Method for manufacturing a filter unit

Abstract

A filter unit (1) is composed of a filter section (3) having a first filter (31) and a second filter (32) in a pleated shape, and a frame (4) having a pair of first frames (41) and a pair of second frames having an adhesive layer. The filter unit (1) is manufactured by overlapping the first filter (31) and the second filter (32), disposing a first support member (51) so as to be located on the opposite side of the first frame (41) with respect to a first adhesive portion (32A), disposing a second support member (52) supporting a second adhesive portion (32B) so as to be located on the opposite side of the first frame (41) with respect to the second adhesive portion (32B), fixing the first frame (41) to the first adhesive portion (32A) and the second adhesive portion (32B), and fixing the first frame (41) and the second frame.

Description

Technical Field

[0001] This invention relates to filter units and methods for manufacturing filter units. Background Technology

[0002] Conventional filtration devices are known to consist of a two-layer structure comprising a pre-filter and a filter material (e.g., Patent Document 1). In such devices, the pre-filter and filter material are bound together from above by an upper binding plate and from below by a lower binding plate to form a filter body, which is then fixed to a mounting frame. A linear protrusion is provided on the bottom surface of the mounting frame, guiding the filter body into the frame. In other embodiments, the upper and lower binding plates are configured to be approximately equal in thickness to the filter material. This allows the filter body to be held more securely by the mounting frame.

[0003] In addition, air filters that integrate the pre-filter and filter assembly using a frame are known (e.g., Patent Document 2). A seal for fixing the pre-filter to the frame is located at the upstream ends of the upper and lower surfaces of the pre-filter, and a seal for fixing the filter assembly to the frame is located at the downstream ends of the upper and lower surfaces of the filter assembly. This allows for weight reduction and simplifies filter replacement compared to a case where seals are provided across the entire surface.

[0004] Existing technical documents

[0005] Patent documents

[0006] Patent Document 1: Japanese Patent No. 6275957

[0007] Patent Document 2: Japanese Patent No. 6243146 Summary of the Invention

[0008] The problem that the invention aims to solve

[0009] However, in the filtration device described in Patent Document 1, the pre-filter and filter material are only bound at the upper and lower parts, resulting in an unstable state. Furthermore, since the filtration device is constructed by fixing the filter body, which binds the pre-filter and filter material, to the mounting frame, the number of components also increases.

[0010] In the air filter described in Patent Document 2, since the pre-filter and filter assembly are partially fixed to the frame, a strong adhesive force cannot be ensured. This may result in the seal peeling off when the filter becomes clogged, causing air to leak from the peeled area.

[0011] Furthermore, there is a desire for multi-functional, multi-layered, integrated filter units, but it is difficult to laminate soft non-woven fabrics into multiple layers and embed them seamlessly into the frame. In particular, while high filtration performance can be achieved by laminating pleated filters into multiple layers, this presents technical challenges, and new manufacturing methods are being sought.

[0012] Therefore, the object of the present invention is to provide a filter unit that can hold multiple layers of filters together in one unit.

[0013] Methods for solving problems

[0014] To address the aforementioned issues, a first invention provides a method for manufacturing a filter unit, the filter unit comprising a filter section and a frame, the filter section having at least: a first filter; and a second filter, overlapping the first filter, folded in a pleated shape with alternating peaks and valleys in the telescopic direction, having a first adhesive portion at one end in the telescopic direction and a second adhesive portion at the other end in the telescopic direction, the frame surrounding the filter section having: a pair of first frames supporting the filter section from the telescopic direction, having a first adhesive layer for bonding the filter section; and a pair of second frames supporting the filter section from a folded direction orthogonal to the telescopic direction, having a second adhesive layer for bonding the filter section, wherein the method for manufacturing the filter unit comprises... The following steps constitute: overlapping the first filter and the second filter; arranging a first support member supporting the first adhesive portion on the opposite side of the first frame relative to the first adhesive portion; arranging a second support member supporting the second adhesive portion on the opposite side of the first frame relative to the second adhesive portion; fixing the first adhesive portion and the second adhesive portion to the first adhesive layer; removing the first support member from the first adhesive portion; removing the second support member from the second adhesive portion; fixing the folded end of the first filter and the folded end of the second filter to the second adhesive layer; and fixing the first frame and the second frame.

[0015] In the second invention, according to the method for manufacturing a filter unit according to the first invention, the filter section is characterized in that, when the first filter and the second filter are overlapped, the filter section is supported by an assembly frame supported from the folded direction, the first support member and the second support member are disposed in the assembly frame in a detachable manner, and when the folded direction end of the first filter and the folded direction end of the second filter are fixed to the second adhesive layer of the second frame, the assembly frame is moved away from the filter section.

