JP5004694B2 - Air filter filter pack and air filter using the same - Google Patents
Air filter filter pack and air filter using the same Download PDFInfo
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- JP5004694B2 JP5004694B2 JP2007173512A JP2007173512A JP5004694B2 JP 5004694 B2 JP5004694 B2 JP 5004694B2 JP 2007173512 A JP2007173512 A JP 2007173512A JP 2007173512 A JP2007173512 A JP 2007173512A JP 5004694 B2 JP5004694 B2 JP 5004694B2
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Description
本発明は、ろ材をジグザグ状に折り畳んだエアフィルタ用フィルタパック及びそれを用いたエアフィルタに関する。 The present invention relates to an air filter using a filter pack and it air filter folded folding in a zigzag filter media.
従来、ろ材をジグザグ状に折り畳んで間隔保持されたエアフィルタ用フィルタパックの製造方法としては、特許文献１に開示されており、少なくともろ材の両側部の両面のそれぞれに間隔保持材となる樹脂層を一定の厚さに塗布して樹脂層を形成した後、一定間隔でジグザグ状に折り畳んで、樹脂層を固化してろ材の折り畳み幅を一定間隔とする方法が提案されている。
上記方法では、得られたジグザグ状エアフィルタ用ろ材は空気を通過させるろ材が一定間隔で折り畳まれているので、ろ材の一方の側から入った空気は、ろ材の他方の側から排出される際に気流方向がろ材に対して直交することになり、通過させる空気の圧を高くしなければ所定の気流圧が得られなかった。
この課題を解決するために、特許文献２には、ホットメルトを重ねて塗布し、折筋の頂部から谷部にかけて勾配をつけることにより、プリーツにテーパ形状を持たせる方法が提案されている。
また、特許文献３には、エンボス加工により形成された突出部によりプリーツの間隔を保持する方法が提案されている。
Conventionally, the filter media as a manufacturing method of the filter pack for air filters intervals held folded folding in a zigzag manner is disclosed in Patent Document 1, the space holding member to each of the surfaces of both sides of at least the filter material resin A method has been proposed in which a resin layer is formed by applying a layer to a certain thickness, and then folded into a zigzag shape at regular intervals to solidify the resin layer so that the folding width of the filter medium is constant.
In the above method, since the obtained filter medium for zigzag air filter has the filter medium that allows air to pass through is folded at regular intervals, air entering from one side of the filter medium is discharged from the other side of the filter medium. Thus, the airflow direction is orthogonal to the filter medium, and a predetermined airflow pressure cannot be obtained unless the pressure of the air to be passed is increased.
In order to solve this problem, Patent Document 2 proposes a method in which a pleat has a tapered shape by applying hot melt in layers and applying a gradient from the top of the crease to the trough.
Further, Patent Document 3 proposes a method of maintaining a pleat interval by a protruding portion formed by embossing.
しかしながら、特許文献２に記載の製造方法の場合は、フィルタパックのプリーツの間隔保持のためにホットメルトを使用するため、フィルタパックの質量が増加して取扱いづらく、有効ろ材面積が減少し寿命が短くなるといった問題があった。また、特許文献３では、エンボス突起部の接する部分に発泡プラスチックなどの接着剤を塗布することでフィルタパックを補強していることから、有効ろ材面積の減少は避けられず、所定の気流圧を得るために通過させなければならない空気の圧を、本来期待されるより高くする必要があった。
そこで、本発明は、フィルタパックの質量を増加させず、しかも、有効ろ材面積を減少させず、かつ圧力損失が十分低いフィルタパックを提案するものである。
However, in the case of the manufacturing method described in Patent Document 2, since hot melt is used to maintain the interval between the pleats of the filter pack, the mass of the filter pack increases, making it difficult to handle, reducing the effective filter medium area, and shortening the service life. There was a problem of shortening. Further, in Patent Document 3, since the filter pack is reinforced by applying an adhesive such as foamed plastic to the portion where the embossed protrusion comes into contact, the effective filter medium area is inevitably reduced, and a predetermined airflow pressure is set. The air pressure that had to be passed to obtain it had to be higher than expected.
Therefore, the present invention proposes a filter pack that does not increase the mass of the filter pack, reduces the effective filter medium area, and has a sufficiently low pressure loss.
かかる課題を解決すべく、本発明者等は鋭意検討の結果、以下の構成を見出した。
即ち、本発明のエアフィルタ用フィルタパックは、請求項１に記載のとおり、不織布からなるろ材の表裏面にドット状のエンボス突起部を設け、ジグザグ状に折り畳むとともに、畳まれた際に向かい合う該エンボス突起部どうしを接触させて該ろ材の間隔を保持するようにしたエアフィルタ用フィルタパックであって、前記ドット状エンボス突起部は、ろ材のMD及びCD方向ともに形成され配列されており、ろ材のMD方向に直線状に並んだ複数個のドット状エンボス突起部が、プリーツの折筋の頂部から谷部に向けて漸次低くなるように、高さ方向に勾配を有し、CD方向に直線状に並んだ複数個のドット状エンボス突起部が複数列、各列ごとに一定の高さを有し、前記ドット状エンボス突起部は、ろ材面に平行な上面を有することを特徴とする。
また、請求項２記載のエアフィルタ用フィルタパックは、請求項１記載のエアフィルタ用フィルタパックにおいて、前記MD方向に並んだ複数個のドット状エンボス突起部が、プリーツの折筋の谷部から頂部へ向かうにつれて、その幅が広くなることを特徴とする。
また、請求項３記載のエアフィルタ用フィルタパックは、請求項１記載のエアフィルタ用フィルタパックにおいて、向かい合うドット状エンボス突起の形状が対称形ではなく、接する突起部の各々にさらに凸部と凹部が形成されていることを特徴とする。
また、請求項４記載のエアフィルタ用フィルタパックは、請求項１乃至３の何れかに記載のエアフィルタ用フィルタパックにおいて、前記ろ材に形成されるドット状エンボス突起部分の総面積の割合が、ろ材全体の２０％未満であることを特徴とする。
また、本発明のエアフィルタは、請求項５記載のとおり、請求項１乃至４の何れかのエアフィルタ用フィルタパックを使用したことを特徴とする。
As a result of intensive studies, the present inventors have found the following configuration in order to solve this problem.
