JP5243740B2 - Filter element and manufacturing method thereof - Google Patents

Description

  The present invention relates to a filter element used in general building air conditioning, home air conditioning, trains, automobiles, and the like, and a method for manufacturing the same, and particularly in combination with other filtering methods such as a filter requiring high air flow and electric dust collection. The present invention relates to a honeycomb-type filter element that is suitable for a filter used in the past, has low pressure loss, and is excellent in deodorization and removal of harmful gases, and a method for manufacturing the same.

  Air purifiers are installed in buildings, houses, trains, cars, and other spaces where people live to purify indoor air. In addition to filters intended to remove dust, air purifiers also use gas removal filters that remove bad odors and harmful gases.

  As the gas removal filter, a filter in which gas removal particles having a gas removal action or a gas adsorption action are held in a filter medium made of fiber or the like has been used. However, since such a filter reduces gas permeability by holding gas removal particles, a sheet-like filter medium holding gas removal particles is laminated at a plurality of intervals in the thickness direction of the filter medium to form a honeycomb. There has also been proposed a filter element having a structure or a corrugated structure so as to ensure a predetermined air permeability and a gas removing action.

  As such a filter element, for example, activated carbon paper obtained by mixing at least one activated carbon in the form of particles and fibers and fibers of a polymer compound is used as a substrate, and the substrate is formed into a honeycomb shape, There is one in which an air passage penetrating in the thickness direction of the base material is formed and copper ions are attached to the activated carbon paper (see Patent Document 1).

  However, in this filter element, in the process of mixing the activated carbon and the fibers constituting the activated carbon paper used as the base material, there is a problem that a chemical such as a dispersant is mixed to reduce the surface activity of the activated carbon. .

  On the other hand, the present applicant has proposed a filter element produced by a method that does not rely on papermaking. This filter element is a deodorizing filter 1 attached to a vent as shown in FIG. 13, comprising a deodorizing sheet 2, wherein a filtering surface is provided in the vent to be parallel to the filtration direction of incoming and outgoing air. (See Patent Document 2).

  However, this filter element uses a non-woven fabric made of hot melt resin as a sheet-like member, heat-treats the non-woven fabric in contact with the deodorized powder particles, and forms an agglomerated portion on the sheet. Since the deodorizing sheet 2 was produced by fixing and supporting the powder particles, the deodorized powder particles were exposed on both end faces, and the deodorized powder particles might fall off due to vibration or the like. For this reason, in this filter element, the dust removal filter 3 is arranged on both end faces of the deodorizing filter 1 to prevent dropping.

However, when dust removing filters are arranged on both end faces of the deodorizing filter, there is a problem that pressure loss increases and manufacturing cost increases.
JP 2001-120648 A JP 2004-321651 A

  The present invention has been made in view of the above-described technical problems, and there is no risk of gas removal particles falling off, a sufficient gas removal action is ensured, and pressure loss is prevented to prevent the gas removal particles from falling off. It is an object of the present invention to provide a filter element and a method for manufacturing the same that do not cause a problem of increase in manufacturing cost and manufacturing cost.

To achieve the above object, a first aspect of the present invention, meet the filter element consists of a honeycomb structure made by using the gas removal sheet gas scavenging particles are held between two sheets of air-permeable sheet material And
The honeycomb structure is a structure having a core formed with the gas removal sheet as a face material as an air path,
(1) Constructed by attaching a frame material around a pleated gas removal sheet,
(2) A structure in which a frame material is attached around a plurality of gas removal sheets arranged in parallel so that the surfaces of the gas removal sheets are parallel to each other,
(3) A structure in which a frame material is attached around a pleated folded gas removal sheet and a flat gas removal sheet alternately laminated, or
(4) A configuration in which a frame material is attached around the pleats of a plurality of gas-removal sheet pleats joined together by crests or troughs,
A structure selected from
The gist of the filter element is characterized in that resin processing by impregnation of a resin dispersion is applied to an end portion of a gas removal sheet constituting at least one of the gas inlet side or outlet side of the honeycomb structure. did.

