JP3868391B2 - Ceramic honeycomb filter and manufacturing method thereof - Google Patents

Ceramic honeycomb filter and manufacturing method thereof Download PDF

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Publication number
JP3868391B2
JP3868391B2 JP2003106712A JP2003106712A JP3868391B2 JP 3868391 B2 JP3868391 B2 JP 3868391B2 JP 2003106712 A JP2003106712 A JP 2003106712A JP 2003106712 A JP2003106712 A JP 2003106712A JP 3868391 B2 JP3868391 B2 JP 3868391B2
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ceramic honeycomb
honeycomb filter
cell
filter
molded body
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JP2004305993A (en
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友紀 伊藤
龍夫 馬場
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NGK Insulators Ltd
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NGK Insulators Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
    • B01D46/24491—Porosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0027—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B01D46/003—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions including coalescing means for the separation of liquid
    • B01D46/0031—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions including coalescing means for the separation of liquid with collecting, draining means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
    • B01D46/2429—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material of the honeycomb walls or cells
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
    • B01D46/24492—Pore diameter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2425—Honeycomb filters characterized by parameters related to the physical properties of the honeycomb structure material
    • B01D46/24494—Thermal expansion coefficient, heat capacity or thermal conductivity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/247—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the cells
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
    • B01D46/2488—Triangular
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
    • B01D46/249—Quadrangular e.g. square or diamond
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
    • B01D46/2492—Hexagonal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
    • B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
    • B01D46/2496—Circular
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D63/00—Apparatus in general for separation processes using semi-permeable membranes
    • B01D63/06—Tubular membrane modules
    • B01D63/066—Tubular membrane modules with a porous block having membrane coated passages
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006—Honeycomb structures
    • C04B38/0009—Honeycomb structures characterised by features relating to the cell walls, e.g. wall thickness or distribution of pores in the walls
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00793—Uses not provided for elsewhere in C04B2111/00 as filters or diaphragms

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  • Physics & Mathematics (AREA)
  • Geometry (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Thermal Sciences (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Filtering Materials (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)

Description

【０００１】
【発明の属する技術分野】
本発明は、セラミックスハニカムフィルタ及びその製造方法に関する。さらに詳しくは、被濾過流体及び濾過流体が内部に滞留することを有効に防止し、清浄度の高い濾過流体を供給することが可能なセラミックスハニカムフィルタ及びその製造方法に関する。
【０００２】
【従来の技術】
近年、固液分離あるいは気固分離用のフィルタとして、多孔質の隔壁によって区画されたセルを有するセラミックスハニカムフィルタが用いられている。このセラミックスハニカムフィルタは、同様の用途に用いられる有機高分子膜等と比較して、物理的強度、耐久性、耐蝕性等に優れるため、水処理や排ガス処理、あるいは医薬・食品分野等の広範な分野において、液体やガス中の懸濁物質、細菌、粉塵等の除去に好適に用いられている。
【０００３】
このようなセラミックスハニカムフィルタにおいては、通水量を増加させるとともに、濾過性能を向上させる観点から、図３に示すように、筒状の多孔体の長手方向に形成された、多数の平行な流通路（セル）２１の内周面に、多孔体の孔に比してさらに孔径の小さい濾過膜２２を形成するとともに、多孔体中心近傍の流通路からの通水量を増加するために、多孔体の長手方向にスリット状の空隙部（集水スリット）２３を設け、かつ空隙部（集水スリット）２３に連通する流通路（集水セル）２１ａの縁端部を目詰部材２４により封止し、濾過膜２２を形成した流通路（膜濾過セル）２１ｂに供給した被濾過流体を濾過膜２２で濾過し、濾過した濾過流体を、縁端部を目詰部材２４により封止した流通路（集水セル）２１ａから空隙部（集水スリット）２３を経由して外部に流出することが可能なセラミックスハニカムフィルタ２０が提案されている（例えば、特許文献１参照）。