[0016] In a third invention, according to the manufacturing method of the filter unit of the first or second invention, the filter portion further comprises a third filter that overlaps the second filter and is pleated by alternating peaks and valleys in the telescopic direction. The manufacturing method of the filter unit further comprises: a step of overlapping the third filter with the first or second filter; a step of arranging a third support member supporting a third adhesive portion located at one end of the telescopic direction of the third filter in a manner opposite to the third adhesive portion on the first frame; a step of arranging a fourth support member supporting a fourth adhesive portion located at the other end of the telescopic direction of the third filter in a manner opposite to the fourth adhesive portion on the first frame; a step of fixing the third adhesive portion and the fourth adhesive portion to the first adhesive layer; a step of removing the third support member from the third adhesive portion; and a step of removing the fourth support member from the second adhesive portion.

[0017] In a fourth invention, a filter unit is provided, characterized in that it comprises a rectangular filter section and a frame surrounding the filter section, the filter section having at least: a first filter; and a second filter, overlapping the first filter, which is folded in a pleated shape by alternating peaks and valleys in a telescopic direction, the frame being configured to be separate for each side of the filter section by having a pair of first frames and a pair of second frames, the pair of first frames supporting the filter section from the telescopic direction and having a first adhesive layer for bonding the filter section, the pair of second frames supporting the filter section from a folded direction orthogonal to the telescopic direction and having a second adhesive layer for bonding the filter section, the adhesive portion of the second filter in the filter section located at the end in the telescopic direction being fixed relative to the first adhesive layer, the ends of the first filter and the second filter in the folded direction being fixed in the second adhesive layer, and the first frame and the second frame being bonded to each other.

[0018] In the fifth invention, the filter unit according to the fourth invention is characterized in that the filter section further comprises a third filter that is bent in a pleated shape by alternating peaks and valleys in the extension direction, and the first filter is disposed between the second filter and the third filter in such a way that it is held between the top of the second filter and the top of the third filter.

[0019] In the sixth invention, the filter unit according to the fourth or fifth invention is characterized in that the frame has a U-shaped cross section and has: a base for the filter portion to be bonded; a first protrusion disposed at one end of the stacking direction in which the first filter and the second filter overlap; and a second protrusion disposed at the other end of the stacking direction, wherein the first protrusion and the second protrusion have different heights from the base.

[0020] In the seventh invention, the filter unit according to any one of the fourth to sixth inventions is characterized in that the frame is made of resin and is composed of a light-transmitting material.

[0021] In the eighth invention, the filter unit according to any one of the seventh inventions is characterized in that the frame is a resin with a haze greater than 0% and less than 63%.

[0022] In the ninth invention, the filter unit according to any one of the fourth to sixth inventions is characterized in that a protective net for protecting the filter part is provided on the downstream side of the air flow direction, the compression direction end of the protective net is fixed to the first frame, and the zigzag direction end of the protective net is fixed to the second frame.

[0023] Invention Effects

[0024] According to the first invention, since the first support member supports the first adhesive portion of the second filter from the opposite side of the first frame and the second support member supports the second adhesive portion of the second filter from the opposite side of the first frame, the first frame can be fixed to the filter portion in a stable state. Because the first filter is pleated, it shrinks when the first frame is fixed to the second filter, making installation difficult. However, according to the present invention, since the second filter is supported by the first and second support members, the first frame can be fixed to the second filter in a way that prevents the second filter from shrinking. Since the first and second support members eventually separate from the first and second adhesive portions, they do not become components of the filter unit and do not affect filter performance. Because the filter portion is fixed by a first adhesive layer on the first frame, the filter portion can be stably fixed to the frame. Because the folded end of the second filter is bonded by a second adhesive layer on the second frame, the pleated second filter can be stably fixed to the second frame.

[0025] Since the filter section is held by a pair of divided first frames and a pair of second frames, even if the filter section has multiple layers, it can be held integrally by the frames in a way that keeps the layers from separating. Since the first frames and the second frames are fixed to each other, the filter section can be held more securely by the frames.

[0026] According to the second invention, since the first support member and the second support member are detachably mounted on the assembly frame, the first support member can be easily removed from the first adhesive portion and the second support member can be easily removed from the second adhesive portion. Because the assembly frame is removed from the filter portion when the folded-line end of the first filter and the folded-line end of the second filter are fixed to the second adhesive layer of the second frame, the assembly frame will not become an obstacle when the second frame is fixed to the filter portion.

