CN203816400U - Filter material and manufacturing device thereof - Google Patents

Abstract

The utility model provides a filter material and a manufacturing device thereof capable of preventing the dimension along the compression direction from becoming shorter than the dimension before compression after the continuously applied force in the compression direction is removed. It is characterized in that it is configured such that each spacer holding portion disposed on one side of the original filter material overlaps with each spacer portion disposed on the other side of the original filter material with each flat plate portion interposed therebetween.

Description

Manufacturing equipment for filter media and filter media

technical field

The utility model relates to a filter material for trapping particles contained in the filtered gas and a manufacturing device thereof, in particular to a filter formed by pleating the raw material of the filter material capable of trapping the particles filter material.

Background technique

Conventionally, the filter medium 100 shown in FIG. 5 is known as a filter medium used in the clean room of the factory which manufactures a semiconductor or a liquid crystal, etc. (refer patent document 1). The filter material 100 is formed in a pleated shape by bending a filter material raw material 200 configured to trap particles contained in a gas to be filtered at multiple places.

This filter material 100 includes a plurality of curved portions 100a formed by bending the filter material original material 200, and a plurality of flat plates formed in such a manner that regions other than the curved portion 100a in the filter material original material 200 face each other. portion 100b, and a plurality of interval maintaining portions 300 for maintaining the interval between adjacent flat plate portions 100b, 100b.

The spacer 300 is formed of a plurality of bead portions 300 a formed by applying an adhesive (hot melt adhesive, etc.) to both surfaces of the original filter material 200 at intervals. Specifically, the spacer 300 is formed by forming the ribs 300a on each flat plate 100b between the flat plates 100b on one side of the filter material 200 and between the flat plates 100b on the other side. formed by joining together. That is, the spacer 300 is formed between the flat plate portions 100b on one side of the filter medium raw material 200 and between the flat plate portions 100b on the other side.

In addition, the spacer 300 formed on one side of the filter medium raw material 200 and the spacer 300 formed on the other side are configured so as not to overlap each other via the flat plate portion 100b. Specifically, the spacer 300 on one side of the filter material raw material 200 is arranged in a plurality along the curved portion 100a at intervals, and the spacer 300 on the other side of the filter material raw material 200 is arranged on adjacent sides. Between the spacers 300 and 300 on one side. Thereby, compared with the case where the spacer 300 is formed by forming the rib 300a in the entire area of the flat plate portion 100b, the amount of adhesive used is reduced.

In addition, such a force (specifically, a force compressing the filter material 100 in a direction intersecting with the flat portion 100b) is sometimes applied to the above-mentioned filter material 100 (hereinafter Also recorded as the force in the direction of compression). For example, when the filter medium 100 is housed in a bag, a force in a compression direction may be applied to the filter medium 100 by the bag. Moreover, when the filter medium 100 is stored so that the flat plate part 100b may become a substantially horizontal state, it will be the state in which the force in the compression direction is applied to the filter medium 100 by its own weight.

Furthermore, if the state in which the force in the compression direction is applied to the filter medium 100 is maintained, the filter medium 100 may be fixed in a state in which the distance between the flat plate parts 100b is narrow.

Specifically, in the filter material 100 before the force in the compression direction is applied, as shown in FIG. The filter material 100 applies a force in the compression direction, as shown in (b) of Figure 6, the spacer 300 on one side of the filter material 200 and the spacer 300 on the other side of the filter material 200 will move along the Approaching in the direction of compression. As a result, deformation occurs in each of the flat plate portions 100b, and the distance between the respective flat plate portions 100b becomes narrow. And if the state that the force on the compression direction is applied to the filter material 100 continues, then the shape of each flat part 100b may not return to the state before deformation (applying the force on the compression direction to the filter material 100). The state before the force) is fixed in a state in which the distance between the flat plate portions 100b is narrow.

In this way, when the distance between the flat plate portions 100b becomes narrower, the size of the filter medium 100 in the direction along the compression direction becomes shorter than desired. Therefore, for example, when the filter medium 100 is attached to a formwork to form a filter unit, a gap is generated between the filter medium 100 and the formwork, resulting in a filter unit with poor airtightness. Moreover, since the space|interval between each flat part 100b becomes narrow, the pressure loss of the filter medium 100 may also become large.

Patent Document 1: Japanese Patent Application Laid-Open No. 09-313856

Utility model content

Therefore, the subject of the present invention is to provide a filter material capable of preventing the dimension in the direction along the compression direction from becoming shorter than the size before compression when the force in the compression direction continuously applied is removed, and its manufacture. device.

The filter material of the present utility model comprises:

a plurality of bent parts, the plurality of bent parts are formed by bending the original filter material configured to trap particles contained in the filtered gas into folds;

a plurality of flat parts formed by arranging areas of the original filter material in an opposing manner except for the bent part; and

A plurality of interval maintaining parts, a plurality of interval maintaining parts are configured to be arranged between each flat part in one side of the filter material raw material and each flat part in the other side for maintaining the interval between adjacent curved parts ,

The filter material is characterized in that,

The spacers arranged on one side of the original filter medium and the spacers arranged on the other side of the original filter medium overlap each other via the flat plates.

