CN101472660B - 陶瓷过滤器 - Google Patents
陶瓷过滤器 Download PDFInfo
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- CN101472660B CN101472660B CN2007800223421A CN200780022342A CN101472660B CN 101472660 B CN101472660 B CN 101472660B CN 2007800223421 A CN2007800223421 A CN 2007800223421A CN 200780022342 A CN200780022342 A CN 200780022342A CN 101472660 B CN101472660 B CN 101472660B
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Abstract
本发明涉及一种陶瓷过滤器,包括:(a)以重量计从约75%至95%的硅藻土;(b)以重量计从约10%至20%的助熔剂;以及(c)以重量计从约0.03%至0.4%的金属化合物;所述以重量计的百分数是以重量计的所述陶瓷过滤器的百分数。
Description
本发明涉及一种陶瓷过滤器。尤其涉及一种用于过滤液体、尤其是自来水(tap water)以便从中除去病原体或污染物(或致污物)的陶瓷过滤器。
由于很多被认为是饮用水源(例如公用设施或集团供水方案、井水)的变化的质量,一般而言,这样的水是不适于饮用的,并且在某些极端情况下,很多还可能含有病原体或污染物,其可以引起严重疾病。例如,一些饮用水源可能含有有害的原生动物或细菌,如隐孢子虫属(Cryptosporidium)、贾第虫属(Giardia)和埃希氏大肠杆菌,由于使用它们能引起疾病。因此,对于购买瓶或其他合适容器中的用于饮用目的的水有增加的趋势,而且购买这样的水也可能是相当昂贵的。例如,对于运动员而言,当练习时,运动员需要有规律地摄入大量的水,因此对于瓶装水的支出可能尤其高。
陶瓷在过滤器中作为介质的使用是已知的,包括用于净化液体如自来水的过滤器。然而,这样的陶瓷过滤器在质量方面有变化,通常体积庞大且是非便携的,并且不能完全依靠于此而从水中除去病原体如原生动物。因此,需要一种能克服这些问题的过滤器。
本发明目的在于提供一种陶瓷过滤器,该过滤器能够从液体如自来水中除去污染物(或致污物),包括但不限于有害的原生动物如隐孢子虫属和贾第虫属、以及细菌和病毒。本发明的陶瓷过滤器具有很多种潜在的应用。例如,它能用于当被从容器中汲取出来时净化盛装在容器如瓶中的干线自来水(mains tap water)。
根据本发明的第一方面,提供了一种陶瓷过滤器,包括:
(a)以重量计从约75%至约95%的硅藻土;
(b)以重量计从约10%至约20%的助熔剂;以及
(c)以重量计从约0.03%至约0.4%的金属化合物;
所述以重量计的百分数是以重量计的所述陶瓷过滤器的百分数。
如在本文中所使用的,术语“助熔剂”用来指玻璃化剂(vitrifyingagent),其降低各组分的熔融温度并诱导陶瓷黏结(或陶瓷结合,ceramic bonding)。
用于本发明的合适的金属化合物包括除了银之外的VI-XII族金属化合物。这样的金属化合物优先选自铬、锰、钴、镍、铜和锌,更优先选自铜和锌。铜是尤其优选的。以所述陶瓷过滤器的重量计,所述金属化合物优选是以重量计从约0.05%至约0.3%、优选从0.1%至约0.25%、更优选从约0.13%至约0.23%、最优选约0.18%的量存在于所述过滤器中。
该陶瓷过滤器能够方便地除去具有1.5μm或更大粒径的物质。
本发明的陶瓷过滤器,优选具有从约0.30至约0.55、更优选从约0.35至约0.50或从0.37至约0.45的压缩比。约0.40的压缩比是优选的。如在本文中所使用的,术语“压缩比”用来指烧成(或烧结,firing)前的陶瓷过滤器的厚度(毫米)与烧成后的陶瓷过滤器的厚度(毫米)的比率,其中该陶瓷过滤器具有在烧成过程中对其施加的大约0.08kg/cm2的重量施加。
