Filter, filter unit, and multi-filter unit

Abstract

A filter unit (200) is provided with a plurality of pleat filters (210) and a frame section (220). In a filter comprising the plurality of pleat filters (210), primary pleats, which are pleated unevenness, and secondary pleats, which are pleated unevenness having a larger pitch than the primary pleats, are formed so as to overlap each other. Preferably, the direction along the crease of the primary pleat is orthogonal to the direction along the crease of the secondary pleat.

Description

Technical Field

[0001] This disclosure relates to filters, filter units, and multiple filter units. Background Technology

[0002] In the past, there have been filters used to filter fluids, namely gases such as air and liquids such as water.

[0003] For this type of filter, a larger area used for fluid filtration (hereinafter referred to as "effective area") results in a lower flow rate per unit area, thus reducing the proportion of particles that are to be removed from passing through the filter, which is therefore preferable. However, if the area of ​​the filter is increased while maintaining its planar shape, the size of the filter will increase proportionally to the increase in the effective area, which is often not preferable depending on the application of the filter.

[0004] Therefore, in order to suppress the size of the filter and easily expand its effective area, there are filters that are bent in a serrated shape to form a pleated shape (see, for example, Patent Document 1).

[0005] Patent Document 1: Japanese Patent Application Publication No. 64-18413.

[0006] While this type of pleated filter makes it easier to increase the effective area compared to a flat filter, it is still insufficient; a filter that can easily further increase the effective area is needed. Summary of the Invention

[0007] The subject of this disclosure is that it is easy to increase the effective area of ​​the filter.

[0008] To address the aforementioned issues, the invention described in technical solution 1 is a filter, wherein...

[0009] It is formed by overlapping a primary fold, which is a fold-like concave-convex shape, and a secondary fold, which is a fold-like concave-convex shape with a larger spacing than the primary fold.

[0010] The invention described in technical solution 2 is the filter described in technical solution 1, wherein,

[0011] The direction of the crease along the first fold is perpendicular to the direction of the crease along the second fold.

[0012] The invention described in technical solution 3 is the filter described in technical solution 1, wherein,

[0013] The direction of the crease along the first fold is parallel to the direction of the crease along the second fold.

[0014] The invention described in technical solution 4 is the filter described in technical solution 1, wherein,

[0015] The aforementioned folds are formed in parallel creases.

[0016] The invention described in technical solution 5 is the filter described in technical solution 1, wherein,

[0017] When viewed from a direction orthogonal to the crease of the first fold, the multiple filter papers with the first fold are connected alternately at one end and the other end, thereby forming the second fold.

[0018] The invention described in technical solution 6 is the filter described in technical solution 1, wherein,

[0019] The creases of the first fold formed on the adjacent fold surfaces of the second fold are parallel.

[0020] The invention described in technical solution 7 is the filter described in technical solution 1, wherein,

[0021] The filter paper with the above-mentioned folds is attached with a fastener to fix the filter paper in a folded state.

[0022] The invention described in technical solution 8 is a filter described in technical solution 6, wherein,

[0023] The height of the aforementioned fold is less than 2mm.

[0024] The invention described in technical solution 9 is the filter described in technical solution 7, wherein,

[0025] The aforementioned fasteners are formed of thermoplastic resin.

[0026] The invention described in technical solution 10 is the filter described in technical solution 7, wherein,

[0027] The aforementioned fastener is a thin film.

[0028] The invention described in technical solution 11 is the filter described in technical solution 7, wherein,

[0029] The aforementioned fastener is formed as a plurality of strips spaced apart along the direction of the crease of the aforementioned first fold.

[0030] The invention described in technical solution 12 is the filter described in technical solution 7, wherein,

[0031] The filter paper and the fastener are subjected to point-like pressure.

[0032] The invention described in technical solution 13 is the filter described in technical solution 1, wherein,

[0033] Multiple filter papers with the aforementioned primary folds and multiple flat filter papers are alternately connected at one end and the other end to form the aforementioned secondary folds.

[0034] The invention described in technical solution 14 is the filter described in technical solution 1, wherein,

[0035] An adsorbent is attached to multiple filter papers that have the aforementioned pleats.

[0036] The invention described in technical solution 15 is a filter unit, wherein it comprises:

[0037] The filter described in any one of technical solutions 1 to 14; and

[0038] Installed on the frame of the aforementioned filter.

[0039] The invention described in technical solution 16 is the filter unit described in technical solution 15, wherein,

[0040] The direction in which the fluid is introduced into the frame is along the crease of the first fold.

[0041] The invention described in technical solution 17 is the filter unit described in technical solution 15, wherein,

[0042] The aforementioned frame portion includes: a fluid inlet portion, which is an inlet portion for introducing fluid into the frame portion; and a fluid outlet portion, which is an outlet portion for discharging fluid out of the frame portion.

[0043] The filter is configured such that the creases of the secondary pleats face the fluid inlet or the fluid outlet.

[0044] The invention described in technical solution 18 is the filter unit described in technical solution 17, wherein,

[0045] The frame portion includes a first plate-shaped component and a second plate-shaped component. The first plate-shaped component and the second plate-shaped component are plate-shaped components arranged in opposite positions to connect the fluid inlet portion and the fluid outlet portion. All the pleated surfaces of the secondary pleats are connected to the first plate-shaped component and the second plate-shaped component.

[0046] The invention described in technical solution 19 is the filter unit described in technical solution 18, wherein,

[0047] The aforementioned frame includes:

[0048] A third plate-shaped component connects one end of the first plate-shaped component and one end of the second plate-shaped component; and

[0049] The fourth plate-shaped component connects the other end of the first plate-shaped component and the other end of the second plate-shaped component.

[0050] One end of the filter that is not connected to the first or second plate-shaped component is connected to the third plate-shaped component.

[0051] The other end of the filter that is not connected to the first plate-shaped component or the second plate-shaped component is connected to the fourth plate-shaped component.

[0052] The invention described in technical solution 20 is the filter unit described in technical solution 15, wherein,

[0053] It has a connecting component that connects the creases of the aforementioned secondary folds to each other.

[0054] The invention described in technical solution 21 is the filter unit described in technical solution 15, wherein,

[0055] It has a separator that separates the folded surfaces of the above-mentioned secondary folds.

[0056] The invention described in technical solution 22 is the filter unit described in technical solution 21, wherein,

[0057] The aforementioned spacers are formed in the form of plates or filaments.

[0058] The invention described in technical solution 23 is the filter unit described in technical solution 21, wherein,

[0059] The aforementioned isolation components are flexible.

[0060] The invention described in technical solution 24 is the filter unit described in technical solution 17, wherein,

[0061] It includes a circular plate, which is a plate-shaped component that protrudes from the frame portion and has a circular shape when viewed from the fluid inlet or fluid outlet side.

[0062] The invention described in technical solution 25 is a multi-filter unit, wherein

[0063] The filter unit is connected to multiple technical solutions 14.

[0064] According to this disclosure, the effective area of ​​the filter can be easily increased. Attached Figure Description

[0065] Figure 1 This is a perspective view of the pleated filter according to the first embodiment.

[0066] Figure 2 This is a perspective view of the filter unit according to the first embodiment.

[0067] Figure 3 yes Figure 2 Sectional view of section III-III.

[0068] Figure 4 This is a top view of the filter paper according to the first embodiment.

[0069] Figure 5 This is a flowchart illustrating the filter unit manufacturing method according to the first embodiment.

[0070] Figure 6 This is a schematic diagram illustrating the filter unit manufacturing system according to the first embodiment.

[0071] Figure 7 This is a perspective view of the compression filter according to the first embodiment.

[0072] Figure 8 This diagram illustrates a compression filter manufacturing apparatus according to the filter unit manufacturing system of the first embodiment. Furthermore, the scale is not uniform; the first and second gears of the folding device are shown smaller than the others. Additionally, the diagram shows the folding device with its baffle open.

[0073] Figure 9 This diagram illustrates the arrangement of the compression filters in the compression filter arrangement step of the filter unit manufacturing method according to the first embodiment.

[0074] Figure 10 This is a top view showing the state in which the right and left plates are installed in the right and left plate installation process of the filter unit manufacturing method according to the first embodiment.

[0075] Figure 11 This is a top view showing the state in which the distance between the right plate and the left plate is widened during the opening process of the filter unit manufacturing method according to the first embodiment.

[0076] Figure 12 This is a diagram illustrating a simplified compression filter manufacturing apparatus according to a variation of the first embodiment.

[0077] Figure 13A The diagram shows a method for manufacturing a compression filter using a simplified compression filter manufacturing apparatus according to a variation of the first embodiment, and shows the state in which filter paper is arranged in the compression section.

[0078] Figure 13B This diagram illustrates a method for manufacturing a compression filter using a simplified compression filter manufacturing apparatus according to a variation of the first embodiment, and shows the state in which the compression of the filter paper has begun within the compression section.

[0079] Figure 13C This diagram illustrates a method for manufacturing a compressed filter using a simplified compressed filter manufacturing apparatus according to a variation of the first embodiment, and shows the state in which the filter paper has been compressed within the compression section.

[0080] Figure 13D The diagram illustrates a method for manufacturing a compression filter using a simplified compression filter manufacturing apparatus according to a variation of the first embodiment, and shows the state in which the baffle of the first gate is opened and the filter paper is fed to the temporary bonding section.

[0081] Figure 14A This is a side view showing another example of the compression section of a simplified compression filter manufacturing apparatus according to a variation of the first embodiment.

[0082] Figure 14B This is a top view showing another example of the compression section of a simplified compression filter manufacturing apparatus according to a variation of the first embodiment.

[0083] Figure 14C This is a front view showing another example of the compression section of a simplified compression filter manufacturing apparatus according to a variation of the first embodiment.

[0084] Figure 15 This is a perspective view of the multi-filter unit involved in the first embodiment.

[0085] Figure 16 This is a diagram illustrating a method for performing a compression test on the compression filter according to the first embodiment.

[0086] Figure 17 This is a perspective view of a multi-stage inclined compression filter with left and right plates according to the first embodiment.

[0087] Figure 18 This is a perspective view of a multi-stage parallel compression filter with left and right plates according to the first embodiment.

[0088] Figure 19 This is a perspective view of a filter unit manufactured from the multi-stage parallel compression filter with left and right plates according to the first embodiment.

[0089] Figure 20 This is a diagram showing the oscillating device included in the filter unit manufacturing system according to the first embodiment.

[0090] Figure 21 This diagram shows the state in which the filter unit manufacturing system according to the first embodiment includes a swing device.

[0091] Figure 22AThis diagram illustrates the folding method of the filter paper in the folding device of the filter unit manufacturing system according to the first embodiment, and shows the case where the thickness of the filter paper is approximately half of the belt spacing. Furthermore, for ease of explanation, the belt spacing is set to be constant.

[0092] Figure 22B This diagram illustrates the folding method of the filter paper in the folding device of the filter unit manufacturing system according to the first embodiment, and shows a case where the thickness of the filter paper is significantly smaller compared to the belt spacing. Furthermore, for ease of explanation, the belt spacing is set to constant.

[0093] Figure 23 This is a perspective view of the single-piece filter according to the second embodiment.

[0094] Figure 24 This is a perspective view of the multiple filters involved in the second embodiment.

[0095] Figure 25 This is a perspective view of the filter unit according to the second embodiment.

[0096] Figure 26 yes Figure 25 Sectional view of XXVI-XXVI section.

[0097] Figure 27 yes Figure 25 Sectional view of parts XXVII-XXVII.

[0098] Figure 28 This is a flowchart illustrating the filter unit manufacturing method according to the second embodiment.

[0099] Figure 29 This is a perspective view of the membrane-coated monolithic filter according to the second embodiment.

[0100] Figure 30 This is a perspective view of a multi-stage parallel compression filter with left and right plates according to the second embodiment.

[0101] Figure 31A This is an enlarged view of a portion near the right end of the front surface of the filter unit according to the second embodiment.

[0102] Figure 31B yes Figure 31A A sectional view of the bb section.

[0103] Figure 32 This is a perspective view of the filter unit according to the third embodiment.

[0104] Figure 33 yes Figure 32 Sectional view of XXXIII-XXXIII.

[0105] Figure 34 yes Figure 32 A sectional view of section XXXIV-XXXIV.

[0106] Figure 35 This is a flowchart illustrating the filter unit manufacturing method according to the third embodiment.

[0107] Figure 36 This is a side view of the compressed filter after the grouping process in the filter unit manufacturing method according to the third embodiment.

[0108] Figure 37 This is a side view of the compressed filter after the compressed filter arrangement process in the filter unit manufacturing method according to the third embodiment.

[0109] Figure 38 This is a side view of the compressed filter after the installation process of the right opening frame and the left opening frame in the filter unit manufacturing method according to the third embodiment.

[0110] Figure 39 This is a diagram showing the compression filter manufacturing apparatus according to the fourth embodiment.

[0111] Figure 40 This is a flowchart illustrating the method for manufacturing a micro-pleated filter according to the fourth embodiment.

[0112] Figure 41 This is a cross-sectional view of a portion of a pressurized micropleated filter in an example of a fixed step in the filter unit manufacturing method according to the fourth embodiment, taken at a section parallel to the XZ plane.

[0113] Figure 42 This is a cross-sectional view with the XZ plane showing the state of a portion of a micro-pleated filter in an example of the fixing process of the filter unit manufacturing method according to the fourth embodiment, where a thin film is attached.

[0114] Figure 43 This is a top view showing a portion of a micro-pleated filter in the case of a film being attached, as an example of the fixing process in the filter unit manufacturing method according to the fourth embodiment.

[0115] Figure 44 This is a cross-sectional view of a portion of the front surface of the filter unit according to the fifth embodiment, near the upper left end, parallel to the WH plane.

[0116] Figure 45 This is a flowchart illustrating the filter unit manufacturing method according to the fifth embodiment.

[0117] Figure 46A This is a side view of a portion of the finned pleated filter according to the fifth embodiment.

[0118] Figure 46B This is a top view of a portion of the finned pleated filter according to the fifth embodiment.

[0119] Figure 47 This is a cross-sectional view of a portion of the front surface of the filter unit near the upper left end, parallel to the WH plane, according to a variation of the fifth embodiment, Example 1.

[0120] Figure 48 This is a perspective view of the filter unit involved in Modification 2 of the fifth embodiment.

[0121] Figure 49 This is a cross-sectional view of a portion of the flow path of the filter unit according to the fifth embodiment, parallel to the WH plane.

[0122] Figure 50 This is a cross-sectional view of a portion of the flow path of an existing filter unit used in cross-flow filtering.

[0123] Figure 51 This is a cross-sectional view of a modified example of a filter unit with reinforcing members installed at the front and rear and disposed within a pipe, parallel to the DH plane.

[0124] Figure 52 This is a side view of a modified example of a pleated filter with rubber ropes installed on its upper and lower surfaces.

[0125] Figure 53 This is a cross-sectional view of a modified filter unit having spheres as spacing assurance parts between the folded surfaces, parallel to the WH plane. Detailed Implementation

[0126] The following is based on Figures 1 to 53 The embodiments of this disclosure will be described. However, the technical scope of this disclosure is not limited to the illustrated examples, and various modifications can be made to the embodiments described below without departing from the spirit of this disclosure.

[0127] [1 First Embodiment]

[0128] The following is based on Figures 1-2 2. The first embodiment of this disclosure will be described.

[0129] Furthermore, the axis and direction will be determined as described below.

[0130] First, regarding the compression filter manufacturing apparatus 110, such as Figure 8As shown, the X-axis is determined along the movement direction of the filter paper 211 in the compression filter manufacturing process (step S1-1), with the near-front side of the movement direction designated as "front" and the rear side as "rear". The Y-axis is defined as an axis parallel to the surface of the filter paper 211 and orthogonal to the X-axis, with the right direction (when facing rearward) designated as "right" and the left direction as "left". The Z-axis is defined as an axis perpendicular to both the X-axis and Y-axis, with one side of the Z-axis designated as "up" and the other as "down". Furthermore, when the axes and directions are consistent with those in the compression filter manufacturing process (step S1-1), the pleated filter 210, filter paper 211, and compression filter 210A are... Figure 1 , Figure 4 as well as Figure 7 Determine the axis and direction as shown.

[0131] Regarding the cuboid filter unit 200, Figure 2 Using the setup shown as a reference, the direction facing the air inlet 230 is taken as front, and the direction facing the air outlet 240 is taken as rear, with the axis along the front-rear direction as the D-axis. Additionally, the right direction in the rearward orientation is taken as right, the left direction as left, and the axis along the left-right direction as the W-axis. Furthermore, the up direction in this state is taken as up, the down direction as down, and the axis along the up-down direction as the H-axis.

[0132] In addition, the same applies to filter unit 200A, filter unit 200B, multi-filter unit 400, multi-stage inclined compression filter 500 with left and right plates, and multi-stage parallel compression filter 600 with left and right plates. Figure 15 , Figure 17 , Figure 18 as well as Figure 19 As shown, the axis and direction are defined in the same manner as those of the filter unit 200 for explanation.

[0133] [(1) Regarding pleated filters]

[0134] The pleated filter 210 according to the first embodiment of this disclosure is as follows: Figure 1 The filter paper 211 is obtained by pleating as shown, and is folded alternately to one side and the other side at multiple creases 212 parallel to the Y-axis, forming a pleated surface 213 between the creases 212.

[0135] Furthermore, regarding sheet-like components, when viewed from one side (in... Figure 1 When viewed from above or below, the concave portion on that side and the convex portion on that side are in the same direction (in... Figure 1 The alternating repeating state along the X-axis (with the center as the center) is called a fold, the shape of the fold is called a fold, and the formation of folds is called fold processing.

[0136] Additionally, the interval between a vertex of a convex portion that is convex on one side and a vertex of a convex portion that is convex on the same side located adjacent to it (in...) Figure 1 The distance in the X-axis direction (where the distance is in the middle) is called the spacing of the folds.

[0137] Furthermore, when the spacing of the pleats formed in a filter is different, the average value is taken as the pleat spacing of the filter. When the pleats are multiplexed, such an average value is calculated separately for the pleats at each stage. That is, if a filter is formed with primary and secondary pleats as described later, the spacing of the primary pleats in the filter is calculated based on the average value of the primary pleat spacing, and the spacing of the secondary pleats is calculated based on the average value of the secondary pleat spacing.

[0138] In addition, the distance along the Z-axis from the vertex of a convex part that is convex on one side to the vertex of a convex part that is convex on the other side (or concave on the same side) located at its adjacent position is called the height of the fold.

[0139] Furthermore, when the heights of the pleats formed in a filter are different, their average value is taken as the height of the filter's pleats. When the pleats are multiplexed, such an average value is calculated separately for the pleats at each stage. That is, if a filter is formed with primary and secondary pleats as described later, the height of the primary pleat in the filter is calculated based on the average height of the primary pleats, and the height of the secondary pleats is calculated based on the average height of the secondary pleats.

[0140] Furthermore, the surfaces formed between the vertex of a convex portion that is convex on one side and the vertex of a convex portion that is convex on the other side (or concave on the same side) located at its adjacent position are called fold surfaces.

[0141] Furthermore, when folds are multiplied, they are sequentially referred to as primary folds, secondary folds, and so on, starting with the folds with the smallest spacing.

[0142] In this case, in a secondary fold, the creases in the primary fold are ignored, and only the creases in the secondary fold are referred to as the creases of the secondary fold.

[0143] The filter paper 211 constituting the pleated filter 210 is a sheet-like component formed to allow air to pass through and remove particles from the air that are the objects to be removed.

[0144] The filter paper 211 can be formed from a single layer of filter paper or from multiple layers of filter paper. In addition, the intermediate layer between two, one, or multiple layers of filter paper may have a protective sheet or reinforcing sheet made of non-woven fabric or the like for protecting or reinforcing such filter paper.

[0145] The filter paper 211 in this embodiment broadly includes sheet-like components capable of removing particles that are the target of removal from the fluid. Filter paper formed from single or multiple layers of filter paper, as described above, and filter paper with protective sheets and reinforcing sheets are all equivalent to the filter paper in this disclosure.

[0146] [(2) Regarding the filter unit]

[0147] like Figure 2 and Figure 3 As shown, the filter unit 200 according to the first embodiment of this disclosure is a unit in which 20 pleated filters 210 are housed in the frame portion 220. Furthermore, the term "filter unit" is broadly used to refer to any unit in which the frame portion housing the filters is mounted. Additionally, the frame portion housing the filters broadly includes components mounted to the filters in a manner that covers at least a portion of the filters.

