JP5629599B2 - Air filter, air filter manufacturing method and air filter manufacturing apparatus - Google Patents

Description

  The present invention relates to an air filter for removing dust and contaminants in the air, an air filter manufacturing method, and an air filter manufacturing apparatus.

  2. Description of the Related Art Conventionally, an air filter in which a rectangular filter medium pack formed by folding filter paper or nonwoven fabric into a pleat shape is housed inside a square frame filter frame is widely known. The filter frame is known to be made of metal or resin. In the case of metal, the filter frame is generally composed of four plate-like members bent into a U-shape. The filter medium pack is adhered to each plate member by a fluid adhesive filled inside the U-shape, and the plate members are fixed to each other by screws, connecting fittings, or the like.

  When the filter frame is made of resin, it is known that the filter frame is formed by so-called injection molding in which a molten resin is pressed into the outer periphery of the filter medium pack. In the injection molding, a pair of comb-shaped molds are usually prepared so that the molten resin does not flow into the filter medium pack, and the filter medium pack is sandwiched between these molds.

  Further, as disclosed in Patent Document 1, a filter medium pack cut out in a circular shape is put in a circular filter frame, and a sealing material is poured between the filter medium pack and the filter frame by centrifugal force, so that the filter medium pack is filtered. A method of fixing inside the frame is also known.

JP 2006-35083 A

  However, when the filter frame is constituted by four plate-like members, the number of manufacturing steps and the number of parts increase, and there is a problem in the sealing performance between the filter medium pack and the plate-like members, and between the plate-like members. May occur. On the other hand, in the injection molding, there is a problem that a comb-shaped mold is complicated and a great amount of cost is required to manufacture the mold.

  Moreover, in the method of patent document 1, since a filter medium is circular, a special tool and an apparatus are required in order to cut out a filter medium pack circularly, and also it is necessary to prepare a circular filter frame separately.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide an air filter that can be manufactured with a simple manufacturing apparatus and method with a small number of parts. .

  The method for manufacturing an air filter according to the present invention includes a first step of disposing a frame-shaped mold in which a filter medium is accommodated on a cradle in which a sealing material is stored, and the cradle is rotated to perform centrifugation. The sealing material is injected into the outer periphery of the inside of the frame mold by force, and the outer portion of the filter medium is filled with the sealing material to solidify, and the ventilation portion through which air passes without filling the central portion of the filter medium And a third step of releasing the filter medium integrated with the sealing material from the frame-shaped mold.

  When there is a gap filled with the sealing material between the frame-shaped mold and the filter medium, the sealing material filled in the gap is solidified and laminated on the outer peripheral surface of the filter medium. A tubular member may be disposed in the gap, and the tubular member may be integrated with a sealing material filled in the gap and solidified. In this case, the tubular member is formed of, for example, a pipe or a female screw, and serves as an attachment member for attaching the air filter to another member.

  The frame-shaped mold is preferably an assembly of a plurality of frame members. In this case, by disassembling the frame-shaped mold into a plurality of frame members in the third step, the filter medium integrated with the sealing material can be released from the frame-shaped mold. It is more preferable that the frame-shaped mold has a quadrangular frame shape including four frame members that form each side of the quadrangle.

  An air filter according to the present invention includes a filter medium, and a sealing material that is filled in an outer portion of the filter medium, and that is not filled in the center portion of the filter medium, and has a circular ventilation portion through which air passes. Features.

  A mounting hole along the ventilation direction of the filter medium may be provided in the outer portion. Moreover, the sealing material is laminated | stacked on the outer peripheral surface of the filter medium, and the above tubular members may be provided in the laminated sealing material.

  An air filter manufacturing apparatus according to the present invention is configured to have a mortar-shaped recess having a mortar-like recess in which a sealing material is stored, and is configured to surround the recess when viewed from above, with a filter medium inside. And a rotating means capable of rotating the cradle and injecting the sealing material into the outer periphery of the frame-shaped mold by centrifugal force.

  In the present invention, the filter medium is, for example, formed by folding a sheet-like filter medium into a pleat shape or having a three-dimensional network structure. Moreover, it is preferable that a filter medium is a rectangular parallelepiped from the ease of a cutting | disconnection.

  In the present invention, it is possible to manufacture an air filter by a method that does not specially process the filter medium and uses a relatively simple device with a small number of manufacturing steps.

