JP2001104974A - Contact filter medium and manufacturing method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a contact filter medium that remarkably increases the effective contact area of a contact filter medium using a bundle of fiber yarn and a method for manufacturing the contact filter medium. SOLUTION: A contact filter medium consists of a rod-like supporter 50, a yarn branch tuft 30a which is planted and fixed to the supporter 50 for the contact filter medium and a skeleton yarn tuft 40a maintaining the shape which is planted and fixed to the supporter 50 adjacent to the yarn tuft 30a wherein the yarn tuft 30a split in a liquid is supported with the skeleton yarn tuft 40a to thereby support the fibrillate single yarn of the yarn tuft 30a.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a contact filter medium and a method for producing the same, and more particularly, to a contact filter medium comprising a fiber yarn and a bundle of yarns, and having a high efficiency of adhering microorganisms, which has been spread into constituent single yarns. It relates to the manufacturing method.

[0002]

2. Related Background Art Conventionally, domestic wastewater, sewage or industrial wastewater has been mainly treated by biological treatment using a function of decomposing various microorganisms, and a suspended microorganism method represented by an activated sludge method or various contact filter media. The biofilm method of treating with a biofilm formed on the surface and other microbial decomposition methods are widely used. Among them, the biofilm method is widely used for small- and medium-scale wastewater treatment because sludge treatment is relatively easy, and various contact filter media have been proposed.

[0003] With regard to the contact filter medium, recently, a contact filter medium using a fiber bundle, particularly a carbon fiber bundle having high biocompatibility and capable of retaining microorganisms at a high density, has attracted attention. As a contact filter medium using such a carbon fiber thread bundle, the present applicant has proposed an underwater installation carbon fiber bundle (contact filter medium) as described in Japanese Utility Model Registration No. 3051928 previously registered. .

[0004] This carbon fiber bundle (hereinafter referred to as a contact filter medium)
So-called fringe weaving (technique for manufacturing bands with tufts)
It consists of two ground warp knitting yarns and a rope, and is composed of a main rope part (warp knitting main rope according to the present invention) reinforced with a waving yarn, and a warp knitting yarn. A vertically long fringe knit is formed by knitting a carbon fiber bundle into a loop between the parallel sub-cord portions (the warp-knit sub-cord according to the present invention), and the carbon fiber loop is cut at the sub-cord portion to form a carbon fiber. This is a contact filter medium in which a bundle is hung from a main rope in the form of a rope curtain.

[0005] Although this contact filter medium is easy to manufacture and easy to handle, there is a problem that, depending on the method of use, the carbon fiber bundle hanging in water does not always open sufficiently and the effective contact area as the contact filter medium is small. is there.

Further, as a contact filter medium using a fiber yarn,
A centipede-shaped tufted fabric in which tufts of foot length protrude from the left and right sides of the base fabric has also been proposed (JP-A-11-241255). This also has a problem that the effective contact area is small as in the above-mentioned conventional contact filter since the loop is formed while the yarn bundle is being bundled.

[0007]

SUMMARY OF THE INVENTION The present invention has been made in view of such a problem, and provides a contact filter medium which dramatically increases the effective contact area of a contact filter medium using a fiber yarn bundle, and a method for producing the same. Is what you do.

[0008]

According to the present invention, there is provided a contact filter medium comprising: a rod-shaped support; a thread bundle for the contact filter medium implanted on the support; A skeletal yarn tuft for holding the shape implanted in the support, holding the yarn bundle bunches opened in the liquid with the skeletal yarn tufts, and holding the single yarn of the yarn bundle bunches open It is characterized by having done. This allows
Since the single yarn is held in an open state by the skeletal yarn, it becomes a so-called single-filament open contact filter medium, and the effective contact area is very large and stable contact Provide filter media.

[0009] In addition, when the trunk cord to which the yarn bundle and the skeletal tuft are attached is wound around the support, the production of the material is easy and the productivity is high. When the length of the skeletal tuft is smaller than the length of the thread bundle and the tip of the tuft is suspended from the skeletal tuft, the effective contact area is further increased and the shape is stable. Excellent in nature.

[0010] The skeleton yarn is a thermoplastic synthetic fiber bristle yarn, and the surface of the bristle yarn having a rough surface on which the single yarn constituting the yarn bundle is locked is easy to manufacture, and is easy to manufacture. The retention of the spread is increased and the handleability is good. For carbon fibers whose yarn bundle is bundled with a water-soluble sizing agent,
The open filter of the single yarn is good, the biocompatibility is high and the contact filter medium is excellent. The one in which the thread bundle and the skeletal tuft are attached to both sides of the trunk cord has high productivity of the material, and has a compact and high-density contact filter medium.