[0027] According to the third invention, since the filter section also has a pleated third filter, the filtration performance of the filter unit can be further improved and its lifespan extended. Since the third support member supports the third adhesive portion of the third filter and the fourth support member supports the fourth adhesive portion of the third filter, the first frame can be fixed to the filter section in a stable state. Because the third filter is pleated, it tends to shrink when the first frame is fixed to it, making installation difficult. However, according to the present invention, since the filter section is supported by the third and fourth support members, the first frame can be fixed to the third filter in a way that prevents the third filter from shrinking. Furthermore, by using the first, second, third, and fourth support members in the assembly of the filter unit, the assembly of a filter unit with multiple pleated filters can be achieved. Since the filter section has a protective mesh on its downstream side in the airflow direction, damage to the filter section due to external forces can be suppressed. Additionally, it is possible to prevent the layers of the filter section from detaching from the frame.

[0028] According to the fourth invention, since the filter section is held by a pair of divided first frames and a pair of second frames, even if the filter section is multi-layered, the frames can be used to hold the filter section integrally in a way that prevents the layers from separating. In particular, since the frames are composed of a pair of first frames and a pair of second frames, the pleated second filter can be stably held. Since the first and second frames are fixed to each other, the frames can be used to stably hold the filter section. Since a first adhesive layer is provided on the first frame to fix the filter section, the filter section can be stably fixed to the frame. Since a second adhesive layer is provided on the second frame to bond the folded end of the second filter, the pleated second filter can be stably fixed to the second frame.

[0029] According to the fifth invention, since the first filter is held between the tops of the second filter and the tops of the third filter, the first filter will not shift within the filter section. Therefore, it is possible to suppress the formation of gaps in the first filter due to wrinkles or the like, thereby preventing a decrease in filter performance.

[0030] According to the sixth invention, since the first protrusion and the second protrusion protrude from the base, when applying adhesives or the like, the first protrusion or the second protrusion acts as a tray, thus suppressing leakage to the outside. Since the first protrusion and the second protrusion have different heights from the base, the upstream or downstream airflow direction of the filter unit can be determined based on the height of the protrusions.

[0031] According to the seventh invention, since the frame is made of resin, it possesses a certain degree of rigidity, maintaining the shape of the filter unit even under external force. Furthermore, because the frame is made of a light-transmitting material, the dirt condition of the filter section can be visually assessed from the outside. Therefore, the replacement period for the filter unit can be appropriately determined.

[0032] According to the eighth invention, since the haze of the frame is below 63%, the dirt condition of the filter can be visually confirmed from the outside. Therefore, the replacement period of the filter unit can be appropriately determined.

[0033] According to the ninth invention, since a protective mesh is provided on the downstream side of the airflow direction of the filter section, damage to the filter section due to external forces can be suppressed. Furthermore, it can prevent the layers of the filter section from detaching from the frame. Attached Figure Description

[0034] Figure 1 This is a perspective view of the filter unit of the first embodiment of the present invention assembled in an air purifier.

[0035] Figure 2 This is a front view of the filter unit according to the first embodiment of the present invention.

[0036] Figure 3 This is an exploded perspective view of the filter unit according to the first embodiment of the present invention.

[0037] Figure 4 This is a cross-sectional view of the filter unit according to the first embodiment of the present invention.

[0038] Figure 5 This is a filter unit according to the first embodiment of the present invention. Figure 5 (a) is a sectional view of the first frame. Figure 5 (b) is a sectional view of the second frame.

[0039] Figure 6 This is a flowchart of a method for manufacturing a filter unit according to the first embodiment of the present invention.

[0040] Figure 7 This is a perspective view illustrating the assembly method of the filter unit according to the first embodiment of the present invention.

[0041] Figure 8 This is a filter unit according to the first embodiment of the present invention. Figure 8 (a) is a sectional view of the second frame fixed to the front of the filter section. Figure 8 (b) is a cross-sectional view after the second frame is fixed to the filter section.

[0042] Figure 9 This is a partial enlarged view of the fixed portions of the first frame and the second frame of the filter unit according to the first embodiment of the present invention.

[0043] Figure 10 This is an exploded perspective view of the filter unit according to the second embodiment of the present invention.

[0044] Figure 11 This is a front view of the filter unit according to the third embodiment of the present invention. Detailed Implementation

[0045] based on Figures 1-9 The filter unit 1 of the first embodiment of the present invention will be described below. For example... Figure 3 As shown, the front-back, up-down, left-right directions are defined. The front-back direction corresponds to the extension / retraction direction of this invention, and the left-right direction corresponds to the zigzag direction of this invention.