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According a second aspect of the present invention, which is characterized in that the resin processed from the end of the gas removal sheet which forms at least one inlet side or the outlet side of the gas of the honeycomb structure within an average of 10mm has been subjected The gist of the filter element according to Item 1 .

In the invention according to claim 3, 20 to 150 g / m ² of resin per unit area of the gas removal sheet is impregnated at an end of the gas removal sheet constituting at least one of the gas inlet side and the outlet side of the honeycomb structure. The gist of the filter element according to claim 1 , wherein the filter element is characterized in that:

Fourth aspect of the present invention, the gas removal sheet has an average particle diameter of the gas removing particle to 0.147~1.65mm is linked by a thermoplastic resin gas removing particle layer both surfaces breathable sheet material The filter element according to any one of claims 1 to 3 , which is a sheet-like material having a thickness of 0.2 to 4 mm.

The invention according to claim 5 is the frame material according to any one of claims 1 to 4 , wherein the frame material attached around the honeycomb structure is a frame material coated with hot melt resin. The gist of the filter element.

The gist of the invention according to claim 6 is the filter element according to any one of claims 1 to 5 , wherein a plurality of honeycomb structures are joined.

The invention according to claim 7 forms a gas removal sheet holding gas removal particles between two breathable sheet materials ,
Next, a honeycomb structure is formed using the gas removal sheet,
Here, the honeycomb structure is a structure having a core formed with the gas removal sheet as a face material as an air path,
(1) Constructed by attaching a frame material around a pleated gas removal sheet,
(2) A structure in which a frame material is attached around a plurality of gas removal sheets arranged in parallel so that the surfaces of the gas removal sheets are parallel to each other,
(3) A structure in which a frame material is attached around a pleated folded gas removal sheet and a flat gas removal sheet alternately laminated, or
(4) A configuration in which a frame material is attached around the pleats of a plurality of gas-removal sheet pleats joined together by crests or troughs,
A structure selected from
Thereafter, a resin processing for preventing the gas removal particles from falling off is performed on an end portion of the gas removal sheet constituting at least one of the gas inlet side and the outlet side of the honeycomb structure. The manufacturing method of was made the summary.

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The invention according to claim 8 is that the resin processing is performed after the resin dispersion is adhered to the end of the gas removal sheet constituting at least one of the gas inlet side or the outlet side of the honeycomb structure and then dried. The gist of the method for manufacturing a filter element according to claim 7 is characterized in that.

The invention according to claim 9 is that the resin processing is performed at room temperature after the end of the gas removal sheet constituting at least one of the gas inlet side or the outlet side of the honeycomb structure is immersed in the resin dispersion. The gist of the method for producing a filter element according to claim 7 or 8 , characterized in that:

  In the filter element of the present invention and the manufacturing method thereof, the gas inlet side or outlet of the honeycomb structure manufactured using the gas removing sheet in which the gas removing particles are held between the two breathable sheet members Since the resin processing is applied to the end portion of the gas removal sheet constituting at least one of the sides, the retention of the gas removal particles is increased, the gas removal particles are less likely to fall off, and the gas removal action is sufficient. The problem that the pressure loss is increased and the manufacturing cost is increased to prevent the gas removal particles from falling off is ensured.

  Hereinafter, a preferred embodiment of the filter element of the present invention and the manufacturing method thereof will be described in detail. In addition, the manufacturing method of the filter element of this invention is demonstrated in description of a filter element. The filter element of the present invention comprises a honeycomb structure made using a gas removal sheet. As shown in FIGS. 1 to 3, for example, the gas removal sheet 11 is a sheet in which gas removal particles 13 are held between two air-permeable sheet materials 12 and 12 ′. Various forms can be taken.

  The gas removal sheet 11 shown in FIGS. 1-3 arrange | positions the resin bodies 14 and 14 'which have the resin aggregation part 14a and the connection part 14b which adhere this gas removal particle 13 on both surfaces of the gas removal particle 13, These each The breathable sheet materials 12 and 12 'are laminated and integrated on the outer surfaces of the resin bodies 14 and 14', respectively.

