JP2019063701A - Filter and manufacturing method of the same - Google Patents

Abstract

An object of the present invention is to provide a method of manufacturing a filter capable of reducing the pressure loss of a filtration section and improving the strength of a flange section. A method of manufacturing a filter according to the present invention includes the steps of: disposing a first non-woven fabric that has been folded in a molding die; And a setting step of arranging the sheet-like second nonwoven fabric 8 so as to overlap with the portion including the first nonwoven fabric. And forming the flange portion 3 by integrating the outer peripheral portion of the first nonwoven fabric and the second nonwoven fabric. [Selection diagram] FIG.

Description

  The present invention relates to a filter and a method of manufacturing the same, and more particularly, to a non-woven filter provided with a filter portion formed with folds and a flange portion extending outward from the outer periphery of the bottom portion of the filter portion and a method of manufacturing the same.

  As a conventional filter, for example, as shown in FIG. 11 (a), a non-woven air filter 101 is provided with a filter portion 102 formed with folds and a flange portion 103 extending outward from the outer peripheral side of the bottom portion of the filter portion 102. Are generally known (see, for example, Patent Document 1). In this patent document 1, for example, as shown in FIG. 12, a crimped non-woven fabric 107 (see FIG. 11B) is disposed in a forming die 105, and the forming non-woven fabric 107 is heated and compressed by the forming die 105. The manufacturing method is described in which the air filter 101 is obtained by forming the filter portion 102 inside the outer peripheral portion 111 of the non-woven fabric 107 and forming the flange portion 103 at the outer peripheral portion 111 of the non-woven fabric 107. In the air filter 101, the filtration portion 102 is formed of a single non-woven fabric 107, and the flange portion 103 is formed by folding the non-woven fabric 107 a plurality of times.

JP, 2016-211081, A

  However, in the method of manufacturing the air filter described in Patent Document 1 described above, since the crimped non-woven fabric 107 is simply heated and compressed, the fold direction of the fold is not controlled, and the filtration at the flange portion 103 is performed. A low-weighted portion U (that is, a low-weighted portion U consisting of a single non-woven fabric 107 and having a low-weighted portion equivalent to the filtering portion 102) is generated in a portion connected to the end side of the ridge line direction P of the fold of the portion 102 Will decrease. The reduction in strength of the flange portion 103 is particularly problematic when the low-weight nonwoven fabric 107 is used for the purpose of reducing the pressure loss of the filtration portion 102.

  In addition, in order to improve the intensity | strength of the said flange part 103, although the following measures are considered, a contradictory problem arises. For example, in the countermeasure for partially shifting the low-weighted portion U of the flange portion 103 to a portion where it is difficult to apply strength, it is a provisional measure. Moreover, in the countermeasure which uses the nonwoven fabric 107 of high basis weight, the pressure loss of the filtration part 102 becomes high. Furthermore, in the countermeasure for insert-molding the resin frame with respect to the flange portion 103, the cost is increased, and there is no freedom in the shape (for example, bending and assembling).

  The present invention is made in view of the above-mentioned present situation, and it aims at providing a filter which can aim at strength improvement of a flange part while being able to reduce pressure loss of a filtration part, and a manufacturing method for the same.

In order to solve the above-mentioned problems, the invention according to claim 1 is a method of manufacturing a non-woven filter provided with a filtration part formed with folds and a flange part extending outward from the outer peripheral side of the bottom part of the filtration part. A second sheet-like second sheet so as to overlap a part including at least the edge side of the ridge line direction of the outer part of the first non-woven fabric, The first non-woven fabric and the second non-woven fabric are heated and compressed in the forming step to set the non-woven fabric, to form the filtration portion inside the outer peripheral portion of the first non-woven fabric, and And forming a flange portion by integrating an outer peripheral portion and the second non-woven fabric.
In the invention according to claim 2, in the invention according to claim 1, the second non-woven fabric is formed in a frame shape, and in the setting step, the outer periphery of the first non-woven fabric is formed in the mold. The gist is to arrange the second non-woven fabric so as to overlap over the entire circumference.
The invention according to claim 3 is the invention according to claim 1, wherein, in the setting step, a plurality of the second non-woven fabrics in a plane direction according to a portion of an outer peripheral portion of the first non-woven fabric in the mold. The gist is to arrange them at different positions.
The invention according to a fourth aspect is the invention according to any one of the first to third aspects, wherein, in the setting step, disposing the plurality of second non-woven fabrics superposed in a plurality of sheets in the mold. It is a summary.

  In order to solve the above problems, the invention according to claim 5 is a method of manufacturing a non-woven filter provided with a filtration part formed with folds and a flange part extending outward from the outer peripheral side of the bottom part of the filtration part. Preforming step of forming a first non-woven fabric formed body by heat-compressing the folded first non-woven fabric to form the first non-woven fabric molded body having the filtration portion and a flange portion extending outward from the outer periphery of the bottom portion of the filtration portion; The first non-woven fabric molded body is disposed in a mold, and at least one of the flanges of the first non-woven fabric molded body is in a sheet shape so as to overlap at least a part extending to the ridge line end of the filtration portion. A step of setting a second non-woven fabric, the first non-woven fabric molded body and the second non-woven fabric are heated and compressed by the molding die to integrate the collar portion of the first non-woven fabric molded body and the second non-woven fabric; The flange And summarized in that and a molding step of forming a.

