JPS6341609B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a filter element. Specifically, air filters for internal combustion engines;
The present invention relates to a method for manufacturing a filtration element used in an air conditioner, a ventilation air filter, a filter for oil or other liquids, and the like.

Conventionally, this type of filtration element, as shown in FIG. A bag-like shape is formed by gluing every other wave at both ends (2, 3), and flexible seal packings 6 are attached to all edges of the upper and lower ends (2, 3) and both left and right ends (4, 5). It was tightly fixed. however,
Since such a filter element is partially glued at both the upper and lower ends 2 and 3, the bonded parts 7 and 8 are not strong enough, and these parts are easily torn, and the material of the filter material In the past, for example, when a nonwoven fabric or the like was used as a filter material, it was impossible to bond the filter material. Also, the adhesive portions 7 and 8 are connected to the width l of the filter material 1.
Since an adhesion distance d is required at both the upper and lower ends 2 and 3, the width of the effective filtration section is l-2d, which has the disadvantage that the overall effective filtration area is significantly reduced, especially when the width l is small. In this case, the bonding distance d must be equal to the minimum reduced bonding strength, so the effective filtration area was significantly reduced. Furthermore, in the conventional filter element, both ends of the filter material were bonded together as described above, which resulted in low productivity and poor mass production.

On the other hand, by an injection molding method in which a corrugated filter medium is placed in a mold and a flexible polymer is injected into the space in which the frame wall is to be formed, the end surface of the sheet-like filter medium formed in a corrugated shape is A method of manufacturing a filter made of a flexible polymer along this filter medium is known (Japanese Patent Application Laid-Open No. 130063/1983). However, since filter media is porous and is an aggregate of fibers such as paper and cloth, its thickness is not constant and varies from place to place. A gap is created between the filter material and the corrugated filter medium, and due to this, in the case of injection molding, the weight of several thousand kg/cm ²
The liquid polymer injected under the pressure of The disadvantage was that the filtration area was significantly reduced. In addition, when a coarse filter medium is used, the injected liquid polymer covers not only a predetermined area but also a considerable area where air permeability should be maintained due to capillary action and pressure, making it an effective filter material. The disadvantage was that the area was small. Furthermore, since we use injection molding method,
The disadvantage is that the flexible polymers that can be used are very limited, and the most desirable polymers, such as polyurethane, cannot be used.

Furthermore, the cylindrically bent cross-sectional filter medium is poured into a circular mold for end plate molding with molten vinyl chloride resin and baked in a high-temperature oven for several minutes to form synthetic resin plate flanges on both end faces of the cylindrical wave-shaped filter medium. A method of integrally molding is also known (Japanese Unexamined Patent Publication No. 52-89869). However, with this method, only a cylindrical filter having disc-shaped end plates on both end faces can be obtained, and thus a filter without variety is obtained. Furthermore, for actual use, it is necessary to attach a gasket, which has the disadvantage that the assembly work is complicated.

The present invention has been made in order to eliminate the various drawbacks of the conventional method as described above. The filter material is immersed one end at a time in a flexible polymer liquid contained in a mold having a band-shaped recess whose sides are substantially straight, with the ridge lines of the mountain corresponding to the waveform of the mold, and the polymerization is performed. A pouch-like structure is formed by solidifying the body fluid, each having a flexible end plate having a corrugated shape on one side, and the open side of the pouch-like structure is housed in a separate mold. This is a method for manufacturing a filtration element, characterized in that a flexible packing is integrally formed around the entire opening side of the corrugated filtration material by immersing it in a polymer liquid and solidifying the polymer.

