JP2015180502A - Pleat filter, ballast water treatment device using the same, ballast water treatment method, and pleat filter production method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a pleat filter that is capable of preventing degradation and breaking due to use, and can be used stably for a long term, and a production method of the same, and a ballast water treatment device using the same.SOLUTION: The pleat filter has a structure so that base material is folded so that crest parts and trough parts are provided continuously alternately. And either one of or both of the trough parts and the crest parts, which are folded parts, have a breaking prevention structure.

Description

  The present invention relates to a structure of a pleated filter mainly used for liquid filtration, and more particularly to a pleated filter used in a system for treating ballast water stored in a ship and used for filtering a large amount of water. Related to the device.

  A wide variety of filters are used for the purpose of separating and removing solids as contaminants from gases and liquids, and pleated filters that have a larger filtration area by making the filter into a pleated shape are also mainly used for gases such as air purifiers. It is used in. Patent Document 1 shows an example in which a pleated filter formed in a cylindrical shape is used as a filter device for removing sludge from a cutting fluid of a machine tool. In this device, it is said that a filter device having a high filter cleaning effect can be provided by ejecting liquid toward the outer surface of the filter while rotating the cylindrical filter.

  On the other hand, in recent years, the treatment of ballast water loaded on ships has become a problem. Ballast water is seawater that is loaded on a ship for safe navigation even in an empty state, and various methods for purifying ballast water to remove or kill or inactivate microorganisms have been studied. A method of using filtration for the purpose of removing relatively large microorganisms has also been studied. For example, Patent Document 2 discloses a ballast water treatment apparatus using a filtration membrane by the applicant of the present application.

JP 2008-93783 A Japanese Patent No. 4835785

  When using brackish water and seawater such as seawater desalination and ballast water, or water treatment such as sewage, domestic wastewater, and industrial wastewater, pre-filtration treatment is required to remove foreign substances, dust, and microorganisms in the water. The inventors of the present application are considering the application of a pleated filter to such filtration. Here, it is necessary to filter a large amount of water in as short a time as possible. However, large-scale, high-flow operation is a technical problem that generally tends to cause a reduction in throughput and filtration function due to early clogging. Yes.

The device disclosed in Patent Document 2 is a filtration device that incorporates a cylindrical filter in a cylindrical container and collects the liquid flowing into the inside from the outside of the cylindrical filter as a filtrate. The filtration target liquid is sprayed from a nozzle provided on the side surface of the cylindrical container to a part of the filter filtration surface to clean the filtrate deposited on the filter surface to restore the permeation flux and to filter the washed filtrate. By draining from the front chamber, a stable filtration state is continuously continued. What is important for such a system to stably maintain continuous filtration is the cleaning effect due to the ejection of the liquid to be filtered onto the filter filtration surface. In order to efficiently and effectively clean the entire filter by changing the cleaning part of the filter over time, the cylindrical filter is rotated by a motor drive or the like during filtration, and the ejection from the ejection nozzle The hit location is changed continuously and periodically. In order to reliably perform this rotary cleaning and keep a high filtration flow rate stable, it is necessary to maintain the ejection of the liquid to be filtered from the nozzle at a flow rate level that is higher than a certain level. As a result of receiving a high flow rate, the cylindrical filter may deteriorate over time, break, and part of the liquid to be filtered may be mixed directly into the filtrate without passing through the filter. found.
Accordingly, an object of the present invention is to provide a pleated filter that can be used stably for a long period of time, and a filtering device using the pleated filter that prevents deterioration and breakage due to use.

  As a result of diligent studies on the deterioration of the filter, the inventors of the present application have confirmed that a rupture is likely to occur at a bent portion corresponding to a peak and a valley of a pleat of a filter that has been ejected at a high flow rate, and has reached the present invention.

That is, the invention of this application 1
(1) A pleated filter having a structure in which a base material is bent so that peak portions and valley portions are alternately continuous, and the valley portion or the peak portion, or the valley portion and the peak portion, which are bent portions. It is a pleated filter provided with a fracture prevention structure on both.

  According to the said invention, it becomes possible to provide the pleat filter which prevents the fracture | rupture by use, and contributes to using it stably for a long time, its manufacturing method, and a ballast water treatment apparatus using the same.

It is a perspective schematic diagram explaining the typical structural example of the pleat filter concerning this invention. It is the figure which expanded a part of cross section of the pleat filter of FIG. It is a figure which shows a part which looked at the pleated filter of FIG. 1 from the side. It is the schematic diagram which expanded the bending part reinforced with resin as an example of the fracture | rupture prevention structure by this invention. It is a schematic diagram explaining another aspect of the bending part reinforced with resin as an example of the fracture | rupture prevention structure by this invention. It is a schematic diagram explaining another aspect of the bending part reinforced with resin as an example of the fracture | rupture prevention structure by this invention. It is a schematic diagram explaining another aspect of the bending part reinforced with resin as an example of the fracture | rupture prevention structure by this invention. It is a schematic diagram explaining an example of the resin reinforcement structure similar to FIG. It is a schematic diagram explaining the bending part and tip bending radius as an example of the fracture | rupture prevention structure by this invention. It is the schematic diagram which represented the bending part reinforced by sewing as an example of the fracture | rupture prevention structure by this invention in the cross section. It is a perspective view which represents typically the whole bending part of FIG. It is a figure explaining an example of the manufacturing method of the resin reinforcement structure which is one embodiment of the fracture | rupture prevention structure of this invention. It is a figure which shows an example of the ballast water treatment apparatus which is the embodiment of this invention, and is a cross-sectional schematic diagram which shows the structure of the vertical cross section containing an axis line. It is a figure which shows typically the structure of the horizontal AA cross section in FIG. It is a figure explaining the example of whole composition of the ballast water treatment system using the ballast water treatment device which is an embodiment of the present invention. It is a graph which shows the lifetime estimation result by a Weibull plot.