  In order to solve the above problems, the invention according to claim 5 is a non-woven filter provided with a filtration part formed with folds and a flange part extending outward from the outer peripheral side of the bottom part of the filtration part, The gist of the present invention is that the weight per unit area of the flange portion is larger than the weight per unit area of the filtration portion.

According to the method of manufacturing the filter of the present invention, the crimped first non-woven fabric is disposed in the mold, and at least a portion of the outer circumferential portion of the first non-woven fabric including the edge side in the ridge line direction As described above, the first nonwoven fabric and the second nonwoven fabric are heated and compressed by the forming die in a setting step of arranging the sheet-like second nonwoven fabric, to form a filtration portion inside the outer periphery of the first nonwoven fabric, and Forming a flange portion by integrating the outer peripheral portion of the second nonwoven fabric with the second non-woven fabric. Thereby, in the filter, the filtration portion is formed of the first non-woven fabric to have a low basis weight and maintains low pressure loss, while the flange portion is formed of the first non-woven fabric and the second non-woven fabric to be reinforced. As a result, the pressure loss of the filtration portion can be reduced, and the strength of the flange portion can be improved. In addition, since the filter is formed only of the non-woven fabric, the degree of freedom of the shape can be secured, and the environmental characteristics such as recyclability are excellent. Furthermore, the filter can be easily and inexpensively obtained in one molding step.
In the case where the second nonwoven fabric is formed in a frame shape, and in the setting step, the second nonwoven fabric is disposed so as to overlap over the entire circumference of the outer periphery of the first nonwoven fabric in the mold. The first nonwoven fabric and the second nonwoven fabric can be aligned easily and accurately in the setting process.
Further, in the setting step, when the plurality of second non-woven fabrics are arranged in the plane direction at different positions according to the portion of the outer periphery of the first non-woven fabric in the molding die, the shape of the second non-woven fabric is free Because the degree is high, the material yield of the non-woven fabric can be improved.
Furthermore, in the setting step, in the case of arranging the plurality of second non-woven fabrics stacked in the mold, the strength of the flange portion can be further improved.

  According to another method of manufacturing a filter of the present invention, the first non-woven fabric molded body is provided with a first non-woven fabric formed by heating and compressing the crimped first non-woven fabric to expand the filter portion and the flange portion outwardly from the bottom outer peripheral side of the filter portion. In the preforming step of molding, the first nonwoven fabric molded body is disposed in the molding die, and at least a portion of the collar portion of the first nonwoven fabric molded body is continuous with the end side of the ridge of the filtration portion. And heat-compressing the first non-woven fabric and the second non-woven fabric with a mold, and the flange portion of the first non-woven fabric and the second non-woven fabric are integrated to form a flange Forming a part. Thereby, in the filter, the filtration portion is formed of the first non-woven fabric to have a low basis weight and maintains low pressure loss, while the flange portion is formed of the first non-woven fabric and the second non-woven fabric to be reinforced. As a result, the pressure loss of the filtration portion can be reduced, and the strength of the flange portion can be improved. In addition, since the filter is formed only of the non-woven fabric, the degree of freedom of the shape can be secured, and the environmental characteristics such as recyclability are excellent. Furthermore, since the posture of the first nonwoven fabric molded body is stable, the first nonwoven fabric molded body and the second nonwoven fabric can be aligned easily and accurately in the setting process.

  According to the filter of the present invention, the coated weight at any position of the flange portion is larger than the coated weight of the filtration portion. As a result, the pressure loss of the filtration portion can be reduced, and the strength of the flange portion can be improved. Furthermore, since the filter is formed only of the non-woven fabric, the degree of freedom of the shape can be secured and the environmental characteristics such as recyclability are excellent.

The invention will be further described in the following detailed description referring to the non-limiting examples of exemplary embodiments according to the invention and with reference to the several figures referred to, but like reference numerals in the drawings. Similar parts are shown throughout the several figures.
It is explanatory drawing for demonstrating the manufacturing method of the filter which concerns on Example 1, (a) shows the perspective view of the 1st nonwoven fabric which was fold-processed, (b) shows a top view, (c) shows c-c line sectional drawing is shown. It is explanatory drawing for demonstrating the manufacturing method of the said filter, (a) shows the perspective view of a 2nd nonwoven fabric, (b) shows a top view, (c) shows a c-c line sectional view. It is explanatory drawing for demonstrating the manufacturing method of the said filter, (a) shows a set process, (b) shows a formation process. It is explanatory drawing for demonstrating the arrangement | positioning relationship of the 1st nonwoven fabric and 2nd nonwoven fabric in the said setting process. BRIEF DESCRIPTION OF THE DRAWINGS It is explanatory drawing for demonstrating the filter which concerns on an Example, (a) shows the perspective view of a filter, (b) shows a top view, (c) shows a c-c line sectional view. It is an explanatory view for explaining a usage pattern of the above-mentioned filter. It is explanatory drawing for demonstrating the manufacturing method of the filter which concerns on Example 2, (a) shows a pre-setting process, (b) shows a pre-forming process. It is explanatory drawing for demonstrating the manufacturing method of the said filter, (a) shows a set process, (b) shows a formation process. It is explanatory drawing for demonstrating the arrangement | positioning relationship of the 1st nonwoven fabric molded object and 2nd nonwoven fabric in the said setting process. It is explanatory drawing for demonstrating the setting process which concerns on another form, and (a) shows the form which arrange | positions several 2nd nonwoven fabrics so that it may overlap over the perimeter of the outer periphery of a 1st nonwoven fabric, (b) ( c) shows the form which arranges a plurality of 2nd nonwoven fabrics so that a part of perimeter part of the 1st nonwoven fabric may be overlapped. It is explanatory drawing for demonstrating the manufacturing method of the conventional filter, (a) shows the perspective view of a filter, (b) shows the perspective view of the folded nonwoven fabric. It is explanatory drawing for demonstrating the manufacturing method of the conventional filter, (a) shows a set process, (b) shows a formation process.

