Filter assembly and air filter provided with the same

Abstract

The present application provides a filter assembly (3) and an air filter provided with the filter assembly, the filter assembly (3) being provided with: a filter material (11) having creases (12, 13) alternately appearing on upstream and downstream sides of air, a plurality of pairs of inflow faces (14) for inflow of air and forming a letter V shape continuously via the creases (13), and a plurality of pairs of outflow faces (15) for outflow of air and forming a letter V shape continuously via the creases (12); and a spacing maintaining member (20) configured with a plurality of rows on the inflow faces (14) and the outflow faces (15) in a direction along the creases (12, 13), maintaining a spacing between the inflow faces (14) and a spacing between the outflow faces (15), the filter assembly (3) further being provided with an anti-bulging member (40) configured between the spacing maintaining members (20) on the pair of inflow faces (14), maintaining the spacing between the pair of inflow faces (14), and having contact faces (41) fixed to each other, or the filter assembly (3) further being provided with an anti-bulging member (40) which is configured between the spacing maintaining members (20) on the pair of outflow faces (15), maintaining the spacing between the pair of outflow faces (15) maintained by the spacing maintaining members (20) at the time of ventilation.

Description

Technical Field

[0001] The present invention relates to a filter assembly having pleated filter media and an air filter having the filter assembly. Background Technology

[0002] Previously, filter assemblies were known to have multiple spacer members formed along the fold direction of the pleated filter material to maintain uniform pleat spacing. For example, Patent Document 1 discloses a filter assembly in which the spacing is maintained by the face-to-face spacer members contacting each other.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2020-062610 Summary of the Invention

[0006] The problem the invention aims to solve

[0007] The spacer retainers properly maintain the pleat spacing during transport and in the absence of ventilation. However, when using the filter assembly, i.e., during ventilation, the filter media between adjacent spacer retainers in the pleat direction bulges due to ventilation. The bulging filter media comes into contact with each other on the outflow side, thereby impeding airflow and increasing pressure loss.

[0008] The present invention was made in consideration of such circumstances, and its object is to provide a filter assembly capable of suppressing the rise of pressure loss and an air filter having the filter assembly.

[0009] Solution for solving the problem

[0010] To address the aforementioned problems, the filter assembly of the present invention comprises: a filter media having been pleated to have alternating pleats on an upstream and downstream side of air, a pair of inflow surfaces for air to flow into and continuously forming a letter V shape via the pleats, and a pair of outflow surfaces for air to flow out and continuously forming a letter V shape via the pleats; and a spacing retaining member having multiple rows arranged on the pair of inflow surfaces and the pair of outflow surfaces in the direction along the pleats to maintain the spacing between the pair of inflow surfaces and the pair of outflow surfaces. The filter assembly further comprises an anti-bulging structure. Component: The anti-bulging member is disposed on the pair of inflow surfaces between adjacent spacer members located on the pair of inflow surfaces along the direction of the crease, maintaining the spacing between the pair of inflow surfaces held by the spacer members during ventilation, and having mutually fixed contact surfaces; or, the filter assembly further comprises an anti-bulging member disposed on the pair of outflow surfaces between adjacent spacer members located on the pair of outflow surfaces along the direction of the crease, maintaining the spacing between the pair of outflow surfaces held by the spacer members during ventilation.

[0011] The effects of the invention

[0012] In the filter assembly of the present invention and the air filter having the filter assembly, the increase in pressure loss can be suppressed. Attached Figure Description

[0013] Figure 1 This is a perspective view showing an embodiment of the air filter of the present invention.

[0014] Figure 2 It is a cross-sectional view along the airflow direction including the spacing retaining member in this embodiment.

[0015] Figure 3 This is a cross-sectional view along the airflow direction including the anti-bulging member in this embodiment.

[0016] Figure 4 This is an explanatory diagram of the problems with a filter assembly used as a comparative example.

[0017] Figure 5 This is an explanatory diagram showing the filter assembly in this embodiment from the inflow side.

[0018] Figure 6 This is an explanatory diagram showing the filter assembly in this embodiment from the outflow side.

[0019] Figure 7 This is a perspective view showing another embodiment of the air filter of the present invention.

[0020] Figure 8 It is a cross-sectional view along the airflow direction including the spacer retaining member in another embodiment.

