JP3234165B2 - Deodorizing filter and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a deodorizing filter and a method for producing the same.

[0002]

2. Description of the Related Art In recent years, air purifiers and water purifiers for removing malodorous substances and the like have been widely used.
The cleaning device or the like is often provided with a deodorizing filter formed by forming an adsorbent such as activated carbon into a honeycomb shape (including a lattice shape) having a large number of through holes.

Conventionally, as a method for producing the above-mentioned deodorizing filter having a honeycomb shape or the like, a powdery or granular adsorbent is mixed with a binder, and the mixture is extruded into a continuous body having a honeycomb shape or the like using an extruder. After that, there is a method of cutting into a predetermined shape by cutting into a predetermined size.

[0004] However, the deodorizing filter obtained by the extrusion molding has a problem that the distortion is large, and even when the filter is normally extruded, the filter is liable to be distorted due to subsequent drying and to be defective. Furthermore, the present inventor mixes a catalyst that decomposes harmful substances and malodorous substances and detoxifies and deodorizes them together with the adsorbent and the binder in order to enhance the cleaning action of the deodorizing filter, and extrudes the mixture. Thus, an attempt was made to obtain a deodorizing filter having a predetermined shape. However, what was extruded from the die was not shaped and had a low viscosity, and a deodorizing filter having a uniform shape could not be obtained. This is because the catalyst mixed with the adsorbent and the binder is used in the form of ultra-fine particles from the viewpoint of activity, etc., and the ultra-fine particles have a property close to a liquid state, extremely reduce the viscosity of the mixture, and are used for extrusion molding. Is assumed to be an unsuitable mixture.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and has as its object to provide a deodorizing filter having few defects such as distortion and excellent in deodorizing properties, and a method for producing the same.

[0006]

The invention according to claim 1 is a deodorizing filter compression-molded from a mixture containing powdered activated carbon as an adsorbent, titanium oxide as a photocatalyst, a binder, and water, 30 to 60 parts by weight of titanium oxide based on 100 parts by weight of the total of the powdered activated carbon and titanium oxide, the binder contains both an inorganic binder and an organic binder, and the ratio of the inorganic binder is an organic binder. The present invention relates to a deodorizing filter characterized in that one or both of irregularities and through holes are formed on both surfaces of the deodorizing filter.

On the other hand, according to the invention of claim 2, a mixture containing powdered activated carbon as an adsorbent, titanium oxide as a photocatalyst, a binder and water is filled in one mold, and the one mold and the other are filled. A method for producing a deodorizing filter, comprising compressing and shaping the mixture in a mold and then drying the mixture, comprising 30 to 60 parts by weight of titanium oxide based on 100 parts by weight of the total of the powdered activated carbon and titanium oxide. The binder includes both an inorganic binder and an organic binder,
And the ratio of the inorganic binder is larger than the ratio of the organic binder, and the unevenness is provided on the inner surface of the other mold on the non-filled side of the mixture, and the mixture is compressed by the other mold and one of the molds on the mixture filled side. Then, the present invention relates to a method for producing a deodorizing filter, which is shaped into an uneven shape.

[0008] Further, in the invention of claim 3, a mixture containing powdered activated carbon as an adsorbent, titanium oxide of a photocatalyst, a binder and water is filled in one mold, and the one mold and the other are filled. A method for producing a deodorizing filter, comprising compressing and shaping the mixture in a mold and then drying the mixture, comprising 30 to 60 parts by weight of titanium oxide based on 100 parts by weight of the total of the powdered activated carbon and titanium oxide. The binder includes both an inorganic binder and an organic binder,
And the ratio of the inorganic binder is larger than the ratio of the organic binder, a mixture having a plurality of holes formed on the bottom surface of one of the molds on the mixture filling side, and a plurality of protrusions corresponding to the holes formed on the inner surface. The mixture is compressed by the other mold on the filling side and the one mold, and the projection is pierced into the mixture in the mold, and the tip of the projection is inserted into a hole formed in the bottom surface of the mold on the mixture filling side. Accordingly, the present invention relates to a method for producing a deodorizing filter, wherein a shape having a through hole is formed.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the accompanying drawings. FIG. 1 is a partial perspective view of a deodorizing filter according to one embodiment of the first aspect of the present invention, and FIG. 2 is a partial perspective view of another example of a deodorizing filter. FIG.
FIG. 4 is a cross-sectional view showing a state after the mixture is filled in the embodiment of FIGS. 2 and 3, FIG. 4 is a cross-sectional view showing a state after the mixture is filled in the embodiment, FIG.
FIG. 7 is a cross-sectional view showing a manufacturing time in the embodiments of the first and third aspects of the invention, FIG. 7 is a cross-sectional view showing the manufacturing time in another example, and FIG. 8 is a measurement result of an ammonia adsorption rate.