[Description of Embodiment of Present Invention]
First, the contents of the present invention will be listed and described. The present invention relates to (1) a pleated filter having a structure in which a base material is folded so that peaks and valleys are alternately continuous, and the valley or the peaks, or the valleys, which are bent portions. And a pleat filter having a breakage preventing structure in both of the peak portions.

  As will be described later, the term “break” refers to a crack or a minute hole generated in the filter base material, and damage that impairs the original filtration function and allows an object to be filtered to pass through. The break prevention structure is a general term for a structure in which a member, deformation, processing, or the like is added to a filter in order to prevent such breakage from occurring.

  In a pleated filter, stress and stress fluctuations tend to concentrate on the folded portion of the pleat due to the pressure of the liquid to be filtered or due to fluctuations in the pressure. In particular, when the liquid to be filtered is a liquid such as water, the pressure received by the filter is larger than that of a gas such as air, and the filter is likely to break at the bent portion. Further, even when uniform pressure is applied to the entire pleated filter, the possibility of breakage increases when the pressure concentrates or fluctuates on a part of the pleated filter. According to the study by the inventors, it has been confirmed that this fracture is likely to occur at the bent portion that becomes the above-described peak or valley. It has also been found that the causes of breakage are different between the peak and the valley.

  A force in the direction to open the bend is applied to the trough due to the pressure of the liquid to be filtered, and the bending angle of the bend changes (that is, the pleats open and close) due to the pressure fluctuation. It is thought that the possibility of this will increase.

  Since the pressure is applied in the direction where the folding is closed by the pressure of the liquid to be filtered at the mountain portion, the stress in the opening direction as in the valley portion is not applied, but the repeated bending is applied. Furthermore, in the peak part, when the pressure of the liquid to be filtered is concentrated between two specific peak parts among a plurality of continuous peak parts, a force is applied to open the peak parts. Since the upper and lower ends of the pleated filter as a whole are fixed, when the ridges are opened, the ridge line of the ridge is bent sharply near the center of the ridge. For this reason, it is easy to produce a fracture | rupture in a bending part.

  In order to prevent such breakage, by providing a breakage prevention structure, the occurrence of defective filtration can be suppressed, the strength of the pleated filter is increased, the life is extended, and the filter device can be operated for a long time. Moreover, it becomes possible to aim at reduction of the operation cost including the part and operation | work concerning replacement | exchange of a filter as a filtration apparatus. Furthermore, the filtration amount and filtration speed of the filtration device can be improved.

  (2) The break prevention structure may be a resin reinforcing structure in which a resin covering the surface of the base material or a resin that has penetrated into the base material is used as a reinforcing body. By combining the filter base material with a resin material that is more difficult to break, the possibility of breakage can be reduced.

  (3) The resin reinforcing structure may be formed by impregnating a base material with a resin. This is preferable in that the resin can be strongly reinforced to the inside by a relatively simple means. Strength and life are effectively improved by integrating the base material and the reinforcing body resin. As the impregnation means, various means such as resin application and dipping can be adopted in which the resin penetrates into the base material and is cured. In addition, it includes a mode in which the pores of the porous base material are filled by impregnation, and the impregnated portion becomes nonporous. By becoming non-porous, the strength of the bent portion is further reinforced. The impregnation is particularly preferably performed on the valley side surface of the valley, that is, the surface on the side where the liquid to be filtered is supplied. Moreover, it is preferable when it impregnates along the ridgeline of a peak part.

  (4) The resin reinforcing structure may be formed by attaching a resin member to the surface of the substrate. In particular, the resin covering the surface can be made thick, which is preferable in that it can be reinforced strongly. The affixing may use an adhesive or may utilize the adhesiveness of the resin itself. As one form of these, a form in which a part of the fused resin is impregnated in the base material when the resin sheet as the reinforcing body is attached by heat fusion is also included.

  (5) The resin reinforcing structure may be formed by applying a resin to the surface of the substrate. The resin can be combined by a simple means, which is preferable in terms of easy production.

  (6) The break prevention structure may be a sewing reinforcement structure in which a valley portion or a peak portion of the pleat filter is sewn. Sewing is a structure in which sewing is performed with a thread. Sewing reinforcement can be performed along the ridgeline of the valley or mountain. As a specific sewing method, it is possible to apply a sewing method that is generally used to reinforce an end of a fabric such as clothing.

