CN111315477A - 过滤器 - Google Patents

过滤器 Download PDF

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Publication number
CN111315477A
CN111315477A CN201880072189.1A CN201880072189A CN111315477A CN 111315477 A CN111315477 A CN 111315477A CN 201880072189 A CN201880072189 A CN 201880072189A CN 111315477 A CN111315477 A CN 111315477A
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Prior art keywords
filter
acrylic resin
activated carbon
adsorption layer
alkali metal
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CN201880072189.1A
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日高裕辅
坂口惠子
中泽卓也
吉田贵美子
后藤润
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Dongyang Textile Mc Co ltd
Toyota Boshoku Corp
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Toyota Boshoku Corp
Toyobo Co Ltd
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Publication of CN111315477A publication Critical patent/CN111315477A/zh
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Abstract

本发明的课题在于，提供可以高效率地除去大气中的酸性气体、且耐水性优异的过滤器。一种过滤器，其特征在于，其为具备铝基材、和位于上述铝基材的表面的吸附层的过滤器，上述吸附层包含活性炭、锰氧化物、及pH为3.0～6.5的丙烯酸类树脂。

Description

过滤器
技术领域
本发明涉及可以高效率地除去大气中的酸性气体、且耐水性优异的过滤器。
背景技术
作为除去大气中的有害气体(酸性气体、臭氧、挥发性有机化合物(VOC)等)的方法，已知利用活性炭的吸附作用的酸性气体除去方法。例如，本申请人提出了一种酸性气体吸附·除去过滤器，其在包含有机纤维材料的片状基材上担载有下述化合物、活性炭与锰氧化物的混合物，所述化合物为选自由包含碱金属的氢氧化物、包含碱金属的碳酸盐及包含碱金属的碳酸氢盐组成的组中的1种以上化合物(专利文献1)。另外，本申请人提出了一种酸性气体吸附·除去过滤器，其通过粘结剂树脂(聚乙烯基吡咯烷酮)将下述化合物、活性炭与锰氧化物的混合物担载于片状基材，所述化合物为选自由包含碱金属的氢氧化物、包含碱金属的碳酸盐及包含碱金属的碳酸氢盐组成的组中的1种以上化合物(专利文献2)。
现有技术文献
专利文献
专利文献1:日本特开2017－74309号公报
专利文献2:日本特开2015－134318号公报
发明内容
发明要解决的课题