【０００４】
上述したセラミックスハニカムフィルタ２０においては、濾過膜２２を形成することで濾過性能を向上させ、かつ空隙部（集水スリット）２３を設けることで通水量を増加させている。
【０００５】
【特許文献１】
特開２０００−１５３１１７号公報
【０００６】
【発明が解決しようとする課題】
しかしながら、上述したセラミックスハニカムフィルタにおいては、流通路（集水セル）２１ａの縁端部を封止する目詰部材２４は、単に被濾過流体が流通路（集水セル）２１ａ内に侵入することを防止することができればよいという程度の認識しかされていなかったため、また、余りにも深くまで目詰部材２４を充填すると、流通路（集水セル）２１ａに充填した目詰部材２４が空隙部（集水スリット）２３からはみ出して欠陥の原因や修正の手間が掛かるため、被濾過流体の侵入を防止することができる必要最低限の位置までにしか充填されていなかった。このため、流通路（集水セル）２１ａ内の、目詰部材２４端部から空隙部（集水スリット）２３までの間に、流出されるべき濾過流体が滞留する部分（液溜まり）２５が形成されていた。
【０００７】
このため、前述した液溜まり２５に、濾過流体の一部が滞留して雑菌等が繁殖し、濾過流体全体を汚染することが問題となっていた。また、セラミックスハニカムフィルタ２０は、定期的に薬液を用いて洗浄を行うことがあるが、この洗浄に使用した薬液が前述した液溜まり２５に滞留してセラミックスハニカムフィルタ２０から完全に取り除くことができず、滞留した薬液が徐々に拡散して濾過流体を汚染することが問題となっていた。また、図４に示すように、セラミックスハニカムフィルタ２０を構成する濾過膜２２の成膜工程は、減圧下において、濾過膜２２となる固形成分を含んだ濾過膜スラリーを所定の流通路（膜濾過セル）２１ｂに流し込み、流し込んだ濾過膜スラリーに含まれる固形成分２２ａを流通路（膜濾過セル）２１ｂの内面に付着させた後に、大気圧下において乾燥することによって行われるが、固形成分２２ａが除去された後の濾過膜スラリーの水分２２ｂが前述した液溜まり２５に滞留し、成膜終了後の大気圧への復元に伴い濾過膜スラリーの水分２２ｂが隔壁２６を透過して移動し、流通路（膜濾過セル）２１ｂの内面に付着させたばかりの濾過膜２２を浮き上がらせて剥離させてしまうという問題があった。
【０００８】
本発明は、上述の問題に鑑みなされたもので、被濾過流体及び濾過流体が内部に滞留することを有効に防止し、清浄度の高い濾過流体を供給することが可能なセラミックスハニカムフィルタ及びその製造方法を提供することを目的とする。
【０００９】
【課題を解決するための手段】
上述の目的を達成するため、本発明は、以下のセラミックスハニカムフィルタ及びその製造方法を提供するものである。
【００１０】
［１］ セラミックスからなる多孔質の隔壁によって区画され、その内部に濾過膜が配設された、被濾過流体の流路となる複数の膜濾過セルと、前記隔壁によって区画されるとともに前記隔壁を挟んで所定の前記膜濾過セルに隣接し、前記被濾過流体が前記濾過膜によって濾過された濾過流体の流路となる複数の集水セルと、前記膜濾過セル及び前記集水セルを取り囲む外壁と、前記集水セルを通過した前記濾過流体を外部に流出するための、前記外壁の前記集水セルのそれぞれの両端部から所定の長さ離れた箇所で、前記外壁の一の部位から前記集水セルを貫通して前記外壁の他の部位まで連通する集水スリットと、前記集水セルのそれぞれの端面から前記集水スリットに達するまでの空間内に充填された多孔質の目詰部材とを備えてなることを特徴とするセラミックスハニカムフィルタ。
【００１１】
［２］ 記目詰部材が、複数の連通孔が形成された多孔質体から構成された前記［１］に記載のセラミックスハニカムフィルタ。
【００１２】
［３］ 前記目詰部材が、アルミナ、ムライト、セルベン、及びコージェライトからなる群から選ばれる少なくとも一つの材料を含む多孔質材料から形成された前記［１］又は［２］に記載のセラミックスハニカムフィルタ。
【００１３】