The gas removal particles 13 used in the gas removal sheet 11 can remove unpleasant odorous substances in the living environment, or remove gaseous pollutants contained in air or atmosphere in semiconductor or liquid crystal production facilities or clean rooms. It is a fixed particle having functions such as deodorization, gas removal, catalyst, photocatalyst, ion exchange, etc., and can exert such function against gas or liquid passing through the air-permeable sheet material 12, 12 ′ What can be used can be used. Specifically, activated carbon, zeolite, titanium oxide, ion exchange resin, metal particles, calcium carbonate, and the like can be used, and one or two or more of these can be appropriately selected and used. Among the gas removal particles, for example, when activated carbon is used for the purpose of deodorization, a porous particle having a specific surface area of 200 m ² / g or more is preferable, a particle having a specific surface area of 500 m ² / g or more is more preferable, and 800 m ² / g. The above is more preferable.

  Further, the gas removal particles preferably have an average particle size of 0.147 mm (100 mesh) to 1.65 mm (10 mesh) in order to achieve both high efficiency and bottom pressure loss. The average particle size is more preferably 0.212 mm (70 mesh) to 1.0 mm (16 mesh). When fine gas removal particles having an average particle diameter of less than 0.147 mm (100 mesh) are used, the initial gas removal efficiency can be increased, but there is a problem that the pressure loss increases. Further, when coarse gas removal particles having an average particle diameter exceeding 1.65 mm (10 mesh) are used, there may be a problem that initial gas removal efficiency becomes insufficient. In addition, the average particle diameter in the case where there is a distribution in the particle diameter of the gas removal particles is expressed by a mass average value of each particle diameter.

  As a material of the resin body 14 to which the gas removal particles are fixed, a sheet-like material made of a resin component having air permeability and heat melting property, for example, a porous body such as a nonwoven fabric, a woven fabric, a membrane, a filter paper, a sponge, etc. Can be used. Then, the sheet-like material is plasticized and melted to form a web-like resin body 14 composed of the resin agglomerated portion 14a and the connecting portion 14b, and the gas-removed particles are passed through the resin agglomerated portion 14a of the resin body 14. 13 is fixed. Of the above materials, non-woven fabrics are more preferred because of their high breathability. When using a non-woven fabric, for example, a non-woven fabric including an adhesive fiber composed of one component having a melting point of 160 ° C. or lower, or an adhesive composite fiber composed of two or more components including a low melting point component of 160 ° C. or lower can be applied. .

The breathable sheet material 12 laminated and integrated on the outer surface of the resin body 14 is not particularly limited as long as it is a breathable sheet-like material. For example, a porous material such as a nonwoven fabric, a woven fabric, a membrane, a filter paper, or a sponge A material or the like can be used. Among these, non-woven fabrics are more preferable because they have high air permeability. In addition, when a material made of a polymer material is used as the breathable sheet material, it is more preferable because it has high followability to pleat folding and the like and is excellent in durability. When a nonwoven fabric is used as the breathable sheet material, for example, a staple fiber is formed on a fiber web using a card machine or the like, and then a nonwoven fabric obtained by a dry method in which fibers are bonded to each other by bonding or entanglement, by a spunbond method Nonwoven fabrics made of long fibers or nonwoven fabrics obtained by a wet method can be used. Such breathable sheet material is preferably 10 to 200 g / m ² in areal density, more preferably 10 to 50 g / m ^2. The pressure loss at a surface wind speed of 0.5 m / sec is preferably 100 Pa or less. Further, it is more preferably 50 Pa or less.

  As another form of the gas removal sheet 11, as shown in FIG. 4, gas removal particles are respectively provided between resin bodies 14, 14 ′, and 14 ″ having a resin aggregation portion 14 a and a connection portion 14 b for connecting the gas removal particles 13. 13 is fixed, and a breathable sheet material 12, 12 ′ is laminated and integrated on the outer surface of each of the resin bodies 14, 14 ′. Since the resin bodies 14 and 14 ′ shown in FIG. 4 are the same as the gas removal sheet 11 shown in FIGS. 1 to 3, description thereof is omitted here. Moreover, since the gas removal particle | grains 13 and the air permeable sheet | seat materials 12 and 12 'in the gas removal sheet 11 shown in FIGS. 4-6 are the same as the gas removal sheet 11 shown in FIGS. 1-3, each FIG. Description of the gas removal sheet 11 shown in FIG.

