JPH038764B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a method of manufacturing a box-shaped dust collection filter for a vacuum cleaner.

[Conventional technology]

Conventional box-shaped dust collection filters have a corrugated non-woven fabric filter only on the bottom, and the other 4 filters except for the opening.
The surface is made of resin, and is manufactured by setting a nonwoven fabric filter pre-folded into a corrugated shape only on the ceiling surface of the mold, and then pouring resin into the mold.

[Problem to be solved by the invention]

In the above conventional example, in order to obtain the necessary filtration area on only one side of the box, it is necessary to bend the nonwoven fabric filter into a large wave shape, which has the disadvantage that the entire box-shaped dust collection filter becomes large.
Since the four side surfaces of the box are made of resin, the amount of resin used is large, and the box-shaped dust collecting filter as a whole has the disadvantage of being heavy, making it difficult to handle.

In view of the above-mentioned drawbacks, an object of the present invention is to provide a method for manufacturing a box-shaped dust collection filter for a vacuum cleaner that has a sufficient filtration area, is small and lightweight, and has excellent productivity. There is something to do.

[Means to solve the problem]

The above purpose is to form a nonwoven filter with a raised surface by compressing a sheet of cotton candy-like polyester fiber of 2 to 5 deniers by passing it between rollers and then passing it between rollers for needle punching. a first step of cutting the nonwoven fabric filter into a cross shape, and a second step of partially joining the cut portions so that the raised surface is on the inside and forming a box shape; After inserting the filter into a mold of a molding machine, resin is poured into the mold to integrally form a shape-retaining cage with a large number of support bones and a flange portion forming an opening. This is achieved by manufacturing a box-shaped dust collection filter for a vacuum cleaner from the third step.

[Effect]

First, the nonwoven filter is cut into a cross shape, and the cut parts are partially joined so that the raised side is inside and forms a box shape, and then the nonwoven filter is set in a mold of a molding machine. . In this case, since the non-woven fabric filters forming the five sides of the box-shaped dust collection filter are integrated, there is no need to temporarily attach the non-woven fabric filters to the sides of the mold with tape or the like. Since the non-woven fabric filter does not shift significantly in the predetermined position, it is possible to prevent the production of box-shaped dust collecting filters that become unusable due to gaps between the support bones of the shape-retaining basket and the non-woven fabric filter. , productivity is excellent.

The box-shaped dust collection filter is made up of non-woven fabric filters on five sides excluding the opening, so it has a large filtration area, less clogging, excellent dust collection performance, and is compact and easy to use. The amount of resin is small and the weight is reduced.

The hot water of the resin that forms the support bones of the shape-retaining basket is poured between the naps of the nonwoven filter and hardens, making the connection between the nonwoven filter and the support bones extremely strong.

〔Example〕

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be explained below based on drawings showing one embodiment.

The main body case 1 of the vacuum cleaner is constructed by combining an upper case 2 and a lower case 3, as shown in FIGS. 1 and 2.

The inside of the front side of the main body case 1 is a box-shaped dust collection filter storage section 9. An electric blower 4 (FIG. 12) is provided inside the rear side.

There are small wheels 5 on the bottom of the lower case 3 near the front.
However, large wheels 6 are provided on both sides of the rear.

A carrying handle 7 is provided at the center of the upper surface of the upper case 2, and an operating pedal 8 for a cord reel is provided at the rear side of the upper surface.

A removable box-shaped dust filter 10 is attached to the box-shaped dust filter storage section 9. Outer lid 11 that closes the box-shaped dust collection filter storage section 9
is attached to the upper case 2 so as to be openable and closable.
The outer lid 11 and the carrying handle 7 are rotatably supported on a support shaft 12.

Now, as shown in FIGS. 4 and 6, the box-shaped dust collecting filter 10 has a structure in which a holding basket 13 is covered with a nonwoven fabric filter 14.

Manufacturing of the box-shaped dust collecting filter 10 will be described with reference to FIGS. 5 and 6.