如专利文献1那样，使用包含有机纤维材料的片作为基材的过滤器有时得不到足够的强度。为了提高过滤器的强度，考虑了在专利文献1的过滤器中将铝基材制成片来代替包含有机纤维材料的片，但是使用铝基材会导致耐水性下降。另一方面，专利文献2中将片状基材设为铝基材时，过滤器的耐水性也下降。
用于解决课题的方案
本发明人们进行了深入研究，结果发现：即使将基材设为铝基材，通过在上述铝基材的表面具备包含活性炭、锰氧化物及pH为3.0～6.5的丙烯酸类树脂的吸附层，也可解决上述课题，从而完成了本发明。
即，一种过滤器，其特征在于，其为具备铝基材、和位于上述铝基材的表面的吸附层的过滤器，上述吸附层包含活性炭、锰氧化物、及pH为3.0～6.5的丙烯酸类树脂。
优选通过上述丙烯酸类树脂而在上述铝基材的表面担载有上述活性炭及上述锰氧化物。
优选上述吸附层还包含下述化合物，所述化合物为选自由包含碱金属的氢氧化物、包含碱金属的碳酸盐、及包含碱金属的碳酸氢盐组成的组中的1种以上化合物。
优选上述铝基材为蜂窝结构体。
发明效果
通过使用本发明的过滤器，可以高效率地除去大气中的酸性气体。另外，本发明的过滤器的耐水性优异，因此可以在各种用途中使用。
具体实施方式
本发明的过滤器的特征在于，具备铝基材、和位于上述铝基材的表面的吸附层。通过使用本发明的过滤器，可以高效率地除去大气中的酸性气体。作为酸性气体，可列举：一氧化氮、二氧化氮等氮氧化物；二氧化硫等硫氧化物；氯化氢、氟化氢等卤化氢；硫化氢等。
＜铝基材＞
铝基材包含铝或铝合金。铝基材的形状没有特别限定，可以为板状也可以为蜂窝结构体，优选制成蜂窝结构体。即，本发明的过滤器优选为蜂窝过滤器。需要说明的是，本说明书中，蜂窝过滤器是指：在作为蜂窝结构体的铝基材的表面具备吸附层的过滤器。关于蜂窝过滤器的孔数，没有特别限制，例如可以设为50～1500孔/平方英寸。
铝基材的厚度优选为0.005～0.5mm，更优选为0.01～0.1mm。通过使铝基材的厚度在上述范围内，即使在作为蜂窝过滤器使用时也具有足够的强度，不易产生压力损失。
＜吸附层＞
吸附层包含活性炭、锰氧化物、及pH为3.0～6.5的丙烯酸类树脂(以下称为低pH丙烯酸类树脂)。优选通过丙烯酸类树脂而在铝基材的表面担载有活性炭及锰氧化物。另外，优选吸附层还包含下述化合物，所述化合物为选自由包含碱金属的氢氧化物、由包含碱金属的碳酸盐及由包含碱金属的碳酸氢盐组成的组中的1种以上化合物(以下称为碱金属化合物)。
(活性炭)
活性炭是通过在对碳材料进行炭化或不熔化后进行活化而得到的。作为上述碳材料，可列举例如石墨、矿物系材料(褐煤、烟煤等煤炭系、石油、或石油沥青等)、植物系材料(木质、果壳(椰子壳等)等)、高分子系材料(聚丙烯腈、酚系材料、纤维素等)等，其中，优选椰子壳。以椰子壳为原料的活性炭(椰子壳活性炭)具有微孔，椰子壳活性炭的微孔与二氧化硅等具有微孔的常见无机原料相比，小的微孔的比率高且包含Na、Si、K、Ca、Fe等的灰分(杂质)也少。即，椰子壳活性炭的微孔小，因此分子间力会作用在所吸附的酸性气体成分与微孔壁之间，使吸附的酸性气体成分不易脱离。
关于碳材料的炭化方法、不熔化方法、活化方法，没有特别限定，可以使用公知的加工方法。例如，作为活化方法，可以使用气体活化法、化学活化法等，所述气体活化法为在水、二氧化碳等活化气体中，在500～1000℃左右对实施了炭化或不熔化处理的碳原料进行热处理的方法，所述化学活化法为将实施了炭化或不熔化处理的碳原料与磷酸、氯化锌、氢氧化钾等活化剂混合并在300～800℃左右进行热处理的方法。
活性炭的BET比表面积优选为500～3000m2/g，更优选为1000～2500m2/g，进一步优选为1500～2000m2/g。通过使活性炭的BET比表面积在上述范围内，能够表现出充分的酸性气体除去性能。
