JP2008279451A - Method for manufacturing cylindrical filter member for water purifier - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an effective method for manufacturing a filter member for a water purifier capable of not only enhancing filterability of the water purifier but also enabling the effective filtration of heavy metals such as lead and other substances and moreover having these heavy metals carried by activated carbon. <P>SOLUTION: The method for manufacturing the cylindrical filter member for the water purifier comprises the step of covering a rotary shaft 17 with a cylindrical molding 13 formed of fibers or powders, rotating the cylindrical molding 13 in a mixture solution 21 containing water, activated carbon, a heavy metal adsorbent 16, and a binder with air sucked from inside of the rotary shaft 17 to make a fibrous activated carbon layer 14 adhere to the outer periphery of the cylindrical molding 13, winding a pre-filtering layer 15 of non-woven fabric around the outer periphery of the fibrous activated carbon layer 14 to form a filter member body 10, and subjecting the filter member body 10 to a predetermined drying process after detaching the body 10 from the rotary shaft 17. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

The present invention relates to a method for producing a cylindrical filter member used in a simple water purifier such as drinking water or industrial water.

  Normally, water purifiers are manufactured with a granular or fibrous activated carbon and hollow fiber membrane built into the casing, and filter dust, residual chlorine, odorous substances, fine particles, etc. in raw water from tap water. A water purification structure for supplying purified water has been put into practical use.

  On the other hand, this type of water purifier has an upflow (or downflow) method in which the direction of filtration from raw water to purified water flows from the bottom or top of the filter member, and a sideflow method that flows from the side surface of the filter member to the center. There is. Various types of water purifiers such as an undersink type, a desktop type, or a faucet direct connection type have been proposed.

  By the way, tap water supplied in contact with plumbing equipment such as water pipes containing lead, etc., may contain trace amounts of heavy metals such as lead, and may be contained in tap water, Therefore, there is a demand for a water purifier capable of removing or filtering heavy metals such as lead from tap water. In addition, an effective water purifier that can remove environmental hormones that are said to induce the endocrine disrupting action of the body due to water quality containing industrial chemicals (synthetic detergents, paints, cosmetics, plastic plasticizers), dioxins, agricultural chemicals, and natural substances Need.

As a water purifier for performing this lead removal etc., for example, JP-A-7-275850 and JP-A-2001-232361 are known.
The former publication describes activated carbon for removing lead in water, in which hydroxyapatite is produced in the pores of the activated carbon.
However, this publication does not disclose the structure or method of how to apply this activated carbon to a water purifier.

  The latter publication is mainly a faucet direct connection type, and is a downflow type water purifier, specifically, a separate form of fibrous activated carbon is disposed around the outer periphery of the filter member, This molded body contains a water purifier containing an adsorbent having ion exchange capacity.

JP-A-7-275850 JP 2001-232361 A

  However, although a water purifier with a lead removal structure has been proposed for the above-mentioned water purifier, the water purifier has a side flow type as a basic structure, has a lead removal performance based on this basic structure, and can remove environmental hormones. However, it does not effectively respond to recent requests.

Further, the above-mentioned conventional publication is not a water purifier proposed for a production method for effectively supporting a lead adsorbent on fibrous activated carbon.
Therefore, the development of a water purifier capable of filtering heavy metals such as lead or other substances in addition to the normal water purifying function in the side flow type water purifier has been expected.

  The present invention has been developed in view of the above-mentioned circumstances, and its object is to effectively filter heavy metals and other substances such as lead as well as improve the filtration performance of water purifiers. It is another object of the present invention to provide an effective manufacturing method for supporting heavy metals on activated carbon.

In order to achieve the above-mentioned object, the invention according to claim 1 is characterized in that a cylindrical molded body formed of fiber or powder is coated on the outer periphery of the rotary shaft, and the cylindrical molding is performed while sucking air from the inside of the rotary shaft. The body is rolled in a mixed solution in which water, activated carbon, heavy metal adsorbent, and binder are mixed to adhere a fibrous activated carbon layer to the outer periphery of the cylindrical molded body, and the outer periphery of the fibrous activated carbon layer is made of a nonwoven fabric. This is a method for manufacturing a cylindrical filter member for a water purifier that is manufactured by winding a pre-filter layer to form a main body of a filter member, and removing the main body from a rotating shaft, followed by a predetermined drying step .