[0148] Filter unit 200 is used to allow air to flow in the front-to-back direction to remove particles from the air that are the target of removal, such as... Figure 2 and Figure 3 As shown, the filter unit 200 includes: 20 pleated filters 210, which are arranged to be slightly inclined upward or downward from the front-to-back direction; and a frame 220, which is composed of an upper plate 221 arranged to cover its upper side, a lower plate 222 arranged to cover its lower side, a right plate 223 arranged to cover its right side, and a left plate 224 arranged to cover its left side. The filter unit 200 is formed into a cuboid shape with each side having a length of about 100 mm.

[0149] Furthermore, the front opening for air intake is designated as the air intake section 230, and the rear opening for air exhaust is designated as the air exhaust section 240. Therefore, the filter unit 200 filters the air that is introduced from the front air intake section 230, passes through the pleated filter 210, and is then discharged from the rear air exhaust section 240.

[0150] In addition, in the frame portion 220, the right plate 223 and the left plate 224 are arranged in opposite positions to connect the air inlet portion 230 and the air outlet portion 240. An upper plate 221 is provided to connect the upper end of the right plate 223 and the upper end of the left plate 224, and a lower plate 222 is provided to connect the lower end of the right plate 223 and the lower end of the left plate 224.

[0151] In addition, the right end of all the pleated filters 210 is connected to the right plate 223, and the left end of all the pleated filters 210 is connected to the left plate 224.

[0152] 20-piece pleated filter 210 respectively Figure 1The dimensions of the pleats are 100mm in the X-axis direction, 100mm in the Y-axis direction, and approximately 3.5mm in the Z-axis direction, and the spacing and height of the pleats are constant. Furthermore, the pleated filter 210 is composed of a rectangular pleated surface 213 with a long side of 100mm and a short side of 3.5mm. The pleated surface 213 is arranged at an angle relative to the Z-axis, so that the height of the pleats in the pleated filter 210 is slightly lower than the length of the short side of the pleated surface 213, i.e., 3.5mm, depending on the angle of the pleated surface.

[0153] Additionally, for the pleated filter 210, such as Figure 2 and Figure 3 As shown, when viewed from the H-axis direction, the crease of the fold runs along the D-axis, and as... Figure 3 As shown, the odd-numbered pleated filters are arranged at an angle that increases with the rearward direction, and the even-numbered pleated filters are arranged at an angle that decreases with the rearward direction.

[0154] In addition, such as Figure 3 As shown, by connecting the front end of the uppermost pleated filter 210 to the front end of the second pleated filter 210 in a way that fills the space between them without gaps, and connecting the rear end of the second pleated filter 210 to the rear end of the third pleated filter 210 in a way that fills the space between them without gaps, the 20 pleated filters 210 are connected by alternately repeating the connection of their front ends to each other and the connection of their rear ends to each other. Furthermore, when the connection between these components is completely blocked without gaps, it is considered that the connection is sealed.

[0155] In addition, such as Figure 3 As shown, the rear end of the uppermost pleated filter 210 is connected to the rear end of the upper plate 221 in a way that fills the space between them without gaps, and the rear end of the lowermost pleated filter 210 is connected to the rear end of the lower plate 222 in a way that fills the space between them without gaps.

[0156] Therefore, as Figure 3 As shown, the upper plate 221, the uppermost pleated filter 210 to the lowermost pleated filter 210, and the lower plate 222 are connected in an alternating manner when viewed from the W-axis direction. Considering the 20 pleated filters 210 as a whole, they are formed with alternating concave and convex portions in the H-axis direction when viewed from the front (and alternating concave and convex portions in the rear direction when viewed from the rear). Furthermore, the connection between the rear end of the upper plate 221 and the rear end of the uppermost pleated filter 210, the connection between the rear end of the lower plate 222 and the rear end of the lowermost pleated filter 210, and the connection between the front ends or rear ends of each pleated filter 210 are used as sealing portions 250.

[0157] That is, for the 20 pleated filters 210, the pleats formed in each of them are called primary pleats, and the pleats formed by the 20 pleated filters 210 are called secondary pleats with a larger spacing than the primary pleats. When the 20 pleated filters 210 are regarded as a whole, a filter is formed by overlapping the primary pleats and the secondary pleats.

[0158] Furthermore, the creases of the primary folds (the creases 212 formed in each folded filter 210) extend along the D-axis direction when viewed from the H-axis direction, and the creases of the secondary folds (the creases of the sealing part 250 are equivalent to the creases of the secondary folds) extend along the W-axis direction. Therefore, the direction along the creases of the primary folds is orthogonal to the direction along the creases of the secondary folds.

[0159] In addition, in this case, the crease of the secondary fold (sealing part 250) is arranged toward the air inlet part 230 or the aforementioned air outlet part 240, and the air inlet direction (D-axis direction) into the frame part 220 becomes the direction along the crease of the primary fold (crease 212).

[0160] Furthermore, the pleated filter 210 is set at a slight vertical angle relative to the D-axis direction, so the direction of air introduction is not completely parallel to the direction along the crease of the first pleat. However, in this case, if the direction of air introduction is consistent with the direction along the crease of the first pleat when viewed from above (from the direction where the area of ​​the filter is the largest) when the pleated filter 210 (i.e., the pleated surface of the second pleat) is viewed from above, then it is also considered that the direction of air introduction from the air inlet 230 into the frame 220 is along the direction of the crease of the first pleat.

[0161] As described above, when the pleated filter 210 is set to Figure 1 With an X-axis of 100mm, a Y-axis of 100mm, and a Z-axis of approximately 3.5mm, a single pleated filter 210 is formed by connecting approximately 143 rectangular pleated surfaces 213, each with a long side of 100mm and a short side of 3.5mm.

[0162] Furthermore, if such a pleated filter 210 is unfolded, then as Figure 4 As shown, the filter paper 211 is a filter paper with alternating mountain folds and valley folds formed every 3.5 mm on the filter paper 211 with a thickness of 500 mm in the X-axis direction, 100 mm in the Y-axis direction, and 0.2 mm in the Z-axis direction.

[0163] [(3) Regarding multi-filter units]

[0164] like Figure 15As shown, the multi-filter unit 400 is a unit formed by connecting multiple units (filter unit 200A) that have had their upper plate 221 and lower plate 222 removed from the filter unit 200, arranged vertically and horizontally. Figure 15 The diagram illustrates a multi-filter unit with 4 columns in the W-axis direction, 3 columns in the H-axis direction, and a W-axis diameter of 400mm, a D-axis diameter of 100mm, and an H-axis diameter of 300mm.

[0165] In addition, above the uppermost filter unit 200A and below the lowermost filter unit 200A, there are upper plate 221A and lower plate 222A arranged in a manner that covers the entire W-axis direction.

[0166] Furthermore, in the multi-filter unit 400, regarding the filter units 200A connected vertically, the rear end of the uppermost pleated filter 210 of the lower filter unit 200A is connected to the rear end of the lowermost pleated filter 210 of the upper filter unit 200A in a manner that fills the space between them without gaps.

[0167] In addition, the rear end of the uppermost pleated filter 210 of the uppermost filter unit 200A is connected to the rear end of the upper plate 221A in such a way that the space between them is filled without gaps, and the rear end of the lowermost pleated filter 210 of the lowermost filter unit 200A is connected to the rear end of the lower plate 222A in such a way that the space between them is filled without gaps.

[0168] [(4) Regarding the compression filter]

[0169] like Figure 7 As shown, for the pleated filter 210, the filter that is compressed in the X-axis direction orthogonal to the pleat 212 and thus becomes shorter in the X-axis direction compared to the pleated filter 210 is called the compression filter 210A.

[0170] As will be described later, in the manufacturing process of the filter unit 200, the pleated filter 210 is compressed in the X-axis direction orthogonal to the pleat 212, becoming a filter that is shorter in the X-axis direction than the pleated filter 210, i.e., a compressed filter 210A. This makes each operation in the manufacturing process easier compared to the case of directly operating the pleated filter 210.

[0171] The main advantage of compressing the pleats in the X-axis direction is the ease of operation during the manufacture of the filter unit 200 (especially the ease of holding both ends). Therefore, the compression state of the filter paper 211 in the compression filter 210A is defined as follows.

[0172] [a. Fully compressed state]

[0173] The operation of the compression filter 210A is easiest when the adjacent pleated surfaces 213 are in contact with each other. However, due to the hardness and thickness of the filter paper 211, there are also cases where the adjacent pleated surfaces 213 do not come into contact with each other even when considerable pressure is applied.

[0174] However, if the state is almost uncompressed even when a considerable amount of pressure is applied, there is no significant difference in ease of operation compared to the state where the adjacent folded surfaces 213 are in contact with each other. Therefore, except for the case where the adjacent folded surfaces 213 are in contact with each other, the state that is almost uncompressed even when a considerable amount of pressure is applied is considered equivalent to a fully compressed state.

[0175] Specifically, the fully compressed state refers to the following two states.

[0176] (a) The state in which all adjacent pleated surfaces 213 are in contact with each other. Furthermore, when pleated surfaces 213 are in contact with each other at a location other than the crease 212, it is considered that pleated surfaces 213 are in contact with each other.

[0177] (b) such as Figure 16 As shown, on a plate D3 (made of aluminum) whose upper surface is a plane parallel to the XY plane, a filter paper 211 folded to form creases 212 is passed through a pressure plate D2 having a plane parallel to the YZ plane. With one end of the filter paper in the X-axis direction abutting against the wall D1, a force of 10gf is applied from the other end in the X-axis direction at a length of 10gf per 10mm in the Y-axis direction. Figure 16 When pressing from back to front, the reduction in the X-axis direction (the ratio of the reduction in the X-axis direction due to pressing to the original length) is less than 10%.

[0178] Furthermore, the filter paper 211, folded to form creases 212, becomes a spring-like structure. Therefore, initially, almost no force is required when pressing in the X-axis direction based on the pressure plate D2. However, as the filter paper 211 shrinks in the X-axis direction, the force required for pressing gradually increases. The shrinkage amount referred to here is the amount of shrinkage at the moment when this gradually increasing force reaches 10gf per 10mm of filter paper 211 in the Y-axis direction.

[0179] [b Quasi-compressed state]

[0180] Quasi-compressible state refers to the following state.

[0181] like Figure 16As shown, on a plate D3 (made of aluminum) whose upper surface is a plane parallel to the XY plane, a filter paper 211 folded to form creases 212 is pressed by a pressure plate D2. With one end of the filter paper in the X-axis direction abutting against the wall D1, the filter paper 211 is pressed from the other end along the X-axis direction (in... Figure 16 When pressing from back to front (in the middle), even when the pressure plate D2 and Figure 16 In the case of tilting upwards by 5 degrees (the upper end is tilted backwards by 5 degrees relative to the YZ plane), it is possible to press continuously until the force required to press reaches 100gf per 10mm length in the Y-axis direction.

[0182] Here, similar to the description of (b) for the fully compressed state, almost no force is required after the initial pressing in the X-axis direction based on the pressure plate D2. However, as the filter paper 211 shrinks in the X-axis direction, the force required for pressing gradually increases. Therefore, the state where pressing can be sustained refers to the state where pressing can be sustained until the gradually increasing force reaches 100gf per 10mm length of filter paper 211 in the Y-axis direction.

[0183] Furthermore, the fully compressed state and the quasi-compressible state are collectively referred to as the compressed state.

[0184] In addition, the state in which the folds are fixed under full compression is called the fully fixed state, the state in which the folds are fixed under quasi-compression is called the quasi-fixed state, and the state in which the fully fixed state and the quasi-fixed state are fixed together are called the fixed state.

[0185] In addition, a filter in which the pleats are in a fully compressed state is called a fully compressed filter, and a filter in which the pleats are in a quasi-compressed state is called a quasi-compressed filter. Both fully compressed filters and quasi-compressed filters are included in the category of compressed filters.

[0186] Whether the pleated surfaces 213 are in contact with each other or not, the compression filter 210A is preferably in a fully compressed or quasi-compressed state as described above.

[0187] In addition, the compression filter 210A preferably satisfies at least one of the following two conditions.

[0188] (a) The natural length (the length of the compression filter 210A in the X-axis direction when the force that causes the compression filter 210A to stretch or contract in the X-axis direction is not applied to the compression filter 210A) is less than half of the length in the X-axis direction when in use (pleated filter 210).

[0189] Furthermore, with the compression filter 210A placed on an aluminum plate whose upper surface is a plane parallel to the XY plane, the plate is continuously struck to apply vibration. When the change in the length of the compression filter 210A in the X-axis direction can no longer be confirmed, its length in the X-axis direction is measured, thereby enabling the measurement of its natural length.

[0190] (b) Grasp the folded surface 213 at one end in the X-axis direction and place the other end downwards (so that...) Figure 7 When the X-axis is aligned with the vertical direction and the filter is suspended, the elongation caused by gravity is less than half of the natural length (when the compression filter 210A is elongated along the X-axis due to gravity, the elongation is less than half of the natural length).

[0191] In addition, the compression filter 210A preferably has more than 10 creases per 10 mm in a direction orthogonal to the creases (X-axis direction).

[0192] However, if it is shorter in the X-axis direction compared to the pleated filter 210, it is equivalent to the compression filter 210A in this embodiment, and can achieve the effect of the compression filter 210A as described later to a certain extent.

[0193] Compared to the pleated filter 210, the compression filter 210A is shorter in the X-axis direction orthogonal to the pleat 212, making it easier to handle. Furthermore, by lengthening the compression filter 210A, it can easily be transformed into a pleated filter 210 that is longer in the X-axis direction (e.g., about five times the length) than the compression filter 210A. Additionally, since the compression filter 210A is compressed, its volume does not increase during handling; for example, by being wound into a roller shape, it is also easy to handle during sales.

[0194] [(5) Regarding semi-finished products]

[0195] In this embodiment, the product manufactured during the manufacturing process of the filter unit is referred to as a semi-finished product. An example of such a semi-finished product will be described.

[0196] [a Multi-stage tilting compression filter with left and right plates]

[0197] The multi-stage inclined compression filter 500 with left and right plates is a semi-finished product manufactured through step S3 shown in the description of the manufacturing method described later. Furthermore, a filter with plate-shaped components mounted on it is referred to as a plate-mounted compression filter.

[0198] Specifically, such as Figure 17As shown, in the multi-stage inclined compression filter 500 with left and right plates, 20 compression filters 210A are configured such that the X-axis of the compression filters 210A is aligned with the W-axis, and when viewed from the W-axis direction, compression filters 210A that are inclined in a manner that rises from the front to the rear in the D-axis direction are alternately arranged with compression filters 210A that are inclined in a manner that decreases from the front to the rear in the D-axis direction, and they alternately contact each other at the ends in the D-axis direction, forming a sawtooth shape when viewed from the W-axis direction.

[0199] That is, the 20-piece compression filter 210A is configured such that, when viewed from the W-axis direction orthogonal to the crease of the filter paper, filters arranged in a first direction that rises backward and filters arranged in a second direction that falls backward are alternately arranged.

[0200] In addition, in the multi-stage inclined compression filter 500 with left and right plates, a right plate 223 is attached to the right end of the 20-piece compression filter 210A arranged as described above in the W-axis direction, and a left plate 224 is attached to the left end in the W-axis direction.

[0201] If it is a multi-stage inclined compression filter 500 with left and right plates, it is compressed in the W-axis direction compared with the completed filter unit 200, which is small in size and easy to operate. Therefore, after transporting and selling the multi-stage inclined compression filter 500 with left and right plates, the filter unit 200 is completed through step S4 and subsequent processes, which can reduce the costs incurred during transportation and sales.

[0202] [b. Multi-stage parallel compression filter with left and right plates]

[0203] The multi-stage parallel compression filter 600 with left and right plates is a filter that arranges each compression filter 210A in parallel compared to the multi-stage inclined compression filter 500 with left and right plates.

[0204] For example, such as Figure 18 As shown, in the multi-stage parallel compression filter 600 with left and right plates, the 20 compression filters 210A are configured such that the X-axis of the compression filters 210A is aligned with the W-axis and the Y-axis is aligned with the D-axis. When viewed from the W-axis direction, they are all arranged in parallel and at equal intervals in the H-axis direction. A right plate 223 is attached to the right end of the 20 compression filters 210A in the W-axis direction, and a left plate 224 is attached to the left end in the W-axis direction.

[0205] Additionally, for example, if with Figure 18In the case of having 50 compression filters 210A, 50 compression filters 210A with a diameter of 100mm in the D-axis direction, a diameter of 20mm in the W-axis direction, and a diameter of 5mm in the H-axis direction are bonded at 7mm intervals in the H-axis direction to the right plate 223 and the left plate 224 with a diameter of 100mm in the D-axis direction and a diameter of 350mm in the H-axis direction, thereby manufacturing a multi-stage parallel compression filter 600 with left and right plates having 50 compression filters 210A.

[0206] For such a multi-stage parallel compression filter 600 with left and right plates, by increasing the interval between the right plate 223 and the left plate 224, the compression filter 210A can be made into a pleated filter 210.

[0207] Based on this configuration, the plate-shaped components are installed at the front and rear ends in a manner that connects the right plate 223 and the left plate 224. Then, the right plate 223, the left plate 224, the plate-shaped components installed at the front end, and the plate-shaped components installed at the rear end are divided in the H-axis direction so that the pleated filter 210 is separated piece by piece (if there are 20 compressed filters 210A, it is divided into 20 equal parts in the H-axis direction; if there are 50 compressed filters 210A, it is divided into 50 equal parts in the H-axis direction). This allows the manufacture of a filter in which plate-shaped components (front plate 225, rear plate 226, right plate 223A, and left plate 224A) are installed in front, behind, left, and right of a single pleated filter 210.

[0208] Therefore, as Figure 19 As shown, a filter unit 200B can be manufactured with a frame portion 220A mounted in a manner that surrounds the front, back, left, and right sides of a single pleated filter 210.

[0209] If, as described above, 50 compression filters 210A with diameters of 100mm in the D-axis direction, 20mm in the W-axis direction, and 5mm in the H-axis direction are bonded to the right plate 223 and left plate 224, then 50 filter units 200B with pleated filters 210 mounted on the frame portion 220A with diameters of 100mm in the D-axis direction, 100mm in the W-axis direction, and 7mm in the H-axis direction can be manufactured.

[0210] If it is a multi-stage parallel compression filter 600 with left and right plates, the compression filter 210A used to manufacture multiple filter units 200B is combined into one, and compared with the multiple filter units 200B after completion, it is compressed in the W-axis direction, has a small volume and is easy to operate. Therefore, after transporting and selling in the state of multi-stage parallel compression filter 600 with left and right plates, multiple filter units 200B can be completed as described above, thereby reducing the costs incurred in transportation, sales and other processes.

[0211] [(6) Description of the manufacturing method]

[0212] A method for manufacturing a filter unit 200 using a 20-piece pleated filter 210 using the filter unit manufacturing system 100 described in the embodiment will be explained.

[0213] like Figure 5 As shown, the manufacturing method of manufacturing a filter unit 200 using a filter unit manufacturing system 100 according to the embodiment includes: a compression filter manufacturing process (step S1-1), a compression filter arrangement process (step S1-2), a right plate and left plate installation process (step S1-3), an opening process (step S1-4), an upper plate and lower plate installation process (step S1-5), and a finishing process (step S1-6).

[0214] Additionally, the filter unit manufacturing system 100 is a set of production lines for manufacturing filter units 200, such as... Figure 6 As shown, it includes: a compression filter manufacturing apparatus 110, a compression filter arranging apparatus 120, a left and right plate mounting apparatus 130, a temporary adhesive release apparatus 140, an upper and lower plate mounting apparatus 150, and a finishing processing apparatus 160.

[0215] [a Step S1-1: Compression filter manufacturing process]

[0216] First, the manufacturing process of the compressor filter 210A will be explained.

[0217] Furthermore, as described in the description of the compression filter, such as Figure 7 As shown, a filter that is compressed in the X-axis direction in a direction orthogonal to the pleat 212 and becomes shorter in the X-axis direction compared to the pleated filter 210 is called a compression filter 210A.

[0218] like Figure 4 As shown, in the case where filter paper 211 is formed with a thickness of 500 mm in the X-axis direction, 100 mm in the Y-axis direction, and 0.2 mm in the Z-axis direction, and with creases 212 formed at 3.5 mm intervals in the X-axis direction, Figure 7 The compression filter 210A shown is 20mm in the X-axis direction, 100mm in the Y-axis direction, and 3.5mm in the Z-axis direction.

[0219] In this case, the thickness is 1 / 25th in the X-axis direction and 17.5 times in the Z-axis direction, which leads to a contradiction in simple calculations. However, the thickness of filter paper 211 is a value determined according to method A as described in JIS L 1913:2010 6.1.1. If pressure is applied during the manufacture of the compression filter 210A, it will become thinner.