本发明的陶瓷过滤器,优选具有从约2.0mm至约4.5mm、优选从约2.5mm至约4.0mm的厚度。大约3.2mm的厚度是优选的。
所述硅藻土具有至少70%的二氧化硅。包括二氧化硅、钠、镁和铁酸盐(或铁,ferrite)的硅藻土是优选的。以商品名Celatom(一种硅藻土)出售并包括从约4%至约8%的钠,从约2%至约4%的镁,以及从约1.5%至2.5%的铁酸盐(或铁)的硅藻土是特别优选的。硅藻土优选的是以商品名Celatom FW出售的硅藻土,更优选的是以商品名Celatom FW-12出售的硅藻土(具有约24μm的平均粒径并能够除去具有约0.7μm的颗粒尺寸的物质)、以商品名CelatomFW-14出售的硅藻土(具有约28μm的平均粒径并能够除去具有约0.75μm的颗粒尺寸的物质)、以商品名Celatom FW-18出售的硅藻土(具有约31μm的平均粒径并能够除去具有约0.8μm的颗粒尺寸的物质)、以商品名Celatom FW-20出售的硅藻土(具有约33μm的平均粒径并能够除去具有约0.9μm的颗粒尺寸的物质)、以商品名Celatom FW-40出售的硅藻土(具有约40μm的平均粒径并能够除去具有约1.0μm的颗粒尺寸的物质)、以商品名Celatom FW-50出售的硅藻土(具有约42μm的平均粒径并能够除去具有约1.1μm的颗粒尺寸的物质)、以商品名Celatom FW-60出售的硅藻土(具有约48μm的平均粒径并能够除去具有约1.2μm的颗粒尺寸的物质)、或以商品名Celatom FW-80出售的硅藻土(具有约77μm的平均粒径并能够除去具有约1.6μm的颗粒尺寸的物质),或者它们的混合物。
该硅藻土可以包括不同粒径的两种或多种硅藻土的混合物,例如具有从约25μm至约30μm的平均粒径的硅藻土与一种具有从约75μm至约80μm的平均粒径的硅藻土的混合物。具有约28μm的平均粒径的硅藻土与一种具有约77μm的平均粒径的硅藻土的混合物是优选的。当使用两种硅藻土的混合物时,该硅藻土优选能够过滤具有从约0.5μm至约3.0μm、优选从约1.0μm至约2.5μm、更优选从约1.5μm至约2.0μm的颗粒尺寸的物质。以商品名Celatom FW-14与以商品名Celatom FW-80出售的硅藻土的混合物是优选的,以所述硅藻土的重量计优选的混合物的比例为从约30:70至约70:30、更优选为从约60:40至约40:60、最优选为约50:50。以商品名CelatomFW-14与以商品名Celatom FW-80出售的硅藻土的50:50混合物是尤其优选的。
优选地,以所述陶瓷过滤器的重量计,所述硅藻土是以重量计从约80%至约90%、优选从约81%至约87%、更优选从约83%至约85%、最优选约84%的量存在。
助熔剂起作用以在过滤器制备的烧成过程中黏合各组分,即硅藻土和金属化合物,并对完成的陶瓷过滤器给出额外的强度。用于本发明的合适的助熔剂包括碳酸钡(BaCO3)、硫酸钡(BaSO4)、方解石(CaCO3)、白垩(CaCO3)、科尼什长石(可变的)、白云石(CaCO3.MgCO3)、钾长石(K2O.Al2O3.6SiO2)、钠长石(Na2O.Al2O3.6SiO2)、锂云母(Li2F2.Al2O3.3SiO2)、石灰石(CaCO3)、碳酸锂(Li2CO3)、碳酸镁(MgCO3)、轻质碳酸镁3MgCO3.Mg(OH)2.3H2O、碳酸锰(MnCO3)、二氧化锰(MnO2)、霞石岩正长岩((K)NaO.Al2O3.4SiO2))(大致)、透锂长石(Li2O.Al2O3.8SiO2)、碳酸钾(珍珠灰)(K2CO3)、岩粉例如玄武岩或花岗岩、碳酸钠(苏打灰)(Na2CO3)、锂辉石(Li2O.Al2O3.4SiO2)、碳酸锶(SrCO3)、滑石(3MgO.4SiO2.H2O)、细白垩(或白垩粉,whiting)(CaCO3)、硅灰石(CaO.SiO2)、木灰(可以含有可溶物)(可变的,(通常以高石灰含量)、氧化锌(ZnO)、以及含硼化合物。
含硼化合物是优选的,优选的是硼的氧化物、硼的盐和盐的水合物。合适的盐包括硼或硼酸的碱金属盐。硼酸钠,也称为十水四硼酸钠、四硼酸二钠、十水硼砂或硼砂(Na2B4O7·10H2O),是优选的。
