filter

Abstract

To maintain the function provided by the functional agent downstream of the filter media over a long period of time. [Solution] The filter 11 comprises a sheet-shaped filter material 22 and an end plate 23 that is plate-shaped and extends along the edge of the filter material 22, and is fixed to the edge of the filter material 22 by a thermoplastic or thermosetting adhesive 24. In the filter 11, air passes through the filter material 22 in the direction of its thickness. The filter 11 comprises a functional member 30 on which a functional agent is carried downstream by the air passing through the filter material 22. The functional member 30 extends along the edge of the filter material 22. The functional member 30 and the end plate 23 are arranged side by side along the edge of the filter material 22. The functional member 30 is fixed to the end of the end plate 23 in the direction along the edge of the filter material 22 by adhesive 24.

Description

Technical Field

[0001] The present invention relates to a filter.

Background Art

[0002] A filter used in vehicle air conditioners and the like includes a filter medium and an end plate. The filter medium is formed in a sheet shape. The end plate is formed in a plate shape extending along the edge of the filter medium and is fixed to the edge of the filter medium. For fixing the end plate, it is common practice to use a heat-type adhesive (e.g., hot-melt adhesive) for adhesion and fixation during bonding. In such a filter, air passes through the filter medium in the thickness direction thereof.

[0003] Further, as shown in Patent Document 1, it is known to use a filter medium having predetermined functions such as an antibacterial function and an aroma function as a filter medium for a filter. In this case, the predetermined function acts downstream of the filter medium by air passing through the filter medium in the thickness direction.

Prior Art Literature

Patent Literature

[0004]

Patent Document 1

Summary of the Invention

Problem to be Solved by the Invention

[0005] As shown in Patent Document 1, if the filter material of a filter has a predetermined function, there is a risk that the predetermined function of the filter material will be lost in a short period of time. This is related to the fact that the air passing through the filter material in the thickness direction is fast, resulting in a large airflow rate. In other words, the predetermined function of the filter material decreases as air passes through the filter material in the thickness direction, so as mentioned above, if the airflow rate passing through the filter material in the thickness direction is high, the predetermined function of the filter material will be lost in a short period of time. As a result, it becomes difficult to maintain the predetermined function downstream of the filter material for a long period of time. [Means for solving the problem]

[0006] A filter for solving the above problems comprises a sheet-shaped filter material and an end plate that is plate-shaped and extends along the edge of the filter material and is fixed to the edge by a thermoplastic or thermosetting adhesive, wherein air passes through the filter material in the thickness direction, and the filter comprises a functional member on which a functional agent is carried downstream by the air passing through the filter material, wherein the functional member extends along the edge of the filter material, and the functional member and the end plate are arranged side by side along the edge, and the end of the end plate in the direction along the edge is fixed by the adhesive.

[0007] According to the above configuration, the functional agent supported on the functional component is carried downstream by the air passing through the filter media. The functional component is fixed to the edge of the filter media. Therefore, compared to the center of the filter media, the velocity of air passing through the edge of the filter media is slower, resulting in a lower airflow rate. As a result, the amount of the functional agent supported on the functional component that is carried downstream by the air passing through the filter media is kept to a minimum. This allows the functional agent to flow downstream of the filter over a relatively long period of time.

[0008] In the above configuration, the filter (specifically the adhesive) is heated during the manufacturing of the filter. If the temperature of the functional component becomes high at this time, there is a risk that the functional agent supported on the functional component may unnecessarily detach and be released from the functional component. With the above configuration, the functional component can be positioned to avoid the part where the end plate is bonded and fixed to the edge of the filter material, that is, the part that is heated during the manufacturing of the filter for bonding and fixing of the filter material and the end plate with adhesive. Therefore, the temperature rise of the functional component can be suppressed during the manufacturing of the filter. As a result, the unnecessarily released functional agent from the functional component can be suppressed.

[0009] Therefore, the specified functions, such as antibacterial and aromatic functions, provided by the above-mentioned functional agents can be maintained for a long period of time downstream of the filter. [Brief explanation of the drawing]

[0010] [Figure 1] Figure 1 is a schematic diagram showing an air conditioning system to which a filter according to one embodiment is applied. [Figure 2] Figure 2 is a perspective view of the filter according to the same embodiment. [Figure 3] Figure 3 is a perspective view showing the filter of the same embodiment in an disassembled state. [Figure 4] Figure 4 is a cross-sectional view of the functional member of the same embodiment. [Figure 5] Figure 5 is an explanatory diagram illustrating the filter manufacturing procedure. [Figure 6] Figure 6 is an explanatory diagram illustrating the filter manufacturing procedure. [Figure 7] Figure 7 is a graph showing the change in the remaining percentage of the functional agent over time. [Modes for carrying out the invention]

[0011] A filter according to one embodiment will be described below with reference to Figures 1 to 7. As shown in Figure 1, the vehicle's air conditioning system includes a filter 11, a blower 12, an evaporator 13, and a heater 14. The system draws air into the main passage 17 via an outside air intake passage 15 or an inside air intake passage 16, driven by the blower 12. The air drawn into the main passage 17 is cooled by the evaporator 13 and heated by the heater 14 before being blown into the passenger compartment of the vehicle as conditioned air.

