CN114786798A - 过滤器及其制造方法 - Google Patents
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Abstract
提供了一种能够将多孔树脂牢固且始终如一地保持在支持体上并且在维持杂质阻止率的同时增加透过水量的过滤器及该过滤器的制造方法。提供了能够滤除杂质的过滤器和该过滤器的制造方法,该方法包括:用通过将预定树脂溶解在预定溶剂中制备的树脂溶液含浸包含纤维状结构体的支持体,并将所述支持体在非溶剂液体中浸渍以用所述非溶剂液体置换所述树脂溶液中包含的溶剂,从而在所述支持体内部一体化形成过滤膜,所述过滤膜包含多孔树脂并且能够滤除杂质。
Description
技术领域
本发明涉及一种能够滤除杂质的过滤器及该过滤器的制造方法。
背景技术
例如,在净水厂进行的水处理中使用微滤膜和超滤膜等,在海水淡化的水处理中使用反渗透膜等。包含微滤膜或超滤膜的过滤器的实例包括通过下述方式制成的过滤器:用棒涂机等将树脂溶液均匀地涂布在由PET无纺布等构成的支持体的表面上,并将支持体在水等非溶剂液体中浸渍以通过相分离(NIPS法)用非溶剂液体置换树脂溶液的溶剂,从而在支持体表面上形成多孔树脂。例如,专利文献1中公开了一种超滤膜,其包括支持体和设置在支持体表面上的多孔树脂(致密多孔皮层部分)。
现有技术文献
专利文献
专利文献1:日本特开平9-299772号公报
发明内容
技术问题
在上述现有技术中,由于多孔树脂形成在支持体的表面上,因此可能难以将多孔树脂牢固且始终如一地保持在支持体上。此外,在现有技术中已知的过滤器中,由于难以在保持开口尺寸的同时增加多孔树脂的开口数量(开口率),因此难以在保持杂质阻止率的同时增加透过水量。
鉴于上述情况而完成了本发明。本发明提供了一种能够将多孔树脂牢固且始终如一地保持在支持体上并且在维持杂质阻止率的同时增加透过水量的过滤器及该过滤器的制造方法。
问题的解决方案
权利要求1所述的发明是一种能够滤除杂质的过滤器,该过滤器包括:由纤维状结构体组成的支持体;和在所述支持体内部一体化形成的过滤膜,该过滤膜包含多孔树脂并且能够滤除杂质。
权利要求2所述的发明基于权利要求1所述的过滤器,其中,所述过滤膜包含开口率为6%~30%的多孔树脂膜。
权利要求3所述的发明基于权利要求1或2所述的过滤器,其中,所述支持体包括厚度为0.03~0.5mm的结构体。
权利要求4所述的发明基于权利要求1~3中任一项所述的过滤器,其中,所述过滤膜包含厚度为10~500μm的多孔树脂。
权利要求5所述的发明基于权利要求1~4中任一项所述的过滤器,其中,所述支持体包括含有化学纤维的结构体。
权利要求6所述的发明基于权利要求5所述的过滤器,其中,所述支持体包含芳族聚酰胺树脂或聚对苯二甲酸乙二醇酯树脂。
权利要求7所述的发明基于权利要求1~6中任一项所述的过滤器,其中,所述过滤膜包含聚砜(PSF)、聚偏二氟乙烯(PVDF)、聚醚砜(PES)、聚酰亚胺(PI)、聚氯乙烯(PVC)或醋酸纤维素(CA)。
权利要求8所述的发明是一种能够滤除杂质的过滤器的制造方法,该方法包括:用通过将预定树脂溶解在预定溶剂中制备的树脂溶液含浸由纤维状结构体组成的支持体,并将所述支持体在非溶剂液体中浸渍以用所述非溶剂液体置换所述树脂溶液中包含的溶剂,从而在所述支持体内部一体化形成过滤膜,所述过滤膜包含多孔树脂并且能够滤除杂质。
权利要求9所述的发明基于权利要求8所述的过滤器的制造方法,其中,所述过滤膜包含开口率为6%~30%的多孔树脂膜。
权利要求10所述的发明基于权利要求8或9所述的过滤器的制造方法,其中,所述支持体包括厚度为0.03~0.5mm的结构体。
权利要求11所述的发明基于权利要求8~10中任一项所述的过滤器的制造方法,其中,所述过滤膜包含厚度为10~500μm的多孔树脂。