As is clear from the above, according to the present invention, in particular, the active carbon layer of the fibrous activated carbon layer is made dense and uniform, while the heavy metal adsorbent is effectively supported on the fibrous activated carbon layer by a wet molding method. In the molding of the fibrous activated carbon layer, the process of removing the core from the molded body can be reduced by incorporating the cylindrical molded body as a part of the filtration layer as it is as the core. There is an effect. Moreover, according to the cylindrical filter member, by using a cylindrical molded body composed of fibers or powder as a core for winding the fibrous activated carbon, it has a rough filtration function, and this cylindrical molding The body has a partitioning function with the granular activated carbon layer that fills the cylindrical molded body wall and intervenes as a function of removing residual chlorine and the like, and has a filtration layer made of fibrous activated carbon on the outer periphery of the cylindrical molded body. If you try to molding can provide effective since it is possible to mold a cylindrical filter member which can further improve the filtration performance of the water purifier.

Furthermore, when a predetermined upper and lower cap is bonded to the cylindrical filter member, the cap can be press-fitted and fitted due to the rigidity of the cylindrical molded body.
In addition, when there is no cylindrical molded body with this partitioning function, uneven flow tends to occur in the flow into the granular activated carbon layer, and contact with a uniform fluid cannot be expected. However, when a cylindrical molded body is provided as in the present invention, there is an effect of preventing drift, and this variation can be suppressed, and the entire filter medium can be efficiently used without waste. Since it can be used, it has the effect of extending the life.

  In addition, the fluid that has tried to flow through the prefilter layer is gradually immersed in the fibrous activated carbon layer, once immersed uniformly in the fibrous activated carbon layer, and further, the fiber residence time is increased by increasing the fluid residence time. The filtration performance by the activated carbon layer can be further improved.

  Furthermore, heavy metals such as lead or other substances can be effectively adsorbed and filtered effectively. In addition, in this case, if the heavy metal adsorbent is supported at a certain ratio, it is easy to ensure a uniform flow in the fibrous activated carbon layer.

Therefore, an effective method for manufacturing a cylindrical filter member for supporting heavy metal on activated carbon can be provided.

In addition, the present invention is a side flow type water purifier, and when the raw water flows in, it slowly passes through the activated carbon layer to exert an effective filtration effect, and it is accompanied by pressure loss when the purified water flows out. No water purifier is obtained .

The embodiment of the manufacturing method of the cylindrical filter member for water purifiers in the present invention is explained in full detail based on a drawing.
FIG. 1 is a cross-sectional view showing an example of a water purifier in the present invention, and FIG. 3 is a perspective view showing an example of a filter member in the present invention. In the figure, reference numeral 10 denotes a cylindrical filter member main body (hereinafter referred to as a main body) according to the present invention. Is provided. Of these, the cylindrical molded body 13 is formed in a cylindrical shape with fibers or powders made of polypropylene or polyethylene, or has a filtration function molded into a cylindrical shape with a nonwoven fabric. A fibrous activated carbon layer 14 is laminated on the periphery, and a prefilter layer 15 formed of a nonwoven fabric made of polypropylene or polyethylene is further provided on the outer periphery of the fibrous activated carbon layer 14. In the figure, the prefilter layer 15 is folded back to the end face of the main body 10.

  The cylindrical formed body 13 serves as a core for forming the fibrous activated carbon layer 14 formed by winding, and the granular activated carbon layer 12 as another filtration layer is disposed on the inner wall of the cylindrical molded body 13. It is a partition wall.

  The filtration resistance of the cylindrical molded body 13 is larger than the filtration resistance of the granular activated carbon layer 12. When the filtration resistance of the granular activated carbon layer 12 is 1, the cylindrical molded body 13 is 2-4. It is said. The fibrous activated carbon layer 14 has a filtration resistance of 10.

The fibrous activated carbon layer 14 carries a heavy metal adsorbent 16 capable of adsorbing heavy metals such as lead or copper. As the heavy metal adsorbent 16 in this example, an aluminosilicate that is a zeolite-based structural material is used. Yes.
For example, in the case of adsorbing lead, the aluminosilicate loading is about 20% by weight with respect to the total weight of the fibrous activated carbon layer 14 in this embodiment because of the relationship between the lead adsorption state and the filtration flow rate. Although it is desirable to make the minute, it can be appropriately changed in implementation.

