a dust filter.
[0014]
In the present invention, the breathable urethane foam is a film in which a film portion of a normal urethane foam is melted and only the skeleton is left to ensure breathability. As such urethane foams, there are ester type and ether type, and ether-based breathable urethane foam is preferred in the present invention because ether-based with less hydrolysis is preferable for a single-stage corrugated filter that can be washed with water. Is used . Further, the cells of the urethane foam have various sizes and there is a problem with the thickness, but the size of 30 cells / inch or more is required as described in claim 1. Furthermore, in consideration of air permeability, 100 cells / inch or less is preferable. The thickness is preferably 2 mm or more, and more preferably 10 mm or more. The thicker the urethane foam, the greater the dust holding capacity. As for the color, black is preferable as the coarse dust removing filter, in which dirt is not noticeable, but yellow and green are also preferable in consideration of design. In addition, urethane foam with flame retardant specification or antibacterial agent can be used without any problem.
[0015]
In the present invention, various dust removal filters can be used. Almost all filter media such as electret filters, HEPA filters, and medium performance filters can be used regardless of the dust removal method. Almost all filter media can be used as long as they can be corrugated. Among them, a low pressure loss electret filter can be preferably used.
[0016]
In the present invention, various adhesives can be used as an adhesive for producing a single-stage corrugated dust filter, water-soluble PVA adhesives, cellulose adhesives, latex adhesives, organic solvent adhesives. In order to make a single-stage corrugated dust filter that can be washed with water, a water-resistant adhesive is used .
[0017]
Examples of the water-resistant adhesive that can be preferably used in the present invention include the following. Urea resin adhesives, melamine resin adhesives, phenol resin adhesives, epoxy resin adhesives, acrylic emulsion adhesives, polyurethane adhesives, resorcin adhesives, vinyl acetate adhesives, hot melt adhesives Etc. can be preferably used. Among these, acrylic adhesives can be more preferably used from the viewpoints of handling properties and processability.
[0018]
In the present invention, when single-stage corrugation is performed, corrugates of various cell sizes can be preferably used. It is possible to appropriately change the pitch size depending on the filter installation location. When the installation thickness is very thin, less than 5 mm, a small pitch size is used, and when the installation thickness is 5 mm or more, a larger pitch size can be used.
[0019]
【Example】
EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to the examples.
[0020]
Reference example 1
<Production of single-stage corrugated dust filter 1>
Cell size 30 cells / inch, 5 mm thick ester-based breathable urethane foam (Inoac Corp .: Product No. MF30) liner, electret filter media (Toray: Tremicron ES040) corrugated, polyvinyl alcohol as adhesive use system adhesives, pitch 4.2 mm, a single-stage corrugated size of height 2.5mm was prepared. The single-stage corrugated dust filter 1 was cut into a size suitable for the equipment to be used.
[0021]
Reference example 2
<Production of single-stage corrugated dust removal filter 2>
Cell size 50 cells / inch, 5 mm thick ester-based breathable urethane foam (Inoac: Product No. MF50) liner, electret filter media (Toray: Tremicron ES040) corrugated, polyvinyl as adhesive use alcohol-based adhesive, pitch 4.2 mm, a single-stage corrugated size of height 2.5mm was prepared. This was cut into a size suitable for the equipment to be used to obtain a single-stage corrugated dust removal filter 2.
[0022]
Reference example 3
<Production of single-stage corrugated dust removal filter 3>
Cell size 50 cells / inch, 15 mm thick ester-based breathable urethane foam (Inoac: Product No. MF50) liner, electret filter medium (Toray: Tremicron ES040) corrugated, polyvinyl as adhesive use alcohol-based adhesive, pitch 4.2 mm, a single-stage corrugated size of height 2.5mm was prepared. This was cut into a size suitable for the equipment to be used to obtain a single-stage corrugated dust removal filter 3.
[0023]
Example 1
<Production of single-stage corrugated dust removal filter 4>
Cell-line 50 cell / inch, 15 mm thick ether-based breathable urethane foam (Inoac: Product No. CFH50) liner, electret filter media (Toray: Tremicron ES040) corrugated, acrylic on adhesive A single-stage corrugate having a pitch of 4.2 mm and a height of 2.5 mm was prepared using a system adhesive (manufactured by NSC Japan, product number AD81B). A single-stage corrugated dust filter 4 that can be washed with water by cutting into a size suitable for the equipment to be used.
[0024]
Comparative Example 1
<Preparation of dust removal filter 1>
A dust filter 1 was obtained by cutting the electret filter material (Toray Industries, Inc .: Tremicron ES040) into a size suitable for a device using a single plate.
[0025]
Comparative Example 2
<Production of dust removal filter 2>
Electret filter medium (manufactured by Toray Industries, Inc.: Torre micron ES040) was Tsu folding in height 5mm in the pleat folding machine. Was then a filter to the multiplied by the ribbon at the hot-melt glue on the pitch 4mm. The filter was cut to a size suitable for the equipment in which the filter was used, and the dust removal filter 2 was obtained.
[0026]
Comparative Example 3
<Preparation of dust removal filter 3>
Dry nonwoven fabric (manufactured by Kurashiki Fiber Processing Co., Ltd .: product number FL70) is used for the liner part, electret filter media (manufactured by Toray Industries Co., Ltd .: Tremicron ES040) is used for the corrugated part, and polyvinyl alcohol adhesive is used for the adhesive, pitch 4.2 mm, high It is to prepare a single-stage corrugated of 2.5mm size. This was cut to a size suitable for the equipment to be used, and a dust removal filter 3 was obtained.
[0027]
Comparative Example 4
<Production of dust removal filter 4>
Dry type non-woven fabric (manufactured by Kurashiki Fiber Processing Co., Ltd .: product number FL70) is used for liner, electret filter media (manufactured by Toray Industries, Inc .: Tremicron ES040) is used for corrugated part, and acrylic adhesive (manufactured by NSC Japan: product number AD81B) is used as adhesive. to, to prepare a pitch 4.2 mm, single-stage corrugated size of height 2.5 mm. This was cut to a size suitable for the equipment to be used, and a dust removal filter 4 was obtained.
[0028]
Comparative Example 5
<Preparation of dust removal filter 5>
An ether type air-permeable urethane foam (manufactured by INOAC: product number CFH50) having a cell size of 50 cells / inch and a thickness of 15 mm was cut to a size suitable for the equipment to be used to obtain a dust removal filter 5 made only of urethane.
[0029]
<Evaluation of dust filter>
1-1. Evaluation of dust removal performance
The dust removal efficiency of the filters was measured by the following procedure using Reference Examples 1 to 3, Example 1 and Comparative Examples 1 to 5 using 11 kinds of test dust. The evaluated sample is 100 mm × 100 mm square.
procedure
( 1 ) Install an evaluation filter so that the urethane part is on the windward side.
( 2 ) The test dust is sent to the evaluation filter at 1 m at a wind speed of 2 m / sec.
( 3 ) The weight of the filter after evaluation was measured, and the amount of trapped dust and dust removal efficiency were determined.
[0030]
1-2. Evaluation Results The evaluation results are shown in Table 1 below.
[00 31 ]
[Table 1]

