Filter holder, method of manufacturing thereof, and leaf disc filter element

Abstract

Provided is a filter holder capable of exerting effects such as low pressure loss, high strength, and high pressure resistance. The filter holder is composed of: a first metal plate (10A, 40A) in which flow path forming members each having a prescribed curved or linear shape are arranged in parallel at prescribed intervals on the same plane and the overall shape is a circular ring plate shape; and a second metal plate (10B, 40B) having the same structure as the first metal plate, the filter holder having a structure in which the intersections of the flow path forming members of each metal plate are fixed to each other in a state in which the second metal plate is overlaid on the first metal plate, and the flow path forming members (15A, 50A) of the first metal plate and the flow path forming members (15B, 50B) of the second metal plate form a line-symmetrical shape when viewed from above.

Description

TECHNICAL FIELD

[0001] The present application relates to a holder for a filter, a method for manufacturing the same, and a leaf disc filter element. BACKGROUND

[0002] An optical film used in a liquid crystal display or the like is manufactured by a melt extrusion method.

[0003] In the melt extrusion method, a thermoplastic resin such as a polymer in a molten state is supplied to a filter device through an extruder and impurities are removed, and then extruded from a die and molded into a film shape.

[0004] In the molten resin extruded from the extruder, sometimes, an insufficiently molten foreign matter, a combustion foreign matter solidified by combustion, and other foreign matters are left or mixed, and thus it is necessary to remove the impurities by filtration. As such a filter device, a leaf disc filter device is known.

[0005] The leaf disc filter device of Patent Document 1 has a filter element in a circular ring plate shape as a filter for a polymer filtration and a viscous fluid filtration. The filter element has a holder in a circular ring plate shape composed of a metal mesh or the like for supporting a filter material, and a disc-shaped filter material composed of a sintered body of metal fibers arranged on both surfaces of the holder with a porous support plate (for example, a punched metal) interposed therebetween. The filter element is formed into the leaf disc filter device by stacking a hub in the center around a polymer discharge pipe (a center column) having a polymer introduction hole in the outer peripheral surface.

[0006] The filter element is sealed in a housing, and the molten resin is supplied to the inside of the housing under a relatively high pressure. The molten resin flowing between the stacked filter elements is filtered by the filter material, reaches the holder portion through the porous support plate, flows in the inner diameter direction in the gaps of the metal mesh constituting the holder, and is concentrated in the central portion of the stacked filter element or the like, and the filtered fluid is transported from there to a prescribed destination via the polymer discharge pipe.

[0007] In the case where the pressure loss in the leaf disc filter element is high, it can cause unevenness of the flow rate of the molten resin passing through the inside and stagnation caused thereby, and thus reduction of the pressure loss is an important factor that determines the quality of the product.

[0008] As the main cause of the pressure loss of the leaf disc filter element, in addition to the filtration resistance of the filter material, the resistance of the molten resin passing through the filter material, passing through the porous support plate, and flowing in the inner diameter direction in the holder until reaching the hub is also large. In particular, in the case of the holder composed of a metal mesh, the flow path becomes a complex and narrow route in a non-straight line shape, and the deviation of the resistance of each flow path is also large, and thus there is a limit to the reduction of the pressure loss in the holder, and stagnation is easily generated in the holder.

[0009] Patent Document 2 discloses a structure in which, as a holder for a leaf disc type filter provided with a structure other than a metal mesh, a pair of etching treatment circular plates each having a plurality of through holes formed by chemical etching are arranged in the circumferential direction, are engaged with each other in a state in which positions of the respective through holes corresponding to each other are aligned, and an internal passage extending in the radial direction is formed between the pair of etching treatment circular plates.

[0010] However, since the holder is composed of two etching treatment circular plates, there is a problem that the number of components increases and the thickness increases. In addition, the thickness dimension of the internal passage formed between the two etching treatment circular plates narrows, which becomes a cause of increasing the passage resistance. In addition, the annular region based on half-etching located between the through holes also causes an increase in passage resistance and a reduction in quality due to unevenness of residence time.

[0011] Patent Document 3 discloses a support plate (holder) for a filter in which a plurality of rows of annular rows of slits or long holes are provided on a circular plate-shaped flat plate member in a concentric manner in the radial direction of the circular plate-shaped flat plate member, the portions between the respective slits or long holes are bent alternately in the up-down direction with the positions being staggered in the circumferential direction of the circular plate-shaped flat plate member, and a standing piece portion which is substantially twisted by 90 degrees with respect to the plate surface and protrudes in the up-down direction is formed. However, since the standing piece portion located at the outermost circumference cannot be extended to the outer circumferential edge of the circular plate-shaped flat plate member, the molten resin that has passed through the outermost circumferential portion of the filter material is likely to be retained at the outermost circumferential edge (plate surface portion) of the circular plate-shaped flat plate member. In addition, since the plate-shaped portion of the flat plate member remains between the standing piece portions, this portion becomes a resistance to the flow of the molten resin.

[0012] Patent Document 4 also discloses a structure in which grooves extending in the radial direction are formed on a support and drainage plate serving as a holder composed of one metal plate, but these grooves terminate just before the outermost circumferential edge of the support and drainage plate, so there is a problem that the molten resin that has passed through the filter material is likely to be accumulated in the portion where the grooves are not present. In addition, the plate-shaped portion where the grooves are not formed becomes a resistance to the flow of the molten resin.

[0013] Such adverse situations are not limited to optical films and optical sheets, and are problems that occur regardless of the use and the shape when a resin molded product is manufactured.

[0014] [Related Art Documents]

[0015] Patent Document

[0016] Patent Document 1: Japanese Patent Application Publication No. 2016-185666

[0017] Patent Document 2: Japanese Patent Application Publication No. 2009-279517

[0018] Patent Document 3: Japanese Patent Application Publication No. H10-337415

[0019] Patent Literature 4: Japanese Patent No. 6-98250 SUMMARY

[0020] PROBLEMS TO BE SOLVED BY THE INVENTION

[0021] The present application has been achieved in view of the above circumstances, and provides a filter holder capable of exerting effects of low pressure loss, high strength, and high pressure resistance, a manufacturing method thereof, and a leaf disc filter element.

[0022] MEANS FOR SOLVING THE PROBLEMS

[0023] To solve the above problems, the filter holder of the present application is composed of: a first metal plate material in which a plurality of flow path forming members having a prescribed curved shape or straight line shape when viewed from above are arranged in parallel at prescribed intervals on the same plane so that the overall shape becomes a circular ring plate shape; and a second metal plate material having the same structure as the first metal plate material, the filter holder having a structure in which the intersecting portions of the flow path forming members constituting each metal plate material are fixed to each other in a state in which one face of the first metal plate material overlaps one face of the second metal plate material, characterized in that the flow path forming members constituting the first metal plate material and the flow path forming members constituting the second metal plate material constitute a line-symmetrical shape when viewed from above.

[0024] EFFECTS OF THE INVENTION

[0025] According to the present application, effects of low pressure loss, high strength, and high pressure resistance can be exerted. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 (a) and (b) are plan and front views showing the overall structure of the filter holder of the first embodiment of the present application.

[0027] Figure 2 (a) and (b) are perspective and enlarged plan views of the main portion showing the overall structure of the filter holder of the first embodiment.

[0028] Figure 3 is an explanatory view showing the main flow path formed in the filter holder.

[0029] Figure 4 is a plan view of the metal material 80A forming the metal plate material 10A.

[0030] Figure 5 is a back view of the metal material 80B forming the metal plate material 10B.

[0031] Figure 6 This is a plan view showing the state in which metal material 80A and metal material 80B are temporarily fixed when metal sheet 10A and metal sheet 10B are stacked together.