That is, the filter pack for an air filter according to the present invention is provided with dot-like embossed protrusions on the front and back surfaces of a filter medium made of nonwoven fabric as described in claim 1, folded in a zigzag shape, and faced when folded. A filter pack for an air filter in which embossed protrusions are brought into contact with each other to maintain the distance between the filter media , wherein the dot-shaped embossed protrusions are formed and arranged in both the MD and CD directions of the filter media. A plurality of dot-like embossed protrusions arranged in a straight line in the MD direction have a gradient in the height direction so that they gradually lower from the top of the pleat crease toward the valley, and straight in the CD direction. A plurality of dot-like embossed projections arranged in a line have a plurality of rows, each row having a constant height, and the dot-like embossed projections have an upper surface parallel to the filter medium surface .
Moreover, the filter pack for air filters of Claim 2 is a filter pack for air filters of Claim 1 , The several dot-shaped embossing protrusion part located in a line with the said MD direction is from the trough part of the crease of a pleat. As it goes to the top, the width becomes wider.
Further, the air filter filter pack according to claim 3 is the air filter filter pack according to claim 1, wherein the shape of the dot-shaped embossed protrusions facing each other is not symmetrical, and each of the protruding protrusions is further provided with a protrusion and a recess. Is formed.
The filter pack for an air filter according to claim 4, wherein, in the filter pack for an air filter according to any one of claims 1 to 3, the ratio of the total area of the dot-like embossing protrusion formed on the filter medium, It is characterized by being less than 20% of the entire filter medium.
The air filter of the present invention, as claimed in claim 5, characterized in that using any of the filter pack for an air filter according to claim 1 to 4.
本発明によれば、フィルタパックの質量を増加させず、しかも、有効ろ材面積を減少させず、かつ圧力損失が十分低いフィルタパックと、これを用いたエアフィルタが得られる。 According to the present invention, a filter pack that does not increase the mass of the filter pack, does not reduce the effective filter medium area, and has a sufficiently low pressure loss, and an air filter using the filter pack can be obtained.
本発明のエアフィルタ用フィルタパックは、不織布からなるろ材の表裏面にドット状のエンボス突起部を設け、ジグザグ状に折り畳むとともに、畳まれた際に向かい合う該エンボス突起部どうしを接触させて該ろ材の間隔を保持するようにしたことを特徴とするものである。 The filter pack for an air filter of the present invention is provided with dot-like embossed protrusions on the front and back surfaces of a filter medium made of nonwoven fabric, folded in a zigzag shape, and brought into contact with the embossed protrusions facing each other when folded. This is characterized in that the interval is maintained.
前記エンボス突起部は、ジグザグ状に折り畳んだときに隣接するろ材の間隔を保持できるように表裏面ともに形成される。
ドットは様々な形状に形成することができる。ここで、ろ材に対して、手前側に突出したエンボス突起を凸突起、その逆側に突出したエンボス突起を凹突起と呼ぶことにする。すなわち、ろ材のある一方の面から見た場合の凹突起は、もう一方の面から見れば凸突起となるわけである。
The embossed protrusions are formed on both the front and back surfaces so as to maintain the spacing between adjacent filter media when folded in a zigzag shape.
The dots can be formed in various shapes. Here, with respect to the filter medium, the embossed protrusion protruding toward the front side is referred to as a convex protrusion, and the embossed protrusion protruding toward the opposite side is referred to as a concave protrusion. That is, the concave protrusion when viewed from one surface of the filter medium becomes a convex protrusion when viewed from the other surface.
前記ドットの形状は、エンボス突起部が凸突起である場合で規定することにする。凸突起をろ材平面に対する鉛直線状から眺めた場合、凸突起が立ち上がる部分の輪郭が見えるが、その輪郭において、ろ材のＣＤ方向における最大幅をドット状エンボス突起の幅、ろ材のＭＤ方向における最大長さをドット状エンボス突起の長さ、とここでは呼ぶことにする。
また、ろ材平面に平行な仮想平面が凸突起の最も高い部分と接したときに、その仮想平面とろ材面との間隔をドット状エンボス突起の高さ、またその点を含む平面のことを上面と呼ぶことにする。
The shape of the dot is defined when the embossed protrusion is a convex protrusion. When the convex protrusion is viewed from the vertical line shape with respect to the filter medium plane, the outline of the portion where the convex protrusion rises is visible. In the outline, the maximum width in the CD direction of the filter medium is the width of the dot-shaped emboss protrusion and the maximum in the MD direction of the filter medium. Here, the length is referred to as the length of the dot-like emboss projection.
In addition, when a virtual plane parallel to the filter medium plane is in contact with the highest part of the convex protrusion, the distance between the virtual plane and the filter medium surface is the height of the dot-shaped emboss protrusion, and the plane including that point is the upper surface. I will call it.
ドット状エンボスの形状は、例えば直方体、立方体、角柱、円柱、半球、球帯、角錘台、円錐、角錐、切頭円錐など種々の形状から選択することができる。
また、向かい合うドット状突起の形状が必ずしも対称形である必要はなく、接する突起部の各々にさらに凸部と凹部が形成されている鍵と鍵穴の関係になるような形状でもよい。この形状の場合、接するエンボス突起部がずれにくくなり、より強固なフィルタパックとすることができる。
突起部の上面は直方体や立方体などのように平坦であってもよいし、半球や円柱のようにアールがついていても差し支えない。
The shape of the dot-like embossing can be selected from various shapes such as a rectangular parallelepiped, a cube, a prism, a cylinder, a hemisphere, a sphere, a frustum, a cone, a pyramid, and a truncated cone.
In addition, the shape of the dot-shaped projections facing each other is not necessarily symmetrical, and may be a shape that has a relationship between a key and a keyhole in which convex portions and concave portions are further formed on each of the projecting portions in contact with each other. In the case of this shape, the embossed protrusions that come into contact are less likely to be displaced, and a more robust filter pack can be obtained.
The upper surface of the protrusion may be flat like a rectangular parallelepiped or a cube, or may be rounded like a hemisphere or a cylinder.
