Television Manufacturing Process

Housing

Almost all television housings are made of plastic by the process of injection molding, in
which precision molds are made and liquid plastic is injected under high pressure to fill the
molds. The pieces are released from the molds, trimmed, and cleaned. They are then
assembled to complete the housing. The molds are designed so that brackets and supports for
the various components are part of the housing.

Picture tube

The television picture tube, or cathode ray tube (CRT), is made of precision glass that is
shaped to have a slightly curved plate at the front or screen. It may also have a dark tint added
to the face plate glass, either during production of the glass or by application directly to the
inside of the screen. Darker face plates produce improved picture contrast. When the tube is
manufactured, a water suspension of phosphor chemicals is allowed to settle on the inside of
the face plate, and this coating is then overlaid with a thin film of aluminum that lets
electrons pass through. The aluminum serves as a mirror to prevent light from bouncing back
into the tube.

Glass for picture tubes is supplied by a limited number of manufacturers in Japan and
Germany. Quantities of the quality of glass needed for picture tubes are limited, and the
emergence of large-screen sets has created a shortage in this portion of the industry. The large
screens are also very heavy, so flat-panel displays using plasma-addressed liquid crystal
(PALC) displays were developed in the 1980s. This gas plasma technology uses electrodes to
excite layers of neon or magnesium oxide, so they release ultraviolet radiation that activates
the phosphor on the back of the television screen. Because the gas is trapped in a thin layer,
the screen can also be thin and lightweight. Projection TVs use digital micro mirror devices
(DMDs) to project their pictures.

A shadow mask with 200,000 holes lies immediately behind the phosphor screen; the holes
are precisely machined to align the colors emitted by three electron beams. Today's best
picture tubes have shadow masks that are manufactured from a nickel-iron alloy called Invar;
lesser quality sets have masks of iron. The alloy allows the tube to operate at a higher
temperature without distorting the picture, and higher temperatures allow brighter pictures.
Rare-earth elements have also been added to the phosphor coating inside the tube to improve
brightness.

The electrons are fired by three tubular, metal electron guns that are carefully seated in the
neck, or narrow end, of the tube. After the electron guns are placed inside the tube, the
picture tube is evacuated to a near vacuum so air does not interfere with the movement of the
electrons. The small opening at the rear of the tube is sealed with a fitted electrical plug that
will be positioned near the back of the set. A deflection yoke, consisting of several
electromagnetic coils, is fitted around the outside of the neck of the picture tube. The coils
cause pulses of high voltage to direct the scanning electron beams in the proper direction and
speed.

Audio system

The housing also contains fittings for speakers, wiring, and other parts of the audio system.
The speakers are usually made by a specialized manufacturer to the specifications of the
television manufacturer, so they are assembled in the set as components or a subassembly.
Electronic sound controls and integrated circuitry are assembled in panels in the set as it
travels along the assembly line.

Electronic parts

When the picture tube and the audio speakers and attachments are assembled in the set, other
electronic elements are added to the rear of the set. The antennae, cable jacks, other input and
output jacks, the electronics for receiving remote control signals, and other devices are
prepared by specialty contractors or as subassemblies else-where on the assembly line. They
are then mounted in the set, and the housing is closed.
Refrigerator Manufacturing Process

Outer cabinet and door

Pieces of sheet metal are either welded or clinched together. Clinching is a process closely
resembling stapling in that the two pieces are crimped together under pressure, though no
additional pieces such as staples are added. If the part of the cabinet is to be visible, it will be
welded and ground down to appear as one piece. The extent to which the welding process is
automated depends on the company and the number of refrigerators being produced.

If the sheet metal was not purchased in precoated form, it is now painted. Some
manufacturers use spray equipment to lay a uniform coat of paint on the metal. Others dip
the parts in a paint/solvent mixture before heating them to bake the paint onto the surface.

