JP2003251117A - Mold for filter molded object and manufacturing method for filter molded object - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a mold for a filter molded object excellent in thermal circulation at the time of heating and cooling, having excellent workability in assembling, disassembling, the demolding of the filter molded object, or the like, and capable of reducing molding finish, and a manufacturing method for the filter molded object. <P>SOLUTION: The mold 6 is used for manufacturing the filter molded object 1 used in a water treatment device for removing a pollutant from water by solidifying activated carbon and constituted of a cylindrical outer mold 9 for forming the cylindrical outer surface of the filter molded object 1, an upper mold 8 freely inserted in the outer mold 9 along the inner peripheral surface thereof to form the upper surface of the molded object, a bottom mold 10 freely inserted in the outer mold 9 along the inner peripheral surface thereof and having an assembling hole provided to the center thereof to form the undersurface of the molded object, and a cylindrical core mold 11 fitted in the assembling hole of the bottom mold in a freely detachable manner to form a through- hole to the center of the molded object. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a molding die for manufacturing a filter molded body by filling a mixed raw material of activated carbon and a polymer binder having a high molecular weight and a low melt index, and a method for manufacturing the filter molded body.

[0002]

2. Description of the Related Art A conventional method for manufacturing a filter molded body has been proposed by the present applicant in Japanese Patent Laid-Open No. 2001-187305. According to this, as shown in FIG. 5, first, the molding die 6 is composed of a bottom die 10, a lower die 9 (to be referred to as an outer die) and an upper die 8 as shown in FIG. The middle mold in the central part was constructed as an integral structure fixed to the bottom mold.

Further, in the method of releasing the molded body formed by the above-mentioned constitution, after the molding die 6 is sufficiently cooled, the bottom mold 10 is pulled out to form the solid upper mold 8 as shown in FIG. It was characterized in that the filter-molded body 1 was pressed and punched out.

[0004]

However, the polymer binder is made to flow while heating a predetermined amount of the mixed raw material filled in the molding die, and the mixed raw material is compressed by the upper die weight to form the molding die. Formed on the inner surface. In this heating, the molding die 6 was heated uniformly to raise the temperature of the mixed raw material, and the porous density in the molded body was not uniform.

From this, in order to uniformly heat and raise the temperature of the internal mixed raw material, for example, in the solid pipe-shaped upper die having an outer diameter substantially the same as the inner diameter of the outer die shown in FIG. There is a problem that the difference in the temperature distribution becomes large.

In addition to this, simplification of centering at the time of inserting the upper mold, improvement in spilling powder into the hollow middle mold when the mixed raw material is filled in the mold, and inside the mold after molding It has been desired to improve the mold such that the mold has excellent workability at the time of demolding, and the generated molding burr is easily treated.

An object of the present invention is to improve various problems relating to the structure of the molding die and the handling of the molding die as described above, and it is possible to improve the quality and reduce the cost of the filter molded body to be manufactured. It is to provide a molding die for a filter molded body and a method for manufacturing the filter molded body.

[0008]

In order to solve the above-mentioned problems, the invention of the mold for manufacturing a filter molded body according to claim 1 of the present application is
In a mold for manufacturing a filter molded body in which activated carbon is solidified, which is used in a water treatment device for removing pollutants from water, a cylindrical outer mold forming a cylindrical outer surface of the mold and an inner peripheral surface of the outer mold can be freely fitted and inserted. An upper die that forms the upper surface of the molded body, a bottom die that can be inserted into the inner peripheral surface of the outer die and that has an assembly hole in the center to form the lower surface of the molded body, and can be detachably attached to the assembly hole of the bottom die. It is characterized in that it is formed of a cylindrical middle-sized body which is fitted and forms a through hole at the center of the molded body. In particular, it is to be able to respond to mold die assembly, demolding workability, and improvement of molding quality.

According to the structure of the first aspect, since the bottom mold and the middle mold can be divided, the bottom mold and the middle mold are formed so as to be embedded in the central axis of the cylindrical molded body, and the molded body is contracted due to molding shrinkage. It is easy to deal with demolding, because the middle sized mold can be handled separately from the bottom mold.

