CN110386828A - 过滤器构件及其制备方法 - Google Patents

过滤器构件及其制备方法 Download PDF

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Publication number
CN110386828A
CN110386828A CN201910284880.2A CN201910284880A CN110386828A CN 110386828 A CN110386828 A CN 110386828A CN 201910284880 A CN201910284880 A CN 201910284880A CN 110386828 A CN110386828 A CN 110386828A
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method described
inch
compound mixture
ceramic filter
filter component
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CN201910284880.2A
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CN110386828B (zh
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迈克尔·T·卡森
斯蒂芬妮·R·索德克
凯特林·D·兹沃拉克
霍赛纳利·萨赫布·埃克蒂亚里
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Kohler Co
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Kohler Co
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068—Other inorganic materials, e.g. ceramics
    • B01D39/2072—Other inorganic materials, e.g. ceramics the material being particulate or granular
    • B01D39/2079—Other inorganic materials, e.g. ceramics the material being particulate or granular otherwise bonded, e.g. by resins
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/001—Processes for the treatment of water whereby the filtration technique is of importance
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    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00—Treatment of water, waste water, or sewage
    • C02F1/44—Treatment of water, waste water, or sewage by dialysis, osmosis or reverse osmosis
    • C02F1/444—Treatment of water, waste water, or sewage by dialysis, osmosis or reverse osmosis by ultrafiltration or microfiltration
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Abstract

一种用于制造过滤器构件的方法，其包括：将预定量的沸石与氧化铝混合以形成复合混合物；将涂覆材料喷涂到所述复合混合物上以形成包含颗粒的经涂覆的复合混合物；过滤所述颗粒以获得具有预定长度尺寸的颗粒；对所获得的颗粒成形以形成具有预定厚度的压实盘；以及对所述压实盘进行热处理以形成过滤器构件。

Description