合适的硼的氧化物包括硬硼钙石(2CaO.3B2O3.5H2O(可变的))、gerstley硼酸盐(硬硼钙石[Ca2B6O11.5H2O]和硼钠钙石[NaO.2CaO.5B2O3.5H2O]的混合物)以及具有式B2O3的氧化硼。具有式B2O3的氧化硼是优选的,可选以其无定形形式。包括氧化硼(B2O3)、氧化铝(Al2O3)和/或二氧化硅(SiO2)的助熔剂是优选的,尤其是以下的助熔剂:包括从约10%至约30%的氧化硼、优选约20%的氧化硼;从约2%至约15%的氧化铝、优选约8%的氧化铝;以及从约40%至约60%的二氧化硅、优选约50%的二氧化硅。包括硼的熔料(或玻璃料,frit)是优选的,尤其是包括硼的氧化物的熔料(或玻璃料)。包括氧化硼(B2O3)、氧化铝(Al2O3)和/或二氧化硅(SiO2)的熔料是特别优选的。以下的硼熔料是尤其优选的:包括从约10%至约30%的氧化硼、优选约20%的氧化硼;从约2%至约15%的氧化铝、优选约8%的氧化铝;以及从约40%至约60%的二氧化硅、优选约50%的二氧化硅。
该熔料优选具有从约300℃至约1500℃、优选从约400℃至约1300℃、更优选从约500℃至约1200℃的烧成温度。大约1050℃的烧成温度是优选的。具有大约1085℃的烧成温度的硼熔料是特别优选的。
以所述陶瓷过滤器的重量计,该助熔剂优选以重量计从约12%至约18%、优选从约14%至约16%、更优选约15%的量存在。以约15%的量存在的硼熔料是尤其优选的。
根据本发明的第二个方面,提供了一种用于形成陶瓷过滤器的组合物,所述组合物包括:
(a)以重量计从约10%至约30%的硅藻土;
(b)以重量计从约1%至约6%的助熔剂;
(c)以重量计从约0.05%至约1.0%的金属化合物或其盐或所述盐的水合物;
(d)以重量计从约0.5%至约6%的纤维素胶;
(e)以重量计从约2%至约10%的增量剂;以及
(f)以重量计从约50%至约85%的水;
所述以重量计的百分数是所述组合物总重的百分数。
金属化合物可以是如上所限定的用于陶瓷过滤器的金属化合物,并且优选是以盐或所述盐的水合物的形式存在于所述组合物中。所述盐优先选自硫酸盐、碳酸盐、氯化物和乙酸盐,最优选为硫酸盐。硫酸铜或其水合物是优选的,尤其是硫酸铜五水合物。
以所述组合物总量的重量计,金属化合物或其盐或所述盐的水合物优选是以重量计从约0.07%至约0.8%、更优选从约0.1%至约0.5%、甚至更优选从约0.15%至约0.3%、最优选约0.2%的量存在于所述组合物中。
硅藻土是如上所限定的用于陶瓷过滤器的,并以所述组合物总量的重量计,优选以重量计从约14%至约26%、更优选从约16%至约24%、甚至更优选从约18%至约22%、最优选约20%的量存在于所述组合物中。
助熔剂是如上所限定的用于陶瓷过滤器的,并以所述组合物总量的重量计,优选以重量计从约2%至约5%、更优选从约2.5%至约4.5%、甚至更优选从约3%至约4%、最优选约3.8%的量存在于所述组合物中。
组合物中的纤维素胶起作用以产生可锻组合物。合适的纤维素胶包括甲基纤维素、羧甲基纤维素、羟甲基纤维素、羟丙基纤维素、羟丙基甲基纤维素、以及它们的混合物。羧甲基纤维素是优选的。改性的纤维素胶是特别优选的,优选的是改性的羧甲基纤维素,尤其是羧甲基纤维素钠。可从Hercules S.A(Alizay,France)获得的以商品名Blanose出售的羧甲基纤维素钠是特别优选的。以所述组合物总量的重量计,纤维素胶优选以重量计从约1%至约5%、优选从约1.5%至约4%、更优选从约2%至约3%、最优选约2.3%的量存在。以约2.3%的量存在的羧甲基纤维素钠是特别优选的。
能够用在该组合物中的增量剂包括大麻、棉、亚麻、丝、羊毛、纤维素、以及它们的混合物。纤维素是优选的。以所述组合物总量的重量计,增量剂可以以重量计从约3%至约7%、优选从约3.5%至约6%、更优选从约4%至约5%、最优选约4.3%的量存在。以约4.3%的量存在的纤维素是特别优选的。增量剂在陶瓷过滤器制备中的烧成过程中被燃烧除去,从而在陶瓷中留下蜂窝状结构。纤维素通常在约300℃的温度下被燃烧除去。