Inner cabinet

The inner cabinet is sometimes made from sheet metal very similar to the outer shell. Any
seams are caulked to improve insulation and looks. Some manufacturers and some models
use plastic for inner liners; for example, the inner door is almost exclusively made from
plastic today. The plastic liners are vacuum formed. In this process, a thick piece of plastic
slightly larger than the finished part has its outer edges clamped and is then heated. The hot
plastic is next pulled by vacuum into a mold and cooled. After trimming, the resulting part is
ready for assembly.

The inner cabinet is inserted into the outer cabinet, and the two are snapped together before
the fixtures are inserted. Some tubes and wires are run through the gap between the two
before it is filled with insulation. A dispensing device (sometimes robotically operated,
sometimes a manually operated long 'gun') inserts foam between the walls. When heated in
an oven, this foam expands to add rigidity and insulation to the cabinet. A similar process is
used for the doors.

Cooling system

The refrigeration components are attached to the cabinet using screws and clips. The tubing is
soldered together, and a protective coating is sprayed on the joints. The order of this
assembly varies between manufacturers and models. The copper tubing from which the coils
(condensers and evaporators) have separately been cut, bent, and soldered is then attached to
the refrigerator as a unit.

The seal on the refrigerator door is created by means of magnet laden gaskets that are
attached to the doors with screws. Handles and hinges are also screwed onto the door before
its hinges are screwed onto the cabinet. Some adjustment is allowed for proper operation of
the door.

Testing and adding accessories

Most manufacturers mix testing with manufacturing from this point on. The unit is leak tested
with nitrogen (a safe gas that makes up about 79 percent of the air); if it passes, it is charged
with refrigerant and subjected to further testing. Next, the accessories (shelves, crispers, ice
trays, etc.) are added and taped down for shipping. The unit is given a final look and then
packaged for shipping.

Air Conditioner Manufacturing Process

Creating encasement parts from galvanized sheet metal and structural steel

Most air conditioners start out as raw material, in the form of structural steel shapes and sheet
steel. As the sheet metal is processed into fabrication cells or work cells, it is cut, formed,
punched, drilled, sheared, and/or bent into a useful shape or form. The encasements or
wrappers, the metal that envelopes most outdoor residential units, is made of galvanized sheet
metal that uses a zinc coating to provide protection against corrosion. Galvanized sheet metal
is also used to form the bottom pan, face plates, and various support brackets throughout an
air conditioner. This sheet metal is sheared on a shear press in a fabrication cell soon after
arriving from storage or inventory. Structural steel shapes are cut and mitered on a band saw
to form useful brackets and supports.
Punch pressing the sheet metal forms

From the shear press, the sheet metal is loaded on a CNC (Computer Numerical Control)
punch press. The punch press has the option of receiving its computer program from a
drafting CAD/CAM (Computer Aided Drafting/Computer Aided Manufacturing) program or
from an independently written CNC program. The CAD/CAM program will transform a
drafted or modeled part on the computer into a file that can be read by the punch press, telling
it where to punch holes in the sheet metal. Dies and other punching instruments are stored in
the machine and mechanically brought to the punching arm, where it can be used to drive
through the sheet. The NC (Numerically Controlled) press brakes bend the sheet into its final
form, using a computer file to program itself. Different bending dies are used for different
shapes and configurations and may be changed for each component.

Some brackets, fins, and sheet components are outsourced to other facilities or companies to
produce large quantities. They are brought to the assembly plant only when needed for
assembly. Many of the brackets are produced on a hydraulic or mechanical press, where
brackets of different shapes and configurations can be produced from a coiled sheet and
unrolled continuously into the machine. High volumes of parts can be produced because the
press can often produce a complex shape with one hit.