权利要求12所述的发明基于权利要求8~11中任一项所述的过滤器的制造方法,其中,所述支持体包括含有化学纤维的结构体。
权利要求13所述的发明基于权利要求12所述的过滤器的制造方法,其中,所述支持体包含芳族聚酰胺树脂或聚对苯二甲酸乙二醇酯树脂。
权利要求14所述的发明基于权利要求8~13中任一项所述的过滤器的制造方法,其中,所述过滤膜包含聚砜(PSF)、聚偏二氟乙烯(PVDF)、聚醚砜(PES)、聚酰亚胺(PI)、聚氯乙烯(PVC)或醋酸纤维素(CA)。
发明的有益效果
根据本发明,多孔树脂可以牢固且始终如一地保持在支持体上。此外,可以在保持杂质阻止率的同时增加透过水量。
附图说明
图1是示出根据本发明的实施方式的过滤器的制造方法的流程图。
图2是说明制造过滤器的步骤的示意图。
图3是说明制造过滤器的步骤的示意图。
图4是说明制造过滤器的步骤的示意图。
图5是说明通过本实施方式的制造方法制造的实施例的过滤器的示意图。
图6是说明通过现有技术已知的制造方法制造的比较例的过滤器的示意图。
图7是列出在实施例和比较例各自中测量的透过水量和阻止率的表。
图8是根据本发明的实施方式的过滤器的内部结构的显微照片。
图9包括(a)在过滤器中形成的开口的显微照片和(b)显微照片的二值化图。
图10包括(a)在现有技术中已知的过滤器中形成的开口的显微照片和(b)显微照片的二值化图。
具体实施方式
在下文中,将参照附图具体描述本发明的实施方式。
本实施方式的过滤器能够从水中分离并滤除杂质,是能够阻止蛋白质、病毒和细菌等的“UF膜(或MF膜)”。如图5所示,过滤器5包括内部为纤维状结构体的支持体1和在支持体1内部一体化形成的过滤膜M,该过滤膜M由多孔树脂构成并且能够滤除杂质。
具体而言,本实施方式的支持体1由通过抄纸法(抄造法)以片状(纸张)形成的无纺布等构成。其内部为纤维状(网状)结构体。纤维状结构体的内部用多孔树脂含浸,使得它们形成一体。本实施方式的支持体1由芳族聚酰胺树脂构成,其具有最大孔径约为270μm的开口。在本实施方式中,特别是将开口率设定为6%~30%。
芳族聚酰胺树脂(芳香族聚酰胺)由具有优异耐热性和高机械强度的塑料组成。例如,在多孔树脂由聚砜(PSF)构成的情况下,形成氢键并且是疏水性的,这提供了增加的密着性(亲和性)。与此相对,在支持体1由PET树脂(聚对苯二甲酸乙二醇酯树脂)或纸浆等构成的情况下,在支持体1和由聚砜(PSF)构成的多孔树脂之间不形成氢键。
本实施方式的过滤器5优选包含由多孔树脂构成并且开口率为6%~30%和/或厚度为10~500μm的过滤膜M和厚度为0.03至0.5mm和/或由包含化学纤维的结构体组成的支持体1。优选的是,本实施方式的支持体1由芳族聚酰胺树脂或聚对苯二甲酸乙二醇酯树脂构成,过滤膜M由聚砜(PSF)、聚偏二氟乙烯(PVDF)、聚醚砜(PES)、聚酰亚胺(PI)、聚氯乙烯(PVC)或醋酸纤维素(CA)构成。
下面基于图1所示的流程图,对本实施方式的过滤器的制造方法进行说明。
将聚砜溶解在甲基甲酰胺中以制备树脂溶液2(聚合物溶液)(S1)。如图2和3所示,将通过抄纸法将芳族聚酰胺纤维浆料形成为纸张状而制备的载体1用树脂溶液2含浸以制备树脂含浸体3。
在用棒涂机除去残留在表面上的剩余溶液后,如图4所示,将树脂含浸体3在非溶剂4(在本实施方式中为水)中浸渍(S3)。这引起了用非溶剂4(水)置换树脂溶液2的溶剂的相分离现象。因此,如图5和8所示,可以形成包含在支持体1内部一体化形成的由多孔树脂构成并且能够滤除杂质的过滤膜M的过滤器5。
具体而言,将上述利用相分离现象的膜制造方法称为“NIPS法”。由于树脂溶液2的溶剂通过相分离现象而被非溶剂4(水)置换并且树脂固化,结果树脂部分形成过滤膜M,被水置换的溶剂部分成为过滤膜M的孔(开口)。以上述方式制造的过滤器5包括由芳族聚酰胺纤维构成的支持体1和由聚砜构成的过滤膜M,用作超滤膜(UF膜)。
