CN103889557A - 透析槽用室框的制造方法 - Google Patents

透析槽用室框的制造方法 Download PDF

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CN103889557A
CN103889557A CN201280052331.9A CN201280052331A CN103889557A CN 103889557 A CN103889557 A CN 103889557A CN 201280052331 A CN201280052331 A CN 201280052331A CN 103889557 A CN103889557 A CN 103889557A
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net
chamber frame
framework
distributor
manufacture method
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松村幸夫
大川秀一
结城忠雄
大岛和巳
信田浩二
大泽太护
喜多村和男
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AGC Engineering Co Ltd
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Asahi Glass Engineering Co Ltd
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
    • B29C65/38—Impulse heating
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D61/42—Electrodialysis; Electro-osmosis ; Electro-ultrafiltration; Membrane capacitive deionization
    • B01D61/44—Ion-selective electrodialysis
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Abstract

提供一种制作容易、品质稳定、价格低廉且密封性及耐热性优异的透析槽用室框的制造方法。将裁截后的框架(1)设置于脉冲焊接机(30)的未图示的台座上，将分配器(13)与连通口(9)及连通口(11)嵌合，并且，以覆盖中央开口(3)的方式配置网状物(15)。接着，对焊接部(A、B)及焊接部(C、D)进行脉冲焊接。此外，以一次的冲压操作同时进行作为隔板的网状物(15)及分配器(13)的安装。然后，去除焊接部的毛刺，并对缺陷部进行修正。

