CN106163646B - 平膜元件的制造方法及平膜元件 - Google Patents

平膜元件的制造方法及平膜元件 Download PDF

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CN106163646B
CN106163646B CN201580017859.6A CN201580017859A CN106163646B CN 106163646 B CN106163646 B CN 106163646B CN 201580017859 A CN201580017859 A CN 201580017859A CN 106163646 B CN106163646 B CN 106163646B
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CN106163646A (zh
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石川公博
冈田恭幸
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Kubota Corp
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/12—Composite membranes; Ultra-thin membranes
    • B01D69/122—Separate manufacturing of ultra-thin membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D63/00—Apparatus in general for separation processes using semi-permeable membranes
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
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Abstract

在由热塑性树脂构成的滤板(21)的表面配置薄片状的过滤膜(22)，通过将设于加热板(51)的多个凸状部(521、522)从过滤膜(22)的周缘部的上方以使各凸状部(521、522)与过滤膜(22)抵接的时机不同的方式按压于滤板(21)，从而将深度不同的多个凹状接合部(231、232)形成于滤板(21)，并且在各凹状接合部(231、232)通过热熔接将过滤膜(22)与滤板(21)接合，沿过滤膜(22)的周缘部将过滤膜(22)与滤板(21)之间密封。

Description

平膜元件的制造方法及平膜元件
技术领域
本发明涉及用于膜分离活性污泥法(MBR)的浸渍型膜分离装置的平膜元件，涉及将过滤膜与滤板接合的技术。
背景技术
过去，在例如记载于日本专利公报专利第5079984号的膜元件的制造方法中，形成微孔的微孔性过滤膜将由合成树脂纤维构成的无纺布作为支承体，将此微孔性过滤膜与热塑性树脂制滤板的周缘接合。在此制造方法中，由热板对微孔性过滤膜与热塑性树脂制滤板的周缘进行接合，对该热板进行温度控制,使其成为作为支承体的无纺布的载荷挠曲温度以下、热塑性树脂制滤板的维卡软化温度以上的温度，在热塑性树脂制滤板的周缘形成凹部，并且使微孔性过滤膜向该凹部凹进地进行接合，以位于上述凹部的底部的部分的合成树脂纤维的截面形状相对于位于上述凹部的边缘部的部分的合成树脂纤维的截面形状不变化的方式进行。
另外，在记载于日本专利公报专利第3778758号的浸渍型平膜元件的制造方法中，树脂制的滤板上从滤板的表面突出多个线状熔融部分和位于线状熔融部分的外侧的网眼状熔融部分，而且沿滤板的周缘部成形，在滤板的表面对各线状熔融部分及网眼状熔融部分进行覆盖地配置过滤膜，从过滤膜的上方将升降霍恩部件(日文:アップダウンホーン)在其平坦面上按压于各线状熔融部分及网眼状熔融部分，利用升降霍恩部件的振动在各线状熔融部分及网眼状熔融部分熔融粘着过滤膜。