在以上述方式制造的过滤器5中,支持体1具有0.15mm的厚度。过滤器5的总厚度为0.30mm,平均孔径为0.026μm,开口率为9.0%。此处使用的术语“开口率”是指每单位面积的孔隙部分的面积比例。开口率越高,透过水量越大。本文使用的术语“透过水量”是指每单位面积、压力和时间通过膜的水量。
将以上述方式制造的过滤器5用作实施例并与比较例进行比较。比较例是如图6所示的过滤器,其包括由PET(聚对苯二甲酸乙二醇酯)纤维构成的支持体6和在支持体6的表面上一体化形成并由聚砜构成的树脂膜7。支持体6的厚度为0.1mm。该过滤器的总厚度为0.15mm,平均孔径为0.025μm,开口率为3.4%。
具体而言,虽然实施例和比较例的平均孔径基本相同,但如图9所示,实施例的开口数比比较例多,即,实施例的开口率比比较例高。另一方面,如图10所示,比较例的开口数比实施例少,即,比较例的开口率比实施例低。图7示出了实施例和比较例的杂质阻止率(%)和透过水量(L/(hour·m2·MPa)的比较试验结果。
注意,杂质阻止率是通过使含有具有预定分子量(10万、30万或50万)的PEG(标准物质)的水通过过滤膜(树脂膜)并使用以下算术表达式进行计算来确定的:(原水中的碳含量-透过水中的碳含量)/原水中的碳含量。在本试验中,标准物质的浓度(PEG浓度)设为2,000ppm,压力(MPa)设为0.2,循环时间(min)设为10。
试验结果表明,尽管在使用含有分子量为10万、30万或50万的PEG的水的任何一种情况下,杂质阻止率都没有很大变化,但在实施例中测得的透过水量为在比较例中测得的约两倍以上,极大。据推测这是因为实施例的开口率(9.0%)高于比较例的开口率(3.4%)。开口率可以通过以例如5,000至20,000倍放大率采集过滤器表面的SEM图像并用图像处理软件分析图像来确定。开口率可以例如通过如9(b)和10(b)所示通过二值化将开口部分与其他部分分开来确定。
也就是说,过滤膜(树脂膜)的开口率随树脂部分的比例而变化,可以通过改变树脂浓度来容易地进行调整。开口的孔径随相分离的速率和溶剂被非溶剂置换的速率而变化,可以通过改变树脂的粘度以及非溶剂的类型和纯度来容易地调节。因此,适当地设定上述要素和条件,能够如实施例那样在维持(不增大)开口的孔径的情况下制造开口率高的过滤膜。
因此,根据本实施方式,能够将多孔树脂牢固且始终如一地保持在支持体1上。此外,可以在保持杂质阻止率的同时增加透过水量。此外,在实施例中,由于如芳族聚酰胺树脂等纤维状结构体(多孔结构体)用作支持体并且将该支持体用树脂溶液含浸然后在非溶剂液体中浸渍以进行相置换,因此纤维状结构体的表面粗糙度较高,并且其表面张力增加了树脂溶液的溶剂与非溶剂液体之间的接触面积。结果,可以提高用非溶剂置换溶剂的速度。
另外,在实施例中,由于使用由芳族聚酰胺树脂等构成的结构体(多孔状结构体)作为支持体并且过滤膜由聚砜(PSF)构成,因此与使用PET纤维或纸浆等作为支持体的情况相比,与过滤膜的密着性良好,减少了开裂等的发生。注意,当可以减少开裂等的发生时,也可以使用PET纤维或纸浆作为支持体。
此外,在比较例中,如果在支持体上形成过滤膜之前在支持体中存在褶皱,则在褶皱的凸部处过滤膜的厚度减小,并且在褶皱的凹部处过滤膜的厚度增加,导致膜厚度不均匀。此外,如果存在较大的褶皱,则支持体可能露出,因此杂质过滤效果可能会降低。因此,在比较例中,需要切断容易产生褶皱的支持体的两端。与此相对,在实施例中,即使在支持体中存在褶皱的情况下,也能够在支持体内部适当地形成过滤膜。而且,结构可以灵活改变。
下面对实施例和比较例的易剥离性试验结果进行说明。
将由日东电工CS System株式会社生产的胶带(No.3800K)贴在实施例和比较例各自的表面(膜表面)上。每个胶带用手指摩擦3次。随后,在握住胶带的一端的同时,缓慢拉动胶带的这端,使得胶带弯曲180°。将胶带后方25mm的区域作为有效面积,观察过滤膜(树脂膜)的剥离。尽管在比较例中以100%发生剥离,但是在实施例中以低于100%(约50%)发生剥离。