[0046] Filter unit 1 is the filter mainly used in air purifier 10. Air drawn in from intake 12 by the rotation of fan 11 is filtered to remove dust, and the purified air is discharged from exhaust 13. It should be noted that filter unit 1 is not limited to air purifier 10, but can also be used in appliances such as air conditioners and robot vacuums, automobiles, air conditioning units, clean rooms, etc., and can also be used in dust collection filters and oil filters.

[0047] The filter unit 1 is approximately cuboid and consists of a filter section 3 and a frame 4 that holds the filter section 3. The filter section 3 is composed of multiple layers of filters. In the space of the air purifier 10 that houses the filter unit 1, a porous, elastic element (not shown) such as a sponge is provided, abutting against the four corners of the frame 4. By providing the elastic element, the transmission of vibrations generated by the fan 11 of the air purifier 10 to the filter unit 1 is mitigated.

[0048] like Figure 3 and Figure 4As shown, the filter section 3 consists of a pre-filter 31, a first pleated filter 32, an intermediate filter 33, a second pleated filter 34, a terminal filter 35, and a protective mesh 36. In the filter unit 1, the pre-filter 31 is upstream in the airflow direction, and the protective mesh 36 is downstream in the airflow direction. In other words, air flows from top to bottom in the filter section 3. Each filter in the filter section 3 is made of a fibrous body such as non-woven fabric or woven fabric made of fibers such as glass fiber or resin fiber.

[0049] The first-layer pre-filter 31 is a sheet-like medium-performance filter that uses a material that captures particles larger than 50 μm, i.e., coarse particles.

[0050] The first pleated filter 32, serving as the second layer, is pleated by repeatedly folding peaks and valleys in a manner that aligns folds extending in the left-right direction with those extending in the front-back direction. The first pleated filter 32, being pleated, is capable of expanding and contracting in the front-back direction. Like the pre-filter 31, the first pleated filter 32 is a medium-performance filter, ensuring sufficient dust collection and filtration area through its pleated shape. High-strength filter material is used in the first pleated filter 32, thus suppressing breakage and damage. The first pleated filter 32 has a first adhesive portion 32A as its front end and a second adhesive portion 32B as its rear end.

[0051] The intermediate filter 33, serving as the third layer, is a sheet-like HEPA filter made of material that captures particles larger than 0.3μm. It utilizes filters used in many fields, including semiconductors, LCDs, pharmaceuticals, and food manufacturing, and can handle cleanroom conditions ranging from Class 100 to 10,000. The intermediate filter 33 can also capture PM2.5.

[0052] The second pleated filter 34, serving as the fourth layer, has a structure substantially the same as the first pleated filter 32 and is made of substantially the same material. The second pleated filter 34 has a third adhesive portion 34A as its front end and a fourth adhesive portion 34B as its rear end. The terminal filter 35, serving as the fifth layer, is a HEPA filter identical to the intermediate filter 33 and is made of substantially the same material. The protective mesh 36 is a mesh used to prevent the filter layers from falling from the pre-filter 31 to the terminal filter 35. The protective mesh 36 is located on the downstream side in the airflow direction and is made of a mesh-shaped, elastic resin. The first adhesive portion 32A, the second adhesive portion 32B, the third adhesive portion 34A, and the fourth adhesive portion 34B correspond to the adhesive portions of this invention.

[0053] The filters constituting filter section 3 are not limited to those described above, and any type of filter can be used. For example, a ULPA filter that captures 0.1 μm particles can be used on any of the first to fifth layers, or a non-woven fabric filter that deactivates viruses can be used on any of the first to fifth layers. The high-performance filter is preferably located downstream in the flow direction, and the virus-deactivating filter is preferably located in the middle. Furthermore, if a pleated filter is used on at least one layer of filter section 3, the number of layers is not limited to this. For example, it can be set arbitrarily from 2 to 5 or more layers. Moreover, the shape is not limited to a cuboid and can also be cylindrical. The pre-filter 31 or intermediate filter 33 is an example of the first filter of the present invention, the first pleated filter 32 is an example of the second filter of the present invention, and the second pleated filter 34 is an example of the third filter of the present invention.

[0054] The frame 4 is composed of a pair of first frames 41 and a pair of second frames 42. The frame 4 is made of rigid and translucent polypropylene resin, but is not limited to this; any material can be selected. For example, polyethylene, polyvinyl chloride, polyethylene terephthalate, cellulose-based plastics, polystyrene, polycarbonate, polyvinyl alcohol, etc., can be used. The blurring rate, i.e., haze, of the frame 4 is preferably 63% or less (more specifically, 62.4% or less). The frame 4 can be made of a resin with high transparency and a haze greater than 0%.