  (7) When liquid is filtered from one surface of the pleated filter to the other surface, the bent portion protruding to the one surface side is referred to as a peak portion, and the bent portion protruding to the other surface side is referred to as a valley portion. In this case, the fracture prevention structure has a bending radius R of the bent portion of the valley portion, and the bending radius R (mm) and the thickness t (mm) of the base material are in a relationship of 2t ≦ R ≦ 10t. Good to have. By bending the base material, the thickness of the base material at the top of the bent part is generally thinner than that of the original base material, especially when bent at an acute angle, stress concentration occurs in that part and it is easy to break. . Breaking can be suppressed by setting the bending radius of the bent portion as described above. If it is smaller than 2t, the effect of preventing breakage due to the bending diameter cannot be obtained sufficiently. In addition, considering that the purpose of the pleat is to increase the filter area per volume by folding, it is desirable that the filter gap be within a few millimeters, and accordingly the bend radius should be less than 10t. Is preferred. Preferably it is 5 t or less and 2 t or more. For example, when a 500 μm nonwoven fabric is used as the substrate, the bending radius R is preferably 1 mm or more. A more preferable range is 1 to 2.5 mm. Here, the bending radius R refers to the minimum radius of the circle in contact with the bent valley side surface, and the bending radius of 20 samples or more extracted from the plurality of valleys of the pleated filter to be used is measured with a magnifying glass or a photograph. It is used as an average value measured by a normal dimension measuring method.

  (8) The fracture preventing structure is a resin reinforcing structure provided at the bent portion of the valley portion, and the bending radius R of the bent portion of the valley portion and the thickness t (mm) of the base material are 2t. It is even better if the relationship is ≦ R ≦ 10t. It is because the effect of reinforcement is exhibited more by having both effects.

  The case where the pleated filter is a cylindrical filter will be described below. (9) A pleated filter for filtering the liquid from the outside of the cylinder to the inside of the cylinder with the ridgeline direction of the mountain portion as the direction of the cylinder axis, and the fracture prevention structure projects in the direction of the outside of the cylinder The pleated filter is provided in the ridge or the valley protruding inward of the cylinder, or both. The above-described breakage preventing structure can also be preferably applied to a cylindrical pleated filter.

  (10) It is preferable to use a resin reinforced structure formed by applying a resin along the ridge line of the peak portion. In this case, it is effective to use polyurethane as the (11) resin. Moreover, it is good also as a sewing reinforcement structure which sewed (12) peak parts along the ridgeline.

  On the other hand, (13) the fracture prevention structure provided in the trough is a resin reinforced structure in which a resin covering the surface of the base material or a resin that has penetrated into the base material is used as a reinforcing body, and the resin is preferably polypropylene. .

  This application discloses a ballast water treatment device as a filtration device using the above-mentioned cylindrical pleated filter as follows.

  That is, (14) the pleated filter is water-tightly sealed on the upper surface and the bottom surface of the cylinder and is held rotatably around the cylinder axis, and the treated water flows out of the treated water toward the outer peripheral surface of the pleated filter. A water nozzle, a case provided to surround the pleated filter and having an outer cylinder portion provided therein with a nozzle port of the water nozzle to be treated, and filtered water that has passed through the pleated filter from the inside of the cylinder of the pleated filter The ballast water treatment apparatus includes a filtered water channel that is led out to the outside of the case, and a drain channel that discharges the drained water that has not been filtered by the pleated filter to the outside of the case.

  In the apparatus having such a structure, since the water to be treated is ejected from the nozzle port outside the cylinder of the cylindrical pleated filter toward the outer surface of the pleat filter, the pressure of the water to be treated is concentrated on a part of the pleat. Then, pressure is applied in the direction in which the pleats are opened, and the possibility that the filter breaks at each of the valley and the peak as described above increases. Therefore, by adopting the above-described breakage prevention structure, it is possible to expect effects such as suppression of the occurrence of defective filtration, long-term operation of the apparatus due to the long life of the pleated filter, and reduction of operation costs.

  Accordingly, (15) the ballast water treatment device described above is mounted in the hull, seawater obtained from the outside of the hull is used as the water to be treated, and a killing process is further added to the filtered water treated by the ballast water treatment device. Thereafter, by adopting a method for treating ballast water stored in a tank provided in the hull as ballast water, the same effect can be obtained.

[Details of the embodiment of the present invention]
Configurations of a pleat filter and a ballast water treatment apparatus according to the present invention will be described below with reference to the drawings. In addition, this invention is not limited to these illustrations, is shown by the claim, and intends that all the changes within the meaning and range equivalent to a claim are included.

(Configuration of pleat filter)
FIG. 1 is a schematic perspective view illustrating a typical configuration of a pleated filter as an embodiment of the present invention. The pleated filter 10 is formed by folding the flat belt-like base material 1 alternately in a mountain-and-valley shape to form a so-called pleated shape and further joining them into a cylindrical shape. Hereinafter, a cylindrical pleated filter will be described as a particularly effective representative example. However, the break prevention structure according to the present invention can be applied to a case where a pleated filter is used as a flat filter without using a cylinder, and the same effect can be obtained. It is what you play.

