Apparatus and method for manufacturing pleated air filters

Abstract

To provide a manufacturing apparatus capable of comparatively simply manufacturing a pleated air filter having high degree of freedom of a shape.SOLUTION: A pleated air filter manufacturing apparatus 100 is provided with a filter fixture 20 having a plurality of protrusions 22 and a head 53 where a part of bellows shape filter medium 10 set to the filter fixture 20 is pressed and welded. The plurality of protrusions 22 have groove parts 29 positioning between the plurality of protrusions 22. The head 53 is the head corresponding to the outer edges (23, 24) of a filter fixing region 25 constructed by the plurality of protrusions 22 of the filter fixture 20. The plurality of protrusions 22 of the filter fixture 20 are arranged at regular intervals on a filter fixing plate 21. The outer edge (23) of the filter fixing region 25 has at least one of a curve shape and an inclined shape.SELECTED DRAWING: Figure 15

Description

[Technical field]

[0001] The present invention relates to an apparatus and method for manufacturing a pleated air filter, and more particularly to an apparatus and method for manufacturing a pleated air filter having a curved or complex shape, or a pleated air filter having shape flexibility. [Background technology]

[0002] Conventionally, various air filters have been incorporated into air purifiers, automobile air lines, and clean rooms in order to remove dust contained in the air (Patent Document 1, etc.). A conventional pleated air filter has a structure in which a filtering material is folded into an accordion shape, as shown in Patent Document 1, for example. Specifically, a conventional pleated air filter has an end plate attached with an adhesive to the end of a filtering material folded into an accordion shape. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-267436 Summary of the Invention [Problem to be solved by the invention]

[0004] Figure 18 shows a pleated air filter 1000 investigated by the present inventors. The pleated air filter 1000 shown in Figure 18 is composed of a filtering material 112 bent into an accordion shape, and pleated filter end plates 119 bonded to the end faces (four sides) of the filtering material 112. Grooves 115 are formed at equal intervals in the filtering material 112. Because the pleated filter end plates 119 support the four sides (four edge portions), the pleated air filter 1000 can maintain a firm, flat shape.

[0005] The pleated air filters that are in widespread use today are rectangular (or square) shaped as shown in Figure 18. This is because it is extremely difficult to make the ends of pleated air filters curved or diagonal. We will continue our explanation below.

[0006] 19 shows a schematic diagram of a pleated air filter 1100 in which the upper end of the filtering material 112 has an arc-shaped shape 133. The arc-shaped shape 133 is a schematic diagram showing a shape that makes the arc-shaped shape and the grooves (convex and concave portions) 115 easy to understand.

[0007] Here, in order to produce the pleated air filter 1100 shown in Fig. 19, it is necessary to prepare a flat blank 1110 (developed view) before folding, as shown in Fig. 20, and fold the flat blank 1110. At first glance, the end 135 of the flat blank 1110 seems to have regularity, but in reality, the left and right sides 131, 132 of the end groove 139 are irregular in both angle and length, and it is extremely difficult to accurately cut the sides 131, 132 of such an irregular pattern to produce the flat blank 1110. In other words, it is not possible in reality to first cut the left and right sides 131, 132 of the end groove 139 uniformly and regularly, and then somehow forcibly create the arc-shaped end 133 shown in Fig. 19 by folding.

[0008] 19 and 20 have been described with respect to pleated air filter 1100 having a portion with an arc shape 133, but the development diagram of a pleated air filter having a shape obtained by cutting a rectangular piece diagonally (for example, a shape obtained by cutting along diagonal line 113 shown in FIG. 18) is similarly complicated. FIG. 21 is an example of a development diagram for assembling a pleated air filter having a rectangular piece cut diagonally (for example, along line 113 diagonal to the parallel lines of the rectangle). Specifically, FIG. 21 shows a pattern of end 135 of plane blank 1110, which is different from the pattern of end 135 shown in FIG. 20. When making a pleated air filter that is not rectangular but has a shape with slanted end faces (diagonal lines), it is not realistic to create (cut) and assemble a complex unfolded diagram (flat material 1110) that matches the shape and structure each time, and it is also not realistic to start by cutting the left and right sides 131, 132 of end groove 139 in a uniform, regular pattern and then somehow forcibly create a pleated air filter with a shape with slanted end faces (triangle, trapezoid, etc.) by changing the folding method.

[0009] In addition, the pleated air filter 1000 can maintain a firm flat shape because the pleated filter end plates 119 support the four sides (four edge portions). On the other hand, the pleated air filter 1000 does not have shape flexibility, and the pleated air filter 1000 can only be set in a filter storage section with a flat structure. Nowadays, there are products with various shapes such as convex parts, concave parts, curved surfaces, curvatures, and waves, and if only a filter storage section with a flat structure can be provided, there are large restrictions on product design, which is not preferable. In other words, it would be a great advantage if a pleated air filter could be manufactured that has flexibility to flexibly change shape in products with various shapes such as convex parts, concave parts, curved surfaces, curvatures, and waves. Moreover, it is meaningless if the manufacturing cost is high, and it is preferable that the manufacturing is easy.

[0010] The inventors of the present application have been searching for a way to easily manufacture not only the rectangular pleated air filter 1000 but also pleated air filters with curved or diagonal ends. Furthermore, they have been actively studying whether it is possible to relatively easily manufacture a pleated air filter having flexibility. In the midst of this, they came up with the idea for the present invention and completed it.

[0011] The present invention has been made in consideration of these points, and its main object is to provide a manufacturing apparatus and method that can relatively easily produce pleated air filters having curved or diagonal ends, and / or flexible pleated air filters. [Means for solving the problem]

[0012] The air filter manufacturing apparatus according to the present invention is an air filter manufacturing apparatus for manufacturing pleated air filters, and includes a filter fixing jig having a plurality of protrusions corresponding to the pitch of the pleated air filter, and a head for compressing and welding a portion of a bellows-shaped filtering material set in the filter fixing jig. The plurality of protrusions have grooves located between the plurality of protrusions. The head corresponds to the outer edge of a filter fixing area formed by the plurality of protrusions in the filter fixing jig.