[0021] Figure 9 It is a cross-sectional view along the airflow direction including the anti-bulging member in another embodiment.

[0022] Figure 10 This is an explanatory diagram showing a filter assembly in another embodiment from the outflow side.

[0023] Figure 11 This is an explanatory diagram showing a filter assembly in another embodiment from the inflow side.

[0024] Figure 12 It is a cross-sectional view along the airflow direction of the anti-bulging member in yet another embodiment.

[0025] Figure 13 This is a graph showing the shift in pressure loss during a long-term ventilation test of the filter assembly in this embodiment with anti-bulging components and a filter assembly as a comparative example without anti-bulging components. Detailed Implementation

[0026] Embodiments of the filter assembly and the air filter having the filter assembly of the present invention will be described with reference to the accompanying drawings.

[0027] Figure 1 This is a perspective view showing the appearance of an air filter 1, which is an embodiment of the air filter of the present invention.

[0028] Figure 2 It is a cross-sectional view along the airflow direction including the spacer retaining member 20.

[0029] Figure 3 It is a cross-sectional view along the airflow direction including the anti-bulging member 40.

[0030] The air filter 1 has a filter assembly 3 and a frame 5.

[0031] The frame 5 surrounds and houses the filter assembly 3 in such a way that the inflow surface 14 and the outflow surface 15 of the filter assembly 3 are exposed. That is, the frame 5 surrounds the filter assembly 3 such that the creases 12 and 13 of the filter material 11 are arranged on the upstream and downstream sides of the airflow direction (X direction) through the filter material 11. Furthermore, in this embodiment, for convenience, the crease located on the upstream side (-X direction) of the airflow is referred to as crease 12, and the crease located on the downstream side (+X direction) of the airflow is referred to as crease 13.

[0032] The filter assembly 3 has filter media 11, spacer retaining member 20 and anti-bulging member 40.

[0033] Filter media 11 is a component for capturing particulate matter in a gas. Filter media 11 is used, for example, to remove particles with a diameter of 2.5 μm or less and a concentration of 0.3 mg / m³. 3 The following dust. In filter media 11, for example, the collection efficiency based on counting method is 80% or more, the pressure loss is 79 Pa to 493 Pa, and the dust retention capacity (dust accumulation) is 200 g / m³. 2 ~800g / m 2 In the counting method, the collection efficiency is determined by ventilating air containing atmospheric dust, polyalphaolefin (PAO), or silica particles with a diameter of 0.3 μm. Dust retention capacity is the amount of dust collected by the filter until a specified final pressure loss is reached. Furthermore, the filter media 11 can be, for example, filter media for HEPA filters, filter media for ULPA filters, or filter media for gas removal filters.

[0034] The filter material 11 is, for example, a fibrous body composed of glass fiber, organic fiber, or a mixture of these fibers, such as nonwoven fabric or felt. Filter material 11 made of glass fiber is, for example, produced by papermaking using a wet or dry process. Filter material 11 made of organic fiber is, for example, produced using spunbonding, meltblowing, thermal bonding, chemical bonding, etc. Alternatively, the filter material 11 may also be, for example, formed by laminating multiple nonwoven fabrics with different collection efficiencies.

[0035] The filter media 11 is pleated into a roughly V-shaped form by alternating mountain folds and valley folds (folds 12, 13). The pleating process is performed using a reciprocating or rotary pleating machine. The filter media 11 is pleated to have folds 12, 13, multiple pairs of inflow surfaces 14, and multiple pairs of outflow surfaces 15.

[0036] Creases 12 and 13 alternate on the upstream and downstream sides of the airflow. Multiple pairs of inflow surfaces 14 are surfaces that allow air to flow in and form a letter V shape by continuous creases 12. Multiple pairs of outflow surfaces 15 are surfaces that allow air to flow out and form a letter V shape by continuous creases 13.

[0037] The spacer retaining member 20 maintains the space between a pair of inflow surfaces 14 and the space between a pair of outflow surfaces 15 (pleat spacing). Specifically, the spacer retaining member 20 is arranged face-to-face on the pair of inflow surfaces 14 and the pair of outflow surfaces 15 in the Y direction, maintaining the pleat spacing through mutual contact. The face-to-face spacer retaining members 20 do not need to contact the entire surface, only locally (in...) Figure 2 The two ends (roughly in the X direction) should touch.