FIG. 1 shows a deodorizing filter 10 according to an embodiment of the present invention. This deodorizing filter 10
A mixture containing an adsorbent, a catalyst, a binder, and water was obtained by compressing using a press mold as described below, shaping the mixture into a predetermined shape, and then drying. The concave portions 13 were formed at regular intervals on one surface. It is made of a plate-like body having an uneven shape. Due to this uneven shape, the contact area of the deodorizing filter 10 with air or the like increases, and a better cleaning action can be obtained.

The irregularities are not limited to those having a quadrangular planar shape as in this example, but are circular or have a corrugated cross section, or the deodorizing filter of another example shown in FIG. It may be composed of a large number of through-holes 14 (honeycomb-shaped), such as 10A, or may be composed of both irregularities and through-holes. Also, the through-hole is shown in FIG.
The shape is not limited to a circular shape as described above, but may be a square shape or a lattice shape.

Various adsorbents are used, but those having a large surface area and good adsorbability are preferred. In the present invention, powdered activated carbon is used. The adsorbent may be appropriately treated with a chemical.

As the catalyst, a catalyst for decomposing harmful substances or malodorous substances is used. In the present invention, titanium oxide as a photocatalyst is used. It is known that titanium oxide of this photocatalyst has excellent deodorizing action in the presence of light, action of decomposing harmful substances, action of decomposing and removing air pollutants, and the like. Then, by allowing the adsorbent and the catalyst to coexist, the substance once adsorbed on the surface of the adsorbent moves to the catalyst by surface diffusion, so that decomposition and the like proceed efficiently and the life of the adsorbent is prolonged. Moreover, titanium oxide is chemically stable,
Extremely safe without toxicity. This catalyst is added to the mixture as an ultrafine powder, and has the effect of lowering the viscosity of the mixture. Therefore, it is not preferable when a deodorizing filter is manufactured by conventional extrusion molding. Can be used. The amount of the catalyst is generally 30 to 6 per 100 parts by weight of the adsorbent + the catalyst.
It is reduced to about 0 parts by weight.

The binder is used to fix the shape of the mixture, and inorganic or organic binders can be used alone or in combination. Organic binders can be absorbed by an adsorbent or used as adsorbents. Therefore, it is preferable to increase the proportion of the inorganic material because it may cover the surface and reduce the adsorption capacity. That is, as a weight mixing ratio of each component, the adsorbent + catalyst: inorganic binder: organic binder is 100: 5 to 95:
0.1 to 10 parts by weight, desirably 100: 30 to 60:
0 to 1.5 parts by weight.

Examples of the inorganic binder include sodium silicate, alkyl silicate, clay (Frogme clay, ball clay, bentonite, and talc). On the other hand, organic binders include methylcellulose, carboxymethylcellulose, and hydroxymethylcellulose. , Cellulose amine derivatives, and thermoplastic resins, thermosetting resins, and the like. In addition, as a thermoplastic resin,
Polyethylene, polyester, polypropylene, AB
There are S, nylon, ethylene acrylic resin and the like, and as the thermosetting resin, there are phenol resin, furan resin, melamine resin, urea resin, epoxy resin, urethane resin and the like.

Further, the mixture optionally contains a fiber reinforcing material. For example, a predetermined amount of carbon fiber, alumina fiber, polyester fiber, acrylic fiber, polypropylene fiber, polyethylene fiber, or the like is used in an appropriate size. Its general size is about several μm to 80 μm in diameter and about 0.1 mm to several tens mm in length.

The deodorizing filters 10 and 10A contain a catalyst for decomposing harmful substances in addition to an adsorbent made of activated carbon or the like. The decomposition action acts synergistically to exert an excellent cleaning action. When a photocatalyst is included as the catalyst, the deodorizing filter is used so as to be exposed to light.

Next, an example of a method for manufacturing a deodorizing filter according to the second aspect of the present invention will be described with reference to FIGS. This production method is more effective for a deodorizing filter containing the catalyst, and has an advantage that it can be produced favorably without distortion.

In the manufacturing method of this embodiment, a press die composed of a lower die 21 and an upper die 26 as shown in FIGS. 3 and 4 is used. The press die can be opened and closed by a press device (not shown) so that the press in the die can be compressed.

