Air filter for a paint booth used for spray coating

Abstract

The air filter (1) for spray coating comprises: a housing (3) presenting a cube and designed with a surface (5) forming an air inlet and an opposite surface (7) forming an air outlet; one or more accordion-style panels (9) with folding lines (11) and positioned in the housing (3) to be folded in an accordion style at the folding lines (11) and to form a filtering barrier (8); the one or more accordion-style panels (9) of the filtering barrier (8) comprise at least a pair of flap portions (15) configured to be folded to form a converging profile pneumatically followed by a capture chamber (29) formed in one of the accordion-style panels (9), and an opening forming a discharge passage on the side of the capture chamber (29).

Description

Technical Field

[0001] The present invention relates to a spray coating booth, and more particularly to an air filtration system for a spray coating booth.

Background Art

[0002] Spray coating is widely used in the industry for coating parts or automobiles. It preferably consists of spraying various materials, such as paint in powder form, onto an object by means of a nozzle. This material then forms a uniform coating on the surface of the object. However, spray coating also has significant drawbacks, such as paint mists formed by aerosols of wet and / or dry paint. Therefore, it is necessary to use an air filtration system to improve the safety of individual users.

[0003] For this purpose, the use of air filters for spray coating booths is known and has been developed in the industry. A spray coating booth generally consists of an enclosed room with air outlets that form the walls, roof, or floor made of a plurality of individual air filters. Each filter comprises a housing that forms an air inlet and an air outlet. Panels, which are generally designed to be folded in an accordion-like manner inside the housing, form a filtration barrier against paint particles. These filters can retain the sprayed material with an efficiency in the range of 80 - 99%, depending on the form and / or composition of the filter. However, higher efficiency filters generally cannot hold as much paint and therefore need to be replaced frequently.

[0004] The prior art disclosed in International Publication No. WO 2018 / 140032 discloses a cubic filter for a painting booth, which has an opening and a support part forming an accordion panel. The accordion shape of the panel is maintained by holding panels fixed to both the upper and inner tips of the accordion panel positioned within the housing. Further, this support part preferably comprises a filter material made of a plurality of paper sheets. However, this filter has a complex structure and is difficult to manufacture. It also exhibits limitations in terms of filtration quality, filtration capacity, and the resulting pressure loss.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] The present invention provides a solution to at least one of the drawbacks in the above prior art for the technical problem. More specifically, the present invention improves the amount of paint material that the filter can filter and contain, for the technical problem, while maintaining satisfactory filtration quality, limited pressure loss, and limited cost.

Means for Solving the Problems

[0007] For this purpose, the present invention aims at an air filter for spray coating, the air filter comprising: a housing designed with a cube and having a face forming an air inlet and a face forming an opposite air outlet; one or more accordion panels with fold lines, folded in an accordion manner along the fold lines and positioned in the housing to form a filtration barrier, and at least a pair of flap portions configured to be folded to form a converging profile such that a capture chamber formed by one of the accordion panels is pneumatically followed, and an opening forming a discharge passage on the side of the capture chamber, which is worth noting.

[0008] Advantageously, each air inlet face and air outlet face of the housing comprises a frame and a central opening, and the frame enables each barrier to be maintained in the housing.

[0009] Advantageously, the air filter is in a flat configuration and needs to be folded and assembled for operation.

[0010] According to a preferred embodiment, the opening is adjacent to the corresponding flap portion so as to be away from the bottom of the corresponding capture chamber.

[0011] According to a preferred embodiment, each of the at least a pair of flap portions is formed by an end portion in one of the one or more panels.

[0012] According to a preferred embodiment, each of the at least one capture chamber is formed by two folded main portions in one of the one or more panels, and the angle is greater than 30° and / or less than 60°.

[0013] According to a preferred embodiment, each of the at least one capture chamber comprises two openings formed in each of the two folded main portions in one of the one or more panels.

[0014] According to a preferred embodiment, each of the openings is subdivided along the direction of the fold line into two sub-openings separated by a portion of one or more accordion panels.

[0015] According to a preferred embodiment, the air filter further comprises two holding panels that extend perpendicular to the fold line and engage at opposite ends of each of the one or more accordion panels, thereby holding the one or more accordion panels in a stable folded configuration.