It is a perspective view which shows the air filter in 1st Embodiment. It is a disassembled perspective view which shows the structure of the metal mold | die in 1st Embodiment. It is sectional drawing which shows the air filter manufacturing apparatus in 1st Embodiment, Comprising: It is sectional drawing which follows the III-III line | wire in FIG. It is a perspective view which shows the air filter in 2nd Embodiment. It is a perspective view which shows the air filter in 3rd Embodiment.

Hereinafter, the present invention will be described in more detail with reference to the drawings.
FIG. 1 shows an air filter according to a first embodiment of the present invention. As shown in FIG. 1, the air filter 10 is a filter medium pack 11 filled with a sealing material 12.

  The filter medium pack 11 is formed by folding a filter paper made of glass fiber or the like, or a sheet-like filter medium made of nonwoven fabric such as polyester into a rectangular parallelepiped having a predetermined thickness, and is ventilated in the thickness direction. Is. As will be described later, the sealing material 12 is obtained by solidifying a thermoplastic resin or a thermosetting resin. In the following description, the direction along the folds of the filter media pack 11 is defined as the horizontal direction, orthogonal to the horizontal direction, and the direction in which the pleats are arranged as the vertical direction. Further, the thickness direction of the filter media pack 11 is orthogonal to these vertical and horizontal directions.

  In the air filter 10, the central portion 21 of the filter medium pack 11 is not filled with the sealing material 12, and the central portion 21 of the filter medium pack 11 has a circular (specifically, cylindrical) ventilation for allowing air to pass through. Part. On the other hand, the outer portion 22 of the filter medium pack, that is, the portion other than the central portion 21 is filled with the sealing material 12 and is buried by the sealing material 12 and becomes a non-ventilated portion that does not allow air to pass therethrough. Thereby, the circular ventilation part is surrounded by the non-ventilation part (outer part 22) filled with the sealing material 12 of the filter pack 11 and the air passing through the ventilation part is, for example, the outer peripheral surfaces 11B and 11D of the filter pack 11. It is prevented from getting out of it. In addition, the shape of the air filter 10 is held by the outer portion 22 and is prevented from being greatly deformed even when an external force is applied.

  The sealing material 12 is filled between the pleats on both the front surface 11E and the back surface 11F of the filter material pack 11, and the front surface 11E and the back surface 11F in the outer portion 22 are substantially flat due to the sealing material 12. Further, the sealing material 12 is thinly laminated not only on the ridges but also on the outer peripheral surfaces 11A to 11D of the filter medium pack 11, so that the air filter 10 has the vertical and horizontal dimensions of the filter medium pack 11. It is a substantially rectangular parallelepiped that is slightly larger than the vertical and horizontal dimensions.

  A mounting hole 23 is formed in the outer portion 22 of the filter medium pack 11 along the thickness direction (ventilation direction). The attachment holes 23 are provided at the four corners of the air filter 10. The air filter 10 is used by being attached to, for example, the fan 30 with an attachment member such as a screw inserted into the attachment hole 23. The vent 31 of the fan 30 connected to the ventilation portion of the air filter 10 is circular, and the diameter thereof is substantially the same as the diameter of the circular ventilation portion of the filter 10.

  Of course, the air filter 10 may be attached to other than the fan. For example, the air vent may be connected to a circular pipe or the like, or may be connected to a non-circular vent.

  2 and 3 are views showing an air filter manufacturing apparatus. As shown in FIG. 3, the air filter manufacturing apparatus is configured by placing a mold 40 on a rotating jig 41. The mold 40 includes a pedestal 42, a frame-shaped mold 43 disposed on the pedestal 42, and a lid portion 44 that closes the frame-shaped mold 43.

  The upper surface of the cradle 42 constitutes the bottom surface of the mold. The cradle 42 is provided with a mortar-shaped recess 46 that has a circular shape when viewed from above, and whose diameter gradually decreases downward. The recess 46 is for storing the liquid sealing material 12. The outer peripheral portion 47 surrounding the concave portion 46 has a flat upper surface. A protrusion 48 that protrudes upward is provided in the center of the recess 46. The upper surface of the protruding portion 48 is disposed on the same plane as the upper surface of the outer peripheral portion 47. By providing the protruding portion 48, as will be described later, when the filter media pack 11 is placed on the cradle 42, the center of the filter media pack 11 is prevented from sinking downward due to its own weight.

  The frame-shaped mold 43 has a rectangular or rectangular square frame shape that is open at the top and bottom, and is placed on the outer peripheral portion 47 of the cradle 42. When viewed from above, the frame-shaped mold 43 is disposed so as to surround the concave portion 46 without being in contact with the concave portion 46. The frame-shaped mold 43 is an assembly of four frame members 43 </ b> A to 43 </ b> D constituting each side of a quadrangle. Each of the frame members 43A to 43D has a rectangular plate shape, and is arranged such that the width direction of each frame member is along the vertical direction.