[0012] The outside air intake passage 15 opens outwards from the vehicle and is connected to the main passage 17. The recirculating air intake passage 16 opens towards the passenger compartment of the vehicle and is connected to the main passage 17. A switching valve 18 is positioned between the outside air intake passage 15 and the recirculating air intake passage 16 and the main passage 17. The switching valve 18 switches the main passage 17 to connect to either the outside air intake passage 15 or the recirculating air intake passage 16.

[0013] In the main passage 17, a filter 11, a blower 12, an evaporator 13, and a heater 14 are arranged in order from upstream to downstream. The filter 11 is for separating foreign matter such as dust contained in the air passing through the main passage 17 from that air. The blower 12 is for drawing air into the main passage 17 as described above and blowing that air into the vehicle interior.

[0014] The evaporator 13 forms part of the refrigeration circuit 19 that circulates the refrigerant. The evaporator 13 facilitates heat exchange between the refrigerant circulating in the refrigeration circuit 19 and the air passing through the main passage 17. This cools the air passing through the main passage 17. The heater 14 also forms part of the coolant circuit 21 through which the coolant of the engine 20 mounted on the vehicle circulates. The heater 14 facilitates heat exchange between the coolant circulating in the coolant circuit 21 and the air passing through the main passage 17. This heats the air passing through the main passage 17.

[0015] As shown in Figures 2 and 3, the filter 11 comprises a filter medium 22, an end plate 23, and a functional member 30. <Filter medium 22> The filter medium 22 is formed into a rectangular sheet shape by non-woven fabric. The filter medium 22 is folded such that peaks 22a and valleys 22b are alternately continuous along the direction in which one side of the filter medium 22 extends.

[0016] <End plate 23> The end plate 23 has a rectangular flat plate shape and extends in the direction in which the peaks 22a and valleys 22b are alternately continuous in the filter medium 22 (hereinafter referred to as a first direction D). The filter 11 is provided with two end plates 23. Each end plate 23 is fixed to the edge of the filter medium 22 so as to extend along the edge of the filter medium 22. Specifically, the two end plates 23 are individually fixed one by one to the two sides extending in the first direction D among the four sides of the quadrangle of the filter medium 22 by an adhesive 24. As the adhesive 24, an adhesive of a type that requires heat application during bonding, specifically a hot-melt adhesive, is used.

[0017] <Functional member 30> The functional member 30 is provided downstream of the filter medium 22 to exert predetermined functions such as an antibacterial function and an aromatic function. The filter 11 is provided with two functional members 30. Each functional member 30 has a rectangular flat plate shape. The functional members 30 are provided one by one on two sides extending in a direction intersecting the first direction D among the four sides of the quadrangle of the filter medium 22. The two functional members 30 are each bridged between the two end plates 23 so as to extend along the edge of the filter medium 22. Specifically, both end portions in the longitudinal direction of the functional member 30 are respectively fixed to the end portion in the first direction D of one end plate 23 and the end portion in the first direction D of the other end plate 23 by the adhesive 24. In the present embodiment, the functional member 30 is not adhesively fixed to the edge of the filter medium 22.

[0018] In the filter 11, the two end plates 23 and the two functional members 30 are arranged such that the end plates 23 and the functional members 30 are alternately arranged along the edge of the filter medium 22. Accordingly, in the filter 11, the two end plates 23 and the two functional members 30 form a rectangular frame shape surrounding the filter medium 22.

[0019] As shown in FIG. 4, the functional member 30 includes a base material 31 and a bag material 32. The base material 31 is formed into a rectangular flat plate shape from nonwoven fabric. A functional agent is supported on the base material 31. Specifically, the nonwoven fabric constituting the base material 31 is impregnated with the functional agent by dipping, spraying, coating, or the like. As the functional agent, an antibacterial agent that exerts an antibacterial function downstream of the filter medium 22 is employed. As such an antibacterial agent, it is conceivable to employ plant-derived substances having an antibacterial function, for example, benzyl isothiocyanate (BITC) and allyl isothiocyanate (AITC).

[0020] The bag material 32 is formed into a bag shape from a polyethylene film. The bag material 32 covers the entire outer surface of the base material 31 so as to enclose the base material 31. In the present embodiment, the base material 31 carrying the functional agent is enclosed in the bag material 32. Since the bag material 32 is formed of a polyethylene film, it is provided with a sustained release function that gradually releases the internal functional agent to the outside. Accordingly, the functional member 30 releases the functional agent downstream of the air flow as air passes through the filter medium 22.