  As a method of obtaining the gas removal sheet 11 having such a structure, for example, a hot melt nonwoven fabric is used as a material for forming the resin body 14, gas removal particles 13 are arranged on the surface of the hot melt nonwoven fabric, and then heated. A resin agglomerated portion 14a is formed at a portion where the hot melt nonwoven fabric and the gas removal particles are in contact with each other, and a web-like resin body 14 comprising the resin agglomerated portion 14a and a connecting portion 14b made of hot melt resin is formed. After removing the gas removal particles that are not fixed on the web-like resin body 14 in one step, the hot-melt nonwoven fabric is laminated in contact with the gas removal particles 13 that are fixed on the web-like resin body 14; Subsequently, after the gas removal particles 13 'are arranged on the surface of the hot melt nonwoven fabric, the portions where the hot melt nonwoven fabric and the gas removal particles 13' come into contact with each other by heat treatment. A second step of forming a fat aggregation part 14''a and forming a web-like resin body 14 '' comprising a resin aggregation part 14''a and a connecting part 14''b made of a hot-melt resin; In the same manner as in the second step, after laminating the hot melt nonwoven fabric in contact with the gas removal particles 13 ′ fixed on the web-like resin body 14 ″, the hot melt nonwoven fabric and the gas removal particles 13 ′ are heated. Forming a resin agglomerated portion 14'a at the portion where the contact is made and forming a web-like resin body 14 'composed of the resin agglomerated portion 14'a and a connecting portion 14'b made of hot melt resin And a fourth step of sequentially laminating and integrating the air-permeable sheet materials 12 and 12 ′ on the outer surfaces of the web-like resin bodies 14 and 14 ′. In addition, instead of the hot melt nonwoven fabric used as the web-like resin bodies 14 and 14 ′, the breathable sheet materials 12 and 12 ′ are laminated by using the hot melt nonwoven fabric to which the breathable sheet materials 12 and 12 ′ are attached. An integrated gas removal sheet 11 can be obtained.

  The gas removal sheet 11 can also take the form shown, for example in FIG.5 and FIG.6. That is, the gas removing sheet 11 shown in FIGS. 5 and 6 includes the first air-permeable sheet material 12a having the gas removing particles 13a fixed on the surface via the first adhesive 16a and the second air-permeable sheet material 12a on the surface. A gas permeable particle 13a in the first gas permeable sheet 12a and a gas in the second gas permeable sheet 12b. This shows a form in which the removed particles 13b are joined via the third adhesive 16c.

  In the form shown in FIG. 5, the second air-permeable sheet material 12 b has a second portion excluding the band-like void portions 17 (portions where no gas removal particles exist) provided at regular intervals on the surface of the second air-permeable sheet material 12 b. The gas removal particles 13b are fixed through the adhesive 16b. On the other hand, in the form shown in FIG. 6, the position of the gap portion 17a or 17b in one of the breathable sheets 12a or 12b is an intermediate position of the position of the gap portion 17b or 17a in the other breathable sheet 12b or 12a. The gas removal particles 13a or 13b are fixed on the surface of the breathable sheet material 12a or 12b via the first sign 16a or the second adhesive 16b.

The amount of the first adhesive 16a or the second adhesive 16b attached or applied on the surfaces of the first and second breathable sheet materials 12a and 12b is that the adhesive is attached or applied. in regions where there is preferably 5 to 50 g / m ² in areal density, more preferably 5 to 40 g / m ^2. The adhesives 16a and 16b to be used are not particularly limited as long as the gas removing particles 13a and 13b can be fixed on the surfaces of the air-permeable sheet materials 12a and 12b. Thermoplastic resins and thermosetting resins And moisture curable resins.