活性炭的平均粒径优选为1～50μm，更优选为2～30μm，进一步优选为5～15μm。若平均粒径在上述范围内，则活性炭粒子在浆料中不易聚集，并且不易发生由外力引起的活性炭脱落。需要说明的是，活性炭的平均粒径是指重量中位径。
吸附层中的活性炭的含有率优选为5～35质量％，更优选为10～25质量％。通过使活性炭的含有率在上述范围内，能够表现出充分的酸性气体除去性能。
(锰氧化物)
作为锰氧化物，没有特别限定，可以使用氧化锰(II)(MnO)、三氧化二锰(III)(Mn2O3)、氧化锰(IV)(二氧化锰、MnO2)、氧化锰(II，III)(四氧化三锰、Mn3O4)等，优选为二氧化锰。
本发明中使用的锰氧化物的BET比表面积优选为50～400m2/g，更优选为100～300m2/g。通过使锰氧化物的BET比表面积在上述范围内，能够表现出充分的酸性气体除去性能。
吸附层中的锰氧化物的含有率更优选为50～85质量％，进一步优选为60～75质量％。通过使锰氧化物的含有率在上述范围内，能够表现出充分的酸性气体除去性能。
(低pH丙烯酸类树脂)
通过在吸附层中使用pH为3.0～6.5的低pH丙烯酸类树脂，从而可以兼顾高酸性气体除去性能和高耐水性。若pH小于3.0，则酸性气体除去性能下降。另外，若pH超过6.5，则与铝基材的亲和性变低，耐水性下降。
pH的调节可以通过利用中和剂对丙烯酸类树脂所具有的羧基等酸性基团进行中和来进行。作为中和剂，只要是可以中和酸性基团的物质就没有特别限定，可列举例如氢氧化钠、氢氧化钾、三甲胺、2－(二甲基氨基)乙醇、2－氨基－2－甲基－1－丙醇、三乙胺、氨水等。通过根据需要适宜使用这些中和剂，可以将丙烯酸类树脂的pH调整到3.0～6.5。需要说明的是，本说明书中，丙烯酸类树脂的pH是指：丙烯酸类树脂乳液的pH。另外，专利文献1中使用的有机硅－丙烯酸类树脂的pH为8以上。
吸附层中的低pH丙烯酸类树脂的固体成分(以下称为低pH丙烯酸类树脂(固体成分))的含有率优选为3～20质量％，更优选为5～10质量％。通过使低pH丙烯酸类树脂的含有率在上述范围内，可以维持过滤器的耐水性、并且表现出充分的酸性气体除去性能。
(碱金属化合物)
碱金属化合物只要为选自由包含碱金属的氢氧化物、包含碱金属的碳酸盐及包含碱金属的碳酸氢盐组成的组中的1种以上化合物即可，作为包含碱金属的氢氧化物，可列举例如NaOH、KOH等，作为包含碱金属的碳酸盐，可列举例如Na2CO3、K2CO3等，作为包含碱金属的碳酸氢盐，可列举例如NaHCO3、KHCO3等。通过使吸附层包含碱金属化合物，可以更进一步提高酸性气体除去性能。碱金属化合物可以单独使用或组合2种以上而使用。其中，优选为包含碱金属的碳酸盐，更优选K2CO3。
相对于活性炭100质量份，碱金属化合物的含量优选为30质量份以下，更优选为1～30质量份，进一步优选为3～25质量份，特别优选为5～15质量份。通过使碱金属化合物的含量在上述范围内，能够表现出充分的酸性气体除去性能。需要说明的是，在使用2种以上的碱金属化合物的情况下，“碱金属化合物的含量”是指全部碱金属化合物的合计含量。
相对于锰氧化物100质量份，碱金属化合物的含量优选为10质量份以下，更优选为1～5质量份，进一步优选为2～4质量份，特别优选为2～3质量份。通过使碱金属化合物的含量在上述范围内，能够表现出充分的酸性气体除去性能。
(其他)