  The matter set forth herein is illustrative and is for the purpose of illustrating the embodiments of the invention and is intended to provide the most effective and easily understood explanation of the principles and conceptual features of the invention. It is stated for the purpose of providing what seems to be. In this respect, it is not intended to show the structural details of the present invention beyond what is necessary for a fundamental understanding of the present invention, and some forms of the present invention will It will be apparent to those skilled in the art how it may be embodied in practice.

<Method of manufacturing filter A>
The filter manufacturing method A according to the present embodiment is a manufacturing method of a non-woven filter (1) including a filtration part (2) formed with folds and a flange part (3) extending outward from the outer periphery of the bottom part of the filtration part In the method, a crimped first non-woven fabric (7) is disposed in a forming die (5), and at least a ridge line direction (P) of the pleats of an outer peripheral portion (11) of the first non-woven fabric. The step of setting the sheet-like second non-woven fabric (8) so as to overlap the portion including the end side (12), and heat-compressing the first non-woven fabric (7) and the second non-woven fabric (8) with the mold (5) And form the filtration portion (2) inside the outer peripheral portion (11) of the first nonwoven fabric, and integrate the outer peripheral portion (11) of the first nonwoven fabric and the second nonwoven fabric (8) to form a flange portion (3) A forming step of forming the optical system) (see, eg, FIGS. 1 to 3).

  As a manufacturing method A of the filter according to the present embodiment, for example, the second non-woven fabric (8) is formed in a frame shape, and in the setting step, the first non-woven fabric (7) is formed in the mold (5). The form (for example, refer FIG. 4 etc.) which arrange | positions a 2nd nonwoven fabric (8) so that it may overlap over the perimeter of the outer peripheral part (11) is mentioned.

  As a manufacturing method A of the filter according to the present embodiment, for example, in the setting step, a plurality of second nonwoven fabrics in the mold (5) according to the portion of the outer peripheral portion (11) of the first nonwoven fabric (7) There is a form (see, for example, FIG. 10 and the like) in which (8) is arranged with the position shifted in the plane direction.

  As a manufacturing method A of the filter according to the present embodiment, for example, in the setting step, a mode in which a plurality of second non-woven fabrics (8) stacked one on another are arranged in the mold (5) (see, eg, FIG. 2) Can be mentioned. In this case, for example, 2 to 7 (preferably 2 to 5, particularly 2 to 4) of the second non-woven fabrics can be stacked.

In addition, the material of the said 1st nonwoven fabric (7) and 2nd nonwoven fabric (8), a shaping | molding method, etc. do not ask | require. Each of these nonwoven fabrics can be formed from the same material, for example. Thereby, the filter excellent in environmental characteristics, such as recycling, can be provided. Moreover, as a fabric weight of each nonwoven fabric, 30-150 g / m < ² > (preferably 50-100 g / m < ² >, especially 50-80 g / m < ² >) is mentioned, for example. In addition, each non-woven fabric can contain, for example, heat fusible fibers (in particular, a plurality of heat fusible fibers having different melting points). The material of the heat fusible fiber is, for example, polyamide resin such as nylon 6, nylon 66, polycarbonate resin, polyester resin such as polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, acrylic resin, polyethylene, polypropylene, etc. Polyolefin resins can be used. In addition, each non-woven fabric can contain, for example, the above-described heat-fusible fiber and reinforcing fiber. As the reinforcing fibers, for example, inorganic fibers (glass fibers and the like) and organic fibers (natural fibers such as plant fibers and animal fibers and chemical fibers) can be used. These configurations are also applied to a filter manufacturing method B according to an embodiment described later.

<Method of manufacturing filter B>
The filter manufacturing method B according to the present embodiment is a manufacturing method of a non-woven filter (1) comprising a filtration part (2) formed with folds and a flange part (3) extending outward from the outer periphery of the bottom part of the filtration part A method for forming a first nonwoven fabric comprising heating and compressing a crimped first nonwoven fabric (7) to form a filtration portion (2) and a flange portion (32) extending outward from the outer periphery of the bottom portion of the filtration portion A preforming step of shaping the body (31) and disposing the first nonwoven fabric molded body (31) in the molding die (5), and at least a filter portion of the collar portion (32) of the first nonwoven fabric molded body (2) a setting step of arranging a sheet-like second nonwoven fabric (8) so as to overlap with a portion continuous with the end side (14) of the ridge line direction (P) of the pleats; The body (31) and the second nonwoven fabric (8) are heated and compressed to form the first nonwoven fabric Comprising a forming step of forming the flange portion (3), the integral flange portion of the form (32) and a second nonwoven (8) (e.g., see FIG. 7 and FIG. 8).