With this technical solution, the spacer (also referred to as one side spacer) arranged on one side of the filter material and the spacer arranged on the other side of the filter material (also referred to as another spacer) One surface side spacer) is overlapped with the flat plate portion interposed therebetween, and when a force in the compressive direction is applied to the filter medium, deformation of each flat plate portion can be prevented, and the distance between the flat plate portions can be prevented from being narrowed.

Specifically, by overlapping the spacer on one side and the spacer on the other side via the flat plate, when a force in the direction of compression is applied to the filter material, it is also possible to prevent the spacer on one side and the other side from The spacers approach along the compression direction. Accordingly, it is possible to prevent deformation of the flat plate portion located between the spacer on one side and the spacer on the other side, and to prevent the distance between the flat plate portions from being narrowed. Accordingly, it is possible to prevent the size of the filter medium in the direction along the compression direction from becoming short.

In addition, it is preferable that the spacer arranged on one side of the original filter material and the spacer arranged on the other side of the original filter material overlap at the center of the flat plate via the flat plate.

By adopting this technical solution, it is possible to more effectively prevent deformation of the flat plate portion that occurs when a force in the compression direction is applied to the filter material. Therefore, the size of the filter medium in the direction along the compression direction can be more effectively maintained.

Specifically, the rigidity of the central portion of the flat plate portion (specifically, the central portion between a pair of curved portions connected to one flat plate portion, or the central portion in the direction in which the curved portion extends) is lower than that of the outer periphery of the flat plate portion. Rigidity of the part. Therefore, when a force in a compressive direction is applied to the filter medium, the central portion of the flat plate portion is likely to deform. Therefore, by overlapping the one-side spacer and the other-side spacer at the center of the flat plate via the flat plate, deformation of the flat plate can be effectively prevented as described above. Thereby, the size of the filter medium in the direction along the compression direction can be more effectively maintained.

Preferably, each spacer that is arranged on one side of the filter material raw material and each spacer that is arranged on the other side of the filter material raw material are along the flat plate portion in a manner that intersects the curved portion that extends linearly. formed in a straight line,

The length from the connection position of the curved portion and the flat plate portion to one end of each spacer is greater than 50% of the length between the connection positions of the one flat plate portion and the pair of curved portions.

With this technical scheme, the length from the connecting position of the curved part and the flat part to one end of each spacer is greater than 50% of the length between the connecting positions of the pair of curved parts in the flat part, and the spacer on one side The holding part and the other surface side spacing holding part are overlapped at the center part of the flat plate part via the flat plate part. In addition, since the spacer on one side and the spacer on the other side are arranged continuously from the position intersecting the bent portion to the central portion of the flat plate, the spacer on the flat plate is located between the spacer on one side and the spacer on the other side. Rigidity of the portion between them is increased, and deformation of the flat portion can be further suppressed.

The filter material manufactured by the manufacturing device of the filter material of the present utility model comprises:

a plurality of bending parts, the plurality of bending parts are formed by bending the original filter material configured to trap particles contained in the filtered gas into folds;

a plurality of flat parts, the plurality of flat parts are formed by arranging areas of the original filter material in an opposite manner except for the bent part; and

A plurality of interval maintaining parts, a plurality of interval maintaining parts are configured to be arranged between each flat part in one side of the filter material raw material and each flat part in the other side for maintaining the interval between adjacent curved parts ,

The manufacturing device of this filter material is characterized in that,

The manufacturing equipment of this filter filter material comprises:

A device for disposing an adhesive in an overlapping manner via a filter material on both sides of the region where each flat plate portion is formed in the above-mentioned filter material raw material;

The original filter material is bent into folds to form a plurality of curved parts and a plurality of flat parts, and the adhesive on one side of the original filter material is placed between each flat part on one side of the original filter material. Join each other and between each flat plate portion in the other side of the filter material original material, the adhesive agent on the other side of the filter material original material is joined to each other and overlap each other through each flat plate portion. A device in which a spacer is formed on one side and the other side.

As above, according to the present invention, when the force in the compression direction continuously applied is removed, the dimension in the direction along the compression direction can be prevented from becoming shorter than the dimension before compression.

Description of drawings

FIG. 1 is a perspective view showing a filter medium of the present embodiment.

Fig. 2 is a perspective view and a partially enlarged view showing the original filter material of the embodiment.

(a) of Fig. 3 is a cross-sectional view of the filter material of this embodiment cut by the plane intersecting with the flat part, and (b) of Fig. A cross-sectional view of the overlapping portion of the interval holding portion cut from the plane of .

4( a ) is a cross-sectional view showing a spacer of a filter medium according to another embodiment, and FIG. 4( b ) is a cross-sectional view showing a spacer of a filter medium according to still another embodiment.

Fig. 5 is a perspective view showing a conventional filter medium.

