JP2006062120A - Manufacturing method of air filter - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To inexpensively manufacture an air filter by one process for integrating a frame and a metal net by insert injection molding in manufacturing the air filter. <P>SOLUTION: The manufacturing method of the air filter includes a process for inserting a standard length metal net 21 in the space part of a recessed mold C to fix the same and a process for moving a protruded mold D toward the recessed mold C to perform mold closing operation and subsequently injecting a resin in the cavity formed by the recessed mold C and the protruded mold D to mold the air filter 2 wherein the edge part of the metal net 21 is surrounded by a resin body. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

The present invention relates to an air filter used for combustion equipment such as oil or gas stoves, oil or gas fan heaters. More specifically, the present invention relates to a method of integrally manufacturing a resin frame and a wire mesh by insert injection molding of an air filter for combustion or hot air such as petroleum or gas stove, petroleum or gas fan heater.

The example of the air filter provided in the back surface of the oil or gas fan heater main body exterior is shown in FIG. This air filter is provided at the intake of air for combustion or hot air, and the taken-in air enters the burner through the air suction portion of the blower and is discharged to the outside air through the exhaust outlet.

The dust contained in the air accumulates in the exterior of the oil or gas fan heater main body or accumulates in the electrical component, and when these are accompanied by moisture, it causes a malfunction of the electrical component. In addition, if dust accumulates in a high-temperature part such as an exhaust muffler, dust may heat up and ignite. An air filter is used to prevent this. On the other hand, an invention of an air filter has been proposed in which dust does not collect in the exterior of the combustion equipment device and does not block dust in a short period (Patent Document 1).

By the way, in the conventional air filter, a metal thin plate is press-molded to form a frame, the metal mesh is sandwiched from the front and back by this frame, bent by press, and then caulked to be integrated with the metal mesh. FIG. 2 is a perspective view of the air filter as viewed from the back side. The whole shows a rectangular shape, and the frame 22 goes around so as to surround the wire net 21 to form an outer peripheral edge. The frame 22 includes a plurality of crimping holes 23 for fixing the wire mesh 21 to the frame 22 during press bending. This is then electrodeposited to complete the air filter.

JP-A-5-332527

However, the conventional air filter has the following problems.

That is, the first problem of the conventional air filter is that the air filter is formed by press-molding a metal thin plate to form a frame, and then the wire mesh is sandwiched by this frame and bent by a press to be integrated with the wire mesh. The Thus, an air filter is manufactured by the process of manufacturing a frame, the process of integrating the frame and the wire mesh, and finally the process of electrodeposition coating this. Therefore, since the manufacturing process is multi-step, the cost of the air filter is increased.

Therefore, the manufacturing method of the air filter of the present invention was made in order to solve such a conventional problem, by integrating the frame and the wire mesh by insert injection molding in one step, The object is to provide a method for manufacturing an air filter at low cost.

In order to achieve the above object, the invention of claim 1 includes a step of inserting and placing a fixed wire mesh 21 in the space of the concave mold C, and a closed mold operation by moving the convex mold D in the direction of the concave mold C. And then injecting resin into a cavity formed by the concave mold C and the convex mold D, thereby forming the air filter 2 in which the edge of the wire mesh 21 is surrounded by a resin body. It is a manufacturing method of an air filter.

Since the present invention manufactures an air filter composed of a frame and a wire mesh by insert injection molding in one process, the manufacturing process can be simplified because it does not require a frame press bending process and a painting process as in the prior art. Yes, an increase in manufacturing cost can be suppressed. Further, it is possible to separately form a plurality of window frames for combustion or window frames for hot air separately according to the specifications of the air filter.

Embodiments of the present invention will be specifically described below based on the embodiments of the present invention illustrated in the accompanying drawings.

First, an embodiment of the present invention will be described with reference to FIGS. FIG. 3 is a perspective view of the wire mesh in a state before molding according to the present embodiment. FIG. 4 is an explanatory view of insert injection molding as above. FIG. 5 is a perspective view of the air filter according to the manufacturing method as seen from the front side. FIG. 6 is a perspective view of the air filter as seen from the back side.