In the invention of the mold for manufacturing a filter molded body according to claim 2, in the structure of claim 1, the upper die which forms the upper surface of the molded body has a lower end at the time of pressure molding, and the upper die is above the outer die. It has a collar that abuts the end face. According to this, there is no deviation in the mold closing height during molding. In addition, it is possible to prevent troubles during closing and improve the finishing accuracy of the molded body.

According to the invention of the mold for manufacturing a filter molded body as defined in claim 3, in the construction of claim 1, the middle mold is provided with a draft in the axial direction. According to this, when the molded body is contracted by molding as described above and the middle die in a state where it is hit by the central axis thereof is released from the die, the punching distance can be minimized, so that it can be loosened with a minimum stroke.

According to a fourth aspect of the present invention of a mold for manufacturing a filter molded body, in the structure of the first aspect, the upper end portion of the middle die has a removable insert. According to this, by mounting a nest on the upper end of the middle mold, it is possible to make a tight plug on the top of the middle mold that has a pipe-shaped opening, and it is possible to further project from the upper end of the outer mold to the center of the cylindrical outer mold. When inserting the upper mold, if the center hole of the upper mold is inserted into the nest while skewing it, the center of the inner mold of the cylindrical outer mold can be aligned. In addition, since it can be removed, it does not stick out from the upper surface of the outer mold, and the protrusions when pressing from the upper surface or when housing the mold can be eliminated.

According to a fifth aspect of the present invention of a mold for manufacturing a filter molded body, in the structure of the first or second aspect, the upper die and the bottom die that form the outer peripheral edges of the upper and lower surfaces of the molded body are formed. A ring-shaped convex ridge is provided on the outer peripheral portion.
According to this, the ring-shaped convex ridges are located in the mold matching gaps appearing on the inner peripheral surface of the outer mold and the lower surface of the upper mold, and on the inner peripheral surface of the outer mold and the upper surface of the bottom mold, thereby forming a cylindrical filter. Molding can be done by notching the corners of the upper and lower surfaces of the body.

In the invention of the method for producing a filter molded body according to claim 6, the method for producing a filter molded body, in which activated carbon is solidified, used in a water treatment device for removing pollutants from water, is molded by using a split mold. After assembling the mold, the bottom mold, and the middle mold, attaching a nest to the upper end of the middle mold, charging the mixed raw material into the mold, shaking it, and filling it, then covering the upper mold, removing the nest, and heating the upper mold. Is pressed so as to come into contact with the upper end surface of the outer mold, and after cooling, the molded product is extracted from the outer mold together with at least the middle mold which is skewered.

According to this manufacturing method, since the bottom mold and the middle mold can be divided first, it can be removed from the outer mold at least integrally with the molded product skewered into the middle mold, and the middle mold has a draft angle so that the molding is performed. It became easier to remove the middle sized mold located on the axis of the body. In addition, since the insert is detachably provided at the upper end of the middle mold, a closed plug can be formed in the hollow pipe-shaped middle mold when the mixed raw materials are charged, and an upper mold that has a through hole in the center and is fitted into the middle mold. Can be guided centering when it is fitted into the outer mold. Further, since a flange is provided on the upper die and the upper end surface of the outer die is abutted against the upper die to set the pressure lowering limit, it is possible to prevent variations in the pressure end position.

[0016]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of a molding die for a filter molded body and a method for manufacturing a filter molded body of the present invention will be described with reference to FIGS. Prior to this, first, the filter molded body 1 itself will be outlined with reference to FIGS.

A filter molded body 1 obtained by solidifying activated carbon obtained by the manufacturing method of the present invention is, for example, a faucet direct coupling type water treatment device S and a water treatment device filter 2 as shown in FIG.
It is used as a filter. As the structure of the water treatment device filter 2, for example, FIG.
As shown in (c), the outer periphery of the cylindrical filter molded body 1 is covered with the filtration layer 3, and the top surface and the bottom surface of the cylindrical filter molded body 1 are covered with the cap 4.
The cap 4 is water-tightly connected to the filter molded body 1 with an adhesive so that water containing dirt does not pass through.

