Dust collector and method for intake air of a dust collector

Abstract

The objective is to provide a compact dust collector that can be used in a limited space while minimizing the risk of dust explosions. [Solution] The dust collector 1 comprises a lower body 2 on which a dust collection container 2e is provided and a suction port 2c is formed, a filter section 3 positioned above the lower body 2, and an upper body 4 positioned above the filter section 3. The upper body 4 has a built-in fan 4d and an electric motor 5, and an exhaust port 4c formed therein for discharging gas that has passed through the filter section 3. The lower body 2 has an expanded metal 7 positioned at the suction port 2c to straighten the airflow so that the gas drawn in from the suction port 2c is directed towards the filter section 3.

Description

Technical Field

[0001] The present invention relates to a dust collector and a method for sucking air into the dust collector.

Background Art

[0002] In a food manufacturing area, a pharmaceutical manufacturing area, or a cosmetic manufacturing area, dust containing powder such as raw materials diffuses. In a battery manufacturing area or a semiconductor manufacturing area, dust containing contaminants such as metal powder diffuses. In a soldering work area or a welding work area, dust containing fumes diffuses. In these work areas, workers must avoid the risk of being affected by the body by sucking the dust. Therefore, a dust collector that sucks a gas containing dust and collects the dust is installed in these work areas where the dust diffuses.

[0003] Conventionally, a dust collector having a configuration in which the sucked metal dust is made to collide with a collision plate and fall into a dust collection container has been proposed (Patent Document 1: Japanese Patent Publication No. 59-016489). Conventionally, a dust collector having a configuration in which a net-like trap is provided on the opening surface of a dust collection container has also been proposed (Patent Document 2: Japanese Patent Application Laid-Open No. 2013-078747).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] In recent years, there has been a demand for compact dust collectors that can be used in space-saving environments. However, conventional technology requires multiple impact plates and traps, resulting in a complex airflow path, making miniaturization difficult. If the number of impact plates and traps is reduced, dust will be stirred up inside the machine, reducing dust removal capacity and increasing the risk of dust explosions. [Means for solving the problem]

[0006] This invention has been made in view of the above circumstances, and aims to provide a compact dust collector that can be used in a space-saving manner while suppressing the risk of dust explosion.

[0007] As one embodiment, the above problem is solved by the solution disclosed below.

[0008] The dust collector according to the present invention comprises a lower body having a suction port for sucking in gas containing dust and a dust collection container for storing the dust, a filter section positioned above the dust collection container, and an upper body having a fan and an electric motor built into it above the filter section and an exhaust port for discharging the gas that has passed through the filter section, and is characterized by having an expanded metal provided at the suction port to straighten the airflow of the gas sucked in from the suction port so that it is directed toward the filter section. With this configuration, since the air sucked in from the suction port is straightened so that it is directed toward the filter section positioned above, a compact dust collector that can be made to fit in a space while suppressing the risk of dust explosion can be made.

[0009] The present invention relates to a dust collector intake method comprising a lower body having a suction port for sucking in a gas containing dust and a dust collection container for storing the dust, and an upper body having a filter section positioned above the dust collection container and an exhaust port above the filter section, which houses a fan and an electric motor and discharges the gas that has passed through the filter section, characterized in that an expanded metal is provided at the suction port to straighten the gas sucked in from the suction port so that it is directed toward the filter section. With this configuration, since the gas sucked in from the suction port is straightened so that it is directed toward the filter section positioned above, a compact dust collector that can be made to fit in a space while suppressing the risk of dust explosion can be made.

[0010] For example, the suction port is formed on the back or side. For example, the exhaust port is formed on the back or side. This makes it easy to place the device under a workbench or similar location.

[0011] For example, the expanded metal has a mesh with a short axis in the vertical direction, a mesh with a long axis in the horizontal direction, and an opening in the mesh facing upward. This configuration makes it possible to more reliably straighten the airflow toward the filter section located above, and prevents the airflow from hitting the dust collected in the dust collection container and causing the dust to be stirred up.

[0012] For example, the mesh has a short diameter of 1 mm or more and 5 mm or less, and a long diameter of 1.5 to 3 times the short diameter. This configuration prevents dust from being scattered while ensuring the necessary intake volume for dust collection. For example, the openings of the mesh are diamond-shaped or tortoise-shell-shaped. For example, the mesh has a thickness of 0.2 mm or more and 2.5 mm or less. By regulating the thickness, the expanded metal can be manufactured with high precision by press working, and the rectifying effect necessary for dust collection can be obtained more reliably.

