JP6060288B2 - Air filter manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing various air filters used for masks, fan filter units, and the like.

  Conventionally, a relatively large air filter used in a fan filter unit or the like is generally configured by storing a filter medium inside a filter frame formed by assembling four plate members made of metal or the like. It is. In order to increase the airtightness, such a filter is provided with a gasket provided at the peripheral edge of one opening of the filter frame and pressed against the ceiling surface or the contact surface of the casing via the gasket (for example, patents). Reference 1).

  On the other hand, a relatively small air filter used for a protective mask, for example, is generally obtained by insert molding of a filter frame (see, for example, Patent Document 2). Such an air filter is generally screwed and attached to the main body of the protective device while being housed in a case. However, in order to ensure airtightness, a rubber on the main body of the protective device is usually used. It is pressed against the packing (see, for example, Patent Document 3).

JP 2007-260655 A JP 2010-269462 A JP 2002-301165 A

  However, in any air filter, sealing members such as gaskets and rubber packings for ensuring airtightness are provided as separate members from the filter medium and filter frame, which increases the number of parts and complicates the manufacturing process. There is a risk of becoming. Furthermore, in a large filter, in order to ensure airtightness between each plate constituting the filter frame and the filter medium, it is necessary to fill a sealant between them, which may make the manufacturing process more complicated. .

  Moreover, since the small air filter is disposed on a business trip from the protective equipment body in the protective mask, the visual field may be obstructed. Although it is conceivable to form the air filter along the face in order to prevent the field of view from being blocked, the filter media pack folded in a pleated form is usually shaped along the face because the filter frame is rigid. It was difficult.

  Conventionally, a flexible filter is also known, but such a filter usually has a small filter medium surface area and poor filter performance, for example, while low filtration efficiency and high pressure loss, The lifetime was short.

  Therefore, the present invention provides an air filter manufacturing method that can easily ensure airtightness without increasing the number of parts and that can be easily deformed into a desired shape while having relatively good filter performance. Objective.

  The present invention includes a frame-shaped member having a frame shape surrounding the outer periphery of a rectangular parallelepiped filter medium, the frame-shaped member is formed of an elastic body, and has a protruding portion that is molded to protrude to the outer periphery over the entire circumference. A method of manufacturing an air filter, wherein the first to fourth frame members provided with grooves including recesses corresponding to the protrusions are opened by extending the grooves to one end surface, and the other end surface Until one end of each of the first to fourth frame members is connected to the other end of the adjacent frame member, so that the groove extends over the entire circumference of the inner peripheral surface. A frame-shaped mold is formed on the inside of the frame-shaped mold, a filter medium is disposed inside the frame-shaped mold, and a casting material is injected into the groove.

  In the present invention, by making the frame-like member that supports the filter frame an elastic body, it is easy to ensure airtightness between the air filter and other members with a small number of parts, and relatively high filter performance is achieved. An air filter manufacturing method that can be easily deformed into a desired shape while maintaining it can be obtained.

It is a perspective view which shows the air filter which concerns on 1st Embodiment. It is sectional drawing which shows the fan filter unit to which the air filter which concerns on 1st Embodiment was applied. It is a perspective view which shows the process of manufacturing the air filter which concerns on 1st Embodiment. It is a perspective view which shows the process of manufacturing the air filter which concerns on 1st Embodiment. It is a perspective view which shows the process which manufactures the air filter which concerns on 1st Embodiment, and shows the state by which the filter media pack is arrange | positioned inside the frame shape type | mold. It is a perspective view which shows the air filter which concerns on 2nd Embodiment. It is sectional drawing which shows a part of mask to which the air filter which concerns on 2nd Embodiment was applied. It is sectional drawing which shows a part of mask with which the air filter which concerns on 3rd Embodiment was applied. It is sectional drawing which shows a part of mask with which the air filter which concerns on 4th Embodiment was applied. It is sectional drawing which shows the air filter manufacturing apparatus in 4th Embodiment. It is a perspective view which shows the air filter which concerns on 5th Embodiment. It is sectional drawing which shows a part of mask to which the air filter which concerns on 5th Embodiment is applied. It is a disassembled perspective view which shows the air filter manufacturing apparatus in 5th Embodiment. It is sectional drawing which follows the III-III line in FIG. It is a perspective view for showing the usage condition of the air filter concerning a 6th embodiment. It is a perspective view which shows the filter material pack of the air filter which concerns on 6th 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 includes a filter medium pack 11 and a frame-like member 12 arranged so as to surround the filter medium pack 11.

  The frame-shaped member 12 includes a frame main body 14 that has a rectangular or rectangular square frame shape, and a flange portion (protrusion portion) 15 that protrudes from the outer edge portion of the end face on one opening side of the frame main body 14 to the outer peripheral side over the entire circumference. Prepare. The flange portion 15 is a rectangular frame-like plate-like member that is provided perpendicularly to the frame main body 14, and constitutes an end face on one opening side of the frame-like member 12 together with the end face of the frame main body 14. The frame main body 14 and the flange portion 15 are elastic bodies integrally formed of an elastomer.