Fig. 6(a) and Fig. 6(b) are cross-sectional views of the filter material in Fig. 5 by cutting the plane intersecting with each flat part, wherein Fig. 6(a) shows the 6( b ) is a cross-sectional view showing a state in which a force in the compression direction is applied to the filter medium.

Explanation of reference signs

1. Filter material; 1a, curved part; 1b, flat part; 2. raw material of filter material; 2a, porous layer; 2b, base material layer; 3. interval maintenance part; 3a, rib part; Predetermined area; A2, predetermined area of the flat part; B1, overlapping part of the interval holding part.

Detailed ways

Next, an embodiment of the present invention will be described with reference to FIGS. 1 to 3 . In addition, in the following drawings, the same or corresponding parts are given the same reference numerals, and the description thereof will not be repeated.

As shown in Figure 1, the filter material 1 of the present embodiment includes: a plurality of curved parts 1a, the plurality of curved parts 1a are formed by making the original filter material 2 capable of trapping the particles contained in the filtered gas It is formed by bending into folds (hereinafter also referred to as pleat processing); a plurality of flat parts 1b, the plurality of flat parts 1b is formed by making the area of the original filter material 2 except the curved part 1a opposite to each other. and a plurality of spacers 3, the plurality of spacers 3 are configured to be arranged between each flat part 1b in one side of the filter material 2 and each flat part in the other side 1b, while maintaining the interval between adjacent curved portions 1a, 1a.

As shown in FIG. 2 , the above-mentioned filter medium raw material 2 is formed in a flat shape in which one direction is vertical in a state before it is bent into a pleated shape. In addition, the filter material raw material 2 can be configured to become a planar shape by unwinding from a state in which one direction becomes a long strip and is rolled up, or it can be formed in a way that one direction becomes a longitudinal direction. Flat monolithic body.

In addition, the filter material raw material 2 includes a porous layer 2a for trapping particles contained in the gas to be filtered, and a base material layer 2b which has air permeability and is laminated on the porous layer 2a. In the present embodiment, the filter material raw material 2 includes a plurality of (specifically, two) porous layers 2a, and the base material layer 2b is arranged between the porous layers 2a. In this way, by forming the filter medium original material 2 using a plurality of porous layers 2a, it is possible to suppress pressure loss and variations in collection efficiency compared to the case where the filter medium original material 2 is formed of a single porous layer 2a. In addition, since the formation of pinholes penetrating through the filter medium original material 2 can be suppressed, the filter medium original material 2 with a structure without leakage can be obtained.

The porous layer 2 a is formed using a porous sheet (hereinafter also referred to as a porous sheet) configured to trap the particles. The porous sheet is not particularly limited, and can be appropriately selected according to the use of the filter medium 1 . For example, a PTFE sheet obtained by forming polytetrafluoroethylene (PTFE) into a sheet can be used. As a method for forming the PTFE sheet, for example, the following method can be employed.

Specifically, a liquid lubricant is added to PTFE fine powder to form a pasty mixture. The PTFE fine powder is not particularly limited, and for example, polyflon (polyflon) F-104 (manufactured by Daikin Industries, Ltd.), fluorolon (fluon) CD-123 (manufactured by Asahi ICI Fluoropolymers Co., Ltd.), Freon 6J (manufactured by Mitsui DuPont Fluorochemical Co., Ltd.) and the like. The liquid lubricant is not particularly limited as long as it can impart moderate wettability to the surface of the mixture, and it is particularly preferable if the liquid lubricant can be removed by extraction treatment or heat treatment. For example, in addition to hydrocarbon oils such as fluid paraffin, naphtha, white oil, toluene, and xylene, alcohols, ketones, esters, and mixtures of two or more of them can also be used as liquid lubricants. The amount of the liquid lubricant to be added is not particularly limited, and can be appropriately adjusted according to the types of the PTFE fine powder and the liquid lubricant, and the method of forming the PTFE sheet. Specifically, the added amount of the liquid lubricant is preferably 5 to 50 parts by weight with respect to 100 parts by weight of the PTFE fine powder.

Then, the above-mentioned mixture composed of PTFE fine powder and liquid lubricant was preformed to produce a preformed body. Specifically, a preform is produced by extruding the above-mentioned mixture into a rod shape. It is preferable to carry out this preforming under a pressure of such an extent that the liquid lubricant does not separate from the mixture.

Next, the obtained preform is formed into a sheet shape by extrusion molding and roll forming. Specifically, a method of supplying a preform between a pair of rolls and rolling it to form a sheet, a method of extruding a preform into a sheet, or extruding a preform A method in which the sheet is formed into a sheet and the sheet is further supplied between a pair of rolls and rolled to form a sheet. The thickness of the obtained sheet-like molded body is not particularly limited, but is preferably 0.05 mm to 0.5 mm, for example.

Next, the obtained sheet-like molded body is made porous by uniaxially stretching or biaxially stretching the obtained sheet-like molded body, thereby forming a PTFE sheet. In this embodiment, the sheet-shaped molded article is stretched in the longitudinal direction and also in the width direction perpendicular to the longitudinal direction (biaxial stretching). In addition, it is preferable to remove the liquid lubricant from the molded article before stretching the sheet-shaped molded article. As a method of removing the liquid lubricant, a method of heating the molded body (heating method), and a method of extracting the liquid lubricant by immersing the molded body in a solvent (extraction method) can be employed.