［４］ 前記目詰部材に形成された複数の前記連通孔のそれぞれが、孔径が２０μｍ以下の部位を有する前記［２］又は［３］に記載のセラミックスハニカムフィルタ。
【００１４】
［５］ 前記目詰部材の気孔率が、２５〜５０％である前記［１］〜［４］のいずれかに記載のセラミックスハニカムフィルタ。
【００１５】
［６］ 前記目詰部材の熱膨張率が、前記隔壁の熱膨張率より低いか又は同一である前記［１］〜［５］のいずれかに記載のセラミックスハニカムフィルタ。
【００１６】
［７］ 複数の前記膜濾過セルの、前記被濾過流体の流れ方向に垂直な断面のそれぞれの形状が、円形、楕円形、長円形、三角形、四角形、五角形、六角形及び七角形からなる群から選ばれる少なくとも一つの形状である前記［１］〜［６］のいずれかに記載のセラミックスハニカムフィルタ。
【００１７】
［８］ 複数の前記集水セルの、前記濾過流体の流れ方向に垂直な断面のそれぞれの形状が、円形、楕円形、長円形、三角形、四角形、五角形、六角形及び七角形からなる群から選ばれる少なくとも一つの形状である前記［１］〜［７］のいずれかに記載のセラミックスハニカムフィルタ。
【００１８】
［９］ 原材料を押出し成形して被濾過流体及び濾過流体の流路となるセルを有する所定形状の未焼成フィルタ成形体を得、得られた前記未焼成フィルタ成形体に、その側面の一の部位から所定の前記セルを貫通して他の部位まで連通する集水スリットを形成して集水スリット付き未焼成フィルタ成形体を得、得られた前記集水スリット付き未焼成フィルタ成形体に、所定の前記セルのそれぞれの端面から、所定の前記セルを貫通する前記集水スリットに達するまでの空間内に目詰材を充填して目詰材充填未焼成フィルタ成形体を得、得られた前記目詰材充填未焼成フィルタ成形体を焼成して目詰材充填フィルタ成形体を得、得られた前記目詰材充填フィルタ成形体を構成する所定の前記セルの内周面に濾過膜を成膜した後に焼成することを特徴とするセラミックスハニカムフィルタの製造方法。
【００１９】
［１０］ 前記目詰材が、骨材粒子、無機結合材、バインダー、増粘剤及び保水剤を含んだものである前記［９］に記載のセラミックスハニカムフィルタの製造方法。
【００２０】
［１１］ 前記目詰材を構成する前記バインダーが、前記骨材粒子１００質量部に対して、０．０８〜０．１２質量部含まれる前記［１０］に記載のセラミックスハニカムフィルタの製造方法。
【００２１】
［１２］ 前記目詰材を構成する前記増粘剤が、前記骨材粒子１００質量部に対して、０．０４〜０．１質量部含まれる前記［１０］又は［１１］に記載のセラミックスハニカムフィルタの製造方法。
【００２２】
［１３］ 前記目詰材を構成する前記保水剤が、前記骨材粒子１００質量部に対して、５〜６質量部含まれる前記［１０］〜［１２］のいずれかに記載のセラミックスハニカムフィルタの製造方法。
【００２３】
［１４］ 前記目詰材充填フィルタ成形体に前記濾過膜を成膜した後に、その両端面を所定の長さ切断する前記［９］〜［１３］のいずれかに記載のセラミックスハニカムフィルタの製造方法。
【００２４】
［１５］ 前記目詰材を構成する前記骨材粒子が、アルミナ、ムライト、セルベン、及びコージェライトからなる群から選ばれる少なくとも一つの化合物である前記［１０］〜［１４］のいずれかに記載のセラミックスハニカムフィルタの製造方法。
【００２５】
［１６］ 前記目詰材を構成する前記無機結合材が、アルミナ、シリカ、ジルコニア、ガラスフリット、長石、及びコージェライトからなる群から選ばれる少なくとも一つの化合物である前記［１０］〜［１５］のいずれかに記載のセラミックスハニカムフィルタの製造方法。
【００２６】
［１７］ 前記目詰材を構成する前記バインダーが、ポリビニルアルコール、ポリエチレングリコール、澱粉、及び粘土からなる群から選ばれる少なくとも一つの化合物である前記［１０］〜［１６］のいずれかに記載のセラミックスハニカムフィルタの製造方法。
【００２７】
【発明の実施の形態】
以下、本発明のセラミックスハニカムフィルタ及びその製造方法の実施の形態を、図面を参照しつつ具体的に説明する。
【００２８】