  The filter medium pack 11 is formed in a rectangular parallelepiped shape by folding a filter paper made of glass fiber or the like and a sheet-like filter medium made of nonwoven fabric such as polyester. The end portions 11A to 11D constituting each side surface of the filter medium pack 11 are bonded while being embedded in each side of the frame main body 14, whereby the frame main body 14 is bonded to the outer periphery of the filter medium pack 11 over the entire circumference. It will be.

  The hardness of the frame-like member 12 (that is, the frame main body 14 and the flange portion 15) that is an elastic body is 20 to 80 degrees, preferably 40 to 80 degrees. When the hardness of the frame-shaped member 12 falls within such a range, it is possible to ensure airtightness between the air filter 10 and the contact surface by the flange portion 15 as described later, and to the frame main body 14. It becomes possible to have a certain strength. In this specification, the hardness is an Asker A type measured in accordance with JIS K6253.

  FIG. 2 shows a fan filter unit to which the air filter according to this embodiment is applied. The fan filter unit 20 includes a casing (case member) 21, an air filter 10 and a fan (blower) 22 disposed inside the casing 21. The casing 21 is attached to the ceiling surface 23 so as to close the opening 23A provided in the ceiling surface 23 from above.

  The casing 21 is a rectangular box that is open at the bottom, and has a vent hole 21B in the center of the upper surface 21A. Further, the casing 21 includes a case flange portion 25 that protrudes perpendicularly from the lower end to the outer peripheral side over the entire circumference.

  Inside the casing 21, a fan 22 is disposed below the ventilation port 21 </ b> B, and an air filter 10 is further disposed below the fan 22. When the fan 22 is rotated, outside air is introduced from the ventilation opening 21B, and the introduced outside air is purified by the air filter 10 and then flows into the room below the ceiling surface 23 through the opening 23A.

  The air filter 10 is placed on the ceiling surface 23 so that the flange portion 15 constituting the end surface on the one opening side of the frame-shaped member 12 abuts the periphery of the opening 23 </ b> A of the ceiling surface 23. The casing 20 is placed on the flange portion 15 so that the case flange portion 25 contacts the flange portion 15. Further, the casing 20 is arranged so that the inner peripheral surface of each side surface of the box body is along each of the outer peripheral surfaces of the four sides of the frame body 14. The casing 20 and the air filter 10 are attached to the ceiling surface 23 by screws 26 passed through the screw holes 25H and 15H of the case flange portion 25 and the flange portion 15.

  In this embodiment, since the frame-shaped member 12 (namely, flange part 15) is comprised with an elastic body, the flange part 15 plays the role of a gasket. That is, the flange portion 15 having elasticity is pressed against the ceiling surface 23 by the case flange portion 25 over its entire circumference, thereby closely contacting the case flange portion 25 and the ceiling surface 23 and sealing between them to air Prevent leakage.

  3-5 is a figure for demonstrating the manufacturing method of the air filter which concerns on this embodiment. As shown in FIG. 5, the air filter 10 according to the present embodiment is molded by using a rectangular or square frame 30. Hereinafter, the structure of the frame mold 30 will be described first.

  As shown in FIG. 5, the frame-shaped mold 30 is obtained by assembling first to fourth frame members 31 to 34 constituting each side of a quadrangle. The end surfaces of the first to fourth frame members 31 to 34 in the longitudinal direction of the first to fourth frame members 31 to 34A are respectively adjacent to the other end 32B to the second to fourth and first frame members 32 to 34, 31 adjacent to each other. It abuts against the inner surfaces of 34B and 31B and is connected to the adjacent frame member.

  As shown in FIG. 3, the first frame member 31 is provided with a groove 42 on one surface (inner surface) 41 constituting the inner peripheral surface of the frame-shaped mold 30. The groove 42 extends along the longitudinal direction of the first frame member 31. The groove 42 forms one side of the frame-shaped member 12 and has a shape corresponding to one side of the frame-shaped member 12 (see FIG. 1). Therefore, the groove 42 becomes a concave portion 43 that is recessed from the other portion at one end side in the width direction in order to form the flange portion 15.

  The groove 42 extends to the end surface 31C of the one end 31A in the first frame member 31, and opens in the end surface 31C, but does not extend to the end surface of the other end 31B. Moreover, in the edge part of the groove | channel 42 by the side of the other end 31B, the one end side in the width direction in which the recessed part 43 was provided becomes the extension part 44 extended in the longitudinal direction from the other part. The extending portion 44 is for forming the flange portion 15 together with the recessed portion 43. Note that the second to fourth frame members 32 to 34 have the same shape as the first frame member 31, and therefore the description thereof is omitted.

  When one end 31A to 34A of each frame member 31 to 34 is connected to the other end 32B to 34B and 31B of the adjacent frame members 32 to 34 and 31, the grooves 42 and 42 provided in these frame members are also connected. As a result, a groove extends on the inner peripheral surface of the frame mold 30 over the entire circumference. Then, as will be described later, the frame-shaped member 12 (see FIG. 1) is formed by the casting material filled in the groove. Further, when the grooves 42 and 42 are connected to each other, the extending portion 44 on the other end 31B to 34B side is connected to the concave portion 43 opened on the end surface on the one end 31A to 34A side, thereby, as shown in FIG. The frame member 12 is provided with a flange portion 15 over its entire circumference.