[0013] In a preferred embodiment, the head has a collective welding portion for welding the outer edge of the filter fixing region all at once.

[0014] In a preferred embodiment, the plurality of protrusions of the filter fixing jig are arranged at regular intervals on a filter fixing plate. At least a part of an outer edge of the filter fixing region has a curved shape.

[0015] In a preferred embodiment, the plurality of protrusions of the filter fixing jig are arranged at regular intervals on a filter fixing plate. An outer edge of the filter fixing region has a diagonal line portion.

[0016] In a preferred embodiment, the filter fixing plate is made of wood, and a metal plate member is disposed on the filter fixing plate.

[0017] In a preferred embodiment, an end portion of each of the plurality of protrusions has a tapered shape.

[0018] In a preferred embodiment, the head is connected to a mechanism that can raise and lower the head, and the head has a replaceable structure.

[0019] In a preferred embodiment, the filter fixing device further includes a filter cutting tool for cutting off unnecessary portions of the bellows-shaped filtering material all at once along the outer edge of the filter fixing region.

[0020] The air filter manufacturing method according to the present invention is an air filter manufacturing method for manufacturing a pleated air filter, and includes the steps of arranging a bellows-shaped filtering material on a filter fixing jig having a plurality of protrusions corresponding to the pitch of the pleated air filter, and welding a portion of the bellows-shaped filtering material arranged on the filter fixing jig. The filter fixing jig has a filter fixing region formed by the plurality of protrusions, and at least a portion of the outer edge of the filter fixing region has at least a portion of a curved shape and an oblique line shape. In the welding step, at least a portion of the bellows-shaped filtering material is welded along the outer edge of the filter fixing region.

[0021] In a preferred embodiment, the welding step includes welding a portion along an outer edge of the filter fixing region all at once.

[0022] In a preferred embodiment, an end portion of each of the plurality of protrusions has a tapered shape. In the welding step, an inclined portion is formed in the bellows-shaped filtering material at a portion corresponding to the end portion having the tapered shape.

[0023] In a preferred embodiment, after the welding step, a step of cutting off unnecessary portions of the bellows-shaped filtering material is carried out.

[0024] In a preferred embodiment, in the step of cutting away the unnecessary portions, the unnecessary portions are cut away all at once by a filter cutting tool that corresponds to the shape of the outer edge of the filter fixing region.

[0025] In a preferred embodiment, after the cutting step, a step of attaching a flexible protective material to the welded portion of the bellows-shaped filtering material is carried out.

[0026] The air filter manufacturing method according to the present invention is a method for manufacturing a pleated air filter, and includes the steps of placing a bellows-shaped filtering material on a filter fixing jig having a plurality of protrusions corresponding to the pitch of the pleated air filter, and welding a portion of the bellows-shaped filtering material placed on the filter fixing jig. The filter fixing jig has a filter fixing region formed by the plurality of protrusions. In the welding step, at least a portion of the bellows-shaped filtering material is welded all at once along the outer edge of the filter fixing region.

[0027] In a preferred embodiment, an end portion of each of the plurality of protrusions has a tapered shape. In the welding step, an inclined portion is formed in the bellows-shaped filtering material at a portion corresponding to the end portion having the tapered shape.

[0028] In a preferred embodiment, the bellows-shaped filtering material is curved after the welding step.

[0029] In a preferred embodiment, after the welding step, the bellows-shaped filtering material is formed into a cylindrical shape.

[0030] The pleated air filter according to the present invention includes a bellows-shaped filtering material having protrusions and a welded portion formed around the periphery of the bellows-shaped filtering material. The pleated air filter is bendable in a thickness direction perpendicular to the direction in which the protrusions extend.

[0031] In a preferred embodiment, an inclined portion is formed at an end of the convex portion of the bellows-shaped filtering material.

[0032] In a preferred embodiment, the welded portion is formed around the entire periphery of the bellows-shaped filtering material.

[0033] In a preferred embodiment, at least a part of an outer edge of the bellows-shaped filtering material surrounded by the welded portion has at least one of a curved shape and an oblique line shape.

[0034] In a preferred embodiment, the pleated air filter has a cylindrical shape. Effect of the Invention

[0035] The pleated air filter manufacturing device according to the present invention includes a filter fixing jig having a plurality of protrusions corresponding to the pitch of the air filter, and a head for welding a portion of the bellows-shaped filtering material, and at least a portion of the outer edge of the filter fixing area constructed by the plurality of protrusions has a curved and / or oblique shape. Therefore, by welding the bellows-shaped filtering material along the outer edge of the filter fixing area, an air filter having curved and / or oblique ends can be produced relatively easily.

[0036] In addition, in the method for manufacturing a pleated air filter according to the present invention, a bellows-shaped filtering material is placed on a filter fixing jig having a plurality of protrusions, and then a portion of the bellows-shaped filtering material is welded. The filter fixing jig has a filter fixing area formed by the plurality of protrusions, and in the welding step, the bellows-shaped filtering material is welded all at once along the outer edge of the filter fixing area (25). This allows a flexible pleated air filter to be produced relatively easily. [Brief description of the drawings]