而且，由形成于内侧的线状熔融部分的线状的内侧固定部将过滤膜保持为张紧状态，由形成于中央的线状熔融部分的止水部遍及过滤膜的全周确保止水功能，由形成于外侧的网眼状熔融部分的网眼状的固定部将过滤膜的周缘断续地固定于滤板，使网眼状熔融部分与各线状熔融部分的高度不同，在滤板的表背面另行熔融粘着各线状熔融部分和网眼状熔融部分。
发明内容
发明所要解决的课题
在日本专利公报专利第5079984号的构成中，由于由热板在热塑性树脂制滤板上形成凹部，并且，使微孔性过滤膜向凹部凹进进行接合，所以，可将微孔性过滤膜设置成张紧的状态，但从凹部向外侧超出的微孔性过滤膜的周缘部与滤板不接合，此周缘部受曝气流等处理槽内的流动的影响而摇摆，对凹部的微孔性过滤膜与热塑性树脂制滤板的接合部产生不良影响，存在引起剥离、破断等问题。
另外，在使微孔性过滤膜向凹部凹进的时候，从凹部向外侧超出的微孔性过滤膜的周缘部是自由状态，所以，起因于在微孔性过滤膜向凹部凹进的时候产生的过滤膜的变形，在微孔性过滤膜的周缘部发生皱纹。因此，在由热板在一条凹部对热塑性树脂制滤板与微孔性过滤膜进行接合，一重地对热塑性树脂制滤板与微孔性过滤膜进行密封后，即使再由另外的后工序将微孔性过滤膜的周缘部与热塑性树脂制滤板接合，也难以消除已经在微孔性过滤膜的周缘部发生的皱纹地进行接合，存在皱纹受曝气流等处理槽内的流动的影响而成为引起剥离、破断等的原因的问题。
在日本专利公报专利第3778758号的构成中，过滤膜在内侧的线状熔融部分、中央的线状熔融部分、网眼状熔融部分被熔融粘着，内侧的线状熔融部分、中央的线状熔融部分、网眼状熔融部分从滤板的表面突出，所以，在熔融粘着的动作中过滤膜与滤板的表面之间没有以遍及过滤膜的整个区域贴紧的方式作用。因此，在平膜元件于处理槽内暴露于与曝气相伴的上升流的状态下,在平膜元件上产生振动，因为起因于此振动的过滤膜的从滤板的鼓起、贴着动作，弯曲应力在过滤膜的熔融粘着部变大，存在因为疲劳而容易发生膜的破断、剥离的问题。
本发明就是解决上述的课题的发明，其目的在于提供一种平膜元件的制造方法及平膜元件，该平膜元件的制造方法，可将过滤膜抻展成张紧的状态地熔接在滤板上，并且，可将过滤膜的外周缘以平滑地展开的状态与滤板熔接。
用于解决课题的技术手段
为了解决上述课题，本发明的平膜元件的制造方法的特征在于，在由热塑性树脂构成的滤板的表面配置薄片状的过滤膜，通过将设于加热板的多个凸状部从过滤膜的周缘部的上方以使各凸状部与过滤膜抵接的时机不同的方式按压在滤板上，从而将深度不同的多个凹状接合部形成在滤板上，并且，在各凹状接合部通过热熔接将过滤膜与滤板接合，沿过滤膜的周缘部对过滤膜与滤板之间进行密封。
在本发明的平膜元件的制造方法中，特征在于，多个凹状接合部通过将加热板的高度不同的多个凸状部按压在平坦的滤板面上来形成。
在本发明的平膜元件的制造方法中，特征在于，加热板的多个凸状部构成为沿过滤膜的外周形状的多重的连续体，通过加热板的一次按压操作，将多个凹状接合部沿过滤膜的周缘部多重地形成，在多个凹状接合部同时对过滤膜与滤板之间进行密封。
在本发明的平膜元件的制造方法中，特征在于，加热板的多个凸状部沿过滤膜的外周形状多重地形成，而且处于内侧的凸状部比处于外侧的凸状部形成得高，多个凹状接合部沿过滤膜的周缘部多重地形成，而且处于内侧的凹状接合部比处于外侧的凹状接合部形成得深。
在本发明的平膜元件的制造方法中，特征在于，使加热板的多个凸状部高度不同地形成，而且形成得越高则与单位长度的过滤膜抵接的按压面积变得越大，使多个凹状接合部深度不同地形成，而且形成得越深则单位长度的过滤膜与滤板的熔接接合面积变得越大。
在本发明的平膜元件的制造方法中，特征在于，在使沿过滤膜的外周形状多重地形成而且形成为不同的高度的加热板的多个凸状部从内侧的凸状部到外侧的凸状部依次与过滤膜抵接后，由多个凸状部的全体多重地压紧过滤膜的周缘部，一面将过滤膜保持为张紧的状态，一面通过一次按压操作将多个凸状部向滤板推入，将多个凹状接合部沿过滤膜的周缘部多重地而且同时形成，对过滤膜与滤板之间进行密封。