  As an attachment form of the first adhesive 16a or the second adhesive 16b attached or applied on the surfaces of the first and second air-permeable sheet materials 12a and 12b, for example, a gravure roll is used to form an emulsion. There is a form obtained by applying a paste-like or hot-melt adhesive on the surfaces of the first and second breathable sheet materials 12a and 12b. Moreover, there exists a form obtained by the method of apply | coating the adhesive agent 16a or 16b by the spray method. Further, there is a form obtained by a method in which a particulate adhesive made of a heat-fusible resin is sprayed on the surfaces of the first and second breathable sheet materials 12a and 12b. Further, the thermoplastic resin is heated and melted to be ejected from a nozzle or the like and applied onto the surfaces of the first and second breathable sheet materials 12a and 12b, or a releasable support sheet. There is also a form obtained by preparing a spider web-like hot melt nonwoven fabric on the top and placing the hot melt nonwoven fabric on the surfaces of the first and second breathable sheet materials 12a and 12b.

  As the thermoplastic resin that can be used for the hot melt nonwoven fabric, it is preferable to select one having an MI of 50 or more and 500 or less. A resin having an MI lower than this range has low fluidity during heat treatment, and may cause imperfect fixation of gas removal particles during heat treatment. On the other hand, a resin having a MI higher than the above range has high fluidity during heat treatment, and the gas removal particles may not be firmly fixed.

  The third adhesive 16c for joining the gas removal particles 13a in the first breathable sheet 12a and the gas removal particles 13b in the second breathable sheet 12b can join the gas removal particles 13a and 13b. As long as there is no particular limitation. As such an adhesive, for example, a heat-fusible resin such as a thermoplastic polyamide resin, a thermoplastic polyester resin, a thermoplastic urethane resin, a polyolefin resin, or an ethylene-vinyl acetate copolymer resin is preferable. Alternatively, a moisture curable resin such as a polyurethane resin is preferable. Also, for example, if the polyurethane resin has both moisture curable and thermoplastic properties, the resin is melted and then applied to the gas removal particles 13a or 13b of the first or second breathable sheet 12a or 12b. Then, it can be cured without any heating by simply joining with the gas removal particles 13b or 13a of the second or first air-permeable sheet 12b or 12ba and exposing it to the atmosphere as it is. .

  In order to apply such a heat-fusible resin to the surface of the gas removal particles, for example, the heat-fusible resin is heated to a molten state and ejected from a nozzle or the like to form a gas in a spider web. There is a method of applying to the surface of the removed particles. In addition, such a heat-fusible resin is heated to be melted and ejected from a nozzle or the like and laminated on a releasable support sheet to form a spider web-like hot melt nonwoven fabric. It is also possible to peel the substrate from the releasable support sheet and place it on the surface of the gas removal particles. The method using the spider web-shaped hot-melt nonwoven fabric joins the gas removal particles 13a and 13b shown in FIG. 4 in addition to joining the gas removal particles 13a and 13b shown in FIGS. It can also be applied to.

The adhesion amount of the third adhesive 16c, is preferably 5 to 50 g / m ² in areal density, more preferably 10 to 40 g / m ^2. In addition, if the contact bonding layer formed with the 3rd adhesive agent 16c becomes a form which has air permeability, the gas removal sheet 11 by this invention can be used effectively as a filter medium.

  When the third adhesive 16c is applied in the form of a spider web to the surface of the gas removal particles, it is preferable to use, for example, the apparatus shown in FIG. 7 (disclosed in JP-A-2007-90804). In the apparatus X shown in FIG. 7, the nozzle X1 for spraying and applying the third adhesive 16c in a molten state is disposed above the pair of pressure rolls 15a and 15b. Between the pressure rolls 15a and 15b, the air permeable sheets 12a and 12b are respectively conveyed with the side surfaces to which the gas removal particles (not shown) are fixed, and the molten third adhesive 16c is ejected from the nozzle to the fixed side surfaces. In this state, the breathable sheets 12a and 12b are pressed and joined between the pressure rolls 15a and 15b. According to this example, since the gas removal particles can be firmly bonded to each other even if the amount of the third adhesive applied is small, there is an advantage that a gas removal sheet with little pressure loss can be manufactured. There is also an advantage that the cost can be reduced.

The thickness of the gas removal sheet 11 is preferably 0.3 to 5.0 mm, and more preferably 0.4 to 3.0 mm. The mass per unit area of the gas removal sheet 11 is preferably an 100~700g / m ^2, and more preferably 150~500g / m ^2. The above thickness refers to the thickness when a weight of 0.5 g is applied per 1 cm ² .