  Next, a method for manufacturing the air filter according to the present embodiment will be described. In this manufacturing method, first, as shown in FIG. 3, the casting material 50 is injected into the groove 42 of the first frame member 31, and the end portion 11 </ b> A of the filter medium pack 11 is inserted into the groove 42. The

  Next, as shown in FIG. 4, the casting material is injected into the groove 42 of the second frame member 32, and the end portion of the filter medium pack 11 in which the end portion 11 </ b> A is inserted into the first frame member 31. 11B is inserted into the groove 42 of the second frame member 32. Then, one end 31A of the first frame member 31 is connected to the other end 32B of the second frame member 32, and the one end 31A and the other end 32B are fixed by screws (not shown).

  At this time, the end portions 11 </ b> A and 11 </ b> B of the filter medium pack 11 are in a state in which the casting material 50 enters the gap and is embedded in the casting material 50. Further, the filter media pack 11 is appropriately held in the groove 42 so that the end portions 11A and 11B are separated from the bottom surface 42D of the groove 42. Thereby, in the air filter 10, the end portions 11 </ b> A and 11 </ b> B of the filter medium pack 11 are bonded to the inner periphery of the frame body 14 so as to be embedded in the frame body 14, and the filter medium pack 11 is attached to the frame body 14. It is prevented from being exposed to the outer peripheral surface of the.

  The casting material injected into the groove 42 of each frame member has thixotropy. Thixotropy refers to the property of exhibiting high fluidity while a force is applied and deformation continues, but does not flow unless a large force is applied in a stationary state. As an adhesive having thixotropic properties, for example, a known thixotropic agent is added to a known curable elastomer in order to develop thixotropic properties. In addition, as curable elastomer, it has elasticity after hardening, for example, urethane, silicone, etc. are used.

  In FIG. 4, the filter medium pack 11 is appropriately held so as not to move with respect to the first frame member 31. Thereby, the filter media pack 11 does not give a large force to the casting material 50 inside the groove 42 of the frame member 31, and does not cause the casting material 50 to exhibit substantially fluidity. Therefore, as shown in FIG. 4, when the end portion 11 </ b> B of the filter pack 11 is inserted into the groove 42 of the second frame member 32, the first frame member 31 is in an upright state, for example, and the frame member 31. The opening of the groove 42 is directed downward and laterally, but the casting material 50 inside the groove 42 does not flow and does not sag.

  The above steps are repeated, and the end portions 11C and 11D of the filter media pack 11 are inserted into the grooves 42 and 42 of the third and fourth frame members 33 and 34 while the casting material is being injected. The frame mold 30 is assembled from the first to fourth frame members 31 to 34. Thereby, the outer periphery of the filter media pack 11 is inserted into the groove 42 over the entire circumference, and is disposed inside the frame-shaped mold 30 as shown in FIG. In addition, the casting material 50 is injected into the groove on the inner peripheral surface of the frame mold 30 over the entire circumference.

  In the state of FIG. 5, the opening of the groove of the frame-shaped mold 30 is sideways, but the casting material inside the groove is kept in a substantially non-flowing state and does not sag. In the state of FIG. 5, the end portions 11 </ b> A to 11 </ b> D of the filter medium pack 11 are supported by, for example, the side surface 42 </ b> E (see FIGS. 3 and 4) of the groove 42 and are not moved downward. However, the filter media pack 11 may be supported by a support member (not shown) provided on the lower side thereof.

  Thereafter, in the state of FIG. 5, the casting material is cured by heating or the like as necessary, and the filter media pack 11 is integrated with the casting material 50. The cured casting material constitutes a rectangular frame-shaped frame member 12 (see FIG. 1). Next, a screw (not shown) is removed, and the frame-shaped mold 31 is disassembled into first to fourth frame members 31 to 34, whereby the filter media pack 11 integrated with the casting material 50 is frame-shaped. The mold is released from the mold 30 to obtain the air filter 10 shown in FIG.

  As described above, in the present embodiment, the frame-shaped member 12 that supports the filter media pack 11 is formed of an elastic body. Therefore, it is possible to ensure the airtightness between the air filter 10 and the mounting portion by bringing the frame-shaped member 12 itself into close contact with the contact surface of the mounting portion (ceiling surface) without providing a gasket separately. Become. In addition, since the frame-shaped member 12 is closely attached to the mounting portion without using a gasket which is a separate member, the sealing surface becomes one surface, and the sealing performance is easily improved. In addition, since the frame-shaped member 12 is formed not by a plate member but by a casting material, the frame-shaped member 12 can be manufactured at a low cost and the sealing performance between the frame-shaped member 12 and the filter media pack 11 can be ensured. There is no need to use a separate sealing material.