过滤器构件及其制备方法
相关申请的交叉引用
本申请要求于2018年4月18日提交的美国临时申请No.62/659,436的权益和优先权，所述申请的全部公开内容特此通过引用并入本文。
背景技术
本申请涉及一种用于水纯化应用中的陶瓷过滤膜材料。更具体地，本申请涉及一种陶瓷过滤器构件，其包括用于微生物的液体过滤的高强度的基于氧化铝的过滤膜。
用于水过滤的过滤器的现有技术可使用由硅藻土制成的膜过滤器。这些过滤器是易碎的并且可能在清洗过程中容易断裂。另外，用于此类膜过滤器的制造工艺需要烧尽重有机物以在过滤器中形成孔结构。此外，基于硅藻土的过滤器在水过滤工艺中往往不会充分地去除微生物(例如，细菌、微生物体、真菌等)，消除颜色、味道和气味或将副产物前体消毒。基于硅藻土的过滤器对于具有低浊度的液体受限并且可能需要用于有效去除微生物的额外组分(例如，凝结剂和助滤剂)，从而增加此类过滤器的使用成本。
提供克服上述挑战的用于微生物的液体过滤的改进的陶瓷过滤膜材料将是有利的。这些和其他有利特征对于查看本公开的人将是显而易见的。
发明内容
示例性实施方案涉及一种用于制造过滤器构件的方法，其包括：将预定量的沸石与氧化铝混合以形成复合混合物；将涂覆材料喷涂到所述复合混合物上以形成包含颗粒的经涂覆的复合混合物；过滤所述颗粒以获得具有预定长度尺寸的颗粒；对所获得的颗粒成形以形成具有预定厚度的压实盘；以及对所述压实盘进行热处理以形成过滤器构件。
在一些示例性实施方案中，所述混合和喷涂同时执行。
在一些示例性实施方案中，实施所述喷涂，直至所述经涂覆的复合混合物达到在约6％L至约18％L范围内的含水量。
在一些示例性实施方案中，所述过滤保留具有至少一个小于约840μm的长度尺寸的颗粒。
在一些示例性实施方案中，所述成形通过在约45巴至约85巴范围内的压紧力下操作的压模来实施。
在一些示例性实施方案中，所述压实盘具有在约0.1英寸至约0.4英寸范围内的厚度。
在一些示例性实施方案中，所述压实盘具有在约0.200英寸至约0.365英寸范围内的厚度。
在一些示例性实施方案中，热处理包括第一热处理步骤和第二热处理步骤。
在一些示例性实施方案中，所述第一热处理步骤在约400℃至约800℃范围内的温度实施达在约2小时至约5小时范围内的时间。
在一些示例性实施方案中，所述第二热处理步骤在约950℃至约1400℃范围内的温度实施达在约15分钟至约45分钟范围内的时间。
在一些示例性实施方案中，所述氧化铝的含量在总复合混合物的约30重量％至约60重量％的范围内。
在一些示例性实施方案中，所述沸石的含量在总复合混合物的约25重量％至约60重量％的范围内。
在一些示例性实施方案中，所述复合混合物还包含硬脂酸锌。
在一些示例性实施方案中，所述硬脂酸锌的含量在约0重量％至约15重量％的范围内。
在一些示例性实施方案中，沸石是含水铝硅酸钠、无水铝硅酸钠、铝硅酸钾或含水铝硅酸钙钠中的至少一种。
另一个示例性实施方案涉及一种通过本文所述的方法中的任一种形成的陶瓷过滤器构件，其具有在约1μm和约10μm范围内的孔径。
在一些示例性实施方案中，孔径在约3μm至约6μm的范围内。
在一些示例性实施方案中，所述陶瓷过滤器构件具有在约4.0英寸至约8.0英寸范围内的直径。
在一些示例性实施方案中，所述陶瓷过滤器构件具有在约0.1英寸至约0.6英寸范围内的厚度。
在一些示例性实施方案中，所述陶瓷过滤器构件具有在约0.2英寸至约0.5英寸范围内的厚度。
在一些示例性实施方案中，所述陶瓷过滤器构件具有在约0.1μm至约2μm范围内的孔颈(pore necking)大小。
在一些示例性实施方案中，所述陶瓷过滤器构件具有在约0.8μm至约1.2μm范围内的孔颈大小。
附图说明
图1是根据示例性实施方案的陶瓷过滤器构件的侧视图。
图2是图1的陶瓷过滤器构件的顶视图。
图3是图1的陶瓷过滤器构件的透视图。
图4是图1的陶瓷过滤器构件的底视图。
图5是沿线B-B截取的图4的陶瓷过滤器构件的横截面图。
图6是沿线A-A截取的图4的陶瓷过滤器构件的横截面图。
图7至图8是图6的陶瓷过滤器构件的细部图。
图9是说明根据示例性实施方案的形成图1的陶瓷过滤器构件的方法的流程图。
具体实施方式
本公开涉及一种过滤器构件(例如，膜等)，其包含煅烧氧化铝主体结构并且利用沸石/硬脂酸锌材料来帮助在基体材料内形成孔。这种构造的一些益处包括：例如，(1)减少粘合剂材料的使用，(2)显著减少烧失量，以及(3)孔径形成更稳定且可再现。本文所述的制造方法产生更坚固的陶瓷过滤膜材料，其使用氧化铝并且在某种程度上由于热处理工艺期间的最少重量损失(即，“燃烧损耗”接近零)而具有更长的使用寿命。