ドット状エンボス突起の高さは０．５ｍｍ〜５．０ｍｍであることが好ましく、１．０ｍｍ〜３．０ｍｍであることがさらに好ましい。高さが５．０ｍｍより高い場合はエンボス加工に伴いろ材の破損が生じるおそれがあり、また高さが０．５ｍｍより低い場合はろ材の間隔保持が困難になるからである。
また、ドット状エンボス突起の幅は、１．０ｍｍ〜１０ｍｍが好ましく、２．０ｍｍ〜６．０ｍｍがさらに好ましい。幅が１０ｍｍより広い場合はフィルタパックにして風を流した場合に構造抵抗となり圧力損失上昇のおそれがあり、また幅が１．０ｍｍより狭い場合はプリーツに折り畳んだ場合にエンボス突起部どうしがずれて間隔を保持できないおそれがあるからである。
また、ドット状エンボス突起の長さは、１．０ｍｍ〜１５ｍｍであることが好ましく、３．０ｍｍ〜１０ｍｍであることがさらに好ましい。１５ｍｍより長い場合は、ろ材の有効ろ材面積が減少することで圧力損失上昇のおそれがあり、１．０ｍｍより短い場合はプリーツに折り畳んだ場合にエンボス突起部どうしがずれて間隔を保持できないおそれがあるからである。
The height of the dot-like emboss projection is preferably 0.5 mm to 5.0 mm, and more preferably 1.0 mm to 3.0 mm. This is because when the height is higher than 5.0 mm, the filter medium may be damaged due to the embossing, and when the height is lower than 0.5 mm, it is difficult to maintain the distance between the filter media.
Moreover, 1.0 mm-10 mm are preferable and, as for the width | variety of a dot-like embossing protrusion, 2.0 mm-6.0 mm are more preferable. If the width is larger than 10 mm, the filter pack will be subjected to structural resistance when air is flown, and pressure loss may increase. If the width is narrower than 1.0 mm, the embossed protrusions will be misaligned when folded into pleats. This is because the interval may not be maintained.
Further, the length of the dot-like emboss projection is preferably 1.0 mm to 15 mm, and more preferably 3.0 mm to 10 mm. If it is longer than 15 mm, there is a risk of increased pressure loss due to a decrease in the effective filter medium area of the filter medium, and if it is shorter than 1.0 mm, the embossed projections may be misaligned when folded into pleats and the spacing may not be maintained. Because there is.
ドット状エンボス突起の形状として、幅と長さについては以下の通りとする。
一つのドット状エンボス突起について、長さと幅の比率（長さ／幅）すなわちアスペクト比が０．５〜３であることが好ましく、１〜２であることがさらに好ましい。アスペクト比が０．５より小さい場合は、プリーツに折り畳んだ場合にエンボス突起部どうしがずれて間隔を保持できないおそれがあり、３より大きい場合はろ材の有効ろ材面積が減少することで圧力損失上昇のおそれがあるためである。
As the shape of the dot-like emboss projection, the width and length are as follows.
About one dot-like embossed protrusion, the ratio of length to width (length / width), that is, the aspect ratio is preferably 0.5 to 3, and more preferably 1 to 2. If the aspect ratio is less than 0.5, the embossed protrusions may be misaligned when folded into pleats, and the spacing may not be maintained. If the aspect ratio is greater than 3, the effective filter media area of the filter media decreases, resulting in increased pressure loss. It is because there is a possibility of.
ドット状エンボス突起の形状として、ろ材平面から仰ぎ見たエンボス突起部の立ち上がり角度については以下の通りとする。
ドット状エンボス突起部の立ち上がりの輪郭の線の中で最も折筋の頂部に近い側の点と、ドット状エンボス突起部の最も高い点とを結ぶ直線が、ろ紙平面となす角度を立ち上がり角度とする。
ドット状エンボス突起の上面が平面である場合、前述の最も高い点は、折筋の頂部に最も近い点とする。
立ち上がり角度は、形成されるドット状エンボス突起の高さに応じて適した角度が異なる。高さが２．０ｍｍ以上の場合、立ち上がり角度が小さいと突起部の上面の面積も小さくなり、向かい合うドット状エンボス突起との接触面積が稼げず、プリーツの間隔保持に支障をきたすおそれがある。一方、エンボス突起の高さが２．０mm未満の場合は、立ち上がり角度が低くとも上面の面積が小さくなることもない。
よって、立ち上がり角度は、ドット状エンボス突起部の高さが２．０ｍｍ以上の場合は、３０度〜９０度であることが好ましく、３０度〜６０度であることがさらに好ましい。９０度をこえる場合、ろ紙への負担が著しく大きくなり、３０度未満の場合は上述のように、上面の面積が小さくなるためである。
また、ドット状エンボス突起部の高さが２．０ｍｍ未満の場合は、立ち上がり角度が９０度以下であることが好ましく、６０度以下であることがさらに好ましい。
As the shape of the dot-like emboss projection, the rising angle of the emboss projection seen from the filter medium plane is as follows.
The rising angle is the angle formed by the straight line connecting the point closest to the top of the fold line in the rising contour line of the dot-like embossed protrusion and the highest point of the dot-like embossed protrusion with the filter paper plane. To do.
When the upper surface of the dot-like emboss projection is a flat surface, the highest point is the point closest to the top of the crease.
The rising angle differs depending on the height of the dot-shaped emboss projections to be formed. When the height is 2.0 mm or more, if the rising angle is small, the area of the upper surface of the protrusion is also reduced, and the contact area with the opposing dot-like emboss protrusion cannot be gained, which may hinder the pleat spacing. On the other hand, when the height of the emboss projection is less than 2.0 mm, the area of the upper surface does not decrease even if the rising angle is low.
Therefore, the rising angle is preferably 30 degrees to 90 degrees, and more preferably 30 degrees to 60 degrees, when the height of the dot-like embossed protrusion is 2.0 mm or more. This is because when the angle exceeds 90 degrees, the load on the filter paper is remarkably increased.
Moreover, when the height of the dot-like embossed protrusion is less than 2.0 mm, the rising angle is preferably 90 degrees or less, and more preferably 60 degrees or less.
ドット状エンボス突起部は、ろ材のMD方向に複数個配列しており、その各々の高さは折筋の頂部から谷部へ次第に低くなることにより、プリーツ形状をV字に保つことができる（V字は圧損が低いことが特許文献２で示されている。）。
また、ろ材のCD方向に複数個配列したエンボス突起部は、その列ごとに一定の高さを有することで、フィルタパックを均一にすることができる。
A plurality of dot-like embossed protrusions are arranged in the MD direction of the filter medium, and the height of each of the dot-like embossed protrusions gradually decreases from the top of the crease to the valley, thereby keeping the pleat shape V-shaped ( Patent Document 2 shows that V-shaped pressure loss is low.)