Further, the cylindrical filter molded body 1 has a hole 5 in the central axis of the cylinder. When the water treatment device filter 2 is attached to the water treatment device S, the flow of water is such that the water is taken in from the side of the filtration layer 3 to remove dirt such as large-sized dust in the filtration layer 3, Residual chlorine and organic substances are adsorbed and removed through the cylindrical cross section of No. 1, and the treatment is performed in the process of springing into the hole 5 and flowing out from the water purification port J of the water treatment device S.

The filter molded body 1 obtained by the production method of the present invention is a porous solid activated carbon molded body obtained by solidifying activated carbon with a polymer binder having a high molecular weight and a low melt index. It is configured to perform water treatment by passing through.

First, for the molding die 6 of the filter molded body 1, aluminum having a high thermal conductivity, iron containing a stainless steel material, or the like is preferably used and subjected to anticorrosion / abrasion treatment. FIG. 1 shows the mold splitting structure and the assembled state. The mold splitting is configured by being divided into four points of a bottom mold 10, an outer mold 9, a middle mold 11, and an upper mold 8, and the upper surface of the pallet 51 on the manufacturing line. The lower end hole of the middle die 11 is fitted and positioned on the centering pin 52 arranged at the position.

At this time, the insert 14 in the drawing is used as a working jig, and as shown in FIGS. 3 (a) and 3 (b), the insert 14 is placed on the top of the middle mold 11 when the raw material P is charged and the upper mold 8 is assembled. It is worn and removed after the upper mold 8 is assembled. As a result, the raw material P does not enter the inside of the pipe-shaped middle mold 11, and when the upper mold 8 is fitted into the outer mold 9, it can be easily assembled without any difficulty in centering. Since the nest 14 is removed from the top of the mold and opened, the heat of the middle mold 11 in the axial direction can be secured.

Next, regarding the assembled state of the molding die 6, as shown in FIG. 1, the middle die 11 is inserted into the bottom die 10 and the pallet 51 is inserted.
The upper die 8 is positioned above, the outer die 9 is fitted therein, and the upper die 8 is assembled through a series of working steps described later, and the assembly is completed as shown in FIG. 2B.

Next, among the above-mentioned divided bottom mold 10, outer mold 9, middle mold 11, and upper mold 8, the bottom mold 10, middle mold 11, and upper mold 8 according to the present invention will be described in detail. I will describe.

First, with respect to the bottom mold 10, the maximum outer diameter is suppressed to be within the inner diameter of the outer mold 9, and the bottom mold 10, the filter molding 1 and the upper mold 8 are integrated into the middle mold 11 in a skewered state.
Is easily pulled out from the outer mold 9 in the flange direction of the upper mold 8.

Since the filter molded body 1 which is skewered and integrated with the middle mold 11 is molded and contracted at the time of taking out, the outer diameter and the molding length are slightly reduced, and a gap is formed to form the outside. The mold release on the inner surface of the mold 9 and the molding surfaces of the bottom mold 10 and the upper mold 8 can be relatively easily performed. The convex ring-shaped crests 18 will be described later.

Next, the middle die 11 is, as shown in FIG.
A draft 15 is provided in which the shaft diameter increases in the shape of a gentle trumpet in the axial direction in which the bottom die 10 is fitted and inserted.
As a result, the fitting gap in the radial direction of the shaft becomes large together with the amount of shaft slippage, and the fitting length can be favorably dealt with when the molded product is released from the mold. Also medium 11
Has a hollow shaft body so that the heat distribution is improved.

Subsequently, the upper die 8 is hollowed out as shown in FIG. 1 to have a hollow bottom plate having an opening through the middle die 11 and a flange 13 on the outer peripheral edge on the upper surface. It is equipped with it. As a result, the heat distribution such as the temperature distribution on the molding surface and the heating rate can be improved, and the weight of the upper die 8 can be finely adjusted by the wall thickness. Given.