  The filter element of the present invention is composed of a honeycomb structure manufactured using the gas removal sheet that can take the various forms described above, and has a hexagonal shape, a quadrangular shape, or a triangular shape using the gas removal sheet as a face material. The core that forms the air path. The filter element shown in FIGS. 1 to 3 is composed of a honeycomb structure 10 made by using a gas removing sheet 11 that has been folded into a single pleat.

  In the case of the filter element shown in FIGS. 1 to 3, a frame member 18 is attached around the gas removal sheet 11 that has been pleated, and a honeycomb structure having a triangular core is formed. It is supposed to function as.

  As the pleat shape of the gas removal sheet 11 constituting the honeycomb structure of the filter element shown in FIGS. 1 to 3, the peak height H of the pleats is preferably 5 to 80 mm as shown in FIG. More preferably. Further, the peak interval P is preferably 2 to 50 mm, and more preferably 4 to 20 mm. In the case of this embodiment, the pleated folded shape can be fixed by applying hot melt resin in a direction perpendicular to the fold mountain.

  The frame member 18 attached around the honeycomb structure 10 is a gas-impermeable plate member, and the material thereof is not particularly limited as long as the shape of the honeycomb structure 10 can be maintained. Fibers, resins, metals, and the like are possible, and in the case of fibers, a nonwoven fabric (or a nonwoven fabric impregnated with resin) is particularly preferable because of its excellent adhesion to the gas removal sheet and cushioning properties. It is also possible to include a flame retardant in the resin for impregnation.

  The frame member 18 is attached by inserting a comb member between folds of the pleat-folded gas removal sheet 11 to hold the folded shape, and in this state the frame member is attached to the top of the gas removal sheet 11 with an adhesive (for example, hot Bonding via a melt resin). Next, after removing the comb member, a frame member can be joined to the side surface of the gas removal sheet 11 via an adhesive (for example, hot melt resin) to obtain a filter element made of the honeycomb structure 10 shown in FIG. .

  9 to 11 show a filter element formed of a honeycomb structure formed by laminating a plurality of gas removal sheets at intervals in the thickness direction. The filter element shown in FIG. 9 is a gas removal sheet. A frame member 18 is attached to the periphery of a honeycomb structure 10 composed of quadrangular cores arranged in parallel so that the surfaces of 11 are parallel to each other. The filter element shown in FIG. 10 is obtained by attaching a frame 18 around the honeycomb structure 10 in which pleated gas removal sheets 11a and flat gas removal sheets 11b are alternately laminated. In the case of this form, it is also possible to apply a gas-impermeable plate member or a resin sheet instead of the flat gas removal sheet 11b. The filter element shown in FIG. 11 is a honeycomb structure 10 formed by joining ridges or valleys of pleated gas removal sheets 11a and 11b, and a frame member 18 is attached around the pleats. It has been.

  In addition, the filter element of the present invention can take a form formed by joining a plurality of honeycomb structures as described above. FIG. 12 shows frame structures 18, 18 ′ and honeycomb structures 10, 10 ′, 10 ″ obtained by pleating the gas removal sheets 11, 11 ′, 11 ″ shown in FIGS. The one with 18 ″ attached is stacked and integrated one above the other. In the case of this embodiment, the pleated folded shape can be fixed by applying hot melt resin in a direction perpendicular to the fold mountain.

  Although the outer dimension of this honeycomb structure is not particularly limited, in the case of equipment, the W direction shown in FIG. 12 is preferably 30 to 600 mm, and more preferably 50 to 500 mm. The D direction is preferably 7 to 600 mm, more preferably 10 to 500 mm. In general-purpose air conditioning, the W direction and the D direction are preferably 100 to 700 mm, more preferably 200 to 600 mm.

  In the filter element of the present invention, for example, as shown in FIGS. 1 and 2, resin processing is applied to an end portion of a gas removal sheet 11 constituting at least one of a gas inlet side and an outlet side of the honeycomb structure 10. Therefore, the resin processed portion 20 can ensure the joining of the two air permeable sheet materials 12 and the gas removal particles 13 held between the air permeable sheet materials 12. That is, the gas removal particles 13 in the gas removal sheet 11 are already bonded to the breathable sheet material 12, but are caused by vibration or contact with other objects during the manufacturing process, transportation or use of the filter element. However, the resin processed portion 20 can reliably catch the gas removal particles 13 at the end of the gas removal sheet 11 and reliably prevent the removal. .