  Furthermore, in this embodiment, the frame-shaped member 12 is provided with a flange portion 15, and the flange portion 15 is pressed by a case flange portion 25 disposed on the outer peripheral side of the frame-shaped member 12 to ensure airtightness. Is done. Therefore, the frame main body 14 itself supporting the filter medium pack 11 is not pressed by the casing 21 and is not deformed, so that the filter medium pack 11 is stably supported by the frame main body 14.

  Next, a second embodiment of the present invention will be described with reference to FIGS. The air filter according to the present embodiment is a small filter and is used for a mask. The mask is an intake mask for purifying intake air, and is, for example, a gas-proof or dust-proof mask. Hereinafter, the difference between the second embodiment and the first embodiment will be described.

  As shown in FIG. 6, the air filter 60 according to the present embodiment is a small round filter, and includes a column-shaped filter medium pack 61 and a frame-shaped member 62 that is made of an elastomer and is an elastic body. The frame-shaped member 62 includes a cylindrical frame main body 64 and a flange portion 65 that are arranged so as to surround the filter medium pack 61. The flange portion 65 protrudes from the end face on one opening side of the frame body 64 to the outer peripheral side over the entire circumference, and has an annular shape.

  The hardness of the frame-like member 62 is 20 to 80 degrees as in the first embodiment, but in this embodiment, the hardness may be relatively low because it is a small filter used for a mask. , Preferably 20 to 40 degrees. The configuration of the air filter 60 other than that described here is the same as that of the air filter according to the first embodiment, and the description thereof is omitted.

  As shown in FIG. 7, the mask protector body 52 attached to the face is provided with a cylindrical mounting portion 53 having an external thread portion on the outer peripheral surface. The front end surface 53A of the mounting portion 53 serves as a contact surface for the air filter 60 to be pressed and mounted.

  The air filter 60 is housed inside the case member 71 and constitutes an air filter unit 70 together with the case member 71. As shown in FIG. 7, the case member 71 is a bottomed cylindrical member in which one end portion is an opening 73 and the other end portion is provided with a bottom portion 72 having a vent (not shown). . The air ventilated through the vent of the bottom 72 is purified by the air filter 60 and then vented to the protector main body 52 side.

  The cylindrical part 71D of the case member 71 includes a cylindrical small diameter part 71A disposed on the bottom part 72 side, a cylindrical large diameter part 71B having a diameter larger than that of the small diameter part 71A and disposed on the opening side, and these small diameter parts. The connecting portion 71C connects the 71A and the large diameter portion 71B. The connecting portion 71C is an annular member arranged perpendicular to the axial direction of the case member 71, and is formed so as to protrude from the one end in the axial direction of the small diameter portion 71A to the outer peripheral side over the entire circumference. The large-diameter portion 71B is provided with a female screw on its inner peripheral surface.

  In the air filter 60, the flange portion 65 is disposed along the connection portion 71C, and the outer peripheral surface of the frame main body 64 is disposed along the inner peripheral surface of the small-diameter portion 71A. Combined and attached. The filter unit 70 is attached by screwing the large diameter portion 71B to the attachment portion 53.

  As described above, when the filter unit 70 is attached to the attachment portion 53, the flange portion 65 disposed on the connection portion 71 </ b> C is sandwiched between the connection portion 71 </ b> C and the distal end surface 53 </ b> A of the attachment portion 53. The flange portion 65 is pressed against the distal end surface 53A and the connecting portion 71C over the entire circumference. Thereby, the flange part 65 airtightly connects the frame-shaped member 62 and the attachment part 53, and prevents that air leaks from these.

  The air filter 60 according to the present embodiment is manufactured by, for example, insert molding. However, the manufacturing method is the same as that of a conventional small filter, and thus the description thereof is omitted. The casting material used for insert molding is the same as the casting material in the first embodiment except that no thixotropic agent is added. However, similarly to the first embodiment, it may be formed by a frame-shaped mold.

  As described above, in this embodiment as well, as in the first embodiment, a sealing material such as a gasket is not separately provided, and the frame main body itself is not deformed, and the gap between the air filter 60 and the mounting portion 53 is reduced. Airtightness can be secured.

  Next, a third embodiment of the present invention will be described with reference to FIG. FIG. 8 is a schematic cross-sectional view showing a part of a mask to which an air filter according to the third embodiment is attached. Hereinafter, a difference between the third embodiment and the second embodiment will be described.

  As shown in FIG. 8, the air filter 80 according to the present embodiment is the same as that of the second embodiment except that the flange portion is omitted, and is configured by a cylindrical frame-shaped member 82 and a filter medium pack 81. Is done. The case member 83 is a bottomed cylindrical member provided with a bottom portion 85 having an opening 84 at one end and a vent hole (not shown) at the other end, and an end on the opening 84 side. A female screw is provided on the inner peripheral surface of the part.

  The protector body mounting portion 87 includes a cylindrical base portion 87A and a cylindrical mounting tip portion 87C that is connected to the tip surface 87B of the base portion 87A and has an inner diameter larger than that of the base portion 87A. The tip surface 87B of the base portion 87A is a surface that connects the inner peripheral surface of the base portion 87A and the inner peripheral surface of the mounting tip portion 87C. The front end surface 87B is a surface perpendicular to the axial direction of the case member 83 and serves as a contact surface against which the end surface 82A on one opening side of the frame-shaped member 82 is pressed.