以所述组合物总量的重量计,水可以以重量计从约55%至约80%、优选从约60%至约75%、更优选从约65%至约70%、最优选约68%的量存在。
根据本发明的第三个方面,提供了一种用于形成根据本发明的陶瓷过滤器的前体过滤器,该前体过滤器包括:
(a)以重量计从约50%至约98%的硅藻土;
(b)以重量计从约2%至约20%的助熔剂;
(c)以重量计从约0.1%至约1.5%的金属化合物或其盐或所述盐的水合物;
(d)以重量计从约2%至约20%的纤维素胶;以及
(e)以重量计从约5%至约35%的增量剂;
所述以重量计的百分数是以重量计的所述前体过滤器总量的百分数。
在前体过滤器中的所述金属化合物或其盐或所述盐的水合物、所述硅藻土、所述助熔剂、所述纤维素胶以及所述增量剂中的每一种都如上对于组合物那样所限定。
以所述前体过滤器总量的重量计,所述金属化合物或其盐或所述盐的水合物优选以重量计从约0.2%至约1.2%、更优选从约0.3%至约1.0%、甚至更优选从约0.4%至约0.8%、最优选约0.5%的量存在。
优选地,以所述前体过滤器总量的重量计,所述硅藻土以重量计从约55%至约90%、优选从约60%至约85%、更优选从约62%至约80%、最优选约65%的量存在。
以所述前体过滤器总量的重量计,所述助熔剂可以以重量计从约5%至约15%、优选从约8%至约14%、更优选约12%的量存在。
优选地,以所述前体过滤器总量的重量计,所述纤维素胶以重量计从约4%至约15%、优选从约5%至约10%、更优选约8%的量存在。
优选地,以所述前体过滤器总量的重量计,所述增量剂以重量计从约8%至约30%、优选从约10%至约25%、更优选约13%的量存在。
根据本发明,还提供了一种用于制备根据本发明的陶瓷过滤器的方法,所述方法包括以下步骤:
(A)通过混合以下组分来形成根据本发明的组合物:
(a)以重量计从约10%至约30%的硅藻土;
(b)以重量计从约1%至约6%的助熔剂;
(c)以重量计从约0.05%至约1.0%的金属化合物或其盐
或所述盐的水合物;
(d)以重量计从约0.5%至约6%的纤维素胶;
(e)以重量计从约2%至约10%的增量剂;以及
(f)以重量计从约50%至约85%的水;
所述以重量计的百分数是以重量计的所述组合物总量的百分数;
(B)从所述组合物中除去一部分水,以便形成具有成形稳定性(或成形坚实度,shaping consistency)的组合物;
(C)干燥所述组合物以便除去任何残留的水,以形成根据本发明所述的前体过滤器;以及
(D)烧成(或烧结)所述前体过滤器以形成所述陶瓷过滤器。
在步骤(A)中,所述组分优选在从约20℃至约40℃、优选30℃的温度下混合。
在步骤(A)中,组合物的所述组分优选以下列的添加顺序混合:
(i)向水中添加金属化合物或其盐或所述盐的水合物;
(ii)向得到的混合物中添加纤维素胶;
(iii)向得到的混合物中添加助熔剂;
(iv)向得到的混合物中添加增量剂;以及
(v)向得到的混合物中添加硅藻土。
在步骤(B)中,优选使得所述组合物在优选约20℃至约40℃、更优选约30℃下静置约30分钟至约5小时,更优选约1小时至3小时,最优选约2小时。组合物的成形稳定性使得它能被方便地切割成希望的形状。
在步骤(B)之后并在步骤(C)之前,所述组合物优选被切割成所希望的形状。希望的形状可以取任意合适的形状,但优选的是基本上是圆形的盘,更优选的盘具有约20mm至约25mm、优选大约22mm的直径。
步骤(C)优选包括在从约90℃至约110℃、优选约100℃的温度下加热约30分钟至约2小时、优选约1小时的时间段。
在步骤(D)中,所述烧成(或烧结)优选在从约800℃至约1200℃、更优选从900℃至约1150℃、甚至更优选从约1000℃至约1100℃、最优选1085℃的温度下进行。前体过滤器优选烧成(或烧结)从约4小时至约11小时、优选从约6小时至约9小时、最优选约8.25小时的时间段。
在步骤(D)的过程中,本方法包括方便地将负载施加于所述前体过滤器,以便在烧成(或烧结)过程中引起压缩。优选所述负载为从约0.05kg/cm2至约0.1kg/cm2,优选约0.08kg/cm2。