[0038] From the viewpoint of suppressing the reduction of ventilation area, the spacer retaining member 20 is arranged intermittently along the general X direction. In other words, the spacer retaining member 20, which is composed of multiple member pieces, is arranged along the general X direction.

[0039] Furthermore, the spacing retaining member 20 has different appropriate heights (approximately Y-direction length) depending on the pleat spacing. For example, in Figure 2 In the middle, the pleat spacing between a pair of inflow surfaces 14 increases from crease 12 toward crease 13, so the height of the spacing retaining member 20 is larger on the crease 12 side and smaller on the crease 13 side.

[0040] like Figure 1 As shown, multiple rows of spacer members 20 are arranged along the Z direction on a pair of inflow surfaces 14 and a pair of outflow surfaces 15. The spacer members 20 are preferably arranged evenly in the Z direction, for example, at intervals of 30 mm.

[0041] The spacer retaining member 20 is made of, for example, a thermoplastic resin called a hot melt adhesive. Examples of such thermoplastic resins include polyamide-based, urethane-based, or olefin-based thermoplastic resins. The spacer retaining member 20 is formed, for example, by directly applying a softened hot melt adhesive to the filter material 11 using a paint gun filled with the hot melt adhesive in a direction orthogonal to the creases 12 and 13. Alternatively, the spacer retaining member 20 can be formed, for example, by bonding a cured hot melt adhesive to the filter material 11, in addition to direct application. Furthermore, the spacer retaining member 20 can also be made of other materials such as ceramic.

[0042] The anti-bulging member 40 maintains the spacing between the pair of inflow surfaces 14 held by the spacer retaining member 20 during ventilation, preventing the inflow surfaces 14 from bulging downstream. Specifically, the anti-bulging member 40 is disposed only on the pair of inflow surfaces 14 in a face-to-face manner in the Y direction (see reference). Figure 5 , Figure 6 The anti-bulging member 40 is intermittently arranged along a generally X direction (a direction approximately orthogonal to the crease 12). In other words, the anti-bulging member 40, composed of multiple member pieces, is arranged along a generally X direction. In addition, similar to the spacer retaining member 20, the anti-bulging member 40 has different appropriate heights depending on the pleat spacing.

[0043] The anti-bulging members 40, respectively disposed on a pair of inflow surfaces 14 and facing each other, have contact surfaces 41 that contact each other. The contact surfaces 41 are fixed together, for example, using an adhesive, in a manner that prevents them from separating. Specifically, the two ends 42 of the contact surface 41 of one member piece disposed on one of the pair of inflow surfaces 14 are fixed to the contact surfaces 41 of two member pieces disposed on the other inflow surface 14 in the generally X direction. Furthermore, for the spacer retaining members 20, although the face-to-face spacer retaining members 20 are in contact, they are not fixed together.

[0044] Anti-bulging member 40 is disposed between spaced retaining members 20 located adjacent to each other on a pair of inflow surfaces 14 in the Z direction. Figure 1 As shown, the anti-bulging member 40 is preferably positioned approximately in the middle of a pair of adjacent spacer members 20 located on the inflow surface 14 in the Z direction. That is, when the adjacent spacer members 20 in the positive and negative Z directions are arranged at a 30mm interval, the anti-bulging member 40 is preferably positioned 15mm away from each spacer member 20.

[0045] The anti-bulging member 40 is made of substantially the same material as the spacer retaining member 20, for example, it is made of hot melt adhesive.

[0046] Next, the functions of the filter assembly 3 and the air filter 1 in this embodiment will be explained.

[0047] Figure 4 This is an explanatory diagram illustrating the problem of filter assembly 3, which serves as a comparative example.

[0048] Figure 5 This is an explanatory diagram showing the filter assembly 3 in this embodiment from the inflow surface 14 side. Figure 6 This is an explanatory diagram showing the filter assembly 3 in this embodiment from the outflow surface 15 side.