For example, a hollow fiber membrane 11 that is a porous molded body is disposed inside the main body 10, and a granular activated carbon layer 12 is filled between the cylindrical molded body 13 and the hollow fiber membrane 11 to form a cylinder. A granular activated carbon layer 12 is provided on the inner wall of the shaped molded body 13 and purified from the flow path side through the cylindrical molded body 13, the granular activated carbon layer 12 and the polypropylene hollow fiber membrane 11.
Reference numeral 22 denotes an upper cap, and reference numeral 23 denotes a lower cap. The upper cap 22 and the lower cap 23 are formed with protrusions 22a and 23a and protrusions 22c and 23b having circular cross sections. The lower cap 23 is press-fitted so that the main body 10 which is the cylindrical molded body 13, the fibrous activated carbon layer 14, and the prefilter layer 15 is sandwiched between the protruding portion 23a and the protruding portion 23b. After the activated carbon layer 12 is filled in the space between the hollow fiber membrane 11 and the cylindrical molded body 13, the main body 10 is sandwiched between the protruding portion 22 a and the protruding portion 22 c of the upper cap 22 and press-fitted. Then, the filter cartridge 24 composed of the five active layers is integrally formed to be a rigid body, and the filter cartridge 24 is built in the container 7.

  The container 7 constituting the water purifier main body 1 is molded by a resin having high pressure resistance such as ABS resin (acrylonitrile, butadiene, styrene copolymer), and the container 7 has a bottom wall 7a. When the filter cartridge 24 is built in the container 7, the male screw 22 b of the filter cartridge 24 provided on the upper cap 22 is first replaced with the female screw 2 a of the cap member 2. Then, the cap member 2 and the filter cartridge 24 are integrated with each other, and then the screw portion 2b is provided in the cap member 2 so as to be screwed into the screw portion 7b of the container 7 so as to be built in the container 7. The water purifier body 1 is provided.

The cap member 2 has a raw water inlet 3 and a purified water outlet 4, and these inlets 3, 4 have plugs 5, 6 that are paired with sockets 25, 26 having a quick coupling structure by a coupler system. The sockets 25 and 26 are connected to the plugs 5 and 6, respectively. The socket 25 is connected to the water line, and the socket 26 is connected to the purified water outflow path.
In the figure, 17a and 17b are sealing members, 18 is an outer cylinder, and 18a is a potting portion.

Next, the operation in the above embodiment will be described.
Since the fibrous activated carbon layer 14 is laminated on the outer periphery of the cylindrical forming body 13 of the main body 10 in the present invention, and the prefilter layer 15 is provided on the outer periphery of the fibrous activated carbon layer 14, the main body 10 is a side flow type. In this case, an effective filtering function can be provided.

  Since the cylindrical formed body 13 has a core function at the time of forming the fibrous activated carbon layer 14, it is not necessary to prepare a separate core when forming the main body 10. When the granular activated carbon layer 12 that is a filtration layer is disposed, the cylindrical forming body 13 has a partitioning function, so that a highly functional filter structure can be obtained.

  In addition, since the filtration resistance of the cylindrical formed body 13 is larger than the filtration resistance of the granular activated carbon layer 12, when the fluid flows into the fibrous activated carbon layer 14 around the outer periphery of the main body 10, the partition function is exhibited higher. In addition, the fluid residence time in the fibrous activated carbon 14 can be increased.

Since the fibrous activated carbon layer 14 carries the heavy metal adsorbent 16, it is possible to remove heavy metals such as lead, environmental hormones, and the like contained in tap water, which are harmful substances to human health.
In the case where lead contained in raw water such as tap water is removed by the heavy metal adsorbent 16, the hollow fiber membrane 11 can filter and remove solid lead (Pb) by a filter function. It is difficult to remove water-soluble lead (Pb ⁺ ). Therefore, in this embodiment, the water-soluble lead can be removed by adding the heavy metal adsorbent 16 made of an aluminosilicate capable of removing water-soluble lead to the fibrous activated carbon layer 14, and the water can be passed. In contrast, an efficient lead removal process can be performed.

Aluminosilicate has regularly arranged 1 to 3 dimensional molecular pores, and as a mechanism for adsorption of heavy metals such as lead, lead ions are bound to molecules composed of an aluminosilicate lattice structure. When heading, lead ions are adsorbed by the ion-exchange ability that is characteristic of zeolite-based structural materials, and are exchanged with ions such as Na, K, and Ca that are waiting in the lattice instead.
Aluminosilicate has various functions such as ion exchange capacity, solid acidity, and shape selectivity in addition to the function of adsorbing and separating heavy metals.