[0013] For example, the surface of the mesh pressed by the cutting blade during press processing becomes the outlet side for the gas drawn in from the suction port. The bonded portion of the mesh on this surface is smooth and rounded. On the other hand, the back surface opposite to this surface has curved lines formed by being received by the receiving blade during press processing. Therefore, by making the surface of the mesh the outlet side for the gas, the rectifying effect of the gas can be further improved.

[0014] As an example, the upper body is detachably attached to the lower body, sandwiching the filter section. This configuration makes it easy to replace the filter, clean the inside of the device, and perform maintenance. As an example, the upper body has the suction port located on the side opposite to the side from which the dust collection container is pulled out. This configuration makes it easy to place the device under a workbench or similar location. [Effects of the Invention]

[0015] According to the present invention, a compact dust collector that can be used in a space-saving manner while suppressing the risk of dust explosions can be realized. [Brief explanation of the drawing]

[0016] [Figure 1] Figure 1 is a schematic perspective view of an example of a dust collector according to this embodiment, viewed from the front. [Figure 2] Figure 2 is a schematic perspective view of the dust collector shown in Figure 1, viewed from the rear. [Figure 3] Figure 3 is a schematic structural diagram of the dust collector shown in Figure 1. [Figure 4] Figure 4 is a schematic longitudinal cross-sectional view of the dust collector shown in Figure 1, viewed from the side. [Figure 5] Figure 5A is a front view showing an example of expanded metal according to this embodiment. Figure 5B is a partially enlarged view of the expanded metal shown in Figure 5A. Figure 5C is a schematic longitudinal cross-sectional view of the expanded metal shown in Figure 5B, viewed from the side. [Figure 6]FIG. 6A is a schematic plan view showing the arrangement of the electric motor and the duct when the upper body of the dust collector shown in FIG. 1 is viewed from above. FIG. 6B is a schematic perspective view showing the arrangement of the electric motor and the duct in the upper body shown in FIG. 1. FIG. 6C is a schematic bottom view of the upper body shown in FIG. 1 viewed from below.

DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a schematic perspective view of the dust collector 1 according to the present embodiment viewed from the front side. FIG. 2 is a schematic perspective view of the dust collector 1 viewed from the back side. FIG. 3 is a schematic structural development view of the dust collector 1. The dust collector 1 includes a lower body 2 provided with a dust collection container 2e for storing dust, a filter unit 3 disposed above the dust collection container 2e, and an upper body 4 provided above the filter unit 3.

[0018] In this specification, in order to facilitate the explanation of the positional relationship of each part in the dust collector 1, the directions are indicated by arrows X, Y, and Z in the drawing. When viewing the front of the dust collector 1 from the operator, the arrow X in the drawing indicates the right side direction, the arrow Y indicates the front direction, and the arrow Z indicates the upward direction. In all the drawings for explaining the embodiments, members having the same function are denoted by the same reference numerals, and repeated explanations may be omitted.

[0019] The lower body 2 has a receiving port 2d formed in the front 2a, and the dust collection container 2e is accommodated so as to be pullable forward. A suction port 2c for sucking the gas containing dust is provided on the back 2b of the lower body 2. Inside the lower body, an expanded metal 7 is disposed so as to cover the suction port 2c. The dust collection container 2e is disposed below the expanded metal 7.

[0020] [[ID=1十九]] The upper body 4 has a built-in fan 4d and an electric motor 5 above the filter unit 3. The operation panel 6a and the power switch 6b operated by the operator are provided on the front surface 4a of the upper body 4. The control unit 6 for driving and controlling the electric motor 5 is built in a position closer to the front surface of the upper body 4. As an example, the control unit 6 is a control board having a CPU composed of a one-chip microcomputer. As an example, the operation panel 6a is a touch panel capable of data input / output.

[0021] The power supply unit 6c for supplying power to the electric motor 5 and the control unit 6 is provided on the back surface 4b of the upper body 4. The power cable led out from the power supply unit 6c is connected to a commercial power supply. The upper body 4 has an exhaust port 4c for discharging the gas that has passed through the filter unit 3 provided on its back surface 4b.

[0022] The filter unit 3 has a rectangular frame body 3b and a filter 3a provided inside the frame body 3b. As an example, the filter 3a can repair 99% or more of particles with a diameter of 5 micrometers and is a so-called medium-performance filter. As an example, a bug filter can be applied to the filter 3a.