[0049] In the absence of ventilation, the filter assembly 3 (air filter 1) utilizes the spacing retaining member 20 to appropriately maintain the pleat spacing. When air flows into the filter assembly 3 during use, the air passes from the inlet surface 14 to the outlet surface 15, but resistance is generated on the filter media 11. Thus, as... Figure 4 As shown, the inflow surface 14 bulges towards the outflow surface 15 with increasing pleat spacing. Consequently, the pleat spacing on the outflow surface 15 narrows, hindering airflow and contributing to increased pressure loss.

[0050] Therefore, as Figure 5As shown, in this embodiment, the filter assembly 3 has an anti-bulging member 40 disposed on the inflow surface 14 of the filter media 11. The anti-bulging members 40 are fixed to each other at the contact surface 41. Therefore, the anti-bulging member 40 functions in such a way as to resist the force that causes the filter media 11 to bulge in the direction of increasing pleat spacing due to air, such as... Figure 6 As shown, maintain the pleat spacing.

[0051] Therefore, in the filter assembly 3, when there is no ventilation, the spacer retaining member 20 maintains the pleat spacing, and on the other hand, when there is ventilation, the anti-bulging member 40 maintains the pleat spacing, thus suppressing the increase of pressure loss during use.

[0052] Next, another embodiment of the filter assembly of the present invention and an air filter having the filter assembly will be described with reference to the accompanying drawings. This other embodiment differs from the previous embodiment only in the configuration of the anti-bulging member 40.

[0053] Figure 7 This is a perspective view showing the appearance of an air filter 1, which is another embodiment of the air filter of the present invention.

[0054] Figure 8 It is a cross-sectional view along the airflow direction including the spacer retaining member 20.

[0055] Figure 9 It is a cross-sectional view along the airflow direction including the anti-bulging member 40.

[0056] In another embodiment, the anti-bulging member 40 maintains the spacing between a pair of outflow surfaces 15 held by the spacer retaining member 20 during ventilation, preventing the pleat spacing of the outflow surfaces 15 from narrowing. Specifically, the anti-bulging member 40 is disposed only on a pair of outflow surfaces 15 in a face-to-face manner in the Y direction (see reference). Figure 10 , Figure 11 The anti-bulging member 40 is intermittently arranged along a generally X direction (a direction approximately orthogonal to the crease 13). In other words, the anti-bulging member 40, composed of multiple member pieces, is arranged along a generally X direction. In addition, similar to the spacer retaining member 20, the anti-bulging member 40 has different appropriate heights depending on the pleat spacing.

[0057] The anti-bulging members 40, respectively disposed on a pair of outflow surfaces 15 and facing each other, have contact surfaces 41 that contact each other. Specifically, the two ends 42 of the contact surface 41 of one member piece disposed on one of the pair of outflow surfaces 15 contact the contact surfaces 41 of the two member pieces disposed on the other outflow surface 15 in the generally X direction.

[0058] The anti-bulging member 40 is disposed on a pair of outlet surfaces 15, between adjacent spacer members 20 located on the pair of outlet surfaces 15 in the Z direction. The anti-bulging member 40 is preferably disposed approximately in the middle of the adjacent spacer members 20 located on the pair of outlet surfaces 15 in the Z direction (see reference). Figure 10 That is, when adjacent spacer members 20 are arranged at 30mm intervals in the positive and negative Z directions, the anti-bulging member 40 is preferably arranged at a position 15mm away from each spacer member 20.

[0059] The anti-bulging member 40 is made of a material substantially the same as that of the spacer member 20, for example, it is made of hot melt adhesive. In addition to direct coating, the anti-bulging member 40 can also be formed by bonding a cured hot melt adhesive to the filter material 11. Furthermore, the anti-bulging member 40 can also be a stabilizer inserted between each convection surface 15, made of a metal plate such as aluminum, a resin plate, or thick paper in a comb-like shape, or a metal plate such as aluminum, a resin plate, or thick paper that has been corrugated.

[0060] Next, the functions of the filter assembly 3 and the air filter 1 in another embodiment will be explained.

[0061] Figure 4 This is an explanatory diagram illustrating the problem of filter assembly 3, which serves as a comparative example.

[0062] Figure 10 This is an explanatory diagram showing the filter assembly 3 in this embodiment from the outflow surface 15 side. Figure 11 This is an explanatory diagram showing the filter assembly 3 of this embodiment from the inflow surface 14 side.