Cleaning the parts

All parts must be completely clean and free of dirt, oil, grease, and lubricants before they are
powder coated. Various cleaning methods are used to accomplish this necessary task. Large
solution tanks filled with a cleaning solvent agitate and knock off the oil when parts are
submersed. Spray wash systems use pressurized cleaning solutions to knock off dirt and
grease. Vapor degreasing, suspending the parts above a harsh cleansing vapor, uses an acid
solution and will leave the parts free of petroleum products. Most outsourced parts that arrive
from a vendor have already been degreased and cleaned. For additional corrosion protection,
many parts will be primed in a phosphate primer bath before entering a drying oven to
prepare them for the application of the powder coating.
Powder coating

Before brackets, pans, and wrappers are assembled together, they are fed through a powder
coating operation. The powder coating system sprays a paint-like dry powder onto the parts
as they are fed through a booth on an overhead conveyor. This can be done by robotic
sprayers that are programmed where to spray as each part feeds through the booth on the
conveyor. The parts are statically charged to attract the powder to adhere to deep crevices and
bends within each part. The powder-coated parts are then fed through an oven, usually with
the same conveyor system, where the powder is permanently baked onto the metal. The
process takes less than 10 minutes.

Bending the tubing for the condenser and evaporator

The condenser and evaporator both act as a heat exchanger in air conditioning systems and
are made of copper or aluminum tubing bent around in coil form to maximize the distance
through which the working fluid travels. The opposing fluid, or cooling fluid, passes around
the tubes as the working fluid draws away its heat in the evaporator. This is accomplished by
taking many small diameter copper tubes bent in the same shape and anchoring them with
guide rods and aluminum plates. The working fluid or refrigerant flows through the copper
tubes and the opposing fluid flows around them in between the aluminum plates. The tubes
will often end up with hairpin bends performed by NC benders, using the same principle as
the NC press brake. Each bend is identical to the next. The benders use previously
straightened tubing to bend around a fixed die with a mandrel fed through the inner diameter
to keep it from collapsing during the bend. The mandrel is raked back through the inside of
the tube when the bend has been accomplished.

Tubing supplied to the manufacturer in a coil form goes through an uncoiler and straightener
before being fed through the bender. Some tubing will be cut into desired lengths on an
abrasive saw that will cut several small tubes in one stroke. The aluminum plates are punched
out on a punch press and formed on a mechanical press to place divots or waves in the plate.
These waves maximize the thermodynamic heat transfer between the working fluid and the
opposing medium. When the copper tubes are finished in the bending cell, they are
transported by automatic guided vehicle (AGV) to the assembly cell, where they are stacked
on the guide rods and fed through the plates or fins.
Joining the copper tubing with the aluminum plates

A major part of the assembly is the joining of the copper tubing with the aluminum plates.
This assembly becomes the evaporator and is accomplished by taking the stacked copper
tubing in their hairpin configuration and mechanically fusing them to the aluminum plates.
The fusing occurs by taking a bullet, or mandrel, and feeding it through the copper tubing to
expand it and push it against the inner part of the hole of the plate. This provides a thrifty, yet
useful bond between the tubing and plate, allowing for heat transfer.

The condenser is manufactured in a similar manner, except that the opposing medium is
usually air, which cools off the copper or aluminum condenser coils without the plates. They
are held by brackets which support the coiled tubing, and are connected to the evaporator
with fittings or couplings.It allows the pressure of the working fluid to decrease and re-enter
the pump.

Installing the pump

The pump is also purchased complete I h from an outside supplier. Designed to increase
system pressure and circulate the working fluid, the pump is connected with fittings to the
system and anchored in place by support brackets and a base. It is bolted together with the
other structural members of the air conditioner and covered by the wrapper or sheet metal
encasement. The encasement is either riveted or bolted together to provide adequate
protection for the inner components.

Washing Machine Manufacturing Process

Fabrication

Most sheet metal parts are formed by a machine called a press. This name is quite descriptive,
as the machine actually presses (or squeezes) a piece of sheet metal between two halves of a
mold called a die. The metal will take the form of the space between the halves of the die.
Because metal in parts shaped by only one die tends to wrinkle, crack, or tear, multiple dies
are generally used to form each component. Where possible, the metal is fed directly from a
coil into the press. When this is not possible, the metal is cut to length and manually (or, with
larger parts like the cabinet, automatically) placed into the die.