When stretching a sheet-like molded article in the longitudinal direction, a larger draw ratio can promote fibrillation of the molded article and easily make the molded article porous. The draw ratio is preferably, for example, 10 times to 30 times. In addition, the temperature condition at the time of stretching the molded body is not particularly limited, and is, for example, 150°C or more and less than 327°C.

By stretching the sheet-shaped molded article stretched in the longitudinal direction in the width direction, the molded article is effectively fibrillated, and a PTFE sheet having a small variation in pore diameter can be obtained. The conditions for stretching the sheet-like molded article in the width direction are not particularly limited, but the stretching ratio is preferably 20 to 100 times, for example. In addition, it is preferable to stretch the sheet-shaped molded article in the width direction to an area stretch ratio represented by the product of the stretch ratio in the width direction and the previous stretch ratio in the longitudinal direction to 450 times or more. The larger the area draw ratio is, the more the fibrillation can be promoted, and a porous PTFE sheet with a larger PF value can be obtained. Moreover, it does not specifically limit as stretching temperature, For example, it is preferable that it is 40 degreeC - 100 degreeC.

The PTFE sheet formed as above has excellent characteristics of a pressure loss of 50 mmH ₂ O or less and a collection efficiency of 99.9% or more. In particular, when the area draw ratio is 450 times or more, the pressure loss is reduced to less than 20 mmH ₂ O without greatly reducing the collection efficiency, and the PF value is 22 or more, which is a porous material with extremely excellent performance. PTFE sheets. In addition, the variation in pressure loss between the obtained PTFE sheets is also reduced. Therefore, it becomes a porous PTFE sheet which shows low running cost and extremely excellent dust removal performance.

In addition, in order to obtain strength improvement and dimensional stability, the PTFE sheet obtained as above may be further subjected to heat treatment (firing treatment). Usually, the PTFE sheet is heat-treated to fix the dimensions of the PTFE sheet at or above the melting point of the PTFE sintered body. In addition, this heat treatment can reduce pressure loss. Therefore, even when the PF value of the PTFE sheet is 22 or more and the pressure loss is 20 mmH ₂ O or more, the heat treatment can reduce the pressure loss to less than 20 mmH ₂ O.

Preferably, the PTFE sheet formed as above has an endothermic peak in a temperature region of 345±5° C. on a crystal melting curve obtained by a differential scanning calorimeter. In addition, it is preferable that the crystal conversion rate of the PTFE sheet is 0.25 to 0.85. In addition, it is preferable that the specific gravity (the "apparent specific gravity" obtained by dividing the mass by the apparent volume) of the PTFE sheet is 1.4 or less.

The base material layer 2b is formed of an air-permeable sheet (hereinafter also referred to as an air-permeable sheet). It does not specifically limit as an air-permeable sheet, For example, a nonwoven fabric, a woven fabric, a mesh, etc. are mentioned. In particular, when the porous layer 2 a (porous layer sheet) and the base material layer 2 b (air-permeable sheet) are thermally welded (thermally laminated), an air-permeable sheet made of a thermoplastic material is preferable.

As the material of the air-permeable sheet, for example, polyolefins such as polyethylene and polypropylene, nylon, polyester, aramid (specifically, aromatic polyamide, etc.), or materials composed of them (such as Non-woven fabrics composed of fibers with a core/sheath structure, double-layer non-woven fabrics of low-melting point materials and high-melting point materials, etc.). In addition, examples of the material of the air-permeable sheet include PFA (tetrafluoroethylene/perfluoroalkyl vinyl ether copolymer), FEP (tetrafluoroethylene/hexafluoropropylene copolymer), and porous materials such as PTFE. Fluorine-based porous membranes such as membranes.

In particular, non-woven fabrics made of composite fibers with a core-sheath structure and synthetic fibers whose melting point of the core component is higher than that of the sheath component, and non-woven fabrics made of two layers of a low-melting-point material and a high-melting-point material can be used. A breathable sheet made of cloth or the like. By using such a nonwoven fabric, it is possible to suppress shrinkage in the base material layer 2 b when the porous layer 2 a (porous layer sheet) and the base material layer 2 b (air-permeable sheet) are thermally laminated. In addition, by using this nonwoven fabric, the processability of the original filter material 2 when it is pleated is improved, and the bendable parts of the original filter material 2 can be increased (the pleating pitch is reduced).

The method for forming the above-mentioned filter material raw material 2 is not particularly limited. For example, it may be as follows: a porous sheet for forming the porous layer 2a and an air-permeable sheet for forming the base material layer 2b A hot-melt adhesive or a pressure-sensitive adhesive is arranged between the sheets, and the porous sheet and the air-permeable sheet are crimped. Alternatively, a method of pressure-bonding (thermally laminating) the air-permeable sheet to the porous sheet in a heated and softened state may also be used.