  The air filter 80 is attached to the case member 83 with the other opening-side end face 82 </ b> B of the frame-shaped member 82 bonded to the bottom 85 of the case member 83, and constitutes the air filter unit 86 together with the case member 83. There is a gap between the outer peripheral surface of the frame-shaped member 82 and the inner peripheral surface of the cylindrical case member 83, and a mounting tip portion 87 </ b> C inserted into this gap is screwed to the inner peripheral surface of the case member 83. Thereby, the air filter unit 86 is attached to the attachment portion 87.

  Here, the frame-shaped member 82 of the air filter 80 is disposed so as to be sandwiched between the distal end surface 87 </ b> B and the bottom portion 85. Then, the frame-shaped member 82 is pressed against the distal end surface 87B over the entire circumference by being pressed against the bottom portion 85 of the case member 83, whereby the space between the frame-shaped member 82 of the air filter 80 and the mounting portion 87. Air is prevented from leaking from the gap.

  In the present embodiment, since the flange portion is omitted, the entire frame-shaped member 82 that holds the filter material pack 81 is pressed by the bottom portion 85 of the case member 83. Therefore, the hardness of the frame-shaped member 82 is better than that of the second embodiment so that the frame-shaped member 82 does not buckle due to such pressing, for example, 40 to 80 degrees, preferably 60 to 80 degrees. .

  As described above, in the present embodiment, it is possible to easily ensure the airtightness between the air filter and the contact surface while omitting the flange portion to simplify the structure of the air filter.

  Next, a fourth embodiment will be described with reference to FIG. In each of the above embodiments, in the air filter, the filter medium pack is supported only by the frame-shaped member. However, in this embodiment, the filter medium pack is supported by the composite frame integrally formed by the frame-shaped member and the outer frame-shaped member. Is done. Hereinafter, the fourth embodiment will be described focusing on differences from the second embodiment.

  The air filter 90 according to the present embodiment includes a cylindrical filter medium pack 91, a frame-shaped member 94, and an outer frame-shaped member 93. The frame-shaped member 94 is an elastic body formed from an elastomer, and a cylindrical frame body 95 and a bulging portion 96 are integrally formed. The frame body 95 is disposed so as to surround the filter medium pack 91 by adhering to the outer periphery of the filter medium pack 91 while burying the outer periphery of the filter medium pack 91.

  The outer frame member 93 is disposed on the outer peripheral side of the frame main body 95, the inner peripheral surface thereof is bonded to the outer peripheral surface of the frame member 94 over the entire periphery, and the composite frame body 98 is integrated with the frame member 94. Form. The outer frame member 93 has a cylindrical shape and is made of hard plastic or the like, and has substantially no elasticity.

  One end portion in the axial direction of the frame main body 95 extends upward from the end surface 93A of the outer frame-shaped member 93 along the axial direction, and a bulging portion 96 that bulges to the outer peripheral side is formed in the extended portion. Are connected. The bulging portion 96 is disposed on the end surface 93A of the outer frame-shaped member 93 and bonded to the end surface 93A. As described above, the end portion 98A on one opening side of the composite frame body 98 is formed by integrating the bulging portion 96 and the frame body 95, and has a substantially semicircular cross section.

  In the present embodiment, the attachment portion 87 and the case member 83 have the same configuration as that of the third embodiment. In the air filter 90, an end surface 98 </ b> B on the other opening side of the composite frame body 98 is bonded to the bottom portion 85 of the case member 83 and constitutes an air filter unit 99 together with the case member 83. The air filter unit 99 is attached to the attachment portion 87 as in the third embodiment.

  In the present embodiment, the composite frame body 98 is disposed so as to be sandwiched between the distal end surface 87B and the bottom portion 85. Then, the end portion 98A (that is, the bulging portion 96) of the composite frame body 98 is pressed against the distal end surface 87B by the outer frame member 93 over the entire circumference by pressing from the bottom portion 85 of the case member 83, and the composite frame body. The sealing property between 98 and the attachment portion 87 is ensured.

  Next, the manufacturing method of the air filter which concerns on 4th Embodiment is demonstrated using FIG. In the first to third embodiments, the air filter is manufactured by molding using a frame-shaped mold or insert molding. In the present embodiment, the air filter is molded using centrifugation.

  An air filter manufacturing apparatus 100 used in the manufacturing method includes a rotating jig 101 and a mold 102 placed on the rotating jig 101. The mold 102 is placed on the mold main body 106 in which the lower opening of the cylindrical frame-shaped portion 104 is closed by the bottom portion 103, and the upper opening of the frame-shaped portion 104. And a lid 109 for closing.

  In the center of the bottom 103 of the mold 102, a mortar-shaped recess 105 is provided which has a circular shape when viewed from above and becomes smaller as the diameter decreases downward. The recess 105 is for storing a liquid casting material 107. Further, in the bottom portion 103, the outer peripheral portion 108 surrounding the central concave portion 105 has a flat upper surface.