図１（ａ）及び図１（ｂ）は、本発明のセラミックスハニカムフィルタの一の実施の形態を模式的に示す説明図であって、図１（ａ）は一部を切り欠いた斜視図、図１（ｂ）は中心軸を含む平面で切断した断面図である。図１（ａ）及び図１（ｂ）に示すように、本実施の形態のセラミックスハニカムフィルタ１は、セラミックスからなる多孔質の隔壁２によって区画され、その内部に濾過膜３が配設された、被濾過流体の流路となる複数の膜濾過セル４と、隔壁２によって区画されるとともに隔壁２を挟んで所定の膜濾過セル４に隣接し、被濾過流体が濾過膜３によって濾過された濾過流体の流路となる複数の集水セル５と、膜濾過セル４及び集水セル５を取り囲む外壁６と、集水セル５を通過した濾過流体を外部に流出するための、外壁６の集水セル５のそれぞれの両端部から所定の長さ離れた箇所で、外壁６の一の部位から集水セル５を貫通して外壁６の他の部位まで連通する集水スリット７と、集水セルのそれぞれの端面から集水スリット７に達するまでの空間内に充填された多孔質の目詰部材８とを備えてなることを特徴とする。図１（ａ）においては、円柱状のセラミックスハニカムフィルタ１を示しているが、本実施の形態のセラミックスハニカムフィルタ１の形状は、円柱状に限定されることはなく、中心軸に垂直な平面における断面の形状が四角形等の柱状等の形状であってもよい。
【００２９】
本実施の形態のセラミックスハニカムフィルタ１においては、被濾過流体が、端面から膜濾過セル４の内部に流入し、膜濾過セル４の内部に配設された濾過膜３を通過することによって被濾過流体が濾過され、濾過膜３によって濾過された濾過流体が、多孔質の隔壁２を経由して集水セル５に流入し、集水セル５から集水セル５を貫通する集水スリット７に流入し、そして、外壁６に形成された集水スリット７の開口部から外部に流出するものである。また、濾過膜３によって濾過された濾過流体の一部が、隔壁２から集水セル５に流入することなく、そのまま外壁６を経由して外部に流出する構成としてもよい。このように本実施の形態のセラミックスハニカムフィルタ１は、集水スリット７を備えた構成とすることで通水抵抗が軽減されており、優れた通水性を有している。また、従来の集水セルを備えたセラミックスハニカムフィルタにおいては、集水セル内の、目詰部材の端部から集水スリットまでの間に、流出すべき濾過流体が滞留する部分（液溜まり）が形成され、この液溜まりに一部の濾過流体が滞留することによって雑菌等が繁殖して濾過流体全体を汚染することや、セラミックスハニカムフィルタを洗浄する際に使用する薬液が液溜まりに滞留し、滞留した薬液が徐々に拡散して濾過流体を汚染すること等が問題となっていたが、本実施の形態のセラミックスハニカムフィルタ１においては、目詰部材８が、集水セル５のそれぞれの端面から集水スリット７に達するまでの空間内に充填されているために、濾過流体や薬液等が滞留する部分が形成されず、濾過流体が汚染されることがない。
【００３０】
また、本実施の形態のセラミックスハニカムフィルタ１は、濾過されるべき被濾過流体が、セラミックスハニカムフィルタ１の端面の隔壁２部分から直接流入し膜濾過セル４の内面の濾過膜３で濾過されることなく外部に流出することを防止するために、セラミックスハニカムフィルタ１の端面の隔壁２を覆うようにシール部９が形成されている。このシール部９は、セラミックスハニカムフィルタ１の端面にシリカガラス等の釉薬を塗布し、焼成して形成されたものである。
【００３１】
本実施の形態においては、集水スリット７を形成する位置及びその開口部の形状については、セラミックスハニカムフィルタ１の大きさにより適宜設定することが好ましく、例えば、セラミックスハニカムフィルタ１の形状が円柱状で、その端面の直径１８０ｍｍ、軸方向の長さが１０００ｍｍの場合には、外壁６に形成される集水スリット７の開口部の形状は、一辺の長さが２０〜８０ｍｍの長円形、正方形又は長方形であることが好ましい。
【００３２】
本実施の形態のセラミックスハニカムフィルタ１は、目詰部材８が、集水セル５のそれぞれの端面から集水スリット７に達するまでの空間内に充填されたものであるが、本実施の形態にいう、「集水セル５のそれぞれの端面から集水スリット７に達するまでの空間内に充填される」とは、目詰部材８を充填する際の精度上の観点から、集水セル５のそれぞれの端面から集水スリット７に達するまでの空間内の、集水セル５のそれぞれの端面から８０〜１００％の範囲に目詰部材８が充填されることをいう。このように構成することによって、被濾過流体及び濾過流体が内部に滞留することを有効に防止し、清浄度の高い濾過流体を供給することができるセラミックスハニカムフィルタ１となる。
【００３３】