以上是本实施方式的说明。本发明不限于此。例如,支持体或过滤膜可以由其他材料构成。可以适当地设定上述部件的厚度和总厚度。尽管在本实施方式的过滤器中将支持体的内部用过滤膜全部含浸从而使它们形成为一体,但是也可以将支持体的仅一部分用过滤膜含浸从而使它们形成为一体。
虽然在本实施方式中过滤器适用于超滤膜(UF膜),但是该过滤器也可以适用于如MF膜等其他过滤膜。虽然过滤膜通过将树脂溶液的溶剂用非溶剂置换的NIPS法形成,但在本实施方式的过滤器的制造方法中,也可以通过其他方法形成过滤膜。
工业适用性
本发明也适用于具有其他结构或通过其他制造方法制造的过滤器,只要其是由包含纤维状结构体的支持体和在该支持体内部一体化形成的过滤膜(该过滤膜包含多孔树脂并且能够滤除杂质)构成的过滤器以及该过滤器的制造方法即可。
附图标记列表
1 支持体
2 树脂溶液
3 树脂含浸体
4 非溶剂
5 过滤器
6 支持体
7 树脂膜。
Claims (14)
1.一种能够滤除杂质的过滤器,所述过滤器包括:
由纤维状结构体组成的支持体;和
在所述支持体内部一体化形成的过滤膜,该过滤膜包含多孔树脂并且能够滤除杂质。
2.如权利要求1所述的过滤器,其中,所述过滤膜包含开口率为6%~30%的多孔树脂膜。
3.如权利要求1或2所述的过滤器,其中,所述支持体包括厚度为0.03~0.5mm的结构体。
4.如权利要求1至3中任一项所述的过滤器,其中,所述过滤膜包含厚度为10~500μm的多孔树脂。
5.如权利要求1至4中任一项所述的过滤器,其中,所述支持体包括含有化学纤维的结构体。
6.如权利要求5所述的过滤器,其中,所述支持体包含芳族聚酰胺树脂或聚对苯二甲酸乙二醇酯树脂。
7.如权利要求1至6中任一项所述的过滤器,其中,所述过滤膜包含聚砜(PSF)、聚偏二氟乙烯(PVDF)、聚醚砜(PES)、聚酰亚胺(PI)、聚氯乙烯(PVC)或醋酸纤维素(CA)。
8.一种能够滤除杂质的过滤器的制造方法,该方法包括:
用通过将预定树脂溶解在预定溶剂中制备的树脂溶液含浸由纤维状结构体组成的支持体,并将所述支持体在非溶剂液体中浸渍以用所述非溶剂液体置换所述树脂溶液中包含的溶剂,从而在所述支持体内部一体化形成过滤膜,所述过滤膜包含多孔树脂并且能够滤除杂质。
9.如权利要求8所述的过滤器的制造方法,其中,所述过滤膜包含开口率为6%~30%的多孔树脂膜。
10.如权利要求8或9所述的过滤器的制造方法,其中,所述支持体包括厚度为0.03~0.5mm的结构体。
11.如权利要求8至10中任一项所述的过滤器的制造方法,其中,所述过滤膜包含厚度为10~500μm的多孔树脂。
12.如权利要求8至11中任一项所述的过滤器的制造方法,其中,所述支持体包括含有化学纤维的结构体。
13.如权利要求12所述的过滤器的制造方法,其中,所述支持体包含芳族聚酰胺树脂或聚对苯二甲酸乙二醇酯树脂。
14.如权利要求8至13中任一项所述的过滤器的制造方法,其中,所述过滤膜包含聚砜(PSF)、聚偏二氟乙烯(PVDF)、聚醚砜(PES)、聚酰亚胺(PI)、聚氯乙烯(PVC)或醋酸纤维素(CA)。
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WO2021153255A1 (ja) | 2021-08-05 |
TW202142311A (zh) | 2021-11-16 |
EP4098352A1 (en) | 2022-12-07 |
JP2021115537A (ja) | 2021-08-10 |
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