When forming the filter medium 1 using the filter medium original material 2 comprised as mentioned above, first, the filter medium original material 2 is pleat-processed. Specifically, the original filter material 2 is bent at multiple places along a width direction perpendicular to one direction (longitudinal direction) to form a pleated shape. As a result, the curved portion 1 a and the flat portion 1 b in the filter medium 1 are formed on the filter medium original material 2 . In addition, in the following description, the area|region in which the bending part 1a is formed in the filter medium original material 2 is called bending plan area|region A1.

Next, an adhesive is applied to both surfaces of the original filter material 2 to form the ribs 3a. Specifically, the pleated original filter material 2 is stretched to a flat state before pleating, and an adhesive is applied to both surfaces of the original filter material 2 to form the ribs 3a. Ribs 3 a are partially formed on both surfaces of the filter medium original material 2 . Specifically, the ribs (hereinafter also referred to as the ribs on one side and the rib on the other side) 3a formed on one side and the other side of the filter material 2 are spaced along the longitudinal direction of the filter material 2 respectively. A plurality is formed at intervals, and a plurality (three in this embodiment) is formed at intervals along the width direction of the filter medium raw material 2 . In addition, the one-surface side rib 3 a and the other-surface side rib 3 a are formed on the same straight line along one direction (longitudinal direction) of the filter medium raw material 2 .

In addition, the shape of the rib 3 a is not particularly limited, but in the present embodiment, it is formed in a linear shape along one direction (longitudinal direction) of the filter medium raw material 2 . Moreover, the rib part 3a is formed in the vicinity of the surface which becomes the peak side when the bending part 1a is formed in the bending plan area|region A1. Specifically, the rib 3 a is formed so as to intersect the planned bending area A1 in the filter medium original material 2 . In the present embodiment, the linear rib 3a is configured to intersect the planned bending area A1 at a substantially central portion thereof. Moreover, the rib part 3a is formed in the surface which becomes the peak side when the bending part 1a was formed. That is, one of the adjacent planned bending regions A1 and A1 intersects the rib 3 a on one side, and the other planned bending region A1 intersects the rib 3 a on the other side.

The length from the intersection of the rib 3a and the planned bending area A1 to the end of the rib 3a is not particularly limited, but is preferably a length in which the rib coating length ratio exceeds 50%. The rib coating length ratio refers to the ratio of the length from the intersection of the rib 3a and the planned bending area A1 to one end of the rib 3a to the distance between the adjacent planned bending areas A1 and A1. That is, the rib 3a is formed from the intersection position with the planned bending area A1 to the area A2 between the adjacent planned bending areas A1 and A1 (that is, the area A2 serving as the flat plate portion 1b) (hereinafter referred to as the flat plate portion). The position of the central part of the predetermined area A2). In addition, the distance between adjacent planned bending areas A1 and A1 means that the central portion of one planned bending area A1 and the center of another planned bending area A1 are connected along one direction (longitudinal direction) of the original filter material 2. Department distance.

Moreover, the rib part 3a of one surface side and the rib part 3a of the other surface side are formed so that the filter medium original material 2 (specifically, planar part plan area|region A2) may overlap. In more detail, in one side rib 3a and the other side rib 3a intersecting the adjacent bending predetermined areas A1 and A1 respectively, one direction (longitudinal direction) along the filter material raw material 2 is formed in the The ribs 3 a on the same straight line are formed so as to overlap each other in the planned flat plate portion area A2 via the filter medium original material 2 . In addition, the one side rib part 3a and the other side rib part 3a are formed so that the edge part located in the inner side of the planar part predetermined area|region A2 may mutually overlap|interpose the filter medium original material 2, and are formed. In addition, there is no particular limitation on the overlapping position of the one-side rib 3a and the other-side rib 3a in the planar portion predetermined area A2, but it is preferably along one direction (longitudinal direction) of the original filter material 2. The approximate center of the top.

Although it does not specifically limit as an adhesive agent used for forming the rib part 3a, For example, a hot-melt adhesive is mentioned. The temperature at the time of applying the hot-melt adhesive to the original filter material 2 varies depending on the components of the hot-melt adhesive, but is preferably 100°C to 250°C, more preferably 140°C to 230°C.

Then, the filter medium original material 2 on which the rib part 3a was formed as mentioned above is bent again in each planned bending area|region A1, and is formed into a pleated shape. As a result, as shown in FIG. 3( a ), a plurality of bent portions 1 a and a plurality of flat plate portions 1 b are formed, and portions of the ribs 3 a between the flat plate portions 1 b are joined to each other to form a spacer. 3, thereby forming the filter material 1. Therefore, in the case of using a hot melt adhesive as the adhesive for constituting the ribs 3a, it is preferable to remove the filter material when the hot melt adhesive is softened to the extent that the hot melt adhesives can be bonded to each other (in the exposure time). The raw material 2 is again formed into a folded shape.