  Two air holes 109 </ b> A and 109 </ b> B are formed in the lid portion 109. Since the inside of the mold 102 communicates with the outside through the air holes 109A and 109A, the fluidity of the casting material 107 inside the mold 102 is improved. Further, an annular ring groove 109 </ b> C for forming the end portion 98 </ b> A of the composite frame body 98 is provided on the lower surface of the lid portion 109. When viewed from above, the annular groove 109 </ b> C is provided at a position overlapping the outer frame member 93 disposed inside the mold 102 as will be described later.

  In the present embodiment, first, the casting material 107 is stored in the recess 105, and the outer frame member 93 is disposed in the mold 102. The outer frame-shaped member 93 is placed on the outer peripheral portion 108 and disposed so that the outer peripheral surface thereof is along the inner peripheral surface of the frame-shaped portion 104. At this time, the filter medium pack 91 placed on the outer peripheral portion 108 is accommodated in the outer frame member 93. The casting material 107 is the same as the casting material of the second embodiment.

  Next, after the lid portion 109 is placed on the mold body 106 and the lid portion 109 is fixed to the mold body 106, the mold body 106 includes the outer frame member 93 and the filter material pack 91 accommodated therein. At the same time, the rotating jig 101 is rotated at about 700 to 1500 rpm, for example. By this rotation, the liquid casting material 107 stored in the concave portion 105 travels upward through the inclined surface of the concave portion 105 by centrifugal force. Then, the casting material 107 is injected into the inner peripheral side of the outer frame member 93 and the inside of the annular groove 109C.

  Thereafter, the casting material 107 is solidified, and the casting material injected into the inner peripheral side of the outer frame member 93 becomes a frame member 95 in which the outer periphery of the filter pack 91 is embedded. The frame member 95 is integrated with the outer frame member 93 to form a composite frame 98. The casting material filled in the annular groove 108 constitutes an end portion 98 </ b> A of the composite frame 98 including the bulging portion 96.

  When the casting material 107 is solidified, the rotation of the rotating jig 101 is stopped, and the outer frame member 93 and the filter material pack 91 integrated by the casting material 107 are taken out from the mold 102, and FIG. An air filter 90 as shown in FIG.

  As described above, also in the fourth embodiment, as in the above embodiments, the air filter having a relatively simple structure can easily ensure the airtightness between the air filter and the contact surface. become. In addition, the composite frame body 98 that supports the air filter includes a hard outer frame-shaped member 93 that does not substantially have elasticity. Therefore, compared to a case where only the frame-shaped member formed of an elastic body is formed, High strength.

Next, an air filter according to a fifth embodiment of the present invention will be described with reference to FIG.
As shown in FIG. 11, the air filter 110 according to the present embodiment is such that a part of the filter medium pack 111 is filled with an elastomer and a frame-like member 130 is formed by the elastomer. The filter media pack 111 is formed in a rectangular parallelepiped, and the elastomer is a solidified casting material as described later.

  In the air filter 110, the central portion 121 of the filter medium pack 111 is not filled with elastomer, and the central portion 121 of the filter medium pack 111 has a circular (specifically, cylindrical) ventilation portion for allowing air to pass through. Become. On the other hand, the outer portion 122 of the filter medium pack, that is, the portion other than the central portion 121 is filled with the elastomer and is embedded by the elastomer, and becomes a non-ventilated portion that does not allow air to pass therethrough. That is, the elastomer filled in the outer portion 122 of the filter medium pack 111 is a frame-shaped member 130 having a circular inner peripheral surface and a rectangular outer peripheral surface, and the inner side of the frame serves as a ventilation portion of the filter medium pack 111. is there. The elastomer constituting the frame member 130 is the same as that of the second embodiment, and the frame member 130 is an elastic body.

  The elastomer is filled between the pleats on both the front surface 111E and the back surface 111F of the filter medium pack 111, and each end surface 130A, 130B of the frame-shaped member 130 surrounding both openings of the ventilation portion (center portion 121) is made of elastomer. It is a substantially flat surface. Further, the elastomer is thinly laminated not only on the ridges but also on the end portions 111A to 111D constituting the respective side surfaces of the filter medium pack 111, so that the air filter 110 has vertical and horizontal dimensions. It is a substantially rectangular parallelepiped that is slightly larger than the vertical and horizontal dimensions of the filter medium pack 11.

  As shown in FIG. 12, the air filter 110 according to the present embodiment is housed inside the case member 83 and attached to the attachment portion 87 as an air filter unit 135, for example, as in the third embodiment. That is, as in the third embodiment, the frame-shaped member 130 is disposed between the tip end surface 87B and the bottom portion 85. Since the frame-shaped member 130 is an elastic body, it is pressed against the distal end surface 87B by the bottom portion 85 and attached, thereby sealing between the air filter 110 and the attachment portion 87. Note that the end surfaces 130A and 130B of the frame-shaped member 130 are surfaces that are pressed against the tip surface 87A (contact surface) and surfaces that are bonded to the bottom 85, respectively.