[0037] [Figure 1] FIG. 1 is a perspective view showing a configuration of a pleated air filter manufacturing apparatus 100 according to an embodiment of the present invention. [Diagram 2] 1A to 1C are diagrams showing the configuration of a pleated filter fixing jig 20 according to the present embodiment. [Diagram 3] 1A and 1B are diagrams showing the configuration of a bellows-shaped filtering material 10 according to the present embodiment. [Figure 4] 4 is a flowchart illustrating a method for manufacturing a pleated air filter according to the present embodiment. [Diagram 5] 10 is a diagram for explaining a process of compressing and welding a part of the bellows-shaped filtering material 10. FIG. [Figure 6] 13 is a view for explaining a process of attaching protective materials (18, 19) to a crimped portion 35 of the bellows-shaped filtering material 10. FIG. [Figure 7] FIG. 1 is a perspective view showing a configuration of a pleated air filter manufacturing apparatus 50 according to an embodiment of the present invention. [Figure 8] FIG. 1 is a perspective view showing a configuration of a pleated air filter manufacturing apparatus 50 according to an embodiment of the present invention. [Figure 9] 1A to 1C are diagrams showing a configuration of a cutting tool (cutter) 60 according to the present embodiment. [Figure 10] 1A to 1C are diagrams showing a configuration of a pleated air filter 101 according to an embodiment of the present invention. [Figure 11] 1A to 1C are diagrams showing the configuration of a pleated cylindrical air filter 200 according to an embodiment of the present invention. [Figure 12]FIG. 1 is a perspective view showing a configuration of a pleated air filter 101 according to an embodiment of the present invention. [Figure 13] 1A to 1C are diagrams showing the configuration of a pleated filter fixing jig 20 according to the present embodiment. [Figure 14] FIG. 1 is a perspective view showing a configuration of a pleated filter fixing jig 20 according to the present embodiment. [Figure 15] FIG. 1 is a perspective view showing a configuration of a pleated filter fixing jig 20 according to the present embodiment. [Figure 16] FIG. 1 is a perspective view showing a pleated air filter 101 according to an embodiment of the present invention having a corrugated shape. [Figure 17] FIG. 1 is a perspective view showing a pleated air filter 101 according to an embodiment of the present invention in a semicircular (curved) shape. [Figure 18] 1A and 1B are diagrams showing the configuration of a pleated air filter 1000 investigated by the present inventors. [Figure 19] 1 shows a configuration of a pleated air filter 1100 in which the upper end of the filtering material 112 has an arcuate shape 133. FIG. [Figure 20] FIG. 1 shows a flat material (developed view) 1110 of a pleated air filter 1100 before folding. [Figure 21] FIG. 11 is a diagram showing a flat material (developed view) 1110 before folding for a pleated air filter having a diagonal line shape. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0038] Hereinafter, a preferred embodiment of the present invention will be described with reference to the drawings. In the following drawings, for the sake of brevity, the same reference numerals are used for components and parts that perform the same function, and duplicated descriptions may be omitted or simplified. In addition, the dimensional relationships (length, width, thickness, etc.) in each drawing may not necessarily accurately reflect the actual dimensional relationships. In addition, matters other than those specifically mentioned in this specification that are necessary for carrying out the present invention may be understood as design matters of a person skilled in the art based on the prior art in the field. The present invention can be carried out based on the contents disclosed in this specification and the drawings and the technical common sense in the field. In addition, the present invention is not limited to the following embodiments.

[0039] Fig. 1 is a diagram (perspective view) that shows a schematic configuration of a pleated air filter manufacturing apparatus 100 according to an embodiment of the present invention. Fig. 2 shows a filter fixing jig 20 that fixes a bellows-shaped filtering material (10) in the manufacturing of a pleated air filter. Fig. 3 is a diagram (top view) that shows the configuration of the bellows-shaped filtering material 10 of this embodiment.

[0040] First, as shown in Fig. 1, a pleated air filter manufacturing apparatus 100 of this embodiment includes a filter fixing jig (pleated filter fixing jig) 20 and a head 53 that compresses and welds a part of a bellows-shaped filtering material 10 set in the filter fixing jig 20. The head 53 is attached as a part of a crimping machine 50. Furthermore, as shown in Fig. 2, the filter fixing jig 20 includes a plurality of protrusions 22 that correspond to the pitch of the air filter (pleated air filter).

[0041] The bellows-shaped filtering material 10 of this embodiment has a structure in which the filtering material is folded into a bellows shape, as shown in Fig. 3. The bellows-shaped filtering material 10 is formed in a pleated shape, which increases the surface area per volume and improves the filtering performance (filtration performance). Specifically, the bellows-shaped filtering material 10 is produced by folding the filtering material 15 so as to form filter convex portions (mountain portions including ridges) 12. The filter convex portions 12 of this embodiment are spaced at equal intervals (or at regular intervals), and the pitch is, for example, 2 mm to 10 mm (in one example, 5 mm ± 0.5 mm), but is not limited thereto. In the configuration of this embodiment, the bellows-shaped filtering material 10 and the filtering material 15 are made of a resin material (for example, polyethylene (PE), polypropylene (PP), polyvinyl chloride resin (PVC), nylon (PA), etc., and suitable examples are polyethylene (PE) and polypropylene (PP). The thickness of the filtering material 15 is, for example, 0.5 mm to 3.0 mm (in one example, 1.0 mm±0.2 mm), but is not limited to this.

[0042] In the filter fixing jig 20 shown in FIG. 2, a plurality of convex parts 22 corresponding to the pitch of the pleated air filter to be a product (here, the pitch of the filter convex parts 12 of the bellows-shaped filtering material 10 shown in FIG. 3) are formed on the filter fixing plate 21. The filter fixing plate 21 is a member for fixing the plurality of convex parts 22. The filter fixing plate 21 of the present embodiment is made of, for example, wood, metal material, or resin material, but is not limited thereto, and may be made of other materials (ceramic material, etc.). The plurality of convex parts 22 are made of, for example, metal material, resin material, or wood, but is not limited thereto, and may be made of other materials (ceramic material, etc.). The filter fixing plate 21 made of wood has the advantage of being inexpensive and light. In addition, when the part to be pressed by contacting the head 53 is made of a material that is weak against heat or absorbs vibrations, it is preferable to use a member made of a heat-resistant material (for example, metal, thermosetting resin, etc.) attached on the filter fixing plate 21.

