JP2005305420A - Production method of filter molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a production method of a filter molding capable of molding a filter for water treatment in which water purifying components are uniformly dispersed in a whole molding, there is no variation in performance and which has good appearance. <P>SOLUTION: The water purifying components are mixed with a binder consisting of a polymer by agitation to obtain a mixed raw material, a predetermined amount of the mixed raw material is charged into a mold M. Then the mixed raw material 6 is heated to bring the binder into a fluidized state, is pressurized, is cooled and is released. In this production method of the filter molding 1, when the mixed raw material 6 is charged into the molding M, a funnel R a lower end of which reaches at least a half position of height of the charged mixed raw material is inserted into the mold M and the mixed raw material 6 is charged into the funnel R in this condition, then the funnel R is drawn out and the mixed raw material 6 is charged into the molding M. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for producing a filter molded body for use in a water treatment filter that removes contaminants in water obtained by solidifying a water purification component with a polymer binder. More specifically, the water purification component such as activated carbon is uniformly dispersed. The present invention relates to a production method capable of producing a filter molded body having excellent water treatment capacity and performance.

  Conventionally, replacement cartridge filters for water treatment equipment called water purifiers and water purifiers used in general households remove residual chlorine and organic substances with granular or fibrous activated carbon, and microfiber dirt and red with hollow fiber membranes. Generally, it has a structure that takes rust and bacteria.

  As a specific structure, for example, in Patent Document 1, the activated carbon chamber and the hollow fiber membrane chamber are respectively housed and disposed in a cartridge made of a cylindrical container, and water is introduced into the cartridge to enter the activated carbon chamber. It can be sent to remove the smell of woody and moldy odors, then sent to the hollow fiber chamber, and remove those that could not be removed with activated carbon.

  In Patent Document 2, a tube made of a hollow fiber membrane is arranged at the center of a cartridge made of a cylindrical container, activated carbon is arranged on the outer peripheral side thereof, water is allowed to flow from the outer peripheral side, and the activated carbon layer is passed through. After that, a structure having a structure in which the treated water is taken out from the cartridge through the hollow fiber membrane is also used.

  In either configuration, the activated carbon is used in a state where it is simply stored in a granular or fibrous form in a room partitioned by a membrane having a small-diameter hole through which activated carbon does not pass and only water passes. there were.

  However, first, in the filter having a structure as disclosed in Patent Document 1 or Patent Document 2, simply stored granular or fibrous activated carbon cannot remove fine dirt or turbidity, and therefore, when passing through the activated carbon. Since fine dirt is hardly removed, the hollow fiber is easily clogged and its life is short.

  Furthermore, when granular activated carbon is used, when water passes through the layer of activated carbon, there are many cases where the water is naturally attached. Once the water is attached, the flow of water concentrates on that part, Since it can only be used partially, the lifetime of the performance of removing chlorine and the like will be shortened.

  Patent Document 3 discloses a water treatment device in which activated carbon particles are trapped in a porous plastic matrix. Activated carbon having a small particle size can be used by dispersing activated carbon in a porous plastic matrix.

  Patent Document 4 also discloses a filter obtained by solidifying activated carbon with a polymer, and using a polymer having a low melt index that is less than 1.0 g / 10 min (ASTM D1238, 190 ° C., 15 kg Load) as the polymer. ing.

  Further, Patent Document 5 discloses a method of forming a filter by solidifying activated carbon by using a polymer as a binder and heating and pressurizing in a mold to melt and solidify the binder.

JP-A-10-85729 JP-A-8-71541 JP-A-2-17989 U.S. Pat. No. 4,753,728 JP 2001-187305 A

  In Patent Document 3 and Patent Document 4, a filter obtained by dispersing and solidifying activated carbon in a porous plastic matrix is used. With this structure, activated carbon with a smaller particle size can be used, which improves efficiency and allows water to flow through the entire filter. It is possible.