Polyester fibers of 2 to 5 deniers, which are shaped like cotton candy, are made into a sheet, and this is passed between rollers and lightly compressed. Thereafter, by passing it between rollers for needle punching, a material for the nonwoven filter 14 as shown in FIG. 5A is obtained.
The upper surface is raised, and the lower surface is almost flat. The thickness of the nonwoven fabric filter 14 is 1.5 mm.
The height of the nap is approximately 0.5 mm.

Next, as shown in FIG. 6C, the material for the nonwoven filter 14 is cut into a cross shape, and then formed into a box shape as shown in FIG. 6B, with the raised side facing inside. The upper end joint portions 15 are joined by thermal welding. This box-shaped nonwoven fabric filter 14 is inserted into a mold of a molding machine to mold the shape-retaining basket 13, and at the same time, the non-woven fabric filter 14 and the shape-retaining basket 13 are integrated.

The shape-retaining cage 13 has a large number of support bones 16. Most of this support bone 16 is covered with non-woven fabric filter 1.
4, the support ribs 16 and the nonwoven fabric filter 14 are well connected. That is, when the thermoplastic resin that is the material of the support ribs 16 becomes liquid and enters the mold, it flows into the raised interior of the nonwoven fabric filter 14 and becomes a coin to form the support ribs 16. The support bones 16 go deep inside the naps of the non-woven filter 14, and as shown in FIG.
4 bond is very strong.

When the thermoplastic resin hot water flows inside the mold, some of it escapes to the outside of the nonwoven fabric filter 14. Since the supporting bones 16 may be formed on the outside, the supporting bones 16 protruding from the inside of the nonwoven fabric filter 14
Although the heights are not necessarily the same, the average protrusion height is approximately 4 mm.

A flange portion 17 is formed at the opening of the box-shaped dust collecting filter 10. An annular airtight packing 18 as shown in FIG. 4 is attached to the flange portion 17.

The corners of the airtight packing 18 are marked with the markings shown in Fig. 10.
As shown in FIG. 11, an indicator packing 19 having a flap-like upper part is integrally formed.
The lower cylindrical portion of this packing 19 fits into a hole 20 formed in the flange portion 17. This hole 20 is located outside the box-shaped dust collection filter 10.

The filter support plate 21 is rotatably attached to the opening of the box-shaped dust collecting filter 10.
This filter support plate 21 has a size that closes approximately half of the opening.

A disposable bag-shaped paper filter 22, which is detachably attached to the box-shaped dust collecting filter 10, has an attachment plate 23 attached thereto. Mounting plate 23
is made of thick hard paper and has a suction opening. As shown in FIG.
It is set in the box-shaped dust collecting filter 10 by extending it over the edge of the opening of the box-shaped dust collecting filter 10.

A filter storage chamber 24 in which a spare bag-shaped paper filter 22 is stored is formed inside the outer lid 11. The lid 25 of the filter storage chamber 24 is attached to the support shaft 2
The outer cover 27 is screwed to the inside of the outer cover 11 with 6.

A communication pipe 29 is connected to the back side of the hose connection port 28 provided on the front side of the outer cover 11.
The outlet of the communication pipe 29 is inserted into a suction opening formed in the mounting plate 23 of the bag-shaped paper filter 22 when the outer lid 11 is closed.

A suction seal packing 30 attached to the lower surface of the inner lid 27 so as to surround the outlet of the communication pipe 29 comes into close contact with the mounting plate 23 of the bag-shaped paper filter 22 when the outer lid 11 is closed. , are placed so as to surround the suction opening formed in the mounting plate 23.

A communication pipe 29 is integrally formed on the upper surface of the inner lid 27, and an indicator device is also provided. That is, as shown in FIG. 4, a support base 32 for supporting the display tube 31 is integrally formed with the inner lid 27. The flexible pipe 33 has one end connected to the display tube 31 and the other end connected to the inner lid 27.
The display tube 31 side of the pipe 33 is square, and the inner lid 27 side is circular. The connection on the inner lid 27 side is clearly shown in FIG.