[0043] In the configuration of this embodiment, the multiple protrusions 22 have grooves 29 located between the multiple protrusions 22. The filter protrusions 12 of the bellows-shaped filtering material 10 are housed in the grooves 29. In other words, the multiple protrusions 22 are housed in the filter recesses (grooves between the filter protrusions 12) of the bellows-shaped filtering material 10.

[0044] The filter fixing jig 20 of this embodiment is provided with a filter fixing region 25 constructed by a plurality of protrusions 22. The outer edge (23, 24) of the filter fixing region 25 has a curved shape (23). In the example shown in FIG. 2, the upper outer edge 23 of the filter fixing region 25 in the filter fixing jig 20 is an arc-shaped curve. The lower outer edge 24 of the filter fixing region 25 in the filter fixing jig 20 is a straight line. The filter fixing region 25 of this embodiment is not limited to the one shown in FIG. 2, and may be curved as a whole (for example, a circle, an ellipse, an oval, a wave shape, etc.), or the upper outer edge 23 may be an outer edge that combines a curve and a straight line, or may be composed of only straight lines (for example, a diagonal line (a line inclined with respect to the ridge line 12t)).

[0045] The pleated air filter manufacturing apparatus 100 shown in FIG. 1 includes a crimping machine 50. The crimping machine 50 is a device capable of simultaneously applying heat and pressure (for example, an ultrasonic welding device, a high-frequency welding device, etc.). In the illustrated example, an ultrasonic welding device is shown as the crimping machine 50. In the air filter manufacturing apparatus 100 shown in FIG. 1, an ultrasonic welding main body 55 that supports the ultrasonic head 53 is positioned above the ultrasonic head 53, and a handle 57 is provided for moving the ultrasonic head 53 up and down (raising and lowering). A mechanism (cylinder) that can raise and lower the ultrasonic head 53 is provided inside the ultrasonic welding main body 55, and the head 53 is connected to the mechanism (cylinder) that can raise and lower the ultrasonic head 53. By operating the handle 57, the height of the ultrasonic head 53 can be adjusted to accommodate pleated filters of various thicknesses. By pressing the switch 52, the ultrasonic head 53 descends, and the pressure and ultrasonic vibration force (energy that generates heat and welds and hardens the object by vibrating the object pressurized by the ultrasonic vibration) that are preset in the ultrasonic welding main body 55 are applied to the bellows-shaped filtering material 10, compressing a part of the bellows-shaped filtering material 10 set in the filter fixing jig 20, thereby ultrasonically welding it. In the configuration of this embodiment, the switch 52 is compatible with both hands, but it may be a single switch (for one hand).

[0046] In the example shown in FIG. 1, a filter workbench 51 on which the filter fixing jig 20 is placed is provided below the ultrasonic head 53. In the configuration of this embodiment, the filter fixing jig 20 is placed on the filter workbench 51, and a metal member 30 (paperweight or filter holding member) 30 for holding the bellows-shaped filtering material (pleated filtering material) 10 is placed on the pleated filter fixing jig 20. The metal member 30 has a function of suppressing amplitude. In the illustrated configuration example, a switch 52 for turning on and off the operation of the ultrasonic head 53 is provided below the filter workbench 51. The metal member 30 may be placed below the bellows-shaped filtering material 10. When the filter fixing plate 21 in the filter fixing jig 20 of this embodiment is made of wood, the metal member 30 is placed below the bellows-shaped filtering material 10, so that the vibration and energy (energy for welding and hardening) from the head 53 can be received by the metal member 30, which contributes to good crimping and welding.

[0047] Next, the air filter manufacturing method of this embodiment will be described with reference to Fig. 4 to Fig. 6. Fig. 4 is a flow chart for explaining the air filter manufacturing method of this embodiment. Fig. 5 and Fig. 6 are process diagrams (partially enlarged top views) for explaining the air filter manufacturing method, and the structure of the bellows-shaped filtering material 10 is shown in schematic form to easily express the process.

[0048] First, a bellows-shaped filtering material (pleated filter material) 10 as shown in Fig. 3 is prepared (step S100). Next, the bellows-shaped filtering material 10 is set in a filter fixing jig 20 (step S200). Specifically, the bellows-shaped filtering material 10 is set so that concave portions of the bellows-shaped filtering material 10 are fitted into a plurality of convex portions 22 of the filter fixing jig 20 as shown in Fig. 2. In other words, the filter convex portions 12 of the bellows-shaped filtering material 10 are fitted into the groove portions 29 of the filter fixing jig 20. In this manner, the bellows-shaped filtering material 10 is fixed onto the filter fixing jig 20.

[0049] Next, in a state where the bellows-shaped filtering material 10 is placed on the filter fixing jig 20, the ultrasonic head 53 is used to ultrasonically weld the bellows-shaped filtering material 10 along the outer edge (23, 24) of the filter fixing region 25 formed by the filter protrusion 12 (step S220). Specifically, as shown in FIG. 5, ultrasonic welding is performed along the region (curved end) 33 corresponding to the outer edge (curved end) 23 of the filter fixing region 25 of the bellows-shaped filtering material 10 placed on the filter fixing jig 20 to form the crimped region 35. Similarly, ultrasonic welding is performed along the region (straight end) 34 corresponding to the outer edge (straight end) 24 of the filter fixing region 25 to form the crimped region 35. The outside of this crimped region 35 becomes an unnecessary portion 37. Note that FIG. 5 shows a state where the region (straight end) 34 corresponding to the outer edge (straight end) 24 of the filter fixing region 25 is crimped by ultrasonic welding up to a middle portion, and then the remaining portion is ultrasonically welded along the straight end 34.