  Further, Patent Document 5 describes a method in which activated carbon is solidified and molded with a binder made of a low melt index polymer that is heated to a fluidized state, and powdered activated carbon and polymer, and other materials as required. A molding method is described in a state in which a mixed raw material blended with is filled in a mold, heated and pressurized to melt a polymer, and activated carbon and the like are dispersed. However, the size and specific gravity of each raw material are different, and separation may occur, for example, when a raw material with a low specific gravity rises and is biased to the upper layer when the raw material is introduced into the mold. If the mixed raw material is separated before it is molded and hardened with a binder, it becomes a molded product in the separated state, and the resulting filter has partial variations in performance and adversely affects the appearance. Effect.

  Therefore, the present invention provides a water treatment filter manufacturing method in which a water purification component such as activated carbon is solidified and molded using a polymer as a binder, and the water purification component such as activated carbon as a raw material is uniformly dispersed throughout the molded body. It is an object of the present invention to provide a production method capable of forming a water treatment filter having no variation and good appearance.

  In order to solve the above-mentioned problems, in claim 1 of the present invention, a purified water component such as activated carbon that removes contaminants from water is mixed with a binder made of a polymer to obtain a mixed raw material, and the mixed raw material is placed in a mold. In the method of manufacturing a filter molded body in which the binder is fluidized and heated by heating the mixed raw material, and then cooled and demolded, the lower end of the mixed raw material is filled in the mold. Including a step of charging the mixed material into the mold with the funnel reaching at least half of the height of the mixed material after filling being inserted in the mold, and then pulling out the funnel and filling the mold with the mixed material. It is characterized by.

  According to claim 2, when the funnel is fitted into the mold, the funnel is arranged at the center of the mold.

  According to a third aspect of the present invention, a filter manufacturing method has a guide rib for supporting the funnel at the center of the mold around the funnel.

  According to a fourth aspect of the present invention, a method for producing a filter molded body in which a stirring protrusion is provided inside the funnel.

  According to the fifth aspect of the present invention, the lower end of the funnel is a method for producing a filter molded body located at a height within 5 mm from the bottom of the mold.

  Separation occurs once in the charging of the mixed raw material into the funnel by taking the step of charging the mixed raw material mixed by stirring and dispersing as in claim 1 with a funnel and pulling the funnel into the mold. The mixed raw material is dispersed again when the funnel is withdrawn. Therefore, since it can be filled in the mold while maintaining the dispersed state, a good molded product can be obtained without variation in the performance of the filter.

  In the second and third aspects, the funnel is arranged in the center of the mold, and the entire mixed raw material in the funnel can be dispersed by pulling the funnel out of the mold.

  According to the fourth aspect, by providing the stirring protrusion inside the funnel, the dispersion of the mixed raw material when the funnel is pulled out is further improved.

  Since the lower end of the funnel is located at a height within 5 mm from the bottom of the mold as in claim 5, the adhesion of the raw material to the side surface of the mold due to the rising at the time of starting the raw material can be almost eliminated. The dispersed state can be kept higher.

  1 is a perspective view showing an example of a filter molded body obtained by the production method of the present invention, FIG. 2 is a perspective view of a filter for water treatment using the filter molded body, and FIG. 3 is a cross-sectional view taken along line AA in FIG. FIG. 4 is a cross-sectional view of the water treatment device.

  A filter molded body 1 obtained by solidifying activated carbon obtained by the production method of the present invention is used as a filter for a water treatment filter 2 in a faucet direct connection type water treatment device S as shown in FIG. As the structure of the water treatment filter 2, for example, as shown in FIGS. 2 and 3, the filter layer 3 is coated on the outer periphery of a cylindrical filter molded body 1 having a size of about 45 to 50 mmφ × 90 to 100 mm, A cap 4 covers the top and bottom portions of the cylindrical filter molded body 1, and the cap 4 is connected to the filter molded body 1 with water tightness so that water containing dirt does not pass through.

  Moreover, the cylindrical filter molded body 1 has a hole 5 of about 10 to 15 mmφ at the center axis position of the cylinder.

  When the water treatment filter 2 is attached to the water treatment device S, the water flow is taken in from the filtration layer 3 side, and after removing dirt such as large-sized dust from the filtration layer 3, a filter molded body is obtained. Residual chlorine and organic substances are removed by passing through 1, and the process is carried out in a process of springing into the hole 5 and exiting 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 filter molded body obtained by solidifying a water purification component such as activated carbon with a binder composed of a polymer having a high molecular weight and a low melt index. It is comprised so that a water treatment may be performed by letting it pass.