[0055] like Figure 3 As shown, the cross-section of the first frame 41 is approximately U-shaped, and the first frame 41 holds the filter section 3 in the front-to-back direction. Figure 5 As shown in (a), the first frame 41 has a first adhesive layer 41A, a base 43 for bonding the filter portion 3, a first protrusion 44 at one end of the base 43, and a second protrusion 45 at the other end of the base 43. The first protrusion 44 protrudes higher than the second protrusion 45. The first adhesive layer 41A is provided in a manner that covers the base 43, but is not limited thereto, as long as it is provided in a manner that covers at least a portion of the base 43.

[0056] like Figure 3 As shown, the cross-section of the second frame 42 is approximately U-shaped, and the second frame 42 holds the filter section 3 from the left and right directions. Figure 5 As shown in (b), the second frame 42 has a second adhesive layer 42A, a base 46 for bonding the filter section 3, a first protrusion 47 at one end of the base 46, and a second protrusion 48 at the other end of the base 46. The first protrusion 47 protrudes higher than the second protrusion 48. The second adhesive layer 42A is provided to cover the base 46, but is not limited thereto, as long as it is provided to cover at least a portion of the base 46.

[0057] Next, refer to Figure 6and Figure 7 The assembly method of filter unit 1 will be explained below. Filter unit 1 is assembled using an assembly frame 5 when the layers are overlapped and fixed to the frame 4. The assembly frame 5 has a pair of side walls 50, a first support member 51, a second support member 52, a third support member 53, a fourth support member 54, and rubber bands 55. The length of the side walls 50 in the front-to-back direction is approximately the same as the length of the filter section 3 in the front-to-back direction. Rubber bands 55 are provided on each side wall 50.

[0058] The third support member 53 is a thin, flat plate. Its vertical height is shorter than the interval between the folds of the second pleated filter 34, and its horizontal width is longer than the interval between the sidewalls 50. The operator hooks the rubber bands 55 on both sides onto the parts of the third support member 53 that protrude from the sidewalls 50. Thus, the third support member 53 is fixed to the lower front part (S1) of the sidewalls 50.

[0059] The fourth support member 54 has a shape approximately the same as the third support member 53, with both ends protruding from the side wall 50 in the left and right directions. The operator hooks the rubber bands 55 on both sides onto the parts of the fourth support member 54 that protrude from the side wall 50 in the left and right directions. Thus, the fourth support member 54 is fixed to the lower rear part of the side wall 50. Figure 7 As shown in (a), the operator places a protective net 36 in the assembly space 5a of the assembly frame 5.

[0060] like Figure 7 As shown in (b), the operator overlaps the terminal filter 35 on the protective net 36 and places the second pleated filter 34 on it (S2). At this time, the second pleated filter 34 is placed in such a way that the third adhesive part 34A is hooked to the third support member 53 and the fourth adhesive part 34B is hooked to the fourth support member 54. In other words, the third support member 53 is located behind the third adhesive part 34A, and the fourth support member 54 is located in front of the fourth adhesive part 34B. That is, the third support member 53 is located on the opposite side of the first frame 41 relative to the third adhesive part 34A, and the fourth support member 54 is located on the opposite side of the first frame 41 relative to the fourth adhesive part 34B.

[0061] The operator positions the first support member 51 directly above the third support member 53 and secures it to the side wall 50 using rubber bands 55. The operator also positions the second support member 52 directly above the fourth support member 54 and secures it to the side wall 50 using rubber bands 55 (S3). Specifically, similar to the third support member 53, the operator hooks the rubber bands 55 on both sides to the portions of the first and second support members 51 and 52 that protrude from the side wall 50 to the left and right. The operator then overlaps the intermediate filter 33 onto the second pleated filter 34 and places the first pleated filter 32 on the intermediate filter 33 (S4).

[0062] like Figure 7 As shown in (c), the first pleated filter 32 is mounted such that the first adhesive part 32A is hooked onto the first support member 51 and the second adhesive part 32B is hooked onto the second support member 52. In other words, the first support member 51 is located behind the first adhesive part 32A, and the second support member 52 is located in front of the second adhesive part 32B. That is, the first support member 51 is located on the opposite side of the first frame 41 relative to the first adhesive part 32A, and the second support member 52 is located on the opposite side of the first frame 41 relative to the second adhesive part 32B. At this time, as Figure 4 As shown in the enlarged view enclosed by a single-dotted line, the intermediate filter 33 is sandwiched between the first top 32C of the first pleated filter 32 and the second top 34C of the second pleated filter 34. In other words, the first top 32C is positioned in a generally straight line with a gap between it and the second top 34C, and the intermediate filter 33 is disposed between them.