Plastic parts are formed in an injection molding machine, a metal mold with one or more
cavities in the shape of the desired part. After being heated to its melting point, the plastic is
forced into the mold under high pressure. Next, water is passed through the mold to cool and
solidify the part. The mold is then opened and the part pushed out by ejector pins. When you
look at a plastic part, you often can see small circles created by these pins.

Aluminum transmission parts are formed into a rough shape in a die cast machine, which
works much like an injection mold except that it does not use pressure. The. molten metal is
mechanically ladled into the mold and cooled. The ensuing rough casting is then given its
final shape by various machines which drill holes, shave excess metal off critical surfaces, or
cut metal away from the part.

Sub-assemblies

The transmission is assembled manually by workers who bolt, snap, or press (tight fit) several
shafts and gears together. Workers then add a metered amount of oil and bolt the unit
together.

The pump is assembled automatically. Robots place the impeller and seals in the cover and
body, and seal the pump. Some manufacturers use heat and others vibration (which generates
heat) as a sealant.

The tub parts are made in presses, and the sub-assembly is manufactured automatically. After
being rolled into a drum shape, the side is welded. The weld is then smoothed out and the
drum is placed on a unit called an expander, which stretches the tub into its final shape. A
bottom is then welded onto the drum, and this weld is also smoothed. If the tub is stainless
steel it is polished so it won't snag the clothes. Otherwise the tub is dipped in a solution called
a ground coat and heated to about 1600 degrees until this coating hardens. If the tub will not
be visible (the wash tub), the unit is done. If the tub will be visible (the spin tub), a finish coat
is applied following the same procedure used with the ground coat; this final coat gives the
tub either a white or blue color.
The balance ring is a large weight that stabilizes the washer. Its outside structure is plastic,
with a ring of metal melted into the plastic for strength. Cement is added and balanced
precisely. This ring, which weighs more than twenty pounds, keeps the machine from
"walking," or moving about, when it is in use.

Washing machine manufacturers use any one of several painting processes. One
manufacturer uses steel that has been prepainted by the steel manufacturer. Although cheaper,
this type of steel does not offer the best rust protection because the cut edges are not painted.
Other companies treat their parts with various chemicals to clean and ready them before
applying paint. In some cases, the paint comes in a powder with a flour-like consistency.
Mixed with air and given an electrical charge, the powder is sprayed on the part, which is
hung from an overhead conveyor and given an opposite charge so that it and the powder will
attract one another. After spraying, the conveyor moves the part into an oven that melts the
paint; when the part cools, the paint process is completed.

Assembly

This process begins with mounting the transmission on the balance ring. The transmission is
set on a bearing that is bolted on the wash tub; the wash tub is sitting on a conveyor. Another
bearing (the lower bearing), the brake assembly, and the drive pulley are put on the end of the
transmission. Next, a pivoting mechanism called the pivot dome and legs are bolted on the
assembly to hold all the pieces together.

Using a hydraulically operated mechanism, workers then lift this assembly, called
the module, onto the washer base. Springs are added to hold module and base together. A seal
is added, the spin tub is bolted to the transmission inside of the wash tub, and its plastic
covers are snapped into place. A plastic hub, which attaches the agitator to the transmission,
is bolted onto the output end of the transmission shaft. Then the agitator is snapped onto the
hub.

The pump and a mounting bracket are now bolted onto the motor, which is then fitted with a
shield to protect against potential leaks. This assembly is bolted to the base of the washing
machine and connected to the transmission module with a belt and hoses.
Next, the lid hinges are attached to the lid and the top. The top of the washer is bolted to the
cabinet with a hinge for easy maintenance. A mixing valve to control the mixture of hot and
cold is bolted to the back of the cabinet. The graphics panel, which provides words and
pictures to explain the controls, is mounted on the control panel; the controls themselves are
attached from the back. The wiring, connected as one unit, is called a harness. The harness is
clipped to the control connectors at one end, and the other end is passed through a hole in the
top to be mounted to the motor. Because of its large size and weight, the cabinet assembly is
then placed in the washer by a robot.