[0220] When manufacturing a compression filter 210A using the compression filter manufacturing apparatus 110 provided in the filter unit manufacturing system 100, firstly, as... Figure 8 As shown, filter paper 211 is continuously fed out from the filter paper roller 111 of the compression filter manufacturing apparatus 110 (step S1-1-1).

[0221] The filter paper roller 111 is configured to wind and continuously feed a strip of filter paper 211 with a width of 100 mm and a thickness of 0.2 mm.

[0222] like Figure 8 As shown, the filter paper 211 fed from the filter paper roller 111 is sent to the crease application device 112 and is subjected to crease application processing (step S1-1-2) through the crease application device 112.

[0223] like Figure 8 As shown, the crease-applying device 112 is formed by meshing two gears (first gear 1121 and second gear 1122) so that the filter paper 211 passes between the two gears, thereby applying creases 212 along the Y-axis to the filter paper 211 in a manner that alternates between mountain folds and valley folds every 3.5 mm in the X-axis direction.

[0224] like Figure 8 As shown, the filter paper 211 with creases applied by the crease application device 112 is sent to the folding device 113 and folded through the folding device 113, thereby undergoing the folding process (step S1-1-3).

[0225] like Figure 8 As shown, the folding device 113 includes a first wall portion 1131, a second wall portion 1132, a belt 1133, and a set of multiple rollers (first roller 1134 and second roller 1135), which are symmetrically arranged opposite each other in the Z-axis direction. In addition, a baffle 1136 is provided near the rear end of the second wall portion 1132 to allow the second wall portions 1132 to open and close freely.

[0226] like Figure 8 As shown, in the first wall portion 1131, a pair of first wall portions 1131 are arranged opposite each other in the Z-axis direction, and the opposite surfaces are formed as planes.

[0227] In addition, such as Figure 8As shown, the first wall portion 1131 is configured such that the spacing (distance in the Z-axis direction) between opposing surfaces gradually increases as it moves toward the filter paper 211 in the direction of travel (from front to rear). Regarding the spacing between the opposing surfaces of the first wall portion 1131, the space between them is narrower at the entrance (front end) than the length (3.5 mm) of the pleated surface 213 of the compression filter 210A to be formed in the direction orthogonal to the crease 212, and slightly wider at the exit (rear end) than the length (3.5 mm) of the pleated surface 213 of the compression filter 210A to be formed in the direction orthogonal to the crease 212.

[0228] like Figure 8 As shown, the second wall portion 1132 is disposed behind the first wall portion 1131, and the pair of second wall portions 1132 are arranged opposite each other in the Z-axis direction, with the opposing surfaces (second opposing surfaces 11321) being planar. The main purpose of providing the second wall portions 1132 is to connect the gap between the outlet portion of the space between the filling strips 1133 and the fixing device 114.

[0229] like Figure 8 As shown, unlike the first wall portion 1131, the second wall portion 1132 is configured such that the opposing surfaces (second opposing surfaces 11321) are parallel to each other and their spacing (distance in the Z-axis direction) is constant. The spacing of the second opposing surfaces 11321 is the same as the length (3.5 mm) of the pleated surface 213 of the compression filter 210A to be formed in the direction orthogonal to the crease 212.

[0230] In addition, the gap between the first wall portion 1131 and the second wall portion 1132 is preferably as narrow as possible within the range that the belt 1133 can pass through.

[0231] Belt 1133 is a strip-shaped component having a constant width in the Y-axis direction that is the same as or exceeds the width of filter paper 211 in the Y-axis direction (100 mm). Figure 8 As shown, they are wound on the first roller 1134 and the second roller 1135, and are arranged along each of the opposite surfaces of the first wall portion 1131.

[0232] like Figure 8 As shown, in strip 1133, the opposite surface of the portion arranged in a manner opposite to another strip 1133 in the Z-axis direction is designated as the first opposing surface 11331. The first opposing surface 11331 is planar along the first wall portion 1131.

[0233] Because the filter paper 1133 is thin and lightweight, when folding the filter paper 211, if the folded filter paper 211 is pressed from the inside (from the opposite side of the first opposing surface 11331), then... Figure 8It is pressed against the first wall portion 1131 as shown.

[0234] Furthermore, for the first opposing surfaces 11331, even if they are not parallel, they are considered to be arranged in a relative manner as long as either one intersects the other when it is moved parallel to that surface. This point also applies to other components constituting the system.

[0235] Alternatively, the strip 1133 can be divided into multiple strips in the Y-axis direction, with the multiple strips arranged side by side with gaps in the Y-axis direction. In this case, the filter paper 211 is also folded at the crease 212 along the Y-axis direction, so the filter paper 211 will not fall into the gap.

[0236] As a result, the belt 1133 rotates in the direction of the arrow in the figure along with the first roller 1134 and the second roller 1135, and is conveyed in the direction of travel of the filter paper (from front to back) along the first opposing surface 11331 opposite the first wall portion 1131.

[0237] In this part, the first opposing surface 11331 of the strip 1133 is formed as a surface with a constant width in the Y-axis direction, and a pair of first opposing surfaces 11331 are arranged in a relative manner, as described later, the filter paper 211 is folded between them and compressed in the X-axis direction.

[0238] As described above, the spacing between the opposing surfaces of the first wall portion 1131 is narrower than 3.5 mm at the front end and slightly wider than 3.5 mm at the rear end, thus, as Figure 8 As shown, regarding the spacing (distance in the Z-axis direction) between the first opposing surfaces 11331 of the belt 1133, when the belt 1133 is pressed against the first wall portion 1131, the front end of the first opposing surfaces 11331 (the entrance portion of the space between them) becomes a spacing narrower than the length (3.5 mm) of the pleated surface 213 of the compression filter 210A to be formed in the direction orthogonal to the crease 212, and the rear end of the first opposing surfaces 11331 (the exit portion of the space between them) becomes a spacing approximately the same as the length (3.5 mm) of the pleated surface 213 of the compression filter 210A to be formed in the direction orthogonal to the crease 212.

[0239] That is, the spacing between the first opposing surfaces 11331 with 1133 is the narrowest (1 mm) at the entrance portion of the space between them, and gradually widens to the spacing (3.5 mm) at the exit portion of the space.

[0240] like Figure 8 As shown, a baffle 1136 is provided near the rear end of the second wall portion 1132, and the baffle 1136 is configured to allow the gap between the second wall portions 1132 to open and close freely.

[0241] like Figure 8 As shown, the filter paper 211, with creases applied by the crease-applying device 112, is fed to the folding device 113. Furthermore, at this time, with... Figure 8 The difference is that the gap between the second wall portions 1132 is closed by the baffle 1136.

[0242] First, such as Figure 8 As shown, filter paper 211 is fed between a pair of first rollers 1134 (between a pair of belts 1133 flowing from front to rear in this section), in contact with the belts 1133 in this section, and is conveyed rearward through the belts 1133.

[0243] The filter paper 211, which is being conveyed rearward through the belt 1133, stops when its leading edge touches the baffle 1136 that closes the gap near the rear end of the second wall portion 1132. Thus, as... Figure 8 As shown, the filter paper 211 is folded into a serrated shape at the crease 212 applied in step S1-1-2, and is folded between the second wall portions 1132 near the front of the baffle 1136, and is stacked in a state where it is compressed and shortened in the X-axis direction compared to the pleated filter 211 to be formed. At this time, it is preferably equivalent to the fully compressed state described above, and even if it is not equivalent to the fully compressed state, it is preferably equivalent to the quasi-compressed state, but it is not limited to this.

[0244] Furthermore, regardless of the state of such compression, as long as the filter paper 211 is folded at the crease, it is considered to be folded filter paper.

[0245] When the filter paper 211 is folded, in the portion between the belts 1133 from the first roller 1134 along the first wall portion 1131 to the second roller 1135, the first opposing surfaces 11331 of a pair of belts 1133 arranged in opposite directions restrict the serpentine movement of the filter paper 211 in the Z-axis direction, and the filter paper 211 is folded between a pair of belts 1133 arranged in opposite directions.

[0246] Furthermore, as described above, in the portion between the belt 1133 extending from the first roller 1134 along the first wall portion 1131 to the second roller 1135, the first opposing surface 11331 of the belt 1133 flows from front to rear. Therefore, if the crease 212 of the folded filter paper 211 comes into contact with such belt 1133, the filter paper 211 is conveyed from front to rear in the portion in contact with the belt 1133.

[0247] That is, in the portion between the first opposing surfaces 11331 of the belt 1133 from the first roller 1134 along the first wall portion 1131 to the second roller 1135, the belt 1133 applies a frictional force to the filter paper 211 in the direction of travel of the filter paper 211 (from front to back).

[0248] Furthermore, in the portion between the second opposing surfaces 11321 of the second wall portion 1132 without the second opposing surface 1133, a frictional force is applied to the filter paper 211 in the opposite direction to the direction of travel of the filter paper 211 (from rear to front) through the second opposing surface 11321.

[0249] In this case, the belt 1133 flows from front to rear, thereby allowing the filter paper 211, which has been creased by the crease-applying device 112, to be introduced into the space between the belts 1133 by the friction of the belt 1133. The filter paper 211 is folded in the space between the belts 1133, so that when the crease 212 of the filter paper 211 comes into contact with the belt 1133, the friction generated between the filter paper 211 and the belt 1133 compresses the filter paper 211 in the X-axis direction, which acts as a force for folding.

[0250] If a specified amount of filter paper 211 is folded and stacked in front of the baffle 1136, the baffle 1136 is opened, and the filter paper 211 in this state... Figure 8 As shown, it is conveyed to the fixing device 114 and passed through the fixing device 114, thereby being subjected to a strengthening / fixing process (step S1-1-4).

[0251] Furthermore, if the baffle 1136 is opened, the folded filter paper 211 is pushed to the rear fixing device 114 and then pushed to the cutting device 116 by the output roller 115 at a constant speed. After a period of time in this state, it becomes a stable state in which the filter paper 211 is folded at a constant speed, which is mainly determined by the friction of the belt 1133 and the rearward speed of the output roller 115 on the filter paper 211. This state is called the "normal state".

[0252] Furthermore, the baffle 1136 is not essential, but is only temporarily needed during the period before entering the normal state. For example, the baffle 1136 may be omitted, and a pre-folded filter paper 211 and a suitable filler thereof may be arranged from the position of the baffle 1136 to the position of the fixing device 114.

[0253] In this case, during startup, the front end of filter paper 211 touches the filler at the position of baffle 1136, thereby folding filter paper 211 between belts 1133. The folded filter paper 211 accumulates at the position of baffle 1136. If the backward pressure based on the folded filter paper 211 becomes a certain value or higher, the filler begins to move backward. Soon after, if the filler passes through the fixing device 114, it is pushed out by the output roller 115 to the cutting device 116. If the folded filter paper 211 fills the cutting device 116, it becomes a normal state.

[0254] As part of the reinforcement / fixation process, a temporary bonding process based on the temporary bonding device 1141 is first performed. The temporary bonding device 1141 is a device used to fix the spacing between the front and rear pleated surfaces 213 when the filter paper 211 is folded.

[0255] For example, the temporary bonding device 1141 bonds the creases 212 located at the front and rear ends (upper and lower surfaces) of the folded filter paper 211 in the Z-axis direction, thereby fixing the filter paper 211 in a state folded by the folding device 113 or close to such a state. For bonding the creases 212 together, for example, an adhesive can be applied to the upper and lower surfaces of the filter paper 211 in a filamentary or planar manner extending along the X-direction in the folded state or close to such a state by the folding device 113, and bonding can be achieved using this adhesive.

[0256] In this case, it is not necessary to glue the entire Y-axis direction of the crease 212; it is acceptable to glue only a portion of it in the Y-axis direction. Alternatively, it is preferable to glue the crease 212 together at both ends (upper and lower surfaces) of the folded filter paper 211 in the Z-axis direction, but it is also possible to glue the crease 212 together only on either the upper or lower surface.

[0257] With the creases 212 glued together in this way, the gap between the glued creases 212 will be greatly expanded during the opening process in step S1-4, which will reduce the possibility of unresolved glue in step S1-1-4.

[0258] The temporary bonding device 1141 fixes the spacing between the front and rear pleated surfaces 213, and the filter paper 211 is fixed in a state folded by the folding device 113 or close to such a state.

[0259] Alternatively, the filter paper 211 can be fixed solely by heat treatment based on the heat treatment device 1142, without the temporary bonding treatment based on the temporary bonding device 1141. In the heat treatment device 1142, the filter paper 211, which has been heated with the crease 212 folded, can be cooled immediately after heating to fix the shape of the filter paper 211, thus fixing the filter paper 211 in a state folded by the folding device 113 or close to that state.

[0260] In addition, if the filter paper 211 contains fibers, it can be vibrated in step S1-1-3 while the folded surfaces 213 are in contact with each other, causing the adjacent folded surfaces 213 to rub against each other, so that the fibers protruding from the folded surfaces 213 become entangled with each other, thereby fixing the filter paper 211 in a state folded by the folding device 113 or close to that state.

[0261] like Figure 8 As shown, the filter paper 211, which is fixed in a folded state, is sent to the heat treatment apparatus 1142 via the temporary bonding device 1141 and undergoes heat treatment as part of the strengthening / fixing process.

[0262] In the heat treatment apparatus 1142, a pair of plate-shaped components, namely heating plates, are arranged opposite each other in the Z-axis direction to heat the contacted portion of the filter paper 211. This allows for the heating of the entire folded area of ​​the filter paper 211, including the creases 212 above and below the fold.

[0263] The heat treatment device 1142 heats both ends of the fold 212 of the folded filter paper 211 in the Z-axis direction, thereby removing the deformation of the fold and stabilizing the shape through subsequent cooling.

[0264] The shape is stabilized in the folded state or near the folded state in step S1-1-3, thereby enhancing the force of the filter paper 211 attempting to return to the state of the compressed filter 210A after the opening process (step S1-4) described later (reducing the force of the filter paper 211 attempting to unfold in the X-axis direction).

[0265] In addition, the heat treatment apparatus 1142 can be a method that heats only the crease 212 with a plate-shaped heating plate and then cools it, as described above, but other than that, various general heat treatment techniques can also be used.

[0266] The filter paper 211, which has been reinforced / fixed by the fixing device 114, is fed to the cutting device 116 by the output roller 115 and cut by the cutting knife 1161 at 20mm intervals in the X-axis direction (step S1-1-5).

[0267] Thus, it was manufactured Figure 7 The filter 210A shown has multiple rectangular pleated surfaces 213 with a long side of 100mm and a short side of 3.5mm, and is compressed in the X-axis direction by 20mm, the Y-axis direction by 100mm, and the Z-axis direction by 3.5mm compared to the pleated filter 210 in use.

[0268] Here, the folded state of the filter paper 211 in the folding device 113 and the folded state after the strengthening / fixing treatment in the fixing device 114 will be described.

[0269] At the exit of the space between the first opposing surfaces 11331 of the belts 1133 of the folding device 113, the friction-based force acting on the filter paper 211 from the belts 1133 becomes maximum, thus the filter paper 211 is in a state of maximum compression in the X-axis direction. After leaving the space between the belts 1133, the compression of the filter paper 211 in the X-axis direction gradually eases due to friction from the second wall portion 1132, friction from subsequent devices, etc.

[0270] If there is no friction between the filter paper 211 and the output roller 115, the compression ratio in the X-axis direction (the ratio of the length of the filter paper 211 in the X-axis direction in the stretched state to the length of the filter paper 211 in the X-axis direction in the folded state) is the same when the filter paper 211 is located at the exit of the space between the belts 1133 and the output roller 115. However, if friction is applied at a specific point in between, the compression ratio of the filter paper 211 in the X-axis direction from that point to the output roller 115 is lower than the compression ratio of the filter paper 221 in the X-axis direction from the exit of the space between the belts 1133 to that point.

[0271] In the above description, "the state close to that state (the state folded by the folding device 113)" means the situation where the compression ratio decreases from the state folded by the folding device 113 due to subsequent friction.

[0272] Furthermore, the compression ratio of the filter paper 211 immediately preceding the output roller 115 in the X-axis direction is determined by the ratio of the speed at which the filter paper 211 is input to the folding device 113 to the speed at which the filter paper 211 is output from the cutting device 116.

[0273] Preferably, near the outlet of the space between the first opposing surfaces 11331 of the belt 1133, the filter paper 211 is folded in the fully compressed state described above, but the compression rate gradually decreases due to frictional forces encountered in subsequent processes. However, it is preferable to maintain at least the aforementioned quasi-compressed state when fixed by the fixing device 114.

[0274] [b Step S1-2: Compression filter arrangement process]

[0275] If a compression filter 210A is manufactured in step S1-1, then 20 manufactured compression filters 210A are arranged in the compression filter arrangement device 120 of the filter unit manufacturing system 100. Furthermore, after this process, if... Figure 9 As shown, the alignment direction and axis of the completed filter unit 200 will be explained.

[0276] Specifically, such as Figure 9 As shown, Figure 7The compression filter 210A shown is configured such that the X-axis of the compression filter 210A is aligned with the W-axis, and when viewed from the W-axis direction, the compression filter 210A is arranged at an angle that rises from the front to the rear in the D-axis direction and the compression filter 210A is arranged at an angle that falls from the front to the rear in the D-axis direction, and they are alternately in contact at their ends in the D-axis direction, forming a sawtooth shape when viewed from the W-axis direction.

[0277] There are no particular limitations to this configuration method. For example, by housing 20 compression filters 210A in a serrated container with slits, it is possible to achieve the desired effect. Figure 9 Configure the compression filter 210A as shown.

[0278] [c Step S1-3: Installation process of the right and left panels]

[0279] Next, in the left and right plate mounting devices 130 of the filter unit manufacturing system 100, the components as described in step S2 are mounted... Figure 9 The 20-piece compression filter 210A, as shown, has a right plate 223 attached to the right end in the W-axis direction and a left plate 224 attached to the left end.

[0280] As an adhesive, for example, a hot melt adhesive can be used. After applying the hot melt adhesive to the right panel 223 and the left panel 224, it is pressed together as follows: Figure 9 The 20-piece compression filter 210A is configured as shown. Therefore, as... Figure 10 As shown, the right end of each compression filter 210A has a pleated surface 213 bonded to the right plate 223 without gap, and the left end has a pleated surface 213 bonded to the left plate 224 without gap.

[0281] Specifically, after the left plate 224 coated with adhesive is placed on a horizontal surface, one end of the 20 compressed filters 210A, which were arranged in a container with slits in step S2, is pressed onto the left plate 224 for bonding.

[0282] After removing the container and positioning the 20-piece compression filter 210A upright from the left plate 224, press the right plate 223, which has been coated with adhesive, from above to bond it.

[0283] At this time, the compression filter 210A is compressed in the W-axis direction, which makes it easy to press the right plate 223 relative to the right end of each compression filter 210A with the pleated surface 213, and also makes it easy to press the left plate 224 relative to the left end of each compression filter 210A with the pleated surface 213, thereby improving the connection strength between the right plate 223 and the left plate 224 and the compression filter 210A.

[0284] Through the processes up to step S3, it is possible to manufacture as described above. Figure 17 The multi-stage inclined compression filter 500 with left and right plates shown is illustrated.

[0285] Furthermore, in step S2, the container housing the compression filter 210A is preferably fixed relative to the container by means of adjusting the width of the slit, for example using a piezoelectric element, so that the compressed filter 210A will not move. In this case, after the left plate 224 is glued as described above while the compressed filter 210A is fixed relative to the container, the fixation is released and the container is pulled out.

[0286] [d Step S1-4 Opening process]

[0287] Next, in the temporary adhesive release device 140 of the filter unit manufacturing system 100, the temporary adhesive between the pleated surfaces 213 of the 20 compression filters 210A that were bonded with the right plate 223 and the left plate 224 in step S3 is released, and the filters are stretched and unfolded in the W-axis direction.

[0288] That is, in the state of the compression filter 210A, the adjacent pleated surfaces 213 are in contact with each other, so each pleated surface 213 cannot function as a filter. Therefore, in order to enable each pleated surface 213 to function as a filter and to apply tension to the pleated filter 210, the spacing between the adjacent pleated surfaces 213 is rationalized.

[0289] Specifically, by increasing the distance between the right plate 223 and the left plate 224 to about 300mm, the adhesion between the adjacent pleated surfaces 213 in the compression filter 210A is released, and the distance between the right plate 223 and the left plate 224 is returned to 100mm, which is the distance in the filter unit 200.

[0290] In this process, after the adhesion between the pleated surfaces 213 in the compression filter 210A is removed, the spacing between the pleated surfaces 213 is rationalized, thereby enabling the manufacture of the 20 pleated filters 210 in the filter unit 200.