The lower mold 21 has a mixture filling recess 22 inside.
Are formed. The mixture-filled concave portion 22 has a concave shape corresponding to the deodorizing filter 10 to be molded, and as shown in FIG.
Is charged in a required amount.

The mixture 11 filled in the lower mold 21 is
The one described in the example of the first aspect of the present invention is used, the viscosity of which is adjusted by water or the like. The adsorbent, the catalyst, the binder and the like are mixed by known mixing means, for example, a mixer or a kneader.

After filling the mixture 11 into the lower mold 21,
As shown in FIGS. 4 and 5, the inner surface 27 facing the lower mold 21 is formed.
The mixture 11 in the lower mold 21 is compression-molded by the upper mold 26 having the unevenness 28 formed thereon and the lower mold 21. The unevenness 28 of the upper mold 26 is the same as that of the deodorizing filter 10 shown in FIG.
Corresponds to the uneven shape of the surface of the above.

By the compression, the mixture 1 in the lower mold 21 is
1 is shaped into the inner surface of the lower mold 21 and the upper mold 2 is formed.
The upper surface of the uneven shape is formed by the unevenness 28 of 6. At this time, the mixture 11 is densely packed in the lower mold 21 and does not have a chipped portion due to insufficient filling, and is shaped into a good outer shape. Further, even when the viscosity of the mixture is low due to the addition of the catalyst, the mixture is compression-molded in a mold, so that the mixture does not flow and cannot be shaped at that time, and the shape can be surely formed.

Thereafter, the molded product is taken out by opening the space between the upper mold 26 and the lower mold 21 and dried by a drier to obtain a deodorizing filter 10 having a shape shown in FIG. Is obtained. The conditions such as temperature and time for drying are appropriately set.

Next, a third embodiment of the present invention will be described. The manufacturing method of this example is suitable for manufacturing a deodorizing filter 10A having a plurality of through holes 14 as shown in FIG.

The method for producing the deodorizing filter 10A is as follows.
The pressing is performed using a press die including a lower die 31 and an upper die 36 as shown in FIG. 6 and the mixture 11A prepared as described above. The lower mold 31 is formed with a mixture-filled concave portion 32 having a concave shape corresponding to the shape of the deodorizing filter 10A.
Are formed through the inner and outer surfaces. On the other hand, in the upper die 36, a needle-like projection 38 is formed on an inner surface 37 facing the lower die 31 at a position corresponding to the hole 34 of the lower die. 31 are inserted into the holes 34. The protrusion 38 and the hole 34
The through holes 14 provided in the deodorizing filter 10A are formed in accordance with the size, number, position, and the like.

The mixture filling recess 3 of the lower mold 31
2 is filled with the mixture 11A, and the mixture 11A is compressed by the upper mold 36 to form a mold. At this time, the protrusions 38 of the upper mold 36 penetrate the mixture 11A so that
The 9 side is inserted into the hole 34 of the lower mold 31. Thereby,
In the mixture 11A formed in the mold, a large number of through holes 14 formed by the protrusions 38 are formed. Moreover, the protrusion 38
Since the mixture 11A at the entry portion, that is, the mixture 11A at the through-hole portion 14 is pushed out into the hole 34 of the lower mold 31 by the tip 39 of the projection 38, the mixture 11A may remain in the mixture filling recess 32 and hinder the shaping of the mixture. And a good molded product is obtained. In addition, the mixture may be added by adding a catalyst or the like.
Even in the case of low viscosity that cannot be formed by conventional extrusion molding, since it is filled into a mold and compression-molded, it can be reliably shaped and a good molded product can be obtained.

Thereafter, the molded product is taken out by opening the space between the upper mold 36 and the lower mold 31 and dried at a predetermined temperature for a predetermined time to obtain a deodorizing filter 10A having a good shape without distortion as shown in FIG. . In addition, the obtained deodorizing filter 1
0A exhibits a good cleaning action because the contact area with air or the like is increased by the large number of through holes 14.

FIG. 7 shows a production example of a deodorizing filter having a plurality of through-holes and further having irregularities on the surface. The manufacturing method is the same as the manufacturing method of the deodorizing filter 10A shown in FIG. 2 except that the upper mold of the inner surface of the unevenness 47 is used in addition to the projection 48, that is, by the press molding using the lower mold 41 and the upper mold 46. This is performed by compressing the mixture 11B while inserting the protrusion 48 into the hole 44 of the lower mold 41. In the examples of FIGS. 6 and 7, the through-hole of the deodorizing filter has a circular cross section, but may have a honeycomb shape such as a lattice shape.