[0032] Figure 7 It shows the excision site Figure 6 A plan view of the process that does not require the holding device in its state.

[0033] Figure 8 (a) and (b) are plan views and front views showing the structure of the filter retainer of the second embodiment.

[0034] Figure 9 (a) and (b) are perspective views (photographs) and plan views (photographs) of the main parts of the filter retainer according to the second embodiment.

[0035] Figure 10 This is an explanatory diagram showing the main flow paths formed within the retainer.

[0036] Figure 11 It is a plan view of the metal material 85A formed by the metal sheet 40A.

[0037] Figure 12 It is a plan view of metal material 85B formed by metal sheet 40B.

[0038] Figure 13 This is a plan view showing the state in which metal material 85A and metal material 85B are temporarily fixed when metal plates 40A and 40B are stacked together.

[0039] Figure 14 It shows the excision site Figure 13 A plan view of the process that does not require the holding device of the state.

[0040] Figure 15 (a) and (b) are front longitudinal sectional views and partial enlarged views of the disc filter element using the retainer 1, 30 of the present invention.

[0041] Figure 16 (a) and (b) are a front longitudinal sectional view and a partial enlarged view of a disc filter element using a modified example of the vortex retainer 1 of the present invention. Detailed Implementation

[0042] The present invention will now be described in detail with reference to the embodiments shown in the accompanying drawings.

[0043] [First Implementation Method]

[0044] <Basic Structure>

[0045] Figure 1 (a) and (b) are plan and front views showing the overall structure of a filter holder of a first embodiment of the present application, Figure 2 (a) and (b) are perspective and enlarged plan views showing the overall structure of the filter holder, Figure 3 is an explanatory view showing the main flow path formed in the filter holder.

[0046] The filter holder (hereinafter referred to as holder) 1 of the present example is used as a means for supporting filter materials in a leaf disc type filter element 100 shown in Figure 15 and Figure 16 The holder 1 has a structure in which a first metal plate 10A and a second metal plate 10B are overlapped and sintered integrally, the first metal plate 10A and the second metal plate 10B being formed by forming a plurality of curved slits (gaps) 20A, 20B in parallel and at equal intervals in a spiral shape on a stainless steel (SUS304) plate having a thickness of, for example, 1.5 to 2 mm.

[0047] Each metal plate 10A, 10B can be manufactured, for example, by forming the slits 20A, 20B on a circular ring-shaped flat plate made of stainless steel using laser processing. In addition, the holder 1 is formed by sintering (fixing) the intersection portions of a plurality of flow path forming members, which have a involute curve shape when viewed from above, in the present embodiment, rods (or wires) 15A, 15B, to each other, thereby being integrated, by overlapping one face of each of the two metal plates 10A, 10B with each other, the two metal plates 10A, 10B having a structure in which the rods 15A, 15B are arranged at equal intervals with the slits 20A, 20B therebetween. Each rod 15A, 15B has an involute curve shape, and thus the slits 20A, 20B formed between each rod also have an involute curve shape (spiral shape).

[0048] The rods (flow path forming members, skeleton members) 15A, 15B constitute the skeleton of the holder 1 by intersecting with each other. The rods (flow path forming members) 15A, 15B refer to elongated members that are narrow and belt-shaped when viewed from above regardless of the longitudinal cross-sectional shape, and broadly include members having a planar shape that is curved. The spiral-shaped slits 20A, 20B formed between the rods are elongated gaps that form the flow paths F1, F2 described later. In the present embodiment, the rod 15A is a curved lattice that is curved in the clockwise direction from the inner diameter side toward the outer diameter side, and the rod 15B is a curved lattice that is curved in the counterclockwise direction from the inner diameter side toward the outer diameter side.

[0049] When viewed from above, the rods 15A and 15B have an involute curve shape, which allows the width of the slits 20A and 20B formed between the rods to be uniform along their entire length. Furthermore, by adjusting and modifying the pattern of the involute curve, the width of each slit in the longitudinal direction (inner and outer radial directions) can be made different. For example, it is also possible to adjust the width of the slit in a conical shape so that the width on the inner diameter side is wider (gradually increasing) or narrower (gradually decreasing) than the outer diameter side. This reduces the flow resistance relative to the molten resin within the slits.

[0050] The retainer 1 comprises the following components: a first metal plate 10A, which consists of multiple rods (or wires) 15A, which, when viewed from above, have a predetermined curved shape (in this example, an involute curve shape), serving as flow path forming components, arranged on the same plane at even intervals, with slits 20A, forming a ring-shaped plate as a whole; and a second metal plate 10B, which consists of multiple rods (or wires) 15B, which, when viewed from above, have an involute curve shape, arranged on the same plane at even intervals, with slits 20B, forming a ring-shaped plate as a whole. The retainer 1 is formed by laminating the two metal plates together. Since the first metal plate 10A and the second metal plate 10B have the same shape, no special manufacturing method is required, making it suitable for mass production. The vortex-shaped slits 20A and 20B are planar curves that move away from the center as they rotate.

[0051] When the second metal plate 10B overlaps with the first metal plate 10A, as Figure 1 As shown in (b), the second metal plate 10B's back surface 10B' is overlapped (joined) with the first metal plate 10A's back surface 10A' facing each other. In other words, the retainer 1 is fixed with the surfaces 10A' of the first metal plate 10A and 10B' of the second metal plate 10B facing outwards. Therefore, each rod 15A constituting the first metal plate 10A and each rod 15B constituting the second metal plate 10B forms a curved grid (mesh) with a line symmetry shape when viewed from above.

[0052] Various methods can be considered as a method for manufacturing metal plates 10A and 10B by forming slits 20A and 20B on a flat metal material using laser processing. One example is laser processing of a metal material pre-processed into a ring shape. In this case, the slits are not allowed to extend (open) to the inner circumference (inner diameter) and outer circumference (outer diameter) of the metal material, which has a concentric central opening CO at the center of the ring, but rather each slit terminates in front of the inner and outer circumferences. That is, the inner diameter ends of each bar 15A and the outer diameter ends of each bar 15B are maintained in a state of connection without separation. Two metal materials with their inner and outer perimeters connected are overlapped and fixed by sintering at the intersections of the rods. The ends of the rods connecting the inner and outer perimeters are then cut off, creating a non-connected state. This results in a structure where the slit passes through the inner diameter (central opening CO) and the outer diameter (open). Since the rods 15A and 15B constituting the two metal materials are sintered at their intersections, shape retention is ensured, and the rods will not scatter even after the ends are cut off. Furthermore, when assembled into a disc-type filter element, the load applied to the retainer 1 can be borne by each rod, and this load can be borne by the intersection C between the rods, which serves as the pressure-bearing part, thus maintaining strength and shape retention. Moreover, due to… Figure 1 As can be seen from (a), the spacing between adjacent intersections C is not constant depending on the distance from the center of the retainer, and sometimes deviations may occur, but there is no adverse situation such as affecting the flow resistance in the flow path formed in each slit.

[0053] In addition, slits and bars can also be formed on metal plates that have not been processed into a circular shape using laser processing. This manufacturing method will be described later.

[0054] In this example, the bars 15A constituting the first metal sheet 10A have the same shape, meaning they are bars with the same cross-sectional shape (quadrilateral) along their entire length. However, this is just one example; the cross-sectional shape can also vary at different points along the length. The same applies to the bars 15B constituting the second metal sheet 10B.

[0055] The dimensions and shapes (spaced) of the slits 20A and 20B constituting each metal sheet 10A and 10B do not need to be exactly the same, and errors and deformations in μm and mm units are permissible. Alternatively, the slit width can be configured as described above, gradually decreasing or increasing along the length direction (inner and outer radial directions).