Next, the convex ring-shaped crests 18 according to the present invention provided on the outer peripheral edges of the molding surfaces of the bottom mold 10 and the upper mold 8 will be described. As shown in FIG. 4A, the convex ring shape in the molding die 6, first, the ring-shaped corner portion formed by the bottom surface of the upper mold 8 and the inner surface of the outer mold 9 is formed into a ring shape on the bottom surface of the upper mold 8. A projecting crest 18 is provided, and the size thereof is a size determined in advance that can absorb the protrusion of the adhesive and the protrusion of the molding burr described later, and is a mountain having a substantially triangular cross section. Similarly, ridges 18 projecting from the upper surface of the bottom die 8 are also provided at the ring-shaped corner portions formed by the upper surface of the bottom die 10 and the inner surface of the outer die 9.

Subsequently, in FIG. 4 (b), a partial cross-sectional shape of the filter molded body 1 molded by the projecting ridges 18 of the molding die 5 and having the corner grooves 21 on the upper and lower surfaces and the upper and lower surfaces thereof are attached. The state where the cap 4 is integrated with the molded body 1 by the adhesive 25 is shown in a partial cross section. The corner groove 21 formed by the convex ring-shaped crest 18 is
By accommodating the molding burr 23 on the circumference generated at the time of molding and the surplus adhesive 25 overflowing the outer peripheral portion in the corner groove 21, it is possible to perform a process manufacturing which does not require finishing.

Next, regarding the method of manufacturing the filter molded body according to the present invention, FIG. 3 (a) is a mixture raw material charging, (b) is heating by using the upper mold fitting / dropping lid, and (c) heating / pressurizing / cooling. The procedure for molding a cylindrical molded body having a predetermined density and a uniform grain size by using (d) inner mold release will be described in detail.

First, the raw material mixture P is a mixture of activated carbon and a polymer binder having a high molecular weight and a low melt index, which are mixed and stirred at a predetermined ratio to uniformly disperse both. At this time, the activated carbon is fine particles or powder finer than 60 mesh, and the polymer binder has a particle size of about 100 μm so that the activated carbon is dispersed in the entire area of the filter molded body 1 and the effect of the water treatment can be sufficiently exerted. I use the one.

Next, as shown in FIG. 3A, the middle die 11 is inserted into the bottom die 10 and the outer die 9 is attached to the outer periphery of the bottom die 11 to assemble the container portion of the molding die 6 to form the middle die 11 The insert 14 having a thin tip is attached to the top, the funnel 42 is attached to the upper opening surface of the outer mold 9, and the measured mixed raw material P is charged. At this time, the middle top of the central part is tightly plugged with a nest.

When a predetermined amount is filled, the height of the molded filter body becomes 150 to 200%. Then, the molding die 6 containing the mixed raw material P is vibrated for 5 to 10 seconds at an amplitude of 1 to 3 mm and a vibration frequency of 5 to 10 times / second by a vibrating device to increase the predetermined height by 5 to 15%. Reduce the bulkiness of raw materials. Here, the height of the filter molded body after molding is the height of the finished filter molded body 1, and also takes into account the molding shrinkage during cooling after molding.

When the molding die 6 is vibrated, if the amplitude is too large or the vibration frequency is too large to give too much vibration, the mixed raw material P becomes too clogged and a predetermined density cannot be obtained. In addition, the mixed raw material P may be separated due to the difference in particle size and the difference in weight, so that a uniform molded body 1 may not be obtained, which is not preferable.

On the contrary, if the vibration is insufficient, when the pressure is applied after the heat molding to adjust the height of the filter molded body 1 after the molding, the adjustment amount by the pressurization becomes large, so that the pressure loss at the time of pressurization. Not only does the density difference between the top and bottom of the molded body occur due to
The inner surface of the molding die 5 and the raw material interface rub against each other, causing clogging.
The function as a filter will be impaired.

Next, as shown in FIG. 3 (b), the assembly hole portion on the bottom surface of the upper die 8 is inserted into the insert having a narrow tip, and then the outer die 9 and the inner die 11 are fitted together. The centering can be done easily and the mold matching is easy, and it can descend smoothly.