Below, the manufacturing method of the air filter by insert injection molding is demonstrated.

A method for producing an air filter by insert injection molding will be described with reference to FIG. The left side of the drawing is a fixed mold of the injection molding machine, and the right side is a movable mold. A concave mold C incorporated on the fixed side, a convex mold D incorporated on the movable side, and a metal mesh 21 are shown therebetween. Here, the concave shape C corresponds to the outer shape of the air filter, the convex shape D corresponds to the inner shape of the air filter, and the closed shape in which the convex shape D is combined with the concave shape C is formed inside the concave shape C. This is indicated by a two-dot chain line L. When the convex mold D is moved in the direction of the concave mold C as shown by the large arrow and the mold is clamped, the concave mold C and the convex mold D are combined, and a molding cavity is formed in the gap between both molds. That is, cavities such as an outer peripheral edge cavity E, a bottom cavity F, and a side cavity G are formed by both molds. First, as the first molding step, in the open state of both molds, the wire mesh 21 cut in advance into the cavity of the concave mold C is positioned and inserted and placed in the direction of the small arrow. Next, as shown by the large arrow, the convex mold D is moved in the direction of the concave mold C, and the mold is clamped by operating in the closed mold state. At this time, the wire mesh 21 is fixed at the position F while being pushed by the convex die D. When the mold clamping pressure reaches a predetermined pressure, synthetic resin is injected into the cavities at various locations. When the injection molding is completed, the convex mold D returns in the direction opposite to the large arrow and enters the open mold state. Next, the air filter 2 that surrounds the wire mesh 21 with the synthetic resin is released from the concave mold C. In addition, the synthetic resin used in the present example takes heat resistance into consideration. In addition, a wire mesh that has been previously electrodeposited is used.

It is comprised as mentioned above, Next, an effect | action is demonstrated.

The concave mold C and the convex mold D are combined to form a molding cavity in the gap between the two molds. That is, cavities such as outer peripheral edge cavity E, bottom cavity F, and side cavity G are formed by both molds. When the resin is injected into the outer peripheral edge cavity E, the outer edge frame 22 shown in FIGS. 5 and 6 is formed. Similarly, resin is injected into the bottom cavity F to form the front frame 24, and resin is injected into the side cavity G to form the side frame 25. Both the concave mold C and the convex mold D can be designed as necessary, and the shape of the frame can be changed in any way, and the metal net can be swollen and a step can be provided. By placing the wire mesh 21 in the cavity of the concave mold C, the peripheral end portion of the wire mesh is surrounded by the resin, so that a resin-made frame surrounded by the wire mesh is formed. In addition, since the metal mesh uses what was electrodeposited beforehand, it is not necessary to paint after integral injection molding.

The use of the present invention is not limited to filters for combustion equipment such as oil or gas stoves, oil or gas fan heaters, and may be used for filters used in water heaters and heaters.

It is the perspective view which looked at the oil or gas fan heater from the back side. It is a perspective view concerning the conventional air filter. It is a perspective view of the wire mesh of the state before shaping | molding concerning the Example of this invention. It is explanatory drawing of insert injection molding concerning the Example of this invention. It is the perspective view which looked at the air filter from the front side same as the above. It is the perspective view which looked at the air filter from the back side same as the above.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Petroleum or gas fan heater 2 Air filter 21 Wire mesh 22 Outer edge frame 23 Caulking hole 24 Table frame 25 Side frame C Concave D Convex E Outer peripheral edge cavity F Bottom cavity G Side cavity L Two-dot chain line

Claims (1)

Inserting a fixed wire mesh 21 into the space of the concave mold C and placing it;
Including a step of injecting resin into a cavity formed by the concave mold C and the convex mold D after the convex mold D is moved in the direction of the concave mold C and closed.
A method of manufacturing an air filter, comprising molding an air filter 2 in which an edge of the wire mesh 21 is surrounded by a resin body.

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