JP7507335B2 - Air Purifier Filter - Google Patents

Description

The present invention relates to an air purifying filter for use in, for example, air conditioning equipment.

Conventionally, this type of air purifying filter is composed of a net through which air flows and a reinforcing section. The reinforcing section is lattice-shaped, with multiple bar-shaped horizontal reinforcing sections extending horizontally and multiple bar-shaped vertical reinforcing sections extending vertically perpendicular to the horizontal direction. The horizontal and vertical reinforcing sections that make up the lattice are provided on the windward side of the net. The net is heat-welded to the horizontal and vertical reinforcing sections. (Note that a related prior document is Patent Document 1 listed below.)

JP 2019-060583 A

The problem with such conventional air purification filters is that it is difficult to clean the net along the horizontal reinforcement from the windward surface in the air flow. The horizontal reinforcement and vertical reinforcement are provided along the windward surface. Therefore, when cleaning the net with a vacuum cleaner or the like along the horizontal reinforcement from the windward surface in the air flow, dust tends to get caught in the vertical reinforcement, making it difficult to clean the net.

In order to achieve this objective, the present invention provides a net through which an air flow passes, a plurality of rod-shaped first reinforcing portions provided along the windward surface of the net and extending in a first direction which is the left-right direction, a plurality of rod-shaped second reinforcing portions provided along the leeward surface of the net and extending in a second direction which is perpendicular to the first direction, and a frame portion connecting ends of the net, the first reinforcing portions, and the second reinforcing portions, wherein the plurality of first reinforcing portions are arranged in a line in the second direction, the plurality of second reinforcing portions are arranged in a line in the first direction, the distance between adjacent first reinforcing portions is smaller than the distance between adjacent second reinforcing portions, and only the first reinforcing portions are provided on the windward surface of the net , thereby achieving the desired objective.

According to the present invention, the first reinforcing portion is provided along the windward side, and the second reinforcing portion is provided along the leeward side. Therefore, the second reinforcing portion does not exist on the windward side. As a result, when cleaning the net with a vacuum cleaner or the like along the first reinforcing portion from the windward surface in the air flow, dust is less likely to get caught on the second reinforcing portion, making it easier to clean the net.

FIG. 1 is an external perspective view of a dehumidifier according to a first embodiment of the present invention; FIG. Schematic cross-sectional view of the dehumidifier Schematic cross-sectional view of the dehumidifier FIG. 2 is a perspective view of the appearance of a radiator of the dehumidifier; FIG. 2 is a perspective view of the heat sink of the dehumidifier; FIG. 3 is a perspective view of a partition of the dehumidifier; FIG. 3 is a perspective view of a partition of the dehumidifier;

The following describes an embodiment of the present invention with reference to the drawings.

(Embodiment 1)
FIG. 1 is an external perspective view of the dehumidifier according to the first embodiment of the present invention. FIG. 2 is an exploded perspective view of the dehumidifier according to the first embodiment of the present invention. Note that FIGS. 1 and 2 are views of the dehumidifier as seen from the rear side. FIG. 3 and FIG. 4 are schematic cross-sectional views of the dehumidifier according to the first embodiment of the present invention. Note that FIG. 3 is a cross-sectional view taken along line A-A in FIG. 1. FIG. 4 is a cross-sectional view taken along line B-B in FIG. 1. Note that, for convenience of explanation, the following description may be used. That is, the vertical direction in a state in which the dehumidifier 100 is installed as shown in FIG. 1 may be described as the up-down direction. Similarly, the upper surface of the dehumidifier 100 in a state in which the dehumidifier 100 is installed as shown in FIG. 1 may be described as the "top surface". Similarly, the front surface of the dehumidifier 100 in a state in which the dehumidifier 100 is installed as shown in FIG. 1 may be described as the "front surface", and the rear surface of the dehumidifier 100 may be described as the "rear surface".

As shown in Figures 1, 2, 3, and 4, the main body case 1 has a horizontally long, approximately rectangular parallelepiped shape. Specifically, the main body case 1 has a shape in which the size in the horizontal direction W is larger than the size in the depth direction D and the vertical direction H, and an intake port 2 is arranged on the rear surface of the main body case 1 (one side surface in the depth direction of the main body case 1). An exhaust port 3 is arranged on the upper part of the main body case 1. The exhaust port 3 has a horizontally long rectangular shape and opens to the top and rear surface of the main body case 1. The rear side of the top surface of the main body case 1 (one side surface in the depth direction of the main body case 1) has a louver 4 that changes the direction of air from the exhaust port 3, and the front side of the top surface of the main body case 1 (the other side in the depth direction of the main body case) has an operation unit 5. The operation unit 5 has multiple switches for turning the power on and off, changing the operating mode, etc.