Further, the embossed protrusions arranged in the CD direction of the filter medium have a certain height for each row, so that the filter pack can be made uniform.
MD方向の一列に含まれるドット状エンボス突起の数は、３個以上１５個以下であることが好ましく、５個以上１０個以下であることがさらに好ましい。３個未満の場合はドット状エンボスではプリーツの間隔を保持するのが困難であり、通風時に突起以外の部分の向かい合うろ材が接してしまい圧力損失上昇につながるおそれがある。一方、ドット状エンボス突起の数が１６個以上の場合は、エンボス部の割合が多くなり、ライン状エンボスと比較した場合の有効ろ材面積が多いことのメリットが出せなくなることがある。
MD方向に配列しているドット状エンボス突起の間隔は、５ｍｍ〜２５ｍｍであることが好ましく、７ｍｍ〜２０ｍｍであることがさらに好ましい。５ｍｍよりも狭い場合はプリーツに折り畳んだ場合にエンボス突起部どうしがずれて間隔を保持できないおそれがあり、２５ｍｍよりも広い場合は通風時にプリーツの膨らみが生じて、隣り合うろ材面が接してしまうおそれがあるからである。
The number of dot-like embossed protrusions included in one line in the MD direction is preferably 3 or more and 15 or less, and more preferably 5 or more and 10 or less. When the number is less than three, it is difficult to maintain the pleat interval with dot-like embossing, and there may be a risk that pressure loss increases due to the contact of the filter media facing the portions other than the protrusions during ventilation. On the other hand, when the number of dot-like embossed protrusions is 16 or more, the ratio of the embossed portion increases, and the advantage of having a large effective filter medium area when compared with the line-shaped emboss may not be obtained.
The interval between the dot-like emboss projections arranged in the MD direction is preferably 5 mm to 25 mm, and more preferably 7 mm to 20 mm. If it is narrower than 5 mm, the embossed projections may be misaligned when folded into pleats, and the spacing may not be maintained. If it is larger than 25 mm, the pleat bulges during ventilation and the adjacent filter media faces Because there is a fear.
CD方向に配列しているドット状エンボス突起の間隔は、隣り合う凸突起列と凸突起列の間隔が１５ｍｍ〜６０ｍｍであることが好ましい。凸突起列と凸突起列の間には凹突起列が含まれるが、凹突起列は凸突起列と凹突起列の中間に形成されることが好ましい。偏って配列されると、フィルタパックにして風を流したときに風の流れが不均一になり、圧力損失上昇のおそれがあるためである。 The interval between the dot-like embossed protrusions arranged in the CD direction is preferably 15 mm to 60 mm between the adjacent protruding protrusion rows. Although the concave projection row is included between the convex projection row and the convex projection row, the concave projection row is preferably formed between the convex projection row and the concave projection row. This is because if the air flow is biased, the flow of the air becomes non-uniform when the air is flown as a filter pack, which may increase the pressure loss.
ろ材の折り幅は３０ｍｍから２８０ｍｍであることが好ましい。折り幅が３０ｍｍ未満の場合は、フィルタの寿命の観点からプリーツの山数を多く入れる必要があり、プリーツの間隔を十分に保てないおそれがある。一方、折り幅が２８０ｍｍを超える場合は、プリーツの間隔を広げる必要があり、すなわちドット状エンボス突起部の高さを高くする必要があるため、ろ材の破れを生じる可能性が高くなる。 The folding width of the filter medium is preferably 30 mm to 280 mm. When the folding width is less than 30 mm, it is necessary to increase the number of pleats from the viewpoint of the life of the filter, and there is a possibility that a sufficient interval between the pleats cannot be maintained. On the other hand, when the folding width exceeds 280 mm, it is necessary to widen the interval between the pleats, that is, it is necessary to increase the height of the dot-like embossed protrusions, so that there is a high possibility that the filter medium will be torn.
ドット状エンボス突起部は、ろ材面に平行な上面を有すようにした方が好ましい。これは以下の理由による。不織布ろ材をフィルタパックにするためには、適度な剛軟度が必要であるが、剛軟度の影響でロールに巻いたろ材には巻き癖が残る傾向にある。巻き癖が残るとプリーツ加工した際にプリーツがきれいなV字とならず、圧力損失の上昇を招く。そこで、プリーツ加工後にパックを圧縮加熱することにより、ろ材の巻き癖を除去するとともに、プリーツの折筋をシャープにすることができる。ところで、圧縮加熱を十分にしても、巻き癖は多少残る場合があるのに加え、フィルタの使用中はパックに空気が流れるため、V字が広がり、あたかも巻き癖が残ったような状態になる場合がある。そこで、ドット状エンボス突起内では高さ勾配を持たないようにすることで、巻き癖が多少残った場合でもその影響をできる限り抑制することができる。 It is preferable that the dot-like embossed protrusion has an upper surface parallel to the filter medium surface. This is due to the following reason. In order to make a non-woven filter medium into a filter pack, an appropriate bending resistance is required, but the curl tends to remain in the filtering medium wound around the roll due to the influence of the bending resistance. If the curl remains, the pleats will not be clean V-shaped when pleated, which will lead to an increase in pressure loss. Therefore, by compressing and heating the pack after pleating, it is possible to remove the curl of the filter medium and sharpen the folds of the pleat. By the way, even if compression heating is sufficient, some curl may remain, and since air flows through the pack while the filter is in use, the V-shaped spreads out, as if the curl remains. There is a case. Therefore, by avoiding the height gradient in the dot-like emboss projection, even when some curl remains, the influence can be suppressed as much as possible.