[0016] Advantageously, each holding panel has a folded accordion structure, and this fold is made at the fold line so as to form a holding panel that can maintain each accordion panel in a folded position.

[0017] According to a preferred embodiment, the two holding panels comprise slots or notches for receiving tabs, or protrusions, at opposite ends of each of the one or more accordion panels.

[0018] Advantageously, each main panel has a tab that can fit into a corresponding slot in the holding panel. Each flap portion has a protrusion that can be inserted into a corresponding notch made in the corresponding holding panel.

[0019] According to a preferred embodiment, the one or more accordion panels, and the two holding panels if present, form a continuous air guiding surface.

[0020] According to a preferred embodiment, the filtration barrier is an inlet filtration barrier disposed directly downstream of the air inlet. The air filter comprises an outlet filtration barrier disposed directly upstream of the air outlet. The outlet filtration barrier comprises a frame and a layer of fibrous filter material supported by the frame.

[0021] According to a preferred embodiment, the air filter further comprises an intermediate filtration barrier. This intermediate filtration barrier comprises a filtration panel. This filtration panel has folding lines and is configured to be folded accordion-style along these folding lines.

[0022] According to a preferred embodiment, the filtration panel of the intermediate filtration barrier comprises a perforated panel and a fibrous filter material layer supported by this perforated panel.

[0023] According to a preferred embodiment, the intermediate filtration barrier comprises a cross member. This cross member is configured to engage with the folding lines of the filtration panel located on the rear surface of the intermediate filtration barrier in order to maintain a certain distance between the folding lines on the rear surface of the intermediate filtration barrier when the filtration panel is folded accordion-style.

[0024] According to a preferred embodiment, the intermediate filtration barrier is configured to be located within the housing between the inlet filtration barrier and the outlet filtration barrier.

[0025] According to a preferred embodiment, the housing, one or more accordion panels, two holding panels if present, a perforated panel if present, and / or a cross member if present, are made of cardboard.

[0026] The present invention is interesting in that it improves the amount of paint material that a filter can filter and contain for technical problems while maintaining satisfactory filtration quality, limited pressure loss, and limited cost. In fact, in a preferred embodiment, the present invention increases the effectiveness of the retention of paint particles by air filtration up to 99.45% by using three different barriers in the filter. Each air filter of the present invention also enables a paint retention capacity of more than 30 kg, thereby enabling the economical use of the filter as it requires less frequent filter replacement. Using these filters enables significant cost reduction. Each air filter according to the present invention can also be folded for transportation. Thereby enabling a reduction in transportation costs and in the total cost of the filter. Furthermore, the setting in a painting booth is easy and quick. The materials required for setting are known to those skilled in the art. Finally, the materials used for assembly are low-cost and recyclable.

[0027] Other features and advantages of the present invention will be readily understood from the following detailed description and the drawings therein.

Brief Description of the Drawings

[0028]

Figure 1

Figure 2

Figure 3

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Figure 5

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Figure 11

Figure 12

Mode for Carrying Out the Invention

[0029] FIG. 1 and FIG. 2 are two different views of the air filter according to the present invention.

[0030] The air filter 1 preferably comprises a housing 3 made of cardboard and designed to have a cubic shape. This shape is preferably selected because it is the most widely made as a filter used in a painting booth, more preferably for spray coating. The housing 3 of the air filter 1 comprises a surface 5 forming an air inlet and an opposite surface 7 forming an air outlet. The air flow is shown in the drawing by thick arrows accompanied by reference [R]. Each surface (5, 7) of the housing 3 consists of a frame (5A, 7A) with a central opening (5B, 7B). The frames (5A, 7A) of both surfaces (5, 7) make it possible to maintain each barrier within the housing 3. From the central opening 5B of the surface 5, the filtration barrier 8, more particularly one or more accordion panels 9 of this filtration barrier 8, can be seen. Preferably, the air filter 1 comprises two or more accordion panels 9, which are positioned adjacent to each other continuously within the housing 3.