  Of course, the filter formed of the filter molded body 1 can be used alone as a water treatment filter, or can be used in combination with a filter having another water purification effect such as a hollow fiber membrane.

  The hollow fiber membrane referred to here is a porous and hollow thread having a hollow hole continuous in the longitudinal direction at the center of the thread and a wall surrounding the hollow hole having a pore of about 0.01 to 5 μm. The material is made of polyvinyl alcohol, polyacrylonitrile, polyvinyl chloride, polyethylene, polypropylene, 4-methyl-1-pentene, polyester, polyamide, polysulfone, cellulose derivatives, and the like. Usually, a U-shaped hollow fiber bundle is housed and fixed in a cylindrical container. Moreover, the porosity of the hollow fiber membrane used normally is about 20 to 90%.

  By using the filter molded body 1 solidified with a polymer binder in this way, it has the ability to remove not only chlorine but also dirt and turbidity, and if a hollow fiber membrane is used together, dirt and turbidity are further removed. Therefore, it is possible to provide a water treatment filter that can increase the performance of the hollow fiber membrane and can make the hollow fiber membrane last longer. The present invention proposes a method for producing such a filter molded body, and is a production method in which a water purification component such as activated carbon can be uniformly dispersed throughout the filter molded body.

  FIG. 5 is a cross-sectional view showing a state where the mixed raw material is charged into the mold M using the funnel R, and FIG. 6 is a cross-sectional view where the funnel R is pulled out. FIG. 7 is a cross-sectional view showing a state where vibration is applied by the vibration device 7 after the mixed raw material is filled in the mold M in the manufacturing method of the present invention, and FIG. FIG. 9 is a cross-sectional view of the molded part, and FIG. 9 is a cross-sectional view of the filter molded body 1 being removed.

  The mold M used when the filter molded body 1 is manufactured is a cylindrical frame mold 9 made of aluminum, iron or the like having a high thermal conductivity, and a pipe shape having an outer diameter substantially the same as the inner diameter of the frame mold 9. The upper die 8 and a cylindrical lower die 10 having the same outer shape as the inner diameter of the frame die 9 are also included. Using this mold M, a cylindrical filter molded body having an outer diameter of φ45 to 50 mm and an inner diameter of φ10 to 11 mm × 90 to 95 mm is formed.

  Next, the manufacturing method of the filter molded body 1 of this invention using this mold M is demonstrated. Here, a procedure for forming a cylindrical shaped body having a predetermined density and a uniform particle size will be described as an example.

  First, a mixed raw material 6 in which a water purification component such as activated carbon and a binder composed of a polymer having a high molecular weight and a low melt index are mixed and stirred at a predetermined ratio to obtain a mixed raw material 6 in which both are uniformly dispersed. At this time, the purified water component should be finer than 60 mesh, powder or fiber, and the binder should have a particle size of about 60 mm so that the purified water component can be dispersed throughout the filter molded body and the water treatment effect can be fully exerted. It is preferable to use a thing of about 100 μm.

  In the present invention, the funnel R is first set in the mold M in order to fill the mixed material 6 in the mold M. This funnel R is of such a length that its lower end reaches the bottom mold 9 of the mold M. The mixed raw material 6 is put into the funnel R. Then, the mixed raw material 6 is filled into the mold M by pulling out the funnel R from the mold M. The mixed raw material 6 is a mixture of a binder, a water purification component, and the like, and those having different specific gravities are mixed with each other, so that they are separated when they are put into the funnel R. However, the mixed raw material 6 separated when the funnel R is pulled out from the mold M is again stirred and dispersed.

  When the funnel R used at this time is a funnel in which a cylinder and a cone are combined as shown in the figure, the separation of the mixed raw material is prevented and dispersed by increasing the length of the cylinder fitted into the mold. It is effective and the bottom of the funnel R reaches the bottom mold 9 which is the bottom of the mold M or is at most at a height within 5 mm from the bottom. preferable. However, if a material whose length is such that the lower end of the funnel R reaches at least half the height of the mixed raw material in a state where the mixed raw material is filled in the mold M, there is an effect of eliminating a certain amount of separation of the raw material. . The shape of the funnel R is not limited to a cylindrical shape, and may be a funnel in which a prism and a pyramid are combined.