[0063] The operator overlaps the pre-filter 31 on the first pleated filter 32, pressing the first frame 41 toward the filter section 3 such that the first adhesive portion 32A, the third adhesive portion 34A, and the first adhesive layer 41A abut against each other (S5). At this time, the first frame 41 is bonded to the filter section 3 with the first protrusion 44 of the first frame 41 positioned on the upper side. The filter section 3 is made of non-woven fabric, and therefore has flexibility. It will deform if pressed forcefully, but because it is supported from the back by the first support member 51 and the third support member 53, even a multi-layered filter can be held together by the first frame 41. In addition, since the intermediate filter 33 is held between the first pleated filter 32 and the second pleated filter 34, poor adhesion of the intermediate filter 33 can be prevented. Since the intermediate filter 33 is an intermediate layer, poor adhesion due to lifting can easily occur between the end face of the intermediate filter 33 and the first adhesive layer 41A. However, since the intermediate filter 33 is fixed by being held between the first pleated filter 32 and the second pleated filter 34, it can be firmly bonded to the first adhesive layer 41A.

[0064] The operator presses the first frame 41 onto the filter section 3 such that the second adhesive portion 32B and the fourth adhesive portion 34B abut against the first adhesive layer 41A. Similarly, the first frame 41 is bonded to the filter section 3 with the first protrusion 44 of the first frame 41 positioned on the upper side. The filter section 3 is made of non-woven fabric and is therefore flexible; it will deform under strong pressure, but because it is supported by the second support member 52 and the fourth support member 54, even a multi-layered filter can be held together integrally by the first frame 41. It should be noted that adhesive can also be applied to at least one side of the filter side and the first frame 41, instead of the first adhesive layer 41A.

[0065] like Figure 7 As shown in (d), after the first frame 41 and the filter part 3 are fixed, the first support member 51, the second support member 52, the third support member 53 and the fourth support member 54 are removed from the side wall 50 (S6).

[0066] The operator moves the side wall 50 away from the filter section 3 and presses the second frame 42 toward the filter section 3 from the left and right directions (S7). Figure 8 As shown in (a), the filter section 3 is brought closer to the second frame 42, as shown in (a). Figure 8 (b) Insert the left and right ends of the filter section 3 into the second adhesive layer 42A as shown. At this time, as shown... Figure 9 As shown, the abutting portions of the first frame 41 and the second frame 42 are bonded together at their end faces at approximately 45° relative to the length direction. Thus, as... Figure 2 The filter unit 1 shown is now complete.

[0067] With this structure, since the first support member 51 supports the first adhesive portion 32A of the first pleated filter 32 from the opposite side of the first frame 41 and the second support member 52 supports the second adhesive portion 32B of the first pleated filter 32 from the opposite side of the first frame 41, the first frame 41 can be stably fixed to the filter portion 3. Because the first pleated filter 32 is pleated, it tends to shrink when the first frame 41 is fixed to it, making installation difficult. However, according to the present invention, since the first pleated filter 32 is supported by the first support member 51 and the second support member 52, the first frame 41 can be fixed to it without shrinking. Since the first support member 51 and the second support member 52 eventually separate from the first adhesive portion 32A and the second adhesive portion 32B, they do not become components of the filter unit 1 and do not affect the filter performance. Because the first adhesive layer 41A is provided on the first frame 41 to fix the filter portion 3, the filter portion 3 can be stably fixed to the frame 4. Since the second adhesive layer 42A is provided on the second frame 42 to bond the folded end of the first pleated filter 32, the pleated first pleated filter 32 can be stably fixed to the second frame 42.

[0068] Since the filter section 3 is held by a pair of divided first frames 41 and a pair of second frames 42, even if the filter section 3 is multi-layered, it can be held integrally by the frames 4 in a way that prevents the layers from separating. Since the first frames 41 and the second frames 42 are fixed to each other, the filter section 3 can be held more securely by the frames 4.

[0069] With this structure, since the first support member 51 and the second support member 52 are detachably mounted on the assembly frame 5, the first support member 51 can be easily removed from the first adhesive portion 32A and the second support member 52 can be easily removed from the second adhesive portion 32B. Because the assembly frame 5 is removed from the filter portion 3 when the folded end of the pre-filter 31 or intermediate filter 33 and the folded end of the first pleated filter 32 are fixed to the second adhesive layer 42A of the second frame 42, the assembly frame 5 will not become an obstacle when the second frame 42 is fixed to the filter portion 3.