[0030]

EXAMPLES Example 1-Examples of Claims 1 and 2 As an adsorbent, 40 parts by weight of powdered activated carbon having a particle size of 20 μm and 60 parts by weight of titanium oxide as a photocatalyst are added together with 60 parts by weight of water so as to be uniform. Stir with a mixer. 20 parts by weight of Frogme clay and 15 parts by weight of ball clay are added thereto as a binder of an inorganic substance, and 1.0 part by weight of methylcellulose and 45 parts by weight of water are further added as an organic binder, and the mixture is further stirred, kneaded and mixed. Is prepared.

The mixture of the above composition was mixed with the lower mold 2 shown in FIG.
The mixture 11 in the lower mold 21 is filled with the mixture 11 in the lower mold 21 by the upper mold 26 of FIG.
It is compressed by applying pressure for 2 seconds at kgf / cm ² and shaped into a mold. Next, the shaped article was taken out of the mold and dried by a drier at a temperature of 120 ° C. for 12 hours to obtain a deodorizing filter 10 having a length of 12 cm × width of 10 cm × height of 1.3 cm shown in FIG. Was.

The resulting deodorizing filter had sufficient strength, and had a good appearance without distortion. Also,
In order to confirm the deodorizing performance of the deodorizing filter, a measurement material obtained by pulverizing the deodorizing filter was subjected to JIS.
When the adsorptivity was measured according to K 1474, the iodine adsorption performance was 850 (mg / g), and the benzene adsorption power was 26 (%). On the other hand, the adsorption performance of the activated carbon itself used was iodine adsorption performance 1480 (mg / g),
Benzene adsorption performance is 50 (%), and the deodorizing filter of Example 1 shows a small decrease in adsorption performance even when considering that the ratio of activated carbon is reduced by the addition of titanium oxide and a binder. It can be seen that it has the property.

Further, in order to confirm the action of the photocatalyst in the deodorizing filter of Example 1, 1 g of the measurement material obtained by crushing the deodorizing filter of Example 1 was placed in a 2.8 liter glass container, and ammonia was added. 2.5
While circulating at 1 / min, the concentration of ammonia was measured at predetermined time intervals by irradiation with an ultraviolet lamp from outside.
For comparison, a similar measurement was performed for activated carbon alone. As a result of the measurement, as shown in FIG. 8, the sample of the example was superior to the activated carbon alone in ammonia adsorption.

Embodiment 2-Embodiments of Claims 1 and 3 Using a mixture having the same composition as in Embodiment 1 and containing a titanium oxide as a photocatalyst, the mixture filling recess 32 of the lower mold 31 shown in FIG. The mixture 11A in the lower mold 31 was filled with 100 mml, and the mixture 11A in the lower mold 31 was pressured by the upper mold 36 at a pressure of 80 kgf / cm.
² for 2 seconds to compress and shape into a mold. Next, the shaped article was taken out of the mold and dried by a dryer at a temperature of 120 ° C. for 12 hours.
A deodorizing filter 10A having a large number of through-holes 14 having a size of 6 cm in width and 1.0 cm in height and shown in FIG. 2 was obtained.
The obtained deodorizing filter had sufficient strength, had almost no distortion, and had a good appearance. In addition, the adsorption performance and the action of the photocatalyst were the same as in Example 1.

[0035]

As described above, the deodorizing filter according to the first aspect of the present invention is characterized in that a mixture containing powdered activated carbon, titanium oxide as a catalyst for decomposing harmful substances, a binder and water is compressed into a predetermined shape. Since it is a molded product, unlike a conventional extruded product, it not only has a small distortion and has a good appearance, but also has an excellent deodorizing and harmful substance removing effect due to the synergistic action of the activated carbon and the catalyst. further,
Since the adsorption of odors and harmful substances is carried out not only by activated carbon but also by a catalyst, the life of activated carbon itself is extended, and there is also an effect that the deodorizing filter can be used for a long time.

On the other hand, according to the method for producing a deodorizing filter according to the second and third aspects of the present invention, since the deodorizing filter is produced by compression molding, the deodorizing filter having less distortion can be obtained. Moreover, since the mixture contains a catalyst for decomposing harmful substances and the like, a deodorizing filter having an excellent deodorizing action and an action of removing harmful substances and the like can be obtained by the synergistic action of activated carbon and the catalyst. In addition, even if the mixture is too low in viscosity to extrude due to the addition of the catalyst, the mixture can be reliably shaped by compression molding using a mold, and a deodorizing filter having a desired shape can be obtained.