本发明的陶瓷过滤器的优点包括以下方面:
·它们能够从自来水中除去基本上所有的原生动物,包括隐孢子虫属和贾第虫属。
·当过滤器中的金属化合物是铜时,它方便地用作抗菌剂。
·它们既具有优异的过滤性能又具有优异的抗菌性能。
以下实施例用来说明本发明,但应该明了本发明并不局限于这些实施例。
实施例1
由在表1中列出的各组分制备陶瓷过滤器,并根据表2中的步骤制备:
表1
组分 | 重量%(基于陶瓷过滤器) |
水 | 68.6 |
硫酸铜五水合物 | 0.2 |
Blanose1 | 2.6 |
硼熔料2 | 3.8 |
纤维素 | 4.3 |
硅藻土3 | 20.6 |
总计 | 100.0 |
1羧甲基纤维素钠;27.5% Al2O3、18.0% B2O3,、50.0% SiO2、14.0% CaO+MgO、10.3% Li2O+Na2O+K2O,由Johnson Mathey Ceramics(Stoke-on-Trent,UnitedKingdom)得到;3以商品名Celatom FW-14和Celatom FW-80出售的硅藻土的50:50混合物。
表2
步骤 | |
1 | 使用400g的水(在300℃,±10) |
2 | 添加1g硫酸铜五水合物 |
3 | 在铜(盐)中掺合20秒 |
4 | 添加15g的Blanose,食品级 |
5 | 掺合混合物60秒 |
6 | 添加22g的硼熔料 |
7 | 掺合混合物30秒 |
8 | 添加25g的纤维素 |
9 | 掺合混合物100至140秒 |
10 | 添加120g的硅藻土 |
11 | 掺合混合物180秒 |
12 | 浇注到石膏砖坯(plaster bat)(板坯(slab))上以形成该组合物 |
13 | 静置混合物直到适合于成形(>2小时),其导致该组合物具有成形稳定性 |
14 | 将混合物置于平面上并碾压成厚度为大约6mm的平板形 |
15 | 使用切割工具(或刀具)以产生希望尺寸(大约22mm直径)的9个圆形的盘 |
16 | 将盘置于100℃的炉中并当盘基本上干燥时移出以使得在烧成过程中压缩,从而形成前体过滤器 |
17 | 将盘均匀地隔开并置于粘土瓷砖(clay tile,15mm×15mm)上,然后放入窑中 |
18 | 将负载置于盘上,其等同于0.08kg/cm2的载荷,以在烧成(或烧结)过程中引起压缩 |
19 | 对于窑的程序温度设定如下指出:(i)0℃至3000C,以每小时100℃升高(总共180分钟);(ii)300至1085℃,以每小时150℃升高(总共314分钟);(iii)在达到1085℃后自然下降 |
20 | 使得盘的温度降至<700℃以下,这样的盘的耐久性足以在从窑中移出过程中经受住常规处理,从而形成陶瓷过滤器 |
实施例2
分析在表2的步骤16中产生得到的前体过滤器,并将结果在表3中示出:
表3
组分 | 重量%(基于前体过滤器) |
硫酸铜 | 0.5% |
Blanose1 | 8.2% |
硼砂熔料2 | 12.0% |
纤维素 | 13.7% |
硅藻土 | 65.6% |
总计 | 100% |
1羧甲基纤维素钠;27.5% Al2O3、18.0% B2O3,、50.0% SiO2、14.0% CaO+MgO、10.3% Li2O+Na2O+K2O,由Johnson Mathey Ceramics(Stoke-on-Trent,UnitedKingdom)得到;3以商品名Celatom FW-14和Celatom FW-80出售的硅藻土的50:50混合物。
实施例3
分析在表2的步骤20中得到的本发明的陶瓷过滤器,并将其含量在表4中示出:
表4
组分 | 重量%(基于陶瓷过滤器) |
元素铜 | 0.18% |
硅藻土1 | 83.9% |
1以商品名Celatom FW-14和Celatom FW-80出售的硅藻土的50:50混合物。
该陶瓷过滤器还包括熔料(或玻璃料)和其他成分。
实施例4:
在实施例1中得到的并具有如在实施例3中示出的典型含量的6个陶瓷过滤器,利用掺加有200个贾第虫属孢囊和200个隐孢子虫属卵囊的去离子水进行过滤试验。在试验前,对于每一个过滤器测定厚度和压缩比。使得10升掺有菌的(spiked)水在10kPa的压力下以1升/分钟的流速流过每个陶瓷过滤器。在过滤前和过滤后分析水中的隐孢子虫属和贾第虫属的含量。得到的结果在表5中示出。