根据图9所示的示例性实施方案，示出根据示例性实施方案的用于制造过滤器构件10(在图1至图8中示出)的方法100。方法100包括将预定量的沸石与氧化铝材料混合以形成复合混合物的步骤110。所述混合可在具有加压粘合剂递送系统的强力混合器中发生。其他混合方法包括螺带式混合器和行星式混合器。在一些实施方案中，煅烧氧化铝的含量可在总复合混合物的约30重量％至约60重量％范围内。在一些实施方案中，煅烧氧化铝可具有在约0.5m2/g至约0.9m2/g(例如，0.7m2/g)范围内的比表面积。在一些实施方案中，煅烧氧化铝可具有在约30μm至约60μm范围内(例如，45μm)的粒度分布(D90)。氧化铝可通过使用陶瓷介质在连续进料球磨机中进行干磨来预制备，并由正常苏打煅烧氧化铝和低苏打煅烧氧化铝研磨而成。
在一些实施方案中，沸石的含量可在总复合混合物的约25重量％至约60重量％范围内。在一些实施方案中，沸石可以是含水铝硅酸钠、无水铝硅酸钠、铝硅酸钾或含水铝硅酸钙钠中的至少一种。沸石可被预调质以制备在约1μm至约480μm范围内的沸石颗粒。在一些实施方案中，沸石颗粒可具有在约1μm至约45μm范围内的直径。在其他实施方案中，沸石颗粒可具有在约45μm至约270μm范围内的直径。在又一些其他实施方案中，沸石颗粒可具有在约270μm至约480μm范围内的直径。
在一些实施方案中，复合混合物还可包含在总复合混合物的约0重量％至约15重量％范围内的低水平硬脂酸锌。在一些实施方案中，硬脂酸锌颗粒可具有在约40μm至约60μm范围内的直径。在一些实施方案中，硬脂酸锌颗粒可具有在约50μm至约55μm范围内(例如，53μm)的直径。在一个实施方案中，复合混合物通过以下来形成：在具有加压雾化粘合剂递送系统(例如，无气喷嘴)的强力混合器中将煅烧氧化铝、沸石和硬脂酸盐材料混合达在约15秒至约2分钟范围内(例如，30秒)的时间，或混合直至复合混合物为均质的为止。
仍然参考图9，方法100还包括将涂覆材料喷涂到复合混合物上以形成经涂覆的复合混合物的步骤120。经涂覆的复合混合物可包含具有各种大小的颗粒。在一些实施方案中，涂覆材料包括粘合剂/水混合物，其包含基于非离子丙烯酸共聚物的乳液(例如，等)、石蜡和蜡的稳定乳液(例如，等)和水。在一个示例性实施方案中，粘合剂/水混合物包含约1％-10％范围内(例如，7％)的蜡乳液。粘合剂/水混合物可在混合期间被喷涂在干燥复合混合物上(即，混合和喷涂同时执行)。在一些实施方案中，混合在喷涂工艺的循环过程中发生。例如，混合可在发生的同时，在约15-40秒‘进行’(例如，25-35秒)和约0-40秒‘停止’(例如，25-35秒)的范围内的间隔下循环。在其他实施方案中，粘合剂/水混合物可在混合之前喷涂在干燥复合混合物的单个组分上。在又一些其他的实施方案中，粘合剂/水混合物可在混合之后喷涂在干燥复合混合物上。可实施所述喷涂，直至经涂覆的复合混合物达到在约5％L至约20％L范围内的含水量。在示例性实施方案中，可实施所述喷涂，直至经涂覆的复合混合物达到在约6％L至约18％L范围内的含水量。粘合剂的含量可在总的经涂覆的复合混合物的约1重量％至约5重量％范围内。
方法100还包括过滤(例如，筛选等)具有经涂覆的复合结构的颗粒以获得具有预定长度尺寸的颗粒的步骤130。在一个实施方案中，过滤可使用不锈钢筛网(即，筛子等)来实施，使得所述过滤保留具有至少一个小于约840μm的长度尺寸的颗粒。以这种方式，从干燥的经涂覆的复合混合物去除较大的聚集体或颗粒。
仍然参考图9，方法100还包括对所获得的颗粒成形以形成具有预定厚度的压实盘的步骤140。在一个实施方案中，所获得的颗粒使用压模来成形。在已过滤颗粒之后，然后将颗粒负载到具有腔体的压模中，所述腔体具有至少一个为至少六英寸的长度尺寸。例如，压模可具有腔体，所述腔体具有至少六英寸(例如，6.125英寸等)的直径。在另一个实施方案中，压模可具有腔体，所述腔体具有至少一个小于六英寸的长度尺寸。在一个实施方案中，所述腔体具有在约0.1英寸至约1英寸范围内的深度。例如，所述腔体可具有在约0.25英寸至约0.8英寸范围内或在约0.5英寸至约0.7英寸范围内(例如，0.66英寸)的深度(垫片深度)。将经筛选的颗粒材料加载到腔体中，使得粉末基本上均匀地沉积，并且与压模腔体的顶部边缘平齐。在一个实施方案中，然后可将压模在以约45巴至约85巴范围内(例如，约70-75巴)的压紧力操作的70T-C框式压机上挤压。低于或高于所公开的范围的压紧力导致所得的盘的机械特性劣化(即，可见的裂纹和/或碎裂边缘)。在所公开的压紧力范围内，良好压实的盘从压模脱出，不具有可见的缺陷(即，裂纹、碎裂边缘等)。在一个实施方案中，压实盘具有在约0.1英寸至约0.4英寸范围内的厚度。在另一个实施方案中，压实盘具有在约0.200英寸至约0.365英寸范围内(例如，0.249英寸)的厚度。在一个实施方案中，压实比(即，压紧前颗粒的厚度与压紧后压实盘的厚度之间的比率)在约1.8至约2.4的范围内(例如，2.0)。