[0056] The filter material 108 is made of stainless steel in a nonwoven fabric or felt shape, and thus has low strength and hardness. In addition, the surface of the holder is in a concave-convex shape, and thus, in order to hold the filter material in a sheet shape while maintaining a prescribed form, a perforated support plate (punching plate, etc.) 106, which is perforated at a prescribed pitch on a flat plate, is interposed between the holder and the filter material.

[0057] In the holder 1, not only is strength required to stably support the filter material and not to be crushed and deformed by pressure, but also a low-resistance flow path is needed inside to move the molten resin that has passed through the filter material in the inner diameter direction in a manner that reduces pressure loss.

[0058] In the holder of the present embodiment, each of the rod materials 15A of one of the metal sheet materials 10A forms a curved first flow path F1 composed of slits 20A at equal intervals from the outer peripheral portion toward the inner peripheral portion. Each of the rod materials 15B of the other of the metal sheet materials 10B forms a curved second flow path F2 composed of slits 20B at equal intervals from the outer peripheral portion toward the inner peripheral portion. The first flow path F1 and the second flow path F2 intersect to be line-symmetrical in plan view, and communicate in the thickness direction at the intersection flow path portions C' of each slit (each flow path F1, F2). Thus, as shown in FIG. 1, in addition to the main flow paths F1, F2 inside each of the metal sheet materials 10A, 10B, other main flow paths F3, F4 are formed that communicate between the flow paths F1, F2 via the intersection flow path portions C'. That is, a flow that varies little in the up-down direction along the spiral flow paths F1, F2 and a zigzag flow path F3, F4 that passes between the flow paths F1, F2 are formed in combination. The flow paths F3, F4 represent the shortest paths from the outer diameter portion toward the inner diameter portion, and the molten resin can flow smoothly toward the center opening portion CO while changing direction (meandering) in the up-down direction in a zigzag manner at the intersection flow path portions C'. The cross-sectional area of the flow path in the intersection flow path portion C' does not narrow compared to the cross-sectional area of the flow paths F1, F2, and thus the flow resistance at this portion does not increase significantly, and the flow rate does not decrease. Figure 3

[0059] Each of the flow paths F1, F2, F3, F4 is continuously formed throughout the entire peripheral surface (entire circumferential direction) of the holder 1, but the flow rate and flow volume in each of the flow paths F1, F2, F3, F4 are constant regardless of the difference in the circumferential position of each flow path. For example, the flow rate and flow volume in each of the flow paths F1 do not vary depending on the difference in the circumferential position of each flow path F1, but are constant. That is, even if the flow rate and flow volume in each of the flow paths F1, F2 are different from the flow rate and flow volume in each of the flow paths F3, F4, the flow rate and flow volume in all of the flow paths F1, F2 are constant, respectively. With respect to the flow rate and flow volume in the other flow paths F3, F4, the flow rate and flow volume in each of the flow paths F3, F4 are also constant regardless of the difference in the circumferential position. ​

[0060] On the other hand, in the existing metal mesh holder (grid holder), the flow rate and flow volume of the molten resin are not uniform according to the circumferential position of the flow path, and can greatly deviate, so that the residence of the molten resin is generated and it is difficult to maintain the quality of the product.

[0061] In addition, Figure 3 The main flow paths F1 to F4 shown are one example for simplifying the explanation, and in fact, a complex flow of the molten resin in which the flow paths are combined is formed.

[0062] Next, the width of each slit 20A, 20B is determined according to the pressure of the molten resin in the leaf disc filter device to which it is applied. On the other hand, in the case where the width D1, D2 of each slit 20A, 20B is too wide, when the porous support plate 106 is supported by each rod 15A and each rod 15B, the portion of the porous support plate between the rods is easily bent and deformed by the pressure from the molten resin falling into the slit. If each porous support plate portion is bent and deformed, the filter material 108 supported by the porous support plate will be bent and deformed, and it is difficult to maintain the posture required to maintain the appropriate filtering performance, and it becomes a cause of reducing the filtering performance.

[0063] In addition, in the case where each width D1, D2 of each slit 20A, 20B is too narrow, an adverse situation in which the resistance to the flow of the molten resin in the holder from the porous support plate into the holder is increased can be caused.

[0064] That is, the interval D1 between the adjacent rods 15A and the interval D2 between the adjacent rods 15B are appropriately set, so that both the resistance to the molten resin as the filtered fluid and the posture maintaining performance of the porous support plate can be appropriately balanced. According to the structure of the present application, each width D1, D2 of each slit 20A, 20B (i.e., the interval D1, D2 between the rods) constituting each metal plate 10A, 10B can be regularly arranged with high dimensional accuracy, so that each width D1, D2 can be maintained constant.

[0065] The metal plate 10A, 10B can be manufactured by laser processing a flat plate-shaped raw material, so that the dimensional accuracy can be ensured, and is constituted by a metal such as stainless steel having high strength, so that the strength (thickness, shape) of the rod can be set in such a manner that it does not break and deform even under high pressure. Therefore, each width D1, D2 of each slit 20A, 20B can be maintained optimal, and the passage resistance of the molten resin can be maintained constant at a low value. In addition, each metal plate is of the same shape, so that it is suitable for mass production.

[0066] Further, a method of manufacturing using laser processing with a metal plate as a raw material is an example, and each of casting, press processing, a three-dimensional printer, and the like can also be used for manufacturing.

[0067] By applying the retainer 1 of the present embodiment to a leaf disc type filter element, a second flow path F2 is formed on a back surface side metal plate 10B in a state of being misaligned in a line-symmetrical manner with a first flow path F1 formed on a surface side metal plate 10A.

[0068] In Figure 1 and Figure 2 , the first flow path F1 is a curved (vortex) flow path bent in a counterclockwise direction from an outer diameter side toward an inner diameter side, and the second flow path F2 is a curved (vortex) flow path bent in a clockwise direction from the outer diameter side toward the inner diameter side.

[0069] Each flow path F1, F2 is curved in a uniform width, a uniform height, respectively, along the upper and lower sides of the boundary surface of the two metal plates 10A, 10B. That is, each flow path F1, F2 is at the same height position. Also, there are no obstructions within each flow path F1, F2, and there are no jagged routes in the up and down, left and right directions, so that the resistance of the molten resin when passing through can be reduced to reduce pressure loss. Therefore, it is possible to prevent unevenness of the flow rate of the molten resin and stagnation caused thereby to maintain the quality of the product.

[0070] That is, each flow path F1, F2 is a gentle curved linear route (flow path) or a gentle conical shape with little displacement in the up and down direction and a uniform width over the entire length, so that the passing resistance of the molten resin can be greatly reduced.

[0071] It is known that there are almost no obstructions within each flow path F1, F2, and a route with a uniform width and a determined path is formed. That is, according to the present application, by forming each flow path F1, F2 toward the inner diameter portion without deviation in the path, the directionality of the flow path of the molten resin can be improved, and the molten resin can be efficiently flowed through each flow path F1, F2 toward the inner diameter portion and to the discharge pipe located in the inner diameter portion.

[0072] If this is described in detail, according to Figure 1 , Figure 2As is apparent, the first and second flow paths F1, F2 form flow paths that curve from the outermost circumference of the circular ring plate-shaped holder 1 to the innermost circumference. Therefore, the molten resin that flows into the first and second flow paths F1, F2 via the filter material can efficiently flow toward the discharge pipe located in the inner diameter portion. In particular, the molten resin that flows into the outermost circumference portion of the holder 1 and easily stagnates there can also stably flow toward the inner diameter portion. This is a significant difference from the documents 3 and 4 in which stagnation at the outer circumference portion of the holder is a problem.