The method for producing a contact filter medium according to the present invention is a method for producing a contact filter medium as described above, wherein a thread bundle for the contact filter medium and a skeleton for maintaining the form are provided between the warp knitting main rope and the warp knitting auxiliary rope. After manufacturing the base material on which the loop of the yarn is formed, the warp knitting sub-cord portion of the base material is removed, and the warp knitting main rope becomes an intermediate material in which the thread bundle tuft and the skeleton tuft are formed. It is characterized in that the intermediate material is spread on a rod-shaped support. Thereby, it is easy to manufacture, high productivity, and it is possible to easily produce contact filter media of various sizes. In addition, those obtained by cutting the loop of the yarn bundle or the skeleton yarn have good single yarn opening properties, and can increase the apparent volume of the contact filter medium.

[0012] Two warp knitting sub ropes are arranged on both sides of one warp knitting main rope, and a thread bundle and a skeletal thread loop are formed between the warp knitting main rope and both warp knitting sub ropes, respectively. Increases productivity.
As for the skeletal yarn, the use of a bristle yarn of a thermoplastic synthetic fiber having a roughened surface is easy to manufacture, a contact filter medium having a high single yarn opening property can be manufactured, and the yarn bundle is made of a water-soluble yarn. The carbon fiber bundled with the sizing agent of (1) can produce a contact filter medium with high biocompatibility and high performance.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the drawings showing embodiments of the present invention.

FIG. 1 is a schematic plan view of a fringe knitted structure which is an example of a substrate manufactured by the method of the present invention, FIG. 2 is a plan view of an intermediate material processed with the fringe knitted structure, and FIG. FIG. 3 (b) is a virtual side view showing the structure of the skeleton yarn when the warp main rope of the intermediate material is spirally wound around the support rod. FIG. 4 is a schematic side view of a spirally wound contact filter medium, FIG. 4 is a schematic plan view of another example of a fringe knitting structure manufactured by the present invention, and FIG. 5 is a schematic view of the intermediate material shown in FIG. It is a figure showing a mesh pattern of a substrate to be manufactured.

Hereinafter, embodiments of the present invention will be described. For convenience of description, first, a method for producing a contact filter medium will be described.

Manufacturing method and structure of substrate

In the method of the present invention, a substrate is first manufactured by fringe knitting. FIG. 1 shows a schematic plan view of an example of the substrate. In FIG. 1, reference numeral 10 denotes a warp knitting main rope;
A main warp knitting yarn 11 of a book and a main rope serving as a core between the main warp knitting yarns 11
(A string, a strand, etc.) 12 and the main warp knitting yarn 11 are woven by the main rope 12 and the main warp knitting yarn 11, and the two front and back waving yarns
(Not shown). The main rope structure is the same as that described in the aforementioned Utility Model Registration No. 3051928. Numeral 20 denotes a warp knitting sub-cord which is made of a sub- warp knitting yarn running parallel to the main warp knitting cord 10.

Reference numeral 30 denotes a bundle of carbon fibers for the contact filter medium, which is a bundle of single yarns having a diameter of about 10 μm bundled with a large number (several tens of thousands) of sizing agents. It is braided in a loop between 10 and the warp knitting auxiliary rope 20. In the base material of FIG. 1, the yarn bundle 30 is folded in a W-shape on the way, and an auxiliary warp knitting yarn using a water-soluble yarn at each of the folding points.
Woven at 21 and 22. The yarn bundle 30 is a warp main rope
Weaving points A, B, C, D, E,
A continuous loop is formed at each of the points F, G, H at ABC, CDE, EFG,.

A skeletal yarn 40 indicated by a dotted line in FIG. 1 is knitted by the warp knitting main rope 10, the auxiliary warp knitting yarns 21 and 22, and the warp knitting auxiliary rope 20, and is restrained by these warp knitting yarns. Are the knitting points A ', B', C ', D' of the warp main cord 10 and the warp sub cord 20;
A'B'C 'of each point of E', F ', G', H '...
A continuous tuft loop is formed at C'D'E ', E'F'G', .... In this base material, bristle yarn (thick denier monofilament) made of a thermoplastic polyester resin is used as the skeleton yarn 40, and fine irregularities on the order of microns are formed on the surface thereof. As a method for imparting this fine unevenness, a zigzag bristle thread is rubbed in a gap between two disk-shaped grinding wheels facing each other and rotating with a predetermined gap, and the grinding wheel is moved in the radial direction of the grinding wheel. Alternatively, a method of roughening the surface of the bristle yarn can be adopted. In this method, the surface of the bristle thread is rubbed by a grindstone and becomes a rough surface with fine irregularities, but at the same time the surface is finely damaged, projections that are locally melted and temporarily solidified by frictional heat are formed, A rough surface having fine and uniform protrusions can be formed.