本发明的平膜元件的特征在于，薄片状的过滤膜在沿周缘部多重地形成的多个凹状接合部通过热熔接与由热塑性树脂构成的滤板的表面接合，凹状接合部距离过滤膜表面的深度不同。
在本发明的平膜元件中，特征在于，多个凹状接合部的处于内侧的凹状接合部比处于外侧的凹状接合部形成得深。
在本发明的平膜元件中，特征在于，多个凹状接合部形成得越深，则单位长度的过滤膜与滤板的熔接接合面积变得越大。
发明的效果
如以上的那样根据本发明，由于由加热板的凸状部将薄片状的过滤膜向滤板推入来形成凹状接合部，通过热熔接将过滤膜与滤板接合，所以，过滤膜与滤板的表面之间以遍及过滤膜的整个区域贴紧的方式作用。因此，即使在平膜元件在处理槽内暴露于上升流的状态下，起因于平膜元件的振动的过滤膜的振动也难以产生。
另外，通过各凸状部与过滤膜抵接的时机不同，作用于加热板的负荷分级地增加，所以，可对在加热板一次作用大的负荷的情况进行抑制，可减轻加热板的热容量及电源容量。
另外，由于滤板可以是平坦的滤板面，所以，滤板的构造成为简易的构造。
另外，由于通过加热板的一次按压操作在多个凹状接合部同时将过滤膜与滤板接合，所以，可使接合操作。
另外，由于加热板的多个凸状部形成得越高则与在沿过滤膜的外周形状的方向上的单位长度的过滤膜抵接的按压面积变得越大，凹状接合部形成得越深则熔接接合面积变得越大，所以，通过熔融粘着接合面积变大的凹状接合部先开始熔接，可实现凹状接合部的确实的密封性。
由于在使加热板的多个凸状部从内侧的凸状部到外侧的凸状部依次与过滤膜抵接后，由多个凸状部的全体多重地将过滤膜的周缘部压紧，一面将过滤膜保持为张紧的状态，一面通过一次按压操作将多个凸状部向滤板推入，沿过滤膜的周缘部多重地而且同时形成多个凹状接合部，所以，可将过滤膜抻展成张紧的状态地熔接在滤板上，并且，可将过滤膜的外周缘以平滑地展开的状态与滤板熔接。
附图说明
图1是表示本发明的实施方式中的膜元件的正视图。
图2是表示本发明的实施方式中的膜元件的要部放大图。
图3是表示使用本发明的实施方式中的膜元件的浸渍型膜分离装置的立体图。
图4是表示本发明的另一实施方式中的膜元件的要部放大图。
图5是表示本发明的膜元件的制造方法的工序图之1。
图6是表示本发明的膜元件的制造方法的工序图之2。
图7是表示本发明的膜元件的制造方法的工序图之3。
图8是表示本发明的膜元件的制造方法的工序图之4。
具体实施方式
下面，根据附图说明本发明的实施方式。如图3所示，膜分离装置1在盒4的内部以相等间隔配置多片平膜元件2和从其下方喷出膜面清洗气体的散气装置3。盒4分割形成为膜盒5和散气盒6，形成为从散气装置3喷出的膜面清洗气体的全部量进入到膜盒5内。
平膜元件2在由ABS树脂等热塑性树脂构成的滤板21的两表面配置呈薄片状的有机性的过滤膜22，通过熔接将过滤膜22在其周缘部的凹状接合部23与滤板21接合，沿过滤膜22的周缘部对过滤膜22与滤板21之间进行密封。在滤板21与过滤膜22之间及滤板21的内部形成透过液流路，将与透过液流路连通的透过液取出口24形成于滤板21的上端缘。
各平膜元件2经与透过液取出口24连接的管7与集水管8连通，将导出膜透过液的透过液导出管9与集水管8连接。
如图1、图2所示，在平膜元件2上以直线状或带状延伸的多条凹状接合部231、232沿薄片状的过滤膜22的周缘部形成多重，而且形成为沿过滤膜22的外周缘部连续的沟状。在这里，虽然表示了形成2个凹状接合部231、232的例，但也可如图4所示的那样设置3个以上的凹状接合部23。
在本实施方式中，内侧的凹状接合部231呈直线状，外侧的凹状接合部232呈以带状延伸的网眼状。虽然在这里网眼的模样呈方形，但也可以是三角、圆、椭圆等形状。另外，也可如图4所示的那样凹状接合部23的形状全部是直线状，另外，也可做成其它的形状，例如波形。
在形成多个凹状接合部23以前，滤板21构成为形成凹状接合部23的部位平坦的滤板面。各凹状接合部231、232的从配置于熔接前的平坦的滤板面的过滤膜22的表面到各凹状接合部231、232的底部的过滤膜22的表面的距离，即深度，在处于内侧的凹状接合部231和处于外侧的凹状接合部232不同，处于内侧的凹状接合部231比处于外侧的凹状接合部232形成得深。处于内侧的凹状接合部231的深度最大可设定为0.7mm，处于外侧的凹状接合部232的深度最大可设定为0.4mm，两者的差在0.05mm至0.5mm之间设定。