  When the funnel R is set in the mold M, it is preferably arranged at the center of the mold. By doing so, the entire mixed raw material 6 can be evenly stirred when the funnel R is pulled out. In order to arrange the funnel R in the center, it is also possible to use one provided with a guide member G outside the funnel R as shown in FIG.

  Furthermore, in order to increase the effect of stirring when the funnel R is pulled out from the mold M, it is also a preferable form to provide a stirring protrusion inside the funnel R. The stirring protrusions may be shaped like blades, for example, or may be rod-shaped protrusions.

  After the mixed raw material 6 is filled in the mold M to a height of about 150 to 200% of the height of the molded filter body after molding, the mold M containing the mixed raw material 6 has an amplitude of 1 to 3 mm and a frequency of 5 to 10 times with a vibration device. The bulk of the raw material is reduced until it increases by 5 to 15% of the predetermined height. Here, the filter molded body height after molding is a target value of the height when the filter molded body is completed. Note that this target value includes a target value that takes into account the difference in dimensions due to shrinkage of the molded body during cooling after molding.

  When the mold M is vibrated, if the amplitude becomes too large or the vibration frequency becomes too large and the vibration is given too much, the mixed raw material 6 becomes too clogged and a predetermined density cannot be obtained. Further, the mixed raw material 6 may be separated due to the difference in particle diameter and weight, and a uniform molded body may not be obtained.

  On the other hand, if the vibration is insufficient, when the pressure is adjusted after heat molding and the height of the molded filter body after molding is adjusted, the amount of adjustment due to pressurization is large. The inner surface of the mold and the material interface are rubbed and clogged, impairing the function as a filter.

  Following the filling of the mixed raw material 6 and the vibration of the mold M, the upper mold 8 is lowered and 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 into a fluid state. When the polymer binder is in a fluid state, the mold M is taken out from the oven, and the upper mold 8 is further lowered to pressurize the molded filter to a height after molding.

  In demolding, after the mold M is sufficiently cooled, the bottom mold 10 is pulled out, and the upper filter 8 is used to demold the filter molded body 1.

Thus, the mold M is mixed with a water purification component and a binder composed of a polymer, filled in the mold M, adjusted for vibration and bulkiness, heated at a temperature of about 200 ° C. for a predetermined time, adjusted for compression, cooled, By releasing the mold, the filter molded body 1 having a uniform particle size and a density adjusted in the range of 0.5 to 0.65 g / cm ³ as described above can be produced.

  In the above description, the pressurization is performed after taking out from the oven, but the method is not limited to this, and the pressurization may be performed in the oven. Moreover, when heating, since the polymer binder is not yet in a fluid state, the heating may be performed while applying a certain amount of pressure by the weight of the upper die 8, for example.

  Hereinafter, the raw materials used in the present invention and their properties will be described in detail. The filter molded body obtained by the present invention is a porous body obtained by solidifying a water purification component such as activated carbon with a binder made of a polymer, and a low melt index high molecular weight porous polymer is used as the binder.

  As the water purification component, not only activated carbon but also an ion exchange resin, an inorganic compound, or the like can be used, for example, by molding a plurality of water purification components with a binder.

  Taking activated carbon as an example, it is preferable to use one having 60 mesh pass or more. If it is less than 60 mesh pass, it becomes difficult to harden the activated carbon with the binder, and the voids of the filter molded body 1 become too large, and there is much water that passes through the filter molded body 1 without contacting the activated carbon. Therefore, the performance of removing chlorine and dirt is deteriorated, which is not preferable.

  Also, two types of water purification components, one having large particles and one having small particles, are used, granular activated carbon of 60-100 mesh pass is used as activated carbon with large particles, and powdered activated carbon of 100 mesh pass is used as activated carbon with small particles. . Then, activated carbon having a large particle and activated carbon having a small particle are mixed at a ratio of 1: 1 to 4: 1, and such activated carbon is solidified with a binder having a low melt index.