Subsequently, the mixture is heated in an oven at 180 to 260 ° C. for about 30 to 90 minutes to bring the polymer binder in the mixed raw material P into a fluid state. When the polymer binder is in a fluidized state, the molding die 6 is taken out of the oven, and the end of the upper die 8 which has almost descended is further pushed down to apply pressure.
As shown in (a) upper mold dropping lid state (b) heat molding completed state, the flange 13 surface of the upper mold 8 is brought into contact with the upper surface of the outer mold 9 as shown in FIG. 3 (c). The molding complete state shown is reached.

Next, the molding die 6 is sufficiently cooled, and the outer die 9
The molding surface shrinks and a gap is formed on the molding surface, which facilitates pulling out, and the bottom mold 10, the filter molding 1, and the upper mold 8 skewered in the middle mold 11 are integrally removed from the outer mold 9 to remove the molding 1. The bottom mold 10 and the upper mold 8 on both sides are removed.

As shown in FIG. 3 (d), the middle mold 11 skewed by the middle mold 11 and squeezed by the filter molded body 1 which has been shrunk by molding is placed in the through hole on the fixed table of the press with the side having a large shaft diameter facing downward. The upper part of the middle mold 11 is pushed from above and the mold is released to release the mold.

In this way, a predetermined amount of activated carbon and the polymer binder are mixed, filled in the molding die 6, and shaken to adjust the bulkiness uniformly, and then heated at a temperature of about 200 ° C. for a predetermined time. After that, the upper mold 8 is brought into close contact, cooled, and released from the mold so that the particle size is uniform and the density is 0.5 to 0.65 as described above.
The filter molded body 1 adjusted within the range of g / cm ³ can be prepared.

The mold for molding the filter molded body and the method for manufacturing the filter molded body of the present invention are not limited to those shown in FIGS. 1 to 7, and the following forms can be adopted, for example. 1) When inserting the middle mold 11 into the central portion of the bottom mold 10, all of them are of the through type in the above figure, but the middle mold 1
It is also possible to make a configuration in which 1 is abutted and positioned at a depth in the middle without penetrating.

[0042]

According to the molding die of the filter molding according to claim 1, the cylindrical filter molding can be separated from the bottom mold before it is separated from the middle mold, which has been shrunk due to molding shrinkage. Since it is easier to deal with molds, the number of demolding steps can be reduced and the manufacturing cost can be reduced to a considerable extent. In addition, it was possible to save the mold manufacturing cost and maintenance cost because it was possible to eliminate the loss of the integrated processing in the mold manufacturing.

In the molding die of the filter molding according to the second aspect, the mold closing height during molding does not vary, and
In addition, since it is possible to prevent troubles during closing and improve the finish accuracy of the molded body, it is possible to improve the quality of assembly and fitting to the water treatment device.

In the mold for molding the filter molded body according to the third aspect, when the middle mold is demolded, the punching distance can be minimized and loosened with a minimum of one blow. It is possible to relieve much, eliminate the fear of damage, and it is easy to handle with a machine. There was also no damage to the medium size.

In the molding die of the filter molding according to the fourth aspect, since the top of the pipe-shaped open middle mold can be tightly closed, the mixed raw material does not enter the pipe-shaped middle mold when the outer mold is charged. In addition, the upper mold can be dropped in the state of being skewered and aligned with the inner peripheral surface of the cylindrical outer mold, so the fitting gap can be reduced without impairing workability, the molding quality is improved, and the working time is also reduced. It was possible to reduce.

In the molding die of the filter molding according to the fifth aspect, since the corners of the upper and lower surfaces of the cylindrical filter molding can be cut out by the ring-shaped convex ridges, the ring-shaped corner voids can be formed. Since the circumferential burr that occurs at the corner can be stored on the inner surface side of the corner, there is no obstacle to the cap fitting work in the subsequent process, and the finishing loss can be eliminated.

In the method for manufacturing a filter molded body according to the sixth aspect, since the bottom mold, the molded body and the upper mold can be removed from the outer mold integrally as a skewered middle mold, the upper mold having a mold height can be removed. There is no need to insert the inner surface of the outer mold, and the filter molded body that has been eroded due to mold shrinkage in the middle mold can be easily removed in the draft direction, so the time required for mold separation and mold release can be shortened. The centering of the upper mold and centering of the upper mold by the insertion of the middle mold shortened the mold matching time and eliminated the fluctuation of the pressurization end position, which reduced the molding fluctuation.
Therefore, the mold matching and demolding workability are improved, the molding variation is improved, and the manufacturing cost can be reduced.