Description

透析槽用室框的制造方法
技术领域
本发明涉及透析槽用室框的制造方法，尤其涉及制作容易、品质稳定、价格低廉且密封性及耐热性优异的透析槽用室框的制造方法。
背景技术
目前，以直流电为驱动电源进行脱盐、浓缩的电气透析槽已为公众所知。
该电气透析槽通过室框将阳离子交换膜与阴离子交换膜相互交替地进行多层配置，并在其两端配置电极，由此在膜间形成脱盐室、浓缩室。并且，通过选定使用各种不同的烯烃类热塑性树脂，可有选择地确定该室框的使用温度。
目前，室框是以如下的方法制造的。即，首先，将片材状的烯烃类热塑性树脂裁截成中央具有开口的镜框形状，来形成室框的框架部。并且，与此同时形成供被处理液流过的进液口及出液口。
然后，用注射焊接方法将分配器装配在室框上，该分配器用于从该进液口及出液口朝框架中央开口确保液体流路。接着，将用烯烃聚合物制成的成为隔板的网状物以覆盖框架的中央开口的方式设置于安装了该分配器的室框上。并且，在该网状物的数个位置用超声波点焊机使之与框架部分暂时固定。
之后，对该被暂时固定的半成品用超声波焊机分数次地进行焊接，以使框架部分与网状物焊接成为一体，从而制得完成品。
然而，由于该方法存在诸如暂时定位时网状物发生挠曲、分数次地焊接引起皱曲以及烯烃类热塑性树脂与烯烃聚合物制成的网状物间的焊接部的厚度不均匀的程度严重等原因，在作为室框使用时会发生因离子交换膜损伤、漏液量增大而引起的对透析性能的不利影响。
另外，有关作业工序的简化方面，从以往以来就有种种不同的探讨。
例如，有人提议，以加热变形温度低于用作隔板的网状物的发泡体作为室框的材料、使室框与网状物加热成为一体(专利文献1)。
现有技术文献
专利文献
专利文献1：日本专利特公平2-43528
发明内容
发明所要解决的技术问题
然而，在该方法中，将材料限定为发泡体材质并将加热成形温度预设为120℃以下，因而由该方法制造出的室框预计只能在常温下使用。
另外，还存在需要对进液管道孔部进行裁截、将薄片另行配置于分配器部等工序的不利因素。
本发明为解决这些以往存在的课题而作，其目的在于提供一种制作容易、品质稳定、价格低廉且密封性及耐热性优异的透析槽用室框的制造方法。
解决技术问题所采用的技术方案
为此，本发明的透析槽用室框的制造方法(技术方案一)，该透析槽用室框包括：框架，该框架形成有作为被处理液流路的中央开口、进液口及出液口并由热塑性树脂制成；以及树脂制的网状物，该网状物绕着上述中央开口被焊接，上述透析槽用室框的制造方法的特征是，在上述框架的从上述中央开口的内周缘起10mm以内的宽度范围内，以140℃～220℃加热温度通过脉冲加热焊接使该网状物与上述框架一体成形。
利用脉冲加热焊接使树脂制网状物与由热塑性树脂制成的框架一体成形。出于对室框的热变形及网状物安装部的强度方面的考虑，以将焊接部的宽度定为10mm以内为宜。
加热温度因所使用的网状物材质、框架材质不同而略有差异，需要与加热按压压力与加热时间相符地进行调节，以140℃～220℃为宜，以150℃～165℃为佳。
根据该制造方法，可获得制作容易、品质稳定、价格低廉且密封性及耐热性优异的透析槽用室框。
另外，本发明的制造方法(技术方案二)的特征是，上述脉冲加热焊接中使用的焊接加热器的尺寸为：长度为200mm～2000mm、宽度为3mm～12mm，以单位面积压力为0.05MPa～2.0MPa的压力加压的同时进行加热，且加热时间为0.5～5秒。
网状物焊接加热器的长度因室框的大小而有差异，但以200mm～2000mm左右为宜。此外，这样大范围的焊接对于目前采用的超声波焊机而言是难以实现的。
有关脉冲加热焊接机加热时的按压压力，对加热焊接部的变形量及厚度精度加以考量，加热器部的单位面积压力以0.05MPa～2.0MPa为宜，以0.5MPa～1.0MPa为佳。加热部的加热时间因室框片材材质、网状物材质、加热温度及按压压力等因素而不同，但从防止室框热变形以及厚度精度与作业便利性等方面考虑，以0.5～5秒以内为宜。
进一步地，本发明的制造方法(技术方案三)的特征是，在上述开口与进液口之间或上述开口与出液口之间的连通口处设置分配器，通过上述脉冲加热焊接，在将上述网状物焊接至上述框架的同时，使上述分配器与上述框架一体成形。
通过用脉冲焊接机以一次注射方式进行加热按压加工，能同时使网状物的安装和分配器的安装一体化。为此，可实现作业工序的简化及制造人工成本的削减。
发明效果
如上所述，根据本发明的制造方法，以140℃～220℃的加热温度、利用脉冲加热焊接在框架的从开口的内周缘起10mm以内的宽度范围内使网状物与框架一体成形，因此，可获得制作容易、品质稳定、价格低廉且密封性及耐热性优异的透析槽用室框。
附图说明
图1为室框的后视图。
图2为室框的主视图。
图3为脉冲焊接机的结构图。
图4是表示挠曲尺寸的测定方法的图。
具体实施方式
以下，对本发明的实施方式进行说明。作为本发明实施方式为室框的结构示于图1及图2。图1表示室框的后视图，图2表示室框的主视图。在图1中，室框10的框架1在其中央形成有四方形的开口3，并呈镜框状。进液口5及出液口7分别通过连通口9及连通口11与开口3连通。在连通口9及连通口11上嵌合有用于确保液体流路的分配器13。该分配器13上刻设有使进液口5及出液口7与开口3连通的形成液体通路的数根未图示的细槽。