  By using the activated carbons having such two kinds of particle size distributions mixed in the above ratio, there is suitably powdered activated carbon of 100 mesh pass or more in the gap between the granular activated carbons of 60-100 mesh pass. And it can be set as the filter molded object 1 which has the capability that a sufficient flow volume is obtained over the long term, and the performance which removes chlorine, dirt, etc.

  Here, when the activated carbon having a large particle size is less than 60 mesh pass, it becomes difficult to harden the activated carbon with the binder, and the voids in the filter molded body 2 become too large to come into contact with the activated carbon. Since the amount of water that passes through the filter molded body 2 increases, the removal performance of water such as chlorine deteriorates, which is not preferable.

  If activated carbon with small particles is finer than 100 mesh pass, for example, activated carbon of 300 mesh pass or more, the void portion of the filter molded body 2 is reduced and a sufficient flow rate cannot be obtained.

The binder composed of the low melt index polymer must be non-toxic because it can be used as a filter for a water treatment device without problems, and forms a porous body when molded as a single unit. It is preferable that the resin is easy. Specifically, it is an ultrahigh molecular weight polyethylene having a molecular weight of about several hundred thousand to several million, a resin having a raw material particle size of about 100 μm and a bulk density of less than 0.3 g / cm ³ , and having a melt index of 1.1. -2.3 g / 10 min (ASTM D1238, 190 ° C., 15 kg Load).

  When the melt index of the binder is less than 1.1 g / 10 min (ASTM D1238, 190 ° C., 15 kg Load), the flow during melting when forming the filter molded body is poor, and in order to harden the purified water component, The amount of must be increased. As a result, the amount of the purified water component in the filter is reduced, and the performance for treating water is lowered.

  In addition, if the melt index of the binder exceeds 2.3 g / 10 min (ASTM D1238, 190 ° C., 15 kg Load), the polymer melted at the time of molding the filter covers the surface of the water purification component, and the water purification effect is reduced. Therefore, it is not preferable.

  Since the binder is a polymer having a melt index as described above, it has an appropriate viscosity at a high temperature, so that the polymer melted at the time of forming the filter covers the pores of the activated carbon which is a water purification component. Absent.

Further, the mixing ratio of the purified water component and the binder is such that the binder is blended in an amount of 10 to 25% by weight with respect to the purified water component, and the density of the filter molded body is 0.5 to 0.65 g / cm ³ . For example, it is possible to ensure a flow rate exceeding 2.0 L / min that is normally required in a faucet direct-coupled water treatment device at a dynamic water pressure of 0.1 MPa.

  When the blending amount of the binder with respect to the purified water component is less than 10% by weight, it becomes difficult to solidify the purified water component, and when it exceeds 25% by weight, the binder covers the surface of the purified water component too much, and the purified water performance. Is not preferable because it cannot be fully exhibited.

Moreover, when the density of the filter molded body after solidification is less than 0.5 g / cm ³ , the rigidity is lowered, and the filter molded body is fragile and easily collapses. If it exceeds 0.65 g / cm ³ , it will be too hard and there will be no voids in the filter molded body, making it impossible to obtain a sufficient flow rate.

  When the filter molded body obtained by the production method of the present invention is used in combination with a hollow fiber membrane filter, most of the dirt is removed by the filter molded body. A filter molded body that reduces clogging, extends the service life, and has sufficient performance and ability even when the weight and size of the filter are limited, such as a faucet direct-attached water treatment device. Can be provided. In addition to the hollow fiber membrane filter, it can be used in combination with other filters having a water purification effect.

  Next, a test for confirming the effect of the present invention was conducted.

As Example 1, 60-100 mesh pass granular activated carbon and 100 mesh pass powdered activated carbon were mixed in a ratio of 2 to 1, and 1.5 g / 10 min (ASTM D1238, 190 ° C., 15 kg Load) high molecular weight porous polymer ( 15% by weight of Ticona Gmbh, Hostalen GUR2105) is used as a mixed raw material, and a funnel having a length whose lower end is in contact with the bottom of the mold is set. Filled. Heated at 200 ° C for 1 hour, cooled, adjusted compression amount, molded activated carbon block with outer diameter φ45 x inner diameter φ11 x length 92L so that the solidified activated carbon block density would be 0.55 g / cm ³ , filter A molded body was obtained.