[0291] At this time, by shortening the time it takes to expand the interval between the right plate 223 and the left plate 224 to about 300mm, the tension that the pleated filter 210 attempts to contract in the W-axis direction can be retained to a degree that can maintain the shape of the pleated filter 210.

[0292] [e Step S1-5: Installation process of upper and lower plates]

[0293] Next, in step S4, with each compression filter 210A stretched in the W-axis direction to become a pleated filter 210, the upper plate 221 and the lower plate 222 are installed in the upper and lower plate mounting device 150 provided in the filter unit manufacturing system 100.

[0294] Specifically, such as Figure 2 As shown, the upper plate 221 is installed across the upper ends of the right plate 223 and the left plate 224, and the lower plate 222 is installed between the lower ends of the right plate 223 and the left plate 224. The installation method is not particularly limited as long as there are no gaps between the upper plate 221 and the right plate 223, between the upper plate 221 and the left plate 224, between the lower plate 222 and the right plate 223, and between the lower plate 222 and the left plate 224; for example, a specified type of adhesive can be used for bonding.

[0295] [f Steps S1-6: Finishing process]

[0296] Next, with the upper plate 221 and lower plate 222 installed in step S5, the filter unit 200 is finished by finishing process in the finishing process device 160 of the filter unit manufacturing system 100.

[0297] Specifically, the following processing is performed.

[0298] like Figure 2 As shown, on the front surface of the filter unit 200, in the air inlet section 230, the portion between the connecting portions (sealing portions 250) of the pleated filters 210, the portion between the front end of the upper plate 221 and the uppermost sealing portion 250, and the portion between the front end of the lower plate 222 and the lowermost sealing portion 250 are openings for air circulation. Therefore, all other portions are covered with hot melt adhesive with a thickness of about 3 mm to seal them.

[0299] First, a container is prepared having grooves with shapes corresponding to the front ends of the upper plate 221, lower plate 222, right plate 223, and left plate 224 on the front surface of the filter unit 200, as well as the sealing portion 250. That is, such a container has square grooves on its planar bottom surface corresponding to the front ends of the upper plate 221, lower plate 222, right plate 223, and left plate 224. In these square grooves, 10 parallel grooves corresponding to the 10 sealing portions are formed by connecting opposite sides to each other.

[0300] The groove is about 5mm deep, and the grooves parallel to the 10 sealing parts become narrower as they go downwards.

[0301] After the low-viscosity hot melt adhesive flows in such a tank and fills to a depth of about 2mm, the semi-finished product completed up to step S5 is inserted into the tank with its front surface facing down, and removed after the hot melt adhesive has cured.

[0302] All the gaps in the groove are filled with hot melt adhesive, so by going through this process, the front surface of the filter unit 200 can be completely sealed except for the opening for air circulation.

[0303] Furthermore, the grooves parallel to the 10 sealing portions are formed to become narrower towards the bottom, thereby crushing the pleats at the front end of the pleated filter 210 and flattening it. As a result, the width of the sealing portion 250 in the vertical direction becomes narrower, which can improve the opening ratio of the air inlet portion 230.

[0304] In addition, the same treatment can be applied to the rear surface of the filter unit 200.

[0305] [(7) Explanation of the effect]

[0306] According to this embodiment, in the folding process of step S1-1-3 in the compression filter manufacturing process of step S1-1, the filter paper 211 is folded between a pair of belts 1133 provided by the folding device 113 in a state where the serpentine motion in the Z-axis direction is restricted.

[0307] Therefore, the filter paper 211 will not snake and fly out from between the belts 1133 in the Z-axis direction when folding. Thus, even if the folding speed of the filter paper 211 is increased, the possibility of not being able to fold correctly due to the snaked nature of the filter paper 211 can be reduced, thereby improving the manufacturing efficiency of the pleated filter.

[0308] Furthermore, the belt 1133 is configured to move in the direction of travel of the filter paper 211 (from front to back), and the filter paper 211 is folded therein. Thus, when the filter paper 211 comes into contact with the belt 1133, no frictional force is generated in the direction that stops the travel of the filter paper 211. Instead, a frictional force is generated in the direction that makes the filter paper 211 travel. Therefore, the filter paper 211 can travel smoothly between the belts 1133, and the manufacturing efficiency of the pleated filter is further improved.

[0309] Furthermore, by making the spacing between the strips 1133 gradually widen from the entrance portion of the space between them toward the exit portion, it is possible to achieve the following: Figure 8 The creases of the filter paper 211, which are gradually folded as shown, are in contact with the belt 1133 for a longer period of time, and the effect of using the friction of the belt 1133 to move the filter paper 211 is further improved.

[0310] Furthermore, in the compression filter manufacturing process of step S1-1, by including the crease application process of step S1-1-2, which pre-applies creases to the filter paper 211 before the folding process of step S1-1-3, the folding position in the folding process can be predetermined, irregular folding can be prevented, and thus the manufacturing efficiency of the pleated filter can be further improved.

[0311] Furthermore, according to this embodiment, after the compression filter 210A, which was folded in the folding process of step S1-1-3 in the compression filter manufacturing process of step S1-1, has its right plate 223 and left plate 224, which are part of the frame portion 220, installed in the right plate and left plate installation process of step S3, is opened in the direction orthogonal to the crease 212 in the opening process of step S4. Figure 7 It is stretched and unfolded (in the X-axis direction) to become a pleated filter 210.

[0312] Furthermore, the case where the filter paper is unfolded is also included if the distance between the folded surfaces of the folded filter paper increases and the length of the filter paper in the direction orthogonal to the folds increases.

[0313] The shape of a pleated filter without any frame is easily deformed, making it difficult to operate and install the frame. However, if the distance between the pleated surfaces is close and the length in the direction perpendicular to the folds is shortened, it is relatively easy to operate and install the frame.

[0314] Therefore, by installing at least a portion of the frame in a shortened state in a direction orthogonal to the crease and then unfolding it, the pleated filter is easy to operate during the manufacturing process of a product with a pleated filter, i.e., a filter unit, thereby improving the manufacturing efficiency of such a product.

[0315] In addition, in the strengthening / fixing process of step S1-1-4, after the compression filter 210A is temporarily fixed in a folded state, in the opening process of step S4, the fixation is released and the filter paper 211 is unfolded. Thus, in the state before the fixation is released, the filter paper 211 is fixed in a plate-like state with its length shortened in the direction orthogonal to the crease 212, which makes it easier to operate and easier to perform operations such as frame installation.

[0316] In addition, in the folding process of step S1-1-3, by folding the filter paper 211 in a fully compressed state, the filter paper 211 can be made into a plate-like state in which the length in the direction orthogonal to the fold (X-axis direction) is shortened to the maximum extent. Therefore, it is easier to operate, easier to install the frame, and easier to improve the strength of the compression filter 210A.

[0317] Furthermore, in the strengthening / fixing process of step S1-1-4, the portion of the crease 212 formed in the folded filter paper 211 in step S1-1-3 is heated, thereby removing the deformation of the crease 212 of the folded filter paper 211 and adjusting the shape of the formed compression filter 210A. Moreover, the shape of the compression filter 210A can be stabilized in the folded state in step S1-1-3, and after the opening process in step S4, the tension of the pleated filter 210 attempting to contract in the W-axis direction can be increased (the force of the pleated filter 210 attempting to unfold in the W-axis direction can be reduced), thus easily maintaining the shape of the pleated filter 210 in the filter unit 200.

[0318] In addition, in the right and left plate installation process of step S3, after the right plate 223 and left plate 224 are installed at both ends of the compression filter 210A in the direction orthogonal to the crease 212 (X-axis direction), the gap between them is widened in the opening process of step S4, so that the compression filter 210A can be easily unfolded.

[0319] Furthermore, by alternating between the compression filter 210A manufactured in step S1-1 and the compression filter 210A that is inclined from front to rear in the D-axis direction when viewed from the W-axis direction and the compression filter 210A that is inclined from front to rear in the D-axis direction before the right and left plate installation process in step S3, it is possible to manufacture a filter unit 200 in which multiple pleated filters 210 are connected alternately on the front and rear sides.

[0320] Furthermore, according to the compression filter 210A of this embodiment, the filter paper 211 is folded into a pleated shape. Compared to its state during use (pleated filter 210), it is compressed and shortened in a direction orthogonal to the crease 212 of the filter paper 211 (X-axis direction). Therefore, compared to its state of being unfolded into a pleated filter 210, it is less prone to deformation and easier to handle. Thus, with the compression filter 210A in this state, steps S2 and S3 are performed in the manufacturing process of the product equipped with the pleated filter 210, i.e., the filter unit 200, thereby making the filter easier to handle during the manufacturing process of the filter unit 200.

[0321] In addition, by making the compression filter 210A in a fully compressed or quasi-compressed state, the compression filter 210A is less prone to deformation and is easier to handle during the manufacturing process of the filter unit 200.

[0322] Furthermore, in the filter unit 200 of this embodiment, by forming pleats (primary pleats) in each pleated filter 210 and combining multiple pleated filters 210, secondary pleats with a larger spacing than primary pleats are formed, and the multiple pleated filters 210 as a whole constitute a filter having primary and secondary pleats.

[0323] Therefore, compared with existing filter units that have only one level of pleats, it is easier to increase the effective area of ​​the filter.

[0324] That is, when the filter has only one layer of pleats, the cross-section of the pleated surface is straight. In contrast, when a double layer of pleats is formed as in this embodiment, the cross-section of the pleated surface of the secondary pleat becomes serrated due to the primary pleat. Therefore, the linear length of the cross-section of the pleated surface becomes longer, and the area of ​​the filter paper 211 that can be used in the filter can be increased proportionally.

[0325] Furthermore, according to the filter unit 200 of this embodiment, the air supply direction (the direction in which air is introduced from the air inlet 230 into the frame 220) is the D-axis direction, which is along the crease 212 of the pleats of the pleated filter 210. Therefore, the resistance of the circulating air due to the creases and each pleated surface can be reduced, and the increase in air resistance caused by the multiple layers of pleats can be suppressed.

[0326] Furthermore, as described above, the pleated filter 210 is mounted in an inclined manner relative to the D-axis direction. Therefore, the air introduction direction (D-axis direction) and the extension direction of the crease 212 (the direction that is inclined up and down from the D-axis) are not completely parallel. However, as described above, even in this case, if the air introduction direction is consistent with the extension direction of the crease when the pleated filter 210 is viewed from above, it also includes the case where the air introduction direction from the air inlet 230 into the frame 220 is along the direction of the crease of the pleated filter 210.

[0327] In addition, when multiple pleated filters 210 are regarded as a single filter, the sealing portion 250, which is equivalent to a secondary pleat, is configured to face the air inlet portion 230 or the air outlet portion 240, so that air can be smoothly introduced and discharged from between the sealing portions 250.

[0328] In addition, the right end of all the pleated filters 210 is connected to the right plate 223, the left end is connected to the left plate 224, the rear end of the uppermost pleated filter 210 is connected to the upper plate 221, and the rear end of the lowermost pleated filter 210 is connected to the lower plate 222, so that the entire filter formed by multiple pleated filters 210 can be installed on the frame 220 in a way that no gap is created between it and the frame 220.

[0329] [(8) Variations]

[0330] Hereinafter, variations of the above-described embodiments will be described.

[0331] [a. Variation 1: Change in the manufacturing process of a compression filter]

[0332] In the above description of the manufacturing method, the case in which the filter paper 211 is folded, reinforced / fixed and cut using the folding device 113, the fixing device 114, the output roller 115 and the cutting device 116 in step S1-1 to manufacture the compression filter 210A has been described. However, instead of this, the compression filter 210A can also be manufactured using a simplified compression filter manufacturing apparatus 300 as a more basic device as shown below.

[0333] like Figure 12 As shown, the simplified compression filter manufacturing apparatus 300 includes a compression section 310 formed by two parallel plates 311 arranged with an X-axis distance of 550 mm and a Y-axis distance of 100 mm, and a Z-axis distance of 3.5 mm. The parallel plates 311 are formed of a material with a low coefficient of dynamic friction, and their opposing surfaces are planar.

[0334] A first gate 320 is formed at the rear end of the compression section 310, with the interval in the Z-axis direction reduced to 3.0 mm. The opening of the first gate 320 with an interval of 3.0 mm is provided with a baffle 330 that allows the opening to be opened and closed freely.

[0335] Additionally, a temporary bonding portion 340 and a heating portion 350 having a heating plate 351 arranged in a counter-arranged manner are provided behind the first gate 320. A second gate 360 ​​is formed at the rear end of the heating portion 350, with the interval in the Z-axis direction reduced to 3.3 mm.

[0336] When manufacturing the compression filter 210A using the simplified compression filter manufacturing apparatus 300, Figure 4 A filter paper 211, which has 500 mm in the X-axis direction, 100 mm in the Y-axis direction, and 0.2 mm in the Z-axis direction (thickness), and has alternating mountain and valley folds 212 every 3.5 mm, is placed after the compression section 310. The front end of the filter paper 211 (the end that contacts the pressure plate 370) is pushed toward the rear of the compression section 310 by a pressure plate 370 with a width (3.5 mm) that is the same as the spacing between the parallel plate 311 in the Z-axis direction.

[0337] Specifically, firstly, such as Figure 13A As shown, the first filter paper 211 is positioned in an extended state so that its front end reaches near the first gate 320.

[0338] Next, as Figure 13B As shown, after the baffle 330 of the first gate 320 is closed, the pressure plate 370 moves rearward, pushing the filter paper 211 in. Thus, the filter paper 211, in a state where its Z-axis serpentine motion is restricted by the parallel plate 311, alternately folds at creases 212 formed at 3.5mm intervals, as... Figure 13C As shown, the object is pressed against the baffle 330 when the folded surfaces 213 are in contact or close together.

[0339] Next, as Figure 13D As shown, the baffle 330 is opened. Then, the filter paper 211, which is folded with each folded surface 213 in contact, is pressed by the pressure plate 370 and pushed out from the first gate 320, and conveyed to the temporary bonding part 340.

[0340] After the filter paper 211, which is fed to the temporary bonding section 340, has its adjacent pleated surfaces 213 bonded together at both ends in the Y-axis direction, it is sent to the heating section 350. After the deformation of the crease 212 portion is removed by heating the two ends in the Z-axis direction through the heating plate 351, the manufactured compression filter 210A is pushed out from the second gate 360.

[0341] If the first filter paper 211 is pushed out from the first gate 320, then the second filter paper 211 is then pushed out as follows: Figure 13A The same process is set up and performed as shown. Furthermore, the same process is performed on the third, fourth, and subsequent filter papers 211, thereby enabling the production of individual filters. Figure 7 The compression filter 210A is shown with an X-axis diameter of 20mm, a Y-axis diameter of 100mm, and a Z-axis diameter of 3.5mm.

[0342] Furthermore, in the above example, the use of a pressure plate 370 as a means of pushing and folding the filter paper 211 backward within the compression section 310 has been described. However, the means of pushing the filter paper 211 in is not limited to the pressure plate 370. For example, air can be injected from the inlet to the outlet of the compression section 310 (from front to back) to push the filter paper 211 in by the pressure of the air. Alternatively, the filter paper 211 can be pushed in by the friction of the surface moving from front to back, as with the belt 1133 of the folding device 113 described above.

[0343] Furthermore, in the above example, the case where a planar component made of a material with a low coefficient of kinetic friction is used as the parallel plate 311 of the compression part 310 and arranged in a relative manner is described.

[0344] Regarding this point, the main purpose of forming the compression section 310 by a set of parallel plates 311 is to restrict the filter paper 211 from snaking in the Z-axis direction when compressing the filter paper 211 toward the first gate 320. Therefore, it is preferable that the frictional force generated when the filter paper 211 contacts the parallel plates 311 is small.

[0345] Therefore, from the viewpoint of reducing the frictional force generated when the filter paper 211 comes into contact with the parallel plate 311, the parallel plate 311A ​​can also be made to have a planar flat portion 3111 and a protrusion portion 3112 that is a strip-shaped protrusion extending along the X-axis direction, just like the compression portion 310A shown in FIG14.

[0346] The protrusions 3112 are formed on one side of the planar portion 3111 in such a way that they extend along the X-axis direction and are arranged in a plurality of ways along the Y-axis direction. The parallel plates 311A ​​are configured such that the surfaces of the planar portion 3111 on which the protrusions 3112 are formed are opposite to each other.

[0347] In this case, a set of parallel plates 311A ​​are configured such that the planar portions 3111 are spaced 5.0 mm apart and the front ends of the protrusions 3112 are spaced 3.5 mm apart.

[0348] In this case, when the filter paper 211 moving between the parallel plates 311A ​​comes into contact with the parallel plates 311A, it only contacts the front end of the protrusion 3112, and the contact area becomes narrower. Therefore, when the filter paper 211 is compressed toward the first gate 320, it can restrict the filter paper 211 from snaking in the Z-axis direction and further reduce the friction force generated when the filter paper 211 comes into contact with the parallel plates 311A.

[0349] Furthermore, the planar portion 3111 is not necessary and can be removed. In this case, only the protrusion 3112 in FIG14 is retained, and multiple elongated plates are arranged in a strip shape above and below the filter paper 211 to form a compression section. In addition, regardless of whether the planar portion 3111 is present, multiple components that are longer in the first direction (X-axis direction) than in the second direction (Y-axis direction) orthogonal to it are arranged in a strip shape at intervals in the second direction.

[0350] In this case, the elongated plate, retaining only the protrusion 3112, is preferably formed such that its width is wider in the Z-axis direction, orthogonal to the surface of the filter paper 211 before folding within the compression section, than in the Y-axis direction, which is orthogonal to it. This prevents the plate from easily flexing in the Y-axis direction when it expands due to important factors such as thermal expansion, thus preventing changes in the Z-axis spacing of the compression section due to flexing in the Z-axis direction.

[0351] For example, if the width of filter paper 211 in the Y-axis direction is 100mm, then four slender plates with a width of 10mm in the Y-axis direction and a width in the Z-axis direction that is wider than that in the Y-axis direction and a length of 550mm in the X-axis direction can be arranged at 20mm intervals in the Y-axis direction to form a compression section, and these plates can be arranged in two groups, one above the other, to form a compression section.

[0352] The creases 212 formed on the filter paper 211 extend along the Y-axis direction, so it is not necessary to restrict the movement in the Z-axis direction throughout the entire Y-axis direction. As long as the movement in the Z-axis direction can be restricted in a part of the Y-axis direction, the movement of the filter paper 211 in the Z-axis direction can be restricted and the filter paper 211 can be prevented from serpentinizing in the Z-axis direction.

[0353] That is, any component that is disposed on both sides (top and bottom) of the filter paper 211 and can restrict the filter paper 211 from moving in a direction orthogonal to the surface of the filter paper 211 before folding (Z-axis direction) is equivalent to a restricting component that restricts the movement of the filter paper 211 in the Z-axis direction when the filter paper 211 is folded, regardless of whether it is plate-shaped.

[0354] However, if only the protrusion 3112 is retained, its position cannot be fixed. Therefore, for the flat portion 3111, for example, only its peripheral portion (the front, back, left and right ends) can be retained as a frame, so that the protrusion 3112 is connected to such a frame at the front and back ends.

[0355] With all or part of the flat portion 3111 removed, the upper and lower surfaces of the filter paper 211 during the folding process are exposed. Therefore, heat, light, etc., can be applied to the filter paper 211 during the folding process from above and / or below, and the width of the processing that can be performed is widened. For example, by blowing hot air from above and below, the filter paper 211 can be folded while being heated.

[0356] Furthermore, from the viewpoint of limiting the serpentine movement of the filter paper 211 while reducing the frictional force generated on the filter paper 211, it is most preferable to compress the filter paper 211 between two surfaces that are arranged in opposite directions and move along the X-axis direction (from front to rear), as is the belt 1133 provided by the folding device 113 of the filter unit manufacturing system 100 described above.

[0357] [b. Variation Example 2: Change in the method for determining the folding interval]

[0358] In the above description of the manufacturing method, the method for determining the interval of folding the filter paper 211 in the folding process of step S1-1-3 was described in the case where the folding process is performed by the folding device 112 in the folding process of step S1-1-2. However, alternatively, it is also possible to use... Figure 20 and Figure 21The swinging device 117 shown causes the filter paper 211 to swing in the Z-axis direction.

[0359] like Figure 20 As shown, the swing device 117 includes a swing portion 1171 with a slit 11711 through which the filter paper 211 can pass, a base 1172, and a connecting shaft 1173 connecting the swing portion 1171 and the base 1172, and is configured such that the swing portion 1171 swings relative to the base 1172 in the Z-axis direction.