[0070] With this structure, since the filter section 3 also has a pleated second pleated filter 34, the filtration performance of the filter unit 1 can be further improved and its lifespan extended. Because the third support member 53 supports the third adhesive portion 34A of the second pleated filter 34 and the fourth support member 54 supports the fourth adhesive portion 34B of the second pleated filter 34, the first frame 41 can be fixed to the filter section 3 in a stable state. Since the second pleated filter 34 is pleated, it tends to shrink when the first frame 41 is fixed to it, making installation difficult. However, according to the present invention, since the filter section 3 is supported by the third support member 53 and the fourth support member 54, the first frame 41 can be fixed to the second pleated filter 34 without shrinking it. Furthermore, by using the first support member 51, the second support member 52, the third support member 53, and the fourth support member 54 in the assembly of the filter unit 1, the assembly of a filter unit having multiple pleated filters can be achieved. Because the filter section 3 has a protective mesh 36 on the downstream side in the airflow direction, damage to the filter section 3 due to external forces can be suppressed. In addition, it can prevent the layers of the filter section 3 from falling off the frame 4.

[0071] With this structure, since an elastic element is provided in the space where the filter unit 1 is housed in the air purifier 10, even if there is a slight gap when the filter unit 1 is installed in the air purifier 10, the elastic element will fill the gap and prevent loosening. In addition, it can prevent vibrations from the motor and the like from being directly transmitted to the filter unit 1.

[0072] With this structure, since the filter section 3 is held by a pair of divided first frames 41 and a pair of second frames 42, even if the filter section 3 is multi-layered, it can be integrally held by the frame 4 in a way that prevents the layers from separating. In particular, since the frame 4 is composed of a pair of first frames 41 and a pair of second frames 42, it can stably hold the pleated first pleated filter 32. Since the first frames 41 and the second frames 42 are fixed to each other, the frame 4 can stably hold the filter section 3. Since the first adhesive layer 41A is provided on the first frame 41 to fix the filter section 3, the filter section 3 can be stably fixed. Since the second adhesive layer 42A is provided on the second frame 42 to bond the folded end of the first pleated filter 32, the first pleated filter 32 can be stably fixed to the second frame 42.

[0073] With this structure, since the intermediate filter 33 is held between the first top 32C of the first pleated filter 32 and the second top 34C of the second pleated filter 34, the intermediate filter 33 will not shift within the filter section 3. Therefore, it is possible to suppress the formation of gaps in the intermediate filter 33 due to wrinkles or the like, thereby preventing a decrease in filter performance.

[0074] With this structure, since the first protrusion 44 and the second protrusion 45 protrude from the base 46 of the first frame 41, the first protrusion 44 or the second protrusion 45 acts as a tray when applying adhesives, etc., thus preventing leakage to the outside. Since the first protrusion 44 and the second protrusion 45 have different heights from the base 43, the upstream or downstream airflow direction of the filter unit can be determined based on the height of the protrusions.

[0075] Based on this structure, the frame 4, being made of resin, possesses a certain degree of rigidity, maintaining the shape of the filter unit 1 even under external force. Furthermore, since the frame 4 is made of a light-transmitting material, the dirt condition of the filter section 3 can be visually inspected from the outside. Therefore, the replacement period for the filter unit 1 can be appropriately determined.

[0076] With this structure, since the haze of the frame 4 is below 63%, the dirt status of the filter unit 1 can be visually confirmed from the outside. Therefore, the replacement period for the filter unit 1 can be appropriately determined.

[0077] With this structure, since a protective mesh 36 is provided at the downstream end of the airflow direction of the filter section 3, damage to the filter section 3 due to external forces can be suppressed. In addition, it can prevent the layers of the filter section 3 from falling off the frame 4.

[0078] Next, refer to Figure 10The second embodiment of the present invention will now be described. Structures identical to those in the embodiments described above will be labeled with the same reference numerals and their descriptions will be omitted.

[0079] The filter unit 1 of the first embodiment consists of 5 layers, while the filter unit 101 of the second embodiment consists of 2 layers. The filter section 103 of the filter unit 101 of the second embodiment includes a pre-filter 31, a first pleated filter 32, and a protective mesh 36.

[0080] The frame 104 is composed of a first frame 141 and a second frame 142. The vertical height of the frame 104 is slightly higher than the height of the filter section 103. The structure of the frame 104 is substantially the same as that of the frame 4 in the first embodiment, so detailed description is omitted.

[0081] When assembling the filter unit 101, only the first support member 51 and the second support member 52 are used to fix the frame 104 to the filter section 103. The assembly method is substantially the same as that of the first embodiment, so detailed description is omitted.