分配器13具有耐热性及液体分散性优异、并防止内部泄漏的结构。分配器13以注射成形方式制成。
框架1是通过利用恢复成初始状态的冲裁模具对规定的材料进行冲裁加工而生成的。
在开口3中配置有成为室框10的流路部的隔板的网状物15。该网状物15是以不使阳离子交换膜与阴离子交换膜相互附着的方式配置的，此外，还是为了分散被处理液而配置的。
如图2所示，网状物15的焊接部A、B这两处部位在纵向上焊接于开口3的周围，网状物15的焊接部C、D这两处部位在宽度方向上焊接于开口3的周围。焊接部A、B分别在与开口3的纵向长度相同的长度b、宽度方向长度a的范围内焊接。即，网状物15的左右部分比开口3的横向长度超出相当于宽度方向长度a的距离。
另一方面，焊接部C、D分别在纵向长度c、宽度方向长度d的范围内焊接。即，网状物15的上下部分局部比开口3的纵向长度超出相当于纵向长度c的距离。不过，依据室框10的大小，也可酌情考虑是否将焊接部C、D省略。
框架1的材质为热塑性树脂，本发明的热塑性树脂中包括在热塑性树脂基质中含有橡胶成分的热塑性弹性体。框架1的材质，以烯烃类热塑性树脂为佳，尤以烯烃类热塑性弹性体更佳。作为烯烃类热塑性弹性体，可例举三菱化学社生产的ZELAS(日文：ゼラス)(商品名)。
作为框架1的材质，从耐热性及紧固密封性方面考虑，可采用软化温度为120℃以上、材质硬度(JIS K6301、A型)处于硬度50以上的烯烃类、聚氨酯类、苯乙烯类及聚酯类等热塑性树脂。
有关框架1的尺寸，依据被处理液的量等作适宜选定。
作为网状物15的材质，从加热焊接时的软化温度方面考虑，以聚丙烯或聚乙烯为宜。
对焊接部A、B、C及D采用脉冲焊接。
接着，对用于朝焊接部A、B、C及D进行脉冲焊接的机构进行说明。
如图3的脉冲焊接机的结构图所示，框架1载置于脉冲焊接机30的未作图示的台座上。
在脉冲焊接机30的上板31的背面左右分别地配置有四个分配器焊接用加热器33，这四个分配器焊接用加热器33用于对分配器13与连通口9之间及分配器13与连通口11之间进行焊接。另外，左右分别地各自配置有一个网状物焊接用加热器35，该网状物焊接用加热器35用于在焊接部C与D处使网状物15与框架1焊接。
并且，在上板31的背面的正前侧和后背侧分别各自配置有一个网状物焊接用加热器37，该网状物焊接用加热器37用于分别在焊接部A与B处使网状物15与框架1焊接。
为了使得对焊接部的定位变得容易，考虑到室框片材的尺寸精度等，将分配器焊接用加热器33、网状物焊接用加热器35及网状物焊接用加热器37的宽度设为3mm～12mm为宜，以5mm～10mm为佳。另一方面，网状物焊接用加热器37的长度因室框10的大小而不同，考虑到尺寸b的长度，以200mm～2000mm左右为宜。另外，这样大范围的焊接对于目前采用的超声波焊机而言是难以实现的。
接着，对作为本发明的实施方式的室框的制造方法进行说明。
首先，作为第一步骤，将片材状烯烃类热塑性弹性体(例如三菱化学社生产的ZELAS)裁截成镜框形状而形成室框10的框架1。
另外，此时，供被处理液流过的进液口5及出液口7也同时形成。
接着，作为第二步骤，将裁截后的框架1安放在脉冲焊接机30的未图示的台座上，将分配器13嵌合于连通口9及连通口11中，然后，以覆盖开口3的方式配置网状物15。此时，以具有比开口3大相当于焊接部A、B、焊接部C、D部分的面积的方式配置网状物15。
考虑到室框10的热变形及网状物安装部的强度，将焊接部A、B的宽度a、焊接部C、D的宽度c设为3～10mm为宜，设为3～5mm为佳。
接着，作为第三步骤，对焊接部A、B及焊接部C、D实施脉冲焊接。
加热按压的温度因使用的网状物材质及室框片材材质的差异而略有不同，需与加热按压压力及加热时间相符地进行调节，以140℃～220℃为宜，以150℃～165℃为佳。
有关脉冲焊接机的加热按压时的压力，考虑到加热焊接部的变形量及厚度精度，加热器部的面积压力以0.05MPa～2.0MPa为宜，以0.5MPa～1.0MPa为佳。加热部的加热时间因室框10的片材材质、网状物材质、加热温度及按压压力等因素而不同，但从防止室框10热变形以及厚度精度与作业便利性等方面考虑，以0.5～5秒以内为宜。
并且，通过1次按压操作，同时进行对作为隔板的网状物15及分配器13的安装。
之后，作为第四步骤，去除网状物焊接部的毛刺，对缺陷部进行修正。
此外，图3中示出了对焊接部A、B及焊接部C、D的部分从所有表面进行脉冲焊接的例子，然而，也可以例如对焊接部A、B从表面进行脉冲焊接，而对焊接部C、D从背面侧进行脉冲焊接。
实施例
以下，利用实施例对本发明进行说明，但本发明并不受其限定。
实施例1
以下，对实施例1进行说明。
首先，第一步骤，作为片材状的热塑性树脂，将板状烯烃类热塑性弹性体(三菱化学社生产的ZELAS)裁截成外尺寸为横向(宽)180mm、纵向(长)550mm、中央开口尺寸为横向130mm、纵向380mm的镜框形状，从而制作出室框10的框架1(图1、2)。框架1上的进液口大小为17mm见方、出液口大小为17mm见方。