[0050] The ultrasonic welding conditions in this embodiment are, for example, pressure 0.35 MPa, power 600W, amplitude time (ultrasonic wave generation time) 0.7 seconds, and HOLD (cooling time) 1 second, but are not limited to these and can be appropriately selected according to the characteristics and structure of the finished pleated filter. The welding strength is not increased by a synergistic effect of increasing the pressure, power, and amplitude time, but increases or decreases depending on the balance between the type and thickness of the material and the pressure, power, and amplitude time. If the strength is too weak, the shape cannot be maintained, and if it is too strong, the bellows-shaped filter material (pleated filter material) 10 will melt. However, in the case of ultrasonic welding, appropriate conditions can be obtained by adjusting according to the preset condition setting method of the ultrasonic welding machine. In the configuration of this embodiment, ultrasonic head 53 with a contact surface (crimping) of approximately rectangular (or approximately square) was used, and ultrasonic welding was performed in multiple steps to form crimped region 35 so that the process would be easy to understand, but it is possible to fabricate ultrasonic head 53 with a shape (structure) corresponding to the outer edge (23, 24) of pleated filter fixing region 25 within the capacity of the ultrasonic welding machine, and form crimped region 35 in one step (all at once) using ultrasonic head 53. For example, in the case of a curve, head 53 (all at once head) of this embodiment can be constructed with a maximum size of 120 mm x 240 m or less for a curve, and a head with a width of 10 mm and a size of 350 mm or less for a straight line, but the range can be increased or decreased depending on the equipment used.

[0051] Next, ultrasonic welding is performed along the area (33, 34) corresponding to the outer edge (23, 24) of the filter fixing area 25 to form the crimped area 35, and then the unnecessary portion 37 is cut off (step S240). The unnecessary portion 37 can be cut off along a part of the crimped area 35 (for example, the center or the outer edge of the crimped area 35) with a cutting tool (cutter, scissors, etc.). Alternatively, the unnecessary portion 37 can be cut off by cutting (or punching) in a single (batch) step using a filter cutting tool corresponding to the shape of the outer edge (23, 24) of the filter fixing area 25. In this manner, the pleated air filter of this embodiment can be obtained.

[0052] After the unnecessary portion 37 is removed, the protective material 18 (18a, 18b) can be attached to the pressure-bonded region 35 as shown in FIG. 6 (step S300). In the illustrated example, the protective material 18a having a curved shape is attached to the pressure-bonded region 35 (upper side) having a curved shape (13), and the protective material 18b having a straight shape is attached to the pressure-bonded region 35 (lower side) having a straight shape (14). When the protective material 18 is made of a flexible material (e.g., urethane foam, expanded foam, or other flexible material), the shape flexibility (flexibility) of the pleated air filter 101 can be maintained. In the pleated air filter 101 of this embodiment, the pleated filter end plate 119 of the pleated air filter 1000 shown in FIG. 18 does not exist, so that the pleated air filter 101 can be flexibly deformed in the thickness direction (vertical direction when the air filter 101 is horizontal). If the protective material 18 shown in FIG. 6 is flexible, the pleated air filter 101 can be easily changed in the thickness direction in the same way.

[0053] The air filter manufacturing apparatus 100 of this embodiment includes a filter fixing jig 20 having a plurality of protrusions 22 corresponding to the pitch of the pleated air filter, and a head 53 that compresses and welds a portion of the bellows-shaped filtering material 10. The outer edge (23, 24) of the filter fixing region 25 formed by the plurality of protrusions 22 can be formed into various shapes, such as a curved line or a diagonal line. Therefore, by welding the bellows-shaped filtering material 10 along the outer edge of the pleated filter fixing region 25 with the head 53, a pleated air filter 101 having an end face with various shapes, such as a curved line or a diagonal line, can be produced relatively easily.

[0054] Fig. 7 shows another configuration of a pleated air filter manufacturing apparatus 50 according to this embodiment. The head 53A (53) in the air filter manufacturing apparatus 50 shown in Fig. 7 is equipped with a collective welding portion 59 that collectively welds the outer edge of the filter fixing area (25). The collective welding portion 59 has a shape corresponding to the outer edge (welding portion 35, outer edge of the filter fixing area (25)) of the pleated air filter 101 as shown in Figs. 5 and 6. If the shape of the outer edge of the pleated air filter 101 changes, the shape of the collective welding portion 59 also changes accordingly. The head 53 is also constructed to be replaceable.

[0055] Fig. 8 shows another configuration of the pleated air filter manufacturing apparatus 50 according to this embodiment, in which the crimping portion (welding portion) of the head 53B has a straight line shape. Using this head 53B, the ends of the oblique lines (the welded portion 35, the outer edge of the filter fixing area (25)) can be manufactured. It is also possible to combine the air filter manufacturing apparatus 50 (straight line crimping portion) shown in Fig. 8 with an air filter manufacturing apparatus having a crimping portion with a curve such as an arc (semicircle) to manufacture the outer edge (the welded portion 35, the outer edge of the filter fixing area (25)) of the pleated air filter 101 as shown in Figs. 5 and 6 in multiple steps (two steps in this case). The combination method can be determined according to the outer edge (the welded portion 35, the outer edge of the filter fixing area (25)) of the pleated air filter 101.

[0056] 9 is a schematic diagram showing the configuration of a filter cutting tool 60 that cuts off the unnecessary portion (37) all at once. The filter cutting tool 60 is equipped with a cutting blade (cutter) 62 that corresponds to the outer edge of the pleated air filter 101 (the outer edge of the crimped region (welded portion) 35 and the filter fixing region (25)). The cutting blade 62 in this embodiment is disposed on a cutting blade support portion 61. The illustrated cutting blade 62 is configured by combining a curved portion 62a and a straight portion 62b. It is also possible to use one in which the curved portion 62a and the straight portion 62b are connected together (integral).