The cabinet is bolted to the base, and the controls are snapped together with the mating
connectors on the module and motor. The drain hose is pulled through the cabinet and a part
called the gooseneck is added. This part is what gives the hose its hook shape so that it will
fasten into the drain. After being tested, the front panel is bolted on, and a packet of
information and accessories is added.

The finished unit is crated automatically. A machine opens the cardboard box, which was flat
for shipment, and drops it over the washer. The top and bottom flaps are simultaneously
folded over and glued. Then the machine applies pressure on the top and bottom of the crate
to make sure the glue sets properly. After the glue has set, the machine puts a banding strap
around the top of the crate to add strength for lift truck transportation (the units are carried
from the top to reduce the risk of damage).

Microwave Oven Manufacturing Process

Oven cavity and door manufacture

The process of manufacturing a microwave oven starts with the cavity and the door. First,
the frame is formed using automatic metal-forming presses that make about 12 to 15 parts per
minute. The frame is then rinsed in alkaline cleaner to get rid of any dirt or oil and further
rinsed with water to get rid of the alkaline solution.

Next, each part is treated with zinc phosphate, which prepares it for electro-deposition.
Electro-deposition consists of immersing the parts in a paint tank at 200 volts for 2.5 minutes.
The resulting coating is about 1.5 mils thick. The parts are then moved through a paint bake
operation where the paint is cured at 300 degrees Fahrenheit (149 degrees Celsius) for 20
minutes.

After the door has been painted, a perforated metal plate is attached to its window aperture.
The plate reflects microwaves but allows light to enter the cavity (the door will not be
attached to the cavity until later, when the chassis is assembled).

The magnetron tube subassembly

The magnetron tube assembly consists of a cathode cylinder, a filament heater, a metal
anode, and an antenna. The filament is attached to the cathode, and the cathode is enclosed in
the anode cylinder; this cell will provide the electricity that will help to generate the
microwaves. Metal cooling fins are welded to the anode cylinder, and a powerful magnet is
placed around the anode to provide the magnetic field in which the microwaves will be
generated. A metal strap holds the complete assembly together. A thermal protector is
mounted directly on the magnetron to prevent damage to the tube from overheating.

An antenna enclosed in a glass tube is mounted on top of the anode, and the air within the
tube is pumped out to create a vacuum. The waveguide is connected to the magnetron on top
of the protruding antenna, while a blower motor used to cool the metal fins of the magnetron
is attached directly to the tube. Finally, a plastic fan is attached to the motor, where it will
draw air from outside the oven and direct it towards the vanes. This completes the magnetron
subassembly.

Main chassis assembly

The chassis assembly work is performed on a pallet—a work-holding device used in

conjunction with other tools—located at the station. First, the main chassis is placed on the
pallet, and the cavity is screwed on to the chassis. Next, the door is attached to the cavity and
chassis by means of hinges. The magnetron tube is then bolted to the side of the cavity and
the main chassis.

The circuit that produces the voltage required to operate the magnetron tube consists of a
large transformer, an oil-based capacitor, and a high voltage rectifier. All of these
components are mounted directly on the chassis, close to the magnetron tube.
Stirrer fan

The stirrer fan used to circulate the microwaves is mounted on top of the cavity. Some
manufacturers use a pulley to drive the fan from the magnetron blower motor; others use a
separate stirrer motor attached directly to the fan. Once the stirrer fan is attached, a stirrer
shield is screwed on top of the fan assembly. The shield prevents dirt and grease from
entering the waveguide, where they could produce arcing and damage the magnetron.