吸附层优选仅由活性炭、锰氧化物、低pH丙烯酸类树脂及碱金属化合物构成，但也可以包含上述以外的物质，例如，可以含有锆、铜、钴、银、碱金属的氧化物、碱土金属的氧化物等。另外，为了赋予阻燃性，也可以根据需要向吸附层中添加氢氧化铝、三聚氰胺等非水溶性阻燃剂。其原因在于，上述非水溶性阻燃剂即使在浆料中也保持粒子形状，不易由于表面被覆等而引起酸性气体除去性能的下降。另外，在浸渍于水时不会溶出，因此即使在过滤器浸渍于水时，也可以维持阻燃性。
活性炭、锰氧化物及低pH丙烯酸类树脂(固体成分)的合计含量优选为吸附层整体的90质量％以上，更优选为93质量％以上，进一步优选为97质量％以上。另外，活性炭、锰氧化物、低pH丙烯酸类树脂(固体成分)及碱金属化合物的合计含量优选为吸附层整体的90质量％以上，更优选为95质量％以上，进一步优选为99质量％以上。
(添附于蜂窝过滤器的吸附层的量)
在铝基材为蜂窝结构体时，添附于蜂窝过滤器的吸附层的量(以下称为添附量)优选为50～200g/L，更优选为100～150g/L。通过使添附量在上述范围内，从而蜂窝过滤器的孔不会发生网眼堵塞，能够表现出充分的酸性气体除去性能。
＜制造方法＞
对本发明的过滤器的制造方法没有特别限定。例如，制作包含活性炭、锰氧化物、低pH丙烯酸类树脂等的浆料，将铝基材浸渍在该浆料中，之后使其干燥，由此可以制作在铝基材表面具备吸附层的过滤器。上述浆料的固体成分比率为10～50％，优选为25～50％。若固体成分比率小于10％，则有活性炭、锰氧化物、低pH丙烯酸类树脂等未充分负载于铝基材表面之虞。另外，若固体成分比率超过50％，则有增粘、浆料的流动性下降而变得不能浸渗之虞。干燥温度通常为60～200℃，优选为100～150℃。若干燥温度超过200℃，则有浆料劣化之虞。另外，若干燥温度低于60℃，则干燥时间变长、成本增加，不优选。
作为蜂窝过滤器的制造方法，可列举例如：在将铝基材制成蜂窝结构体后，将吸附层添附在铝基材表面而制成蜂窝过滤器的方法。关于蜂窝结构体的剖面，只要能够流通气体就没有特别限定，作为蜂窝结构体的剖面，可列举例如六边形、四边形、正弦波形、辊形，从强度的观点出发，蜂窝结构体的剖面优选为六边形。另外，也可以为中空多边形柱、中空圆柱等中空柱体相连接而形成的蜂窝结构体。
本发明的过滤器可以广泛用于室内、交通工具内、壁纸、家具、内饰材料、树脂成型体、电气设备等以减少酸性气体。特别优选用于除去大气中所含的酸性气体的目的，例如，优选将粒状物填充于通气性的箱、袋、网等容器并静置或通气使用。另外，由于除去速度快、已除去的酸性气体发生脱离的问题少，因此更优选在通风状态下使用，具体而言，可以用于：用于净化汽车·轨道车辆等车辆内的空气的空气过滤器；在健康住宅·宠物友好型公寓、养老设施、医院·办公室等中使用的空气净化机用过滤器；空调用过滤器；OA设备的吸气·排气过滤器；楼房空调用过滤器；工业洁净室用过滤器；等。
本申请基于2017年11月10日提交的日本专利申请第2017－217558号要求优先权。将2017年11月10日提交的日本专利申请第2017－217558号的说明书的全部内容援引到本申请中以作参考。
实施例
以下通过实施例进一步详细说明本发明，但下述实施例不限制本发明，在不脱离本发明的主旨的范围内加以变更而成的技术方案均包含在本发明内。
首先对实施例中使用的测定·评价方法说明如下。
(与铝基材的亲和性)
向铝基材上滴加浆料的液滴，测定铝基材与上述液滴的接触角。浆料如后所述。
(耐水性评价方法)
将样品(蜂窝过滤器)在离子交换水中浸渍24小时后，从水中提起，由浸渍处理前后的质量变化计算来自吸附层的脱落量[mg]，将该吸附层的脱落量[mg]除以样品的体积[cc]，从而计算每1cc样品的吸附层脱落量[mg/cc]。
(二氧化硫除去性能)