Next, one embodiment of the present invention will be described with reference to the drawings. That is, as shown in Figures 2 and 3,
In a mold 10 having a band-shaped concave portion having a waveform on one side and a linear shape on the other side, non-foamed urethane resin, soft vinyl chloride resin, vinyl acetate resin, polybutadiene, polyethylene, polypropylene,
A predetermined amount, for example, is finally formed by injecting a flexible synthetic resin such as ethylene-vinyl acetate copolymer resin or polyamide, or a synthetic rubber such as natural rubber, styrene-butadiene rubber, chloroprene rubber, or butyl rubber in liquid form. A liquid layer 11 is formed to a depth corresponding to the thickness of the end plate. In this case, if the polymer used is essentially a liquid, emulsion or solution, it is injected as is;
When the polymer is a solid, it is injected in a molten state, or it is supplied to a mold as a solid such as powder or pellets and then melted. However, as the polymer for forming the end plate, unfoamed polyurethane gives the most preferable results.

Next, one end of the sheet-like filter material 12, which has been previously formed into a wave shape, with respect to the ridge line 13 of the ridge corresponds to the waveform side of the mold 10, and the mold 10 is
After being immersed in the polymer liquid 11 inside, it is solidified to form approximately triangular flexible end plates at each peak. In this case, if the polymer used is a molten thermoplastic resin, it will solidify simply by cooling it after immersing it in the filter medium, but if it is a reactive resin (for example, urethane resin) or rubber, it will solidify at a specified temperature. Curing is performed by heating for a required period of time to form the end plate as described above. In addition, sheet-like filter material 1
As the material 2, nonwoven fabric, woven fabric, knitted fabric, filter paper, glass cloth, wire mesh, etc. are used.

After forming a flexible end plate on one side of the corrugated filter material 12 in this way, a fourth flexible end plate having the same shape is formed on the other side in the same manner as described above. A bag-like structure is formed with flexible end plates 14 and 15 at both ends as shown in FIGS.

Furthermore, as shown in FIG. 6, a flexible polymer liquid is injected into the recessed part 16 of the mold 17, which is provided with a recessed part 16 at a location corresponding to the seal packing part.
Next, the wave-shaped filter material 12 having the bag-like structure as described above is placed in a mold 17 as shown in FIG.
The end plates 14 and 15 are set so that the lower ends (bottoms of the corrugated filter material 12) are substantially in contact with the polymer liquid 18. Furthermore, as shown in FIG. 8, by covering the upper mold 19 and maintaining it at a predetermined temperature, a flexible seal packing 20 is formed between the corrugated filter medium 12 and the end plate 1.
4 and 15 in close contact with each other. Polymers used to form the flexible seal packing include polyurethane foams with low expansion ratios (e.g., expansion ratio 3).
~10 times), polybutadiene, soft polyvinyl chloride resin, natural rubber, styrene-butadiene rubber, chloroprene rubber, and other synthetic rubbers, as well as their low foaming foam rubbers, especially low foaming polyurethane foam and foam rubber. gives the desired result. In this case, if the polymer used is essentially a liquid, emulsion or solution, it is injected as is, whereas if the polymer is a solid, it is injected in the molten state or in the form of a solid such as a powder or pellet. It is melted after being supplied to the mold. Then, it is solidified at a predetermined temperature, foamed, or cured.

For example, when the seal packing 20 is formed of polyurethane foam with a low degree of foaming, a foaming stock solution adjusted to a predetermined composition is poured into the recessed part 16 of the mold 17, and the filter medium 12 and the upper mold 19 are After setting the foam, it is heated at a predetermined temperature and for a certain period of time to form foam, forming not only the concave portion 16 but also the upper mold 1.
Polyurethane foam is also formed in the cavity 21 of 9, and the flexible seal skin 20 is integrally formed.

Next, by removing the upper mold and releasing the seal packing 20, as shown in FIG. A substantially triangular flexible end plate 14, 1 formed of a polymer for each peak.
5, and a flexible seal packing 20 formed around the entire opening side of the wave-shaped filter material having a bag-like structure formed by the filter material 12 and the end plates 14 and 15. can get.

The filter element manufactured according to the present invention can be attached to a rectangular filter 24 by locking means such as bolts 22 and nuts 23 as shown in FIG. (not shown) and used in air conditioners or ventilation air filters, internal combustion engine air filters, oil and other liquid filters, etc.