The main body case 1 contains a heat pump 6, a blower section 7, a dehumidifier rotor section 8, a mounting base 9, a water tank section 10, and a control section 11.

The heat pump 6 is configured to circulate the refrigerant by sequentially connecting a compressor 12, a radiator 13, an expander 14, and a heat absorber 15 in a ring shape.

The compressor 12 is located on the left side of the main body case 1 (one side in the horizontal (longitudinal) direction of the main body case) when viewed from the front side of the main body case 1. The compressor 12 is fixed to the bottom surface of the main body case 1.

The heat sink 13 is disposed on the rear side of the main case 1 (one side in the depth direction of the main case). The heat sink 13 is disposed on the bottom surface of the main case 1 so that the gaps between adjacent heat sink fins of the heat sink 13 (described later) face the air intake 2 of the main case 1.

Figure 5 is an external perspective view of the heat radiator of the dehumidifier according to the first embodiment of the present invention. Note that Figure 5 is a view of the heat radiator of the dehumidifier as seen from the rear side.

As shown in FIG. 5, the heat sink 13 has a number of heat sink fins 13a and a connecting pipe 13b that connects the fins.

The heat dissipation fins 13a are in the shape of vertically elongated rectangular plates and are made of aluminum. The numerous heat dissipation fins 13a are arranged so that the faces of adjacent heat dissipation fins 13a face each other. The gaps between adjacent heat dissipation fins 13a form air passages.

The connecting pipe 13b is cylindrical and made of copper. The cylindrical connecting pipe 13b is provided in multiple stages in the longitudinal direction of the heat dissipation fin 13a and is bent in a serpentine shape multiple times. A large number of heat dissipation fins 13a are fixed to the straight pipe portion of the connecting pipe 13b. The large number of heat dissipation fins 13a are stacked at a predetermined interval in the central axial direction of the straight pipe portion of the connecting pipe 13b.

As shown in Figures 2 and 4, the heat absorber 15 is located on the right side of the main case 1 (the other side of the main case 1 in the horizontal direction) when viewed from the front of the main case 1, and is fixed to the mounting base 9 so that the central axis of the air passage, which is the gap between adjacent heat absorption fins 15a in the heat absorber 15 described below, extends in the left-right direction of the main case 1.

Figure 6 is an external perspective view of the heat absorber of the dehumidifier according to the first embodiment of the present invention. Note that Figure 6 shows the heat radiator of the dehumidifier as viewed from the left side of the main body case.

As shown in FIG. 6, the heat sink 15 has a number of heat absorbing fins 15a and a connecting pipe 15b that connects the fins.

The heat absorbing fins 15a are rectangular plates that are elongated and made of aluminum. The numerous heat absorbing fins 15a are arranged so that the faces of adjacent heat absorbing fins 15a face each other. The gaps between adjacent heat absorbing fins 15a form air passages.

The connecting pipe 15b is cylindrical and made of copper. The cylindrical connecting pipe 15b is provided in multiple stages in the longitudinal direction of the heat absorption fins 15a and is bent in a serpentine shape multiple times. A large number of heat absorption fins 15a are fixed to the straight pipe portion of the connecting pipe 15b. The large number of heat absorption fins 15a are stacked at a predetermined interval in the central axial direction of the straight pipe portion of the connecting pipe 15b.

As shown in Figures 2 and 4, the blower 7 is disposed opposite the heat sink 13 and is fixed to the mounting base 9. The blower 7, the heat sink 13, and the intake port 2 of the main body case 1 are disposed on a straight line in the depth direction of the main body case 1. The blower 7 has a motor 16, a fan 17 rotated by the motor 16, and a casing 18 surrounding the fan 17.

The fan 17 is a turbofan and has a main plate 17a, multiple blades 17b, and a suction ring 17c.

The main plate 17a is generally disk-shaped with a downwardly convex central portion, and a cylindrical rotating shaft fixing portion 17d is provided in the central portion. The rotating shaft fixing portion 17d is structured so that the rotating shaft of the motor 16 can be inserted and fixed to this rotating shaft. The peripheral portion of the main plate 17a has a plurality of blades 17b extending downward from the main plate 17a, and the blades 17b have a wing-like horizontal cross-sectional shape. The end of the blades 17b on the peripheral side of the main plate 17a is shaped to face in the opposite direction to the rotation direction of the fan 17. The lower ends of the plurality of blades 17b have an annular suction ring 17c.