また、ろ材のMD方向に複数個配列したエンボス突起部の幅は、折筋の谷部から頂部へ次第に広くなっているのが好ましい。これは、高さの高いドット状エンボス突起部を形成する場合に、突起部の幅が狭い場合は、ろ材の単位面積あたりにかかる力が大きくなるため、ろ材の破れのおそれがあるが、高さの高いドット状エンボス突起部の幅を広くすることで、ろ材の破れを防ぐことができるためである。
本発明に使用するろ材は、ポリオレフィン系、ポリエステル系等から構成されるが、濾過性能を満足する不織布であればこれらに特に限定はされない。
Moreover, it is preferable that the width | variety of the embossing protrusion part arranged in the MD direction of the filter medium becomes gradually wide from the trough part of a crease to the top part. This is because when the dot-shaped embossed protrusion is formed with a high height, if the width of the protrusion is narrow, the force per unit area of the filter medium increases, so the filter medium may be torn. This is because it is possible to prevent the filter medium from being broken by increasing the width of the high-sized dot-like embossed protrusion.
Although the filter medium used for this invention is comprised from polyolefin type | system | group, polyester type, etc., if it is a nonwoven fabric which satisfies filtration performance, it will not specifically limit to these.
また、ろ材に形成されるドット状エンボス突起部分の総面積の割合は、ろ材全体の２０％未満であることが好ましい。２０％以上の場合は、ろ材の有効面積が少なくなり、圧力損失の上昇、粉塵保持量の低下を招くおそれがあるためである。 Moreover, it is preferable that the ratio of the total area of the dot-shaped embossing projection part formed in a filter medium is less than 20% of the whole filter medium. If it is 20% or more, the effective area of the filter medium decreases, which may increase the pressure loss and decrease the amount of dust retained.
また、上記のエアフィルタ用フィルタパックを使用したエアフィルタは、高風量、低圧力損失のエアフィルタとして使用することができる。 An air filter using the above-described filter pack for an air filter can be used as an air filter having a high air volume and a low pressure loss.
次に、本発明の実施例を、比較例、従来例とともに説明する。尚、本発明のエアフィルタ用フィルタパックは、以下の例に限定して解釈されるものではない。
図１は本発明のドット状エンボス突起を形成し折り畳む前のエアフィルタ用フィルタパックの斜視図、図２は図１の平面図、図３（ａ），（ｂ），（ｃ），（ｄ），（ｅ），（ｆ）,（ｇ），（ｈ）は本発明のドット状エンボス突起を形成し折り畳んだエアフィルタ用フィルタパックの側面図、図４は従来例のライン状エンボス突起９を形成し折り畳んだエアフィルタ用フィルタパックの側面図である。
１０は複合ろ材、１，２，３，４，５，６はドット状エンボスを示し、前記ドット状エンボス１，２，３，４，５，６は折筋の頂部から谷部にかけてそれぞれＡ，Ｂ，Ｃ，Ｄ，Ｅ，Ｆを付与した。
Next, examples of the present invention will be described together with comparative examples and conventional examples. In addition, the filter pack for air filters of this invention is limited to the following examples, and is not interpreted.
Figure 1 is a perspective view of the filter pack for an air filter before folding dotted embossing protrusions to form folding of the present invention, FIG. 2 is a plan view of FIG. 1, FIG. 3 (a), (b) , (c), ( d), (e), ( f), (g), (h) is a side view of the dot-like embossing protrusions to form folded collapsed but the filter pack for an air filter of the present invention, FIG. 4 is conventional linear embossments of folded folded to form a protrusion 9 is a side view of the filter pack for an air filter.
10 is a composite filter medium, 1, 2, 3, 4, 5 and 6 are dot embosses, and the dot embosses 1, 2, 3, 4, 5 and 6 are respectively A, B, C, D, E, and F were assigned.
（実施例１）
ろ材層としてのポリプロピレン製の非帯電メルトブローン不織布と、補強層としてポリエステル製サーマルボンド不織布を貼り合わせた複合ろ材を用い、図３（ａ）に示す通り以下のような形状のドット状エンボス突起１Ａ，１Ｂ，１Ｃ，１Ｄ，１Ｅ，１Ｆを形成した。
ドット状エンボスの形状は四角錘台形として、MD方向の一列には６個形成し、それらの一つ一つの高さは折筋の頂部から谷部にかけて２．０ｍｍ、１．８ｍｍ、１．５ｍｍ、１．３ｍｍ、１．０ｍｍ、０．８ｍｍとした。CD方向の一列には片面で２３列のドット状エンボス突起を形成し、それらの高さは同一の列においては意図的に変えることはしなかった。
ドット状エンボスの幅は、折筋の頂部から谷部にかけて５．０ｍｍ、４．８ｍｍ、４．６ｍｍ、４．４ｍｍ、４．２ｍｍ、４．０ｍｍとした。このようなドット状エンボスを表裏面交互に配列した。
また、ドット状エンボスの底辺長さは７ｍｍで全て一定にした。
ドット状エンボス突起部の立ち上がり角度は、折筋の頂部から谷部にかけて４５、４２、３７、３３、２７、２２度とした。
上記ろ材を１２５ｍｍの折り幅でジグザグ状に折り畳み、エアフィルタ用フィルタパックを製作した。
Example 1
Using a composite filter medium in which an uncharged melt-blown nonwoven fabric made of polypropylene as a filter medium layer and a thermal bond nonwoven fabric made of polyester as a reinforcing layer are bonded together, as shown in FIG. 1B, 1C, 1D, 1E, and 1F were formed.
The shape of the dot-like emboss is a square frustum, and six are formed in one row in the MD direction, and the height of each of them is 2.0 mm, 1.8 mm, 1.5 mm from the top to the valley of the fold line. 1.3 mm, 1.0 mm, and 0.8 mm. In one row in the CD direction, 23 rows of dot-shaped emboss projections were formed on one side, and their heights were not intentionally changed in the same row.
The width of the dot-shaped emboss was 5.0 mm, 4.8 mm, 4.6 mm, 4.4 mm, 4.2 mm, and 4.0 mm from the top to the valley of the folding line. Such dot-like embosses were arranged alternately on the front and back surfaces.
Further, the base length of the dot-like emboss was 7 mm and was all constant.
The rising angle of the dot-like embossed protrusions was 45, 42, 37, 33, 27, and 22 degrees from the top of the crease to the valley.
The filter medium was folded in a zigzag shape with a folding width of 125 mm to produce a filter pack for an air filter .