当两者的差比0.05mm小时，与过滤膜22的厚度相比大幅度地变小，因此，如在后述的平膜元件2的制造方法中说明的那样，使加热板51的各凸状部521、522时机不同地与过滤膜抵接的作用效果受损。另外，当两者的差比0.5mm大时，熔接工序需要过多的时间和能量，所以不理想。
凹状接合部23形成得越深，在沿过滤膜22的外周形状的方向上的单位长度的过滤膜22与滤板21的熔接接合面积变得越大，在这里，处于内侧的凹状接合部231的熔接接合面积被设定得比处于外侧的以带状延伸的网眼状的凹状接合部232的熔接接合面积大。
在将具备此平膜元件2的膜分离装置1用于活性污泥处理设施的场合，将膜分离装置1浸渍在曝气槽内部的活性污泥混合液中，在从散气装置3喷出曝气空气的状态下，由活性污泥对原水中的有机物、氮进行处理。活性污泥混合液以在槽内的水头作为驱动压力，由平膜元件2进行重力过滤，或在透过液导出管9途中安装吸引泵进行吸引过滤。透过了平膜元件2的膜面的透过液作为处理水通过透过液导出管9导出到槽外。
此时，通过从散气装置3喷出的曝气空气的气泡及由其产生的上升流流过相互邻接的平膜元件2之间的狭小流路(5～10mm的宽度)，对平膜元件2的膜面进行清洗，对分离功能的降低进行抑制，防止膜分离装置1变得功能不全的情况发生。
本实施方式的平膜元件2由于将薄片状的过滤膜22推入到凹状接合部231、232，通过热熔接与滤板21接合，所以，过滤膜22与滤板21的表面之间遍及过滤膜22的整个区域成为贴紧的状态，通过外侧的凹状接合部232呈网眼状，过滤膜22的外周缘边25被断续地推入到凹状接合部232地与滤板21接合，所以，过滤膜22的外周缘边25成为伸展的状态，不会从滤板21的滤板面浮起，被保持成与滤板面贴紧的状态。
因此，即使在平膜元件2在处理槽内暴露于与曝气相伴的的上升流的状态下，也可对在过滤膜22发生振动进行抑制，对起因于振动的、过滤膜22从滤板21鼓起、贴着动作的情况进行抑制，使过滤膜22的在熔接部的弯曲应力减少，对疲劳进行抑制。
下面，对平膜元件2的制造方法进行说明。另外，图5至图8是图2中的A-A向视剖视图，表示平膜元件2的制造工序。
如图5所示，在滤板23的表面配置薄片状的过滤膜22。在本实施方式中，由于滤板23至少与过滤膜22的周缘部相当的部位构成为平坦的滤板面，所以，滤板的构造成为简易的构造。
在加热板51上设置直线状的凸状部521和以带状延伸的网眼状的凸状部522，多个凸状部521、522沿过滤膜22的外周形状构成为连续体，而且沿过滤膜22的外周形状配置多重。多个凸状部521、522使高度不同地形成，处于内侧的凸状部521形成得比处于外侧的凸状部522高，而且构成为与在沿过滤膜22的外周形状的方向上的单位长度的过滤膜22抵接的按压面积变大的形状。
接下来，如图6所示的那样使加热板51朝过滤膜22下降，使内侧的高的凸状部521先与过滤膜22抵接，由内侧的凸状部521包围过滤膜22的过滤有效区域。
接下来，如图7所示的那样，进一步使加热板51朝过滤膜22下降，使内侧的高的凸状部521以与外侧的低的凸状部522的高度的一点点的差，约0.2mm左右先行地向滤板21推入，将过滤膜22的过滤有效区域保持为张紧的状态，使外侧的低的凸状部522以延迟的时机与过滤膜22抵接。
通过这样使得各凸状部521、522与过滤膜22抵接的时机不同，在外侧的凸状部522不与过滤膜22抵接的状态下，仅由内侧的高的凸状部521将过滤膜22向滤板21稍微推入，可减轻推入时作用于过滤膜22的应力，并且，作用于加热板51的负荷分级地增加，所以，可对在加热板51一次作用大的负荷的情况进行抑制，可减轻加热板51的热容量及电源容量。
另外，通过由内侧的高的凸状部521先行将过滤膜22向滤板21稍微推入，可在没有皱纹的抻展的状态下的过滤膜22与滤板21贴紧的状态下，对过滤膜22与滤板21之间进行密封，通过先熔接的内侧的凹状接合部231被形成得深，而且单位长度的过滤膜22与滤板21的熔接接合面积形成得大，可实现确实的密封性和确实的接合强度。