[0057] When cutting off the unnecessary parts (37) all at once, the bellows-shaped filtering material 10 having the unnecessary parts (37) and the crimped region (welded portion) 35 is placed on the filter cutting tool 60, and pressed in this state using a press machine, so that the unnecessary parts can be removed all at once. Note that a method of cutting off the unnecessary parts (37) by moving the cutting blade 62 may also be used. By using such a filter cutting tool 60 that can be removed all at once (at once), the unnecessary parts (37) of the bellows-shaped filtering material 10 can be efficiently removed, and throughput can be improved.

[0058] Next, the air filter manufacturing method and the air filter of this embodiment will be described with reference to Fig. 10 and Fig. 11. Fig. 10 is a diagram (plan view) showing the configuration of an air filter 101 according to this embodiment. Also, Fig. 11 is a diagram (perspective view) showing the configuration of a cylindrical air filter 200 of this embodiment.

[0059] The air filter 101 shown in Fig. 10 has a compression region 38 formed by welding (ultrasonic welding) the outer periphery of the bellows-shaped filtering material 10 (pleated filter material) shown in Fig. 3. Specifically, after preparing a filter fixing jig 20 shown in Fig. 2 having a rectangular (or substantially rectangular or substantially square) filter fixing region 25, the bellows-shaped filtering material 10 is placed on the filter fixing jig 20, and then the bellows-shaped filtering material 10 is compressed by a head 53 along regions (16, 17) corresponding to the outer edge of the filter fixing region 25. In this manner, the air filter 101 shown in Fig. 10 is produced.

[0060] The pleated air filter 200 shown in Fig. 11 is made by rolling the pleated air filter 101 shown in Fig. 10 into a cylindrical shape (cylinder shape) and fixing (gluing, crimping, etc.) it. Such a cylindrical filter can be made because the air filter 101 shown in Fig. 10 is flexible, but a cylindrical filter cannot be made from the air filter 1000 shown in Fig. 18.

[0061] Fig. 12 is a perspective view of the air filter 101 shown in Fig. 10. The air filter 101 of this embodiment can be curved along a thickness direction 91 (see arrow 90). This allows a cylindrical air filter 200 as shown in Fig. 11 to be easily constructed. Here, the thickness direction 91 is the vertical direction (up-down direction) when the air filter 101 is placed horizontally. The curved direction (arrow 90) is the thickness direction 91 along a direction (93) perpendicular to a direction 92 in which the protruding portion 12 (ridge line 12t) extends. The protruding portion 12 provides structural resistance in the direction 92 in which the protruding portion 12 (ridge line 12t) extends, making it impossible or difficult to bend.

[0062] In addition, in the air filter 101 of this embodiment, it is sufficient that the crimped portion (welded portion) 38a extending at least along the long side 16 (arrow 93 direction) is formed, but it is preferable that the crimped portion (welded portion) 38b extending along the short side 17 (arrow 92) is also formed. If the crimped portions (welded portions) 38 (38a, 38b) are present so as to surround the entire periphery (16, 17), the shape of the region (filter region) 15 in which the multiple protrusions 12 are present can be more stable. Depending on the structure of the filter storage section (not shown) that stores the air filter 101, the air filter 101 may have the crimped portion 38a in the portion along the long side 16 (arrow 93) and no crimped portion 38b in the portion along the short side 17 (arrow 92).

[0063] Furthermore, in the air filter 101 of this embodiment, an inclined portion 19 is formed at the end of the protrusion 12 of the bellows-shaped filtering material 10. This inclined portion 19 is provided to prevent the end of the protrusion 12 from being torn or thinned due to the application of force (tension) to the end of the protrusion 12 when the crimped portion 38 (38a) is formed. The inclined portion 19 will be further described with reference to Figs. 13 and 14.

[0064] Figures 13 and 14 are a top view and a perspective view, respectively, of the filter fixing jig 20 for producing the air filter 101 shown in Figure 12. In the filter fixing jig 20 shown in Figures 13 and 14, the end of the convex portion 22 has a tapered structure, and an inclined surface 27 is formed. In addition, a metal member (metal plate) 30 (30A) is disposed on the filter fixing plate 21 at a position corresponding to the crimped portion (welded portion) 38 (38a) of the bellows-shaped filtering material 10. The metal member 30 may be either a fixed type or a movable type.

[0065] When the thickness (top surface height) of the metal member 30 is set to the center of the height of the protrusion 22, the position of the crimping portion 38 is located at the center of the thickness (the distance between the front ridge 12t and the back ridge 12t) of the air filter 101. In other words, the position of the crimping portion 38 can be positioned at the center of the thickness of the air filter 101 based on the thickness direction 91. By setting the position of the crimping portion 38 at the center of the thickness of the air filter 101 (for example, within a distance of ±15% from the middle line between the front ridge 12t and the back ridge 12t (preferably within a distance of ±10% from the center line), the force (tension, etc.) applied to the protrusion 22 after crimping can be made constant, which is preferable in terms of shape stability, life, etc. Also, by adjusting the thickness (top surface height) of the metal member 30, it is possible to form the reference position of the crimping portion 38 at a desired position in the thickness direction 91.