When raw water flows into the water purifier main body 1, the raw water that flows into the side flow type removes red rust and the like by the filter member made of the prefilter layer 15, followed by water-soluble lead and water by the fibrous activated carbon layer 14. After removing residual chlorine, environmental hormones, odorous substances, trihalomethane, etc., which are easily soluble, and after removing dust, red rust, etc. that could not be captured by the prefilter layer 15 by the cylindrical molded body 13 constituting the main body 10 respectively. The particulate activated carbon layer 12 removes the environmental hormones in the form of oil droplets that could not be removed by the fibrous activated carbon layer 14, and then the solid fiber and dioxins that are not soluble in water remaining by the hollow fiber membrane 11. Filtration is performed by removing metal oxide fine particles and the like, and the filtered purified water flows out from the purified water outlet 3.
When the actual flow test was performed by the water purifier main body 1 in this example, the soluble lead removal rate could be maintained at 90% or more at a total filtered water amount of 10 t.

Next, an example of the manufacturing method of the cylindrical filter member for water purifiers in this invention is demonstrated based on figures.
At the time of forming the hollow fibrous activated carbon layer 14 constituting the main body 10 shown in FIG. 3, in order to make the fibrous activated carbon layer 14 uniform with no coarseness, it is wet or dry. Manufacture by either method. First, in FIG. 4, it shows an explanatory diagram of a case where the molded fibrous activated carbon layer 14 by wet type (dip molding), illustrating the molding step in this case.

  In FIG. 4A, by inserting an appropriate shaft 17 serving as a rotation axis into the cylindrical molded body 13, the cylindrical molded body 13 is provided on the outer periphery of the shaft 17, and the cylindrical molded body 13 rotates. It is designed to be the core of time.

Next, as shown in FIG. 4 (b), lead adsorbent material that becomes the heavy metal adsorbent 16 and activated carbon made of granular and (short) fibers are added to water, and the necessary binder is mixed as a specific gravity adjuster and binder. Then, the mixed liquid 21 in a state of being mixed and uniformly dispersed is provided in the container 19, and the cylindrical molded body 13 is immersed in the mixed liquid 21.
In this state, as shown in FIG. 5C, the cylindrical shaped body 13 is rolled inside the container 19 while air is sucked from the inside of the shaft 17, and the mixed liquid 21 is attached to the outer periphery of the cylindrical shaped body 13. Then, the fibrous activated carbon layer 14 containing the heavy metal adsorbent 16 is attached.

  Next, in FIG. 4D, a pre-filter layer 15 is wound around the outer periphery of the fibrous activated carbon layer 14 to protect the activated carbon portion, and the main body 10 is formed. As shown in (e), the main body 10 is hardened through a predetermined drying process such as an oven after the shaft 17 is removed.

  According to the present invention, the main body 10 can be molded while the heavy metal adsorbent 16 is effectively supported on the fibrous activated carbon layer 14 by a wet molding method while the activated carbon layer of the fibrous activated carbon layer 14 is made uniform without being rough.

  When the fibrous activated carbon layer 14 is molded, the process of removing the core from the molded main body 10 can be reduced by incorporating the cylindrical molded body 13 as a core as it is as a part of the filtration layer.

It is sectional drawing which showed an example of the water purifier in this invention. It is the sectional view on the AA line of FIG. It is the perspective view which showed the filter member in this invention. (A), (b), (c), (d), (e), (f) is explanatory drawing which showed the manufacturing method of the cylindrical filter member in other invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Water purifier main body 3 Inlet 4 Outlet 10, 20 Filter member main body 11 Hollow fiber type membrane 12 Granular activated carbon layer 13 Cylindrical molded body 14 Fibrous activated carbon layer 14a Sheet member 15 Pre filter layer 16 Heavy metal adsorbent 17 Shaft 21 Mixing liquid

Claims (1)

A liquid mixture in which water, activated carbon, heavy metal adsorbent, and binder are mixed with a cylindrical molded body coated with fibers or powder on the outer periphery of the rotary shaft, while sucking air from the inside of the rotary shaft. Rolling the inside to attach a fibrous activated carbon layer to the outer periphery of the cylindrical molded body, winding a pre-filter layer made of a nonwoven fabric around the outer periphery of this fibrous activated carbon layer, and forming the main body of the filter member, A manufacturing method of a cylindrical filter member for a water purifier, wherein the main body is manufactured by passing through a predetermined drying step after being removed from the rotating shaft .

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