[0063] In the absence of ventilation, the filter assembly 3 (air filter 1) utilizes the spacing retaining member 20 to appropriately maintain the pleat spacing. When air flows into the filter assembly 3 during use, the air passes from the inlet surface 14 to the outlet surface 15, but resistance is generated on the filter media 11. Thus, as... Figure 4 As shown, the inflow surface 14 bulges towards the outflow surface 15 with increasing pleat spacing. Consequently, the pleat spacing on the outflow surface 15 narrows, hindering airflow and contributing to increased pressure loss.

[0064] Therefore, as Figure 10 As shown, in another embodiment, the filter assembly 3 has an anti-bulging member 40 disposed on the outflow surface 15 of the filter media 11. The anti-bulging members 40 are in contact with each other at the contact surface 41. Therefore, the anti-bulging members 40 function in such a way as to resist the force that causes the filter media 11 to narrow the pleat spacing due to air, such as Figure 11 As shown, maintain the pleat spacing.

[0065] Therefore, in the filter assembly 3, when there is no ventilation, the spacer retaining member 20 maintains the pleat spacing, and on the other hand, when there is ventilation, the anti-bulging member 40 maintains the pleat spacing, thus suppressing the increase of pressure loss during use.

[0066] In the two embodiments described above, examples are shown where the anti-bulging member 40 is disposed on a pair of inflow surfaces 14 or on a pair of outflow surfaces 15, but as Figure 12 As shown, the anti-bulging member 40 can also be disposed on both a pair of inflow surfaces 14 and a pair of outflow surfaces 15.

[0067] Furthermore, in this case, the anti-bulging member 40 on the inflow surface 14 side and the anti-bulging member 40 on the outflow surface 15 side are preferably configured to not face each other across the filter material 11.

[0068] exist Figure 12 In the example shown, two rows and one row are alternately arranged in the Y direction and Z direction between the spaced members 20, 20 on the inflow side 14 and the outflow side 15.

[0069] In addition, the anti-bulging member 40 shown in the figure is formed with a cross-section smaller than that of the spacer member 20.

[0070] Here, Figure 13 This is a graph showing the shift in pressure loss during a long-term ventilation test of the filter assembly 3 of the above-described embodiment with anti-bulging member 40 and a filter assembly as a comparative example without anti-bulging member 40.

[0071] like Figure 13 As shown, in the comparative filter assembly without the anti-bulging member 40, as indicated by result D2, the pressure loss increases proportionally with time. On the other hand, in the filter assembly 3 of this embodiment, as indicated by result D1, due to the reduction in ventilation area caused by the presence of the anti-bulging member 40, a larger pressure loss is initially observed compared to the comparative filter assembly. However, no increase in pressure loss was observed in the filter assembly 3 of this embodiment even after 500 hours, and the pressure loss remained almost the same as in the initial stage. That is, it can be seen that in the filter assembly 3 of this embodiment, the increase in pressure loss caused by the narrowing of the pleat spacing on the outflow surface 15 side due to the bulging of the filter material 11 is suppressed.

[0072] Therefore, the filter assembly 3 and the air filter 1 equipped with the filter assembly 3 in this embodiment can suppress the increase in pressure loss by appropriately maintaining the pleat interval.

[0073] Several embodiments have been described in this disclosure, but these embodiments are provided by way of example and are not intended to limit the scope of the invention. These new embodiments can be implemented in various other ways and can be omitted, substituted, or modified in various ways without departing from the spirit of the invention. These embodiments and their variations are included in the scope and spirit of the invention, and are included in the scope of the invention as set forth in the claims and its equivalents.

[0074] For example, the spacing retaining member 20 of the filter assembly 3 is one example, but it is not limited thereto. In this embodiment, for the anti-bulging member 40 of the filter assembly 3, an example is described where one member piece of the anti-bulging member 40 disposed on one of the pair of inflow surfaces 14 contacts and is fixed to the two member pieces of the anti-bulging member 40 disposed on the other of the pair of inflow surfaces 14. However, the shape of the anti-bulging member is not limited to this; it can be any shape as long as the face-to-face anti-bulging members can be fixed to each other and maintain the pleat spacing.