本実施の形態のセラミックスハニカムフィルタ１の隔壁２は、例えば、骨材粒子と無機結合材とに、メチルセルロース等の有機バインダー、分散材及び水を加えて混錬した坏土を、公知のハニカム成形機で押出し成形することで形成することができる。骨材粒子としては、アルミナ、ムライト、セルベン、及びコージェライトからなる群から選ばれる少なくとも一の化合物を好適に用いることができる。無機結合材としては、アルミナ、シリカ、ジルコニア、チタニア、ガラスフリット、長石、及びコージェライトからなる群から選ばれる少なくとも一の化合物を好適に用いることができる。
【００３４】
本実施の形態に用いられる目詰部材８は、上述した隔壁２と同様の材料を好適に用いることができ、例えば、アルミナ、ムライト、セルベン、及びコージェライトからなる群から選ばれる少なくとも一つの材料を含む多孔質材料から形成されたものであることが好ましい。なお、製造過程に用いられる目詰材（目詰材スラリー）には、得られるセラミックスハニカムフィルタ１において、集水セル５のそれぞれの端面から集水スリット７に達するまで目詰部材８が充填されているように、バインダー、増粘剤及び保水剤がさらに加えられたものを用いることが好ましい。目詰材（目詰材スラリー）の構成については、セラミックスハニカムフィルタの製造方法を説明する際に具体的に説明する。
【００３５】
また、この目詰部材８は、濾過膜３を成膜する際に用いられる濾過膜スラリーに含まれる水分が排出される程度に粗であることが好ましく、具体的には、複数の連通孔が形成された多孔質体から構成されていることが好ましい。さらに、目詰部材８が、複数の連通孔が形成された多孔質体から構成されている場合には、複数の連通孔のそれぞれが、孔径が２０μｍ以下の部位を有することが好ましい。また、本実施の形態においては、目詰部材８の気孔率が２５〜５０％であることが好ましい。複数の連通孔のそれぞれが、孔径が２０μｍ以下の部位を有していない場合及び／又は目詰部材８の気孔率が５０％を超える場合には、濾過膜３を成膜するために用いられる濾過膜スラリーに含まれる固形成分が目詰部材８を通過して集水セル５に侵入してしまうことがある。また、気孔率が２５％未満の場合には、濾過膜３を成膜する際に用いられる濾過膜スラリーに含まれる水分の排出が困難となることがある。なお、本実施の形態における連通孔とは、目詰部材８の表面の一の部位から他の部位に連通する細孔のことである。また、目詰部材８は、その内部に体積が０．０６５ｍｍ3を超える空隙がないように、均一に充填されていることが好ましい。体積が０．０６５ｍｍ3を超える空隙がある場合には、セラミックスハニカムフィルタ１の端部における不良部分を切断した際に、その切断面に凹凸が形成されることがある。セラミックスハニカムフィルタ１の端面に凹凸が形成された場合、シール部９を形成する際に、釉薬等を均一に塗布することが困難となることがある。なお、気孔率は水銀圧入法によって測定することができる。
【００３６】
また、目詰部材８の熱膨張率は、隔壁２の熱膨張率より低いか又は同一であることが好ましい。目詰部材８の熱膨張率が隔壁２の熱膨張率よりも大きいと焼成の際に目詰部材８が膨張して、隔壁２を破損することがある。
【００３７】
また、本実施の形態においては、複数の膜濾過セル４の、被濾過流体の流れ方向に垂直な断面のそれぞれの形状が円である場合を示しているが、膜濾過セル４の形状はこれに限定されることはなく、例えば、円形、楕円形、長円形、三角形、四角形、五角形、六角形及び七角形からなる群から選ばれる少なくとも一つの形状であることが好ましい。また、複数の集水セル５の、被濾過流体の流れ方向に垂直な断面のそれぞれの形状が円である場合を示している、集水セルの形状もこれに限定されることはなく、例えば、円形、楕円形、長円形、三角形、四角形、五角形、六角形及び七角形からなる群から選ばれる少なくとも一つの形状であることが好ましい。
【００３８】
また、膜濾過セル４の内部に配設された濾過膜３は、チタニア、アルミナ、又はその両方を含むものであることが好ましい。この濾過膜３は、隔壁２の平均気孔径よりも小さい平均気孔径を有してなるものであり、例えば、その平均気孔径が０．１〜１．０μｍであることが好ましい。また、図示は省略するが、本実施の形態においては、濾過膜が、上述した濾過膜を上層濾過膜とし、隔壁と上層濾過膜との間に、その中間にあたる平均気孔径を有する中間膜をさらに備えた構成であってもよい。
【００３９】