表5
陶瓷(过滤器)标号 | 厚度(mm) | 压缩比 | 隐孢子虫属去除(%) | 贾第虫属去除(%) |
1 | 3.40 | 0.49 | 94.0% | 95.0% |
2 | 3.00 | 0.43 | 98.0% | 99.5% |
3 | 3.00 | 0.38 | 90.5% | 100.0% |
4 | 2.84 | 0.36 | 90.5% | 100.0% |
5 | 3.66 | 0.52 | 97.5% | 100.0% |
6 | 3.04 | 0.43 | 98.0% | 100.0% |
测得本发明的陶瓷过滤器除去高达98%的隐孢子虫属和高达100%的贾第虫属。最好的结果是使用具有3.04mm的厚度和0.43压缩比的6号陶瓷过滤器得到的。
综上所述,本发明的陶瓷过滤器已经显示出具有优异的原生动物过滤性能,并且能够在各种应用场合广泛使用。
Claims (51)
1.一种陶瓷过滤器,包括:
(a)以重量计从75%至95%的硅藻土;
(b)以重量计从10%至20%的助熔剂;以及
(c)以重量计从0.03%至0.4%的金属化合物,所述金属化合物包括除了银之外的VI-XII族金属化合物;
所述以重量计的百分数是以重量计的所述陶瓷过滤器的百分数并且所有组分的总量不超过100wt%,所述陶瓷过滤器通过包括以下步骤的方法获得:
(A)通过混合以下组分来形成组合物:
(a)以重量计从10%至30%的所述硅藻土;
(b)以重量计从1%至6%的所述助熔剂;
(c)以重量计从0.05%至1.0%的金属化合物或所述金属化合物的盐或所述盐的水合物,所述金属化合物包括除了银之外的VI-XII族金属化合物;
(d)以重量计从0.5%至6%的纤维素胶;
(e)以重量计从2%至10%的增量剂,所述增量剂选自大麻、棉、亚麻、丝、羊毛、纤维素、以及它们的混合物;以及
(f)以重量计从50%至85%的水;
所述以重量计的百分数是以重量计的所述组合物总量的百分数;
(B)从所述组合物中除去一部分水,以便形成具有成形稳定性的组合物;
(C)干燥所述组合物以便除去任何残留的水,以形成前体过滤器,所述前体过滤器包括:
(a)以重量计从50%至98%的所述硅藻土;
(b)以重量计从2%至20%的所述助熔剂;
(c)以重量计从0.1%至1.5%的上述限定的金属化合物或所述金属化合物的盐或所述盐的水合物;
(d)以重量计从2%至20%的所述纤维素胶;以及
(e)以重量计从5%至35%的所述增量剂;
所述以重量计的百分数是以重量计的所述前体过滤器总量的百分数并且所有组分的总量不超过100wt%;以及
(D)烧成所述前体过滤器以形成所述陶瓷过滤器,其中,所述增量剂在烧成过程中被燃烧除去。
2.根据权利要求1所述的陶瓷过滤器,其中,所述金属化合物中的金属选自铬、锰、钴、镍、铜和锌。
3.根据权利要求2所述的陶瓷过滤器,其中所述金属化合物中的金属选自铜和锌。
4.根据权利要求3所述的陶瓷过滤器,其中,所述金属化合物中的金属是铜。
5.根据权利要求1所述的陶瓷过滤器,其中,以所述陶瓷过滤器的重量计,所述金属化合物是以从0.05%至0.3%的量存在于所述过滤器中,并且所有组分的总量不超过100wt%。
6.根据权利要求1所述的陶瓷过滤器,其中所述陶瓷过滤器能够除去具有1.5μm或更大粒径的物质。
7.根据权利要求1所述的陶瓷过滤器,具有从0.30至0.55的压缩比,所述压缩比是烧成后的陶瓷过滤器的厚度与烧成前的陶瓷过滤器的厚度的比率。
8.根据权利要求1所述的陶瓷过滤器,具有从2.0mm至4.0mm的厚度。
9.根据权利要求1所述的陶瓷过滤器,其中,所述硅藻土包括至少70%的二氧化硅,从4%至8%的钠,从2%至4%镁,以及从1.5%至2.5%的铁酸盐。
10.根据权利要求9所述的陶瓷过滤器,其中,所述硅藻土包括以商品名Celatom FW-14和FW-80出售的硅藻土的混合物,以所述硅藻土的重量计,优选的混合物的比例为从30∶70至70∶30。