[0075] In another embodiment, for the anti-bulging member 40 of the filter assembly 3, an example is described where one member piece of the anti-bulging member 40 disposed on a pair of outflow surfaces 15 contacts and is fixed to two member pieces of the anti-bulging member 40 disposed on the other outflow surface 15 of the pair of outflow surfaces 15. However, the shape of the anti-bulging member is not limited to this; it can be any shape as long as the face-to-face anti-bulging members can contact each other while maintaining the pleat spacing.

[0076] Explanation of reference numerals in the attached figures

[0077] 1. Air filter; 3. Filter assembly; 5. Frame; 11. Filter media; 12. 13. Crease; 14. Inlet surface; 15. Outlet surface; 20. Spacer; 40. Anti-bulging component; 41. Contact surface; 42. Both ends.

Claims

1. A filter assembly, wherein, This filter assembly includes: The filter media, having been pleated to have alternating pleats on the upstream and downstream sides of the airflow, a pair of inflow surfaces forming a continuous letter V shape through the pleats, and a pair of outflow surfaces forming a continuous letter V shape through the pleats; and A spacing retaining member, having multiple rows arranged along the crease on the pair of inflow surfaces and the pair of outflow surfaces, maintains the spacing between the pair of inflow surfaces and the pair of outflow surfaces. The filter assembly also includes an anti-bulging member disposed between adjacent spacer members on the pair of inflow surfaces along the direction of the crease, maintaining the spacing between the pair of inflow surfaces held by the spacer members during ventilation, and having mutually fixed contact surfaces, or... The filter assembly also includes an anti-bulging member disposed on the pair of outflow surfaces, adjacent to the spacer members on the pair of outflow surfaces in the direction along the crease, to maintain the spacing between the pair of outflow surfaces held by the spacer members during ventilation.

2. The filter assembly according to claim 1, wherein, The anti-bulging member is disposed approximately in the middle of the spacer members located on the pair of inflow surfaces adjacent to each other along the direction of the crease.

3. The filter assembly according to claim 1, wherein, The anti-bulging member is disposed approximately in the middle of the spacer members located on the pair of outflow surfaces adjacent to each other along the direction of the crease.

4. The filter assembly according to claim 2, wherein, The spacer members located on the pair of inflow surfaces adjacent to each other along the direction of the crease are arranged at approximately 30 mm intervals.

5. The filter assembly according to claim 3, wherein, The spacer members located on the pair of outflow surfaces adjacent to each other along the direction of the crease are arranged at approximately 30 mm intervals.

6. The filter assembly according to claim 1, wherein, The anti-bulging component has a plurality of component pieces arranged intermittently along a direction substantially orthogonal to the crease. The contact surface of one of the component pieces disposed on one of the pair of inflow surfaces is fixed at both ends in a direction substantially orthogonal to the crease to two of the component pieces disposed on the other of the pair of inflow surfaces.

7. The filter assembly according to claim 1, wherein, The anti-bulging component has a plurality of component pieces arranged intermittently along a direction substantially orthogonal to the crease. One of the component pieces disposed on one of the pair of outflow surfaces contacts two of the component pieces disposed on the other of the pair of outflow surfaces at its two ends in a direction substantially orthogonal to the crease.

8. The filter assembly according to claim 1, wherein, The spacer retaining member and the anti-bulging member are hot melt adhesives.

9. The filter assembly according to claim 1, wherein, The filter assembly includes an anti-bulging member disposed between adjacent spacer members on the pair of inflow surfaces along the direction of the crease, maintaining the spacing between the pair of inflow surfaces held by the spacer members during ventilation, and having mutually fixed contact surfaces. The filter assembly includes an anti-bulging member disposed on the pair of outflow surfaces between adjacent spacer members located on the pair of outflow surfaces in the direction along the crease, maintaining the spacing between the pair of outflow surfaces held by the spacer members during ventilation.

10. The filter assembly according to claim 9, wherein, The anti-bulging member on the inflow side and the anti-bulging member on the outflow side are configured to be separated from each other by the filter material.

11. An air filter, characterized in that, This air filter has the following features: The filter assembly according to any one of claims 1 to 10; and A frame that surrounds and houses the filter assembly in a manner that exposes the inflow and outflow surfaces of the filter assembly.

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