[0031] Each accordion panel 9 is provided with folding lines 11, which enable the panel 9 to be folded in an accordion fashion for positioning in the housing 3. These folding lines 11 may be perforation lines or the like and are made to allow the panel 9 to be folded by creating a weakness in the material. The accordion panel 9 is made up of two main parts 13 and at least a pair of flap parts 15. The filtration barrier 8 preferably comprises three consecutive accordion panels 9 and thus has six main parts 13 and six flap parts 15 with nine folding lines 11.

[0032] The opposite face 7 of the housing 3 shows an outlet filtration barrier 17 made of a basically single-layer polyester material 17A at its central opening 7B.

[0033] Figs. 3 to 5 show the filtration barrier according to the present invention.

[0034] The filtration barrier 8 comprises one or more accordion panels 9 and two holding panels 19. Each accordion panel 9 comprises two main parts 13 folded by folding lines 11 and a pair of flap parts 15 formed by the end parts 9A of the panel 9. More preferably, the panel 9 is constituted by the end parts of each main part 13. Each flap part 15 is further hingedly connected to the main part 13 by a folding line 11. Advantageously, each free end part of each flap part 15 is directed towards the rear end part of the housing once attached to the housing (visible in Figs. 1 and 2), and the flap part 15 and the main part 13 form a converging profile.

[0035] Two consecutive main parts 13 are folded at an angle greater than 30° and / or less than 60°. Each main part 13 is provided with an opening adjacent to the flap part 15. This opening is preferably subdivided into two secondary openings 13A separated by a part 13B of the respective main part 13 along the direction of the folding line 11.

[0036] The filter barrier 8 also includes two holding panels 19. Each holding panel 19 is made of a continuous longitudinal portion 19A and is folded by a fold line 19B to take an accordion form for easy conveyance. Each longitudinal portion 19A includes at least one slot 19C that receives a corresponding tab 13C from the corresponding main portion 13. Each longitudinal portion 19A includes at least one notch 19D that receives a corresponding protruding portion 15A of the corresponding flap portion 15. Each holding panel 19 extends perpendicular to the fold line 11 and engages with each opposite end of the accordion panel 9 after being attached to the accordion panel 9 to form the filter barrier 8. The holding panel 19 is used to hold the accordion panel 9 in a stable folded configuration. Further, the accordion panel 9 and the two holding panels 19 form a continuous guiding surface for air.

[0037] Figures 6 - 9 disclose different views of an intermediate filter barrier according to the present invention.

[0038] The presence of the intermediate filtration barrier 21 increases the effectiveness and the paint holding capacity of the filter of the present invention. However, in some implementations, such as in a small-sized filter, the intermediate barrier 21 may not be necessary. The intermediate barrier 21 comprises a filtration panel 23 with a fold line 25. This panel 23 is folded in an accordion manner along the fold line 25. The filtration panel 23 comprises a perforated panel 23A and a fibrous material layer 23B supported by the perforated panel 23A. The perforated panel 23A comprises several orifices 23C, and the fibrous material layer 23B is preferably made of polyester fibers and has a thickness configured to be 15 - 25 mm. The intermediate filtration barrier 21 also comprises a cross member 27. This cross member 27 has notches 27A positioned equidistantly from each other. This cross member 27 is configured to engage with the fold line 25 of the filtration panel 23, more specifically, to engage with the fold line 25 located on the rear face 21A of the intermediate barrier 21 when the filtration panel 23 is folded. The cross member 27 is made to be inserted into corresponding notches 25A positioned at the corresponding fold lines 25 of the filtration panel 23. These notches 25A correspond to the notches 27A positioned on the cross member 27. Thus, the cross member 27 does not come off easily and maintains a constant distance between each fold line 25 at the rear face 21A. The fibrous filtration material layer 23B is fixed to the perforated panel 23A by fixing means 21B. The perforated panel 23A and the cross member 27 are preferably made of cardboard.

[0039] Figure 10 shows a perspective view of an outlet filtration barrier according to the present invention.

[0040] This outlet filtration barrier 17 comprises a frame 17B on which a fibrous material layer 17A is mounted. This outlet filtration barrier 17 is disposed directly upstream of the air outlet. The frame 17B of the outlet filtration barrier 17 is preferably made of cardboard, and the fibrous material layer 17A is preferably made of polyester.