  Next, a method for manufacturing an air filter according to the present embodiment will be described with reference to FIGS. Note that the manufacturing method according to the present embodiment is a manufacturing method using centrifugation, as in the fourth embodiment. Hereinafter, the manufacturing method of the air filter in the present embodiment will be described focusing on differences from the third embodiment.

  The mold 140 in the present embodiment has a frame-shaped portion that can be separated from the bottom 142 as a frame-shaped mold 143, and the bottom 142 has a recess 146 and a recess 146, as in the fourth embodiment. And an outer peripheral portion 147 surrounding the. A protrusion 148 that protrudes upward is provided at the center of the recess 146. The upper surface of the projecting portion 148 is disposed on the same plane as the upper surface of the outer peripheral portion 147. In the present embodiment, the provision of the protruding portion 148 prevents the center of the filter media pack 111 from sinking downward due to its own weight when the filter media pack 111 is placed on the bottom portion 142.

  The frame-shaped mold 143 has a rectangular or rectangular square frame shape that is open at the top and bottom, and is placed on the outer peripheral portion 147 of the bottom portion 142. The frame-shaped mold 143 is obtained by assembling four frame members 143A to 143D constituting each side of a quadrangle with screws passed through screw holes 143F. The lid portion 144 is formed in a rectangular plate shape, and air holes 149A and 149B are formed in the same manner as in the fourth embodiment.

  Next, an air filter manufacturing method using the filter manufacturing apparatus will be described. In this manufacturing method, first, the liquid casting material 150 is stored in the recess 146. Next, the frame-shaped mold 143 is fixed on the bottom 142 by screws passed through the screw holes 147A, and the filter medium pack 111 is housed inside the frame-shaped mold 143. At this time, the back surface 111F side of the filter pack 111 is directed downward, and the end portions 111A to 111D face the frame members 143A to 143D. However, there is a slight gap S between the end portions 111 </ b> A to 111 </ b> D of the filter medium pack 111 and the frame-shaped mold 143.

  Next, the lid part 144 is fixed to the upper part of the frame-shaped mold 143 by screws passed through the screw holes 144A and 143H. Thereafter, the bottom portion 142 is rotated by the rotating jig 141, whereby the bottom portion 142, the frame-shaped mold 143, and the lid portion 144 are rotated together. By this rotation, the liquid casting material 150 inside the recess 146 advances upward by centrifugal force, is injected into the outer peripheral side inside the frame-shaped mold 143, and is filled in the outer portion of the filter media pack 111.

  Specifically, the casting material 150 is filled between the pleats from the back surface 111 </ b> F side of the filter material pack 111 and is filled in the gap S between the end portions 111 </ b> A to 111 </ b> D and the frame-shaped mold 143. Further, the casting material 150 passes through the gap S, wraps around the front side of the filter medium pack from the end portions 111B and 111D, and is filled between the pleats on the front side 111E side.

  After that, when the casting material 150 is solidified, as shown in FIG. 11, the outer portion 122 of the filter medium pack 111 is embedded in the elastomer, and the frame-shaped member 130 is configured by the elastomer. On the other hand, the center part 121 of the filter medium pack 111 is not filled with the casting material 150 and becomes a circular ventilation part. In addition, the casting material 150 filled in the gap S becomes a portion that is thinly laminated on the end portions 111A to 111D.

  When the casting material 150 is solidified, the rotation by the rotating jig 141 is stopped. Thereafter, the lid 144 is removed from the frame-shaped mold 143, and the frame-shaped mold 143 is disassembled into four frame members 143A to 143D, so that the air filter 110 in which the filter medium pack 111 and the elastomer 112 are integrally formed is formed. The mold is released from the mold 140.

  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. Moreover, since the frame-shaped member 130 has elasticity, it is possible to seal between the attachment portion 87 and the air filter 110 without providing a separate packing.

  Also in this embodiment, the filter medium pack 111 may be cylindrical. If the filter media pack 111 is cylindrical, the frame-shaped mold 143 of the mold 140 is also cylindrical, and the frame-shaped member 130 is also cylindrical, and the shape of the air filter 110 is the same as that of the third embodiment. . In addition, the mold 140 may be appropriately provided with a recess or the like, and the frame member 130 may be provided with a flange portion as in the second embodiment.

  Next, a sixth embodiment of the present invention will be described with reference to FIGS. In the present embodiment, the filter medium pack has a deformable structure and can be curved and deformed together with the frame-shaped member. Hereinafter, the air filter according to the present embodiment will be described focusing on differences from the second embodiment.

  The air filter 220 according to the present embodiment is a round small filter, and as shown in FIG. 15, as in the second embodiment, a frame-shaped member 222 having a frame body 224 and a flange portion 225, and a filter medium pack. The frame-shaped member 222 is an elastic body formed of an elastomer.

  As shown in FIG. 16, the filter medium pack 221 is a sheet-shaped filter medium folded in a pleat shape and zigzag. Glued. The separator 225 extends in a zigzag manner along the orthogonal direction Y (the direction in which the filter media pack pleats 42 are arranged) perpendicular to the crease direction X in accordance with the zigzag sheet-shaped filter medium.