Production of intermediate materials

Next, an intermediate material is manufactured. This intermediate material
After cutting the base material to the required length according to the application (cutting the warp main cord 10, the warp sub cord 20, each auxiliary warp yarns 21 and 22), cut the warp Cut and manufactured. That is, the base material is cut along a cutting line indicated by XX in FIG. Then, when the auxiliary warp knitting yarns 21 and 22 are unwound, the respective loops of the yarn bundle 30 and the skeletal yarn 40 are cut at their ends, and as shown in the plan view of FIG. It becomes an intermediate material in the form of a rope curtain consisting of a large number of thread bundles 30a and skeletal tufts 40a that alternately extend as tufts. Here, the skeleton yarn 40 is desirably shorter than the yarn bundle 30. As will be described later, when forming the contact filter medium,
This is because 30a hangs downward from the end of the skeletal tuft 40a, which facilitates the opening of the contact filter medium and increases the apparent volume.

The structure shown in FIG. 2 is the same as that shown in FIG. 1 for the fringe knitting of the yarn bundle and the skeletal yarn. The loop of the yarn bundle 30 and the skeletal thread 40 is extended on both sides of the warp knitting main rope 10. As a result, productivity can be increased and the density of the contact filter medium can be increased. FIG. 5 shows a stitch pattern of a base material for producing the intermediate material of FIG. Although the knitting configuration is the same as that of FIG. 1, FIG. 5 shows that there are mesh points where the yarn bundle 30 and the skeletal yarn 40 are knitted simultaneously with the mesh points which are separate meshes. In FIG. 5, the mesh points are indicated by hatched blocks.

In the substrate shown in FIG. 1, when cutting the loop, the carbon fiber yarn bundle 30 and the bristle yarn skeleton yarn 40 were simultaneously cut along the cutting line XX. In this case, the load on the blade and knife for simultaneously cutting the carbon fiber and the polyester bristle yarn having different physical properties is increased, so that, for example, as shown in FIG. Then, the skeletal yarn 40 and the loop end of the yarn bundle 30 are separated from each other.
-Y is cut with a knife, and the bristle yarn skeletal yarn 40 is blown with a heater at the fusing line Z-Z, so that the knife can be easily selected and the life can be extended, and the bristle yarn can be cut easily.
It is convenient.

Regarding the cutting of the yarn bundle and the loop of the skeletal yarn, it is preferable to cut the loop of the yarn bundle for opening the single yarn. However, depending on the physical properties of the skeletal yarn, it is possible to cut the loop without cutting the loop. It can also be used as a contact filter medium as it is in a loop-shaped skeletal tuft. Furthermore, depending on the physical properties and length of the yarn bundle, the yarn bundle can be used as a loop-shaped yarn bundle as a contact filter medium without cutting the loop of the yarn bundle. When the loop is not cut, the intermediate material can be manufactured simply by removing the warp knitting sub-cord, but in the above-described embodiment, the auxiliary warp knitting yarn is used. The knitting yarn also needs to be removed. By unwinding and removing all warp knitting yarns (called warp knitting sub-cord portions) other than the warp knitting main rope, a loop-shaped intermediate material of the tuft can be formed.

Formation of contact filter media

The formation of the contact filter medium will be described.

A method of winding the warp knitting main rope 10 (which becomes a trunk rope as a contact filter medium) around a support rod 50 which is a rod-shaped support will be described. As shown in the imaginary view of FIG.
When the warp main cord 10 is spirally wound around 0, the skeletal thread tufts 40a
Due to its rigidity, is wound around the support rod 50 so as to extend spirally as shown in the figure. At the same time, thread bundle bunch 30a
4A is also supported by the skeletal tufts 40a and turns, and as shown in FIG. In this state, when the contact filter medium is immersed in water, the sizing agent of the carbon fiber dissolves in the water, and the single yarn of the thread bundle 30a is opened in the liquid to open. Since the surface of the bristle yarn, which is the skeleton yarn, is roughened and fine irregularities are formed, the single yarn of the carbon fiber of the yarn bundle 30a serving as the contact filter medium is
The surface of the bristle yarn of No. 0a is entangled with the rough surface having fine projections, and as shown in FIG. 3 (b), becomes a single-filament open contact filter medium, has a large effective contact area, and has excellent shape retention. Filter media can be manufactured.