将样品(蜂窝过滤器)切成直径26mm、高度20mm，将切割后的样品放置在内径26mm的玻璃柱内，以2.0L/分钟的流量流通包含二氧化硫气体100ppm的温度25℃、相对湿度50％的空气。玻璃柱内的温度稳定在25℃。对于玻璃柱的入口、出口处的浓度，利用光声气体监测器1312(INNOVA公司制)连续测定从测定开始起至经过1小时时为止的二氧化硫气体的浓度变化。然后，对二氧化硫气体的浓度变化进行数值积分而算出1小时的二氧化硫气体除去量[mg]。将该二氧化硫气体除去量[mg]除以切割而成的样品的体积[cc]，从而算出每1cc样品的二氧化硫气体除去量[mg/cc]。
(丙烯酸类树脂的pH)
使用堀场制作所公司制pH计测定丙烯酸类树脂乳液的pH。
〔实施例1〕
将椰子壳活性炭350g(BET比表面积：1800m2/g、粒径：13μm)、二氧化锰1300g(BET比表面积：200m2/g)及pH为3的丙烯酸类树脂乳液325g(丙烯酸类树脂的固体成分：30质量％)添加到2300g离子交换水中，搅拌过夜而使其充分地分散，制备了浆料。接着，将以厚度0.015mm的铝箔为基材的蜂窝结构体(剖面：六边形、850孔/平方英寸)浸渍在上述浆料中，在确认上述浆料充分渗透到蜂窝结构体内部后，将蜂窝结构体提起。用空气流从蜂窝结构体吹掉多余的浆料后，在干燥机内在120℃下干燥3小时，从而得到在蜂窝结构体的表面具备吸附层的蜂窝过滤器。由具备吸附层前的蜂窝过滤器的质量及具备吸附层后的蜂窝过滤器的质量算出蜂窝过滤器中的吸附层添附量的结果是130g/L。
〔实施例2〕
使用pH为6的丙烯酸类树脂乳液，除此以外，通过与实施例1同样的方法得到蜂窝过滤器。蜂窝过滤器中的吸附层的添附量为130g/L。
〔实施例3〕
使用pH为6的丙烯酸类树脂乳液，并且向离子交换水中进一步添加碳酸钾40g，除此以外，通过与实施例1同样的方法得到蜂窝过滤器。蜂窝过滤器中的吸附层的添附量为133g/L。
〔比较例1〕
使用pH为2的丙烯酸类树脂乳液，除此以外，通过与实施例1同样的方法得到蜂窝过滤器。蜂窝过滤器中的吸附层的添附量为130g/L。
〔比较例2〕
使用pH为10的丙烯酸类树脂乳液，除此以外，通过与实施例1同样的方法得到蜂窝过滤器。蜂窝过滤器中的吸附层的添附量为130g/L。
〔比较例3〕
使用pH为10的丙烯酸类树脂乳液，并且向离子交换水中进一步添加碳酸钾40g，除此以外，通过与实施例1同样的方法得到蜂窝过滤器。蜂窝过滤器中的吸附层的添附量为133g/L。
将实施例及比较例的构成及各种物性示于表1。就实施例1～3的过滤器而言，铝基材与吸附层制作用浆料的亲和性高，耐水性优异，并且可以高效率地除去二氧化硫气体。另外，实施例1～3的过滤器中，通过丙烯酸类树脂在铝基材的表面担载有椰子壳活性炭及二氧化锰。另一方面，比较例1的过滤器由于丙烯酸类树脂的pH过低，因此二氧化硫气体的除去不充分。比较例2及3的过滤器由于丙烯酸类树脂的pH过高，因此铝基材与吸附层制作用浆料的亲和性低，耐水性不充分。
[表1]
Figure BDA0002481237960000091

Claims (4)

1.一种过滤器，其特征在于，其为具备铝基材、和位于所述铝基材的表面的吸附层的过滤器，
所述吸附层包含活性炭、锰氧化物、及pH为3.0～6.5的丙烯酸类树脂。
2.根据权利要求1所述的过滤器，其中，通过所述丙烯酸类树脂而在所述铝基材的表面担载有所述活性炭及所述锰氧化物。
3.根据权利要求1或2所述的过滤器，其中，所述吸附层还包含下述化合物，所述化合物为选自由包含碱金属的氢氧化物、包含碱金属的碳酸盐及包含碱金属的碳酸氢盐组成的组中的1种以上化合物。
4.根据权利要求1～3中任一项所述的过滤器，其中，所述铝基材为蜂窝结构体。
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