[0021] <Manufacture of Filter 11> The filter 11 is manufactured by the following procedure. As shown in FIG. 3, first, one filter medium 22, two end plates 23, and two functional members 30 are respectively formed separately. An adhesive 24 is applied to one surface of the end plate 23.

[0022] Then, as shown in FIG. 5, the functional members 30 and the filter medium 22 are arranged such that one filter medium 22 is sandwiched between the two functional members 30. At this time, the functional members 30 and the filter medium 22 are not bonded to each other.

[0023] Subsequently, as shown in Figure 6, the two end plates 23 (more specifically, the adhesive 24) are heated and pressed against the longitudinal ends of the two functional members 30 and the edges of the filter material 22. As a result, the two end plates 23 are bonded and fixed to the longitudinal ends of the two functional members 30 and the edges of the filter material 22 by the adhesive 24.

[0024] In this way, a filter 11 is manufactured in which one filter medium 22, two end plates 23, and two functional members 30 are integrated. <Operation of this embodiment> The operation of this embodiment will now be described.

[0025] As shown in Figure 1, in the air conditioning system, the air flowing through the main passage 17 passes through the filter material 22 of the filter 11, and then passes through the evaporator 13 and heater 14 before being blown into the passenger compartment. If the air flowing downstream of the filter 11 in the main passage 17 is hot and humid, condensation is likely to occur in the equipment located downstream of the filter 11. In particular, the evaporator 13 is prone to condensation because the air is cooled by the refrigerant, causing moisture in the air to adhere to it. When condensation occurs in this way, mold and other fungi can easily grow.

[0026] In this type of air conditioning system, the air passing through the main passage 17 passes through the filter material 22 of the filter 11 in the thickness direction. At this time, foreign matter such as dust contained in the air is collected by the filter material 22 of the filter 11, thereby separating the foreign matter from the air.

[0027] Furthermore, when air passes through the filter material 22 in the thickness direction, the functional agent (antibacterial agent) released from the functional component 30 is carried downstream by the air. As a result, the antibacterial agent, along with the air, reaches the equipment downstream of the filter 11 in the main passage 17, thereby suppressing the growth of bacteria in such equipment.

[0028] <Effects of this embodiment> The effects of this embodiment will now be explained. (1) The functional agent supported on the functional member 30 is carried downstream by the air passing through the filter media 22 of the filter 11. The functional member 30 is fixed to the edge of the filter media 22. Therefore, compared to the center of the filter media 22, the velocity of the air passing through the filter media 22 in the thickness direction is slower at the edge of the filter media 22, resulting in a lower airflow rate. As a result, the amount of the functional agent supported on the functional member 30 that is carried downstream by the air passing through the filter media 22 is kept to a minimum. This allows the functional agent to flow downstream of the filter 11 for a relatively long period of time.

[0029] During the manufacturing of the filter 11, the filter 11 is heated, and if the temperature of the functional member 30 rises at this time, there is a risk that the functional agent supported on the functional member 30 may unnecessarily detach and be released from the functional member 30. In the filter 11, the functional member 30 is positioned to avoid the portion where the end plate 23 is bonded and fixed to the edge of the filter material 22, that is, the portion that is heated during the manufacturing of the filter 11 for bonding and fixing of the filter material 22 and the end plate 23 with adhesive 24. Therefore, the temperature rise of the functional member 30 during the manufacturing of the filter 11 can be suppressed. As a result, the unnecessarily released functional agent from the functional member 30 during the manufacturing of the filter 11 can be suppressed.

[0030] Therefore, the antibacterial function of the functional agent can be maintained for a long period of time downstream of the filter media 22. Consequently, the proliferation of bacteria in equipment located downstream of the filter 11 can be suppressed for a long period of time.

[0031] (2) The functional member 30 includes a base material 31 that carries a functional agent and a bag material 32 that has a sustained-release function and encloses the base material 31 inside. With the above configuration, the sustained release function of the bag material 32 allows the functional agent supported on the base material 31 to be gradually released from the inside of the bag material 32 to the outside. Therefore, compared to a configuration without the bag material 32, the amount of the functional agent supported on the functional member 30 that flows downstream by the air passing through the filter material 22 can be reduced.

[0032] Figure 7 shows the relationship between the release period of the functional agent (specifically BITC) and the remaining percentage of the functional agent. In Figure 7, "◇" indicates the measurement results for the functional agent dropped into a petri dish. In Figure 7, "□" indicates the measurement results for the functional agent supported on a gel-like substrate. In Figure 7, "Δ" indicates the measurement results for the gel-like substrate with the functional agent supported covered with a polyethylene film.