次に、本実施の形態のセラミックスハニカムフィルタの製造方法について説明する。まず、原材料を、例えば、真空押出し成形機を用いて押出し成形して被濾過流体及び濾過流体の流路となるセルを有する所定形状の未焼成フィルタ成形体を得る。原材料は、図１（ａ）に示したセラミックスハニカムフィルタ１の隔壁２の好ましい材料として説明した、骨材粒子と無機結合材とに、メチルセルロース等の有機バインダー、分散材及び水を加えて、ニーダー混練機等を用いて混錬した坏土を好適に用いることができる。
【００４０】
次に、得られた未焼成フィルタ成形体に、その側面の一の部位から所定のセルを貫通して他の部位まで連通する集水スリットを形成して集水スリット付き未焼成フィルタ成形体を得る。この集水スリットは、例えば、成形時に集水スリット形成部の外壁に溝加工を施し、砥石等で外周部集水セル壁を破り、その後先端が鋭角な治具で集水セルを突き破り集水スリットを形成することができる。集水スリットは、最終製品であるセラミックスハニカムフィルタを浄水設備等に設置する際に、その端部に被濾過流体と濾過流体とを隔離するシール部材を配設するための部位として２５ｍｍ程度確保することができ、さらに、後述する濾過膜の成膜工程において、その端面を把持する把持部分に不良が発生し、不良が発生した部分を最大で３０ｍｍ程度除去する必要が生じることを考慮して、集水スリット付き未焼成フィルタ成形体の、その端面から５５ｍｍ程度離れた側面に形成することが好ましい。これまでの工程は、従来のセラミックスハニカムフィルタの製造方法に準じて行うことができる。
【００４１】
次に、図２（ａ）及び図２（ｂ）に示すように、得られた集水スリット付き未焼成フィルタ成形体１０に、所定のセル１２のそれぞれの端面から、所定のセル１２を貫通する集水スリット７に達するまでの空間内に目詰材（目詰材スラリー）１３を充填して目詰材充填未焼成フィルタ成形体を得る。具体的には、集水スリット付き未焼成フィルタ成形体１０の両端面にポリエステル等のフィルム１１（マスキング）を添付し、所定のセル１２に対応する部分に孔を穿設する。その後に、集水スリット付き未焼成フィルタ成形体１０のフィルム１１を添付した端面を、目詰材１３が満たされた容器１４内に押し付け、さらに、エアシリンダー等で、例えば、２００ｋｇで加圧して、所定のセル１２に目詰材を充填する。
【００４２】
本実施の形態に用いられる目詰材１３としては、目詰材１３は、集水スリットに達するまで、所定のセル１２に充填することができるように、骨材粒子、無機結合材、バインダー、増粘剤及び保水剤を含んだものであることが好ましい。骨材粒子及び無機結合材は、未焼成フィルタ成形体を製作する際に用いられる骨材粒子及び無機結合材と同様のものを好適に用いることができる。
【００４３】
目詰材１３を構成するバインダーは、目詰材１３の乾燥時点での乾燥強度を持たせ、乾燥時にクラックの発生を防止する働きがあり、ポリビニルアルコール、ポリエチレングリコール、澱粉、及び粘土からなる群から選ばれる少なくとも一つの化合物であることが好ましい。また、目詰材１３には、このバインダーが、骨材粒子１００質量部に対して０．０８〜０．１２質量部含まれることが好ましい。バインダーが０．０８質量部未満であると、目詰材１３の乾燥時にクラックが発生することがある。また、バインダーが０．１２質量部を超えると、目詰材１３の強度が高くなり集水スリット付き未焼成フィルタ成形体１０にクラックが発生することがある。
【００４４】
目詰材１３を構成する増粘剤は、集水スリット付き未焼成フィルタ成形体１０の所定のセル１２の内部に目詰材１３を入り込ませ易いように、目詰材１３に適正な粘度を発現させる働きがあり、メチルセルロースやカルボキシルメチルセルロース等を好適に用いることができる。また、目詰材１３には、この増粘剤が、骨材粒子１００質量部に対して、０．０４〜０．１質量部含まれることが好ましい。増粘剤が０．０４質量部未満であると、目詰材１３が所定のセル１２の内部にスムーズに入らず、所定の深さまで目詰材１３を充填することが困難になることがある。また、増粘剤が０．１質量部を超えると、それぞれのセル１２に充填した目詰材１３の深さが異なり、所定の深さまで目詰材１３を均等に充填することが困難になることがある。
【００４５】