[0360] like Figure 21 As shown, the swinging device 117 is positioned in front of the entrance to the space between the two belts 1133 of the folding device 113, and is configured such that when the filter paper 211 passes through the slit 11711 of the swinging part 1171, the swinging part 1171 moves up and down at a frequency f (the number of swings per second is f).

[0361] By setting the width of the manufactured compression filter 210A in the Z-axis direction (in this case, the interval of the second opposing surfaces 11321 of the second wall portion 1132 of the folding device 113 (the interval of the outlet of the space between the belts 1133) to h (mm), the feed speed of the filter paper 211 to the folding device 113 (the feed speed of the filter paper 211 from the filter paper roller 111) to v (mm / s), and setting the frequency f to f = v / 2h (for example, f is 100Hz when v is 1000mm / s and h is 5mm), the filter paper 211 is made to swing in the Z-axis direction, so that the filter paper 211 vibrates up and down in the X-axis direction every 5mm. The filter paper 211 is folded in the folding device 113 at 5mm intervals, and a compression filter 210A with a height of 5mm in the Z-axis direction can be manufactured.

[0362] Furthermore, from the viewpoint of accurately aligning and folding the sizes of each folded surface 213, it is preferable to include either the crease application process of step S1-1-2 or the process of swinging the filter paper 211 as described above. However, it is also generally possible to omit the crease application process of step S1-1-2 or the process of swinging the filter paper 211 as described above.

[0363] Even in this case, the filter paper 211 is conveyed from front to rear in the folding device 113 via the belt 1133 and stacked in front of the gate 1135, and the serpentine movement of the filter paper 211 in the Z-axis direction is restricted by the belt 1133. Therefore, although the accuracy of the position of the crease 212 (the uniformity of the size of each fold surface 213) is reduced, folding the filter paper 211 itself is feasible.

[0364] Furthermore, regardless of the thickness of the filter paper 211, the filter paper 211 is folded between the bands 1133, but the folding method varies depending on the relationship between the interval of the bands 1133 and the thickness of the filter paper 211.

[0365] Figure 22 is an explanatory diagram showing the different folding methods resulting from the relationship between the spacing of the strip 1133 of the folding device 113 and the thickness of the filter paper in the folding process of step S1-1-3. Furthermore, for ease of explanation, the spacing of the strip 1133 is set to be constant.

[0366] Figure 22A The illustration shows a case where the thickness of filter paper 211 is approximately half the spacing of band 1133. In this case, it is difficult to consider any folding method other than a folded shape where the width of the folded surface 213 is approximately the same as the spacing of band 1133, so the necessity of the folding process in step S1-1-2 and the process of swinging the filter paper 211 as described above is relatively low.

[0367] In contrast, Figure 22B The illustration shows a case where the thickness of filter paper 211 is significantly smaller compared to the spacing of bands 1133. In this case, the folding pattern of filter paper 211 is not necessarily limited to a pleated shape where the width of the pleated surface 213 is approximately the same as the spacing of bands 1133, such as... Figure 22B As shown, sometimes creases of that shape are produced at the upper or lower end, which are introduced into the direction of the belt's travel.

[0368] Although also affected by other conditions, if the thickness of filter paper 211 is approximately 0.2 to 0.6 times that of the spacing between 1133, then... Figure 22A As shown, it is difficult to consider cases where the filter paper is folded into shapes other than pleats. If the thickness of the filter paper 211 is less than 0.2 times the spacing of the band 1133, then as... Figure 22B As shown, creases of that shape are easily produced by the direction of the belt's travel.

[0369] Therefore, in the latter case, although not necessary, the necessity of the crease application process in step S1-1-2 and the process of waving the filter paper 211 as described above is higher than in the former case.

[0370] [c. Variation Example 3: Changes in the structure of the manufactured filter unit]

[0371] In the description of the above manufacturing method, such as Figure 2 and Figure 3As shown, a filter unit 200 is described in which 20 pleated filters 210 are arranged in a sawtooth pattern when viewed from the W-axis direction, thus forming two layers of pleats: the pleats formed in each pleated filter 210 and the pleats formed by the 20 pleated filters 210. However, the structure of the manufactured filter unit is not limited to this.

[0372] For example, multiple pleated filters 210 can be used and each pleated filter 210 can be configured to be... Figure 2 and Figure 3 Different configurations of sawtooth shapes are shown, such as Figure 19 As shown, a single pleated filter 210 can also be used and the frame can be mounted by surrounding its ends.

[0373] [d. Variation Example 4: Change of strengthening / fixing process]

[0374] In the above description of the manufacturing method, the cases of temporary bonding treatment based on temporary bonding device 1141 and heat treatment based on heat treatment device 1142 in the strengthening / fixing treatment process (step S1-1-4) have been described, but the strengthening / fixing treatments that can be performed are not limited to these. The following are examples of the strengthening / fixing treatments that can be performed.

[0375] [(a) First approach]

[0376] It is a method of fixing the shape of the crease 212 by simply cooling after heating.

[0377] Specifically, the crease 212 is heated to a temperature corresponding to the material of the filter paper 211, causing the crease 212 to undergo plastic deformation, and then returned to room temperature, thereby fixing the deformation.

[0378] When the compression filter 210A is unfolded into a pleated filter 210 with residual deformation of creases, the force of the pleats attempting to unfold may sometimes remain. However, such residual force can be easily prevented by eliminating the deformation of creases 212 through heat treatment.

[0379] [(b) Second method]

[0380] This is a temporary bonding process based solely on adhesive. That is, adhesive is applied to the surface to connect the folds 212 of the folded filter paper 211 to each other and the side ends (ends in the Y-axis direction) to each other.

[0381] Specifically, for example, if the creases 212 are to be bonded together, a hot melt adhesive (such as paraffin wax) with a melting temperature of less than 120 degrees Celsius is used as the adhesive, and such hot melt adhesive is applied to the upper and lower surfaces in a linear manner extending along the X-axis.

[0382] [(c) Third method]

[0383] This is a temporary bonding process that only involves melting the side end face (end in the Y-axis direction) of the folded filter paper 211. The melting temperature and other conditions depend on the material of the filter paper 211.

[0384] [(d) Fourth method]

[0385] The method involves using auxiliary materials. Specifically, after overlapping the filter paper 211 with auxiliary materials made of other materials, a process corresponding to the material of such auxiliary materials is performed, and the auxiliary materials are bonded together, thereby slowly bonding the pleated surfaces 213 together.

[0386] [(e) Fifth Method]

[0387] This is a method of strengthening the folding device 113 and forcefully compressing the filter paper 211 in the X-axis direction. That is, when the compression of the filter paper 211 in the X-axis direction based on the folding device 113 is strong and the force on the filter paper 211 to unfold in the X-axis direction from the folded state of the folding device 113 is very small, no additional treatment for fixing is required.

[0388] Alternatively, instead of reinforcing the folding device 113, a device (hereinafter referred to as a "compression device") can be provided behind the folding device 113 to keep the distance between the first opposing surfaces 11331 of the tape 1131 constant at 3.5 mm. In this way, the filter paper 211 folded by the folding device 113 can be further compressed in the X-axis direction by such a compression device, so that it becomes a state as described above where no additional treatment for fixing is required.

[0389] [(f) Sixth method]

[0390] This method combines multiple approaches from the first to the fifth method mentioned above.

[0391] [(g) Seventh Method]

[0392] This is a method that omits the strengthening / fixing process in step S1-1-4. That is, if the filter paper 211 is folded while a strong material (such as a metal mesh) that can plastically deform at room temperature is superimposed on it as a reinforcing sheet, the filter paper 211 is strengthened by such a reinforcing sheet and fixed in the folded state, so there is no need to perform additional strengthening / fixing process in step S1-1-4.

[0393] [e. Variation 5: Manufacturing methods for other products]

[0394] In the above description of the manufacturing method, the manufacturing method of the multi-stage inclined compression filter 500 with left and right plates and the filter unit 200 utilizing it has been described. The manufacturing methods of other products will also be described below.

[0395] [(a) Multistage parallel compression filter with left and right plates]

[0396] In manufacturing Figure 18 In the case of the multi-stage parallel compression filter 600 with left and right plates as shown, in the compression filter arrangement process of step S2 in the description of the above manufacturing method, a container with parallel slits is used instead of a container with slits formed in a serrated shape, so that the multiple compression filters 210A can be arranged in parallel when viewed from the W-axis direction.

[0397] The other manufacturing methods are the same as those for the multi-stage inclined compression filter 500 with left and right plates.

[0398] [(b) Multi-filter unit]

[0399] In manufacturing Figure 15 In the case of the multi-filter unit 400 shown, firstly, multiple semi-finished products manufactured up to step S4 are prepared (for the multi-stage inclined compression filter 500 with left and right plates, the spacing between the right plate 223 and the left plate 224 is increased). If as shown... Figure 15 In the case shown, where filter units 200A are arranged in 4 columns in the W-axis direction and 3 columns in the H-axis direction, 12 filter units 400 are prepared.

[0400] Next, the prepared semi-finished products are arranged according to the configuration of the multi-filter unit 400 to be manufactured. If so... Figure 15 In the case of manufacturing multiple filter units 400 in which filter units 200A are arranged in 4 columns in the W-axis direction and 3 columns in the H-axis direction, the filter units 200A are arranged in a manner with 4 columns in the W-axis direction and 3 columns in the H-axis direction.

[0401] Next, an upper plate 221A is installed on the upper end of the arranged semi-finished products in such a way that it covers the entire upper end, and a lower plate 222A is installed on the lower end in such a way that it covers the entire lower end.

[0402] Next, a finishing process is performed. The finishing process is the same as described in step S6, except for the container size and the shape of the groove. After preparing a container with a groove corresponding to the shape of the portion excluding the airflow opening, the groove is filled with hot melt adhesive. Multiple semi-finished products, with the upper plate 221A and lower plate 222A installed in a row, are inserted into this groove, thereby covering the entire front and rear surfaces except for the airflow opening. This completely seals the front and rear surfaces except for the airflow opening.

[0403] [f. Variation 6: Change of filter material]

[0404] As described above, filter paper 211 broadly includes sheet-like components capable of removing particles, which are the objects of removal, from the fluid. For example, filter paper 211 can also be a membrane filter. Membrane filters are composed of MF membranes (precision filtration membranes), RO membranes (reverse osmosis membranes), etc.

[0405] When filter paper 211 is a membrane filter, since it is a thin film, it is preferable to have a reinforcing material. As a reinforcing material, for example, a nonwoven fabric of polypropylene fibers can be used.

[0406] [g Variation 7: Change of the filtering object]

[0407] In the description of the structure and manufacturing method above, the case where the filter unit 200 filters air has been described, but the filter can be any fluid, and is not limited to air. For example, it can be a gas other than air, or it can be a liquid.

[0408] In particular, when filtering liquids, the mainstream method is to filter the liquid flowing in the pipeline. Therefore, long cylindrical filters that match the shape of the pipeline are often used. As cylindrical filters, there are also many filters with standardized outer diameters.

[0409] However, existing pleated filters with only one pleat are difficult to construct into slender cylindrical filters. Therefore, when the filtered object is a liquid, it is especially difficult to fully achieve the effect of increasing the effective area of ​​the pleated filter.

[0410] In contrast, if a filter unit with double-layer pleats is formed in a filter as in this embodiment, it is easy to increase the depth, and when used for filtering liquids in pipelines, it is also easy to fully obtain the effect of increasing the effective area of ​​the filter based on the pleat shape.

[0411] Furthermore, the above points are not limited to liquid filtration; they also apply to gas filtration in ventilation ducts and pipes. Therefore, even for gases in ventilation ducts and pipes where it is difficult to use existing pleated filters with only one pleat, the effect of significantly increasing the effective area of ​​the pleated filter can be easily achieved.

[0412] [2 Second Embodiment]

[0413] The following is based on Figures 23-3 1. A second embodiment of this disclosure will be described. Furthermore, the same reference numerals are used for parts identical to those in the first embodiment, and descriptions are omitted.

[0414] [(1) Regarding block filters]

[0415] A block filter is a filter composed of multiple compressed filters stacked together, preferably stacked in the Z-axis direction with their folded portions in contact with each other. When the compressed filters are cuboid in shape, the block filter is shaped like a cuboid that is longer than a single compressed filter in the Z-axis direction.

[0416] Block filters can compactly combine long and large filter papers, making them highly portable.

[0417] In block filters, such as Figure 23 As shown, one of the filters (a filter formed by stacking multiple compression filters 210A in the Z-axis direction) of the multi-stage parallel compression filter 600A with left and right plates described later is referred to as a single filter 700.

[0418] In addition, such as Figure 24 As shown, a filter formed by connecting multiple individual filters 700 is called a multi-filter 800. Typically, it is a three-dimensional assembly (multiple individual filters 700 connected in the X-axis, Y-axis and Z-axis directions), but it is not limited to this, and also includes an assembly formed by connecting multiple individual filters 700 in only one or two directions.

[0419] Multiple individual filters 700 can be manufactured by cutting multiple filters 800 along a cross section parallel to the XY plane, XZ plane and / or YZ plane.

[0420] Furthermore, the container used for transporting and storing the block filter is preferably configured with its internal dimensions in the X-axis direction such that each compressed filter constituting the block filter is in a fully compressed state when the block filter is contained in the container.

[0421] This point also applies to the containers used during the transportation and storage of compression filters that are not block filters.

[0422] [(2) Regarding the filter unit]

[0423] like Figures 25-27 As shown, the filter unit 200C according to the second embodiment of this disclosure has 28 pleated filters 210 housed in the frame portion 220.

[0424] Filter unit 200C is used to remove particles that are the target of removal from the air by allowing air to circulate in the front-to-back direction, such as... Figures 25-27 As shown, it includes: 28 pleated filters 210, configured such that the X-axis aligns with the W-axis, the Y-axis aligns with the D-axis, and the Z-axis aligns with the H-axis; and a frame 220, configured such that the upper plate 221 is located on the upper side, the lower plate 222 is located on the lower side, the right plate 223 is located on the right side, and the left plate 224 is located on the left side; the air inlet 230 is located on the front side, and the air outlet 240 is located on the rear side; the right end of all pleated filters 210 is connected to the right plate 223, and the left end of all pleated filters 210 is connected to the left plate 224.

[0425] like Figures 25-27 As shown, the 28-piece pleated filter 210 is configured such that the pleat creases are parallel to the D-axis (front-to-back direction), and Figure 25 The DW surface in the filter unit 200C shown is... Figure 1 The XY planes of the pleated filter 210 shown are parallel. Among the adjacent pleated filters 210, the crease 212 on the lower side of the upper pleated filter 210 and the crease 212 on the upper side of the lower pleated filter 210 are at approximately the same height in the H-axis direction.

[0426] In addition, such as Figure 26 As shown, in the filter unit 200C, similar to the filter unit 200 of the first embodiment, the upper plate 221, the uppermost pleated filter 210 to the lowermost pleated filter 210, and the lower plate 222 are connected in an alternating manner when viewed from the W-axis direction to form a sealing part 250. When the 28 pleated filters 210 are considered as a whole, pleats are formed in which concave portions and convex portions that are concave in the front are alternately repeated in the H-axis direction when viewed from the front (and concave portions and convex portions that are concave in the rear are alternately repeated in the H-axis direction when viewed from the rear).

[0427] That is, in this case, for the 28 pleated filters 210, the pleats formed in each of them are called primary pleats, and the pleats formed by the 28 pleated filters 210 are called secondary pleats with a larger spacing than the primary pleats. When the 28 pleated filters 210 are regarded as a whole, a filter is formed by overlapping the primary pleats and the secondary pleats.

[0428] In addition, in this case, the direction in which air is introduced from the air inlet 230 is parallel to the direction along the crease of the first fold, which is the D-axis direction.

[0429] In addition, such as Figure 25 and Figure 26 As shown, a front surface side connecting post 260 is formed on the front surface of the filter unit 200C. This front surface side connecting post 260 connects to the central portion of the front end of the upper plate 221 in the W-axis direction, the central portion of the front end of each pleated filter 210 in the W-axis direction (the central portion of each sealing part 250 on the front surface side), and the central portion of the front end of the lower plate 222 in the W-axis direction. The front surface side connecting post 260 and each sealing part 250 on the front surface side are integrally formed with a hot melt adhesive several mm thick.

[0430] In addition, such as Figure 26 As shown, a rear surface-side connecting post 270 is formed on the rear surface of the filter unit 200C. This rear surface-side connecting post 270 connects to the central portion of the rear end of the upper plate 221 in the W-axis direction, the central portion of the rear end of each pleated filter 210 in the W-axis direction (the central portion of each sealing part 250 on the rear surface side) and the central portion of the rear end of the lower plate 222 in the W-axis direction. The rear surface-side connecting post 270 and each sealing part 250 on the rear surface side are integrally formed with a hot melt adhesive several millimeters thick.

[0431] [(3) Description of the manufacturing method]

[0432] The manufacturing method of the filter unit 200C, which uses 28 pleated filters 210, is described.

[0433] Through the following processes, a compression filter 210B with an X-axis length of 1000mm, a Y-axis length of 200mm, and a Z-axis length of 3.5mm can be manufactured from multiple filters 800 with an X-axis length of 1000mm, a Y-axis length of 200mm, and a Z-axis length of 98mm, to produce 100 filter units 200C with 28 pleated filters 210 arranged in parallel at 3.5mm intervals along the Z-axis direction.

[0434] The manufacturing method for producing a filter unit 200C having 28 pleated filter pieces 210 includes: Figure 28 The processes shown are as follows.

[0435] [a Step S2-1: Compression filter manufacturing process]

[0436] Except for using a filter paper roller 111 with a width of 200 mm in the Y-axis direction and cutting it at 1000 mm intervals in the X-axis direction during the cutting process to manufacture a compression filter 210B with an X-axis width of 1000 mm, a Y-axis width of 200 mm, and a Z-axis width of 3.5 mm, the compression filter manufacturing process in step S2-1 is the same as step S1-1 of the manufacturing method according to the first embodiment. The compression filter 210B to be manufactured here is preferably equivalent to the fully compressed filter described in the first embodiment. Even if it is not equivalent to a fully compressed filter, it is preferably equivalent to a quasi-compression filter, but it is not limited thereto.

[0437] [b Step S2-2: Compressed Filter Stacking Process]

[0438] 28 layers of compression filter 210B are stacked in the Z-axis direction. This allows for the manufacture of... Figure 24 The multi-piece filter 800 has an X-axis diameter of 1000mm, a Y-axis diameter of 200mm, and a Z-axis diameter of 98mm, as shown.

[0439] [c Step S2-3: Block filter cutting process]

[0440] First, the multiple filters 800 manufactured in step S2-2 are cut along the XZ plane at the center position in the Y-axis direction, thereby manufacturing two multiple filters with X-axis length of 1000mm, Y-axis length of 100mm, and Z-axis length of 98mm.

[0441] Furthermore, each of the two multi-piece filters manufactured is cut along the ZY plane at 20mm intervals in the X-axis direction, thus enabling the production of 100 filters. Figure 23 The single filter 700 is shown as having an X-axis diameter of 20mm, a Y-axis diameter of 100mm, and a Z-axis diameter of 98mm. Furthermore, the state of the single filter 700 is the same as in steps S1-2 of the first embodiment, equivalent to the state where the compressed filters 210A are arranged in a predetermined configuration after the compressed filter arrangement process.

[0442] Furthermore, when cutting along the ZY plane, if a heating wire with a spacer is used to heat and cut simultaneously, the cut surface of the compression filter 210B melts, thereby connecting adjacent compression filters 210A. A membrane 710 (a membrane that forms the filter paper 211, which melts and solidifies, covering the entire surface of the end in the X-axis direction) can be formed on the cut surface. Thus, multiple compression filters 210A are connected by membranes 710 formed on both end faces in the X-axis direction. Figure 29 The 700A is a single-piece filter with a membrane, as shown in the image.

[0443] Furthermore, in cases where the compression ratio of the compressed filter 210A is lower than the specified compression ratio, or the length in the X-axis direction is longer than the specified length, pressure is applied from a direction orthogonal to the cutting surface (X-axis direction), and cutting is performed while compressing in that direction, thereby enabling the length in the X-axis direction of the manufactured membrane-bearing monolithic filter 700A to be adjusted to the specified length.

[0444] Alternatively, the same effect can be achieved by cutting multiple filters 800 within a container that has a specified internal size in a direction orthogonal to the cut surface (X-axis direction).