[0023] The upper body 4 is detachably attached to the lower body 2 with the filter unit 3 interposed therebetween. The lower part of the frame body 3b of the filter unit 3 engages with the upper part of the lower body 2, and the frame part 4f of the upper body 4 engages with the upper part of the frame body 3b. Then, the lower body 2 and the upper body 4 are fixed in position by the first metal fittings 11 respectively arranged on both side surfaces of the lower body 2. Also, the lower body 2 and the dust collection container 2e are fixed in position by the second metal fittings 12 respectively arranged on both side surfaces of the lower body 2. Known retaining metal fittings can be applied to the first metal fitting 11 and the second metal fitting 12. As an example, the retaining metal fitting is a tee-type fastener. The retaining metal fitting is also called a patch lock or an arm catch.

[0024] The lower body 2 is designed so that its front-to-back length is greater than its left-to-right width. The upper body 4 has dimensions and a shape corresponding to the lower body 2, and the control unit 6 is positioned towards the front. This allows the filter 3a to have a rectangular shape while increasing its effective area. In addition, since the fan 4d and electric motor 5 are positioned directly above the filter 3a, the dust collection efficiency can be further improved. As an example, the dust collector 1 has a stainless steel housing.

[0025] Figure 4 is a schematic longitudinal cross-sectional view of the dust collector 1 as seen from the side. The arrows in the figure indicate the airflow F1. A fan 4d is attached to the downward-facing drive shaft 5a of the electric motor 5. The upper body 4 has ducts 9 arranged at multiple locations that are rotationally symmetric with respect to the axis P1 passing through the drive shaft 5a. The upper body 4 has a partition wall 4g on its lower surface, and the intake port 4e of the fan 4d is located in the partition wall 4g.

[0026] [Suction port 2c] Next, the arrangement of the suction port 2c and the expanded metal 7 in the dust collector 1 of this embodiment will be described below. Figure 5A is a front view showing an example of the expanded metal 7 according to this embodiment. Figure 5B is a partially enlarged view of the expanded metal 7 shown in Figure 5A. Figure 5C is a schematic longitudinal cross-sectional view of the expanded metal 7 shown in Figure 5B, viewed from the side.

[0027] Expanded metal 7 is manufactured from sheet metal such as stainless steel or steel by a cold drawing method. Expanded metal 7 is also called lath mesh. Lath mesh conforms to JIS G3351-1987. As an example, expanded metal 7 is a smaller version of lath mesh. In this embodiment, expanded metal 7 is arranged inside the lower body 2 so as to cover the suction port 2c. The expanded metal 7 straightens the gas drawn in from the suction port 2c so that it is directed towards the filter 3a.

[0028] In the expanded metal 7, the minor axis 7c of the mesh is in the vertical direction, and the major axis 7d of the mesh is in the horizontal direction. In the expanded metal 7, the opening 7e of the mesh is rhombus-shaped, and the opening 7e of the mesh faces upward. In the expanded metal 7, the minor axis 7c of the mesh is 1 mm or more and 5 mm or less, and the major axis 7d of the mesh is 1.5 times or more and 3 times the minor axis 7c. In the expanded metal 7, the surface 7a pressed by the cutting blade when the mesh is pressed becomes the outlet side for the gas sucked in from the suction port 2c. In the expanded metal 7, the mesh thickness T is 0.2 mm or more and 2 mm or less. In the expanded metal 7, the mesh width W is 0.3 mm or more and 3 mm or less.

[0029] [Duct 9] Next, the arrangement of the electric motor 5 and duct 9 in the dust collector 1 of this embodiment will be described below. Figure 6A is a schematic plan view showing the arrangement of the electric motor 5 and duct 9 in the upper body 4 of the dust collector 1. Figure 6B is a schematic perspective view showing the arrangement of the electric motor 5 and duct 9 in the upper body 4. As an example, ducts 9 are arranged at four corners that are rotationally symmetric with respect to the axis P1. Figure 6C is a schematic bottom view of the upper body 4 viewed from below. The upper body 4 has a partition wall 4g on its lower surface, and the intake port 4e of the fan 4d is located on the partition wall 4g. The intake port 4e is located on the axis of the axis P1. The airflow F1 is drawn in from the intake port 4e and discharged from the discharge port 9c of the duct 9.

[0030] Of the four ducts 9 arranged around the housing 5b of the electric motor 5, those located in the two corners closer to the front have an intake port 9a for drawing in airflow F1 from the fan 4d, a conduit 9b for passing the airflow F1, and an outlet port 9c for discharging the airflow F1 toward both the housing 5b of the electric motor 5 and the exhaust port 4c. Additionally, the two corners located closer to the rear of the four ducts 9 also have an intake port 9a for drawing in airflow F1 from the fan 4d, a conduit 9b for passing the airflow F1, and an outlet port 9c for discharging the airflow F1 toward the housing 5b of the electric motor 5. Since the gas discharged from the outlet port 9c absorbs heat from the housing 5b before being discharged outside the machine, it is easy to suppress the heat rise associated with the operation of the electric motor 5 while performing more efficient exhaust.