[0073] In addition, since the cross flow path portions C' that pass through the slits communicate between the flow paths F1, F2 in the up-and-down positional relationship, the molten resin between the flow paths can also be mixed by flowing into each other. That is, in addition to the flow paths F1, F2, the zigzag flow paths F3, F4 are formed as shown in the drawing, so the respective molten resins that pass through the filter materials located above and below can be mixed via the cross flow path portions C', and the deviation in the quality of the molten resin caused by the deviation in the filtering capacity of the respective filter materials can be eliminated in the holder. Figure 3 The zigzag flow paths F3, F4 are formed in the holder 1, so the respective molten resins that pass through the filter materials located above and below can be mixed via the cross flow path portions C', and the deviation in the quality of the molten resin caused by the deviation in the filtering capacity of the respective filter materials can be eliminated in the holder.

[0074] In addition, in the holder 1, the respective flow paths F1, F2 are formed in the radial direction, and the respective flow paths F3, F4 are formed in the radial direction and the circumferential direction. Figure 3 In the document 3, the zigzag flow paths F3, F4 are shown as the shortest routes in the radial direction in addition to the flow paths F1, F2, but in addition to this, zigzag flow paths at various angles (directions other than the radial direction) from the outer diameter direction toward the inner diameter direction can also be formed.

[0075] In the leaf disc type filter element, it is necessary to ensure the flow of the molten resin toward the radial direction between the filter materials (the holder portion) and the other inner diameter portion, but in the holder composed of a metal mesh, the direction of the flow easily greatly deviates in the up-and-down and left-and-right directions in addition to the direction toward the inner diameter portion. In contrast to this, in the present embodiment, the direction of the flow can be concentrated in the direction toward the inner diameter portion.

[0076] In particular, in the case of filtering a high-viscosity fluid such as a molten polymer, the pressure loss in the filter material portion becomes large, and the pressure difference before and after the filter material also becomes large, so in the holder that is disposed in the passage of the molten resin, performance such as low pressure loss, high pressure resistance, and high bending strength is required, but in the holder 1 having a simple shape, there are almost no sites that become obstacles to the molten resin in the respective flow paths F1, F2, so these requirements (low pressure loss, high pressure resistance, and high bending strength) can be sufficiently satisfied. In the zigzag flow paths F3, F4, the flow resistance in the cross flow path portions C' is also small to the extent that it can be ignored, so the flow paths in the shortest routes toward the radial direction via the flow paths F1, F2 can be formed.

[0077] In the case of retainers made of metal mesh or the like, the retainer itself cannot guarantee the retention strength of the filter media; therefore, most of the retention strength of the filter media depends on the porous support plate. In contrast, the retainer 1 of the present invention has higher mechanical strength. Therefore, by maintaining the widths D1 and D2 of each slit 20A and 20B at appropriate values, the retention strength of the retainer on the filter media can be improved, reducing the dependence on the porous support plate. As a result, the porous support plate can also be made thinner or omitted. Therefore, it is possible to achieve an overall thinner design for the impeller-type filter device (impeller-type filter element), and to increase the number of filter elements assembled, thereby increasing the filtration area.

[0078] In this example, the cross-sectional shape of each rod (wire) is quadrilateral, so the surfaces of each metal plate 10A, 10B opposite the filter media rod are flat. Therefore, the porous support plate can be stably supported on a flat surface.

[0079] Furthermore, in the retainer of this embodiment, each bar 15A and 15B is configured as an involute curve shape, but this is only one example. Each bar can be any arc shape or other spiral curve (bending) shape. Therefore, spiral curve shapes also widely include logarithmic spiral shapes and algebraic spiral shapes.

[0080] <Method for manufacturing the retainer according to the first embodiment>

[0081] Figures 4 to 7 This is an explanatory diagram showing the process of manufacturing the retainer 1 according to the first embodiment. Figure 4 This is a plan view of the metal material 80A formed from the metal sheet 10A. Figure 5 This is a back view of the metal material 80B that forms the metal sheet 10B. Figure 6 This is a plan view showing the state in which metal materials 80A and 80B are temporarily fixed (positioned) when metal plates 10A and 10B are stacked together. Figure 7 It shows the excision site Figure 6 A plan view of the process that does not require the holding device of the state.

[0082] Figure 4 and Figure 5 The metal sheets 10A and 10B shown are identical in shape, differing only in their orientation when viewed from the surface and back sides. Besides being processed using lasers to work the metal material, the metal sheets 10A and 10B can also be manufactured using casting, powder metallurgy, or 3D printing.

[0083] In the first step, two flat metal materials 80A, 80B are prepared. That is, in the case where the metal plates 10A, 10B are manufactured by laser processing, the metal materials 80A, 80B each composed of a flat plate of stainless steel are used. The metal materials 80A, 80B have the same structure as the metal plates 10A, 10B.

[0084] In the second step, a plurality of slits 20A, 20B of a prescribed shape are formed in parallel through each of the metal materials 80A, 80B, respectively, so that the first metal plate 10A and the second metal plate 10B are formed in the area of each of the metal materials, respectively. That is, a plurality of slits 20A, 20B each having a regular shape as illustrated are formed in parallel through each of the metal materials 80A, 80B in a manner so as to have a spiral shape, so that each of the metal plates 10A, 10B is formed in the area of each of the metal materials 80A, 80B. The rod members (or wire members) 15A as flow path forming members are located between the slits 20A which are parallel to each other, and the rod members (or wire members) 15B as flow path forming members are located between the slits 20B. In the case where the metal plates 10A, 10B are manufactured by laser processing, the slits 20A, 20B are formed by laser processing. Figure 4 、 Figure 5 In the processing stage, the inner diameter side end portions of the rod members 15A, 15B are not separated from the central portions of the metal materials 80A, 80B, and the outer diameter side end portions of the rod members 15A, 15B are not separated from the outer peripheral portions of the metal materials 80A, 80B.

[0085] In the third step, one of the metal materials is overlapped and temporarily fixed (positioned) on the other metal material in a manner so that the back surface (one surface) of the other metal plate 10B is aligned with the back surface of one metal plate 10A in a prescribed positional relationship. That is, the metal material 80A is overlapped and temporarily fixed on the metal material 80B in a manner so that the back surface 10B" of the metal plate 10B is aligned with the back surface 10A" of the metal plate 10A having the same shape as illustrated in FIG. 10B (see FIG. 11B). Figure 6 Figure 1 (b)). At this temporary fixing, a special positioning jig not illustrated is used, and the positioning is performed using the positioning holes 81A, 81B provided at appropriate positions (corners) of each of the metal materials 80A, 80B.

[0086] In the fourth step, the intersecting portions C of the rod members or wire members constituting the two metal plates 10A, 10B are integrated and fixed (sintered). That is, in the stage of Figure 6 , the intersecting portions C of the rod members constituting the two metal plates 10A, 10B are sintered using a sintering means not illustrated, so that the two metal plates are partially fixed.

[0087] In the fifth step, the excess portions of each of the metal materials located at the inner and outer peripheral edges of each of the metal plates are cut off and removed. That is, as illustrated in FIG. 12B, the excess portions of each of the metal materials 80A, 80B are cut off and removed. Figure 7 ​As shown, the inner and outer peripheral edge portions of the two metal plates 10A, 10B are cut and removed along the cut lines CL indicated by the double-dot chain lines, thereby obtaining the holder 1 in the shape of a circular ring plate as a finished product. Figure 1 As shown, the inner and outer peripheral edge portions of the two metal plates 10A, 10B are cut and removed along the cut lines CL indicated by the double-dot chain lines, thereby obtaining the holder 1 in the shape of a circular ring plate as a finished product.