  In the filter manufacturing method B according to the present embodiment, for example, the second non-woven fabric (8) is formed in a frame shape, and in the setting step, the first non-woven fabric formed body (in the forming die (5)) 31) A mode (see, for example, FIG. 9, etc.) in which the second non-woven fabric (8) is disposed so as to overlap over the entire circumference of the collar portion (32).

  As the filter manufacturing method B according to the present embodiment, for example, in the setting step, a plurality of the second nonwoven fabric molded articles (31) are provided with a plurality of the second nonwoven fabric molded articles (31) in the molding die (5). The form (for example, refer FIG. 10 grade | etc.,) Which shifts | deviates and arrange | positions 2 non-woven fabrics (8) in a plane direction is mentioned.

  As a method of manufacturing a filter according to the present embodiment, for example, in the setting step, a configuration in which a plurality of second non-woven fabrics (8) stacked one on another are arranged in the forming die (5) (for example, FIG. See etc.). In this case, for example, 2 to 7 (preferably 2 to 5, particularly 2 to 4) of the second non-woven fabrics can be stacked.

<Filter>
The filter according to the present embodiment is a non-woven filter (1) comprising a filtration part (2) formed with folds and a flange part (3) extending outward from the outer periphery of the bottom part of the filtration part The weight per unit area of (3) is larger than the weight per unit area of the filtration part (2) (see, for example, FIG. 5 and the like).

  In the filter according to the present embodiment, for example, the ratio (T1 / T2) of the basis weight (T1) of the flange portion (3) to the basis weight (T2) of the filtration portion (2) is 1.5 to 10 The form which is (preferably 2.0-7, especially 2.5-5) is mentioned. Thereby, the reduction of the pressure loss of the filtration part and the improvement of the strength of the flange part can be effectively achieved at the same time.

  As the filter according to the present embodiment, for example, the above-mentioned filter is an air filter (1) for filtering the air sent out from the vehicle cabin (R) to the outside (for example, see FIG. 6 etc.) Be Thus, in the air filter for filtering the air in the vehicle cabin, the pressure loss of the filtration portion can be reduced, and the strength of the flange portion can be improved.

  In addition, the code | symbol in the parenthesis of each structure described by the said embodiment shows the correspondence with the specific structure as described in the Example mentioned later.

  Hereinafter, the present invention will be specifically described by way of examples using the drawings. In the present embodiment, as the "filter" according to the present invention, a non-woven fabric provided with the filter portion 2 in which pleats (also referred to as "pleats") are formed and the flange portion 3 extending outward from the outer peripheral side of the bottom portion of the filter portion 2 The air filter 1 made of aluminum is illustrated (refer FIG. 5).

Example 1
(1) Method of Manufacturing Filter A method of manufacturing a filter according to the present embodiment is a method of manufacturing an air filter 1 and, as shown in FIG. 1 and a setting step of arranging the sheet-like second nonwoven fabric 8 so as to overlap with the outer peripheral portion 11 of the first nonwoven fabric 7 while arranging the first nonwoven fabric 7, and as shown in FIG. The non-woven fabric 7 and the second non-woven fabric 8 are heated and compressed to form the filtration portion 2 inside the outer peripheral portion 11 of the first non-woven fabric 7 and to integrate the outer peripheral portion 11 of the first non-woven fabric 7 and the second non-woven fabric 8 And a forming step of forming the flange portion 3.

As shown in FIG. 1, the first non-woven fabric 7 is folded by regularly folding a sheet-like non-woven fabric so that peaks and valleys are continuous. The first non-woven fabric 7 that has been folded is provided with a fold PL and an end 13 connected to the end of the continuous direction Q of the fold of the fold PL. The end 13 is configured to be folded back in a plurality. Furthermore, the weight per unit area of the first nonwoven fabric 7 is about 60 g / m ² .

As shown in FIG. 2, the second non-woven fabric 8 is formed in a frame shape by cutting out a central portion of a sheet-like non-woven fabric by punching or the like. The frame-shaped second non-woven fabric 8 has a shape corresponding to the outer peripheral portion 11 of the first non-woven fabric 7. In addition, the second non-woven fabric 8 is configured to be folded back at the connection portion 16 and to be stacked in a plurality (two in the drawing). The second nonwoven fabric 8 is formed of the same material as the first nonwoven fabric 7. Furthermore, the basis weight of the second nonwoven fabric 8 is about 60 g / m ² .

  In the present embodiment, as the first and second non-woven fabrics 7 and 8, a fiber web is formed by mixing fibers, carding and wrapping, and the fiber web is heated to thermally fuse the fibers (ie, Use a non-woven fabric obtained by thermal bonding). The above-mentioned fiber web may be needle-punched to form a preliminary non-woven fabric, and the non-woven fabric obtained by heating the preliminary non-woven fabric to thermally fuse the fibers may be employed. Further, in the present embodiment, in order to arrange the air filter 1 at a place where it can be seen from the vehicle interior, a non-woven fabric colored in black or the like is employed.