[0033] As can be seen from Figure 7, by covering a gel-like substrate on which a functional agent is supported with a polyethylene film, the release period of the functional agent can be extended compared to simply dropping the functional agent into a petri dish or simply supporting the functional agent on a gel-like substrate. Thus, by using a functional member 30 in which a substrate 31 on which a functional agent is supported is sealed in a polyethylene film bag 32, the release period of the antibacterial agent from the functional member 30 can be extended compared to simply using a substrate 31 on which a functional agent is supported.

[0034] (3) Functional members 30 are provided one on each of the two sides of the rectangle of the filter material 22 that extend in a direction intersecting the first direction D. With the above configuration, the total amount of functional agent placed in the filter 11 can be increased compared to the case where only one functional member 30 is provided. Moreover, such a large amount of functional agent can be distributed evenly and balanced around the periphery of the filter media 22, minimizing any uneven distribution.

[0035] <Example of changes> The above embodiment can be implemented with the following modifications. The above embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically.

[0036] • As for adhesive 24, any adhesive that uses heat during bonding (specifically, thermoplastic adhesives or thermosetting adhesives) can be used, not limited to hot melt adhesives.

[0037] Although an antibacterial agent was given as an example of a functional agent supported on the functional member 30, an aromatic agent having a fragrance function may be supported on the end plate 23 as a functional agent instead or in addition to the antibacterial agent. The above-mentioned aromatic agent may contain components that help relax the user inside the vehicle.

[0038] One of the two functional components 30 may be omitted. A sheet-like material that is almost impermeable to air may be placed on top of the outer surface of the functional material 30 so as to cover a portion of its outer surface. For example, aluminum foil or polypropylene film can be used as the sheet-like material. With this configuration, the amount of functional agent released from the functional material 30 can be adjusted with a high degree of freedom. Therefore, the period during which an appropriate amount of functional agent can be released from the functional material 30 can be determined with a high degree of freedom.

[0039] - A sheet-like material that is almost impermeable to air may be placed over the outer surface of the functional material 30 so as to cover the entire outer surface of the functional material 30, and so as to be able to peel off at least a portion of it from the outer surface. With this configuration, by peeling off the sheet-like material when the filter 11 is attached to the air conditioning system or when the filter 11 is put into use, it is possible to suppress the unnecessary release of the functional agent from the functional material 30 before the functional material 30 is put into use.

[0040] • As the functional component 30, a bag material 32 in which the functional agent is directly sealed can be used. In this case, the base material 31 can be omitted. • The method is not limited to sealing the bag material 32 while the base material 31 is contained within it; a portion of the bag material 32 may be left open.

[0041] The bag material 32 can be, for example, a resin material formed into a bag shape from a resin material other than polyethylene, paper formed into a bag shape, or a metal plate with numerous holes formed into a bag shape. In addition, a resin case made of a rigid resin material may be used as the bag material 32.

[0042] The bag material 32 may be omitted. The functional member 30 can be constructed using only the base material 31. The base material 31 can be formed from a nonwoven fabric, a hard resin material, or a gel-like material.

[0043] The filter 11 according to the above embodiment can be applied to rectangular filters, as well as filters of any shape, such as hexagonal, circular, or elliptical shapes. The filter 11 according to the above embodiment can also be applied to filters having one end plate 23 and one functional member 30, or filters having three or more end plates 23 and three or more functional members 30, and so on. [Explanation of symbols]

[0044] 11…Filter 12... Blower 13... Evaporator 14… Heater 15…Outside air intake passage 16…Recirculation intake passage 17…Main aisle 18… Switching valve 19…Refrigeration circuit 20… Engine 21…Cooling water circuit 22...filter medium 22a…Mountain 22b…Valley 23...End plate 24…Adhesive 30…Functional components 31...Base material 32...Bag material

Claims

1. A filter comprising a sheet-shaped filter material and an end plate extending along the edge of the filter material and fixed to the edge by a thermoplastic or thermosetting adhesive, wherein air passes through the filter material in the thickness direction, The functional member comprises a functional agent that is carried downstream by the air passing through the filter material, The functional member extends along the edge of the filter material, and is arranged so that the functional member and the end plate are aligned along the edge, and is fixed to the end of the end plate in the direction along the edge by the adhesive. filter.

2. The functional member includes a base material that carries the functional agent, and a bag material that has a sustained-release function and contains the base material so as to cover the outer surface of the base material. The filter according to claim 1.

3. The filter material is a rectangular sheet, and is folded such that peaks and valleys alternate along the direction in which one side of the filter material extends. The end plates are two end plates that are separately fixed to two of the four sides of the filter material that extend in the direction of the continuous line, The functional member is installed between the two end plates. The filter according to claim 1 or 2.

4. The functional members are provided one on each of the two sides of the filter material that extend in a direction intersecting the direction of connection. The filter according to claim 3.

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