  In FIG. 1, it is assumed that the liquid to be filtered is supplied from the outside of the cylinder of the cylindrical pleated filter 10 and the liquid filtered by the filter substrate 1 is discharged from the inside of the cylinder. The surface on the side in contact with the liquid to be filtered (the liquid to be filtered) is referred to as the front surface for filtration, and the surface on the side from which the filtered filtrate is discharged is referred to as the post-filtration surface. In the configuration of this example, the filter surface outside the cylinder corresponds to the front surface of filtration, and the filter surface inside the cylinder corresponds to the rear surface of filtration. Even when the filter is a flat plate or the like, it may be read as the front side of the filtration or the rear side of the filtration in accordance with the utilization form of filtration. The peak and valley of the pleat-shaped fold when viewed from the front of the filtration are defined. In FIG. 1, for example, the V part in the figure is a valley part and the M part is a mountain part.

  A porous resin sheet is used as the filter substrate. For example, a porous structure such as a stretched porous body, a phase-separated porous body, or a nonwoven fabric made of polyester, nylon, polyethylene, polypropylene, polyurethane, polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVdF), etc. is used. However, for the purpose of performing a high flow rate treatment, a nonwoven fabric made of polyester such as polyethylene terephthalate is particularly preferably used.

  In FIG. 1, a break prevention structure is provided in a valley portion or a mountain portion, or both a valley portion and a mountain portion, which are bent portions. Each of the valley and the mountain will be described. FIG. 2 is an enlarged view of a part of a cross section perpendicular to the cylindrical axis direction of the pleated filter of FIG. V indicates a valley and M indicates a mountain. In the pleated filter that has received the pressure of the liquid to be filtered from the front surface of the filtration, a force P in a direction to spread is applied to the valley, and tensile stress concentrates on the base material 1 in the valley. Further, when there is a fluctuation in pressure, bending is repeatedly applied to the bent portion. By these, especially in a trough part, it is thought that the hole by tearing along a bending part ridgeline tends to arise. In this way, it is preferable to prevent breakage at the trough, which makes it difficult to tear the bent portion.

  FIG. 3 is a view of a part of the pleated filter of FIG. 1 as viewed from the side surface of the cylinder. V indicates a valley and M indicates a mountain. In a pleated filter that receives the pressure of the liquid to be filtered from the front of the filtration, when almost uniform pressure is applied to all of the pleats, the mountain is closed with the mountain located in the mountain opposite to the valley. A force in the direction to be applied is applied. On the other hand, when a larger pressure is applied between one pleat (between the hills) than between adjacent pleats, the force is a force that attempts to widen the ridge line interval of the ridges. If the entire pleat is free, this force is absorbed by the expansion and contraction of the entire pleat. However, in many cases, a pleated filter configured as a filtration device is fixedly sealed at an end portion for filtration. In FIG. 3, the filter ends corresponding to the top and bottom of the figure are fixed to other members. Therefore, when the above-described force is applied, the upper and lower end portions are fixed while the upper and lower central portions of the mountain ridge line are about to expand, so that a force in the direction of extending the entire ridge line is applied. Furthermore, by repeatedly receiving such pressure, the ridge line of the mountain portion is repeatedly deformed in the left-right direction. As a result, as shown in FIG. 3B, there is a case where it is bent in the vicinity of the central portion (D in the figure), and a hole is likely to be formed in that portion. As described above, it is preferable to prevent the ridges from breaking so that the ridge lines of the bent portions are not easily bent.

(Resin reinforcement structure)
As one of the rupture prevention structures at the portion where the base material which is such a porous resin sheet is bent, the vicinity of the bent portion can be reinforced with resin. The simplest method for applying the resin to the substrate is to apply the resin along the ridgeline of the folded substrate. Application | coating can be performed by known means, such as a brush and a roller. The applied resin is cured after adhering to the substrate surface. In addition, as an example of a reinforcing structure using a resin as a reinforcing body, impregnation of resin into a base material is preferably used. This is because the base material can be further reinforced. Even when the resin is applied to the surface of the base material, it is more preferable that the resin is cured while at least a part of the resin is impregnated in the base material.

  FIG. 4 to FIG. 7 are schematic diagrams for enlarging and explaining the bent portion of the pleated filter. With these figures, the resin reinforcement structure will be described by taking the valley V as an example, but the same applies to the peaks. FIG. 4 shows a state where the bending inner surface of the base material 1 is impregnated with the reinforcing resin 2 in the valley V. The substrate 1 is a porous resin, and the resin 2 adheres to the substrate surface on the surface of the pores in the porous holes of the substrate 1. If the hole is filled by impregnation and the impregnated part becomes non-porous, a stronger reinforcing effect can be obtained by obtaining the reinforcing effect of the bent portion by the force of the pressure of the filtrate not causing the hole to expand and tear. It is done.

  5 and 6 exemplify another aspect of impregnation, in FIG. 5 the resin 2 is impregnated on the outer surface of the base material 1 in the bent portion, and in FIG. 2 is impregnated. In FIG. 6, the impregnated resin 2 is attached with a thickness so as to further cover the surface of the base material 1. Thus, it is not limited to only impregnating the inside of the base material 1, and even if the resin adheres to the surface, there is an effect. In the valley, at least the front surface of the filter is impregnated with resin is preferable as reinforcement against tensile stress.