  As for each frame member 43A, 43B, 43C, 43D, the end surface of the one end part in the longitudinal direction is faced | matched by the inner surface of the other edge part of adjacent frame member 43B, 43C, 43D, 43A. The frame member 43A passes through a screw hole 43F formed in the other end of the adjacent frame member 43B and a screw hole (not shown) formed in the end surface 43E of one end of the frame member 43A. The frame member 43B is fixed by a screw (not shown). Similarly, one end of the other frame members 43B, 43C, and 43D is fixed to the adjacent frame member. Further, the frame members 43A to 43D are screwed into screw holes 47A formed in the outer peripheral portion 47 of the pedestal 42 and screw holes (not shown) provided in the frame members 43A to 43D. It is fixed to the cradle 42.

  The lid portion 44 is formed in a quadrangular plate shape that matches the quadrangular shape of the frame-shaped mold 43, and is placed on the frame-shaped mold 43. The lid portion 44 is fixed to the frame-shaped die 43 by a screw hole 44 </ b> A drilled in the outer edge thereof and a screw passed through a screw hole 43 </ b> H provided in the frame-like die 43. Two air holes 49 </ b> A and 49 </ b> B are formed in the lid portion 44 so as to sandwich the center of the lid portion 44. The air holes 49 </ b> A and 49 </ b> B are arranged at positions that overlap the recess 46 when viewed from above. Since the inside of the mold 40 communicates with the outside through the air holes 49A and 49B, the fluidity of the sealing material 12 inside the mold 40 is improved.

  The cradle 42, the frame-shaped mold 43, and the lid portion 44 are made of metal or the like, but may be made of any material as long as they can be released from the solidified sealing material 12.

  Next, an air filter manufacturing method using the filter manufacturing apparatus will be described. In this manufacturing method, first, the liquid sealing material 12 is stored inside the recess 46, the frame-shaped mold 43 is fixed on the cradle 42, and the filter material pack 11 is stored inside the frame-shaped mold 43. Is done. At this time, the back surface 11F side of the filter media pack 11 is directed downward, and the outer peripheral surfaces 11A to 11D face the frame members 43A to 43D.

  The filter media pack 11 is longer than the diameter of the recess 46 in the vertical and horizontal dimensions, but is shorter than the distance between the frame members 43A and 43C (or 43B and 43D) of the frame-shaped mold 43 facing each other. Therefore, the filter pack 11 is disposed so as to close the recess 46 and is placed on the upper surfaces of the outer peripheral portion 47 and the protruding portion 48 of the cradle 42, but the outer peripheral surfaces 11 </ b> A to 11 </ b> D of the filter media pack 11 and the frame-shaped mold 43. There is a slight gap S between them.

  Next, after the lid portion 44 is fixed to the upper part of the frame-shaped mold 43, the receiving table 42 is rotated by the rotating jig 41 at, for example, about 700 to 1500 rpm, whereby the receiving table 42 and the frame fixed to each other are fixed. The mold 43 and the lid 44 are rotated together. By this rotation, the liquid sealing material 12 accumulated in the concave portion 46 travels upward along the inclined surface of the concave portion 46 by centrifugal force, and is injected into the outer peripheral side inside the frame-shaped mold 43, so that the outer portion of the filter media pack 11. Filled.

  Specifically, the sealing material 12 is filled between the pleats from the back surface 11 </ b> F side of the filter material pack 11, and is filled in the gap S between the outer peripheral surfaces 11 </ b> A to 11 </ b> D and the frame-shaped mold 43. Further, the sealing material 12 passes through the gap S, wraps around from the outer peripheral surfaces 11B and 11D to the front side of the filter material pack, and is filled between pleats on the front surface 11E side. Thereafter, when the sealing material 12 is solidified, the outer portion 22 of the filter media pack 11 is embedded in the sealing material 12 as shown in FIG. On the other hand, the central portion 21 of the filter media pack 11 is not filled with the sealing material 12, and becomes a circular ventilation portion that can ventilate in the thickness direction of the filter media pack 11. Further, the sealing material 12 filled in the gap S becomes a portion that is thinly laminated on the outer peripheral surfaces 11A to 11D.