  The degree of the resin processing may be a processing such that the shape of the gas removal particles remains in the shape before the processing. That is, taking the case where the breathable sheet is composed of fibers as an example, the particle size of the particles is larger than the fiber diameter, so even if the shape of the gas removal particles remains in the shape before processing, the gas removal It is possible to prevent the particles from falling off. It is also possible to maintain the function of the gas removal particles. On the other hand, as in the prior art, in the case of a filter medium in which particles having a particle diameter smaller than the diameter of the fibers are bonded and held between the fibers by an adhesive or the like, the resin processing of the resin There is a problem that the particles are buried and the function of the particles is lost.

  The resin used for the resin processing can be organic or inorganic as long as it is a resin having an adhesive strength sufficient to prevent the gas removal particles from falling off, and the material is not particularly limited. As the resin used for resin processing, for example, polyvinyl alcohol resin, polyvinyl acetate resin, polyacrylic resin, etc. can be used. Among these resins, they can be cured by exposure to air and drying at room temperature. Organic resins are preferred, and it is desirable to select a resin that generates as little odor as possible. It is also possible to use aqueous resins such as polyvinyl alcohol resins and polyvinyl acetate resins sold for general household use. is there.

The degree of the resin processing is preferably within an average of 10 mm from the end of the gas removal sheet 11 constituting at least one of the gas inlet side or the outlet side of the honeycomb structure 10, and more preferably within an average of 7 mm. More preferably, the average is within 3 mm. The degree of resin processing is preferably 0.5 mm or more on average from the end of the gas removal sheet 11 constituting at least one of the gas inlet side or the outlet side of the honeycomb structure 10, and preferably 1 mm or more. More preferred. Further, the resin amount (solid content) is preferably 20 to 150 g / m ² , more preferably 30 to 100 g / m ² , and more preferably 45 to 75 g / m ² per unit area of the gas removal sheet 11 in the attached portion. it is more preferably m ^2.

  The method of resin processing is not particularly limited, and the resin dispersion can be dried and applied by a known processing method such as impregnation or coating. Specifically, a resin dispersion is sprayed on the gas inlet side and / or outlet side (end portion of the gas removal sheet) of the honeycomb structure, or the gas of the honeycomb structure is put into a container containing the resin dispersion. This is performed by immersing the inlet side and / or the outlet side (the end of the gas removal sheet).

More specifically, a liquid obtained by diluting a water-based adhesive (quick-drying bond for woodworking, manufactured by Konishi Co., Ltd., vinyl acetate resin 55% (water 45%)) three times by weight with water. A depth of about 2 mm was accumulated in an aluminum pallet, and the gas inlet side and outlet side of the honeycomb structure were immersed for 3 to 5 seconds. Thereafter, the honeycomb structure was taken out from the pallet and air-dried for about 15 minutes. As a result, resin processing could be applied to the portion from the end of the gas removal sheet to an average of 2.5 mm. In addition, the amount of resin adhered (solid content) was 60 g / m ² per unit area of the gas removal sheet at the adhered portion.

  In addition, this invention is not limited to the example mentioned above, It can implement freely within the range described in the claim.

It is a perspective view which shows an example of the filter element of this invention. It is a principal part enlarged view of the filter element of this invention. It is a principal part expanded sectional view of the gas removal sheet in the filter element of this invention. It is a principal part expanded sectional view which shows another example of the gas removal sheet | seat in the filter element of this invention. It is a principal part expanded sectional view which shows another example of the gas removal sheet | seat in the filter element of this invention. It is a principal part expanded sectional view which shows another example of the gas removal sheet | seat in the filter element of this invention. It is a schematic diagram which shows the apparatus used for manufacture of a gas removal sheet. It is a principal part expanded sectional view which shows the gas removal sheet by which the pleat process was carried out. It is a perspective view which shows another example of the filter element of this invention. It is a perspective view which shows another example of the filter element of this invention. It is a perspective view which shows another example of the filter element of this invention. It is a perspective view which shows another example of the filter element of this invention. It is a principal part expanded sectional view which shows the conventional filter element.