（実施例２）
ドット状エンボスの高さが、折筋の谷部に最も近い端を０．８ｍｍ、頂部に最も近い端を２．０ｍｍとして、その間を連続(断続)勾配としたこと以外は実施例１と同様にして、ドット状エンボス突起２Ａ，２Ｂ，２Ｃ，２Ｄ，２Ｅ，２Ｆを形成し、図３（ｂ）に示す通りエアフィルタ用フィルタパックを製作した。
(Example 2)
The height of the dot-shaped embossing is the same as in Example 1 except that the end closest to the valley of the crease is 0.8 mm, the end closest to the top is 2.0 mm, and a continuous (intermittent) gradient is provided between them. Then, dot-like embossed protrusions 2A, 2B, 2C, 2D, 2E, 2F were formed, and a filter pack for an air filter was manufactured as shown in FIG.
（実施例３）
ドット状エンボスのろ材のMD方向の列における、各々のドットの幅を全て４．０ｍｍとしたこと以外は実施例１と同様にして、ドット状エンボス突起３Ａ，３Ｂ，３Ｃ，３Ｄ，３Ｅ，３Ｆを形成し、図３（ｃ）に示す通りエアフィルタ用フィルタパックを製作した。
(Example 3)
The dot-shaped emboss protrusions 3A, 3B, 3C, 3D, 3E, and 3F are the same as in Example 1 except that the width of each dot in the MD-direction row of the dot-shaped embossed media is 4.0 mm. And a filter pack for an air filter was manufactured as shown in FIG.
（実施例４）
ドット状エンボスのろ材のMD方向の列における、各々のドットの幅を全て４．０ｍｍとし、かつドット状エンボスの高さが、折筋の谷部に最も近い端を０．８ｍｍ、頂部に最も近い端を２．０ｍｍとして、その間を連続(断続)勾配としたこと以外は実施例１と同様にして、ドット状エンボス突起４Ａ，４Ｂ，４Ｃ，４Ｄ，４Ｅ，４Ｆを形成し、図４（ｄ）に示す通りエアフィルタ用フィルタパックを製作した。
Example 4
The width of each dot in the MD direction row of dot-embossed filter media is 4.0 mm, and the height of the dot-like emboss is 0.8 mm at the end closest to the valley of the crease and the highest at the top. The dot-like embossed protrusions 4A, 4B, 4C, 4D, 4E, and 4F are formed in the same manner as in Example 1 except that the near end is set to 2.0 mm and the interval between them is a continuous (intermittent) gradient. A filter pack for an air filter was manufactured as shown in d).
（実施例５）
ドット状エンボスの幅は、折筋の谷部から頂部にかけて５．０ｍｍ、４．８ｍｍ、４．６ｍｍ、４．４ｍｍ、４．２ｍｍ、４．０ｍｍとしたこと以外は実施例１と同様にして、ドット状エンボス突起５Ａ，５Ｂ，５Ｃ，５Ｄ，５Ｅ，５Ｆを形成し、図３（ｅ）に示す通りエアフィルタ用フィルタパックを製作した。
(Example 5)
The width of the dot emboss was the same as in Example 1 except that it was 5.0 mm, 4.8 mm, 4.6 mm, 4.4 mm, 4.2 mm, and 4.0 mm from the valley to the top of the folding line. The dot-shaped emboss projections 5A, 5B, 5C, 5D, 5E, and 5F were formed, and a filter pack for an air filter was manufactured as shown in FIG.
（実施例６）
ドット状エンボスの幅は、折筋の谷部から頂部にかけて５．０ｍｍ、４．８ｍｍ、４．６ｍｍ、４．４ｍｍ、４．２ｍｍ、４．０ｍｍとし、かつドット状エンボスの高さが、折筋の谷部に最も近い端を０．８ｍｍ、頂部に最も近い端を２．０ｍｍとして、その間を連続(断続)勾配としたこと以外は実施例１と同様にして、ドット状エンボス突起６Ａ，６Ｂ，６Ｃ，６Ｄ，６Ｅ，６Ｆを形成し、図３（ｆ）に示す通りエアフィルタ用フィルタパックを製作した。
(Example 6)
The width of the dot-shaped emboss is 5.0 mm, 4.8 mm, 4.6 mm, 4.4 mm, 4.2 mm, 4.0 mm from the valley to the top of the folding line, and the height of the dot-shaped emboss is In the same manner as in Example 1 except that the end closest to the valley of the streak is 0.8 mm, the end closest to the top is 2.0 mm, and a continuous (intermittent) gradient is provided between them, the dot-like emboss projection 6A, 6B, 6C, 6D, 6E, and 6F were formed, and a filter pack for an air filter was manufactured as shown in FIG.
（実施例７）
ドット状エンボスの形状を半球とし、立ち上がり角度は、折筋の頂部から谷部にかけて３９、３７、３３、３１、２５、２２度とし、ドット状エンボス突起部の幅をドット状エンボス突起部の長さと等しくしたこと以外は実施例１と同様にして、ドット状エンボス突起７Ａ，７Ｂ，７Ｃ，７Ｄ，７Ｅ，７Ｆを形成し、図３（ｇ）に示す通りエアフィルタ用フィルタパックを製作した。
(Example 7)
The dot-like embossed shape is a hemisphere, the rising angle is 39, 37, 33, 31, 25, 22 degrees from the top of the crease to the valley, and the width of the dot-like embossed protrusion is the length of the dot-like embossed protrusion. In the same manner as in Example 1 except that the dot emboss projections 7A, 7B, 7C, 7D, 7E, and 7F were formed, and a filter pack for an air filter was manufactured as shown in FIG.
（実施例８）
ドット状エンボスの形状を半球とし、向かい合う各々の突起部のうち一方の先端にさらに直径１ｍｍ、高さ1ｍｍの凸部を形成し、もう一方の先端に直径１ｍｍ、深さ１ｍｍの凹部を形成しこと以外は実施例７と同様にして、ドット状エンボス突起８Ａ，８Ｂ，８Ｃ，８Ｄ，８Ｅ，８Ｆを形成し、図３（ｈ）に示す通りエアフィルタ用フィルタパックを作製した。
(Example 8)
The dot-shaped embossing is a hemisphere, and a convex portion with a diameter of 1 mm and a height of 1 mm is further formed at one tip of each of the protruding portions facing each other, and a concave portion with a diameter of 1 mm and a depth of 1 mm is formed at the other tip. Except that, dot-like embossed protrusions 8A, 8B, 8C, 8D, 8E, and 8F were formed in the same manner as in Example 7 to produce an air filter filter pack as shown in FIG.