  The separator 225 is a yarn separator whose outer periphery is coated with an adhesive such as a synthetic resin. The separator 225 is adhered to itself between the adjacent pleats 231 and 231 of the filter medium pack 111 on each of the front and back surfaces of the filter medium pack 221, and the pleats 231 and 231 are separated by the separator 225.

  In each separator 225, the adhesive coated on the surface of the yarn has elasticity, and the yarn itself can be compressed and restored in the radial direction. Thereby, the separator 225 has elasticity and can expand and contract in the direct direction Y. Therefore, the filter media pack 221 that is fold-folded can be expanded and contracted starting from the fold, and has elasticity as a whole. As a result, both the filter pack 221 and the frame-shaped member 222 of the air filter 220 have elasticity, and can be curved and deformed as a whole. For example, in the curved state, the air filter 220 can be used as a mask protector body (not shown). It is attached.

  Specifically, as shown in FIG. 15, for example, the air filter 220 is bent in an arc shape so that both end portions in the orthogonal direction Y are bent toward the back surface 221 </ b> B and the center portion is convex, and the arc shape is In this state, it is attached to the mask protector body (not shown). At this time, as for the air filter 220, the back surface 221B side is arrange | positioned at the protector main body side. Thereby, the air filter 220 can be made to follow the shape of the face, and the field of view is prevented from being shielded by the air filter 220. Of course, the air filter may be attached as a filter unit in a state of being housed in the case member, as in the above embodiments. When the filter pack 221 is curved as shown in FIG. 15, the distance between the pleats 231 and 231 is shortened on the back surface 221B side, and the distance between the pleats 231 and 231 is on the front surface 221A side. Have been long.

  As described above, in the present embodiment, since the air filter can be bent, a desired shape can be obtained according to the application. Moreover, since the filter medium is a filter medium pack formed by folding the sheet-like filter medium into a pleat shape, the filter medium surface area of the air filter becomes relatively large, and the filter performance can be improved.

  In the present embodiment, the flange portion 225 may be pressed against the contact surface of the mounting portion and used as a sealing material as in the above embodiments, but it may not be used as such. Of course, the flange portion 225 may be omitted as in the third embodiment. Further, in the air filter according to the fifth embodiment, similarly to the present embodiment, the filter pack may be elastically deformable and may be curved and deformed as a whole.

  In each of the above-described embodiments, a filter medium pack in which a sheet-like filter medium is folded in a pleated shape is used as the filter medium. For example, a foamed body such as urethane foam, or a fibrous form composed of organic fibers or inorganic fibers It may be a three-dimensional network structure such as a substrate. In this case, countless adsorbents such as activated carbon are attached to the three-dimensional network structure, and contaminants in the air are removed by the adsorbent. Of course, a filter medium other than the three-dimensional network structure may be used as the filter medium.

10, 60, 80, 90, 110, 220 Air filter 11, 61, 81, 91, 111, 221 Filter media pack (filter media)
12, 62, 82, 94, 130, 222 Frame-shaped member 15, 65, 225 Flange (projection)

Claims (6)

An air filter comprising a frame-like member having a frame shape surrounding an outer periphery of a rectangular parallelepiped filter medium, wherein the frame-like member is formed of an elastic body and has a protruding portion formed to protrude to the outer periphery over the entire circumference. A manufacturing method comprising:
The first to fourth frame members provided with grooves including recesses corresponding to the protruding portions are opened so that the grooves extend to the end surface of one end, but do not extend to the end surface of the other end. Molded,
By connecting one end of each of the first to fourth frame members to the other end of the adjacent frame member, a frame-shaped mold is formed so that a groove extends over the entire circumference of the inner peripheral surface,
A method for producing an air filter, wherein the filter medium is disposed inside the frame-shaped mold, and a casting material is injected into the groove. The method for manufacturing an air filter according to claim 1, wherein the groove corresponds to an outer peripheral surface of the frame-shaped member. The method for manufacturing an air filter according to claim 1, wherein the recess is formed such that one end side in the width direction of the groove is recessed from the other part. The end portion of the groove on the other end side has one end side in the width direction in which the concave portion is provided extending in the longitudinal direction from the other portion to form an extension portion. The manufacturing method of the air filter as described. The method for manufacturing an air filter according to claim 1, wherein the casting material has thixotropic properties. A method for producing an air filter comprising a frame-like member having a frame shape surrounding an outer periphery of a filter medium, wherein the frame-like member is formed of an elastic body and has a protruding portion formed to protrude to the outer periphery over the entire circumference. There,
A plurality of frame members provided with grooves including recesses corresponding to the protrusions are formed so that the grooves extend to the end surface of one end and do not extend to the end surface of the other end,
By connecting one end of each of the plurality of frame members to the other end of the adjacent frame member, a frame-shaped mold is formed so that the groove extends over the entire circumference of the inner peripheral surface,
A method for producing an air filter, wherein the filter medium is disposed inside the frame-shaped mold, and a casting material is injected into the groove.

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