Explanation of symbols

10, 10 ', 10 "... honeycomb structure 11, 11', 11", 11a, 11b ... gas removal sheet 12, 12 ', 12a, 12b ... breathable sheet material 13, 13 ', 13a, 13b ... Gas removal particles 14, 14', 14 "... Resin bodies 14a, 14'a, 14" a ... Resin agglomerates 14b, 14'b, 14b " ..Connecting part 16, 16a, 16b, 16c ... Adhesive 17, ... Gap part 18,18 ', 18 "... Frame material 20 ... Resin processed part

Claims (9)

A filter element comprising a honeycomb structure formed using a gas removal sheet in which gas removal particles are held between two air-permeable sheet materials ,
The honeycomb structure is a structure having a core formed with the gas removal sheet as a face material as an air path,
(1) Constructed by attaching a frame material around a pleated gas removal sheet,
(2) A structure in which a frame material is attached around a plurality of gas removal sheets arranged in parallel so that the surfaces of the gas removal sheets are parallel to each other,
(3) A structure in which a frame material is attached around a pleated folded gas removal sheet and a flat gas removal sheet alternately laminated, or
(4) A configuration in which a frame material is attached around the pleats of a plurality of gas-removal sheet pleats joined together by crests or troughs,
A structure selected from
A filter element, wherein an end portion of a gas removal sheet constituting at least one of a gas inlet side and an outlet side of the honeycomb structure is subjected to resin processing by impregnation with a resin dispersion . 2. The filter element according to claim 1 , wherein the resin processing is performed within an average of 10 mm from an end portion of a gas removal sheet constituting at least one of the gas inlet side and the outlet side of the honeycomb structure. Claims the honeycomb structure of the gas inlet and or outlet configuration for gas removal sheet end unit area per 20 to 150 g / m ² of the resin of the gas removal sheet is characterized in that it is impregnated The filter element according to 1 or 2 . The gas removing sheet has a gas permeable sheet material laminated on both sides of a gas removing particle layer formed by connecting gas removing particles having an average particle diameter of 0.147 to 1.65 mm with a thermoplastic resin, and has a thickness. The filter element according to any one of claims 1 to 3 , wherein the filter element is a sheet-like material having a length of 0.2 to 4 mm. Frame material attached to the periphery of the honeycomb structure, the filter element according to any one of claims 1 to 4, characterized in that the hot-melt resin is a frame member coated. The filter element according to any one of claims 1 to 5, wherein a plurality of honeycomb structures are joined. Form a gas removal sheet holding gas removal particles between two breathable sheet materials,
Next, a honeycomb structure is formed using the gas removal sheet,
Here, the honeycomb structure is a structure having a core formed with the gas removal sheet as a face material as an air path,
(1) Constructed by attaching a frame material around a pleated gas removal sheet,
(2) A structure in which a frame material is attached around a plurality of gas removal sheets arranged in parallel so that the surfaces of the gas removal sheets are parallel to each other,
(3) A structure in which a frame material is attached around a pleated folded gas removal sheet and a flat gas removal sheet alternately laminated, or
(4) A configuration in which a frame material is attached around the pleats of a plurality of gas-removal sheet pleats joined together by crests or troughs,
A structure selected from
Thereafter, a resin processing for preventing the gas removal particles from falling off is performed on an end portion of the gas removal sheet constituting at least one of the gas inlet side and the outlet side of the honeycomb structure. Manufacturing method. Resin processing, after the deposition of the dispersion of the resin to the end of the gas removal sheet which forms at least one inlet side or the outlet side of the gas of the honeycomb structure, claims, characterized in that it consists of dried A method for producing the filter element according to claim 7 . Resin processing, claims, characterized by comprising an end portion of the gas removal sheet which forms at least one inlet side or the outlet side of the gas of the honeycomb structure was dipped in the dispersion liquid of resin, because the air drying A method for producing the filter element according to 7 or 8 .

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