接着，作为第二步骤，将框架1安放在脉冲焊接机30上，配置分配器13(长度20mm)及聚丙烯制的网状物15。
在此，使用5mm宽的分配器焊接用加热器33、网状物焊接用加热器35及网状物焊接用加热器37(长度400mm)。作为第三步骤，使用脉冲焊接机(富士脉冲公司制)，在加热温度155℃、加热时间2秒、按压压力1.0MPa的条件下，进行脉冲焊接(图3)。将聚丙烯制的网状物15焊接在框架1的从开口内周缘起5mm的宽度内(图2中的a及c)。
之后，作为第四步骤，去除网状物焊接部的毛刺，对缺陷部进行了修正。通过上述四个工序，制得本发明物即室框10。室框片材的厚度为0.637mm。
[比较例1]
将现有的室框的制造方法作为比较例1，按各工序顺序记述如下。
首先，作为第一步骤，与实施例1同样，将片材状烯烃类热塑性弹性体(三菱化学社生产的ZELAS)裁截成宽180mm、长550mm的镜框形状，制成室框10的框架1。
接着，作为第二步骤，将另行制成的分配器13以注射焊接法安装于室框上下两处位置。此时的作业由于在室框的上侧与下侧分别进行，因而需进行两次工序。
接着，作为第三步骤，裁截作为室框的流路部隔板的聚烯烃制的网状物(例如东京聚合物公司生产)。
接着，作为第四步骤，用超声波点焊机将聚烯烃制的网状物15配置于安装有分配器13的镜框形状的室框内侧并进行暂时固定。
接着，作为第五步骤，使用超声波焊机对被暂时固定的半成品分成六次操作，将片材状烯烃类热塑性树脂与聚烯烃制的网状物焊接成为一体。为此，此处作业需要六次工序。
之后，作为第四步骤，去除网状物焊接部的毛刺，对缺陷部进行了修正。
经此十二个工序，制得现有产品的室框。
如上所述，实施例1与比较例相比，简化成三分之一的工序，削减了本发明产品的制作人工成本。
接着，将实施例1与比较例1的性能品质的评价结果列于表1。
室框片材的厚度为0.637mm。
表1
Figure BDA0000495914550000081
此外，对列于表1的各项目的测定方法作如下叙述。
挠曲尺寸用于评价网状物安装后的室框的变形，如图4所示，测量将网状物安装后的室框重合十块时挠曲状态下的厚度尺寸A，并与网状物安装前不存在挠曲状态下室框重合十块时的厚度之间，以数学式1计算而得出。在尺寸测定时，使用钢皮尺或游标卡尺。
[数学式1]
挠曲尺寸＝(尺寸A－室框重合十块时的厚度)
另外，厚度尺寸是评判密封性及对膜损伤程度的指标，确保网状物安装部的厚度等同于或薄于周边室框片材的厚度是重要的。此处，厚度尺寸使用表盘式厚度规进行测定(刻度=0.01mm)。
有关外部泄漏，室框性能的最佳状态是不存在漏液，测算该外部泄漏量时，将室框与交换膜相互交替地各置入十块，两端设置紧固件并以0.6MPa的紧固部单位面积压力进行紧固后，向室框内部施加0.2MPa的空气压，然后通过测定空气向外部的泄漏量而求出。
由表1可知，实施例1与比较例1相比，无论在性能品质方面，还是在挠曲、厚度精度及外部泄漏量等方面，都获得良好的结果。另外，在制作工序方面也实现了简化，通过削减制造作业工序而大幅减少了生产成本。
产业上应用的可能性
本发明可用于制造品质稳定、价格低廉、密封性及耐热性优异的透析槽用室框。
此外，在此引用2011年10月28日提出申请的日本专利申请2011-237130号的说明书、权利要求书、附图及摘要的全部内容，以作为本发明的说明书的公示内容而加以采用。
符号说明
1     框架
3     中央开口
5     进液口
7     出液口
9、11  连通口
10    室框
13    分配器
15    网状物
30    脉冲焊接机
31    上板
33    分配器焊接用加热器
35、37  网状物焊接用加热器

Claims (4)

1.一种透析槽用室框的制造方法，该透析槽用室框包括：
框架，该框架形成有作为被处理液流路的中央开口、进液口及出液口并由热塑性树脂制成；以及
树脂制的网状物，该网状物绕着所述中央开口被焊接，
所述透析槽用室框的制造方法的特征在于，
在所述框架的从所述中央开口的内周缘起10mm以内的宽度范围内，以140℃～220℃加热温度通过脉冲加热焊接使该网状物与所述框架一体成形。
2.如权利要求1所述的透析槽用室框的制造方法，其特征在于，
所述脉冲加热焊接中使用的加热器的尺寸为：长度为200mm～2000mm、宽度为3mm～12mm，并以单位面积压力为0.05MPa～2.0MPa的压力进行加压，且加热时间为0.5～5秒。
3.如权利要求1或2所述的透析槽用室框的制造方法，其特征在于，
在所述中央开口与进液口之间或所述中央开口与出液口之间的连通口处设置分配器，
通过所述脉冲加热焊接，在将所述网状物焊接至所述框架的同时，使所述分配器与所述框架一体成形。
4.如权利要求1所述的透析槽用室框的制造方法，其特征在于，
所述热塑性树脂为热塑性弹性体。
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