（従来例１）
エンボス突起部を、幅が４．０ｍｍ、高さが折筋の谷部に最も近い端を０ｍｍ、頂部に最も近い端を２．０ｍｍとして、その間を連続勾配とした１個のライン状エンボス突起部７，７とし、ドット状エンボス突起部の立ち上がり角度を４５度としたこと以外は実施例１と同様にして、図４に示す通り（配置は図１，２参照）エアフィルタ用フィルタパックを製作した。ドット状エンボス突起部の立ち上がり角度は４５度とした。
(Conventional example 1)
One embossed protrusion with a width of 4.0mm, height of 0mm at the end closest to the valley of the crease, and 2.0mm at the end closest to the top, with a continuous gradient between them As shown in FIG. 4 (see FIGS. 1 and 2 for the arrangement), the air filter filter pack is formed in the same manner as in Example 1 except that the portions 7 and 7 are used and the rising angle of the dot-like embossed protrusion is 45 degrees. Produced. The rising angle of the dot-like embossed protrusion was 45 degrees.
（従来例２）
ホットメルトを２段塗布して、幅は折筋の谷部から頂部にかけて全て４．０ｍｍとし、高さは折筋の谷部から頂部にかけて０ｍｍ、１ｍｍ、２ｍｍの三段階とし、特開２００３−２８４９１４号公報図２に示す通り、プリーツの間隔を保ったエアフィルタ用フィルタパックを製作した。
(Conventional example 2)
The hot melt is applied in two stages, the width is 4.0 mm from the valley to the top of the crease, and the height is three stages of 0 mm, 1 mm, and 2 mm from the valley to the top. No. 284914 gazette As shown in FIG. 2, a filter pack for an air filter with a pleat interval maintained was manufactured.
（従来例３）
ホットメルトを１段塗布にして、幅は折筋の谷部から頂部にかけて全て４．０ｍｍとし、高さは折筋の谷部を０ｍｍ、頂部を２．０ｍｍとし、中央付近から頂部にかけて一定高さとしたこと以外は従来例２と同様にして、特開２００３−２８４９１４号公報図３に示す通り、エアフィルタ用フィルタパックを製作した。
(Conventional example 3)
The hot melt is applied in one step, the width is 4.0mm from the valley to the top of the crease, and the height is 0mm at the fold, and the top is 2.0mm. The height is constant from the center to the top. Except for this, a filter pack for an air filter was manufactured in the same manner as in Conventional Example 2 as shown in FIG.
次に、本発明の実施例、従来例について、以下のようにしてフィルタの圧力損失、捕集効率、粉塵保持量（DHC）を測定し、それに加え、ろ材破れと総合評価を行った結果を表１に示す。 Next, with respect to the examples of the present invention and the conventional examples, the pressure loss, the collection efficiency, and the dust holding amount (DHC) of the filter were measured as follows, and in addition to them, the results of the comprehensive evaluation with the filter medium breakage were performed. Table 1 shows.
圧力損失：フィルタユニットに面風速に換算して３．１ｍ／ｓｅｃの空気を通風したときのフィルタ前後での圧力差を測定し、圧力損失とした。圧力損失が１５０Ｐａ以上のものを×、１５０Ｐａ以下のものを○とした。 Pressure loss: The pressure difference before and after the filter when 3.1 m / sec of air was passed through the filter unit in terms of the surface wind speed was measured and taken as the pressure loss. Those having a pressure loss of 150 Pa or more were rated as x, and those having a pressure loss of 150 Pa or less were rated as ◯.
捕集効率：JIS B9908 形式２に従い測定した。捕集効率が９０％以上のものを○、９０％未満のものを×とした。 Collection efficiency: Measured according to JIS B9908 format 2. A sample having a collection efficiency of 90% or more was rated as ○, and a sample having a collection efficiency of less than 90% was rated as ×.
粉塵保持量(DHC)：上記JIS B9908 形式２に従い、最終圧力損失を２９４Paと定めたときの粉塵保持量とした。粉塵保持量が６００ｇ／台以上のものを○、６００ｇ／台未満のものを×とした。 Dust retention amount (DHC): According to the above JIS B9908 format 2, the dust retention amount was determined when the final pressure loss was 294 Pa. A sample having a dust holding amount of 600 g / unit or more was evaluated as ◯, and a sample having a dust retention amount of less than 600 g / unit was evaluated as x.
ろ材破れ：ドット状エンボス突起を加工したろ材を目視で確認し、ろ材に破れが認められたものを×、破れはないが一部に傷んだ部分が認められたものを△、破れが認められなかったものを○とした。 Filter media breakage: Check the filter media processed with dot-like embossed protrusions visually. If the filter media is broken, ×, if it is not torn but partly damaged, Δ is broken. What did not exist was set as (circle).
質量：610ｍｍ×610ｍｍの寸法に換算して、フィルタパックの質量３kg未満の場合を○、３kg以上のものを×とした。 Mass: Converted to a size of 610 mm × 610 mm, a case where the weight of the filter pack is less than 3 kg is given as “○”, and a case where the weight is 3 kg or more is taken as “x”.
有効ろ材面積：有効ろ材面積が、８０％以上のものを○、８０％未満のものを×とした。 Effective filter medium area: An effective filter medium area of 80% or more was evaluated as ◯, and an effective filter medium area of less than 80% as X.
総合評価：総合評価は、全て○のものを◎、△を一つ以上含むものを○、×を一つ以上含むものを×とした。 Comprehensive evaluation: Comprehensive evaluation made all the thing of (circle), (circle), the thing containing one or more (triangle | delta), and the thing containing one or more x (s).