As described above, the functions of the invention relating to the molding die for the filter molded body and the manufacturing apparatus for the filter molded body according to claims 1 to 6 of the present application can be sufficiently exerted.

[Brief description of drawings]

FIG. 1 is an overall front view of a center vertical cross section of a mold for a filter molded body of the present invention assembled on a pallet.

FIG. 2 is a central longitudinal section showing the function of the upper collar in the molding die for the filter molded body of the present invention.

FIG. 3 is an explanatory view showing a process flow for explaining a method for manufacturing a filter molded body of the present invention.

FIG. 4 is an explanatory view of convex ring-shaped peaks provided on the molding surfaces of the upper mold and the bottom mold in the molding die for the filter molded body of the present invention.

FIG. 5 is an explanatory view of a conventional method for manufacturing a filter molded body, in which (a) a state in which the upper mold is pressed by its own weight for molding;
(B) This shows the demolded state of the molded body.

FIG. 6 is an explanatory view of a filter molded body obtained by the manufacturing method of the present invention and a water treatment device filter using the same.
(A) A perspective view showing an example of a filter molded body obtained by the production method of the present invention, (b) a perspective view of a filter for a water treatment device using the filter molded body, (c) A- in the previous figure (b). FIG.

FIG. 7 is a cross-sectional view of a water treatment device.

[Explanation of symbols]

1 Filter molded body 6 Mold 8 Upper mold 9 Lower mold 10 Bottom type 11 Medium 13 Tsuba 14 Nesting 18 Convex ring-shaped mountain P mixed raw material

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) B29K 103: 04 B29K 103: 04 B29L 31:14 B29L 31:14 F term (reference) 4D019 AA03 BA03 BB01 BB07 BC05 BD01 CA03 CB02 CB04 CB07 4D024 AA02 AB04 AB11 BA02 BB05 BC01 CA15 DB03 4F202 AB18 AG08 AH03 CA09 CB01 CK12 CK42 CK52 CK81 4F204 AB18 AG08 AH03 FA01 FB01 FF01 FF06 FN20 FQ15

Claims (6)

[Claims] 1. A mold for manufacturing a filter molded body in which activated carbon is solidified, which is used in a water treatment device for removing pollutants from water, and a cylindrical outer mold forming a cylindrical outer surface thereof, and an inner peripheral surface of the outer mold. An upper die that is insertable into the upper surface of the molded body, a bottom die that is insertable into the inner peripheral surface of the outer die and that has an assembly hole in the center to form the lower surface of the molded body, and the assembly of the bottom die A mold for a filter molded body, comprising: a cylindrical middle mold which is detachably fitted into a hole to form a through hole at the center of the molded body. 2. The filter molded body according to claim 1, wherein the upper die forming the upper surface of the molded body has a collar that abuts against the upper end surface of the outer die at the descending end during pressure molding. Molding die. 3. The mold for a filter molded body according to claim 1, wherein the middle mold has a draft in the axial direction. 4. A mold for molding a filter molded body according to claim 1, wherein a removable insert is provided at an upper end portion of the middle mold. 5. The filter molding according to claim 1, wherein ring-shaped convex ridges are provided on outer peripheral portions of the upper mold and the bottom mold that form outer peripheral edges of upper and lower surfaces of the molded body. Mold for body molding. 6. A manufacturing method for molding a filter molded body in which activated carbon is solidified, which is used in a water treatment device for removing pollutants from water, by using a split mold, wherein an outer mold, a bottom mold and a middle mold are assembled and an upper end of the middle mold is assembled. After placing a nest in the part, charging the mixed raw material into the mold, shaking it and filling it, covering the upper mold, removing the nest and heating, pressurizing so that the flange of the upper mold abuts the upper end surface of the outer mold A method for producing a filter molded body, which comprises removing the molded body from the outer mold integrally with at least the skewered middle mold after cooling and cooling.