As described above, the method for manufacturing a filtration element according to the present invention includes a sheet-like filtration material formed in a wave shape, which has a waveform corresponding to the ridgeline of the mountain on one side and is substantially straight on the other side. immersing one end of the filter material one by one in a flexible polymer liquid housed in a mold having a band-shaped recess, with the ridge line of the mountain corresponding to the liquid type of the mold, and solidifying the polymer liquid; to form a bag-like structure with a flexible end plate having a corrugated shape on one side, and the open side of the bag-like structure is immersed in a flexible polymer liquid contained in another mold. However, since a flexible seal packing is integrally formed around the opening side of the corrugated filter material by solidifying the polymer, there are the following advantages.

That is, in the manufacturing method of the filter element of the present invention, first of all, the frame wall is formed one end at a time in an open mold, so the thickness of the filter medium does not need to be constant, and when the filter medium is bent into a corrugated shape, There is no problem even if there is a mechanical error.

Second, even when using a coarse filter medium, the frame wall is formed in an open mold, so
Adsorption of the flexible polymer onto the filter medium due to capillarity of the filter medium can be substantially ignored, and the effective filtration area is substantially as designed.

Thirdly, since the flexible polymer used as the material for forming the frame wall is used in an open mold, it is inherently liquid and
Various flexible polymers can be used as long as they are emulsions or solutions, or solids as long as they can be injected in a molten state or supplied as solids such as powders or pellets. . Therefore, the scope of application of the flexible polymer used in the present invention is quite wide.

Fourth, since the end plate part of the corrugated filter medium and the seal packing part are molded separately, a filtration element with better sealing properties is created by using a flexible polymer such as low-foaming polyurethane in the seal packing part. can be manufactured.

Fifth, there is no need for any expensive equipment; all that is required is a metal mold or wooden mold, and this metal mold or wooden mold does not require precision, so it is extremely inexpensive.

Sixth, since one side of the flexible end plate to be formed is corrugated and the other side is substantially straight, it can be shaped as is as shown in Figure 10, or it can be shaped into a cylindrical shape as shown in Figure 11. Since it can be used in any shape, its range of use is extremely wide.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a conventional filter element, FIG. 2 is a sectional view showing the process of forming an end plate at one end during the manufacturing process of the filter element according to the method of the present invention, FIG. 3 is a plan view, and FIG. FIG. 5 is a sectional view taken along the line - in FIG. 4, FIGS. 6 to 8 are sectional views showing each step of forming a seal packing, and FIG. FIG. 10 is a perspective view of the manufactured filter element, and FIG. 10 is a sectional view showing the state of use of the filter element attached to a square filter, and FIG. 11 is a perspective view of the filter element modified for use in a circular filter. be. 10, 17... Molding mold, 11... Polymer liquid, 1
2...Filtering material, 13...Mountain ridgeline, 14,15...
... Flexible end plate, 16 ... Recessed portion, 18 ... Polymer liquid, 19 ... Upper mold, 20 ... Flexible seal packing.

Claims (1)

[Scope of Claims] 1. A sheet-like filtration material formed into a wave shape is housed in a mold having a band-like recessed portion having a waveform corresponding to the ridgeline of the mountain on one side and a substantially linear shape on the other side. One end of the filter material is immersed in the flexible polymer liquid, with the ridge lines of the ridges corresponding to the corrugations of the mold, and the polymer liquid is solidified to form a flexible polymer having a corrugation on one side. A bag-like structure having flexible end plates formed thereon is formed, and the open side of the bag-like structure is immersed in a flexible polymer liquid contained in a separate mold, and the polymer is solidified. A method of manufacturing a filter element, comprising integrally forming a flexible seal packing around the entire opening side of the wave-shaped filter material. 2. The flexible polymer for forming the flexible end portion is non-foamed polyurethane, and the flexible polymer for forming the flexible seal packing is a low-foaming polyurethane foam.Claim 1 A method for manufacturing a filtration element as described in .