11.根据权利要求1所述的陶瓷过滤器,其中,以所述陶瓷过滤器的重量计,所述硅藻土是以从80%至90%的量存在,并且所有组分的总量不超过100wt%。
12.根据权利要求1所述的陶瓷过滤器,其中,所述助熔剂包括选自以下组中的一种化合物:碳酸钡(BaCO3)、硫酸钡(BaSO4)、方解石、白垩、科尼什长石、白云石、钾长石、钠长石、锂云母、石灰石、碳酸锂(Li2CO3)、碳酸镁(MgCO3)、轻质碳酸镁3MgCO3.Mg(OH)2.3H2O、碳酸锰(MnCO3)、二氧化锰(MnO2)、霞石岩正长岩、透锂长石、碳酸钾(K2CO3)、岩粉、碳酸钠(Na2CO3)、锂辉石、碳酸锶(SrCO3)、滑石、细白垩、硅灰石、木灰、氧化锌(ZnO)、以及含硼化合物。
13.根据权利要求12所述的陶瓷过滤器,其中,所述助熔剂包括含硼化合物。
14.根据权利要求12所述的陶瓷过滤器,其中,所述助熔剂包括硼的氧化物、硼的盐或者所述盐的水合物。
15.根据权利要求13所述的陶瓷过滤器,其中,所述助熔剂包括硼的氧化物。
16.根据权利要求15所述的陶瓷过滤器,其中,所述助熔剂另外包括氧化铝(Al2O3)和/或二氧化硅(SiO2)。
17.根据权利要求16所述的陶瓷过滤器,其中,所述助熔剂包括从10%至30%的氧化硼;从2%至15%的氧化铝;以及从40%至60%的二氧化硅,并且所有组分的总量不超过100wt%。
18.根据权利要求12所述的陶瓷过滤器,其中,所述助熔剂是熔料的形式。
19.根据权利要求1所述的陶瓷过滤器,其中,所述助熔剂具有从300℃至1500℃的烧成温度。
20.根据权利要求1所述的陶瓷过滤器,其中,以所述陶瓷过滤器的重量计,所述助熔剂是以从12%至18%的量存在,并且所有组分的总量不超过100wt%。
21.一种用于形成根据权利要求1所述的陶瓷过滤器的组合物,所述组合物包括:
(a)以重量计从10%至30%的硅藻土;
(b)以重量计从1%至6%的助熔剂;
(c)以重量计从0.05%至1.0%的金属化合物或所述金属化合物的盐或所述盐的水合物,所述金属化合物包括除了银之外的VI-XII族金属化合物;
(d)以重量计从0.5%至6%的纤维素胶;
(e)以重量计从2%至10%的增量剂,所述增量剂选自大麻、棉、亚麻、丝、羊毛、纤维素、以及它们的混合物;以及
(f)以重量计从50%至85%的水;
所述以重量计的百分数是以重量计所述组合物总量的百分数。
22.根据权利要求21所述的组合物,其中,组分(c)是在权利要求1中所限定的金属化合物,并且以盐或所述盐的水合物的形式存在于所述组合物中。
23.根据权利要求22所述的组合物,其中,所述盐选自硫酸盐、碳酸盐、氯化物和乙酸盐。
24.根据权利要求23所述的组合物,其中,组分(c)是硫酸铜或硫酸铜的水合物。
25.根据权利要求24所述的组合物,其中,组分(c)是硫酸铜五水合物。
26.根据权利要求21所述的组合物,其中,以所述组合物总量的重量计,所述金属化合物或所述金属化合物的盐或所述盐的水合物是以重量计从0.07%至0.8%的量存在于所述组合物中。
27.根据权利要求21所述的组合物,其中,以所述组合物总量的重量计,所述硅藻土是以重量计从14%至26%的量存在于所述组合物中,和/或所述硅藻土如在权利要求9中所限定。
28.根据权利要求21所述的组合物,其中,以所述组合物总量的重量计,所述助熔剂以重量计从2%至5%的量存在于所述组合物中,和/或所述助熔剂如在权利要求12中所限定。
29.根据权利要求21所述的组合物,其中,所述纤维素胶选自甲基纤维素、羧甲基纤维素、羟甲基纤维素、羟丙基纤维素、羟丙基甲基纤维素、以及它们的混合物。
30.根据权利要求29所述的组合物,其中,所述纤维素胶是羧甲基纤维素。
31.根据权利要求21所述的组合物,其中,所述纤维素胶是羧甲基纤维素钠。
32.根据权利要求21所述的组合物,其中,以所述组合物总量的重量计,所述纤维素胶以重量计从1%至5%的量存在。
33.根据权利要求21所述的组合物,其中,所述增量剂是纤维素。
34.根据权利要求21所述的组合物,其中,以所述组合物总量的重量计,所述增量剂以重量计从3%至7%的量存在。