[0041] Figures 11 and 12 represent two general outlines of a filtration system according to the present invention. These drawings are also explained in correlation with the aforementioned Figures 1 - 10.

[0042] In the housing 3, the accordion panel 9, with its main portion 13 and flap portion 15, is positioned near the air inlet of the filter 1. The flap portion 15 and the main portion 13 of each accordion panel 9 form the capture chamber 29. Each capture chamber 29 formed by one accordion panel 9 has a secondary opening 13A positioned in the main portion 13, and this secondary opening 13A forms a discharge passage on the side of the capture chamber 29. The flap portion 15 positioned near the air inlet is spaced a certain distance from the bottom of the corresponding capture chamber 29. Each capture chamber 29 is formed by two folded main portions 13. The first filtration barrier 8 can capture up to 74% of the paint particles.

[0043] The intermediate filtration barrier 21 is positioned in the housing 3 between the inlet filtration barrier 8 forming the accordion panel 9 and the outlet filtration barrier 17. The fibrous material layer 23B is directed towards the inlet filtration barrier 8, and the cross member 27, and thus the rear face 21A of the intermediate filtration barrier 21, is positioned towards the outlet filtration barrier 17 of the filter 1. This barrier 21 can capture the remaining paint particles up to 24%.

[0044] The outlet filtration barrier 17 is positioned behind the intermediate barrier 21. It enables the capture of the last paint particles, thereby allowing 99.8% pure air to exit the air filter 1.

[0045] Air R strengthened by paint particles enters the filter 1 between the flap portions 15 and passes through the surface 5 of the filter 1. Most of the air R is directed towards the bottom of each capture chamber 29. Next, the air R is redirected to the secondary openings 13A in each main portion 13 of the filtration barrier 8. The secondary openings 13A are located below the flap portions 15. Therefore, the air R is directed towards the intermediate barrier 21, where the air R passes through the holes in the fibrous material layer 23B located on one side of the perforated panel 23A. Next, the air R is directed towards the outlet filtration barrier 17, where the air R can cross the fibrous material layer 17A and remove most of the remaining paint particles. Next, the air R can leave the painting booth without containing paint particles.

[0046] A method of installing the air filter 1. This method will be described in correlation with FIGS. 1-12. The air filter 1 preferably has a flat configuration and needs to be folded and assembled for operation.

[0047] First Embodiment: The air filter 1 includes two barriers, the filtration barrier 8 and the outlet filtration barrier 17.

[0048] First, expand the housing 3 to form a cubic shape.

[0049] Second, install the filtration barrier 8. Expand each holding panel 19 and the accordion panel 9. Insert each tab 13C of each main portion 13 into the corresponding slot 19C of the corresponding holding panel 19. Next, fold each flap portion 15 along the folding line 11 so that each protruding portion 15A is inserted into the corresponding notch 19D of the holding panel 19. Next, insert the filtration barrier 8 into the housing 3 to position the flap portion 15 near the surface 5 of the housing 3.

[0050] Third, insert the outlet filtration barrier 17 behind the filtration barrier 8 and then close the housing 3. This prepares the air filter 1 for use.

[0051] Second Embodiment: The air filter 1 includes three barriers according to the present invention. This embodiment is the most preferred.

[0052] First, expand the housing 3 so as to form it into a cubic shape.

[0053] Second, insert the outlet filter barrier 17 into the housing 3.

[0054] Third, bend the intermediate filter barrier 21 so as to form an accordion. Next, insert the transverse member 27 into the notch 25A existing at each bending line 25 of the filter panel 23. Next, insert the filter barrier 21 into the housing 3 in order to direct the transverse member 27 toward the rear end portion of the housing 3.

[0055] Fourth, attach the filter barrier 8. Expand each holding panel 19 and the accordion panel 9. Insert each tab 13C of each main portion 13 into the corresponding slot 19C of the corresponding holding panel 19. Next, bend each flap portion 15 along the bending line 11 so as to insert the protruding portion 15A into the corresponding notch 19D of the holding panel 19. Next, insert the filter barrier 8 into the housing 3 in order to position the flap portion 15 near the surface 5 of the housing 3. Next, close the housing 3, whereby the air filter 1 is ready for use.