[0066] When the bellows-shaped filtering material 10 is placed on the filter fixing jig 20 shown in FIG. 14 and pressure-bonded (welded) by the head 53, the convex portion 12 as shown in FIG. 12 is obtained in a form including the unnecessary portion 37 (see FIG. 5). Here, since the inclined portion (tapered portion, chamfered portion) 27 is formed on the convex portion 22 of the filter fixing jig 20 shown in FIG. 14, the inclined portion (tapered portion, chamfered portion) 19 is also formed on the end of the convex portion 12 of the bellows-shaped filtering material 10 shown in FIG. 12. The angle θt of the inclined portion (tapered portion) 27 of the convex portion 22 (here, the angle between the upper surface and the inclined surface) is, for example, 5° to 25° (10° in one example), but is not limited thereto. Then, the inclined surface 19 with the corresponding angle θt is formed on the end of the convex portion 12 of the bellows-shaped filtering material 10. Depending on how the head 35 is crimped (welded), the angle (inclined shape) may not be completely the same, but an inclined surface 19 of the convex portion 12 that roughly corresponds to the inclined portion (tapered portion) 27 of the convex portion 22 is obtained. In the illustrated example, the inclined surfaces 27 (incline angle θt) at both ends of the convex portion 22 of the fixing jig 20 are the same, but they may be different. Unless there is a special reason, it is preferable to make them the same because this results in left-right symmetry.

[0067] Here, in the case where the end of the convex portion 12 of the bellows-shaped filtering material 10 shown in FIG. 12 does not have an inclined portion (tapered portion) 19, the angle between the ridge line 12t of the convex portion 12 and the side surface (wall surface) is 90° (or approximately a right angle). In other words, the angle between the upper surface and the side surface (wall surface) of the convex portion 22 of the filter fixing jig 20 is 90° (or approximately a right angle). In that case, when crimping, the bellows-shaped filtering material 10 located at the 90° corner is excessively pulled by crimping compared to other parts, and may be damaged, thinned, or torn. On the other hand, in the configuration of this embodiment, since there is an inclined surface (tapered surface) 27 at the corner between the upper surface and the side surface (wall surface) of the convex portion 22 of the filter fixing jig 20, when crimping, it is possible to alleviate the application of excessive force (tension) compared to the case of a 90° corner. As a result, it is possible to prevent damage, thinning, and tearing. Therefore, the strength of air filter 101 of this embodiment (particularly the strength of end portion (19) of protrusion 12) can be improved, and the life of air filter 101 can be extended.

[0068] Fig. 15 is a perspective view of filter fixing jig 20 corresponding to the configuration shown in Fig. 2. Filter fixing jig 20 shown in Fig. 15 also has inclined surfaces (tapered surfaces) 27 formed at each end (corner) of protrusion 22. In filter fixing jig 20 shown in the figure, metal member 30 may be disposed.

[0069] 15 shows the filter fixing jig 20 corresponding to the configuration shown in FIG. 2, but the filter fixing region 25 (region formed by the convex portion 22) of the filter fixing jig 20 can be changed according to the shape of the air filter 101 to be manufactured. When the outer edge shape of the air filter 101 is desired to be circular, the filter fixing region 25 of the filter fixing jig 20 may be made circular. When the outer edge shape of the air filter 101 is desired to be triangular, trapezoidal, hexagonal, etc., the filter fixing region 25 of the filter fixing jig 20 is made triangular, trapezoidal, hexagonal, etc., correspondingly. In the case of a triangle, trapezoid, hexagon, etc., a portion of the outer edge is obliquely lined (see oblique line 13 in FIG. 10), so there is a great advantage in manufacturing using the method of this embodiment. That is, when the method of this embodiment is used, even an air filter 101 having oblique lines can be easily manufactured.

[0070] In the pleated air filter manufacturing method of this embodiment, the bellows-shaped filtering material 10 is placed on the filter fixing jig 20 having the convex portion 22, and then a part of the bellows-shaped filtering material 10 is welded. The filter fixing jig 20 has a filter fixing region 25, and in the welding process, the bellows-shaped filtering material 10 is pressed (welded) along the outer edge of the filter fixing region 25, so that a flexible air filter 101 as shown in FIG. 12 can be relatively easily manufactured. Therefore, the air filter 101 shown in FIG. 12 can be deformed (curved) to form a wavy air filter 102 as shown in FIG. 16. Alternatively, it can be a semicircular (approximately semicircular) air filter 103 as shown in FIG. 17. Note that the convex portion 12 (ridge line 12t) located on the back side is omitted in FIG. 17. According to the method of this embodiment, it is possible to accommodate even if the filter storage section (not shown) of the product is not flat but has a complex shape, that is, the air filter 101 (102, 103) of this embodiment can be used to accommodate flexibly. Furthermore, even if the filter storage section (not shown) of the product is not rectangular (oblong, square) but has a complex shape (having curves and / or diagonal lines), the air filter 101 etc. of this embodiment can be flexibly accommodated.

[0071] Furthermore, by using a welding device 50 as shown in Fig. 7, the welding process can be performed in one go, which is convenient. In addition, by using a filter removal tool 60 as shown in Fig. 9, the unnecessary parts 37 can be cut off in one go, which is convenient.

[0072] As described above, according to the air filter manufacturing method of the present embodiment, in addition to manufacturing a flat or curved air filter, it is also possible to further curve the air filter to manufacture a cylindrical air filter 200. The technical advantage of easily manufacturing the cylindrical air filter 200 is also very large.

[0073] For devices for removing dust contained in various air, the inflexible pleated filter 1000 as shown in FIG. 18 has a large restriction, and is further limited by the restriction of a rectangular shape. According to the method of the present embodiment, a pleated filter without such restrictions and with a large degree of freedom in design can be easily (inexpensively) manufactured. In addition, the pleated filter 1000 shown in FIG. 18 requires the work of attaching the pleated filter end plate 119 with adhesive, which is time-consuming. According to the method of the present embodiment, such materials (filter end plate 119, adhesive) are not used, so that material costs and manufacturing costs can be reduced. In addition, when the inflexible pleated filter 1000 is combined or further processed to form a complex three-dimensional structure, it is necessary to use materials other than the filter material to fix such a complex shape, and this requires time and effort, and furthermore, using materials other than the filter material is not preferable in terms of pressure loss performance. In other words, using materials other than the filter material makes it difficult to remove the filter, which has a negative effect on the filter characteristics. On the other hand, the method of the present embodiment does not use such materials that are not related to the filter performance, and therefore, in comparison, there is no deterioration in the filter's ability to be removed, and the cost performance and ecological performance can be improved.