[0088] Further, the method of manufacturing the holder 1 using the two metal materials as illustrated is only one example. For example, the holder 1 of the present embodiment can be manufactured by a casting method in which a mold is filled with molten metal to shape the holder 1, a method of manufacturing using powder metallurgy in which a metal powder is shaped and sintered using a mold, a method of manufacturing using a 3D printer using an inkjet printing technique or the like, a method of manufacturing using cutting or piercing of one metal material by a working machine, and the like.

[0089] In the casting method and the powder metallurgy, a mold can be manufactured using the holder 1 manufactured in advance, and mass production can be performed using the mold, and productivity can be improved.

[0090] In the manufacturing method using cutting, one thick-walled metal material corresponding to the total thickness of the two metal materials 80A, 80B can be used, and the holder 1 can be manufactured by a milling tool. That is, first, using a milling tool, a plurality of curved grooves (non-through slits) corresponding to the slits 20A are formed in parallel from one side of the thick-walled metal material corresponding to the thick-walled portion (1 / 2 thickness portion) of one metal material 80A. Next, by the milling tool, a plurality of curved grooves corresponding to the slits 20B are formed in parallel from the other side of the thick-walled metal material corresponding to the thick-walled portion (1 / 2 thickness portion) of the other metal material 80B. At the time when each groove corresponding to the two slits 20A, 20B is formed, a cross-flow path portion C' is formed at the position where each groove intersects. Thus, the holder 1 can be completed. The sintering step required in the manufacturing method using two metal materials can be omitted.

[0091] As the thick-walled metal material used in the cutting process, a circular ring plate-shaped metal material having a central opening portion can be used, or a simple plate material used in the manufacturing method of the first embodiment can be used. Figures 4 to 7

[0092] That is, the holder of the present embodiment can be manufactured using various manufacturing methods in addition to the two metal materials (metal plates).

[0093] In addition, this also applies to the manufacturing method of the holder 30 of the second embodiment described later.

[0094] [Second Embodiment]

[0095] [Basic Structure]

[0096] ​Figure 8 Figures (a) and (b) are plan views and front views showing the structure of the filter retainer according to the second embodiment. Figures 9(a) and (b) are perspective views (photographs) and plan views (photographs) of the main parts of the filter retainer. Figure 10 This is an explanatory diagram showing the main flow paths formed within the retainer.

[0097] Filter retainer (hereinafter referred to as retainer) 30 in Figure 15 The impeller-type filter element 100 shown is used as a means of supporting the filter media by being disposed between two filter media 108. The retainer 30 includes: a first metal plate 40A, which is formed by forming a plurality of slits 45A extending in a straight line in one direction in parallel and at equal intervals on a stainless steel (SUS304) plate with a thickness of, for example, 1.5 to 2 mm; and a second metal plate 40B, which is formed by forming a plurality of slits 45B extending in a straight line in another direction orthogonal (intersecting) to the aforementioned one direction in parallel and at equal intervals on the same stainless steel plate. The retainer 30 has a structure in which the two metal plates are overlapped and sintered together.

[0098] Each metal plate 40A, 40B can be manufactured, for example, by laser processing to form slits 45A, 45B on a stainless steel plate of any shape, such as a pre-processed annular metal plate. Specifically, the retainer 30 is integrally formed by overlapping one side of two metal plates 40A, 40B and sintering the intersection C of the intersecting bars 50A, 50B that are arranged in a grid pattern. The two metal plates 40A, 40B have a structure in which multiple straight bars (or wires) 50A, 50B, which serve as flow path forming components, are arranged at equal intervals with slits 45A, 45B.

[0099] The bar 50A, which extends in a straight line along the transverse direction, is the longitudinal grid, and the bar 50B, which extends in a straight line along the longitudinal direction, is the transverse grid.

[0100] In this example, bar group 50A and bar group 50B are crossed at a 90-degree angle, but this is just an example. Bar group 50B can also be crossed at an angle other than 90 degrees relative to bar group 50A.

[0101] As a method of manufacturing each metal plate 40A, 40B by forming slits 45A, 45B and rods (or wires) 50A, 50B on a metal material using laser processing, various methods can be considered. One example thereof is laser processing using a metal material that is processed in advance into a circular ring plate shape having a central opening portion CO, as also explained in the first embodiment. In this case, the slits are not made to pass through (open) to the inner and outer peripheral edge portions (inner and outer diameter portions) of the metal material, but are made to end just before the inner and outer peripheral edge portions. Thus, the metal plates 40A, 40B can be prevented from spreading out during the work.

[0102] That is, in the case of manufacturing each metal plate 40A, 40B using a metal material that is processed in advance into a circular ring plate shape, as in the first embodiment, the state in which the inner diameter side end portions of each rod 50A and the outer diameter side end portions thereof, and the inner diameter side end portions of each rod 50B and the outer diameter side end portions thereof, are linked to each other is maintained so that the rods do not spread out from each other. After the two metal materials whose inner and outer peripheral edge portions are linked are overlapped and the intersection portions C of the rods are sintered, the rod end portions to which the inner and outer peripheral edge portions are linked are cut off to become a non-linked state, and thus a structure in which the lengthwise end portions of each slit 45A, 45B pass through (open) to the inner and outer diameter portions, respectively, is obtained. Since the rods 50A, 50B that constitute the two metal materials are sintered at each intersection portion C, the shape retention property can be ensured, and the rods do not spread out even if the rod end portions are cut off.

[0103] In addition, when assembled in a vane disc filter element, the load applied to the holder 30 can be received by the rods, and the load can be received by the intersection portions C between the rods as pressure receiving portions, and thus the strength and shape retention property can be maintained. Furthermore, since the intervals between all the intersection portions C can be made constant, the flow resistance in the flow paths formed in each slit and between the slits can be stabilized.

[0104] The size and shape of the slits 45A, 45B of each metal plate 40A, 40B do not need to be exactly the same, and a few errors or deformations in the order of μm or mm can be allowed.

[0105] In addition, each slit 45A, 45B does not necessarily need to be equally spaced over the entire length, and can be configured so that the width gradually increases or decreases from one end toward the other end in the lengthwise direction.

[0106] In the holder 30, not only is the strength required to stably support the filter medium and not to be crushed and deformed by the pressure, but also a low resistance flow path that moves the molten resin that has passed through the filter medium in the inner diameter direction to reduce the pressure loss needs to be formed inside.

[0107] In the retainer 30 of this embodiment, each rod 50A constituting one side of the metal plate 40A is formed Figure 8 , Figure 9 , Figure 10 A straight flow path F5 is formed by equally spaced slits 45A extending laterally. Each bar 50B constituting the other metal sheet 40B forms a straight flow path F6 formed by equally spaced slits 45B extending longitudinally.

[0108] The upper flow path F5 and the lower flow path F6 intersect in a grid pattern when viewed from above, and are connected at the intersection of the flow paths C' in each slit.

[0109] The flow path in multiple flow paths F5 where the inner edge opens at the central opening CO becomes the shortest flow path along the radial direction of the retainer 30. The flow path in each flow path F6 where the inner edge opens at the central opening CO becomes the shortest flow path along the radial direction of the retainer.

[0110] In flow paths F5 and F6 where the inner edge does not open at the central opening CO, the path can be changed to the other flow path via the cross flow path section C', and the molten resin can flow toward the central opening CO.