  When the sealing material 12 is solidified, the rotation by the rotating jig 41 is stopped, and then the lid portion 44 is removed from the frame-shaped mold 43 and the frame-shaped mold 43 is disassembled, and the filter pack 11 and the sealing material 12 are disassembled. The air filter 10 formed integrally is released from the mold 40. The frame-shaped mold 43 is disassembled by, for example, removing the screws inserted into the screw holes 47A and 43F and then sequentially removing the frame members 43A to 43D from the receiving base 42 and other frame members one by one. Done. Thereafter, mounting holes 23 (see FIG. 1) are opened at the four corners of the air filter 10 by a known means.

  Although it does not necessarily limit as the sealing material 12 in this embodiment, A thermoplastic resin, a thermosetting resin, etc. are used. When the thermosetting resin is used, for example, when the entire mold 40 is heated, the sealing material 12 injected into the frame-shaped mold 43 is solidified by centrifugal force. When a thermoplastic resin is used, the sealing material 12 is injected into the frame-shaped mold 43 by centrifugal force in a heated state, and then cooled and solidified.

  As described above, in this embodiment, the filter can be manufactured with a relatively simple mold, and the filter pack can be a rectangular parallelepiped that can be easily manufactured, so that the manufacturing cost and the number of manufacturing steps of the filter can be reduced. Further, since the filter medium pack 11 is held by the sealing material 12 and a filter frame separate from the sealing material 12 can be omitted, the number of parts can be reduced.

  Furthermore, since the ventilation section is circular, even if it is connected in the middle of a pipe made of a round ventilation pipe or a round pipe, dust and contamination in the air will not occur without causing a large pressure loss. It becomes possible to remove the substance. Further, the non-ventilated portion (outer portion 22) of the filter medium pack is relatively large, and attachment means such as the attachment hole 23 can be provided, so that it can be easily attached to other equipment, piping, and the like.

  FIG. 4 is a perspective view showing the structure of an air filter according to the second embodiment of the present invention. Hereinafter, the difference between the second embodiment and the first embodiment will be described.

  The mounting hole 23 in the first embodiment is opened in the outer portion 22 of the filter medium pack 11 filled with the sealing material 12, but in the air filter 60 in this embodiment, a hole is formed in the filter medium pack 61 itself. First, a tubular member 63 that constitutes the attachment hole is embedded further outside the filter medium pack 61. That is, in this embodiment, as shown in FIG. 4, the sealing material 62 laminated on the outer peripheral surfaces 61 </ b> A to 61 </ b> D of the filter media pack 61 is further thickened, and a tubular member 63 such as a pipe is embedded in the thick laminated portion. Is done.

  In the present embodiment, when the air filter 60 is manufactured, the gap S (see FIGS. 2 and 3) between the outer peripheral surfaces 61 </ b> A to 61 </ b> D of the filter medium pack 61 and the frame-shaped mold 43 is further increased and the gap S is increased. Tubular members 63 are erected at the four corners of the gap S. According to such a configuration, when the sealing material 62 is filled and solidified in the frame-shaped mold 43, the tubular member 63 is embedded in the sealing material. However, the tubular member 63 is sandwiched between a lower end surface of the outer peripheral portion 47 (see FIG. 2) and an upper end surface of the tubular member 63 that are closely attached to the lid portion 44, and the inside thereof is not filled with a sealing material but becomes a mounting hole. . The tubular member 63 is a pipe or a female screw, and is an attachment member for attaching the air filter to another device such as a fan, similarly to the attachment hole of the first embodiment.

  FIG. 5 is a perspective view showing the structure of an air filter according to the third embodiment of the present invention. In the following, the third embodiment will be described only with respect to differences from the first embodiment. In the first embodiment, the filter medium is a filter medium pack formed by folding a sheet-like filter medium. However, in the air filter 70 according to this embodiment, the filter medium is urethane foam or the like as shown in FIG. This is a rectangular parallelepiped three-dimensional network structure 71 made of the above foam.

  Innumerable adsorbents such as activated carbon are attached to the three-dimensional network structure 71, and contaminants in the air are removed by the adsorbents. Note that the three-dimensional network structure 71 is not limited to a foam, and may be, for example, a fibrous base material made of organic fibers or inorganic fibers. The air filter 70 according to the present embodiment is manufactured in the same manner as in the first embodiment, but the filling of the sealing material 72 into the three-dimensional network structure 71 passes through the gaps of the mesh of the three-dimensional network structure. Is also done. In the configuration of FIG. 5, as in the first embodiment, the mounting hole 73 is provided in the outer portion 82 formed by filling the three-dimensional network structure 71 with the sealing material 72. As described above, a tubular member may be provided in a portion composed only of the sealing material 72 outside the three-dimensional network structure.