Since the indicator devices are collectively provided on the upper surface of the inner lid 27, assembly of the indicator devices is easy. When the inner cover 27 is attached to the outer cover 11, the display tube 31 faces the lower window 34 formed in the outer cover 11.

As shown in FIG. 11, when the outer cover 11 is closed, the communication hole 34 at the inner cover 27 to which the pipe 33 is connected is connected to the indicator packing 19 provided on the box-shaped dust collection filter 10. Join. In this way, the display tube 31 is communicated with the box-shaped dust collecting filter storage section 9. Since the upper side of the indicator packing 19 is shaped like a flap, it comes into contact with the lower surface of the inner lid 27 to ensure good airtightness. Therefore, the display tube 31 clearly indicates the negative pressure in the box-shaped dust collecting filter storage reservoir 9.

A clamp 35 is provided on the front side of the lower case 3. This clamp 35 is rotatably supported by a support shaft 36. The engagement claw 37 of the clamp 35 is connected to an engagement recess 38 formed on the front side of the outer lid 11.
engage with. This prevents the outer lid 11 from opening. The clamp 35 is operated against the spring 39 provided on the clamp 35, and the engagement claw 37 is moved into the engagement recess 38.
When removed from the housing, the outer lid 11 is opened by the force of a spring (not shown) provided at the support shaft 12.

A partition plate 40 is provided on the back side of the box-shaped dust collecting filter storage section 9 of the main body case 1. This partition plate 40 has a structure as shown in FIGS. 4 and 7. A ventilation hole 41 is formed in the partition plate 40, and a cam stand 42 is rotatably attached to the partition plate 40. The transmission gear 43 to which the cam stand 42 is attached is placed on the back side of the partition plate 40.
The partition plate 40 is attached so that its surface side faces the box-shaped dust collecting filter storage section 9 side.

A dust remover storage section 44 is formed on the back side of the partition plate 40 and is largely recessed toward the front side. The dust remover storage section 44 is not provided with a ventilation hole 41. Dust remover 45 attached to dust remover storage section 44
protrudes toward the cam stand 42 from a window 46 formed in the side wall of the dust remover storage section 44 whose free end is on the cam stand 42 side. The fixed part side of the dust remover 45 is supported by a support part formed in the dust remover storage part 44. As shown in FIGS. 7 and 8, this support portion is composed of a locking piece 47 and a locking boss 48. The locking piece 47 and the locking boss 48 are formed integrally with the partition plate 40. A locking claw 49 is formed at the tip of the locking piece 47. Locking piece 47
A slit is formed between the locking boss 48 and the locking boss 48 . The dust remover 45 has a fixed portion formed in a curved shape. The dust remover 45 is attached by fitting this curved portion into the slit. Locking piece 47
is made of resin and is somewhat flexible. The outside of the locking pawl 49 is sloped toward the slit. Therefore, when the curved portion is pushed into the slit, the locking piece 47 escapes so that the slit opens, so that the curved portion can be easily inserted into the slit. Once inserted, the locking pawl 49 prevents the curved portion from coming out of the slit. If the outer end of the locking boss 48 is also sloped like the locking pawl 49, the curved portion can be inserted into the slit more easily.

The end of the dust remover 45 immediately beside the curved portion is inserted into an engagement slit provided in the dust remover housing 44.

Since the curved portion of the dust remover 45 is held between the locking boss 48 and the locking piece 47, the dust remover 45 is fixed in the longitudinal direction. The locking pawl 49 prevents it from coming off toward the front side, as described above. Furthermore, since the end immediately next to the curved part is inserted into the engagement slit as described above, the fixed part side of the dust remover 45 is securely attached to the partition wall together with the previous longitudinal fixation. The dust remover 45 is fixed and does not use screws.
Easy to assemble as it can be attached.

The dust remover 45 is made of a steel material with high spring properties. The free end side of the dust remover 45 vibrates within the height range of the window 46. Both sides of the window 46 serve as guides when the dust remover 45 vibrates, so the dust remover 4
The free end of 5 vibrates without sideways vibration.