  As shown in FIG. 3, the mold 5 includes a pair of molds 21 a and 21 b which can be approached and separated from each other. Each of the pair of molds 21 a and 21 b includes filtration part forming surfaces 22 a and 22 b for forming the filtration part 2 and flange part forming surfaces 23 a and 23 b for forming the flange part 3. . The filtration portion forming surfaces 22 a and 22 b are formed in a pleated shape corresponding to the pleats of the filtration portion 2. Further, the flange portion forming surfaces 23a and 23b are disposed on the outer peripheral side of the filtration portion forming surfaces 22a and 22b, and are formed in a flat shape corresponding to the flange portion 3.

  In the setting step, as shown in FIGS. 3A and 4, the outer peripheral portion 11 of the first non-woven fabric 7 (shown by a hatched area in phantom in FIG. 1B) in the mold 5. The sheet-like second non-woven fabric 8 is disposed so as to overlap a portion including the end 12 of at least the ridge line direction P of the fold. Specifically, in the setting step, the frame-shaped second non-woven fabric 8 is disposed in the molding die 5 so as to overlap over the entire circumference of the outer peripheral portion 11 of the first non-woven fabric 7. The central opening 17 of the second non-woven fabric 8 is set to an opening slightly larger than the bottom outer periphery of the filtration portion 2 (for example, an opening with the bottom outer periphery of the filtration portion 2 offset outward by about 5 mm). Thereby, even if the second nonwoven fabric 8 is drawn to the center side at the time of molding, the outer peripheral portion 11 of the first nonwoven fabric 7 and the second nonwoven fabric 8 are integrated at an appropriate position. In addition, by positioning and holding the non-woven fabrics 7 and 8 by the positioning structure in the molding die 5, the drawing-in of the non-woven fabrics 7 and 8 may be prevented at the time of molding.

  In the forming step, as shown in FIG. 3B, the first non-woven fabric 7 and the second non-woven fabric 8 are heated and compressed by the pair of molds 21a and 21b, so that the first flange portion forming surfaces 23a and 23b The outer peripheral portion 11 of the non-woven fabric 7 and the second non-woven fabric 8 are crushed and integrated. And while the filtration part 2 is formed inside the outer peripheral part 11 of the 1st nonwoven fabric 7 pinched between each filtration part formation surface 22a, 22b, the 1st pinched between each flange formation surface 23a, 23b The flange portion 3 is formed by the outer peripheral portion 11 of the nonwoven fabric 7 and the second nonwoven fabric 8. As a result, the air filter 1 provided with the filtration part 2 and the flange part 3 is obtained.

(2) Configuration of Air Filter As shown in FIG. 5, the air filter 1 according to the present embodiment includes the filtration portion 2 formed with folds and the flange portion 3 extending outward from the outer peripheral side of the bottom portion of the filtration portion 2. ing. The filter portion 2 is a portion for collecting dust in the air, and the flange portion 3 is a portion supported by a frame-shaped bezel or the like. Further, in the filtration unit 2, the end side 14 in the ridge line direction P is closed by the side wall 2 a.

The weight per unit area of the main portion of the flange portion 3 (i.e., the portion excluding the outer peripheral edge of the flange portion 3) is the weight per unit area of the main portion of the filtration portion 2 (i.e. the portion excluding the side wall 2a of the filtration portion 2). Greater than the amount. The main part of the flange portion 3 has a multilayer structure including the first non-woven fabric 7 and the second non-woven fabric 8, and the basis weight thereof is about 200 g / m ² or more. On the other hand, the main part of the filtration part 2 is made into the single layer structure which consists of the 1st nonwoven fabric 7, and the area weight is about 70 g / m < ² > or less. Therefore, the ratio (T1 / T2) of the basis weight T1 of the flange portion 3 to the basis weight T2 of the filtration portion 2 is approximately 2.9.

  Depending on the alignment state of the first non-woven fabric 7 and the second non-woven fabric 8, a low basis weight may occur on the outer peripheral edge side of the flange portion 3. Therefore, it is preferable to remove the outer peripheral edge side of the flange portion 3 by punching or the like after the formation of the air filter 1. Furthermore, in the side wall 2 a of the filtration unit 2, a high basis weight portion where the first nonwoven fabric 7 is overlapped is generated.

  The air filter 1 filters air sent from the vehicle interior R to the outside S, as shown in FIG. Specifically, the air filter 1 is mounted on a battery cooling device (not shown) in a hybrid vehicle. The air filter 1 is supported by a curved frame-shaped bezel 26 which is detachably attached to the partition wall 25 of the battery storage chamber S partitioned from the vehicle interior R from the vehicle interior R side. In this supported state, the air filter 1 is bent along the curved shape of the bezel 26. Then, the air filter 1 is removed together with the bezel 26 from the partition wall 25 of the battery storage chamber S, whereby the air filter 1 is inspected and cleaned. In addition, as said air filter 1, the form supported by the bezel with the flange part 3 flat may be sufficient.

(3) Effects of the Embodiment According to the method of manufacturing the air filter of this embodiment, the crimped first nonwoven fabric 7 is disposed in the molding die 5, and the outer circumferential portion 11 of the first nonwoven fabric 7 is selected. The first non-woven fabric 7 and the second non-woven fabric 8 are heated and compressed by the forming die 5 in a setting step of arranging the sheet-like second non-woven fabric 8 so as to overlap at least a part including the end side 12 of the pleat line direction P; A forming step of forming the filter portion 2 inside the outer peripheral portion 11 of the first non-woven fabric 7 and integrating the outer peripheral portion 11 of the first non-woven fabric 7 with the second non-woven fabric 8 to form the flange portion 3. Thus, in the air filter 1, the filtration portion 2 is formed of the first non-woven fabric 7 to be low in basis weight and maintain low pressure loss, while the flange portion 3 is formed of the first non-woven fabric 7 and the second non-woven fabric 8 Be reinforced. As a result, the pressure loss of the filtration unit 2 can be reduced, and the strength of the flange 3 can be improved. Moreover, since the air filter 1 is formed only by the nonwoven fabrics 7 and 8, while being able to ensure the freedom degree of a shape, it is excellent in environmental characteristics, such as recyclability. Furthermore, the air filter 1 can be obtained easily and inexpensively in one molding step.