  In each of the above-described embodiments, the shape of the frame-shaped mold 43 is not limited to a quadrilateral shape as long as the air filter can be released, but may be a frame shape having a polygon other than a quadrilateral or a circular shape. good.

10, 60, 70 Air filter 11, 61 Filter media pack (filter media)
11A to 11D Outer peripheral surface 12, 62, 72 Sealing material 21 Central portion 22, 82 Outer portion 23, 73 Mounting hole 40 Mold 41 Rotating jig (rotating means)
42 cradle 43 frame type 43A-43D frame member 46 recessed part 63 tubular member 71 three-dimensional network structure (filter material)

Claims (14)

A first step of disposing a frame-shaped mold in which a filter medium is housed on a cradle in which a sealing material is stored;
The cradle is rotated, and the sealing material is injected into the outer peripheral side of the inside of the frame-shaped mold by the centrifugal force. A second step in which air is passed through without filling the sealing material in the part;
A third step of releasing the filter medium integrated with the sealing material from the frame mold ,
The method for manufacturing an air filter , wherein the filter medium is a rectangular parallelepiped .   The method for producing an air filter according to claim 1, wherein the filter medium is formed by folding a sheet-like filter medium into a pleat shape or has a three-dimensional network structure.   There is a gap filled with the sealing material between the frame-shaped mold and the filter medium, and the sealing material filled in the gap is laminated on the outer peripheral surface of the filter medium by solidifying. The manufacturing method of the air filter of Claim 1 characterized by the above-mentioned. 4. The method for manufacturing an air filter according to claim 3 , wherein a tubular member is disposed in the gap, and the tubular member is integrated with a sealing material filled in the gap and solidified. The frame-shaped mold is an assembly of a plurality of frame members,
2. The air filter according to claim 1, wherein the frame-shaped mold is disassembled into the plurality of frame members, and the filter medium integrated with the sealing material is released from the frame-shaped mold. Method. The method for manufacturing an air filter according to claim 5 , wherein the frame-shaped mold has a quadrangular frame shape including the four frame members. A first step of disposing a frame-shaped mold in which a filter medium is housed on a cradle in which a sealing material is stored;
By rotating the cradle, the sealing material is injected into the outer periphery of the frame-shaped mold by the centrifugal force, the sealing material is filled in the outer portion of the filtering material and solidified, and the center of the filtering material A second step in which air is passed through without filling the sealing material in the part;
A third step of releasing the filter medium integrated with the sealing material from the frame-shaped mold;
With
The frame-shaped mold is an assembly of a plurality of frame members,
The frame-shaped mold is disassembled into the plurality of frame members, and the filter medium integrated with the sealing material is released from the frame-shaped mold,
The method for manufacturing an air filter according to claim 1, wherein the frame-shaped mold has a square frame shape including the four frame members. Filter media,
A sealing material that fills the outer part of the filter medium and does not fill the central part of the filter medium, and has a circular ventilation part through which air passes through the central part ,
The air filter , wherein the filter medium is a rectangular parallelepiped .   The air filter according to claim 8, wherein the filter medium is configured by folding a sheet-like filter medium into a pleat shape, or has a three-dimensional network structure.   The air filter according to claim 8, wherein an attachment hole along the ventilation direction of the filter medium is provided in the outer portion.   The air filter according to claim 8, wherein the sealing material is laminated on an outer peripheral surface of the filter medium, and a tubular member is provided on the laminated sealing material. Filter media,
A sealing material that fills the outer portion of the filter medium and does not fill the central portion of the filter medium, and has a circular ventilation portion through which air passes.
With
An air filter characterized in that a mounting hole is provided in the outer portion along the ventilation direction of the filter medium. Filter media,
A sealing material that fills the outer portion of the filter medium and does not fill the central portion of the filter medium, and has a circular ventilation portion through which air passes.
With
An air filter, wherein the sealing material is laminated on an outer peripheral surface of the filter medium, and a tubular member is provided on the laminated sealing material. A cradle having a mortar-shaped recess in which a sealing material is stored;
A frame-shaped mold that is arranged on the cradle and is configured to surround the recess when viewed from above, and in which a filter medium is stored,
Rotating means capable of rotating the cradle and injecting the sealing material into the outer periphery of the frame-shaped mold by centrifugal force ;
The air filter manufacturing apparatus , wherein the filter medium is a rectangular parallelepiped .

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