[0074] Although the present invention has been described above using preferred embodiments, these descriptions are not limiting and various modifications are possible. In addition, the features of the above-mentioned embodiments can be applied to each other. For example, it is possible to provide an inclined surface 27 at the end of the convex portion 22 of the filter fixing jig 20 shown in Fig. 2, and it is also possible to use a filter fixing jig 20 shown in Fig. 14 and Fig. 15 in which the end of the convex portion 22 does not have an inclined surface 27. [Industrial Applicability]

[0075] According to the present invention, it is possible to provide a manufacturing apparatus and a manufacturing method that can relatively easily manufacture a pleated air filter having curved or diagonal line ends and / or a flexible pleated air filter. [Explanation of symbols]

[0076] 10 Bellows-shaped filter material (pleated filter material) 12 Filter protrusion 15 Filter media 18 Protective materials 19 Inclined section (tapered section) 20 Filter Fixture 21 Filter fixing plate 22 Convex part (multiple convex parts) 23 Outer edge (curved end) 24 Outer edge (straight edge) 25 Filter Fixed Area 27 Inclined surface (tapered surface) 29 Groove 30 Paperweight 33 Curved end 34 Straight end 35 Crimp Area 37 Unnecessary part 38 Crimp Area 50 Welding equipment 51 Filter Worktable 52 Switch 53 Head 55 Welding body part 57 Handle 59 Bulk welding part 60 Filter removal tool 61 Cutting blade support part 62 Cutting blade 100 Air filter manufacturing equipment 101 Pleated Air Filter 102, 103 Pleated air filter 200 Cylindrical Air Filter

Claims

1. An air filter manufacturing apparatus for manufacturing a pleated air filter, comprising: a filter fixing jig having a plurality of convex portions corresponding to the pitch of a pleated air filter having a structure in which a filtering material is folded in an accordion-like shape; a head for compressing and welding a part of the bellows-shaped filtering material set in the filter fixing jig; The plurality of protruding portions include groove portions located between the plurality of protruding portions, the head corresponds to an outer edge of a filter fixing area formed by the plurality of protrusions in the filter fixing jig, the plurality of protrusions of the filter fixing jig are arranged at regular intervals on a filter fixing plate, The outer edge of the filter fixing area has at least one of a curved shape and an oblique line shape, The filter fixing plate is made of wood, an air filter manufacturing apparatus, wherein a metal plate member is disposed on the filter fixing plate;

2. 2. The air filter manufacturing apparatus according to claim 1, wherein the head has a collective welding portion for collective welding the outer edge of the filter fixing area.

3. 2. The air filter manufacturing apparatus according to claim 1, wherein each of the plurality of protrusions has an end portion that is tapered.

4. The head is connected to a mechanism that can be raised and lowered, The air filter manufacturing apparatus according to claim 1 , wherein the head has a replaceable structure.

5. 5. The air filter manufacturing apparatus according to claim 1, further comprising a filter cutting tool for cutting off unnecessary portions of the bellows-shaped filtering material all at once along the outer edge of the filter fixing region.

6. An air filter manufacturing method for manufacturing a pleated air filter, comprising the steps of: A step of placing a bellows-shaped filter material on a filter fixing jig having a plurality of protrusions corresponding to the pitch of a pleated air filter having a structure in which the filter material is folded in a bellows-like shape; welding a portion of the bellows-shaped filtering material disposed on the filter fixing jig; Including, the filter fixing jig has a filter fixing region formed by the plurality of protrusions, and at least a part of an outer edge of the filter fixing region has at least one of a curved shape and an oblique line shape; In the welding step, at least a portion of the bellows-shaped filter material is welded along an outer edge of the filter fixing area. the plurality of protrusions of the filter fixing jig are arranged at regular intervals on a filter fixing plate, The filter fixing plate is made of wood, The air filter manufacturing method further comprises: disposing a metal plate member on the filter fixing plate.

7. 7. The method for manufacturing an air filter according to claim 6, wherein in the welding step, a portion along an outer edge of the filter fixing region is welded all at once.

8. Each end of the plurality of protrusions has a tapered shape, 7. The air filter manufacturing method according to claim 6, wherein in the welding step, an inclined portion is formed in the bellows-shaped filtering material at a portion corresponding to the end portion having the tapered shape.

9. 9. The method for manufacturing an air filter according to claim 8, further comprising the step of cutting off an unnecessary portion of the bellows-shaped filtering material after the welding step.

10. 10. The air filter manufacturing method according to claim 9, wherein in the step of cutting away the unnecessary portions, the unnecessary portions are cut away all at once by a filter cutting tool that corresponds to a shape of an outer edge of the filter fixing region.

11. After the cutting step, a flexible protective material is attached to the welded portion of the bellows-shaped filtering material.

10. The method of claim 9, further comprising the step of attaching.

12. A pleated air filter having a structure in which a filtering material is folded in an accordion shape, A bellows-shaped filtering material having a convex portion; A welded portion formed around the bellows-shaped filter material; Equipped with The pleated air filter is bendable in a thickness direction perpendicular to a direction in which the protrusions extend, At least a part of an outer edge of the bellows-shaped filtering material surrounded by the welded portion has at least one of a curved shape and an oblique line shape, The welded portion is bendable in the thickness direction.

13. 13. The pleated air filter according to claim 12, wherein an inclined portion is formed at an end of the convex portion of the bellows-shaped filtering material by compressing a part of the bellows-shaped filtering material.

14. 13. The pleated air filter according to claim 12, wherein the welded portion is formed around the entire periphery of the bellows-shaped filtering material.

15. 15. The pleated air filter of claim 12, wherein the pleated air filter has a cylindrical shape.

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