35.根据权利要求21所述的组合物,其中,以所述组合物总量的重量计,所述水以重量计从55%至80%的量存在。
36.一种用于形成根据权利要求1所述的陶瓷过滤器的前体过滤器,包括:
(a)以重量计从50%至98%的硅藻土;
(b)以重量计从2%至20%的助熔剂;
(c)以重量计从0.1%至1.5%的金属化合物或所述金属化合物的盐或所述盐的水合物,所述金属化合物包括除了银之外的VI-XII族金属化合物;
(d)以重量计从2%至20%的纤维素胶;以及
(e)以重量计从5%至35%的增量剂,所述增量剂选自大麻、棉、亚麻、丝、羊毛、纤维素、以及它们的混合物;
所述以重量计的百分数是以重量计的所述前体过滤器总量的百分数并且所有组分的总量不超过100wt%。
37.根据权利要求36所述的前体过滤器,其中,所述金属化合物或所述金属化合物的盐或所述盐的水合物如在权利要求22中所限定,所述硅藻土如在权利要求9中所限定,所述助熔剂如在权利要求12中所限定,所述纤维素胶如在权利要求29中所限定,以及所述增量剂如在权利要求21中所限定。
38.根据权利要求36所述的前体过滤器,其中,以所述前体过滤器总量的重量计,所述金属化合物或所述金属化合物的盐或所述盐的水合物以重量计从0.2%至1.2%的量存在,并且所有组分的总量不超过100wt%。
39.根据权利要求36所述的前体过滤器,其中,以所述前体过滤器总量的重量计,所述硅藻土以重量计从55%至90%的量存在,并且所有组分的总量不超过100wt%。
40.根据权利要求36所述的前体过滤器,其中,以所述前体过滤器总量的重量计,所述助熔剂以重量计从5%至15%的量存在,并且所有组分的总量不超过100wt%。
41.根据权利要求36所述的前体过滤器,其中,以所述前体过滤器总量的重量计,所述纤维素胶以重量计从4%至15%的量存在,并且所有组分的总量不超过100wt%。
42.根据权利要求36所述的前体过滤器,其中所述增量剂以重量计从8%至30%的所述前体过滤器总重的量存在,并且所有组分的总量不超过100wt%。
43.一种用于制备根据权利要求1所述的陶瓷过滤器的方法,所述方法包括以下步骤:
(A)通过混合以下组分来形成根据权利要求21所述的组合物:
(a)以重量计从10%至30%的硅藻土;
(b)以重量计从1%至6%的助熔剂;
(c)以重量计从0.05%至1.0%的金属化合物或所述金属化合物的盐或所述盐的水合物,所述金属化合物包括除了银之外的VI-XII族金属化合物;
(d)以重量计从0.5%至6%的纤维素胶;
(e)以重量计从2%至10%的增量剂,所述增量剂选自大麻、棉、亚麻、丝、羊毛、纤维素、以及它们的混合物;以及
(f)以重量计从50%至85%的水;
所述以重量计的百分数是以重量计的所述组合物总量的百分数;
(B)从所述组合物中除去一部分水,以便形成具有成形稳定性的组合物;
(C)干燥所述组合物以便除去任何残留的水,以形成根据权利要求36所述的前体过滤器;以及
(D)烧成所述前体过滤器以形成所述陶瓷过滤器,其中,所述增量剂在烧成过程中被燃烧除去。
44.根据权利要求43所述的方法,其中,在步骤(B)中,使得所述组合物在20℃至40℃的温度下静置30分钟至5小时。
45.根据权利要求43所述的方法,其中,在步骤(B)之后并在步骤(C)之前,所述组合物被切割成所希望的形状。
46.根据权利要求45所述的方法,其中,所述被切割的形状是基本上圆形的盘。
47.根据权利要求45所述的方法,其中,所述被切割的形状是具有20mm至25mm的直径的圆形的盘。
48.根据前述权利要求任一项所述的方法,其中,步骤(C)包括在从90℃至110℃的温度下加热30分钟至2小时的时间段。
49.根据权利要求43所述的方法,其中,在步骤(D)中,所述烧成在从800℃至1200℃的温度下进行。
50.根据权利要求43所述的方法,其中,在步骤(D)中,将负载施加于所述前体过滤器,以便在烧成过程中引起压缩。
51.根据权利要求50所述的方法,其中,所述负载为从0.05kg/cm2至0.1kg/cm2。
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