  The resin to be impregnated is a thermosetting resin such as silicone, epoxy or polyurethane, a thermoplastic resin such as polyvinyl chloride (PVC), polyester, nylon, polyethylene, polypropylene, ETFE or PVdF, or PVdF or silicone diluted with a solvent. Although it is possible to use those that can be used and are not particularly limited, those that are easy to adapt to the filter material are desirable. When using a non-woven fabric for the substrate, polypropylene is preferable for reinforcing the valley as viewed from the front of the filtration. This is because, in particular, when the pleated structure is manufactured, it can be impregnated with heat, and it is possible to prevent breakage that makes it difficult to tear the bent portion. In addition, when reinforcing after application of pleats, polyvinyl chloride or polyurethane is preferred, and polyurethane is particularly preferred for reasons such as easy application.

In addition, the resin to be impregnated needs fluidity to penetrate into the porous body when impregnated, but after impregnation, the resin must be integrated with the filter so that it cannot be easily separated. A thermosetting resin may be heat-cured after impregnation. In a two-component curable resin, it can be cured after impregnation immediately after mixing. In the case of a resin whose viscosity has been lowered by diluting the solvent, it is better to cure for a while in order to dry the solvent after impregnation.

  FIG. 7 exemplifies still another resin reinforcing structure, and is an example in which the resin sheet 3 is attached to the surface of the substrate 1. Thus, even by means without impregnation, reinforcement is possible by receiving the pressure of the liquid to be filtered and sharing the force received by the base material by adhesion to the base material 1. Although not shown, the effect can also be obtained by attaching a resin sheet to the rear surface of the base material 1 after filtration or by attaching it to both surfaces.

  FIG. 8 is a diagram showing an example in which a resin reinforcement structure similar to that in FIG. 5 is applied along the ridge line of the peak portion, taking the peak portion M as a sharp bent portion as an example. The resin applied along the ridgeline represents a state where the substrate 1 is partially impregnated and cured after application.

(Bending radius)
Next, a bending part and a bending radius are demonstrated. The bend radius of the fold is defined by the minimum radius of the trough filtration front. FIG. 9 is a schematic diagram for explaining the bent portion and the tip bending radius, and is an enlarged view of the trough portion. Here, the inside of the valley is the filtration front surface. A bending part means the part by which the flat base material before bending was bent. When viewed in cross section with reference to FIG. 9, the straight portion L is a portion that is not bent, and a section C that forms a curved portion is a bent portion. The minimum radius R (mm) of the inscribed circle to the curved surface of the folded front portion of the bent portion is defined as a bending radius. The smaller R is, the more easily the fracture of the bent portion, that is, the tearing or the hole. A suitable bending radius R is 2t ≦ R ≦ 10t in relation to the thickness t (mm) of the substrate. More preferably, 3t ≦ R ≦ 5t.

  Moreover, when reinforcing with resin, it is preferable that the resin reinforcement structure is provided so that it may reinforce over the whole bending part. Since the boundary between the reinforced portion and the non-reinforced portion is discontinuous, stress tends to concentrate. If such a boundary exists in the bent portion, it is easy to break in long-term use. Therefore, it is a more preferable aspect that the resin reinforcing structure extends over the entire bent portion, and the end portion (boundary portion) is provided so as to exist in the linear portion of the base material. In other words, it is preferable that the reinforcing length (width) of the reinforcing portion by the resin reinforcing structure is longer than the length (width) of the bent portion. Further, when the bent portion is formed in a shape that is in contact with a substantially uniform circle, the surface length of the bent portion C on the front side of the filtration is almost twice the bending radius, so the reinforcement length is 2 times the bending radius. It is preferably longer than twice.

  It is more preferable that the bend radius is further in the above range after the above-described resin impregnation or the like. It can be manufactured by fixing the bent portion so that the bending radius is in a desired range after the resin reinforcement or in the reinforcement step.

(Sewing structure)
As another example of the break prevention structure, reinforcement by sewing of the bent portion will be described. FIG. 10 is a cross-sectional view of one of the ridges M of the bent portion. The base material 1 is sewn together by a sewing material 5 at the top of the bent portion. FIG. 11 is a perspective view schematically showing the bent portion of FIG. A mode that the base material 1 is sewn by the sewing material 5 along the ridgeline of a mountain part is shown. The sewing material 5 may be any material that is suitable for sewing a base material and hardly deteriorates due to an object to be filtered. Generally, thread-like materials such as cotton yarn, nylon yarn, polyester yarn can be used. As a sewing method, not only a simple main sewing (smooth stitch) as shown in FIG. 11 but also a general method of sewing fabrics such as reverse stitching, half reverse stitching, and overlock stitching can be used.

(Production method of resin reinforced structure)
Hereinafter, an example of a method for manufacturing a resin reinforced structure will be described. A typical example in the case of impregnating a heat fusion resin as a resin reinforcing structure and keeping the shape within a desired bending radius will be described with reference to FIG. FIG. 12 (A) shows a state where a sheet-like resin 2 is attached to one side surface of a portion of the base material 1 where a bent portion is formed. In this example, the case where the front surface of the filtration, which is the inside of the valley, is impregnated will be described. However, the reinforcing resin sheet may be attached to the surface to be impregnated with the resin. In FIG. 12, the base material 1 is shown as a notation for making it easy to understand that it is a porous body. In this example, as an example of a preferable production method, the base material 1 is a porous resin sheet, and the reinforcing resin 2 is a thermoplastic resin having a melting point lower than that of the base material 1. For example, a polyester nonwoven fabric mainly composed of polyethylene terephthalate having a melting point of around 260 ° C. is used as the porous resin sheet, and as a thermoplastic resin to be impregnated, polymethylpentene, 66 nylon, polycarbonate having a melting point of around 230 ° C., Polyethylene having a melting point of generally about 120 ° C., polypropylene having a melting point of about 160 ° C., and the like can be preferably used.