In addition, in the following description, the dimension in the direction corresponding to one direction (longitudinal direction) of the filter medium original material 2 in the filter medium 1 is made into the length L1 of the filter medium 1. In addition, let the dimension in the direction corresponding to the other direction (width direction) of the filter medium original material 2 in the filter medium 1 be the width L2 of the filter medium 1. In addition, the interval between the curved portion 1a formed so that one side of the filter material raw material 2 becomes the peak side and the curved portion 1a formed so that the other surface side of the filter material raw material 2 becomes the peak side is defined as filter material raw material 2. The height L3 of filter material 1.

In the filter medium 1 formed as described above, the spacer 3 is respectively formed on one surface side and the other surface side of the filter medium raw material 2 . In addition, each space|interval holding|maintenance part 3 is formed linearly from one side toward the other side in the height L3 direction of the filter medium 1. In addition, as shown in (a) and (b) of FIG. Each spacer 3 (hereinafter also referred to as the other side spacer 3 ) is alternately arranged along the longitudinal direction of the filter medium 1 (specifically, on a straight line extending along the longitudinal direction).

Furthermore, the spacer 3 on one side and the spacer 3 on the other side are formed so as to overlap each other with the flat plate portion 1 b interposed therebetween. Specifically, the one-side spacer 3 and the other-side spacer 3 are formed so that their end portions on the center side of the flat plate 1b overlap each other with the flat plate 1b interposed therebetween. In addition, the spacer 3 on one side and the spacer on the other side 3 are configured to overlap at approximately the center in the height L3 direction of the filter medium 1 via the flat plate 1b. Specifically, the length from the connecting position of the curved portion 1a and the flat plate portion 1b to one end of each spacer 3 is longer than that between the connecting positions of the one flat plate portion 1b and the pair of curved portions 1a, 1a. 50% of the length. Thus, the one-side spacer 3 and the other-side spacer 3 are configured to overlap at substantially the center in the height L3 direction of the filter medium 1 .

By making one surface side spacer 3 and the other side spacer 3 overlap as described above, each spacer 3 is formed along the longitudinal direction of the filter material 1 through the overlapping position of the flat plate part 1b (hereinafter also referred to as Spacer Overlap) B1. As shown in (a) of FIG. 3 , the spacer overlapping portion B1 is formed at a substantially central portion in the height L3 direction of the filter medium 1 . Moreover, as shown in FIG.3(b), the space|interval holding part overlapping part B1 is formed at intervals in the width L2 direction of the filter medium 1 in plural (specifically, three places). The spacer 3 is not formed between the spacer overlapping portions B1 in the width L2 direction of the filter medium 1, and a space is formed between the flat plate portions 1b.

The filter medium 1 having the above-mentioned structure can be used so that the flat plate portion 1b intersects the flow direction of the gas to be filtered. Thereby, the gas to be filtered mainly permeates the flat plate portion 1b. In addition, the filter material 1 may be housed in a frame ( not shown) and used as a filter unit. As the shape of the frame body, as long as it is a shape that can accommodate the filter material 1, it is not particularly limited, for example, the inner dimension is 1180mm × 1180mm, the outer dimension is 1220mm × 1220mm, and the thickness is a cuboid shape of 75mm, A circular shape with a predetermined inner diameter, etc. In addition, the material of the housing is not particularly limited, and a material made of aluminum can be used.

A caulking agent is filled between the filter material 1 and the frame body. As the caulking agent, for example, a two-component epoxy caulking agent (specifically, a two-component epoxy caulking agent manufactured by Henkel Co., Ltd. by mixing Macroplast 8104MC-18 and Macroplast UK5400 at a ratio of 3:1) ). In addition, the filter medium 1 is suitable for use as a HEPA (High Efficiency Particulate Air) filter and an ULPA (Ultra Low Penetration Air) filter in a clean room or the like.

As above, adopt filter material of the present invention and manufacturing method thereof, when removing the force on the compression direction that continues to apply, can prevent the size along the direction on the compression direction from becoming shorter than before compression size.

That is, the above-mentioned filter material 1 is overlapped by the one side spacer 3 and the other side spacer 3 via the flat plate part 1b, and when the filter material 1 is applied with a force in the compression direction, each The deformation of the flat plate portion 1b can prevent the distance between the flat plate portions 1b from being narrowed.

Specifically, by overlapping the one-side spacer 3 and the other-side spacer 3 via the flat plate portion 1b, it is possible to prevent the one-side spacer 3 and the other-side spacer 3 from approaching in the compression direction. Thereby, deformation of the flat plate portion 1b positioned between the one-surface side spacer 3 and the other-surface side spacer 3 can be prevented, and the space between the flat plate portions 1b can be prevented from being narrowed. Accordingly, it is possible to prevent the dimension of the filter medium 1 in the direction along the compression direction (the dimension in the direction of the length L1 ) from being shortened.

In addition, the rigidity of the central portion of the flat plate portion 1b (specifically, the central portion between the pair of curved portions 1a, 1a connected to one flat plate portion 1b, or the central portion in the direction in which the curved portion 1a extends) is lower than that of the flat plate portion 1b. Rigidity of the outer peripheral portion of the flat plate portion 1b. Therefore, when a force in the compressive direction is applied to the filter medium 1, the central portion of the flat plate portion 1b is easily deformed. Therefore, by overlapping the one-side spacer 3 and the other-side spacer 3 at the center of the flat plate 1b via the flat plate 1b, deformation of the flat plate 1b can be effectively prevented as described above.