表1に示すとおり、実施例１，２，７及び８では、基本性能が十分であることに加えて、質量が軽く、有効ろ材面積が多く（DHCが大きく）、そして圧力損失が十分低いフィルタパックとして使用することができることから、総合評価は◎となった。
実施例３，４，５及び６では、基本性能、質量、有効ろ材面積、圧力損失については十分であるものの、ろ材の一部に傷が認められたため、総合評価は○となった。
従来例１では、有効ろ材面積の減少及びライン状エンボスで横方向に拡散する流れを遮断されるに伴いDHCが少なくなったと考えられ、またろ材の一部に傷が認められたため、総合評価は△となった。
従来例２では、従来例1よりも横方向に拡散する流れは緩和されるが更に有効ろ材面積の減少に伴い圧損がやや高く、有効ろ材面積の減少に伴いDHCが少なく、そしてホットメルトの塗布で質量が大幅に増加したことから、総合評価は×となった。
従来例３では、従来例２よりも横方向に拡散する流れが遮断されるため圧損が非常に高く、有効ろ材面積の減少に伴いDHCが極端に少なく、そしてホットメルトの塗布で質量が大幅に増加したことから、総合評価は×となった。
As shown in Table 1, in Examples 1, 2, 7 and 8, in addition to sufficient basic performance, the filter has a light weight, a large effective filter medium area (large DHC), and a sufficiently low pressure loss. Since it can be used as a pack, the overall evaluation was ◎.
In Examples 3, 4, 5, and 6, although the basic performance, mass, effective filter medium area, and pressure loss were sufficient, since a part of the filter medium was scratched, the overall evaluation was “good”.
In Conventional Example 1, it is considered that the DHC decreased as the effective filter medium area decreased and the flow that spreads in the lateral direction was blocked by the line embossing, and scratches were found on a part of the filter medium. △.
In Conventional Example 2, the flow diffusing in the lateral direction is moderated compared to Conventional Example 1, but the pressure loss is slightly higher as the effective filter medium area is reduced, DHC is reduced as the effective filter material area is reduced, and hot melt coating is applied. Since the mass increased significantly, the overall evaluation was x.
In the conventional example 3, the flow diffusing in the lateral direction is cut off compared to the conventional example 2, so the pressure loss is very high, the DHC is extremely small as the effective filter medium area is reduced, and the mass is greatly increased by applying the hot melt. Since it increased, the comprehensive evaluation became x.
本発明のエアフィルタ用フィルタパックによれば、フィルタパックの質量を増加させず、有効ろ材面積を減少させず、かつ圧力損失を十分低くすることができる。 According to the filter pack for an air filter of the present invention, the mass of the filter pack is not increased, the effective filter medium area is not decreased, and the pressure loss can be sufficiently reduced.
１Ａ，１Ｂ，１Ｃ，１Ｄ，１Ｅ，１Ｆ ドット状エンボス突起
２Ａ，２Ｂ，２Ｃ，２Ｄ，２Ｅ，２Ｆ ドット状エンボス突起
３Ａ，３Ｂ，３Ｃ，３Ｄ，３Ｅ，３Ｆ ドット状エンボス突起
４Ａ，４Ｂ，４Ｃ，４Ｄ，４Ｅ，４Ｆ ドット状エンボス突起
５Ａ，５Ｂ，５Ｃ，５Ｄ，５Ｅ，５Ｆ ドット状エンボス突起
６Ａ，６Ｂ，６Ｃ，６Ｄ，６Ｅ，６Ｆ ドット状エンボス突起
７Ａ，７Ｂ，７Ｃ，７Ｄ，７Ｅ ７Ｆ ドット状エンボス突起
８Ａ，８Ｂ，８Ｃ，８Ｄ，８Ｅ ８Ｆ ドット状エンボス突起
９ ライン状エンボス突起
１０ 複合ろ材
1A, 1B, 1C, 1D, 1E, 1F Dot emboss protrusion 2A, 2B, 2C, 2D, 2E, 2F Dot emboss protrusion 3A, 3B, 3C, 3D, 3E, 3F Dot emboss protrusion 4A, 4B, 4C , 4D, 4E, 4F Dot emboss protrusions 5A, 5B, 5C, 5D, 5E, 5F Dot emboss protrusions 6A, 6B, 6C, 6D, 6E, 6F Dot emboss protrusions 7A, 7B, 7C, 7D, 7E 7F Dot emboss projection 8A, 8B, 8C, 8D, 8E 8F Dot emboss projection 9 Line emboss projection 10 Composite filter medium
Claims (5)
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| DE102006014236A1 (en) | 2006-03-28 | 2007-10-04 | Irema-Filter Gmbh | Fleece material used as a pleated air filter in a motor vehicle comprises thinner fibers homogeneously incorporated into thicker fibers |
| JP4680316B1 (en) * | 2010-03-12 | 2011-05-11 | 小松 正和 | Combustion efficiency improvement tool |
| JP5602521B2 (en) * | 2010-07-02 | 2014-10-08 | ニッタ株式会社 | Air filter insert |
| JP2014064995A (en) * | 2012-09-26 | 2014-04-17 | Japan Vilene Co Ltd | Filter element |
| JP2014184360A (en) * | 2013-03-22 | 2014-10-02 | Japan Vilene Co Ltd | Filter medium for pleat type air filter and pleat type air filter unit |
| DE102013008402A1 (en) | 2013-05-16 | 2014-11-20 | Irema-Filter Gmbh | Nonwoven fabric and process for producing the same |
| JP6159664B2 (en) * | 2014-01-31 | 2017-07-05 | 呉羽テック株式会社 | Non-woven filter medium for pleat type filter with low ventilation resistance and method for producing the same |
| DE102014117506A1 (en) * | 2014-11-28 | 2016-06-02 | Filta Co., Ltd | Filter medium with large pleat spacing |
| BR112018076946B1 (en) * | 2016-06-24 | 2023-05-02 | K&N Engineering, Inc | AIR FILTER AND AIR MOLECULAR CONTAMINANTS REMOVAL METHOD |
| KR102372578B1 (en) * | 2017-02-17 | 2022-03-11 | 한국생산기술연구원 | Method of manufacturing embossed non-woven electrostatic filter and embossed non-woven electrostatic filter using the same |
| JP7370695B2 (en) * | 2018-10-17 | 2023-10-30 | 日本無機株式会社 | Filter pack and air filter |
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| JP3001408B2 (en) * | 1996-02-19 | 2000-01-24 | ニッタ株式会社 | Filter medium for air filter and molding device for filter medium for air filter |
| CA2312825A1 (en) * | 1997-12-03 | 1999-06-10 | "Jacobi" Systemtechnik Gmbh | Filter element and method and adhesive application device for the production thereof |
| JP4761711B2 (en) * | 2004-01-06 | 2011-08-31 | フロイント産業株式会社 | Filter, filter device, and granular material processing device |
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