  Heating by applying pressure in the direction of the arrow in FIG. 12A by a heating and pressing device (not shown) such as a heat sealer, the reinforcing resin 2 is melted inside the porous body of the substrate 1. Impregnated. A process of bending to a desired curvature after the impregnation or in parallel with the impregnation will be described. FIG. 12 (B) shows an example of bending in parallel with impregnation. In the heating of FIG. 12 (A), a metal jig 4 having a desired radius is in contact with the resin 2. is there. By bending while impregnating in such a state, as shown in FIG. 12C, the substrate 1 is bent to a desired curvature while being impregnated with the resin 2. As a method other than this example, after the impregnation is performed only with the base material and the resin as shown in FIG. 12 (A), the metal jig 4 is bent as a cooling member as shown in FIG. 12 (C). The bent portion may be formed by cooling. The member to be contacted is not limited to metal, but considering the cooling effect, it is a member that does not deform at heating temperature and has relatively good thermal conductivity, such as a metal rod, pipe, ceramics, or glass. And good.

  The manufacturing method described above is a method for manufacturing a pleated filter in which a crest and a trough are repeatedly and continuously formed by periodically bending a planar base material, and the base material to be the bent portion Impregnation of impregnating at least a part of the resin sheet into the base material by heating the base material and the resin sheet at a part to which the resin sheet is attached, and attaching the resin sheet to at least one surface It is a manufacturing method of a pleat filter provided with the process and the cooling process of cooling and fixing in the state where the above-mentioned bent part was bent. Here, the cooling step is a step of cooling in a state where a metal jig having a constant radius is in contact with the bent portion.

  The above describes the case where the base material is impregnated with the reinforcing resin, but a resin reinforcing structure other than the impregnation is formed by a method of bonding the resin sheet with an adhesive or a method of bonding by heat fusion. Is possible. In addition, even when impregnated, a predetermined part of the base material is impregnated with a resin other than the thermoplastic resin in advance, and then the part may be bent, or when bent, it is flexible with heating. Then, it may be deformed to a desired curvature. In addition, since the resin application method and sewing method can be based on known application methods and sewing methods, they are not described in detail here.

(Filtering device)
As a preferred application example of the filtration apparatus using the pleated filter described above, the configuration of a ballast water treatment apparatus will be described with reference to the drawings. FIG. 13 and FIG. 14 are diagrams showing an example of a ballast water treatment apparatus for ships as an embodiment of the present invention. FIG. 13 is a diagram schematically showing a configuration of a vertical cross section including an axis, and FIG. 14 is a diagram schematically showing a configuration of a horizontal AA cross section in FIG. The cylindrical pleated filter 101 is disposed so as to surround an axis serving as a rotation center, and is rotatably attached around a central pipe 140 (pipe does not rotate) disposed at the center. The upper and lower surfaces of the pleated filter are closed watertight. The rotatable mounting structure also needs to be a watertight structure, but a known structure is used without any particular limitation. A case 103 is provided so as to cover the entire filter. The case 103 includes an outer cylinder part 131, a lid part 132, and a bottom part 133, and the bottom part 133 is provided with a discharge channel 108. A treated water channel 106 and a treated water nozzle 102 are provided for introducing seawater as treated water into the case 103. The treated water nozzle 102 is extended from the treated water flow path 106 so that the nozzle port 121 is provided in the outer cylinder part 131 of the case 103 so that the treated water flows out toward the outer peripheral surface of the pleated filter. It is configured. A motor 190 is provided on the central axis of the pleat filter for rotating the pleat filter. The motor 190 is covered and accommodated by a motor cover 191 and is driven by electric power from a drive control unit (not shown).

  In the case of this example, the water to be treated ejected from the water nozzle to be treated hits the pleated outer peripheral surface of the pleated filter, and the cleaning effect of the pleated filter is obtained by the pressure. The untreated water to be treated and the suspended matter settled in the case are sequentially discharged from the discharge channel at the bottom of the case. The characteristic of this apparatus is that the filtration proceeds while the turbid component and the remaining water to be treated are continuously discharged, and 10 to 20 tons / hour or even 100 tons / hour required for ballast water. It is effective to secure the processing amount. In the figure, a valve or the like is not shown in the discharge flow path, but equipment necessary for maintenance and flow rate adjustment can be provided. On the other hand, the filtered water filtered by the pleated filter 101 is guided to the filtered water flow path 107 through the water intake hole 141 provided in the central pipe 104 inside the filter, and flows out of the case.