The casing 18 has an intake port 18a on the bottom surface and an exhaust port 18b on the top surface. When the motor 16 rotates the fan 17, air is sucked in through the intake port 18a of the casing 18 and flows into the fan 17 through the suction ring 17c of the fan 17. This air flows in and is blown out in the radial direction of the fan 17 along the blades 17b, and is sent to the air outlet 3 of the main body case 1 through the exhaust port 18b of the casing 18.

The dehumidifying rotor section 8 is disposed between the blower section 7 and the heat absorber 15. The heat absorber 15, the dehumidifying rotor section 8, and the blower section 7 are disposed in a straight line in the horizontal direction of the main body case 1. The dehumidifying rotor section 8 has a dehumidifying rotor 19, a rotor frame 20, a drive section 21, and a heating section 22.

The dehumidifying rotor 19 has an overall shape of a disk. This disk is a circular ring with an air vent inside. The air vent is made by winding a zigzag second band (not shown) between two first bands (not shown) in a spiral shape from the inner circumference to the outer circumference inside the circular ring to create an air vent structure. The first and second bands are made of heat-resistant fibers, and a moisture absorbing material such as zeolite is bonded to their surfaces with, for example, a silica-based adhesive.

The dehumidifying rotor 19 is formed as a disk, and is rotatably mounted on the rotor frame 20 so that its central axis extends in the left-right direction of the main body case 1, and is rotated by a drive part 21. The rotor frame 20 is fixed to the mounting base 9. The dehumidifying rotor 19 has a moisture absorbing section 19a that absorbs moisture from the air, and a moisture releasing section 19b that releases moisture into the air.

The heating portion 22 is installed so as to face the moisture discharging portion 19b of the dehumidifying rotor 19. The heating portion 22 is disposed upstream of the moisture discharging portion 19b of the dehumidifying rotor 19 in the air path described below.

The mounting base 9 is box-shaped with openings on the bottom and front sides of the main case 1, and has a mounting plate 9a and support legs 9b.

The mounting plate 9a is a roughly rectangular plate, and the blower section 7, dehumidifier rotor section 8, and heat sink 15 are fixed to the top surface.

The support legs 9b are three rectangular plates that extend downward from the periphery of the mounting plate 9a, and extend downward from the rear, right, and left sides of the main body case 1 at the periphery of the mounting plate, and the three plates are formed integrally. The support legs 9b have a space 9c of approximately rectangular parallelepiped shape between the mounting plate 9a and the bottom surface of the main body case 1. The height of the space 9c is approximately the same as the height dimension of the support legs 9b, and the water storage tank section 10 is attached to the space 9c.

The water storage tank section 10 is disposed in the space 9c at the bottom of the main body case 1, and is configured to be freely attached and detached from the front of the main body case 1 (one side in the depth direction of the main body case). The attachment and detachment direction of the water storage tank section 10 is the front-rear direction of the main body case 1 (depth direction of the main body case). The air blower section 7, the dehumidification rotor section 8, and the heat absorber 15 are disposed above the water storage tank section 10. The water storage tank section 10 has a flat box-shaped tank 10a with an open top, and a funnel-shaped water collection cover 10b. The water collection cover 10b is detachably provided on the top of the tank 10a. In other words, condensation occurs in the heat absorber 15, and the condensed water is collected by the funnel-shaped water collection cover 10b and flows into the tank 10a.

The control unit 11 is located on the right side of the main body case 1 (one side in the horizontal direction of the main body case 1) when viewed from the front side of the main body case 1. The control unit 11 is fixed on the bottom surface of the main body case 1. The control unit 11 controls the motor 16 of the blower unit 7, the compressor 12, and the drive part 21 and heating part 22 of the dehumidification rotor unit 8 based on the switches of the operation unit 5 pressed by the user.

The main body case 1 includes a first air passage 23 and a second air passage 24.

The first air passage 23 is an air passage that draws air from the air intake 2 by the air blower 7, supplies it to the heat sink 13, the heating section 22, the moisture release section 19b, the heat absorber 15, and the moisture absorption section 19a in that order, and then exhausts it from the air outlet 3 via the air blower 7.

The second air passage 24 is an air passage through which the air blower 7 draws air in through the intake port 2, supplies it to the radiator 13, and exhausts it from the outlet port 3 via the air blower 7.