[0111] Next, flow path F7 forms a zigzag path that connects adjacent flow paths F5 via each intersecting flow path C'. Flow path F8 forms a zigzag path that connects adjacent flow paths F6 via each intersecting flow path C'. Flow path F9 forms a zigzag path that connects multiple intersecting flow paths C' arranged in a straight line along the radial direction.

[0112] The cross-sectional area of ​​the flow path in the cross-flow path section C' is not narrower than that of flow paths F5 and F6, so the flow resistance at this location will not increase and the flow velocity will not decrease significantly.

[0113] also, Figure 10 The flow paths F5 to F9 shown are the main flow paths. In addition, flow paths with various angles and directions are also formed.

[0114] Similar to the first embodiment, the widths D3 and D4 of each slit 45A and 45B are appropriate, thereby appropriately balancing the resistance to the molten resin as the filter fluid and the posture maintenance performance of the porous support plate. According to the structure of this embodiment, the widths D3 and D4 (i.e., the spacing between the bars) of each slit 45A and 45B constituting each metal plate 40A and 40B can be constructed and arranged regularly with high dimensional accuracy, thus maintaining each width D3 and D4 as constant.

[0115] The metal plates 40A, 40B can be manufactured using laser processing, so that dimensional accuracy can be ensured, and are composed of a metal such as stainless steel that has high strength, so that the strength (thickness, shape) of the rod can be set in a manner that will not be crushed and deformed even under high pressure. Thus, the width D3, D4 of each slit 45A, 45B can be maintained at an optimum value, and the passage resistance of the molten resin can be maintained at a constant value at a low value.

[0116] By applying the retainer 30 of the present embodiment to the retainer of a leaf disc filter element, a flow path F6 that intersects the flow path F5 is formed on the metal plate 40B on the back surface side, in addition to the flow path F5 formed on the metal plate 40A on the surface side.

[0117] Each flow path F5, F6 is formed with a uniform width and a uniform height above and below the boundary surface (joint surface) of the two metal plates 40A, 40B. Also, there are no obstructions within each flow path F5, F6, and there are no jagged routes above and below and to the left and right, so that the passage resistance of the molten resin can be reduced to reduce pressure loss. Thus, unevenness in the flow rate of the molten resin and stagnation caused thereby can be prevented to maintain product quality.

[0118] In addition, since the flow paths F5, F6 in the upper and lower positional relationship are connected by the cross flow path portions C' of the respective slits, and flow paths F7, F8, F9 of other various routes are also formed, the molten resin between the respective flow paths F5, F6 can also be mixed by flowing into each other. That is, each molten resin that has passed through the filter medium in the upper and lower positions can be mixed by passing through the cross portions, so that deviations in the quality of the molten resin caused by deviations in the filtration capacity of the respective filter media can be eliminated.

[0119] In particular, each flow path F5, F6 is a gentle linear route (flow path) that has little displacement in the upper and lower directions and is of uniform width over the entire length, so that the passage resistance of the molten resin can be greatly reduced.

[0120] It is understood that there are almost no obstructions within each flow path F5, F6, and a linear path of uniform width and a defined route is formed. That is, according to the present application, by forming each flow path group F5, F6 that has no deviation in the route toward the inner diameter portion, the directionality of the flow path of the molten resin can be improved, and the molten resin can be efficiently caused to flow toward the inner diameter portion by each flow path group F5, F6, and toward the discharge pipe located at the inner diameter portion.

[0121] Also, even in the flow paths F7, F8, F9 other than the main flow paths F5, F6, since the shorter routes in the radial direction are formed by alternately passing through the main flow paths F5, F6, the molten resin can also be efficiently caused to flow toward the inner diameter portion and toward the discharge pipe located at the inner diameter portion.

[0122] Other than those described above, the functions and effects are the same as those in the first embodiment, so repeated descriptions are omitted.

[0123] <Method for manufacturing the retainer according to the second embodiment>

[0124] Figures 11 to 14 This is an explanatory diagram showing the process of manufacturing the retainer 30 of the second embodiment. Figure 11 This is a plan view showing the formation of a 40A metal sheet and an 85A metal material. Figure 12 This is a plan view of the metal material 85B formed from metal sheet 40B. Figure 13 This is a plan view showing the state in which metal material 85A and metal material 85B are temporarily fixed when metal plates 40A and 40B are stacked together. Figure 14 It shows the excision site Figure 13 A plan view of the process that does not require the holding device of the state.

[0125] Figure 11 and Figure 12 The metal sheets 40A and 40B shown are identical in shape, differing only in that their slit extension directions intersect each other at 90 degrees. Besides laser processing of the metal sheets, the metal sheets 40A and 40B can also be manufactured using casting or 3D printing.

[0126] When manufacturing metal sheets 40A and 40B using laser processing, metal materials 85A and 85B, respectively, made of stainless steel plates, are used (steps for preparing metal materials 85A and 85B). Multiple straight slits 45A and 45B of the same shape, as shown in the illustration, are formed parallel to each other on the metal materials 85A and 85B, thereby forming metal sheets 40A and 40B at predetermined positions on each metal material 85A and 85B (steps for forming the first and second metal sheets). Rods (or wires) 50A, serving as flow path forming components, are located between the slits 45A, and rods (or wires) 50B are located between the slits 45B. Figure 11 , Figure 12 During the process, the ends of each bar 50A and 50B along the length direction maintain connection with the outer periphery of each metal material 85A and 85B, so they do not separate.

[0127] Next, with respect to one side of the metal sheet 40A having the same shape, one side of the metal sheet 40B is oriented as follows: Figure 13 The metal material 85A is overlapped and temporarily fixed to the metal material 85B in that alignment manner (the step of temporarily fixing the metal materials to each other). During this temporary fixing, a special positioning fixture (not shown) is used.

[0128] In this stage, each intersection C of the respective rod members constituting the two metal plates 40A, 40B is sintered to each other using a sintering means not shown, thereby fixing and integrating the two metal plates (step of integrating and fixing (sintering) the intersection C).

[0129] Next, as shown in FIG. 6, the inner and outer peripheral edge portions of the two metal plates 40A, 40B are cut and removed along the cut lines CL shown by the double-dot chain line, thereby obtaining the holder 30 in the shape of a circular ring plate as a finished product as shown in FIG. 7 (step of cutting and removing the excess portions of the respective metal materials). Figure 14 Figure 9 Next, as shown in FIG. 6, the inner and outer peripheral edge portions of the two metal plates 40A, 40B are cut and removed along the cut lines CL shown by the double-dot chain line, thereby obtaining the holder 30 in the shape of a circular ring plate as a finished product as shown in FIG. 7 (step of cutting and removing the excess portions of the respective metal materials).

[0130] Further, as with the manufacturing method of the holder 1 of the first embodiment, the manufacturing method of the holder 30 of the second embodiment is also only an example of the method of manufacturing the holder 1 using the two metal materials illustrated. That is, for example, the holder 1 of the present embodiment can also be manufactured by a casting method, a method of manufacturing using a 3D printer, a method of manufacturing using cutting processing, a method of manufacturing using powder metallurgy, or the like. That is, the holder 30 of the present embodiment can be manufactured using various manufacturing methods in addition to using the two metal materials (metal plates).

[0131] [Example of application in a vane disc filter element]

[0132] Next, Figure 15 (a) and (b) are front elevation and partial enlarged views of a vane disc filter element using the holder 1, 30 of the present application.