[0031] [Exhaust port 4c] Next, the arrangement of the exhaust port 4c and the dispersion section 8 in the dust collector 1 of this embodiment will be described below. Figure 4 is a schematic longitudinal cross-sectional view showing the arrangement of the duct 9, exhaust port 4c, and dispersion plate 8a. Figure 6A is a schematic plan view showing the arrangement of the duct 9, exhaust port 4c, and dispersion plate 8a.

[0032] The upper body 4 has an exhaust port 4c for discharging exhaust from the duct 9 to the outside of the machine, a dispersion plate 8a for dispersing the exhaust from the exhaust port 4c in the left-right and up-down directions, and a support column 8b for supporting the dispersion plate 8a while maintaining a distance 8c between the outlet of the exhaust port 4c and the dispersion plate 8a, which is provided on the outside of the upper body 4. With this configuration, since the exhaust from the exhaust port 4c is dispersed in the left-right and up-down directions, a compact dust collector 1 can be made that is space-saving while suppressing noise associated with the operation of the electric motor 5.

[0033] The distance 8c between the outlet of the exhaust port 4c on the upper body 4 and the dispersion plate 8a is the same as the distance between the back surface 4b and the dispersion plate 8a. In this embodiment, the distance 8c is set to 5 to 18 mm. With this configuration, the necessary exhaust volume for the dust collector 1 can be secured while suppressing noise. As an example, the dispersion plate 8a is square or polygonal in shape.

[0034] Next, various embodiments of the dust collector 1 according to the present invention will be described below.

[0035] [Example A] The expanded metal 7 is made of SUS304, with a thickness T of 0.5 mm and a width W of 0.7 mm. The expanded metal 7 has a mesh surface 7a on the outlet side of the gas sucked in from the suction port 2c, and the mesh opening 7e faces upward. The powder collection efficiency under each condition can be estimated by measuring the amount of powder remaining in the dust collection container 2e under different sizes of the expanded metal 7. Therefore, 50 g of potato starch was placed in the dust collection container 2e, the electric motor 5 was operated for 2 minutes to suck in air from outside the machine, and the amount of powder remaining in the dust collection container 2e was measured to calculate the powder collection efficiency. The performance evaluation results of the dust collector 1 are shown in Table 1.

[0036] [Table 1]

[0037] According to Table 1, Example A1, in which the mesh's minor axis was oriented vertically, had a collection efficiency of 83%, and Example A3, in which the mesh's minor axis was oriented vertically, had a collection efficiency of 82%. On the other hand, Examples A2 and A4, in which the mesh's minor axis was oriented horizontally, both showed a decrease in collection efficiency. Therefore, it was confirmed that oriented the mesh's minor axis vertically straightens the airflow so that the gas drawn in from the suction port 2c is directed towards the filter section 3 located above. It was also confirmed that the collection efficiency decreases when the mesh's minor axis is 7 mm or larger.

[0038] [Example B] The expanded metal 7 is made of SUS304, with a thickness T of 0.5 mm, a width W of 0.7 mm, a minor axis 7c of 3 mm, and a major axis 7d of 6 mm. The mesh opening 7e of the expanded metal 7 faces upward. The powder collection efficiency under each condition can be estimated by measuring the amount of powder remaining in the dust collection container 2e under different orientations of the expanded metal 7. Therefore, 50 g of potato starch was placed in the dust collection container 2e, the electric motor 5 was operated for 2 minutes, and air was drawn in from outside the machine. The amount of powder remaining in the dust collection container 2e was then measured to calculate the powder collection efficiency. The performance evaluation results of the dust collector 1 are shown in Table 2.

[0039] [Table 2]

[0040] According to Table 2, in Example B1, where the outlet side of the gas drawn in from the suction port 2c was the surface 7a of the mesh, the collection efficiency was 100%. On the other hand, in Example B2, where the outlet side of the gas drawn in from the suction port 2c was the back surface 7b of the mesh, the collection efficiency was 84%. Therefore, it was confirmed that by making the outlet side of the gas drawn in from the suction port 2c the surface 7a of the mesh, the rectification effect, in which the gas drawn in from the suction port 2c is rectified toward the filter section 3 located above, can be further enhanced. It was also confirmed that the collection efficiency decreased significantly when the opening 7e of the mesh was facing downwards.

[0041] [Example C] The dust collector 1 was operated, and the size of the distance 8c between the back surface 4b of the upper body 4 and the dispersing plate 8a was changed. The noise level was measured at a height of 0.5m above the ground at a position 1m away from the front of the main unit. The performance evaluation results are shown in Table 3.