Further, according to the second aspect of the present invention, since the mold on the non-filled side of the mixture is provided with irregularities, the mixture can be uniformly filled in the mold, and has a good appearance without any underfill due to poor filling. A deodorizing filter can be obtained.

According to the third aspect of the present invention, when the mixture is compressed, an excess amount of the mixture for forming the through-hole is discharged into the hole formed in the mold on the mixture filling side. Since the mixture does not remain in the mold, compression molding of the mixture is not hindered, and a deodorizing filter having a good external appearance can be obtained.

[Brief description of the drawings]

FIG. 1 is a partial perspective view showing one embodiment of a deodorizing filter according to the first aspect of the present invention.

FIG. 2 is a partial perspective view showing another example of the deodorizing filter according to the first aspect of the present invention.

FIG. 3 is a cross-sectional view showing a state in which a mixture is filled in the embodiments of the first and second aspects of the present invention.

FIG. 4 is a cross-sectional view showing a state immediately after compression after filling the mixture in the example.

FIG. 5 is a cross-sectional view showing the same embodiment when compressed.

FIG. 6 is a cross-sectional view showing a manufacturing time in the first and third embodiments of the present invention.

FIG. 7 is a cross-sectional view illustrating another example during manufacturing.

FIG. 8 is a diagram showing a measurement result of an ammonia adsorption speed.

[Explanation of symbols]

 REFERENCE SIGNS LIST 10 Deodorizing filter 10A Deodorizing filter 11 Mixture 11A Mixture 14 Through hole 21 Lower mold 22 Mix filling recess 26 Upper mold 27 Upper mold inner surface 28 Inner unevenness 31 Lower mold 32 Mix filling recess 33 Lower mold bottom surface 34 Hole 36 Upper mold 37 Upper mold Inner surface 38 Needle-like projection 39 Tip of projection

──────────────────────────────────────────────────続 き Continuation of the front page (51) Int.Cl. ⁷ Identification symbol FI B01D 53/86 ZAB (56) References JP-A-8-117524 (JP, A) JP-A-63-240923 (JP, A) JP-A-6-7634 (JP, A) JP-B-52-19194 (JP, B2) (58) Fields investigated (Int. Cl. ⁷ , DB name) B01D 39/14 B01D 53/04 B01D 53/34 A61L 9/00

Claims (3)

(57) [Claims] 1. A deodorizing filter compression-molded from a mixture containing powdered activated carbon as an adsorbent, titanium oxide as a photocatalyst, a binder, and water, wherein a total of 100% by weight of the powdered activated carbon and titanium oxide Parts by weight of titanium oxide, the binder contains both an inorganic binder and an organic binder, and the proportion of the inorganic binder is larger than the proportion of the organic binder. A deodorizing filter characterized in that either or both of irregularities and through holes are formed on both surfaces of the filter. 2. A mixture containing powdered activated carbon as an adsorbent, titanium oxide as a photocatalyst, a binder, and water is filled in one mold, and the mixture is compressed by the one mold and the other mold. A method for producing a deodorizing filter, which is shaped and then dried, comprising 30 to 60 parts by weight of titanium oxide based on 100 parts by weight of the total of the powdered activated carbon and titanium oxide, wherein the binder is an inorganic binder. And the ratio of the inorganic binder is larger than the ratio of the organic binder, and the unevenness is provided on the inner surface of the other mold on the mixture non-filling side, and the other mold and the mixture filling side A method for producing a deodorizing filter, comprising compressing a mixture with one of the molds and shaping the mixture into an uneven shape. 3. A mixture containing powdered activated carbon as an adsorbent, titanium oxide as a photocatalyst, a binder, and water is filled in one mold, and the mixture is compressed by the one mold and the other mold. A method for producing a deodorizing filter, which is shaped and then dried, comprising 30 to 60 parts by weight of titanium oxide based on 100 parts by weight of the total of the powdered activated carbon and titanium oxide, wherein the binder is an inorganic binder. And both containing an organic binder, and the proportion of the inorganic binder is greater than the proportion of the organic binder, providing a plurality of holes in the bottom surface of one of the molds on the mixture filling side,
The mixture is compressed by the other mold and the one mold on the mixture non-filling side in which a plurality of protrusions corresponding to the holes are formed on the inner surface, and at this time, the protrusions are pierced into the mixture in the mold to project the protrusion tips. A method for producing a deodorizing filter, comprising: shaping into a shape having a through hole by inserting into a hole formed in a bottom surface of a mold on a mixture filling side.