[0133] The vane disc filter element 100 generally includes: a holder 1, 30 composed of circular ring plate-shaped metal plates 10A, 10B (40A, 40B); a hub 104 composed of a solid metal material fixed to the center portion (center opening portion CO) of the holder; circular ring plate-shaped punched plates (perforated support plates) 106 respectively arranged on the respective outer surfaces of the upper and lower holders 1, 30, the inner diameter portions of which are welded and fixed to the hub 104; circular ring plate-shaped filter materials 108 arranged on the outer side surfaces of the respective punched plates; a ring 110 as a ring-shaped body arranged on the upper and lower surfaces of the outer periphery of the hub, which is welded and fixed to the hub in a state of sandwiching the inner diameter side outer surface of the filter material 108 between the hub; and spacers 112 arranged on the outer surface of the upper filter material 108, which are composed of a plurality of rod-shaped bodies extending in a spoke shape and a radial shape from the vicinity of the center portion. The outer diameter side end portions of the punched plates 106, the filter materials 108, and the respective spacers 112 are fixed by welding.

[0134] ​The molten resin that has passed through the filter material 108 and the punched plate 106 in this order enters the inside of the retainer 1, 30 from the outer surface thereof, passes through the flow paths Fl to F4 of the retainer 1 and the flow paths F5 to F9 of the retainer 30, and is concentrated in the center portion, and is delivered to the unillustrated discharge pipe in the center portion via the hole provided in the hub 104.

[0135] In addition, a cavity S is formed between the outer periphery of the retainer 1, 30 and the inner wall of the outer periphery of the spacer 112, and the molten resin that has passed through the filter material portion on the outside of the cavity S enters the cavity, moves to the inner diameter side in the retainer 1, 30 via the flow paths thereof, and is delivered to the unillustrated discharge pipe in the center portion via the hole provided in the hub 104. The outer diameter side end portion of each flow path is open (communicates) with respect to the cavity S, and therefore the molten resin that has passed through the filter material does not remain in the outer peripheral portion, and can flow to the inner diameter side in the retainer.

[0136] In addition, it is important that the quality of the molten resin that has passed through the filter material 108 and flows into the retainer 1, 30 is uniform, and in each metal plate material 10A, 10B (40A, 40B) that constitutes the retainer of the present application, the molten resin that has passed through each filter material in each flow path can be mixed and homogenized after confluence.

[0137] Next, Figure 16 (a) and (b) are a front longitudinal sectional view and a partially enlarged view of a leaf disc filter element 100 using a vortex type retainer 1 of a modification example of the present application. In addition, the same parts as those of Figure 15 the same are denoted by the same reference numerals, and overlapping description is omitted.

[0138] In the case of the vortex type retainer 1, the shape of the center opening portion CO can be integrally produced as the shape of the hub 104. That is, by further extending a part of the inner periphery of the center opening portion CO of the retainer to the inner diameter direction, a part of the hub 104 corresponding to Figure 15 is formed with the hub 104' composed of the flow path forming members 15A, 15B. Thereby, the entire or a part of the hub 104 can be used as the inner diameter portion of the retainer. In this case, the retainer 1 having the structure including the hub 104' can be produced in one series of production processes. At this time, the compression strength of the flow path forming members 15A, 15B that constitute the hub 104' is easily set to a sufficient degree (a degree of not being compressed and deformed) for functioning as the hub. In the existing mesh type retainer composed of a metal mesh, the shape of the center opening portion can be made to function as the hub, but the portion that becomes the hub in this case is made of a metal mesh, and therefore the compression strength is low, and compression and deformation occur, and practicality is not good.

[0139] <Summary of the structure, action, and effects of the present application>

[0140] The filter holder 1, 30 of the first invention is composed of a first metal plate 10A, 40A having a plurality of flow path forming members (rods, wires) having a prescribed curved shape or straight line shape when viewed from above arranged in parallel at prescribed intervals on the same plane in a manner that the overall shape becomes a circular ring plate shape, and a second metal plate 10B, 40B having the same structure as the first metal plate 10A, 40A, the filter holder 1, 30 having a structure in which the intersecting portions of the flow path forming members constituting each metal plate are fixed in a state in which one face of the second metal plate is superimposed on one face of the first metal plate, characterized in that the flow path forming members 15A, 50A constituting the first metal plate and the flow path forming members 15B, 50B constituting the second metal plate form a line-symmetrical shape when viewed from above.

[0141] Each metal plate has a structure in which flow path forming members having a prescribed curved shape or straight line shape when viewed from above are arranged in parallel at prescribed intervals on the same plane in a manner that the overall shape becomes a circular ring plate shape, so that a main flow path F1 to F9 can be formed on each of the two sides of the joint surface of the two metal plates as a boundary surface. There are no obstructions within each flow path F1, F2, F5, F6, and each flow path F1, F2, F5, F6 directly communicates the outer peripheral edge portion of each metal plate with the inside (center opening portion CO), so that the flowability of the molten resin toward the center portion can be improved. The flow paths F3, F4 that cross each flow path F1, F2 constituting the holder 1, and the flow paths F7, F8, F9 that cross each flow path F5, F6 constituting the holder 30, although having a thin sawtooth portion toward the thickness direction of the holder, can smoothly guide the molten resin to the center portion of the holder in a short distance close to a straight line.

[0142] Therefore, the effects of low pressure loss, high strength, and high pressure resistance can be exhibited.

[0143] In the holder 1, by providing the flow path forming members 15A, 15B as a spiral-shaped curve (bending line), and arranging each flow path forming member 15A in parallel with each other and each flow path forming member 15B in parallel with each other, the slits (flow paths) 20A, 20B formed between the flow path forming members 15A and between the flow path forming members 15B, respectively, can be provided as the same spiral shape. Each flow path forming member shown in the embodiment is narrow belt-shaped and has a uniform width when viewed from above, but this is only one example.

[0144] By arranging each flow path forming member 50A, 50B configuring the holder 30 in a straight line shape and parallel to each other, and further arranging each flow path forming member 50A, 50B in a lattice shape to each other, each slit (flow path) 45A, 45B formed between the flow path forming members 50A and 50B, respectively, can be provided in the same straight line shape. Preferably, the flow path forming members are in a narrow belt shape and have a uniform width when viewed from above.

[0145] In the concept of the flow path forming member (skeleton member), in addition to the curved or straight rod member (wire member), an elongated belt-shaped plate member is also included.

[0146] By using the filter holder as the holder (circular ring plate shape) of the leaf disc type filter, the molten resin filtered by the filter material can flow in the radial direction (radial direction, direction toward the other radial center portion) of the discharge direction of the molten resin at a stable flow rate in the leaf disc type filter type filtering device.

[0147] In addition, the molten resin filtered by the two pieces of filter material of the leaf disc type filter element and flowing into the holder will be combined after flowing into each flow path formed by the two pieces of metal plate, and thus can be mixed and homogenized in each flow path.

[0148] In addition, if the interval (width of each flow path) D1, D2, D3, D4 between each rod member is too large, the porous support plate (punched plate) located between the filter material and the holder will be deformed and cause deformation of the filter material when subjected to pressure from the molten resin passing through the filter material. On the other hand, if the interval is too small, the porosity will decrease and the resistance will increase. Although it is difficult to balance this, according to the present application, by adjusting the interval between the flow path forming members in such a way that the interval D1, D2, D3, D4 becomes an optimal value, fine adjustment can be performed. Depending on the setting of the value of the interval D1, D2, D3, D4, the filter material is directly received by the holder without the porous support plate, and thus the leaf disc type filter element can also be thinned.

[0149] By configuring the metal plate from a metal material having sufficient strength such as stainless steel, deformation caused by pressure during filtration can be suppressed, and strength, durability over time, and shape retention can be improved.

[0150] The circular ring plate shape refers to a shape having a center opening portion CO passing through the center portion of the circular plate in a concentric circle shape.