  Further, in the present embodiment, the second non-woven fabric 8 is formed in a frame shape, and in the setting step, the second non-woven fabric 8 overlaps the entire periphery of the outer peripheral portion 11 of the first non-woven fabric 7 in the mold 5. Place. Thereby, the 1st nonwoven fabric 7 and the 2nd nonwoven fabric 8 can be aligned simply and correctly in a set process.

  Further, in the present embodiment, in the forming step, the second nonwoven fabric 8 in which a plurality of sheets are stacked is disposed in the forming die 5. Thereby, the strength of the flange portion 3 can be further improved.

  Furthermore, in the present embodiment, the first non-woven fabric 7 and the second non-woven fabric 8 are formed of the same material. Thereby, the air filter 1 excellent in environmental characteristics, such as recycling, can be provided.

  According to the air filter 1 of this embodiment, the weight per unit area of the flange portion 3 is larger than the weight per unit area of the filtration unit 2. Thereby, the pressure loss of the filtration unit 2 can be reduced, and the strength of the flange 3 can be improved. Furthermore, since the air filter 1 is formed only of the non-woven fabrics 7 and 8, it is possible to secure the freedom of the shape and to be excellent in environmental characteristics such as recyclability.

  Further, in the present embodiment, the ratio (T1 / T2) of the basis weight T1 of the flange portion 3 to the basis weight T2 of the filtration portion 2 is 2.9. Thereby, the reduction of the pressure loss of the filtration part 2 and the strength improvement of the flange part 3 can be made to make it compatible effectively.

  Furthermore, in the present embodiment, the air filter 1 for filtering the air sent from the vehicle interior R to the outside is employed. As a result, in the air filter 1 for filtering the air in the vehicle interior R, the pressure loss of the filtering portion 2 can be reduced, and the strength of the flange portion 3 can be improved. Here, the air in the vehicle interior R filtered by the air filter 1 has a lower degree of contamination than the outside air filtered by an air filter used in an air cleaner or the like of an intake system of an internal combustion engine. Therefore, it is required to use a low basis weight non-woven fabric for the purpose of reducing pressure loss in the air filter 1. According to the air filter 1, even if a low basis weight non-woven fabric is used, the required strength of the flange portion 3 is secured.

Example 2
Next, a method of manufacturing the filter according to the second embodiment will be described. Components substantially the same as the method of manufacturing the filter according to the first embodiment are denoted by the same reference numerals, and detailed description will be omitted.

(1) Method of Manufacturing Filter The method of manufacturing a filter according to the present embodiment is a method of manufacturing an air filter 1, and as shown in FIG. 7, the crimped first non-woven fabric 7 is heated and compressed. As shown in FIG. 8 (a), a pre-forming step of forming the first nonwoven fabric molded body 31 provided with the filtration part 2 and the flange part 32 extending outward from the outer peripheral side of the bottom part of the filtration part 2; As shown in FIG. 8 (b), a setting step of arranging the second nonwoven fabric 8 in the form of a sheet so as to arrange the first nonwoven fabric molded body 31 and to overlap the collar portion 32 of the first nonwoven fabric molded body 31. Forming the flange portion 3 by integrating the flange portion 32 of the first nonwoven fabric molded body 31 and the second nonwoven fabric 8 by heating and compressing the first nonwoven fabric molded body 31 and the second nonwoven fabric 8 with the mold 5; And.

  In the above-mentioned preforming process, as shown in FIG. 7, a preforming mold 34 provided with a pair of molds 35a and 35b which can be approached and separated from each other is used. Each of the pair of molds 35a and 35b includes filtration part forming surfaces 36a and 36b for forming the filtration part 2 and collar part forming surfaces 37a and 37b for forming the collar part 32. . The filtration portion forming surfaces 36 a and 36 b are formed in a pleated shape corresponding to the pleats of the filtration portion 2. Further, the collar portion forming surfaces 37 a and 37 b are disposed on the outer peripheral side of the filtration portion forming surfaces 36 a and 36 b, and are formed in a flat shape corresponding to the collar portion 32.

  In the preliminary forming step, the first nonwoven fabric 7 is heated and compressed by the pair of molds 35a and 35b, whereby the outer peripheral portion 11 of the first nonwoven fabric 7 is crushed by the flange portion forming surfaces 37a and 37b. And while the filtration part 2 is formed inside the outer peripheral part 11 of the 1st nonwoven fabric 7 pinched between each filtration part formation surface 36a, 36b, the 1st pinched between each collar part formation surface 37a, 37b The collar portion 32 is formed at the outer peripheral portion 11 of the nonwoven fabric 7. As a result, the 1st nonwoven fabric molding 31 provided with filtration part 2 and collar part 32 is obtained.