In addition, the length from the connecting position of the bent part 1a and the flat part 1b to one end of each spacer 3 is greater than 50% of the length between the connecting positions of the pair of bent parts 1a and 1a in one flat part 1b. %, one side spacer 3 and the other side spacer 3 overlap at the center of the flat plate 1b via the flat plate 1b. In addition, since the spacer 3 on one side and the spacer 3 on the other side are formed from the position intersecting the curved portion 1a to the central portion of the flat plate 1b, the spacer 3 on the side of the flat plate 1b and the spacer on the other side The rigidity of the portion between the side spacer holding portions 3 is increased, and deformation of the flat plate portion 1b can be further suppressed.

In addition, the filter material of this invention and its manufacturing method are not limited to the said embodiment, Various changes can be made in the range which does not deviate from the summary of this invention. In addition, it goes without saying that the structures, methods, etc. of the above-mentioned multiple embodiments can also be combined arbitrarily (the structure, method, etc. of one embodiment can also be applied to the structure, method, etc. of another embodiment ), and it is also possible to arbitrarily select the configurations, methods, etc. of various modified examples described below and apply them to the configurations, methods, etc. of the above-mentioned embodiment.

For example, in the above-mentioned embodiment, the rib 3a is formed so that the rib 3a intersects the bent portion 1a, but it is not limited thereto. As shown in FIG. Part of the holding portion 3' forms a rib 3a'. Alternatively, as shown in FIG. 4( b ), the ribs 3a'' and the spacer 3'' may be formed only of the portion forming the spacer overlapping portion B1 of the filter medium 1 .

In addition, in the above-described embodiment, a plurality of spacers 3 are formed at intervals along the bent portion 1a, but the present invention is not limited thereto, and may be integrally formed along the bent portion 1a.

In addition, in the above-mentioned embodiment, the filter material raw material 2 is bent at many places along the width direction, but it is not limited to this, and it is also possible to make the filter material raw material formed into a monolithic shape in a radial shape. Conical filter material is formed by multiple bends.

In addition, in the above-described embodiment, the filter material 1 is constituted by using the filter material raw material 2 composed of the porous layer 2a and the base material layer 2b, but it is not limited thereto. For example, only the porous layer 2a may be used. The formed filter raw material. In addition, in the above embodiment, the filter material raw material 2 is formed using a plurality of porous layers 2a, but it is not limited thereto, and the filter material raw material may be formed of only a single porous layer 2a and base material layer 2b.

In addition, in the above-mentioned embodiment, the side spacer 3 (one side rib 3 a ) and the other side spacer 3 (other side rib 3 a ) are configured so that they are located in the flat plate 1 b (planar flat area A2 ). ) on the central portion side overlap each other, but are not limited thereto. For example, they may be configured such that their entire portions located inside the flat plate portion 1b (planar flat portion predetermined area A2 ) overlap each other.

In addition, in the above-mentioned embodiment, the one-side spacer 3 and the other-side spacer 3 overlap at the substantially central portion in the height L3 direction of the flat plate portion 1b, but the present invention is not limited thereto, and may be configured such that The spacer 3 on one side and the spacer 3 on the other side overlap at positions shifted from the central portion of the flat plate portion 1b toward the outer peripheral side of the flat plate portion 1b.

Example

Next, embodiments of the present invention will be described.

Make filter media

1. Porous sheet

As the porous sheet, a PTFE sheet was used. Specifically, 19 parts by weight of a liquid lubricant (Normal Decane) was added to 100 parts by weight of PTFE fine powder (trade name: F104 manufactured by Daikin Industries, Ltd.) to form a paste-like mixture. Then, by extruding the mixture after preforming the mixture, a flat plate-shaped molded body whose one direction is the vertical direction is formed. Thereafter, the flat molded body was rolled to a thickness of 0.2 mm. Then, in order to remove the liquid lubricant from the flat molded body, the molded body was heated at 150° C. in a drying furnace. Thereafter, the flat molded article was stretched 15 times in the longitudinal direction in an environment of 280° C., and stretched 15 times in the width direction perpendicular to the longitudinal direction in an environment of 100° C. to form a PTFE sheet.

2. Breathable sheet

As the air-permeable sheet, a PET/PE core-sheath nonwoven fabric (trade name: T1003WDO manufactured by Unicharm) formed so that one direction becomes the longitudinal direction was used.

3. Making filter raw materials

The porous sheet and the air-permeable sheet are conveyed to a pair of rollers while laminating the porous sheet on both sides of the air-permeable sheet so that the longitudinal direction of the porous sheet is substantially parallel to the longitudinal direction of the air-permeable sheet. Between the components (heat roll and back-up roll). In this way, the porous sheet and the air-permeable sheet were heat-sealed and adhered to produce a filter medium original material 2 as shown in FIG. 2 . In addition, as each roller member, a member with an outer diameter of 200 mm was used. In addition, the conveying speed of each sheet was 10 m/min, and the pressure at the time of bonding was 0.8 MPa.