The partition wall 40 is formed of resin using two molds that are punched out on the front side and the back side, so that the window 46 and the locking piece can be punched out.
That is, at the base of the locking piece 47, the part corresponding to the slit side is opened at least by a size corresponding to the locking claw 49. bottom 5 of window 46
At point 0, the corner of the dust remover storage section 44 is removed to the back side by at least the thickness of the window 46.

As shown in FIG. 7, a power cord 52 is wound around the cord reel 51. As shown in FIG. code reel 5
1 is provided with a spring (not shown), so that the power cord 52 is automatically wound up by the force of the spring.

A gear 53 is formed on this cord reel 51. This gear 53 meshes with the transmission gear 43. When the code reel 51 is rotated, the cam base 42 is rotated via the transmission gear 43, and the cam base 42 is rotated via the transmission gear 43.
2 causes the dust remover 45 to vibrate.

As shown in FIG. 8, the shaft boss 54 of the transmission gear 43 has a square engagement hole 55 formed therein. A pair of engagement pieces 56 are integrally formed on the central back surface of the cam base 42. An engaging pawl 57 having a tapered head portion is formed at the tip of the engaging piece 56 . When the engagement piece 56 is inserted into the engagement hole 55, the engagement claw 57 protrudes from the back surface of the transmission gear 43, and the engagement claw 57 engages with the opening edge of the engagement hole 55. Transmission gear 43 attached to partition plate 40
and the cam base 42 are combined.

When the engagement piece 56 enters the square engagement hole 55, the transmission gear 43 and the cam base 42 are prevented from rotating. When the engaging piece 56 is inserted into the engaging hole 55, since the head of the engaging condenser 57 is tapered, the engaging piece 56 is bent inward, and the insertion is easily performed.

A support 59 that rotatably supports a cam 58 is integrally formed on the surface of the cam base 42 . The support shaft 59 is provided at a position offset from the rotation center of the cam base 42. A cap 60 is formed at the tip of the support 59 to prevent it from coming off. A cam stopper 61 is provided beside the support shaft 59 to regulate the rotation angle of the cam 58.
is provided.

A cam spring 62 that applies a force in one direction to the cam 58 is attached to the support shaft 59 . A spindle hole 63 into which the spindle 59 is fitted is formed in the cam 58 . The spindle hole 63 has a shape that allows the umbrella 60 to pass therethrough. Cam spring 62 and cam 58
When the cam spring 62 is attached to the support shaft 59, a hook 64 formed at one end of the cam spring 62 engages with the shoulder of the cam 58, and the other end engages with a groove 65 formed in the cam stopper 61. In this way, the attached cam 58 has a force applied to one side by the cam spring 62.

The relationship between this cam 58 and the dust remover 45 is as follows.
As shown in FIG. 9A, a box-shaped dust collection filter 10
When the dust remover 45 is not stored in the box-shaped dust collecting filter housing 9, the free end of the dust remover 45 does not engage with the cam 58.

When the box-shaped dust collecting filter 10 is stored in the box-shaped dust collecting filter storage section 9, the vibration protrusion 66 formed on the outer back surface of the box-shaped dust collecting filter 10 pushes down the dust remover 45 from above. This is shown in FIG.

When the dust remover 45 is pushed down a little, the dust remover 4
5 comes to be engaged with the cam 58. That is,
When shown in FIG. 9A, the tip of the dust remover 45 is located outward from the tips of the cam base 42 and the cam 58. However, in the case shown in FIG. 9B, the tip of the dust remover 45 is located inside the tip of the cam 58, so when the cam base 42 rotates as shown in FIG. is the dust remover 45
will be engaged in.