[00 32 ]
2-1. Evaluation of dust holding capacity
The dust removal efficiency of the filters was measured by the following procedure using Reference Examples 1 to 3, Example 1 and Comparative Examples 1 to 5 using 11 kinds of test dust. The evaluated sample is 100 mm × 100 mm square.
procedure
( 1 ) Install an evaluation filter so that the urethane part is on the windward side.
( 2 ) The test dust is sent to the evaluation filter at 1 m at a wind speed of 2 m / sec.
( 3 ) Repeat the operation until the initial pressure loss of the evaluation filter is doubled.
( 4 ) When the initial pressure loss of the evaluation filter is doubled, determine the amount of dust trapped and use it as the dust holding capacity.
[00 33 ]
2-2. Evaluation results
The evaluation results are shown in Table 2 below.
[00 34 ]
[Table 2]

[00 35 ]
3-1. Evaluation of Washing Performance Example 1 and Comparative Examples 1, 2, and 4 were cut into a size of 200 mm × 200 mm and evaluated. After soaking in water for about 10 minutes, lightly wash. Then, after draining lightly, drain the water as if squeezing a rag and dry it in the shade.
[00 36 ]
3-2. Evaluation results
The evaluation results are shown in Table 3 below.
[00 37 ]
[Table 3]

[00 38 ]
4-1. Evaluation of washing durability
Reference Example 3 and Example 1 were cut into a size of 200 mm × 200 mm for evaluation. After soaking in water for about 10 minutes, lightly wash. Then, after draining lightly, drain the water as if squeezing a rag and dry it in the shade. This operation was performed 20 times.
[00 39 ]
4-2. Evaluation results
The evaluation results are shown in Table 4 below.
[00 40 ]
[Table 4]

[00 41 ]
【The invention's effect】
Evaluation of the dust removal filter revealed that the single-stage corrugated dust removal filter has high dust removal efficiency and can hold a lot of dust. It was also found that a single-stage corrugated dust filter that can be washed with water returns to its original shape even after hand-washing and can be used after being washed many times.

Claims (1)

A single-stage corrugated dust filter with an ether-based breathable urethane foam having a cell size of 30 cells / inch or more and a corrugated portion consisting of a dust filter, and the adhesive for producing the corrugated dust filter is water-resistant. A single-stage corrugated dust filter, characterized in that the corrugated dust filter can be washed with water .