[0151] The filter holder 1 of the second application is characterized in that the flow path forming members (rod members or wire members) 15A, 15B having a predetermined curved shape are arranged in parallel in a manner forming a spiral shape when viewed from above.

[0152] The flow paths F3, F4, which are sawtooth-shaped flow paths between the flows along the spiral flow paths F1, F2 toward the center (center opening portion CO) of the circular ring-shaped holder, are formed. Each flow path is formed on the entire circumferential surface of the holder, and the flow rate and the flow volume are the same regardless of the circumferential position with respect to each flow path F1, F2, F3, F4.

[0153] The third filter holder 1, 30 of the present application is characterized in that the front and back surfaces of the flow path forming members (rods or wires) are flat surfaces.

[0154] By making the surfaces (front and back surfaces) of the flow path forming members 15A, 15B, 50A, 50B, which constitute each of the metal plates 10A, 10B, flat surfaces, the porous support plate can be stably supported on the flat surfaces.

[0155] The fourth manufacturing method of the filter holder of the present application is characterized by comprising the following steps: preparing two flat metal materials 80A, 80B, 85A, 85B; forming a plurality of slits 20A, 20B, 45A, 45B of a predetermined shape in parallel on each of the metal materials to form a first metal plate and a second metal plate in the area (plate surface) of each of the metal materials; superimposing and temporarily fixing one metal material on the other metal material in such a manner that the back surface (one surface) of the other metal material is aligned with the back surface of one metal material in a predetermined positional relationship; integrating and fixing (sintering, etc.) the intersection portions C of the flow path forming members that constitute the two metal plates; and cutting and removing the excess portions of each of the metal materials at the inner and outer peripheral edges of each of the metal plates.

[0156] Since the two metal plates have the same shape, the number of processes required to process the metal materials can be reduced. Since the sintering of the intersection portions of the flow path forming members is performed after the two processed metal materials are aligned, and then the excess portions of the metal materials are cut off, the total manufacturing processes can be greatly reduced.

[0157] The fifth manufacturing method of the filter holder of the present application is characterized by comprising the following steps: preparing two circular ring-shaped flat metal materials; forming a plurality of slits of a predetermined shape in parallel on each of the metal materials, and not opening the lengthwise ends of each of the slits, to form a first metal plate and a second metal plate in the area (plate surface) of each of the metal materials; superimposing and temporarily fixing one metal material on the other metal material in such a manner that one surface of the other metal material is aligned with one surface of one metal material in a predetermined positional relationship; integrating the intersection portions of the flow path forming members that constitute the two metal plates; and cutting and removing the excess portions of each of the metal materials at the inner and outer peripheral edges of each of the metal plates.

[0158] The fifth invention differs from the manufacturing method of the fourth invention in that the shape of the metal material prepared in advance is a circular ring shape, and the metal material needs to be processed into a circular ring shape in advance.

[0159] The manufacturing method of the filter holder of the sixth invention is characterized in that any of the filter holder 1, 30 described above is manufactured by any one of a casting method, a method of manufacturing using powder metallurgy, a method of manufacturing using a 3D printer, or a method of manufacturing using cutting processing.

[0160] That is, in addition to the use of two pieces of metal material to manufacture the holder 1, a manufacturing method using each of the above manufacturing methods can also be adopted. As a result, productivity improvement such as omission of the sintering process can be achieved.

[0161] The vane disc filter element of the seventh invention is characterized by comprising: a filter holder 1, 30; a hub 104 fixed to a central opening portion of the filter holder; a plurality of perforated support plates 106 arranged on each of the outer surfaces of the filter holder above and below; and filter materials 108 arranged on the outer side surfaces of each of the perforated support plates.

[0162] By applying the filter holder 1, 30 to the vane disc filter element, the effects of low pressure loss, high strength, and high pressure resistance can be achieved.

[0163] Explanation of symbols

[0164] 1: filter holder; 10A: first metal sheet material; 10B: second metal sheet material; 15A, 15B: flow path forming member (rod or wire); 20A, 20B: slit; F1 to F9: flow path; 30: filter holder; 40A: first metal sheet material; 40B: second metal sheet material; 45A, 45B: slit; 50A, 50B: flow path forming member (rod or wire); 80A, 80B: metal material; 85A, 85B: metal material; 100: vane disc filter element; 104: hub; 106: punched plate (perforated support plate); 108: filter material; 110: ring; 112: spacer.

Claims

1. A filter holder comprising: a first metal sheet material having a plurality of flow path forming members having a prescribed curved shape or straight line shape in plan view arranged in parallel at prescribed intervals on the same plane in a manner such that the overall shape is a circular ring plate shape; and a second metal sheet material having the same structure as the first metal sheet material, the filter holder having a structure in which the intersection portions of the flow path forming members constituting each metal sheet material are fixed to each other in a state in which one face of the first metal sheet material overlaps one face of the second metal sheet material, characterized in that: the flow path forming members constituting the first metal sheet material and the flow path forming members constituting the second metal sheet material constitute a line-symmetrical shape in plan view, each first flow path formed between the flow path forming members constituting the first metal sheet material and each second flow path formed between the flow path forming members constituting the second metal sheet material are formed as flow paths that curve or straighten from the outermost circumference to the innermost circumference without an obstacle.

2. The filter holder according to claim 1, characterized in that: the flow path forming members having a prescribed curved shape in plan view are arranged in parallel in a manner such that a spiral shape is formed.

3. The filter holder according to claim 1 or 2, characterized in that: the front surface and the back surface of the flow path forming members are flat surfaces. comprising the steps of: preparing two flat plate-shaped metal materials; forming a plurality of slits of a prescribed shape in parallel on each of the metal materials, thereby forming the first metal sheet material and the second metal sheet material in the area of each of the metal materials; superimposing and temporarily fixing one of the metal materials on the other metal material in a manner such that one face of one of the metal sheet materials is aligned with one face of the other metal sheet material in a prescribed positional relationship; integrating the intersection portions of the flow path forming members constituting the two metal sheet materials; and cutting and removing excess portions of each of the metal materials at the inner circumference and the outer circumference of each of the metal sheet materials. comprising the steps of: preparing two circular ring-shaped flat plate-shaped metal materials; forming a plurality of slits of a prescribed shape in parallel on each of the metal materials without opening both end portions in the length direction of each slit, thereby forming the first metal sheet material and the second metal sheet material in the area of each of the metal materials; superimposing and temporarily fixing one of the metal materials on the other metal material in a manner such that one face of one of the metal sheet materials is aligned with one face of the other metal sheet material in a prescribed positional relationship; integrating the intersection portions of the flow path forming members constituting the two metal sheet materials; and cutting and removing excess portions of each of the metal materials at the inner circumference and the outer circumference of each of the metal sheet materials.

6. A method of manufacturing a filter holder, characterized by: ​ ​ ​ ​ 4. A method of manufacturing a holder for a filter according to any one of claims 1 to 3, characterized by, ​ ​ ​ ​ ​ ​ ​ 5. A method of manufacturing a holder for a filter according to any one of claims 1 to 3, characterized by, ​ ​ ​ ​ ​ ​ ​ ​ The filter holder according to any one of claims 1 to 3 is manufactured by any one of a casting method, a method of manufacturing using a 3D printer, a method of manufacturing using cutting, or a method of manufacturing using powder metallurgy.

7. A leaf disc filter element characterized in that, Possesses: The filter holder according to any one of claims 1 to 3; A hub fixed to a central opening portion of the filter holder; A porous support plate disposed on each of the outer surfaces of the filter holder; And A filter medium disposed on the outer side of each porous support plate.

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