[0445] [d Step S2-4: Installation process of the right and left panels]

[0446] Next, the 100 formed in steps S2-3 Figure 29 Each of the membrane-coated monolithic filters 700A shown has a rectangular right plate 223 with a Y-axis length of 100 mm and a Z-axis length of 98 mm attached to its right end in the X-axis direction, and a rectangular left plate 224 with a Y-axis length of 100 mm and a Z-axis length of 98 mm attached to its left end in the X-axis direction.

[0447] Thus, 100 were formed. Figure 30 The 600A is a multi-stage parallel compression filter with left and right plates, as shown in the image.

[0448] Furthermore, the description of the manufacturing method following this step is the same as that in the first embodiment, such as... Figure 30 As shown, the alignment direction and axis with the completed filter unit 200C will be explained. In this case, each compression filter 210A is configured with the X-axis parallel to the W-axis, the Y-axis parallel to the D-axis, and the Z-axis parallel to the H-axis. Therefore, only the X-axis, Y-axis, and Z-axis are replaced with the W-axis, D-axis, and H-axis, respectively.

[0449] [e Step S2-5 Opening the process]

[0450] As described in steps S1-4, the interval between the right plate 223 and the left plate 224 is increased in the W-axis direction. As a result, each of the compression filters 210A of the multi-stage parallel compression filter 600A with left and right plates is stretched in the W-axis direction, thus becoming a pleated filter 210.

[0451] [f Step S2-6: Installation process of upper and lower plates]

[0452] As described in steps S1-5, an upper square plate 221, 100 mm in the W-axis direction and 100 mm in the D-axis direction, is installed at the upper ends of the right plate 223 and the left plate 224 in a manner that spans between them, and a lower square plate 222, 100 mm in the W-axis direction and 100 mm in the D-axis direction, is installed at the lower ends of the right plate 223 and the left plate 224 in a manner that connects them.

[0453] [g Step S2-7: Sealing process]

[0454] The same processing as described in the finishing process of steps S1-6 is performed to seal the front and rear surface sides. However, in this case, a groove corresponding to the front surface connecting post 260 is provided in the container for processing the front surface side, so that the front surface connecting post 260 is formed simultaneously with the sealing of the front surface side by using hot melt adhesive. Similarly, a groove corresponding to the rear surface connecting post 270 is provided in the container for processing the rear surface side, so that the rear surface connecting post 270 is formed simultaneously with the sealing of the rear surface side by using hot melt adhesive.

[0455] Furthermore, to ensure a complete seal on both the front and rear surfaces, after sealing, the sealing surfaces (front and rear surfaces) can be immersed in a sealing liquid with a lower viscosity than the hot melt adhesive and bonding material used in the first stage of sealing treatment, to fill any tiny gaps. As the sealing liquid used at this time, various liquids can be used, including various sealants, water or solvents formed by melting the sealing substance, and substances that chemically react with the hot melt adhesive used for sealing (such as cyanoacrylate instant adhesives).

[0456] like Figure 25 and Figure 26 As shown, after a sealing process, a sealing part 250 and a front surface side connecting post 260 are integrally formed on the front surface of the filter unit 200C.

[0457] As shown in Figure 31, the sealing part 250 is formed by a flat part 251 corresponding to the bottom surface of the groove of the container used for sealing, and an inclined surface 252 corresponding to the inclined surface of the groove that narrows towards the bottom surface.

[0458] As shown in Figure 31, the front end of the pleated filter 210 is crushed on the inclined surface 252, thereby increasing the opening ratio of the air inlet 230.

[0459] In addition, through the sealing process, a sealing part 250 and a rear surface side connecting post 270 are integrally formed on the rear surface of the filter unit 200C.

[0460] On the rear surface side, the sealing part 250 is constructed in the same way as the front surface side, consisting of a flat part 251 and an inclined surface 252. The rear end of the pleated filter 210 is crushed on the inclined surface 252, thereby increasing the opening ratio of the air exhaust part 240.

[0461] [(4) Explanation of the effect]

[0462] According to the filter unit 200C of this embodiment, the same effect as the filter unit 200 of the first embodiment can be obtained, and the spacing between the pleated filters 210 in the H-axis direction is narrowed, so more pleated filters 210 can be stacked in the H-axis direction. Therefore, compared with the filter unit 200 of the first embodiment, it is easy to further expand the effective area of ​​the filter.

[0463] In addition, all the pleated filters 210 are connected to the front surface side connecting post 260 at the center of the W-axis direction on the front surface side, and all the pleated filters 210 are connected to the rear surface side connecting post 270 at the center of the W-axis direction on the rear surface side, thereby reducing the deflection of the pleated filters 210 caused by time-related changes due to the influence of gravity.

[0464] Furthermore, if the filter unit 200C is rotated 90 degrees so that the right plate 223 or the left plate 224 faces downward, the length direction of the pleated filter 210 is along the vertical direction, thus further reducing the deflection of the pleated filter 210 caused by changes over time due to gravity.

[0465] In addition, filter units 200C are manufactured from the compression filter 210B via multiple filters 800 and single filters 700, thereby enabling the efficient production of a large number of filter units.

[0466] [3 Third Implementation]

[0467] The following is based on Figures 32-38 The third embodiment of this disclosure will be described below. Furthermore, parts identical to those in the first or second embodiment will be labeled with the same reference numerals and their descriptions will be omitted.

[0468] [(1) Regarding the filter unit]

[0469] like Figures 32-34 As shown, the filter unit 200D according to the third embodiment of this disclosure has 14 pleated filters 210 housed in the frame portion 220B. The direction along the crease of the first pleat and the direction along the crease of the second pleat are both in the D-axis direction and parallel to each other.

[0470] In addition, the airflow direction is orthogonal to the crease of the first fold (crease 212 formed in the folded filter 210) (W-axis direction, from right to left in this case).

[0471] That is, 14 pleated filters 210 are continuously formed, such as Figure 34 As shown, the filter paper 211 is alternately connected at the left and right ends. That is, the portion of the filter 210 that connects to each other on the left and right (filter connection surface 214) and the pleated surface 213 connected above and below it are equivalent to the creases of secondary pleats.

[0472] Furthermore, the portion containing such an area, which is the vertex of the convex part of the fold, is equivalent to the crease of the fold, and its length direction (in this case, the D-axis direction) becomes the direction along the crease.

[0473] Additionally, the frame portion 220B includes an upper plate 221, a lower plate 222, a front plate 225A, a rear plate 226A, a right opening frame 227, and a left opening frame 228. That is, the frame portion 220B is surrounded by plates at the front and back and top and bottom, and has openings formed in the right opening frame 227 and the left opening frame 228. The opening of the right opening frame 227 corresponds to the air inlet 230 for introducing air into the filter unit 200D, and the opening of the left opening frame 228 corresponds to the air outlet 240 for discharging air from the filter unit 200D.

[0474] [(2) Description of the manufacturing method]

[0475] The manufacturing method of the filter unit 200D, which uses 14 pleated filters 210, is described.

[0476] Through the following processes, a filter unit 200D can be manufactured from a compression filter 210C with an X-axis length of 280mm, a Y-axis length of 100mm, and a Z-axis length of 3.5mm, by bending it to a state with an X-axis length of 20mm, a Y-axis length of 100mm, and a Z-axis length of 94.5mm, and with 14 pleated filters 210 arranged in parallel at 7.0mm intervals in the Z-axis direction.

[0477] The manufacturing method for producing a filter unit 200D having 14 pleated filter elements 210 includes... Figure 35 The processes shown are as follows.

[0478] [a Step S3-1: Compression filter manufacturing process]

[0479] Except for using a filter paper roller 111 with a width of 100 mm in the Y-axis direction and cutting it at 280 mm intervals in the X-axis direction during the cutting process to manufacture a compression filter 210C with a width of 280 mm in the X-axis direction, 100 mm in the Y-axis direction, and 3.5 mm in the Z-axis direction, the compression filter manufacturing process in step S3-1 is the same as step S1-1 of the manufacturing method according to the first embodiment. The compression filter 210C to be manufactured here is preferably equivalent to the fully compressed filter described in the first embodiment. Even if it is not equivalent to a fully compressed filter, it is preferably equivalent to a quasi-compression filter, but it is not limited thereto.

[0480] [b Step S3-2: Grouping Process]

[0481] like Figure 36 As shown, the compression filter 210C has pleated surfaces arranged at 20mm intervals in the X-axis direction, thus dividing it into 14 blocks. That is, these individual blocks form the compression filter 210A with 20mm in the X-axis direction, 100mm in the Y-axis direction, and 3.5mm in the Z-axis direction.

[0482] [c Step S3-3: Compression filter arrangement process]

[0483] Next, as Figure 37 As shown, the compression filter 210C, which was divided into 14 blocks (compression filter 210A) in step S3-2, is arranged such that each compression filter 210A is arranged in the Z-axis direction and is connected by unfolded pleated surfaces when viewed from the Y-axis direction. Hereinafter, the pleated surface connecting the compression filters 210A to each other will be called filter connection surface 214, to distinguish it from the other pleated surfaces (pleated surfaces 213).

[0484] There are no particular limitations to this configuration method. For example, by preparing a frame with 14 cantilevered shelves (the upper surfaces of each shelf are spaced 7mm apart in the Z-axis direction), for the compression filter 210C, each compression filter 210A is mounted on a shelf of such a frame, thus becoming... Figure 37 The state shown is sufficient.

[0485] like Figure 37 As shown, after this process, the upper and lower adjacent compression filters 210A are staggered at both ends of the filter connection surface 214 in the X-axis direction, forming secondary pleats.

[0486] [d Step S3-4: Installation process of the right and left opening frames]

[0487] Next, for example in step S3-3 Figure 37The compression filter 210C, as shown, has a right opening frame 227 glued to the right end and a left opening frame 228 glued to the left end.

[0488] In this case, a hot melt adhesive can also be used as an adhesive. After applying the hot melt adhesive to the left surface of the right opening frame 227 and the right surface of the left opening frame 228, the right opening frame 227 is pressed from the right and the left opening frame 228 from the left. Figure 37 The compression filter 210C is configured as shown, thus... Figure 38 As shown, the pleated surface 213 at the right end of each compression filter 210A and the filter connecting surface 214 disposed at the right end are bonded to the right opening frame 227, and the pleated surface 213 at the left end and the filter connecting surface 214 disposed at the left end are bonded to the left opening frame 228.

[0489] Thus, a form of Figure 18 The multi-stage parallel compression filter 600 shown is a filter modified by using the left and right plates as the right opening frame 227 and the left opening frame 228, and each compression filter 210A is connected by the filter connection surface 214 (multi-stage parallel compression filter 600B with left and right plates).

[0490] Furthermore, following this step, the description of the manufacturing method will be the same as that in the first and second embodiments, as follows: Figure 38 As shown, the alignment direction and axis with the completed filter unit 200D will be explained. In this case, as with the manufacturing method in the second embodiment, each compression filter 210A is configured with the X-axis parallel to the W-axis, the Y-axis parallel to the D-axis, and the Z-axis parallel to the H-axis. Therefore, only the X-axis, Y-axis, and Z-axis are replaced with the W-axis, D-axis, and H-axis, respectively.

[0491] [e Step S3-5 Opening the process]

[0492] Similar to the descriptions of the right plate 223 and left plate 224 in steps S1-4 and S2-5, the interval between the right opening frame 227 and the left opening frame 228 is increased in the W-axis direction. As a result, the individual compression filters 210A formed by dividing the compression filter 210C in step S3-2 become pleated filters 210 that are stretched in the W-axis direction.

[0493] [f Step S3-6: Installation process of upper and lower plates]

[0494] Similar to the description of the right plate 223 and left plate 224 in steps S1-5 and S2-6, an upper plate 221, which is 100mm in the W-axis direction and 100mm in the D-axis direction, is installed at the upper end of the right opening frame 227 and the left opening frame 228 in a manner that spans between them, and a lower plate 222, which is 100mm in the W-axis direction and 100mm in the D-axis direction, is installed at the lower end of the right opening frame 227 and the left opening frame 228 in a manner that connects between them.

[0495] [g Step S3-7: Front and rear panel installation process]

[0496] Next, a square front plate 225A with a diameter of 100mm in the H-axis direction and 100mm in the W-axis direction is glued to the front ends of the right opening frame 227, left opening frame 228, upper plate 221 and lower plate 222 in the D-axis direction, and a square rear plate 226A with a diameter of 100mm in the H-axis direction and 100mm in the W-axis direction is glued to the rear ends of the right opening frame 227, left opening frame 228, upper plate 221 and lower plate 222 in the D-axis direction, thereby closing the front and rear openings.

[0497] In this case, as an adhesive, a hot melt adhesive can also be used. After applying the hot melt adhesive to the rear surface of the front panel 225A and the front surface of the rear panel 226A, the front panel 225A is pressed from the front and the rear panel 226A is pressed from the rear.

[0498] Therefore, as Figure 33 As shown, in addition to the front ends of the right opening frame 227, the left opening frame 228, the upper plate 221, and the lower plate 222, the front ends of each pleated filter 210 are also bonded to the front plate 225A without gaps.

[0499] In addition, apart from the rear ends of the right opening frame 227, the left opening frame 228, the upper plate 221, and the lower plate 222, the rear ends of each pleated filter 210 are also bonded to the rear plate 226A without gaps.

[0500] [h Step S3-8: Sealing process]

[0501] For example, hot melt adhesive can be used to seal the upper end of the uppermost pleated filter 210 with the upper plate 221, and the lower end of the lowermost pleated filter 210 with the lower plate 222.

[0502] [(3) Explanation of the effect]

[0503] According to this embodiment, such as Figure 32 and Figure 34As shown, at the right end of the filter unit 200D, the following surfaces are arranged: the pleated surface 213 of the uppermost pleated filter 210, the filter connecting surface 214, the pleated surface 213 of the second pleated filter 210 from the top, the opening that becomes the air inlet 230, the pleated surface 213 of the third pleated filter 210 from the top, the filter connecting surface 214, the pleated surface 213 of the fourth pleated filter 210 from the top, the opening that becomes the air inlet 230, and so on.

[0504] In addition, at the left end of the filter unit 200D, the following surfaces are arranged: the pleated surface 213 of the uppermost pleated filter 210, the opening of the air exhaust section 240, the pleated surface 213 of the second pleated filter 210 from the top, the filter connecting surface 214, the pleated surface 213 of the third pleated filter 210 from the top, the opening of the air exhaust section 240, the pleated surface 213 of the fourth pleated filter 210 from the top, the filter connecting surface 214, etc.

[0505] Therefore, in the filter unit 200D, air flows in from the air inlet 230 formed at its right end, passes through the pleated surface 213 of each pleated filter 210, and is discharged from the air outlet 240 formed at its left end.

[0506] Therefore, according to this embodiment, air can be allowed to circulate in a direction orthogonal to the direction along the crease of the first fold (the crease 212 of the pleated filter 210) (the direction along the D-axis), while increasing the effective area of ​​the filter.

[0507] [4 Fourth Implementation]

[0508] The following is based on Figures 39-43 The fourth embodiment of this disclosure will be described. Furthermore, parts identical to those in the first, second, or third embodiments will be labeled with the same reference numerals and their descriptions will be omitted.

[0509] The fourth embodiment of this disclosure relates to a filter (micropleated filter 210D) having tiny pleats and fasteners (in this case, fibers or membranes) attached to both sides to prevent the filter from stretching or contracting in a manner that does not impede the flow of fluid, and a method for manufacturing the same.

[0510] Such a micro-pleated filter 210D can be used in place of filter paper 211 in the first to third embodiments. That is, in this case, the filter paper itself is pleated.

[0511] Furthermore, the following explanation applies to the case where the filter paper used is filter paper 211A, which is a membrane filter.

[0512] In addition, a filter with tiny pleats (pleat height less than 2mm) and a fixing element to prevent the filter from expanding or contracting is called a "micropleated filter".

[0513] [(1) Explanation of the manufacturing method]

[0514] For use Figure 39 The micropleated filter manufacturing apparatus 110A shown is used to manufacture a micropleated filter 210D with a pleat height of 0.4 mm using a continuous membrane filter, i.e., filter paper 211A, for example, with a thickness of 50 μm, a maximum pore size of 1 μm, and a width of 100 mm.

[0515] The manufacturing method for the micropleated filter 210D includes... Figure 40 The processes shown are as follows.

[0516] Furthermore, in the manufacturing method of the micro-pleated filter 210D according to this embodiment, without going through the crease application process and the swinging process described in the compression filter manufacturing process of step S1-1 of the first embodiment, the filter paper 211A is folded into tiny pleats.

[0517] That is, if the spacing of the bands that function as restricting members for the movement of filter paper 211A in the Z-axis direction is set to 20 times or less than the thickness of the filter paper when the filter paper is made of a strong raw material, and 10 times or less when the filter paper is made of a general raw material, and then the filter paper is pushed between the bands that function as restricting members, wrinkles can be formed naturally even without going through the crease application process and the swinging process described in the first embodiment, although there may be cases where the spacing is not uniform and irregular folds occasionally occur.

[0518] [a Step S4-1: Filter paper feeding process]

[0519] First, such as Figure 39 As shown, filter paper 211A is continuously fed out from filter paper roller 111A.

[0520] The filter paper roller 111A is configured to wind and continuously feed a strip of filter paper 211A with a width of 100 mm and a thickness of 50 μm, as described above.

[0521] [b Step S4-2: Folding process]

[0522] The filter paper 211A fed from the filter paper roller 111 does not undergo the crease application process or the oscillation process, but instead... Figure 39As shown, the material is sent to the folding device 113A and passes through the folding device 113A, thereby undergoing folding processing.

[0523] like Figure 39 As shown, the folding device 113A has two belts 1133A configured with a uniform spacing of 0.3 mm. In the portion opposite to each other (the opposite face of this portion is designated as the first opposing face 11331A), the belts 1133A are conveyed from front to rear by a first roller 1134 and a second roller 1135.

[0524] As a result, the filter paper 211A placed between the two belts 1133A is subjected to a force from the front to the rear due to the frictional force from the belts 1133A.

[0525] The filter paper 211A, conveyed rearward by the force described above in the direction from front to rear and pushed out from the space between the belts 1133A, enters the space between two second wall portions 1132A arranged vertically at 0.3 mm intervals, located immediately after the folding device 113A. Moreover, as the filter paper 211A travels rearward in the space between the second wall portions 1132A, it comes into contact with the second wall portions 1132A, which have a large frictional force generated between them, and thus receives a frictional force in the direction that pushes it back towards the folding device 113A (from rear to front).

[0526] Furthermore, by changing the material of the belt 1133A and the area in contact with the filter paper 211A, the friction force generated by the belt 1133A on the filter paper 211A can be adjusted, thereby adjusting the spacing of the pleats in the formed micro-pleated filter 210D.

[0527] As a result, the filter paper 211A snakes in the Z-axis direction from near the center of the folding device 113A. The filter paper 211A is pressed against the upper and lower belts 1133A by the force of the snake, and is folded at an interval of 0.3mm, which is the interval of the belts 1133A, near the outlet of the folding device 113A.

[0528] The folded filter paper 211A is formed into a grid shape between the second wall portions 1132A and is fed into the space between the third wall portions 1137, where it travels backward. The frictional force exerted by the third wall portion 1137 on the filter paper 211A is smaller than that of the second wall portion 1132A. Similarly, the third wall portion 1137 and the second wall portion 1132A are also arranged vertically at a 0.3mm interval.

[0529] [c Step S4-3: Fixed process]

[0530] The filter paper 211A, which is folded and enters between the third wall portions 1137, moves backward while being held by the grids with a 0.3mm interval constituting the third wall portions 1137, and enters the fixing device 118.

[0531] That is, when the paper is sent from the second wall portion 1132A to the third wall portion 1137, the folds formed in step S4-2 are not fixed. If this state is maintained, it is difficult to use it as a substitute for filter paper 211. Therefore, in order to fix it in the folded state to prevent expansion and contraction, in this process, fasteners are provided on the upper and lower surfaces.

[0532] Within the fixing device 118, such as Figure 39 As shown, a thermoplastic resin with a melting point lower than that of the membrane filter forming the filter paper 211A, such as a fiber 215 formed of polypropylene, is sprayed from the fiber blow-out pipe 1181 arranged above and below, onto the upper and lower surfaces of the filter paper 211A folded into a pleated shape. The fiber 215 extends along the X-axis in the length direction of the fiber 215.

[0533] Furthermore, the fiber 215 sprayed in the fixing process is not limited to polypropylene fiber. Other thermoplastic resin fibers can also be used as long as they have a lower melting point than the fibers constituting filter paper 211A.