When the cam stand 42 rotates in the direction shown by C in FIG. 9, the dust remover 45 is pulled down by the cam 58. When the cam base 42 further rotates, the dust remover 45 is removed from the tip of the cam 58, and the dust remover 45 rapidly returns to its original state by its own spring force. As a result, the vibrating protrusion 66 is struck by the dust remover 45.
The vibrations generated at this time cause the box-shaped dust collection filter 1 to
Vibrate 0. The bag-shaped paper filter 20 housed inside the box-shaped dust collecting filter 10 also vibrates at the same time. Dust is removed from the bag-shaped paper filter 20 and the box-shaped dust collection filter 10 at the same time. Since the vibrating protrusion 66 is formed integrally with the shape-retaining basket 13 of the box-shaped dust collecting filter 10, the box-shaped dust collecting filter 10 vibrates well even in areas far from the vibrating protrusion 66. Dust removal is carried out throughout the area, not just locally.

When the cam base 42 rotates in the direction D in FIG. 9, even if the cam 58 touches the dust remover 45, the cam 5
8 turns and escapes, so the dust remover 45 cannot be pulled down. Therefore, the dust remover 45 does not hit the vibration protrusion 66.

The above has described this embodiment mainly from the perspective of structure, but next, this embodiment will be explained from the perspective of operation.

As the electric blower 4 operates, air containing dust passes through the hose connection port 28 and the communication pipe 29 and flows into the bag-shaped paper filter 22. Coarse dust and fine dust are collected in the bag-shaped paper filter 22, and air passes through the ventilation holes of the bag-shaped paper filter 22 and heads toward the nonwoven fabric filter 14 of the box-shaped dust collecting filter 10. The fine dust that has blown through the bag-like paper filter 22 is captured by the nonwoven fabric filter 14. Nonwoven filter 1
4 passes through the ventilation hole 41 of the partition wall 40, further passes through the electric blower 4, and is discharged to the outside of the main body case 1.

Dust attached to the inner surface of the bag-shaped paper filter 22 and the inner surface of the nonwoven fabric filter 14 is removed by rotating the cord reel 51 as described above. When the bag-shaped paper filter 22 is full of dust, open the outer lid 11 and throw away the bag-shaped paper filter 22 together with the dust. Then, by attaching a new bag-shaped paper filter 22 into the box-shaped dust collecting filter 10, cleaning can be performed again.

The amount of dust that accumulates inside the box-shaped dust collection filter 10 is
Although the amount of dust that accumulates in the bag-shaped paper filter 22 is extremely small, since the dust that accumulates here is only fine dust, the nonwoven fabric filter 14 is easily clogged. However, since the dust adhering portion of the nonwoven fabric filter 14 is formed with naps, clogging is less likely to occur compared to a filter without naps. That is, as shown in FIG. 5B, fine dust particles 67
The dust particles are caught at the tips of the naps or adhere to the naps between the naps, reducing the close contact between dust particles. There are also fewer dust particles attached to the base of the nap.
If the filter has a flat, unraised surface, the dust particles will adhere to each other and the ventilation surface of the filter, causing the filter to become clogged, and the suction performance to deteriorate immediately. However, in the case of this example, due to the action of the nap as described above, clogging does not occur easily.
This results in improved suction performance.

According to the present embodiment, (1) The box-shaped dust collecting filter 10 has five sides made of non-woven fabric filters 14, and the non-woven fabric filters 14
is supported by the shape-retaining basket 13, which allows for a large filtration area.Compared to the conventional box-shaped dust collection filter using a corrugated filter, it is smaller, uses less resin, and is lighter. be converted into

(2) The nonwoven fabric filter 14 constituting the box-shaped dust collecting filter 10 has a raised surface, and since dust is allowed to adhere to the raised surface side, clogging with fine dust is less likely to occur, and the suction performance is improved. improves.

(3) When forming the shape-retaining basket 13, the resin hot water that forms the support bones 16 of the shape-retention basket 13 enters between the naps of the non-woven filter 14 and combines with the non-woven filter 14, so that the support bones 16 and the nonwoven fabric filter 14 become strong.

(4) The support bones 16 forming the shape-retaining cage 13 are
Since the box-shaped dust collection case 10 protrudes inside the box-shaped dust collection case 10, a gap is created between the nonwoven fabric filter 14 and the bag-shaped paper filter 22 where the support ribs 16 are located, and the box-shaped dust collection case 10 improves air permeability.
It can be grown.