接下来，如图8所示的那样，由多个凸状部521、522的全体多重地将过滤膜22的周缘部压紧，一面先由内侧的凸状部521以适当的凹进力将过滤膜22保持为张紧的状态，一面在其后与外侧的凸状部522一起由一次按压操作将多个凸状部521、522向滤板21推入，沿过滤膜22的周缘部多重地形成深度不同的多个凹状接合部231、232，而且将处于内侧的凹状接合部231形成得比处于外侧的凹状接合部232深，在多个凹状接合部231、232同时通过热熔接将过滤膜22与滤板21接合，沿过滤膜22的周缘部对过滤膜22与滤板21之间进行密封。
因此，由于通过加热板51的一次按压操作由多个凹状接合部231、232同时将过滤膜22与滤板21接合，所以，可简化接合操作，并且，可防止在过滤膜22作用过度的应力。
另外，由以上的方法制作的平膜元件2由加热板51的凸状部521、522将薄片状的过滤膜22向滤板21推入，形成凹状接合部231、232，在张紧的状态下通过热熔接将过滤膜22与滤板21接合，所以，过滤膜22与滤板21的表面之间遍及过滤膜22的整个区域成为贴紧的状态。
并且，可将过滤膜22的外周缘以平滑地展开的状态与滤板21熔接。在本实施方式中，通过外侧的凹状接合部232呈网眼状，过滤膜22的外周缘边被断续地向凹状接合部232推入，与滤板21接合，所以，过滤膜22的外周缘边成为伸展的状态，不会从滤板21的滤板面浮起，被保持成与滤板面贴紧的状态。
也可如图4所示的那样，凹状接合部23形成为3根直线状。在此场合，也可通过最外侧的凹状接合部233的宽度形成得宽，对过滤膜的尺寸误差、配置误差进行吸收，将过滤膜22的外周缘边遍及全周地与滤板21进行热熔接。由此，可确实地防止过滤膜22的外周缘边的剥离。

Claims (8)

1.一种平膜元件的制造方法，其特征在于，在由热塑性树脂构成的平坦的滤板的表面配置薄片状的过滤膜，通过将设于加热板的高度不同的多个连续的凸状部从过滤膜的周缘部的上方以使各凸状部与过滤膜抵接的时机不同的方式按压在滤板上，从而将从滤板的表面凹陷的深度不同的多个连续的凹状接合部形成在滤板上，并且，在各凹状接合部通过热熔接将过滤膜与滤板接合，沿过滤膜的周缘部将过滤膜与滤板之间密封。
2.根据权利要求1所述的平膜元件的制造方法，其特征在于，加热板的多个凸状部构成为沿过滤膜的外周形状的多重的连续体，通过加热板的一次按压操作，将多个凹状接合部沿过滤膜的周缘部多重地形成，在多个凹状接合部同时将过滤膜与滤板之间密封。
3.根据权利要求1所述的平膜元件的制造方法，其特征在于，加热板的多个凸状部沿过滤膜的外周形状多重地形成，而且处于内侧的凸状部比处于外侧的凸状部形成得高，多个凹状接合部沿过滤膜的周缘部多重地形成，而且处于内侧的凹状接合部比处于外侧的凹状接合部形成得深。
4.根据权利要求1所述的平膜元件的制造方法，其特征在于，使加热板的多个凸状部高度不同地形成，而且形成得越高则与单位长度的过滤膜抵接的按压面积变得越大，使多个凹状接合部深度不同地形成，而且形成得越深则单位长度的过滤膜与滤板的熔接接合面积变得越大。
5.根据权利要求1所述的平膜元件的制造方法，其特征在于，由沿过滤膜的外周形状多重地形成而且形成为不同高度的加热板的多个凸状部的全体多重地压紧过滤膜的周缘部，一面将过滤膜保持为张紧的状态，一面通过一次按压操作将多个凸状部向滤板推入，将多个凹状接合部沿过滤膜的周缘部多重地而且同时形成，将过滤膜与滤板之间密封。
6.一种平膜元件，其特征在于，薄片状的过滤膜在沿周缘部多重地形成且从滤板的表面凹陷的多个连续的凹状接合部通过热熔接与由热塑性树脂构成的平坦的滤板的表面接合，凹状接合部距离过滤膜表面的深度不同。
7.根据权利要求6所述的平膜元件，其特征在于，多个凹状接合部的处于内侧的凹状接合部比处于外侧的凹状接合部形成得深。
8.根据权利要求6或7所述的平膜元件，其特征在于，多个凹状接合部形成得越深，则单位长度的过滤膜与滤板的熔接接合面积变得越大。
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