Control switches, relays, and motors

The cook switch provides power to the transformer by energizing a relay and a timer. The
relay is mounted close to the power transformer, while the timer is mounted on the control
board. The defrost switch works like the cook switch, activating a motor and timer to operate
the defrost cycle. Also mounted on the control board are a timer bell that rings when the
cooking cycle is complete and a light switch that allows viewing of the cavity. A number of
interlocking switches are mounted near the top and bottom of the door area. The interlocking
switches are sometimes grouped together with a safety switch that monitors the other
switches and provides protection if the door accidently opens during oven operation.

Front panel

A front panel that allows the operator to select the various settings and features available for
cooking is attached to the chassis. Behind the front panel, the control circuit board is
attached. The board, which controls the various programmed operations in their proper
sequence when the switches are pushed on the front panel, is connected to the various
components and the front panel by means of plug-in sockets and cables.

Making and assembling the case

The outer case of the microwave is made of metal and is assembled on a roll former. The case
is slipped onto the preassembled microwave oven and bolted to the main chassis.

Testing and packaging the oven

The power cords and dial knobs are now attached to the oven, and it is sent for automatic
testing. Most manufacturers run the oven from 50-100 hours continuously as part of the
testing process. After testing is complete, a palletizer robot records the model and serial data
of the oven for inventory purposes, and the oven is sent for packaging. This completes the
manufacturing process.

Dishwasher Manufacturing Process

 A dishwasher begins to take shape with the injection molding of the tub. Two molds
—the cavity relief mold for the outside of the tub and the core relief mold for the
inside—have previously been etched into a steel tool, that, when fitted together,
contains a void or space that is the shape of the tub. The tool halves are held together
in the chamber of the injection molding machine. Pellets of polypropylene are melted
in the machine at high temperature and injected by pressure into the void in the tool.
The high pressure and liquid state of the plastic forces the plastic into every pocket
and crevice in the mold inside the tool. The tool opens to release the tub, which is still
hot.

 The warm tub is conveyed to a cooling area and cooled to a temperature that is easy
for assembly workers to handle. Other plastic parts are also made by injection
molding, and these smaller pieces are stored in bins (with one kind of part only per
bin) that can be moved to the assembly area as needed.

 In another part of the plant, the steel components of the dishwasher are made. Outer
cabinets for stand-alone models and the doors for all models are cut and stamped into
shape from stainless steel in the form of coils that are prefinished on one side. Flat
steel bars that will be assembled into the dishwasher's frame are sheared to length.
The racks are also formed with tools that trim, de-bur, and shape wire into the racks in
two welding steps. The perimeter of the rack is called the "mat," and a tool welds all
the wire pieces of the mat together at the same time. Similarly, the little pieces or tines
that support the dishes are welded into place simultaneously. The completed rack is
taken by conveyor to a cleaning station where it is cleaned and prepared to receive its
PVC coating. The PVC is in the form of a fine powder that is baked onto the rack.
The coated rack is then cured to finish forming the PVC coating and to allow it to
cool.
  Dishwashers are assembled at work stations along an assembly line. The workers are
responsible for sets of pieces that are taken from bins alongside the workers. The
frame is assembled first, and the motor or motors are attached to special mounts on
the frame. The motors are provided to the line workers as completed assemblies. The
tub is fitted and fastened into the frame over the motor or motors.

 With the tub in place, the interior components are installed beginning with the
filtering system. The washtower and arms are attached followed by sets of rack rollers
to support the racks and allow them to be rolled in and out of the machine so that
dishes can be loaded easily. The racks are put in place along with the cutlery basket.

 The door assembly is completed by installing the detergent dispenser and rinse-agent
cups and the controls. The door is attached to the front of the dishwasher. The exterior
is completed by finishing the electrical connections and feed lines (for clean and dirty
water), and the exterior is insulated to reduce noise and the effects of heat that might
warp counter tops and cabinets. Insulation is prefabricated with the insulating fibers
wrapped in a foil-like covering. Called "bagged insulation," it is wrapped around the
machine and packed inside the toe space. Under-counter models are now complete.
Stand-alone models are finished by attaching the wrap-around cabinet and wood top.
Each completed machine is loaded onto a cart to be moved to the packing area.