[0534] Filter paper 211A, in which fine fibers, namely fibers 215, of thermoplastic resin are sprayed from fiber blow-out pipe 1181, is sent to heating furnace 1182. Heating furnace 1182 heats filter paper 211A to a temperature above but below the melting point of the sprayed fibers 215, thereby melting only the sprayed fibers 215. When the fibers are solidified again, filter paper 211A is fixed in a folded, wrinkled state.

[0535] At this point, as long as the proportion of the sprayed fiber 215 covering the upper and lower surfaces of the folded filter paper 211A is such that it does not significantly impede the contact between the filter paper 211A and the air at the upper and lower surfaces, it is possible to fix the filter paper 211A in a folded state while maintaining its performance as a filter.

[0536] In addition, such as Figure 39 As shown, in the rear part of the heating furnace 1182, two rollers (embossing rollers 1183) with small protrusions on their surfaces are provided in such a way that they pass through the heating furnace 1182 in the Y-axis direction and are opposite each other in the space between the third wall portion 1137.

[0537] As the filter paper 211A, heated by the heating furnace 1182, passes between the embossing rollers 1183, the protrusions on the embossing rollers 1183 apply pressure to the folded filter paper 211A and fibers 215, thereby... Figure 41 As shown, the adhesion between filter paper 211A and fiber 215 can be strengthened in the pressurized portion. Furthermore, in Figure 41 The diagram shows the entire surface of the filter paper 211A covered by fiber 215 on both the upper and lower surfaces. However, in reality, the fiber 215 extending along the X-axis is sprayed in large quantities while being spaced apart in the Y-axis direction.

[0538] Alternatively, filter paper 211A can be fixed in a folded state using a method other than the process of spraying and heating thermoplastic fibers as described above. For example, instead of using fine fibers of thermoplastic resin, long filaments formed of the same thermoplastic resin can be used, and multiple filaments can be arranged at intervals on both sides of the folded filter paper 211A along the X-axis direction, and heated in this state by heating furnace 1182.

[0539] Additionally, for example, such as Figure 42 As shown, a method of attaching a film to the upper and lower surfaces of the folded filter paper 211A can also be used (e.g., Figure 42 As shown, the film pasted on the upper side is designated as the upper film 216, and the film pasted on the lower side is designated as the lower film 217.

[0540] In this case, if a porous membrane with a high opening ratio is used, the membrane can be adhered to the entire upper and lower surfaces of the folded filter paper 211A.

[0541] In contrast, when using a film with a low aperture ratio, the film is not adhered to the entire upper and lower surfaces of the folded filter paper 211A, but rather... Figure 43 As shown in the upper film 216A, the film to be pasted is divided into multiple parts in the Y-axis direction, and gaps are set to paste it in strips.

[0542] In this case, the air that enters between the pleats from the gap of the upper film 216A also moves between the pleats in the Y-axis direction, so the entire area of ​​the filter paper 211A can be utilized as the effective area of ​​the filter.

[0543] In this case, the same applies to the lower surface side (not shown). The film is divided into multiple sections along the Y-axis, and gaps are set between them for strip-like application.

[0544] In addition to using a thin film method, for example, an adhesive such as a hot melt adhesive can be applied in a wide line extending in the X-axis direction, thereby fixing the filter paper 211A in a folded state by the adhesive after it has been applied and cured.

[0545] If the fixed process in step S4-3 is completed, the micro-pleated filter 210D is completed.

[0546] [(2) Explanation of the effect]

[0547] According to the micro-pleated filter 210D of this embodiment, the filter paper 211A can maintain its function (in this case, the function of a membrane filter) while suppressing the increase in thickness (in this case, even taking into account the fibers, membranes, etc. added in the fixing process, it is suppressed to about 0.4 mm), and the surface area is greatly increased.

[0548] The micro-pleated filter 210D formed in this way suppresses the increase in thickness as described above, and is further fixed in this state by a fixing process, so it can be used in place of filter paper 211 in the manufacturing methods described in the first to third embodiments.

[0549] In this case, the filter unit manufactured by the manufacturing method described in the first to third embodiments includes a filter with three layers of pleats, which are composed of tiny pleats formed in the micro-pleated filter 210D (in this case, equivalent to a primary pleat), a primary pleat described in the first to third embodiments (in this case, equivalent to a secondary pleat), and a secondary pleat described in the first to third embodiments (in this case, equivalent to a tertiary pleat).

[0550] Therefore, by using the micro-pleated filter 210D according to this embodiment, a filter unit with a larger effective area can be manufactured compared with the first to third embodiments.

[0551] [5 Fifth Implementation]

[0552] The following is based on Figures 44-50 The fifth embodiment of this disclosure will be described. Furthermore, parts identical to those in the first, second, third, or fourth embodiments will be labeled with the same reference numerals and their descriptions will be omitted.

[0553] [(1) Regarding the filter unit]

[0554] like Figure 44As shown, the filter unit 200E according to the fifth embodiment is the same as the filter unit 200C according to the second embodiment in that a spacer 280, which is a thin plate-shaped component, is placed between the upper and lower adjacent pleated filters 210. Except for this point, it is the same as the filter unit 200C according to the second embodiment.

[0555] When viewed from the H-axis direction, the separator 280 has the same shape and size as the pleated filter 210 and is mounted in parallel with the DW surface to cover the entire cross section parallel to the DW surface in the space between the right plate 223 and the left plate 224.

[0556] The material of the separator 280 is not particularly limited as long as it has the strength to prevent the protrusions from entering the recesses in the adjacent pleated filters 210 as described later and to ensure that they are tightly attached. A resin plate or the like can be used.

[0557] [(2) Description of the manufacturing method]

[0558] Alternatively, after manufacturing the filter unit 200C according to the second embodiment, it can be manufactured by inserting the spacer 280 from either the front or rear direction (the side where the seal 250 is not formed) between the adjacent pleated filters 210, but a different manufacturing method will be described here. The manufacturing method of the filter unit 200E in this case includes... Figure 45 The processes shown are as follows.

[0559] [a Step S5-1: Pleated filter manufacturing process]

[0560] The filter paper 211 is folded using the same apparatus as in the first embodiment to form a pleated filter 210. Here, the pleated filter 210 is manufactured directly without passing through a compression filter 210A.

[0561] [b Step S5-2: Fixed Process]

[0562] The spacing of the pleats in the manufactured pleated filter 210 is fixed to the spacing of one pleat in the filter unit 200E to be manufactured. The fixing method is not limited, and methods such as the following can be considered.

[0563] (a) First method

[0564] A method for fixing the shape of the pleated filter 210 using hot melt adhesive.

[0565] (b) Second method

[0566] The method of fixing the pleated filter 210 by bonding the isolator 280 to one side.

[0567] (c) Third method

[0568] As shown in Figure 46, the finned pleated filter 210E is fixed by forming fins 218 at both ends in the Y-axis direction. Furthermore, the planar portions along the XY plane formed at both ends of the pleated filter in the direction parallel to the creases (in this case, the Y-axis direction) are used as fins 218.

[0569] The fins 218 can be formed by heating and crushing near both ends of the pleated filter 210 in the Y-axis direction. Alternatively, the fins 218 can be reinforced by attaching a reinforcing material made of a polypropylene film or similar material.

[0570] When using a finned pleated filter 210E with fins 218, the fins 218 of the finned pleated filter 210E that are adjacent to each other are connected to each other in the air inlet section 230 and air outlet section 240 at the front and rear of the filter unit 200E, thereby enabling control of the flow of fluid into and out of the filter unit 200E.

[0571] Alternatively, after installing the right plate 223 and the left plate 224 in step S5-4, the fins 218 can be formed, and the spacing of the pleats can be fixed to the spacing of one pleat in the filter unit 200E to be manufactured.

[0572] [c Step S5-3: Lamination process]

[0573] The pleated filter 210 (or the finned pleated filter 210E) and the separator 280 are stacked alternately.

[0574] Furthermore, similar to the case in the second embodiment where multiple filters 800 are divided and a single filter 700 is manufactured, it is also possible to manufacture the filter 700 in a state having dimensions corresponding to multiple filter units, and then divide it using heating wires or the like after stacking.

[0575] [d Step S5-4: Installation process of the right and left panels]

[0576] The steps S2-4 are the same as those in the second embodiment.

[0577] [e Step S5-5: Installation process of upper and lower plates]

[0578] The steps are the same as those in the second embodiment, S2-6. In addition, the upper plate 221 and the lower plate 222 can be stacked on top of the pleated filter 210 stacked in step S5-3 in advance. When the right plate 223 and the left plate 224 are installed in step 5-4, the upper plate 221 and the lower plate 222, and the right plate 223 and the left plate 224 are fixed at the same time.

[0579] [f Step S5-6: Sealing process]

[0580] Perform the same process as steps S2-7 in the second embodiment to seal the front and rear surface sides.

[0581] Furthermore, when using a finned pleated filter 210E with fins 218, sealing can also be achieved by connecting the fins together. That is, in this case, for the portion where the pleated filters 210 adjacent to each other on the front and rear surfaces of the filter unit 200C according to the second embodiment are connected to form a sealing portion 250, by connecting the fins 218 of the adjacent finned pleated filters 210E without gaps, the gap between the adjacent finned pleated filters 210E can be sealed, and sealing can be easily achieved.

[0582] In addition, after connecting the fins 218 to each other before stacking in step S5-3, so that all the finned pleated filters 210E to be used are connected continuously, they are folded alternately in a manner similar to step S3-3 of the third embodiment, thereby making it easier to seal.

[0583] [(3) Explanation of the effect]

[0584] When a filter unit with multiple pleated filters 210 stacked vertically is used to filter liquids with particularly high pressure, there is a risk that the effective area of ​​the filter may be reduced and the function may be slightly reduced because the convex portion of the adjacent pleated filters 210 enters the concave portion and they are in close contact. However, according to the filter unit 200E of this embodiment, the pleated filters 210 (or finned pleated filters 210E) are separated by the separator 280, thereby preventing such a reduction in function.

[0585] In addition, such as Figure 44 As shown, in filter unit 200E, the pleated filter 210 (or finned pleated filter 210E) and the separator 280 form a structure that is close to the truss structure when viewed from the D-axis direction, thus improving the pressure resistance in the vertical direction.

[0586] In particular, by reducing the height and spacing of a single pleat, the pressure resistance in the vertical direction can be significantly improved. Furthermore, needless to say, when each joint of the pleated filter 210 and the isolator 280 is fixed, even if they are not fixed, as long as the spacing of the pleats of the pleated filter 210 on the front and rear surfaces is fixed, the aforementioned effect of improved pressure resistance based on the truss structure can be achieved through the friction between the isolator 280 and the pleated filter 210.

[0587] Furthermore, when the fluid being filtered is a liquid, the flow rate during filtration is typically low, so the increase in resistance caused by the planar separator 280, which is parallel to the direction of fluid flow during filtration (D-axis direction), is minimal.

[0588] In addition, when the fluid to be filtered is a gas, the pressure applied to the filter during filtration is usually low, and as described above, the possibility of the convex portion entering the concave portion in the adjacent pleated filter 210 is small, so the importance of the separator 280 is low.

[0589] Therefore, it can be said that this embodiment is particularly suitable for situations where the fluid to be filtered is a liquid.

[0590] [(4) Variations]

[0591] The following describes variations of this embodiment.

[0592] [a. Variation Example 1]

[0593] As a separator, the resin plate described above may not be used; instead, the same filter paper as filter paper 211 may be used.

[0594] For example, such as Figure 47 As shown in the filter unit 200F, a pleated filter 210 (or a finned pleated filter 210E) and a separator 280A formed of the same filter paper as the filter paper 211 and which serve as both a filter and a separator are alternately stacked.

[0595] In this case, it is possible to include both a pleated filter 210 and a spacer 280A, which are connected in an alternating manner and sealed between them, and in this case, the spacer 280A forms a secondary pleat.

[0596] For example, the rear end of the upper plate 221 can be sealed to the rear end of the uppermost pleated filter 210, the front end of the uppermost pleated filter 210 can be sealed to the front end of the uppermost separator 280A, the rear end of the uppermost separator 280A can be sealed to the rear end of the second pleated filter 210 from the top, the front end of the second pleated filter 210 can be sealed to the front end of the second separator 280A from the top, and the rear end of the second separator 280A can be sealed to the rear end of the third pleated filter 210 from the top. Both the pleated filter 210 and the separator 280A can be connected in an alternating manner.

[0597] Furthermore, the case where a primary fold is formed only on a portion of the fold surface of a secondary fold also includes the case where a primary fold and a secondary fold are formed overlapping.

[0598] Therefore, as Figure 47 As shown, the inlet flow path R1, which is the flow path of the fluid after it is introduced into the filter unit and before it is filtered by the filter, and the outlet flow path R2, which is the flow path of the fluid after it is filtered by the filter and until it is discharged from the filter unit, are separated by the separator 280A in addition to the pleated filter 210.

[0599] In this way, by adding the separator 280A, the number of filter layers, that is, the number of secondary pleats, can be increased, making it easier to expand the effective area of ​​the filter.

[0600] [b. Variation Example 2]

[0601] The filter unit 200G involved in Modification 2 is a further modification of Modification 1, used for cross-flow filtration for desalination that requires high pressure.

[0602] In this modified example, a filter with fins 218 formed on the separation membrane M is used as a pleated filter (as finned pleated filter 210F), and an separator formed using the same separation membrane M is used as a separator (as separator 280B). They are stacked in the same configuration as in modified example 1.

[0603] In addition, fluid is distributed via fins 218 as described later.

[0604] Additionally, as a frame, it is used Figure 48 The cross-flow filter frame 900 shown includes a raw water pipe 910, a distribution frame 920, a pressure-resistant frame 930, a two-flow-path confluence frame 940, a concentrated water discharge pipe 950, and a permeable water discharge pipe 960.

[0605] [(a) Explanation of the change points]

[0606] The changes from Variation 1 are as follows.

[0607] [Changes to the filter paper]

[0608] The filter paper used was changed to a filter paper formed by clamping the reverse osmosis membrane with a protective material with high pressure resistance (as the separation membrane M).

[0609] [Changes in the shape of the folds]

[0610] The separation membrane M, as described above, is folded in a manner that forms folds with a height of approximately 1.5 mm and small spacing. Furthermore, if this size is achieved, as described in the fourth embodiment, folds can be formed solely through the folding process without undergoing a crease application process or a wiggling process.

[0611] [Changes in fin processing]

[0612] By installing the distribution frame 920 on the fins 218 at the front end of each finned pleated filter 210F, and installing the two-flow confluence frame 940 on the fins 218 at the rear end, and storing them in the cross-flow filtration frame 900, cross-flow filtration can be achieved.

[0613] [(b) Description of flow path]

[0614] Figure 49 R3 in the diagram corresponds to the flow path of raw water and concentrated water on the high-pressure side (raw water / concentrated water flow path R3). Figure 49 R4 in the diagram corresponds to the permeate flow path on the low-pressure side (permeate flow path R4). In this case, as... Figure 49 As shown, the above two flow paths are formed above and below each of the loaded filters (finned pleated filter 210F and separator 280B).

[0615] In addition, such a flow path extends from the distribution box 920 at the front end of the filter unit 200G to the two-flow-path merging box 940 at the rear end.

[0616] In the distribution frame 920 connected to the fins 218 at the front end of the finned pleated filter 210F, the raw water pressed in from the raw water pipe 910 is distributed to the raw water / concentrated water flow path R3 by the fins 218 provided by each finned pleated filter 210F. In the two-flow-path merging frame 940 connected to the fins 218 at the rear end, the concentrated water pushed out from the multiple raw water / concentrated water flow paths R3 is guided to the concentrated water discharge pipe 950 by the fins 218 provided by each finned pleated filter 210F, and the permeate water pushed out from the multiple permeate flow paths R4 is guided to the permeate water discharge pipe 960.

[0617] [(c) Description of actions and effects]

[0618] The pressurized supply water (raw water) is supplied to the distribution frame 920 from the raw water pipe 910 connected to the distribution frame 920. Using the fins 218 provided by each finned pleated filter 210F connected to the distribution frame 920, the water is distributed to the raw water / concentrated water flow path R3, which is a gap formed on one side of each finned pleated filter 210F, and moves towards the outlet. During the movement, the water passes through the finned pleated filter 210F located below the raw water / concentrated water flow path R3 or the reverse osmosis membrane of the separator 280B located above it, and moves through the permeate flow path R4.

[0619] The concentrated water reaching the rear end in the raw water / concentrated water flow path R3 and the permeate water reaching the rear end in the permeate water flow path R4 utilize the fins 218 of each finned pleated filter 210F connected to the two flow path confluence frame 940. The concentrated water is confluenced through the two flow path confluence frame 940 and discharged from the concentrated water discharge pipe 950, and the permeate water is confluenced and discharged from the permeate water discharge pipe 960.

[0620] In existing spiral-shaped reverse osmosis membrane elements used for cross-flow filtration, for example, Figure 50 As shown, all separation membranes M are used in a planar shape, so it is necessary to use a mesh separator or the like to ensure the flow path of the supply water and the permeate water. However, in this modified example, the wave-shaped separation membrane M (finned pleated filter 210F) and the planar separation membrane M (separator 280B) are arranged alternately. One space separated by them is the flow path of the supply water, and the other space is the flow path of the permeate water. Therefore, it is not necessary to use a mesh separator to ensure the flow path.

[0621] Furthermore, one of the two filter materials is a corrugated finned pleated filter 210F, which can easily increase the surface area, thus reducing the size and enabling inexpensive manufacturing.

[0622] Furthermore, even in this case, the friction between the protective material of the separation membrane M of the separator 280B, which functions as a separator in addition to the filter material, and the protective material of the separation membrane M of the finned pleated filter 210F, which functions as a structural material in addition to the filter material, is relatively large. Therefore, when viewed from the D-axis direction, it becomes a structure close to a truss structure, which can improve the pressure resistance in the vertical direction. In this case, the pressure resistance of such a truss structure is determined by the compressive strength of the wave pattern. Therefore, the smaller the height and spacing of the finned pleated filter 210F, which also serves as a structural material, the higher the pressure resistance.

[0623] [c. Variation Example 3]

[0624] Variation Example 3 is a variation related to the shape of the isolation member.

[0625] That is, the shape of the spacer is preferably a plate-shaped section that extends across the space between the right plate 223 and the left plate 224 and is parallel to the DW surface, as described above (in this modified example, it refers to the shape of two opposing surfaces (the upper surface and the lower surface in this case) that are parallel to each other). However, except for cases where the spacer functions as a filter, such as in modified examples 1 and 2, the shape of the spacer is not particularly limited as long as it can separate the pleated filters 210, that is, be disposed between adjacent pleated filters 210 and make it difficult for them to stick together.

[0626] However, the preferred configuration is to connect the right plate 223 and the left plate 224 in the W-axis direction and extend the entire pleated filter 210 in the W-axis direction. In addition to the plate shape described above, it can also be formed as multiple filaments connecting the right plate 223 and the left plate 224 (in this modified example, it refers to a shape that is longer in one direction (in this case, the W-axis direction) than in the two directions orthogonal to it (in this case, the D-axis direction and the H-axis direction).

[0627] [d. Variation Example 4]

[0628] Variation 4 is a variation concerning the manufacturing method.

[0629] As for the manufacturing method of the filter unit 200E according to the fifth embodiment, if it is manufactured via the compression filter 210A in the same way as the second embodiment, different from the method described in steps S5-1 to S5-6, a manufacturing method that modifies the manufacturing method of the second embodiment can be used as described below.

[0630] [(a) Use of flexible isolation elements]

[0631] For the manufacturing method of steps S2-1 to S2-7 of the second embodiment, in the compression filter stacking process of step S2-2, the compression filter 210B and a planar separator made of rubber or the like that has elasticity are alternately stacked. The separator has a shape and size that are approximately the same as the compression filter 210B when viewed from the Z-axis direction.

[0632] Therefore, in this case, multiple filters are formed with planar and flexible separators sandwiched between each compression filter 210B. Alternatively, the separators in this case can also be formed from multiple filamentary components that extend along the X-axis, have approximately the same length as the compression filter 210B in the same direction, and are flexible.

[0633] Next, after cutting the multiple filters into a single filter in step S2-3, in step S2-4, the right plate 223 and the left plate 224 are bonded to the left and right sides of the compression filter 210A, and also to the left and right sides of the separator.

[0634] Subsequently, in steps S2-5, when the compression filter 210A is stretched along the W-axis to become a pleated filter 210, the separator is also stretched to the gap between the right plate 223 and the left plate 224 in the filter unit 200E, thereby enabling the filter unit 200E with the separator to be manufactured without making significant changes to the manufacturing method of the second embodiment.