  In the setting step, as shown in FIGS. 8A and 9, at least the ridge line direction P of the pleats of the filter portion 2 of the collar portion 32 of the first nonwoven fabric molded body 31 in the mold 5. The sheet-like second non-woven fabric 8 is disposed so as to overlap the portion connected to 14. Specifically, in the setting step, the frame-shaped second non-woven fabric 8 is disposed in the molding die 5 so as to overlap over the entire circumference of the flange portion 32 of the first non-woven fabric molded body 31.

  In the forming step, as shown in FIG. 8B, the first non-woven fabric molded body 31 and the second non-woven fabric 8 are heated and compressed by the pair of molds 35a and 35b to form the flange portion forming surfaces 23a and 23b. The collar portion 32 of the first nonwoven fabric molded body 31 and the second nonwoven fabric 8 are crushed and integrated. Then, the flange portion 3 is formed by the flange portion 32 of the first nonwoven fabric molded body 31 and the second nonwoven fabric 8 which are sandwiched between the flange portion forming surfaces 23a and 23b. As a result, the air filter 1 provided with the filtration part 2 and the flange part 3 is obtained.

(2) Effects of the Embodiment According to the method of manufacturing the filter of this embodiment, the crimped first non-woven fabric 7 is heated and compressed to expand outwardly from the filter portion 2 and the outer peripheral side of the bottom portion of the filter portion 2 The first nonwoven fabric molded body 31 is disposed in the mold 5 and a preforming step of molding the first nonwoven fabric molded body 31 provided with the portion 32, and at least filtration of the collar portion 32 of the first nonwoven fabric molded body 31 A setting step of arranging the sheet-like second non-woven fabric 8 so as to overlap the end 14 of the ridge line direction P of the fold of the part 2 and heating the first non-woven fabric molded body 31 and the second non-woven fabric 8 with the mold 5 And forming the flange portion 3 by integrating the collar portion 32 of the first nonwoven fabric molded body 31 and the second nonwoven fabric 8 by compression. Thus, in the air filter 1, the filtration portion 2 is formed of the first non-woven fabric 7 to be low in basis weight and maintain low pressure loss, while the flange portion 3 is formed of the first non-woven fabric 7 and the second non-woven fabric 8 Be reinforced. As a result, the pressure loss of the filtration unit 2 can be reduced, and the strength of the flange 3 can be improved. Moreover, since the air filter 1 is formed only by the nonwoven fabrics 7 and 8, while being able to ensure the freedom degree of a shape, it is excellent in environmental characteristics, such as recyclability. Furthermore, since the posture of the first nonwoven fabric molded body 31 is stable, the first nonwoven fabric molded body 31 and the second nonwoven fabric 8 can be aligned easily and accurately in the setting process.

  Further, in the present embodiment, the second non-woven fabric 8 is formed in a frame shape, and in the setting step, the second non-woven fabric 8 overlaps the entire periphery of the collar portion 32 of the first non-woven fabric molded body 31 in the mold 5. The non-woven fabric 8 is placed. Thereby, in the setting process, the first nonwoven fabric molded body 31 and the second nonwoven fabric 8 can be aligned easily and accurately.

  Further, in the present embodiment, in the forming step, the second nonwoven fabric 8 in which a plurality of sheets are stacked is disposed in the forming die 5. Thereby, the strength of the flange portion 3 can be further improved.

  Furthermore, in the present embodiment, the first non-woven fabric 7 and the second non-woven fabric 8 are formed of the same material. Thereby, the air filter 1 excellent in environmental characteristics, such as recycling, can be provided.

  In the present invention, the present invention is not limited to the above-described embodiment, and can be variously modified within the scope of the present invention according to the purpose and application. That is, although the setting process which arrange | positions the single 2nd nonwoven fabric 8 integrally formed in the shaping | molding die 5 in the said Example was illustrated, it is not limited to this, For example, as shown in FIG. According to the portion of the outer peripheral portion 11 of the first non-woven fabric 7 (or the flange 32 of the first non-woven fabric molded body 31), the plurality of second non-woven fabrics 8 are planar A setting process may be employed in which the position is shifted to the inside of the mold 5 and the position is shifted. Thereby, since the shape freedom of the 2nd nonwoven fabric 8 is high, the material yield of a nonwoven fabric can be improved.

  In the above-mentioned embodiment, for example, as shown in FIG. 10A, the outer peripheral portion 11 of the first nonwoven fabric 7 (or the flange 32 of the first nonwoven fabric molded body 31) And the U-shaped second non-woven fabric 8 may be disposed to overlap with each of the divided portions. Furthermore, for example, as shown in FIGS. 10 (b) and 10 (c), in the outer peripheral portion 11 of the first non-woven fabric 7, the end side 12 of the ridge line direction P of the fold and the portion 12 extended in the continuous direction Q of the fold. The second non-woven fabric 8 may be disposed so as to overlap each of the two sides including.

  Moreover, in the said Example, although the edge part 13 of the 1st nonwoven fabric 7 folded in multiple numbers was illustrated, it is not limited to this, For example, you may employ | adopt the edge part of the 1st nonwoven fabric which is not folded back. Further, in the above embodiment, the second nonwoven fabric 8 having a multilayer structure in which a plurality of sheets are stacked is exemplified, but the present invention is not limited to this. For example, the second nonwoven fabric having a single layer structure (that is, one second nonwoven fabric) It may be adopted.