In more detail, in the first air passage 23, the indoor air warmed by the radiator 13 is further warmed by the heating section 22 and supplied to the moisture discharge section 19b of the dehumidifier rotor 19. In the moisture discharge section 19b, the moisture adsorbed by the moisture absorption section 19a moves to the moisture discharge section 19b by the rotational drive of the dehumidifier rotor 19, and is released into the supplied air by the heating of the heating section 22. This highly humid air is supplied to the heat absorber 15, where it is cooled to condense, and the moisture is removed as water droplets. The cooled air is then supplied to the moisture absorption section 19a of the dehumidifier rotor 19, and the moisture in the air is further adsorbed by the moisture absorption section 19a, becoming dry air. Furthermore, since heat of adsorption is generated when the moisture is adsorbed, the indoor air is sucked into the blower section 7 in a state where the humidity is reduced and the temperature is increased, and it is blown into the room from the air outlet 3. In addition, the moisture that condenses in the heat absorber 15 drips downward as water droplets and flows into the tank 10a of the water storage tank section 10.

In the second air passage 24, the indoor air warmed by the radiator 13 is sucked into the air blower 7 and blown into the room from the air outlet 3. In other words, the air passing through the first air passage 23 and the air passing through the second air passage 24 are mixed in the air blower 7 and are blown out of the air outlet 3 by the air blower 7.

An air purifying filter 30 is fixed to the air inlet 2. The air purifying filter may be configured to be detachable from the air inlet 2.

The air purification filter 30 has a net 31, a first reinforcing portion 32, a second reinforcing portion 33, and a frame portion 34.

The net 31 has many small openings through which air can pass. For example, it has a flexible structure in which multiple resin fibers are arranged in parallel at a certain distance from each other and then woven vertically in a lattice pattern.

The first reinforcing parts 32 are rod-shaped and are provided along the windward side (the outer surface of the main body case) of the net 31, extending in a first direction (the left-right direction of the main body case), and are arranged in a line in a second direction (the up-down direction of the main body case) perpendicular to the first direction. The net 31 is fixed to the first reinforcing parts 32.

The second reinforcing parts 33 are rod-shaped and are provided along the downwind side (inner surface of the main body case) of the net 31, extending in the second direction (up-down direction of the main body case), and arranged in a row in the first direction (left-right direction of the main body case). The net 31 is fixed to the second reinforcing parts 33. When the net 31 is viewed from the upwind side in the air flow, the first reinforcing parts 32 and the second reinforcing parts 33 overlap to form a lattice shape. The net 31 is arranged between the first reinforcing parts 32 and the second reinforcing parts 33.

The frame portion 34 is a rectangular ring shape and connects the ends of the net 31, the first reinforcing portion 32, and the second reinforcing portion 33.

The feature of this embodiment is that multiple rod-shaped first reinforcing parts 32 extending in a first direction are provided along the windward surface of the net 31, and multiple rod-shaped second reinforcing parts 33 extending in a second direction are provided along the leeward surface of the net 31.

As a result, the first reinforcement portion 32 is provided along the windward side, and the second reinforcement portion 33 is provided along the leeward side. Therefore, the second reinforcement portion 33 is not present on the windward side. As a result, when the net 31 is cleaned with a brush or the like along the first reinforcement portion 32 from the windward surface in the air flow, dust is less likely to get caught on the second reinforcement portion, making it easier to clean the net.

In addition, the distance between adjacent first reinforcement portions 32 is smaller than the distance between adjacent second reinforcement portions 33.

This makes the net 31 less likely to come off when pushed from the windward or leeward side, increasing its strength. Furthermore, the area of the second reinforcing portion 33 on the leeward side that is visible from the windward side is reduced. This improves the appearance of the air purifying filter 30 when viewed from the windward side.

The dimension of the second reinforcement part 33 in the first direction is smaller than the dimension of the first reinforcement part 32 in the second direction. Specifically, the thickness of the rod-shaped second reinforcement part 33 is smaller than the thickness of the rod-shaped first reinforcement part 32.

This further reduces the area of the second reinforcing portion 33 on the leeward side that is visible from the windward side. This improves the appearance of the air cleaning filter 30 when viewed from the windward side.

The net 31 also has a number of third reinforcement sections 35 that are provided along the leeward side of the first reinforcement sections 32 and connect adjacent second reinforcement sections 33 to each other.

As a result, the net 31 is sandwiched between the first reinforcing part 32 and the third reinforcing part 35. Therefore, when the net 31 is pushed from the windward or leeward side, the net 31 is less likely to peel off, and its strength is increased.