[0635] [(b) Insertion of a spacer with protrusions and recesses at the end]

[0636] In the opening process of step S2-5, after the interval between the right plate 223 and the left plate 224 is made greater in the W-axis direction than the interval between the right plate 223 and the left plate 224 in the filter unit 200E, in this state, a separator with a length in the W-axis direction approximately the same as the interval between the right plate 223 and the left plate 224 in the filter unit 200E, having concave and convex ends at both ends in the same direction, and the convex portion being formed to bite into the right plate 223 and the left plate 224, is inserted between the pleated filters 210.

[0637] Afterwards, the spacing between the right plate 223 and the left plate 224 is made the same as the spacing between the right plate 223 and the left plate 224 in the filter unit 200E. Then, the upper plate 221 and the lower plate 222 are installed in the same manner as in step S2-6, so that the protrusions at both ends of the isolator in the W-axis direction bite into the right plate 223 and the left plate 224. As a result, the isolator can be installed in a state where it is not easy to fall off.

[0638] [6 Other variations, etc.]

[0639] Hereinafter, variations of the above embodiments will be described.

[0640] [(1) Use as a chemical filter]

[0641] As for the filter paper 211 in each embodiment, a case has been described in which a filter paper is used that blocks the passage of particles when the fluid passes through the filter paper and filters the fluid when the fluid passes through the filter paper. However, instead of this, a chemical filter using non-woven fabric as the substrate may also be used.

[0642] In this case, the chemical filter adsorbs particles by attaching filter paper, which is an adsorbent material attached to the substrate and extends long along the direction of fluid flow, thereby reducing the concentration of the particles to be removed. Therefore, the fluid does not penetrate the filter paper, and the fluid flows parallel to the filter paper.

[0643] However, there are also methods that involve attaching an adsorbent to a low-density nonwoven fabric, then pleating the nonwoven fabric and allowing the fluid to flow from the convex to the concave areas of the pleats. In this case, the fluid penetrates the filter paper, especially near the concave areas, but the essence of adsorbing the particles that are to be removed from the fluid flowing near the adsorbent material is the same.

[0644] The following describes an implementation method for a chemical filter as described above.

[0645] For example, for the filter unit before sealing up to steps S2-6 of the second embodiment, if filter paper 211 with an adsorbent is used, the multiple gaps surrounding the filter paper 211 can be formed to extend longer in the front-back direction, thus making it suitable for the application of chemical filters as described above. Activated carbon, zeolite, etc., can be used as adsorbents, for example.

[0646] Furthermore, for those with compression filters installed without gaps between the top and bottom Figure 30 In the case of the multi-stage parallel compression filter 600A with left and right plates shown, if the distance between the right plate 223 and the left plate 224 is slightly increased, almost no gaps will be generated between the vertically adjacent folded filter papers 211, but a small gap can be generated between the horizontally adjacent pleated surfaces 213. In this state, the narrow gaps in the W-axis direction are formed to extend longer in the D-axis direction of airflow, making it suitable for use as a chemical filter.

[0647] In addition, instead of the filter unit that has undergone steps S2-6 of the second embodiment before sealing as described above, the filter unit 200 of the first embodiment that has undergone sealing treatment can also be used, for example.

[0648] In any embodiment, it is suitable to form a filter unit with a long depth and to extend the filter paper 211 a long distance along the direction of fluid flow, thus making it suitable for the applications described above.

[0649] To ensure a stable and small gap, it is preferable not to eliminate the deformation of the pleats during the manufacture of the compression filter 210A through heat treatment, thus preventing the residual force attempting to spread along the X-axis in the pleated filter 210. Therefore, even if the opening between the right plate 223 and the left plate 224 is small, it is easy to make the gap between the pleated surfaces 213 uniform. Although it also depends on the fluid flow rate and viscosity, the smaller the gap, the easier it is for the target material to be adsorbed.

[0650] Furthermore, even if a large force attempting to expand along the X-axis remains in the pleated filter 210 without heat treatment, it is possible to manufacture it, for example, by performing a manufacturing operation in a container that can limit the extension of the pleated filter 210.

[0651] [(2) Increased pressure for fluids with high viscosity]

[0652] For example, when using a filter unit 200 according to the first embodiment, where the folds of the first pleats and the second pleats are orthogonal, for the purpose of filtering high-viscosity liquids, the direction of the applied force is along the direction of the first pleat, thus having high strength, but the force is concentrated in the part facing the fluid inlet (air inlet 230) and the part facing the fluid outlet (air outlet 240).

[0653] Therefore, for any one side, for example, it is preferable to use a strong material as a hot melt adhesive as a sealant in the groove of the container for sealing during the sealing process in steps S1-6, or to pre-place the reinforcing member in the groove and bond the reinforcing member with the sealant, thereby strengthening the sealing part.

[0654] like Figure 51 As shown, for example, when the filter unit 200 is used in the pipe P, a metal frame can be used as a reinforcement for the part facing the air inlet 230 (front reinforcement 290A), which can maximize strength in this case.

[0655] In addition, the rear reinforcement (rear reinforcement 290B) that serves as a reinforcement for the part facing the air exhaust section 240 can be a sturdy mesh reinforcement plate made of metal or the like.

[0656] [(3) Countermeasures against tension generated in the filter due to fluid]

[0657] The filter units in each embodiment are easily formed to be longer in the direction of fluid flow (e.g., the D-axis direction in the first embodiment). Therefore, with the near-front side of the flow direction fixed, tension is applied to the filter paper constituting the pleated filter in the direction of fluid flow.

[0658] Especially when the fluid is liquid, and the flow rate is high and the viscosity is high, such tension increases. To avoid breakage of the filter paper 211 caused by increased tension and instability caused by fluid flow, it can be strengthened, for example, as described below.

[0659] [a. Reinforcement of filter paper in the Y-axis direction]

[0660] For example, the tensile strength of the filter paper 211 in the Y-axis direction can be enhanced by inserting filaments along the Y-axis direction (along the direction of the crease) into the filter paper 211 or by applying adhesive to the crease.

[0661] For example, in the case where a sufficiently strong metal frame, i.e., the front reinforcement 290A, is integrated with the front end of the pleated filter 210 as described above, in order to achieve a filter unit that can withstand, for example, 10 atmospheres of pressure, the pleated filter 210 has a per 1cm spacing in the D-axis direction.2 A tensile strength of approximately 10 kgf is sufficient.

[0662] Therefore, when the folds are miniaturized, for example, every 1 cm when viewed from the front... 2 With 30 pleated surfaces, the tensile strength of each pleated surface in the D-axis direction is approximately 333gf.

[0663] Such tensile strength can be achieved, for example, by methods such as those described below.

[0664] a. A filament extending along the Y-axis is inserted during the manufacture of filter paper 211.

[0665] b. Insert a thread that extends in the same direction when folding.

[0666] c. After folding, slightly unfold the resulting crease, apply adhesive to the apex of the crease, or melt the apex of the crease and then let it solidify.

[0667] [b. Case where stored in a filter box]

[0668] In the case of a cylindrical filter box that is long in the direction of fluid flow and is used in a fluid flow, if the front surface of the filter unit is sealed in a way that integrates a metal frame or the like (a metal frame corresponding to the shape of the groove is placed in the groove of the container used in the sealing process, and it is integrated with the front surface of the filter unit by hot melt adhesive), and the metal frame or the like is fixed to the front end of the filter box, it is easy to stabilize even when the filter paper is under tension.

[0669] Furthermore, the material used for such metal frames is preferably a rough, textured material so that the resin does not easily peel off from the frame after the hot melt adhesive has cured.

[0670] Furthermore, if the filter is fixed to the rear end of the filter box by having a mesh or the same metal frame as the front surface, the tension applied to the filter material can be reduced.

[0671] Alternatively, multiple filter units can be connected in series within the filter cartridge, with the mesh size varying for each unit; coarser meshes are used closer to the upstream side of the fluid flow. Furthermore, in cases of high-viscosity fluids, pressure-resistant meshes can be incorporated between each stage. This disperses the pressure applied to the filter, reduces clogging, and thus improves filter lifespan.

[0672] [(4) Installation of rubber rope]

[0673] In the strengthening / fixing process of step S1-1-4, such as Figure 52 As shown, instead of adhesive, the rubber rope G can be placed on the upper and lower surfaces of the folded filter paper 211 in a manner that extends along the X-axis direction, and is installed in a manner that adheres to the crease of each fold.

[0674] In this case, even after the gap between the right plate 223 and the left plate 224 is opened in steps S1-4, the tension of the stretched rubber rope G remains, thus easily preventing the pleated filter of the filter unit from loosening due to important factors such as the passage of time.

[0675] [(5) Installation of support materials]

[0676] As described in the first embodiment, the second embodiment, etc., when the crease of the primary pleat is perpendicular to the crease of the secondary pleat, in order to prevent the primary pleat filter 210 and other filters with primary pleats from loosening, a thin plate-shaped support material having a surface parallel to the flow direction of the fluid can be installed between the filters with primary pleats.

[0677] If the component is a thin plate-shaped part with a surface parallel to the direction of fluid flow, it is less likely to obstruct the flow of fluid.

[0678] In the second embodiment, the direction along the crease of the first fold is the D-axis direction, so a support material with a width of 7 mm, which is close to the maximum value of the interval between the upper and lower overlapping folded filters 210, can be inserted parallel to the crease of the fold.

[0679] [(6) Spacing and height of folds]

[0680] Apart from the fourth embodiment characterized by forming tiny folds, the spacing of a single fold is not limited, but when the single folds are formed at a tiny spacing of 1.0 mm or less, it is easier to increase the effective area of ​​the filter. The spacing of a single fold can also be set to 0.5 mm or less, in which case the effect can be further improved compared to setting it to 1.0 mm or less but larger than 0.5 mm.

[0681] Furthermore, there are no limitations on the height of the primary fold, except for the fourth embodiment characterized by forming minute folds. However, when the primary fold is formed at a height of 6.0 mm or less, it is easier to increase the effective area of ​​the filter. The height of the primary fold can also be set to 3.0 mm or less, in which case the effect can be further improved compared to setting it to 6.0 mm or less but greater than 3.0 mm.

[0682] [(7) The spacing between filters ensures the increase of components]

[0683] In any embodiment, a spacing ensuring member can be provided between the filter papers with single pleats to ensure the spacing between the pleats. As a spacing ensuring member, for example... Figure 53 As shown, a sphere K is used to fill the spaces between the folded surfaces. This variation of the fifth embodiment, used in cross-flow filtration for desalination applications requiring high pressure, is particularly effective.

[0684] Specifically, for Figure 53 The filter unit 200H shown is the same as the filter unit 200G in the modified example 2 of the fifth embodiment, in which a plurality of spheres K, which serve as spacing assurance parts, fill the spaces between the pleated surfaces of the pleated filter 210F.

[0685] In this case, gaps are formed between multiple spheres K, thus making it easy to maintain sufficient space for fluid flow while ensuring the spacing of the pleated surfaces, preventing the pleated surfaces from contacting each other and reducing the effective area of ​​the filter.

[0686] As for the material of sphere K, any material that has the strength to prevent it from being crushed by the pressure of the fluid, and the weight to prevent it from being crushed or wrinkled due to its own weight, is acceptable. Lightweight spheres made of resin, for example, can be used. Furthermore, from the viewpoint of maintaining space for fluid flow, it is preferable that the size (radius) of sphere K is uniform.

[0687] Furthermore, in this case, it is possible to ensure both the spacing between the pleated surfaces of the first pleat (the spacing between the pleated surfaces of the pleated filter 210F) and the spacing between the pleated surfaces of the second pleat (the spacing between the adjacent pleated filters 210F and the spacer 280B).

[0688] [(8) Other variations]

[0689] In any embodiment, the filter paper 211 can be a composite filter paper formed by overlapping filter papers with different properties, or a filter paper with a density gradient formed by overlapping a coarse-mesh filter paper on the side corresponding to the inflow side and overlapping a fine-mesh filter paper on the side corresponding to the outflow side.

[0690] The micro-pleated filter 210D described in the fourth embodiment can also be used directly as a surface filter such as a mask.

[0691] For the part of the folding device 113 with 1133, multiple units can also be set in series, with the first stage mainly used for folding and the second stage mainly used for compression.

[0692] In the manufacturing process of the compression filter, if heat treatment to eliminate deformation is not performed, leaving residual deformation in the formed pleated filter 211, and thus residual forces attempting to expand along the X-axis, it is preferable to manufacture it in a container where such forces can be suppressed. This manufacturing method is suitable for situations where filter materials that cannot be heat-treated (e.g., filter materials with high heat resistance that do not deteriorate due to heat) are used as filter paper 211. For example, if ceramic fiber is used as the filter material, a filter that can be used even at high temperatures of around 1000 degrees Celsius can be manufactured.

[0693] When used as a bag filter, and where it is necessary to remove particles adhering to the filter surface, the fluid can be made to flow in the opposite direction to the flow from the air inlet 230 to the air outlet 240 as described in each embodiment. In this case, it is preferable to fix a frame made of metal or the like to both sides of the air inlet 230 and the air outlet 240 to reinforce both sides.

[0694] It can also replace the belt 1133 of the folding device 113, and utilize the flow of air that flows at high speed in the same direction as the direction of movement of the first opposing surface of the belt 1133.

[0695] As long as the movement of filter paper 211 in a direction orthogonal to the surface can be restricted, such airflow is also equivalent to a restricting component that restricts the movement of filter paper 211 in a direction orthogonal to the surface.

[0696] In any embodiment, the filter unit is described as rectangular when viewed from the air inlet 230 side or the air outlet 240 side (along the direction of the D-axis in the first embodiment), but it may also include a circular plate for easily placing such a filter unit in a pipe with a circular cross-sectional shape.

[0697] For such a circular plate, its diameter is equal to the inner diameter of the pipe to which it is installed, and it has an opening with a shape corresponding to the shape of the frame portion of the filter unit when viewed from the air inlet 230 side or the air outlet 240 side (in the first embodiment, along the D-axis direction). This opening allows passage between the air inlet 230 and the air outlet 240 of the frame portion, and is closed with respect to the frame portion. That is, such a circular plate is installed on the frame portion in such a way that it protrudes from the frame portion when viewed from the air inlet 230 side or the air outlet 240 side, and has a circular shape when viewed from the same direction.

[0698] Therefore, by placing such a circular plate in close contact with the inner surface of the pipe, the filter unit can be easily installed inside the pipe with a circular cross-sectional shape.

[0699] In any embodiment, unless otherwise specified, the filtering object is the same as that described in variation 7 of the first embodiment, and is not limited to air, as long as it is a fluid.

[0700] Industrial availability

[0701] This disclosure pertains to filter units that can be used to filter liquids or gases.

[0702] Explanation of reference numerals in the attached figures

[0703] 100…Filter unit manufacturing system; 110…Compressor filter manufacturing apparatus; 110A…Micro-pleated filter manufacturing apparatus; 111, 111A…Filter paper rollers; 112…Folding device; 113, 113A…Folding device; 1131, 1131A…First wall section; 1132, 1132A…Second wall section; 1133, 1133A…Belt; 114…Fixing device; 115…Output roller; 116…Cutting device; 117…Oscillating device; 118…Fixing device; 130…Left and right plate mounting device; 140…Temporary adhesive release device; 150…Upper and lower plate mounting device; 160…Fine-finishing device; 200, 200A… 200B, 200C, 200D, 200E, 200F, 200G, 200H… Filter units; 210, 210B, 210C… Pleated filters; 210D… Micro-pleated filters; 210E, 210F… Finned pleated filters; 210A… Compressor filters; 211, 211A… Filter paper; 212… Creases; 213… Pleated surfaces; 214… Filter connection surfaces; 215… Fibers; 216, 216A… Upper membrane; 217… Lower membrane; 218… Fins; 220, 220A, 220B… Frames; 221… Upper plate (third plate-shaped component); 221A… Upper plate; 222… Lower plate (fourth plate-shaped component) Components); 222A…lower plate; 223…right plate (first plate-shaped component); 223A…right plate; 224…left plate (second plate-shaped component); 224A…left plate; 225, 225A…front plate; 226, 226A…rear plate; 227…right opening frame; 228…left opening frame; 230…air inlet; 240…air outlet; 250…sealing part; 260…front surface side connecting post; 270…rear surface side connecting post; 280, 280A, 280B…isolation member; 290A…front reinforcement member; 290B…rear reinforcement member; 300…simple type compression filter manufacturing apparatus; 310, 310A…compression part; 311, 311A …parallel plate; 3111…flat section; 3112…protrusion; 320…first gate; 330…baffle; 340…temporary adhesive section; 350…heating section; 360…second gate; 370…pressure plate; 400…multiple filter unit; 500…multi-stage inclined compression filter with left and right plates; 600, 600A, 600B…multi-stage parallel compression filter with left and right plates; 700…single filter; 700A…single filter with membrane; 800…multiple filter; 900…filter frame for cross-flow; R1…inlet side flow path; R2…outlet side flow path; R3…raw water / concentrated water flow path; R4…permeable water flow path; P…pipe; G…rubber rope.

Claims

1. A filter, characterized in that, It is formed by overlapping a primary fold, which is a fold-like concave-convex shape, and a secondary fold, which is a fold-like concave-convex shape with a larger spacing than the primary fold.

2. The filter according to claim 1, characterized in that, The direction of the crease along the first fold is orthogonal to the direction of the crease along the second fold.

3. The filter according to claim 1, characterized in that, The direction of the crease along the first fold is parallel to the direction of the crease along the second fold.

4. The filter according to claim 1, characterized in that, The folds of the first fold are formed in parallel multiple times.

5. The filter according to claim 1, characterized in that, When viewed from a direction orthogonal to the crease of the first fold, the multiple filter papers with the first fold are connected alternately at one end and the other end, thereby forming the second fold.

6. The filter according to claim 1, characterized in that, The creases of the primary folds formed on adjacent fold surfaces of the secondary folds are parallel.

7. The filter according to claim 1, characterized in that, The filter paper with the first fold is attached with a fastener to secure the filter paper in a folded state.

8. The filter according to claim 7, characterized in that, The height of the first fold is less than 2mm.

9. The filter according to claim 7, characterized in that, The fastener is formed of thermoplastic resin.

10. The filter according to claim 7, characterized in that, The fastener is a thin film.

11. The filter according to claim 7, characterized in that, The fastener is formed as a plurality of strips spaced apart along the direction of the crease of the first fold.

12. The filter according to claim 7, characterized in that, The filter paper and the fastener are pressurized in a point-like manner.

13. The filter according to claim 1, characterized in that, Multiple filter papers with primary pleats and multiple planar filter papers are alternately connected at one end and the other end to form the secondary pleats.

14. The filter according to claim 1, characterized in that, An adsorbent is attached to multiple filter papers that have the aforementioned primary pleats.

15. A filter unit, characterized in that, have: The filter according to any one of claims 1 to 14; and Installed on the frame of the filter.

16. The filter unit according to claim 15, characterized in that, The direction in which the fluid is introduced into the frame is along the direction of the crease of the first fold.

17. The filter unit according to claim 15, characterized in that, The frame portion includes: a fluid inlet portion, which introduces fluid into the frame portion; and a fluid outlet portion, which discharges fluid out of the frame portion. The filter is configured such that the creases of the secondary pleats face the fluid inlet or the fluid outlet.

18. The filter unit according to claim 17, characterized in that, The frame portion includes a first plate-shaped component and a second plate-shaped component. The first plate-shaped component and the second plate-shaped component are plate-shaped components arranged in opposite positions to connect the fluid inlet portion and the fluid outlet portion. All the pleated surfaces of the secondary pleats are connected to the first plate-shaped component and the second plate-shaped component.

19. The filter unit according to claim 18, characterized in that, The frame portion includes: A third plate-shaped component connects one end of the first plate-shaped component and one end of the second plate-shaped component; and A fourth plate-shaped component connects the other end of the first plate-shaped component and the other end of the second plate-shaped component. One end, which is not connected to the first or second plate-shaped component of the filter, is connected to the third plate-shaped component. The other end, which is not connected to the first or second plate-shaped component of the filter, is connected to the fourth plate-shaped component.

20. The filter unit according to claim 15, characterized in that, It has a connecting component that connects the creases of the secondary folds to each other.

21. The filter unit according to claim 15, characterized in that, It has a separator that separates the folded surfaces of the secondary folds.

22. The filter unit according to claim 21, characterized in that, The spacer is formed in the form of a plate or filament.

23. The filter unit according to claim 21, characterized in that, The isolation element is flexible.

24. The filter unit according to claim 17, characterized in that, It includes a circular plate, which is a plate-shaped component that protrudes from the frame portion and has a circular shape when viewed from the fluid inlet side or the fluid outlet side.

25. A multi-filter unit, characterized in that, The filter unit of claim 15 is connected to a plurality of filters.

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