(5) Non-woven filter 14 cut into a cross shape
The cut parts were partially joined together to form a box shape, so the nonwoven fabric filter 14 was attached to the mold.
Easy to insert.

(6) Box-shaped dust collection filter 10 excluding the opening 5
Since the non-woven fabric filter 14 constituting the surface is integral, the non-woven fabric filter 14 is less likely to be misaligned due to the flow of resin from a predetermined set position when resin is inserted into the mold, and the shape-retaining basket 13 support bone 16 and nonwoven fabric filter 14
There is no gap between the two.

In the above embodiment, the dust collection case storage section 9 is formed integrally with the main body case 1, but the dust collection case storage section 9 is constructed separately from the main body case, that is, the electric blower storage section 9 is formed integrally with the main body case 1. A similar effect can be expected even if the part and the dust collection case storage part are configured to be separate and separable.

〔Effect of the invention〕

As described above, according to the present invention, a box-shaped dust collection filter is compressed by passing a sheet of cotton candy-like polyester fibers of 2 to 5 deniers between rollers, and then compressing the box-shaped dust collection filter with a needle punch roller. A first step of forming a non-woven filter with a raised surface by cutting the non-woven filter into a cross shape, and cutting the cut portion so that the raised surface is on the inside and has a box shape. The second step is to partially join the filter, and after inserting this box-shaped nonwoven fabric filter into the mold of a molding machine, resin is poured into the mold to form a flange part that forms a large number of support bones and openings. By manufacturing the shape-retaining basket by the third step of integrally molding it with the non-woven filter, a gap is created between the support bones of the shape-retaining basket and the non-woven filter, making it unusable. To obtain a box-shaped dust-collecting filter for a vacuum cleaner which prevents the manufacture of a box-shaped dust-collecting filter, has a sufficient filtration area, is small and lightweight, and is highly productive and robust.

[Brief explanation of the drawing]

The drawings show one embodiment of the present invention, and FIG. 1 is a perspective view of the vacuum cleaner main body, FIG. 2 is a side view of the vacuum cleaner main body with the dust collection case storage section side cut away, and FIG. A perspective view of the outer lid opened and the dust collection case removed and placed side by side. Figure 4 is a perspective view of the dust collection case, inner lid and partition wall disassembled. Figure 5 is the main parts of the dust collection case. An enlarged view, Figure 6 is a schematic diagram showing the manufacturing process of the dust collection case, Figure 7 is an exploded perspective view of the dust collection case, partition wall, and cord reel lined up, and Figure 8 is a schematic diagram showing the manufacturing process of the dust collection case.
The figure is an exploded perspective view of related parts of the dust remover and cam stand, Figure 9 is a diagram showing the operation of the cam, Figure 10 is an enlarged perspective view of the airtight packing with a spot on the indicator packing, and Figure 11 is an exploded perspective view of related parts of the dust remover and cam stand. The figure is an enlarged sectional view showing the sealed state of the indicator packing and the inner lid, and FIG. 12 is a schematic diagram summarizing the relationship between the dust collection case, the electric blower, and the cord reel from the viewpoint of the suction state. 10... Box-shaped dust collection filter, 13... Shape-retaining basket, 14... Non-woven fabric filter, 16... Support bone, 17... Flange.

Claims (1)

[Claims] 1 A sheet of cotton candy-like polyester fibers of 2 to 5 deniers is passed between rollers and compressed, and then passed between rollers for needle punching to form a nonwoven filter with a raised surface. a second step of cutting the nonwoven cloth filter into a cross shape and partially joining the cut portions so that the raised surface is inside and forming a box shape; After inserting the filter into the mold of the molding machine, pour the resin into the mold,
A method for manufacturing a box-shaped dust collection filter for a vacuum cleaner, comprising a third step of integrally molding a shape-retaining basket comprising a number of support bones and a flange portion forming an opening with the nonwoven fabric filter.