Claims

1. An air filter (1) for spray coating, comprising: A housing (3) designed to have a three-dimensional shape and having a surface (5) forming an air inlet and an opposite surface (7) forming an air outlet; One or more accordion panels (9) with a folding line (11), folded in an accordion manner along the folding line (11) and positioned in the housing (3) to form a filtration barrier (8); The air filter (1) further comprises: At least a pair of flap portions (15) configured to be folded so that one or more of the accordion panels (9) in the filtration barrier (8) form a converging profile with a capture chamber (29) formed by one of the accordion panels (9) being pneumatically followed; and an opening forming a discharge passage on the side of the capture chamber (29); Each of the at least a pair of flap portions (15) is formed by an end portion (9A) of one of the one or more accordion panels (9). An air filter (1) characterized by this.

2. The air filter (1) according to claim 1, wherein the opening is adjacent to the corresponding flap portion (15) so as to be away from the bottom of the corresponding capture chamber (29).

3. Each of at least one of the capture chambers (29) is formed by two folded main portions (13) of one of the one or more accordion panels (9), the angle being greater than 30° and / or less than 60°. The air filter (1) according to any one of claims 1 to 2.

4. The air filter (1) according to claim 3, wherein each of at least one of the capture chambers (29) is provided with two openings formed in each of the two folded main portions (13) of one of the one or more accordion panels (9).

5. The air filter (1) according to any one of claims 1 to 4, wherein each of the openings is subdivided into two sub-openings (13A) separated by a portion (13B) of one or more of the accordion panels (9) along the direction of the folding line (11).

6. Two holding panels (19) that extend perpendicular to the folding line (11) and engage at both opposite ends of each of the one or more accordion panels (9), thereby holding the one or more accordion panels (9) in a stable folding configuration, the air filter (1) according to any one of claims 1 to 5.

7. The two holding panels (19) are provided with slots (19C) or notches (19D) for receiving tabs (13C) or protruding portions (15A) at both opposite ends of each of the one or more accordion panels (9), the air filter (1) according to claim 6.

8. One or more of the accordion panels (9) form a continuous induction surface for air, the air filter (1) according to any one of claims 1 to 7.

9. The filtration barrier (8) is an inlet filtration barrier (8) disposed directly downstream of the air inlet, and the air filter (1) comprises an outlet filtration barrier (17) disposed directly upstream of the air outlet, the outlet filtration barrier (17) comprising a frame (17B) and a fibrous filtration material layer (17A) supported by the frame (17B), the air filter (1) according to any one of claims 1 to 8.

10. Further comprising an intermediate filtration barrier (21), the intermediate filtration barrier (21) having a folding line (25) and being configured to be folded in an accordion manner along the folding line (25), the air filter (1) according to any one of claims 1 to 9.

11. The filtration panel (23) of the intermediate filtration barrier (21) comprises a perforated panel (23A) and a fibrous filtration material layer (23B) supported by the perforated panel (23A), the air filter (1) according to claim 10.

12. The intermediate filtration barrier (21) includes a horizontal member (27), and the horizontal member (27) is configured to engage with the folding lines (25) of the filtration panel (23) located on the rear surface (21A) of the intermediate filtration barrier (21) in order to maintain a constant distance between the folding lines (25) on the rear surface (21A) of the intermediate filtration barrier (21) when the filtration panel (23) is folded in an accordion manner. The air filter (1) according to claim 10 or 11.

13. The filtration barrier (8) is an inlet filtration barrier (8) disposed directly downstream of the air inlet, and the air filter (1) includes an outlet filtration barrier (17) disposed directly upstream of the air outlet. The outlet filtration barrier (17) includes a frame (17B) and a fibrous filtration material layer (17A) supported by the frame (17B). The intermediate filtration barrier (21) is configured to be located in the housing (3) between the inlet filtration barrier (8) and the outlet filtration barrier (17). The air filter (1) according to any one of claims 10 to 12.

14. The housing (3) and one or more of the accordion panels (9) are made of cardboard. The air filter (1) according to any one of claims 1 to 13.

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