4. Pleated mace processing

After performing pleat processing on the obtained filter medium original material 2, the rib part 3a was formed as shown in FIG. Then, the filter medium 1 as shown in FIG. 1 and FIG. 3 was manufactured. As the adhesive (hot melt adhesive) for forming the ribs 3 a, Macromelt 6202 (polyamide type) manufactured by Henkel Corporation or Technomelt Q3115 (EVA type) manufactured by Henkel Corporation was used.

Example 1

filter media

The filter medium 1 was produced by the above method, and the length L1 was 1298 mm, the width L2 was 1180 mm, and the height L3 was 35 mm. In addition, the adhesive (hot melt adhesive) used for forming the rib 3 a and the rib application length ratio are shown in Table 1 below.

Determination of shrinkage

The filter medium 1 was arranged in a planar shape so that the flat plate portion 1b of the obtained filter medium 1 was substantially horizontal (in other words, the length L1 direction of the filter medium 1 was substantially vertical). Then, a load of 3 kg was applied to the filter medium 1 from above along the length L1 direction.

Then, the length L1 of the filter medium 1 to which the load was applied was measured. The shrinkage rate was calculated from the obtained measurement results and the following formula (2). The calculated shrinkage ratios are shown in Table 1 below.

Shrinkage rate (%)={(length of filter material before load - length of filter material after load)/length of filter material before load}×100···(2)

Tightness of the filter unit

The obtained filter medium 1 was housed in a frame to produce a filter unit. Specifically, the filter medium 1 was housed in an aluminum frame body with an inner dimension of 1180 mm×1180 mm, an outer dimension of 1220 mm×1220 mm, and a thickness of 75 mm. Then, a caulking agent was filled between the filter medium 1 and the frame to manufacture a filter unit. As the caulking agent, a two-component epoxy caulking agent was used (specifically, a two-component epoxy caulking agent made by mixing Macroplast8104MC-18 and MacroplastUK5400 manufactured by Henkel at a ratio of 3:1).

When making the filter unit, the case where no gap is formed between the filter material 1 and the frame is designated as "○", and the case where a gap is formed between the filter material 1 and the frame is designated as "×" ”, evaluated the tightness of the filter unit. The evaluation results are shown in Table 1 below.

Embodiment 2～6, comparative example 1 and comparative example 2

The adhesives shown in the following Table 1 were used as the adhesive (hot melt adhesive) for forming the ribs 3a, and the rib coating length ratio was as shown in the following Table 1, except that it was the same as in Example 1. The filter material 1 and the filter unit were produced under the conditions of , and the shrinkage rate was measured. The shrinkage rate and the evaluation of the airtightness of the filter unit are shown in Table 1 below.

Table 1

Summarize

From the comparison of each Example and each Comparative Example, it can be seen that the shrinkage rate of each Example is lower than that of each Comparative Example. The reason is that, as in each embodiment, the rib coating length ratio is 50% or more, so that the spacer 3 on one side and the spacer 3 on the other side overlap at the approximate center of the flat plate 1b via the flat plate 1b. State, along the length L1 direction of the filter medium 1, a spacer overlapping portion B1 is formed. Accordingly, when a load (force in the compression direction) is applied to the filter medium 1 , the load is also supported by the spacer overlapping portion B1 , and deformation of the flat plate portion 1 b can be suppressed. Therefore, the distance between the flat plate parts 1b can be maintained, and shrinkage of the filter medium 1 can be suppressed.

That is, it can be seen that shrinkage of the filter medium 1 can be suppressed by forming the one-side spacer 3 and the other-side spacer 3 so as to overlap each other with the flat plate portion 1 b interposed therebetween.

Claims (3)

1. A filter material, comprising: A plurality of curved parts, the plurality of curved parts are formed by bending the original filter material configured to trap particles contained in the filtered gas into folds; A plurality of flat parts, the plurality of flat parts are formed by arranging areas of the original filter material in an opposite manner except for the curved part; and A plurality of interval maintaining parts, a plurality of interval maintaining parts are configured to be arranged between each flat part in one side of the filter material raw material and each flat part in the other side for maintaining the interval between adjacent curved parts , The filter material is characterized in that, The spacers arranged on one side of the original filter medium and the spacers arranged on the other side of the original filter medium overlap each other via the flat plates. the 2. filter material according to claim 1, is characterized in that, The spacer arranged on one side of the original filter material and the spacer arranged on the other side of the original filter material overlap at the center of the flat plate via the flat plate. the 3. filter material according to claim 1 or 2, is characterized in that, The spacers arranged on one side of the filter material and the spacers arranged on the other side of the filter material are formed in a straight line along the flat plate so as to intersect with the curved portion extending linearly. , The length from the connection position of the bent portion and the flat plate portion to one end of each spacer is greater than 50% of the length between the connection positions of the one flat plate portion and the pair of bent portions. the