Use and installation of contact filter media

When the above-mentioned contact filter medium is used as a contact filter medium for a wastewater treatment apparatus, a necessary number of unit contact filter mediums are installed in the wastewater treatment apparatus by attaching the support rod 50 to the treatment apparatus by an appropriate means. Can be installed. When used as a contact filter medium for purifying the aquatic area or an artificial seaweed bed, a plurality of contact filter materials of one unit can be attached to an appropriate platform or mount.

Next, the contact filter medium of the present invention will be described.

In the above, a rod-shaped support, a thread bundle for contact filter media planted on the support, and a shape holding plant implanted on the support adjacent to the thread bundle are arranged adjacent to the thread bundle. As one embodiment of the contact filter medium of the present invention, which comprises a skeletal yarn tuft, holds the bundle of yarns opened in the liquid in the liquid with the skeletal tuft, and opens and holds the single yarn of the bundle of yarns, An example in which a trunk cord of a tuft-like intermediate material manufactured from a knitted base material is wound around a support (support rod 50) has been illustrated.

However, the contact filter medium of the present invention is not limited to this. For example, a warp-knitted main rope of a fringe knitted base material is twisted so that a thread bundle and a skeletal tuft are stretched around the main rope. You can also put them out. In this case, since the warp main rope serves as a support, it is necessary to increase its strength and rigidity and to attach it to the bracket or the processing device in a directly twisted state.

As described above, the method using the fringe knitted base material is easy to manufacture and can be easily adapted to an arbitrary size. However, the contact filter medium of the present invention is not limited to this. Can be manufactured by forming a branch into a skeletal tuft and implanting a bundle of thread bundles on each skeletal tuft. In addition, since the so-called planting each tuft on the support means that each tuft is attached as if planted on the support,
The attachment or locking method may be indirectly attached via fixing, bonding, or a base cloth, or the like, so that the skeleton tuft can hold the single yarn of the bundle of yarns of the contact filter medium in a state where the single yarn is separated. What is necessary is just to be attached to a support body adjacently. Usually, a plurality of each tuft is attached in multiple stages, but when a large tuft is bundled and a large number of tufts are bundled, a single stage can be used.

In the description of the embodiment, the carbon fiber using the water-soluble sizing agent as the yarn bundle has been described. This carbon fiber is excellent in biocompatibility and also excellent in opening property, but is not necessarily limited to a thread bundle, and may be made of fiber of another material or opening property according to the application and purpose. Any fiber, such as a fiber using an excellent sizing agent, can be used.

As the skeleton yarn, a yarn obtained by roughening the surface of a polyester fiber bristle yarn (monofilament) with a polishing grindstone has been described. This is excellent in shape retention, easy to handle, easy to manufacture and excellent in spreadability, but other methods such as sandblasting or roughening coating can be applied as the surface roughening method. The material of the skeletal yarn is bristle yarn of other thermoplastic resin, metal yarn, and other materials that can be used for fringe knitting. It has moderate rigidity and has a friction surface that does not slip with the yarn bundle. Any material and form can be used as long as it has.

Further, as a mesh structure and pattern of the fringe knitting, a loop in which two skeleton yarns are alternately formed with respect to one loop of the yarn bundle is shown. In addition, an auxiliary warp knitting yarn is provided between the warp knitting main warp and the warp knitting sub rope, and a compact fringe stitch is illustrated as if the yarn bundle is folded. However, these fringe knitting patterns are in the form of the finished contact filter media,
It is designed as needed according to the physical properties and form of the yarn bundle and the physical properties and form of the skeletal yarn, etc. If it is a fringe knit with the yarn bundle and the skeletal yarn folded between the main rope and the auxiliary rope It can be used as a base material for contact filter media. It is preferable that the length of the skeleton yarn is smaller than the length of the yarn bundle from the viewpoint of the form of the contact filter medium. However, the relative length between the skeleton yarn and the yarn bundle also depends on the form of the finished contact filter medium and the yarn. It should be appropriately designed as needed according to the physical properties and form of the bundle or the physical properties and form of the skeleton yarn.