仍然参考图9，方法100还包括热处理压实盘以形成过滤器构件(例如，过滤盘等)，诸如图1至图8中所示的过滤器构件10的步骤150。在一些实施方案中，热处理包括第一热处理步骤和第二热处理步骤。在一个实施方案中，所述第一热处理步骤是在约400℃至约800℃范围内的温度实施达在约2小时至约5小时范围内(例如，3小时)的时间的粘合剂烧尽。在一个实施方案中，所述第二热处理步骤在约950℃至约1400℃范围内的温度实施达在约15分钟至约45分钟范围内(例如，30分钟)的时间。每个压实盘可在窑炉、熔炉、烘箱或相似的热处理容器中被进行热处理，并且被水平地加载在窑炉的平台上或水平地加载在窑炉的耐火瓷砖调节器上。
图1至图8示出根据示例性实施方案通过图9的方法100获得的陶瓷过滤器构件10。陶瓷过滤器构件10可通过本文公开的各种方法来形成以限定具有在约1μm和约10μm范围内的孔径的高强度的基于氧化铝的过滤膜。在一个示例性实施方案中，陶瓷过滤器构件10可具有在约3μm至约6μm范围内的孔径。陶瓷过滤器构件10可具有在约4.0英寸至约8.0英寸的范围内(例如，6.0英寸)的直径在一些实施方案中，陶瓷过滤器构件10可具有在约0.1英寸至约0.6英寸范围内的厚度T。在一个示例性实施方案中，陶瓷过滤器构件10可具有在约0.2英寸至约0.5英寸范围内(例如，0.46英寸)的厚度T。在一些实施方案中，陶瓷过滤器构件10可具有在约0.1μm至约2μm范围内的孔颈大小。在一个示例性实施方案中，陶瓷过滤器构件10可具有在约0.8μm至约1.2μm范围内(例如，1μm)的孔颈大小。以这种方式，在陶瓷过滤器构件10的主体中产生的孔可限定可供沸石组分熔化和汇集的通道。
因此，本公开提供一种陶瓷过滤器设计，其使用煅烧氧化铝主体结构并且形成有可有利地从水过滤细菌剂或其他微生物的沸石/硬脂酸锌孔。所公开的陶瓷过滤器构件的其他用途可作为气体吸附剂、油和气体应用中的污染物过滤装置、水脱盐装置等。本文所述的制造方法的益处包括：例如，(1)减少粘合剂材料的使用，(2)显著减少烧失量，以及(3)孔径形成更稳定且可再现。所得的陶瓷过滤器构件比使用常规方法形成的陶瓷过滤器更坚固并且具有更长的使用寿命。更具体地，热处理步骤期间的燃烧损失产生过滤器构件的最少重量损失。
如本文所用，术语“大约”、“约”、“基本上”以及相似的术语旨在与本公开的主题所属领域的普通技术人员所常见和接受的用法具有一致的广泛意义。查看此公开的本领域技术人员应理解，这些术语旨在允许描述所描述并要求保护的某些特征而不将这些特征的范围限定于所提供的精确数值范围。因此，这些术语应解释为指示，所描述并要求保护的主题的非实质性或不重要修改或改变被认为在如所附权利要求所记载的本发明的范围内。
本文对元件位置的引用(例如，“顶部”、“底部”、“上方”、“下方”等)仅用于描述附图中各种元件的取向。应注意，各种元件的取向可根据其他示例性实施方案而不同，并且这类变化旨在由本公开所涵盖。
如示例性实施方案中所示的陶瓷过滤膜的元件的构造和布置仅是说明性的。虽然已详细描述了本公开的仅仅几个实施方案，但是查看此公开的本领域技术人员将易于认识到，在实质上不背离所记载主题的新颖性教导和优点的情况下，许多修改是可能的(例如，各种元件的大小、尺寸、结构、形状和比例、参数值、安装布置、材料使用、颜色、取向等的变化)。例如，示为一体形成的元件可由多个元件部分构造，元件的位置可反向或以其它方式变化，并且离散元件或位置的性质或数量可改变或变化。
另外，用语“示例性”用于意指充当示例、实例或说明。本文描述为“示例性”的任何实施方案或设计不一定被解释为对于其他实施方案或设计是优选或有利的(并且这类术语不旨在暗示此类实施方案一定是优异或最佳的示例)。相反，词语“示例性”的使用旨在以具体形式呈现概念。因此，所有此类修改旨在包括在本公开的范围内。可在不背离所附权利要求的范围的情况下，在优选和其他示例性实施方案的设计、操作条件和布置方面做出其他置换、修改、改变和省略。