[0082] With this structure, a filter unit 101 can be realized that integrates the first pleated filter 32 and the pre-filter 31, maintaining their pleated shape in one piece.

[0083] Next, refer to Figure 11 The third embodiment of the present invention will now be described. Structures identical to those in the embodiments described above will be labeled with the same reference numerals and their descriptions will be omitted.

[0084] In the third embodiment, the filter unit 201 has elastic members 202 at the four corners of the frame 4. Therefore, when the filter unit 201 is installed in the air purifier 10, even if there are slight gaps, the elastic members 202 will fill those gaps, preventing loosening. Furthermore, it prevents vibrations from the motor, etc., from being directly transmitted to the filter unit 201.

[0085] The filter unit and the method for manufacturing the filter unit of the present invention are not limited to the above-described embodiments, and various modifications can be made within the scope of the spirit of the invention as described in the claims.

[0086] Label Explanation

[0087] 1, 101, 201 filter units

[0088] 3. Filter section

[0089] 4. Frame

[0090] 5 Assembly Frame

[0091] 31 Pre-filter

[0092] 32 First fold filter

[0093] 32A First Adhesive Section

[0094] 32B Second Adhesive Section

[0095] 32C First Top

[0096] 33 Intermediate Filter

[0097] 34 Second fold filter

[0098] 34A Third Adhesive Section

[0099] 34B Fourth Paste Section

[0100] 34C Second Top

[0101] 35 Terminal Filter

[0102] 36 protective nets

[0103] 41 First frame

[0104] 41A First adhesive layer

[0105] 42 Second frame

[0106] 42A Second Adhesive Layer

[0107] 43, 46 Base

[0108] 44, 47 First protrusion

[0109] 45, 48 Second protrusion

[0110] 50 sidewalls

[0111] 51 First Support Component

[0112] 52 Second support member

[0113] 53 Third support component

[0114] 54 Fourth Support Component

[0115] 55 rubber bands

Claims

1. A method for manufacturing a filter unit, The filter unit comprises a filter section and a frame. The filter section includes at least: a first filter; and a second filter, overlapping the first filter, which is pleated by alternating peaks and valleys in the telescopic direction, and has a first adhesive portion at one end in the telescopic direction and a second adhesive portion at the other end in the telescopic direction. The frame surrounds the filter section and includes: a pair of first frames supporting the filter section from the telescopic direction and having a first adhesive layer for bonding the filter section; and a pair of second frames supporting the filter section from a folded direction orthogonal to the telescopic direction and having a second adhesive layer for bonding the filter section. in, The method for manufacturing the filter unit comprises the following steps: The step of overlapping the first filter and the second filter; The step of configuring the first support member supporting the first adhesive part in such a way that it is located on the opposite side of the first frame relative to the first adhesive part; The step of configuring the second support member supporting the second adhesive part in such a way that it is located on the opposite side of the first frame relative to the second adhesive part; The step of fixing the first adhesive part and the second adhesive part to the first adhesive layer; The step of separating the first support member from the first adhesive portion; The step of separating the second support member from the second adhesive portion; The step of fixing the folded end of the first filter and the folded end of the second filter to the second adhesive layer; and The step of fixing the first frame to the second frame.

2. The method for manufacturing a filter unit according to claim 1, characterized in that, The filter section is supported by an assembly frame that supports the first filter and the second filter when the first filter and the second filter are overlapped. The first support member and the second support member are detachably mounted on the assembly frame. When fixing the folded end of the first filter and the folded end of the second filter to the second adhesive layer of the second frame, the assembly frame is separated from the filter section.

3. The method for manufacturing a filter unit according to claim 1 or 2, characterized in that, The filter section also includes a third filter and a protective mesh. The third filter overlaps the second filter and is pleated by alternating peaks and valleys in the expansion and contraction direction. The method for manufacturing the filter unit further includes: The step of overlapping the third filter with the first filter or the second filter; The step of placing the protective net on the downstream side of the airflow direction; The step of configuring a third support member that supports a third adhesive portion located at one end of the telescopic direction of the third filter in such a way that it is located on the opposite side of the first frame relative to the third adhesive portion; The step of configuring a fourth support member that supports the fourth adhesive portion located at the other end of the telescopic direction of the third filter in such a way that it is located on the opposite side of the first frame relative to the fourth adhesive portion; The step of fixing the third adhesive part, the fourth adhesive part and the telescopic end of the protective net to the first adhesive layer; The step of separating the third support member from the third adhesive portion; The step of separating the fourth support member from the second adhesive portion; and The step of fixing the zigzag-direction end of the third filter and the zigzag-direction end of the protective mesh to the second adhesive layer.

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