[0037]

The contact filter medium of the present invention comprises a rod-shaped support,
A yarn opened in the liquid, comprising a bundle of contact filter media planted on the support, and a skeletal tuft of shape retention planted on the support adjacent to the bundle of yarns. Since the bundles are held by the skeletal yarn bunches and the single yarns of the yarn bundles are opened and held, the constituent yarns of the yarn bundles to be opened in the liquid are held open by the skeletal yarn. As a result, a so-called single-filtration contact filter medium is provided, and an effective contact area is very large and a stable contact filter medium is provided.

The method for producing a contact filter medium according to the present invention is a method for producing a contact filter medium as described above, wherein a thread bundle for the contact filter medium and a skeleton for maintaining the form are provided between the warp knitting main rope and the warp knitting auxiliary rope. After manufacturing the base material on which the loop of the yarn is formed, the warp knitting sub-cord portion of the base material is removed to form an intermediate material in which the warp knitting main yarn is formed with the thread bundle tufts and the skeletal tufts. Is spread on the rod-shaped support, so that it is easy to produce, has high productivity, and can easily and industrially produce contact filter media of various sizes.

[Brief description of the drawings]

FIG. 1 is a schematic plan view of a fringe knitted substrate structure, which is an example of a substrate produced by the method of the present invention.

FIG. 2 is a plan view of an intermediate material obtained by treating a fringe knit base material.

FIG. 3 (a) is a virtual side view showing a structure of a skeleton yarn when a warp-knitted main rope (stem rope) of an intermediate material is spirally wound around a support rod. Fig. 3 (b) shows the warp knitting main rope (stem rope) of the intermediate material
FIG. 2 is a schematic side view of a contact filter medium manufactured by spirally winding around a support rod.

FIG. 4 is a schematic plan view of another example of a fringe knitted base material manufactured by the present invention.

FIG. 5 is a view showing a mesh pattern of a base material for producing the intermediate material shown in FIG. 2;

[Explanation of symbols]

 10 Warp knitting main cord (stem cord) 20 Warp knitting auxiliary cord 21, 22 Auxiliary warp knitting yarn 23 Auxiliary warp knitting auxiliary cord 30 Thread bundle (carbon fiber thread bundle) 30a Thread bundle tuft 40 Skeletal thread (bristle thread) 40a Skeleton tress (bristle tress)

Claims (11)

[Claims] 1. A rod-shaped support, a thread bundle for contact filter media planted on the support, and a shape holding plant implanted on the support adjacent to the thread bundle. A contact filter medium comprising a skeletal yarn tuft, wherein the yarn bundles opened in the liquid are held by the skeletal yarn tufts, and single yarns of the yarn bundles are opened and held. 2. The contact filter medium according to claim 1, wherein a trunk cord to which the thread bundle and the skeletal tuft are attached is wound around the support. 3. The method according to claim 1, wherein the length of the skeleton tuft is smaller than the length of the yarn tuft, and the tip of the yarn tuft hangs down from the skeleton tuft. The contact filter medium as described. 4. The yarn according to claim 1, wherein the skeleton yarn is a thermoplastic synthetic fiber bristle yarn, and a rough surface is formed on the surface of the bristle yarn to which the single yarn constituting the yarn bundle is locked. 3. The contact filter medium according to 3. 5. The contact filter medium according to claim 1, wherein the yarn bundle is a carbon fiber bundled with a water-soluble sizing agent. 6. The contact filter medium according to claim 1, wherein said thread bundle and said skeletal tuft are attached to both sides of said trunk cord. 7. A base material having a thread bundle for a contact filter medium and a loop of a skeletal yarn for maintaining a shape formed between a main warp knitting line and a warp knitting sub rope is manufactured. Removing the knitting sub-cord portion to form an intermediate material in which the warp-knitted main rope is formed with a thread bundle and a skeletal tuft, and sprinkling the intermediate material on a rod-shaped support; Method. 8. The method for producing a contact filter medium according to claim 7, wherein when removing the warp knitting sub-cord of the base material, the loop of the yarn bundle and the loop of the skeleton yarn are cut. 9. A warp knitting sub rope is provided on both sides of one warp knitting main rope, and between the warp knitting main rope and the both warp knitting sub ropes, the yarn bundle and the skeleton yarn are respectively provided. 8. A loop having a loop formed therein.
Or a method for producing a contact filter medium according to item 8. The bristle yarn of a thermoplastic synthetic fiber having a roughened surface is used as the skeleton yarn.
3. The method for producing a contact filter medium according to item 1. 11. The method according to claim 7, wherein the yarn bundle is a carbon fiber bundled with a water-soluble sizing agent.