也可在不背离本发明的范围的情况下，在各种示例性实施方案的设计、操作条件和布置方面做出其他置换、修改、改变和省略。例如，在一个实施方案中所公开的任何元件可与本文公开的任何其他实施方案合并或一起使用。另外，例如，任何工艺或方法步骤的顺序或排序可根据可替选实施方案而变化或重新排序。任何装置加功能条款旨在覆盖本文所述的执行所记载功能的结构，并且不仅覆盖结构等效物，还覆盖等效结构。可在不背离所附权利要求的范围的情况下在优选和其他示例性实施方案的设计、操作配置和布置方面做出其他置换、修改、改变和省略。
虽然本说明书包含许多特定实施细节，但是这些不应被解释为对于任何发明或所要求保护的内容的范围的限制，而是解释为对具体发明的具体实施方案特定的特征的描述。在单独实施方案的情况下在本说明书中描述的某些特征也可与单个实施方案组合实施。相反，在单个实施方案的情况下描述的各种特征也可在多个实施方案中单独地或以任何合适的子组合实施。此外，虽然特征在以上可描述为在某些组合中发挥作用并且甚至如此初始地要求保护，但是来自所要求保护的组合的一个或多个特征可从所述组合去除，并且所要求保护的组合可针对子组合或子组合的变型。
相似地，虽然操作在附图中以特定顺序描绘，但是这不应被解释为为了实现所希望的结果，要求此类操作以所示的特定顺序或以先后顺序执行或所有所示的操作均被执行。在某些实施方案中，多重任务处理和并行处理可以是有利的。此外，以上所述的实施方案中各种系统部件的分离不应被解释为在所有实施方案中都要求这种分离，并且应理解，所述的程序部件和系统通常可在单个软件产品中整合在一起或组装到多个软件产品中。
因此，已描述了主题的特定实施方案。在一些情况下，本文记载的动作可以不同顺序执行并且仍然实现所希望的结果。另外，为了实现所希望的结果，附图中描绘的过程不一定需要所示的特定顺序或先后顺序。在某些实施方式中，多重任务处理和并行处理可以是有利的。

Claims (20)

1.一种用于制造过滤器构件的方法，包括：
将预定量的沸石与氧化铝混合以形成复合混合物；
将涂覆材料喷涂到所述复合混合物上以形成包含颗粒的经涂覆的复合混合物；
过滤所述颗粒以获得具有预定长度尺寸的颗粒；
对所获得的颗粒成形以形成具有预定厚度的压实盘；以及
热处理所述压实盘以形成过滤器构件。
2.根据权利要求1所述的方法，其中所述混合和喷涂同时执行。
3.根据权利要求1所述的方法，其中实施所述喷涂，直至所述经涂覆的复合混合物达到约6％L至约18％L范围内的含水量。
4.根据权利要求1所述的方法，其中所述过滤保留具有至少一个小于约840μm的长度尺寸的颗粒。
5.根据权利要求1所述的方法，其中所述成形通过以在约45巴至约85巴范围内的压紧力操作的压模来实施。
6.根据权利要求1所述的方法，其中所述压实盘具有在约0.1英寸至约0.4英寸范围内的厚度。
7.根据权利要求6所述的方法，其中所述压实盘具有在约0.200英寸至约0.365英寸范围内的厚度。
8.根据权利要求1所述的方法，其中热处理包括第一热处理步骤和第二热处理步骤。
9.根据权利要求8所述的方法，其中所述第一热处理步骤在约400℃至约800℃范围内的温度实施约2小时至约5小时范围内的时间。
10.根据权利要求8所述的方法，其中所述第二热处理步骤在约950℃至约1400℃范围内的温度实施约15分钟至约45分钟范围内的时间。
11.根据权利要求1所述的方法，其中所述氧化铝的含量在总复合混合物的约30重量％至约60重量％的范围内。
12.根据权利要求1所述的方法，其中所述沸石的含量在总复合混合物的约25重量％至约60重量％的范围内。
13.根据权利要求1所述的方法，其中所述复合混合物还包含硬脂酸锌。
14.根据权利要求13所述的方法，其中所述硬脂酸锌的含量在约0重量％至约15重量％的范围内。
15.根据权利要求1所述的方法，其中所述沸石是含水铝硅酸钠、无水铝硅酸钠、铝硅酸钾或含水铝硅酸钙钠中的至少一种。
16.一种通过根据权利要求1所述的方法形成的陶瓷过滤器构件，所述陶瓷过滤器构件具有在约1μm至约10μm范围内的孔径。
17.根据权利要求16所述的陶瓷过滤器构件，其中所述孔径在约3μm至约6μm的范围内。
18.根据权利要求16所述的陶瓷过滤器构件，所述陶瓷过滤器构件具有在约4.0英寸至约8.0英寸范围内的直径。
19.根据权利要求16所述的陶瓷过滤器构件，具有在约0.1英寸至约0.6英寸范围内的厚度。
20.根据权利要求16所述的陶瓷过滤器构件，具有在约0.1μm至约2μm范围内的孔颈大小。
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