The net 31 is insert molded into the first reinforcement portion 32, the second reinforcement portion 33, the third reinforcement portion 35, and the frame portion 34. The first reinforcement portion 32, the second reinforcement portion 33, and the third reinforcement portion 35 are made of a resin material and are injection molded, and the net 31 is insert molded into the first reinforcement portion 32, the second reinforcement portion 33, and the third reinforcement portion 35 when the first reinforcement portion 32, the second reinforcement portion 33, and the third reinforcement portion 35 are injection molded. In other words, the first reinforcement portion 32, the second reinforcement portion 33, and the third reinforcement portion 35 are injection molded products made of a resin material. The net 31 is fixed to the first reinforcement portion 32, the second reinforcement portion 33, and the third reinforcement portion 35. The net 31, the first reinforcement portion 32, the second reinforcement portion 33, and the third reinforcement portion 35 are insert molded products.

Here we explain an example of insert molding.

First, the net 31 is attached to the cavity mold (fixed side) when injection molding the air purifying filter 30. The cavity mold (fixed side) has multiple needle-like protrusions, and the net 31 is inserted into these protrusions and attached to the cavity mold (fixed side). When the net 31 is attached to the cavity mold (fixed side), part of one side of the net 31 comes into contact with part of the cavity mold (fixed side).

Next, the core mold (movable side) moves toward the cavity mold (fixed side). At this time, a part of the core mold (movable side) comes into contact with a part of the other surface of the net 31. There is a partial gap between the cavity mold (fixed side) that is not in contact with the net 31 and the core mold (movable side) that is not in contact with the net 31.

Next, resin is poured into the gap between the cavity mold (fixed side) and the core mold (movable side). The resin that has flowed into the gap between the cavity mold (fixed side) and the core mold (movable side) becomes the first reinforcing section 32, the second reinforcing section 33, and the third reinforcing section 35. At this time, some of the resin that has flowed into the gap between the cavity mold (fixed side) and the core mold (movable side) also enters the opening of the net 31.

Next, after the resin has hardened, the core mold (movable side) moves together with the air purification filter 30 and separates from the cavity mold (fixed side).

Finally, the air cleaning filter 30 is pushed out from the core mold (movable side) by the ejection pin protruding from the core mold (movable side) and removed.

Generally, in the case of suction inlets, the cavity type (fixed side) is on the windward side (exterior side) and the core type (movable side) is on the leeward side (interior side).

The third reinforcement portion 35 protrudes from the center of the first reinforcement portion 32 in the second direction toward the downwind side. The dimension of the third reinforcement portion 35 in the second direction is smaller than the dimension of the first reinforcement portion 32 in the second direction.

As a result, when the core mold (movable side) moves toward the cavity mold (fixed side) and a part of the cavity mold (fixed side) comes into contact with a part of the other side of the net 31, the net 31 is less likely to break and its strength is increased.

The air purifying filter of the present invention is useful as an air purifying filter for use in air conditioning systems.

REFERENCE SIGNS LIST 1 main body case 2 suction port 3 outlet port 4 louver 5 operation section 6 heat pump 7 blower section 8 dehumidification rotor section 9 mounting base 9a mounting plate 9b support leg 9c space section 10 water storage tank section 10a tank 10b water collection cover 11 control section 12 compressor 13 radiator 13a heat radiation fin 13b connecting pipe 14 expander 15 heat absorber 15a heat absorption fin 15b connecting pipe 16 motor 17 fan 17a main plate 17b blade 17c suction ring 17d rotating shaft fixing section 18 casing 18a intake port 18b outlet port 19 dehumidification rotor 19a moisture absorption section 19b moisture release section 20 rotor frame 21 Driving part 22 Heating part 23 First air passage 24 Second air passage 30 Air cleaning filter 31 Net 32 First reinforcing part 33 Second reinforcing part 34 Frame part 35 Third reinforcing part

Claims (3)

A net through which the air flow passes;
A plurality of rod-shaped first reinforcing parts provided along the windward surface of the net and extending in a first direction which is the left-right direction;
A plurality of rod-shaped second reinforcing parts are provided along the leeward surface of the net and extend in a second direction perpendicular to the first direction;
A frame portion that connects ends of the net, the first reinforcing portion, and the second reinforcing portion,
The first reinforcing portions are arranged side by side in the second direction,
The second reinforcing portions are arranged side by side in the first direction,
a distance between adjacent first reinforcing portions is smaller than a distance between adjacent second reinforcing portions,
An air cleaning filter, characterized in that only the frame portion and the first reinforcing portion are provided on the windward surface of the net . The air cleaning filter according to claim 1, characterized in that the dimension of the second reinforcing part in the first direction is smaller than the dimension of the first reinforcing part in the second direction. An air cleaning filter as described in claim 1 or 2, characterized in that it has a plurality of third reinforcing parts that are provided on the leeward side of the first reinforcing parts along the leeward surface of the net and connect adjacent second reinforcing parts to the second reinforcing parts.