  The appearance of the finished filter molded body was observed and the quality was evaluated. The results are shown in Table 1. The result is indicated by ○ when the appearance is good, Δ when the appearance is good, and × when the appearance is poor.

  A filter molded body was produced under exactly the same conditions as in Example 1 except that a funnel whose lower end reached half the height of the mold was used.

  The appearance of the finished filter molded body was observed and the quality was evaluated. The results are shown in Table 1. The result is indicated by ○ when the appearance is good, Δ when the appearance is good, and × when the appearance is poor.

Comparative Example 1

  A filter molded body was produced under exactly the same conditions as in Example 1 except that the funnel was not used when filling the mixed material into the mold.

  The appearance of the finished filter molded body was observed and the quality was evaluated. The results are shown in Table 1. The result is indicated by ○ when the appearance is good, Δ when the appearance is good, and × when the appearance is poor.

Comparative Example 2

  A filter molded body was produced under exactly the same conditions as in Example 1 except that the funnel was not used when filling the mixed raw material into the mold, and the mixed raw material filled in the mold was stirred with a sag before molding.

  The appearance of the finished filter molded body was observed and the quality was evaluated. The results are shown in Table 1. The result is indicated by ○ when the appearance is good, Δ when the appearance is good, and × when the appearance is poor.

  From the results in Table 1, in Example 1, the appearance was good as in Comparative Example 2 in which the stirring operation was performed without performing the stirring operation after filling the mixed material into the mold, and a funnel was used. The effect by this can be confirmed. It can also be seen that it is more preferable to use a funnel whose bottom end is in contact with the bottom of the mold because the appearance of the molded body can be improved.

  The present invention relates to a method for producing a filter molded body for use in a water treatment filter that removes contaminants in water obtained by solidifying a water purification component with a polymer binder. More specifically, the water purification component such as activated carbon is uniformly dispersed. It can be applied to the production of a filter molded body having excellent water treatment capacity and performance.

It is a perspective view of the filter molded object obtained by the manufacturing method of this invention. It is a perspective view of the filter for water treatment using a filter fabrication object. It is AA sectional drawing in FIG. It is sectional drawing of a faucet direct connection type water treatment device. It is sectional drawing when the mold was set on the vibration apparatus used for the manufacturing method of this invention, and the mixed raw material was filled. It is sectional drawing of the place which has extracted the funnel. It is sectional drawing of the place which is adding the vibration with a vibration apparatus. It is sectional drawing of the place which is shape | molded by pressurizing with the weight of an upper mold | type. It is sectional drawing of the place which has removed the activated carbon molded object from the mold. It is sectional drawing seen from the bottom of the place which provided the guide member in the outer side of the funnel.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Filter molded object 2 Water treatment filter 3 Filtration layer 4 Cap 5 Hole 6 Mixed raw material 7 Vibrating device 8 Upper mold 9 Frame mold 10 Bottom mold S Water treatment machine M Mold R Funnel

Claims (5)

  A water purification component such as activated carbon that removes pollutants from water is mixed and stirred with a binder made of a polymer to form a mixed raw material. After a predetermined amount of the mixed raw material is filled in a mold, the mixed raw material is heated to flow the binder. In the method for producing a filter molded body that is pressurized, cooled, and demolded, when the mixed raw material is filled into the mold, a funnel whose lower end reaches at least half the height of the mixed raw material after filling is provided. A method for producing a filter molded body comprising a step of charging a mixed raw material into a funnel while being fitted in a mold, and then drawing the funnel and filling the mold with the mixed raw material.   The manufacturing method of the filter molded object of Claim 1 which arrange | positions a funnel in the center of a mold, when fitting a funnel in a mold.   The method for producing a filter according to claim 2, wherein a guide member for supporting the funnel at the center of the mold is disposed around the funnel.   The method for producing a filter molded body according to claim 1, wherein stirring funnels are provided inside the funnel. The manufacturing method of the filter molded object of Claims 1-4 in which the lower end of a funnel is located in the height within 5 mm from the bottom of a mold.

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