  As an example of an apparatus that performs processing at 100 tons / hour, an outer diameter of a pleat filter is 700 mm, an axial length is 320 mm, an effective area is height 280 mm, a pleat depth is 70 mm, and a pleat number is 420 folds. The treated water nozzle 102 may have a rectangular nozzle opening 121. A large amount of water is ejected from the water nozzle to be treated onto the surface of the pleated filter, causing stress concentration in the valley part of the pleated filter, and vibration in the direction of opening and closing of the crease in the valley part. It becomes easy to open holes such as tears. By using the pleated filter with the creases reinforced as described above, the breakage can be effectively suppressed, and the apparatus can be operated stably for a long time.

(Experimental example 1)
In order to confirm the effect of the resin reinforced structure, the strength of the resin impregnated and bent portions was compared. The materials used are as follows.
Porous filter: Non-woven fabric made of polyethylene terephthalate (trade name: Axter G2260-1S BK0 manufactured by Toray)
Impregnating resin: Nonwoven fabric made of polypropylene (trade name: Stratec RW2100, manufactured by Idemitsu Unitech)
Heat sealing machine: Ishizaki Electric Desk Sealer NL-301J
The impregnated resin was placed on the bent portion of the porous filter serving as the base material, and heat sealing was performed with setting 4 (heating time: about 1 second) of the sealing timer of the heat sealing machine. The impregnated resin was completely melted by heat and cooled once in a state of impregnating the porous filter. Further, after heating under the same heating conditions, a stainless steel rod having a diameter of 3 mm was immediately sandwiched and the bent portion was bent along the shape of the stainless steel rod to obtain a bending radius of 1.5 mm. A comparative example was prepared by bending the same porous filter as it was and bending it until it did not return.

  The bent portion was opened and punched into a dumbbell mold so that the bent portion was perpendicular to the tensile direction near the center of the dumbbell, and the breaking strength was measured at a chuck interval of 3 cm and a tensile speed of 100 mm / min. As a result, all the comparative examples were broken at the bent portion and the breaking strength was 33 MPa. Moreover, since the measurement result in the base material itself without bending was 40 MPa, it was suggested that the strength was lowered by bending. On the other hand, in the example, the bent portion impregnated with the resin was not broken but all was broken at the other flat portion, and the breaking strength was 41 MPa. That is, it was confirmed that the bent portion had a strength of 41 MPa or more.

  FIG. 15 is an explanatory view schematically showing the overall configuration of a marine ballast water treatment system using the above-described ballast water treatment device as a filtration device. In FIG. 15, the water to be treated which is seawater taken from the ocean is sent by the pump 21 through the pipe 31 and supplied to the filtration device 12 which is a filtering means through the pipe 32. The filtered water filtered in the filtering device 12 is sent to the killing means 13 (not essential) such as an ultraviolet irradiation device through the pipe 33. Further, the discharged water that has not been filtered in the filtering device 12 is led out of the device through the pipe 35. The seawater that has undergone the killing process is sent to the tank 11 via the pipe 34 and the pipe 36.

(Experimental example 2)
In order to confirm the effect of the resin application, the effectiveness of the fracture preventing structure was confirmed using a ballast water treatment apparatus using a cylindrical pleated filter. The rupture prevention structure employs a resin reinforced structure in which resin is applied to all the peaks of the pleated filter. The application was performed only on the mountain with a roller. For comparison, a pleated filter to which no resin was applied was used. Moreover, the effect of what impregnated the polypropylene used in Experimental Example 1 to the peak and valley was confirmed.

The filters and resins used are as follows.
Porous filter: Non-woven fabric made of polyethylene terephthalate (trade name: Axter G2260-1S BK0 manufactured by Toray)
Coating impregnation resin: Polyurethane resin (trade name: SA-7073, manufactured by Sanyu Rec)

  The used ballast water treatment apparatus has a structure shown in FIG. The pleat filter is a single pleat filter connected as a filter cartridge, and three filter cartridges are stacked in the axial direction. As a result, an effective area of three times is obtained. The single pleat filter has an outer diameter of 700 mm, an axial length of 320 mm, an effective area height of 280 mm, a pleat depth of 70 mm, and a pleat count of 420. The nozzle opening is a long opening having a long side in the length direction of the pleats and a short side in the direction of the pleat interval. As seawater to be treated, standard seawater (salt concentration 2 to 4%, turbidity 1 to 1000 NTU (Nephelometric Turbidity Units)) collected in Imari City, Saga Prefecture was used.

  As the operation time becomes longer, the pleated convex portion is damaged, and the number of damaged portions gradually increases. The life was estimated by Weibull plot from the occurrence time and number of such breakage. FIG. 16 shows a graph in which the filter life is estimated by the Weibull plot. The Weibull plot is generally used for quality assurance and life estimation. In this experiment, the vertical axis indicates failure probability (= number of damaged pleats / total number of pleats), the horizontal axis indicates time, and the number of failures that increase with operating time is plotted to estimate the life with a certain slope. According to the inventors' past experiments, ballast water treatment is a limit when the failure probability is about 1.4%. That is, it has been found that significant leakage of plankton contained in seawater occurs. Referring to FIG. 16, 1.4% breakage time is 50 hours for the filter without reinforcement, whereas it is about 180 hours for urethane impregnation reinforcement and about 140 hours for PP impregnation reinforcement. It was confirmed that the life was extended. Although not described here, even when other resin materials are used, the effect of the structure for preventing breakage can be obtained in the same manner, although there is a difference in degree.