 In the packing area, styrofoam bumper sections are placed along the edges of the
machine and enclosed by a carton. Packets of instructions and other materials are
placed on top of the machine in the carton, and the carton is sealed and moved to a
storage area for shipping.

Air Purifier Manufacturing Process

The case

Pellets of the raw material (high-impact polystyrene, polyvinyl chloride, high-density

polyethylene, or polypropylene) are fed into a hopper and heated to the melting point, 300-
590°F (150-310°C).
The molten plastic is injected under high pressure into a mold of the case. The mold is
usually made from tool steel by a highly skilled mold maker. Vents in the mold allow the
entrained air to escape as the plastic enters. The mold designer must assure that the mold fills
evenly with plastic and that all of the entrained air is allowed to escape, otherwise the final
part might contain small air bubbles or even voids.

Water is forced through channels built into the mold to transfer heat from the molten plastic
into the environment. Once the part is sufficiently cool, which can take up to two minutes, the
mold opens. Hydraulically-operated pins push the part out of the open mold into a receiving
bin.

The fan

An electric fan is used to pull air through the air purifier. The fan is usually purchased from a
small-parts supplier. The fan consists of a small electric motor with metal fan blades attached
to the motor's power take-off. The fan blades are usually spot welded to a collar, which is
slipped onto the power take-off and bolted in place.

The fan is usually attached to the case with steel screws.

HEPA filters

The glass fibers that make up a HEPA filter are created by passing molten glass or plastic
through very fine pores in a spinning nozzle. The resulting glass fibers cool and harden
almost instantly because of their tiny diameters.

The spinning nozzle moves back and forth (causing the glass fibers to form a web) above a
moving conveyor belt onto which the fibers are collected. The speed of the conveyor belt
determines the thickness of the filter material—a slow conveyor belt allows more glass fibers
to build up on the belt.

The melting and cooling of the fiber produces some bonding of the fibers. As the conveyor
progresses, a latex binder is sprayed onto the fabric to provide additional strength. The fabric
can be any width up to the practical size of the machinery and can be cut down to the size
specified by the customer before the fabric is taken up on rollers.
Once the HEPA mats are formed, they are folded into an accordion pattern in an automatic
folder. The accordion pattern allows up to 50 ft 2 (5 m 2 ) of filter material to be enclosed in a
small space.

The accordion-shaped filter is then enclosed in a filter case, usually consisting of an open
wire grid. The purpose of the filter case is to support the filter.

Electrostatic precipitators

The electrostatic precipitator collection system is manufactured by enclosing steel plates into
a plastic casing, often by hand assembly. The plates are arranged parallel to each other in the
case.Wires are then connected to alternate plates through which the high voltage positive
direct current will be applied to the plates. The other plates are grounded.The ionizing unit is
constructed by running small diameter wires in front of the collector plates.

A voltage transformer, which is used to convert 115 volt household alternating current into
high voltage direct current, is fixed to the precipitator case. This voltage is run to both the
positively charged collector plates and the ionizing wires.

The activated carbon filter

The activated carbon filter (for odor reduction) usually consists of carbon-impregnated cloth
or foam. This is manufactured by infusing the raw material with powdered activated carbon.

The carbon filter is then wrapped around the inside or outside of the HEPA filter, or stretched
in a frame at either the inlet or outlet of the electrostatic precipitator.

Assembly

There are very few components in an air purifier. For this reason, they are usually bench
assembled. In bench assembly, moving conveyors bring the individual components or sub-
assemblies (e.g., the fan already attached to the case) to a bench where a person then hand
assembles them. In a typical HEPA air purifier, there may only be five components that
require assembly: casing, fan, particulate filter, carbon filter, and the on/off switch.