  Moreover, in the said Example, although formed from the same material and illustrated the 1st and 2nd nonwoven fabrics 7 and 8 which have the same basis weight, it is not limited to this, For example, the 1st and the 1st formed from a different material 2 Non-woven fabrics may be employed, or first and second non-woven fabrics having different basis weight may be employed.

  Moreover, in the setting process of the said Example, the arrangement | positioning order in particular of the 1st nonwoven fabric 7 (or 1st nonwoven fabric molded object 31) and the 2nd nonwoven fabric 8 with respect to the shaping | molding die 5 does not matter. For example, the two may be arranged simultaneously in an overlapping state, or one may be arranged and the other may be arranged.

  In the above embodiment, the mold 5 in which the mold clamping direction is the vertical direction is exemplified. However, the present invention is not limited to this. For example, a mold having the mold clamping direction in the horizontal direction or an oblique direction may be adopted. .

  Further, in the above embodiment, although the first non-woven fabric molded body 31 is formed by the preforming mold 34 and the air filter 1 is formed by the forming mold 5, the present invention is not limited thereto. The first nonwoven fabric molded body 31 and the air filter 1 may be molded at 5.

  Moreover, although the form which forms perfect filtration part 2 in the pre-forming process was illustrated in the said Example, it is not limited to this, For example, an incomplete filtration part is formed in a pre-forming process May be formed.

  Furthermore, in the above embodiment, the air filter 1 for filtering the air delivered to the outside from the vehicle interior R is illustrated, but the invention is not limited thereto. For example, an air filter used in an air cleaner of an intake system of an internal combustion engine The air filter may be used in an air conditioner. Furthermore, it may be a gas filter for filtering out gas other than air such as fuel gas, or may be a liquid filter for filtering out liquid such as oil.

  The foregoing examples are for illustrative purposes only and are not to be construed as limitations on the present invention. While the present invention has been described by way of exemplary embodiments, it is understood that the words used in the description and illustration of the present invention are illustrative and exemplary rather than restrictive. Changes may be made within the scope of the appended claims without departing from the scope or spirit of the invention in its form, as detailed herein. While the specification herein has been directed to specific structures, materials, and examples, the present invention is not intended to be limited to the particulars disclosed herein, but rather is as follows: It shall cover all functionally equivalent structures, methods, and uses within the scope.

  The invention is not limited to the embodiments detailed above, but various modifications or alterations are possible within the scope of the claims of the invention.

  The present invention is widely used as a technology related to a filter for filtering a fluid.

  DESCRIPTION OF SYMBOLS 1; Air filter, 2; Filter part, 3; Flange part, 5; Mold | molding die, 7; 1st nonwoven fabric, 8; 2nd nonwoven fabric, 11; Outer peripheral part of 1st nonwoven fabric, 12; End side of direction, 14; end side of ridge line direction of pleat of filtration part, 31; first non-woven fabric molded body, 32; collar portion, P; ridge line direction of pleat, Q: continuous direction of pleat.

Claims (6)

A method of manufacturing a non-woven filter, comprising: a filtration part formed with folds; and a flange part extending outward from an outer peripheral side of a bottom part of the filtration part,
A sheet-like second non-woven fabric is disposed so as to arrange the first non-woven fabric folded in folds and to overlap at least a portion of the outer circumferential portion of the first non-woven fabric including the end side in the ridge line direction Set process to arrange,
The first non-woven fabric and the second non-woven fabric are heated and compressed by the molding die to form the filtration portion inside the outer circumferential portion of the first non-woven fabric, and the outer circumferential portion of the first non-woven fabric and the second non-woven fabric Forming a flange portion integrally with each other, and a method of manufacturing a filter. The second non-woven fabric is formed in a frame shape,
The method according to claim 1, wherein in the setting step, the second non-woven fabric is disposed in the mold so as to overlap over the entire circumference of the outer periphery of the first non-woven fabric.   2. The method according to claim 1, wherein in the setting step, the plurality of second non-woven fabrics are arranged in the plane direction at different positions in the mold according to the portion of the outer peripheral portion of the first non-woven fabric.   The method for manufacturing a filter according to any one of claims 1 to 3, wherein in the setting step, the plurality of second non-woven fabrics stacked are disposed in the mold. A method of manufacturing a non-woven filter, comprising: a filtration part formed with folds; and a flange part extending outward from an outer peripheral side of a bottom part of the filtration part,
A preforming step of heat-compressing the crimped first non-woven fabric to form the first non-woven fabric molded body having the filter portion and a flange portion extending outward from the outer periphery of the bottom portion of the filter portion;
The first nonwoven molded article is disposed in the mold, and at least one of the flanges of the first nonwoven molded article is in a sheet form so as to overlap at least the end of the filtration section along the ridge line direction. Setting the second nonwoven fabric of
Forming the flange portion by integrating the first non-woven fabric and the second non-woven fabric by heating and compressing the first non-woven fabric and the second non-woven fabric with the forming die; A method of manufacturing a filter, comprising: A non-woven filter comprising a filtration part formed with folds and a flange part extending outward from the outer periphery of the bottom part of the filtration part,
A filter characterized in that a weight per unit area of the flange portion is larger than a weight per unit area of the filtration unit.

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