  Since the pleated filter of the present invention does not cause performance degradation due to clogging and is excellent in durability, brackish water and seawater use such as seawater desalination and ballast water, or water treatment such as sewage, domestic wastewater, industrial wastewater, Can be suitably used for pre-filtration treatment for removing foreign substances, dust, and microorganisms. In addition, because it is excellent in water treatment and concentration treatment with high turbidity and high SS, it can be applied in the field of valuable resources recovery such as the food field.

DESCRIPTION OF SYMBOLS 1 Base material 2 Resin 3 Resin sheet 4 Metal jig 5 Sewing material 10,101 Pleated filter 11 Tank 12 Filtration apparatus 13 Ultraviolet irradiation apparatus 21,22 Pump 31,32,33,34,35,36,37,38 Piping 102 Processed water nozzle 103 Case 104 Central pipe 106 Processed water flow path 107 Filtration water flow path 108 Discharge flow path 121 Nozzle port 131 Outer cylinder part 132 Cover part 133 Bottom part 140 Central pipe 141 Water intake hole 190 Motor 191 Motor cover

Claims (17)

A pleated filter having a structure in which a base material is bent so that peaks and valleys are alternately continuous,
A pleated filter provided with a break prevention structure in the valley part or the peak part which is a bent part, or both the valley part and the peak part.   2. The pleated filter according to claim 1, wherein the breakage prevention structure is a resin reinforced structure in which a resin that covers a surface of the base material or a resin that has penetrated into the base material is used as a reinforcing body.   The pleated filter according to claim 2, wherein the resin reinforcing structure is formed by impregnating the base material with a resin.   The pleated filter according to claim 2, wherein the resin reinforcing structure is formed by attaching a resin member to a surface of the base material.   The pleated filter according to claim 2, wherein the resin reinforcing structure is formed by applying a resin to a surface of the base material.   2. The pleated filter according to claim 1, wherein the break prevention structure is a sewing reinforcement structure in which a valley portion or a peak portion of the pleat filter is sewn. When the liquid is filtered from one surface of the pleated filter to the other surface, the bent portion protruding to the one surface side is referred to as a peak portion, and the bent portion protruding to the other surface side is referred to as a valley portion. There,
The break prevention structure is a bending radius R of the bent portion of the valley,
The bending radius R (mm) and the thickness t (mm) of the substrate are
2t ≦ R ≦ 10t
The pleated filter according to claim 1, wherein: The rupture prevention structure is a resin reinforced structure provided in a bent part of the valley part,
The pleated filter according to claim 6, wherein a bending radius R of the bent portion of the valley portion and a thickness t (mm) of the base material are in a relationship of 2t ≦ R ≦ 10t. A pleated filter for filtering the liquid from the outside of the cylinder toward the inside of the cylinder, the whole being cylindrical with the direction of the ridgeline of the peak as the direction of the cylinder axis,
2. The pleated filter according to claim 1, wherein the break prevention structure is provided in a peak portion protruding in the cylinder outer direction, a valley portion protruding in the cylinder inner direction, or both.   The pleated filter according to claim 9, wherein the break prevention structure provided in the peak portion is a resin reinforcing structure formed by applying a resin along a ridge line of the peak portion.   The pleated filter according to claim 10, wherein the resin is polyurethane.   The pleat filter according to claim 9, wherein the break prevention structure provided in the peak portion is a sewing reinforcement structure in which the peak portion is sewn along a ridge line.   The break prevention structure provided in the trough is a resin reinforcing structure in which a resin covering the surface of the base material or a resin that has penetrated into the base material is used as a reinforcing body, and the resin is polypropylene. 9. The pleated filter according to 9. A ballast water treatment apparatus using the cylindrical pleated filter according to any one of claims 9 to 13 as a filtration membrane,
The pleated filter seals the upper surface and the bottom surface of the cylinder in a watertight manner, and is held rotatably about the cylinder axis.
A treated water nozzle for flowing the treated water toward the outer peripheral surface of the pleat filter,
A case having an outer tube portion provided inside the pleated filter and provided with a nozzle port of the water nozzle to be treated inside;
A filtrate flow path for leading the filtrate water that has passed through the pleat filter from the inside of the cylinder of the pleat filter to the outside of the case;
A ballast water treatment apparatus comprising: a discharge flow path for discharging discharged water that has not been filtered by the pleated filter to the outside of the case.   After the ballast water treatment device according to claim 14 is mounted in the hull, seawater obtained from the outside of the hull is used as water to be treated, and after further killing treatment is performed on the filtered water treated by the ballast water treatment device A method for treating ballast water stored in a tank provided in the hull as ballast water. A method of manufacturing a pleated filter in which crests and troughs are repeatedly formed continuously by periodically bending a planar substrate,
Attaching a resin sheet to at least one surface of the base material to be the bent portion;
An impregnation step of impregnating at least a part of the resin sheet into the base material by heating the base material and the resin sheet in a portion to which the resin sheet is attached;
And a cooling step of cooling and fixing the bent portion in a folded state.   The method for manufacturing a pleated filter according to claim 16, wherein the cooling step is a step of cooling a metal jig having a constant radius in contact with the bent portion.

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