[0042] [Table 3]

[0043] Table 3 shows that by attaching the diffuser plate 8a, it was confirmed that the noise level could be reduced by 1 to 5 dB while maintaining the airflow required for the dust collector. The noise level decreases as the distance 8c between the diffuser plate 8a and the back surface 2b decreases. In Example C1, the noise level decreased by 5 dB and the airflow decreased by 14%. In Example C2, the noise level decreased by 3 dB and the airflow could be maximized. In Example C3, the airflow required for the dust collector could be maintained, but the noise level reduction effect was small. It was also confirmed that when the distance 8c between the diffuser plates 8a was 20 mm or more, the noise level could be reduced by attaching sound-absorbing material to the back surface.

[0044] [Example D] The dust collector 1 was operated, and the arrangement of the duct 9 was changed. The noise level was measured at a height of 0.5m above the ground, 1m away from the front of the main unit. The performance evaluation results are shown in Table 4.

[0045] [Table 4]

[0046] According to Table 4, it was confirmed that by attaching the dispersion plate 8a and providing ducts 9 in multiple locations, the noise level could be reduced by 3 to 6 dB while maintaining the airflow required for the dust collector. In Example D2, ducts 9 were provided in two corners near the front, and the airflow F1 was discharged towards both the housing 5b of the electric motor 5 and the exhaust port 4c. It was confirmed that the noise level was reduced by 3 dB and the airflow could be maximized. In Example D3, ducts 9 were provided in two corners near the front and two corners near the rear. It was confirmed that the noise level was reduced by 6 dB and the airflow required for the dust collector could be maintained. Similar effects were confirmed when the distance from the discharge port 9c of the duct 9 to the housing 5b of the electric motor 5 was within the range of 35 to 70 mm.

[0047] According to the above-described embodiment, a compact dust collector 1 can be made that is space-saving while suppressing the risk of dust explosion. According to the above-described embodiment, a compact dust collector 1 can be made that is space-saving while suppressing noise during operation. The present invention is not limited to the embodiments described above, and various modifications are possible without departing from the present invention. [Explanation of Symbols]

[0048] 1. Dust collector 2 Lower body, 2a front, 2b back, 2c suction port, 2d socket, 2e dust container 3 Filter section, 3a Filter, 3b Frame 4 Upper body, 4a Front, 4b Rear, 4c Exhaust vent, 4d fan, 4e intake, 4f frame, 4g partition 5 Electric motor, 5a Drive shaft, 5b Housing 6 Control unit, 6a Operation panel, 6b Power switch, 6c Power supply unit 7 Expanded metal, 7a Front surface, 7b Back surface, 7c Short axis, 7d Long axis, 7e Opening 8. Dispersion section, 8a. Dispersion plate, 8b. Support column, 8c. Spacing 9 Duct, 9a Inlet, 9b Pipeline, 9c Outlet 11. First fitting 12. Second fitting F1 Airflow P1 axis

Claims

1. The device comprises a lower body having a suction port for drawing in gas containing dust and a dust collection container for storing the dust, a filter section positioned above the dust collection container, and an upper body having a fan and electric motor built into it above the filter section and an exhaust port for discharging the gas that has passed through the filter section, and an expanded metal is provided at the suction port to straighten the gas drawn in from the suction port so that it is directed towards the filter section. A dust collector characterized by the following.

2. The expanded metal has a mesh with a short axis in the vertical direction, a mesh with a long axis in the horizontal direction, and an opening in the mesh facing upwards. A dust collector according to claim 1, characterized by the following:

3. The mesh has a short diameter of 1 mm or more and 5 mm or less, a long diameter of 1.5 times or more and 3 times the short diameter, and the surface pressed by the cutting blade when the mesh is press-formed faces the outlet side of the gas sucked in from the suction port. A dust collector according to claim 2, characterized by the following:

4. The upper body is detachably attached to the lower body with the filter portion in between, the dust collection container is housed in the lower body so as to be retractable, and the suction port is located on the side opposite to the side from which the dust collection container is pulled out. A dust collector according to any one of claims 1 to 3, characterized by the above.

5. A dust collector comprising a lower body having a suction port for drawing in a gas containing dust and a dust collection container for storing the dust, and an upper body having a filter section positioned above the dust collection container and an exhaust port above the filter section, which houses a fan and an electric motor and discharges the gas that has passed through the filter section, wherein an expanded metal is provided at the suction port to straighten the gas drawn in from the suction port so that it is directed toward the filter section. A dust collector intake method characterized by the following.

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