目詰材１３を構成する保水剤は、目詰材１３を充填する際に、目詰材１３の水分が、乾燥した集水スリット付き未焼成フィルタ成形体１０に吸収されて固化するのを防止し、目詰材１３を均一に所定の深さまで入り込ませる働きがある。この保水剤としては、でんぷん、グリセリン等を好適に用いることができる。また、目詰材１３には、この保水剤が、骨材粒子１００質量部に対して、５〜６質量部含まれることが好ましい。保水剤が５質量部未満であると、目詰材１３を充填する際に、目詰材１３の水分が集水スリット付き未焼成フィルタ成形体１０に瞬時に吸収されて、目詰材１３を所定の深さまで充填することができないことがある。また、保水剤が６質量部を超えると、焼成前の乾燥にて、目詰材１３が十分に乾燥せず、焼成時にクラックが発生することがある。
【００４６】
次に、得られた目詰材充填未焼成フィルタ成形体を、例えば、９００〜１４００℃で焼成して目詰材充填フィルタ成形体を得る。
【００４７】
次に、得られた目詰材充填フィルタ成形体を構成する所定のセルの内周面に濾過膜を成膜した後に焼成する。濾過膜を成膜する方法としては、例えば、中間膜と、中間膜より気孔径の小さい上層濾過膜とから構成された濾過膜を形成する場合には、まず、中間膜を成膜するための中間膜スラリーを形成する。中間膜スラリーは、未焼成フィルタ成形体と同材質の、例えば、平均粒径３．２μｍの、アルミナ、ムライト、チタニア、コージェライト等のセラミックス原料１００質量部に、４００質量部の水を加えて形成することができる。また、この中間膜スラリーには、焼成後の膜強度を上げるために膜用無機結合材を添加してもよい。膜用無機結合材は粘土、カオリン、チタニアゾル、シリカゾル、ガラスフリット等を用いることができ、添加量は膜強度の点から５〜２０質量部添加することが好ましい。また、セラミックス原料のみで焼結し膜強度が得られる場合は、膜用無機結合材を添加しなくてもよい。この中間膜スラリーを特開昭６１−２３８３１５号公報において開示される装置を用いて各セルの表面に成膜し、乾燥した後、所定の焼成温度、例えば、９００〜１０５０℃で焼結させ、目詰材充填フィルタ成形体に固着させて中間膜を形成することができる。
【００４８】
次に、上層濾過膜を成膜するための上層濾過膜スラリーを形成する。上層濾過膜スラリーは、例えば、平均粒径０．４μｍの、未焼成フィルタ成形体と同材質の、例えば、アルミナ、ムライト、チタニア、コージェライト等のセラミックス原料、又はこれらのセラミックス原料よりも熱膨脹率が小さい材料１００質量部に、１０００質量部の水を加えて形成することができる。また、この上層濾過膜スラリーには、焼成後の膜強度を上げるために膜用無機結合材を添加してもよい。膜用無機結合材は粘土、カオリン、チタニアゾル、シリカゾル、ガラスフリット等を用いることができ、添加量は膜強度の点から５〜２０質量部添加することが好ましい。この上層濾過膜スラリーを特開昭６１−２３８３１５号公報において開示される装置を用いて、中間膜の表面に成膜し、乾燥した後、所定の焼成温度９００〜１０５０℃で焼結させ、目詰材充填フィルタ成形体に成膜した中間膜に固着させて濾過膜を形成することができる。本実施の形態においては、上述したように構成された目詰材が、集水スリットに達するまでの空間内に充填されているために、濾過膜スラリー（中間膜スラリー及び上層濾過膜スラリー）に含まれる水分等が液溜まりに滞留して付着させたばかりの濾過膜を浮き上がらせて剥離させることがなく、所定のセルの全域にわたって濾過膜を正常に成膜することができる。
【００４９】
また、濾過膜を成膜する際は、上述したように、その端面を把持する把持部分に不良が発生することがあるために、成膜した目詰材充填フィルタ成形体の端面を３０ｍｍ程度切断する。次に、目詰材充填フィルタ成形体の、切断して新たに形成された端面にガラスフリット等の釉薬を塗布し、一旦乾燥した後に、９００〜１４００℃で焼成してセラミックスハニカムフィルタを製造する。釉薬の塗布及び焼成の条件等は、従来行われているセラミックスハニカムフィルタの製造方法に準じて行うことが可能である。
【００５０】
このようにして得られたセラミックスハニカムフィルタは、被濾過流体及び濾過流体が内部に滞留することを有効に防止し、清浄度の高い濾過流体を供給することができる。
【００５１】
【実施例】
以下、本発明を実施例により具体的に説明するが、本発明はこれらの実施例に限定されるものではない。
【００５２】
（実施例１〜１７）
全実施例を通じて、骨材粒子としての所定の大きさの平均粒径のアルミナと、無機結合材としてガラスフリットとを９：１の質量比で混合し、得られた混合粉末１００質量部に対して、水１５質量部、有機バインダーとしてメチルセルロース４．５質量部、及び分散材１質量部を加えて混練して坏土を得、得られた坏土をハニカム成形機で押出し成形した後乾燥して、外径φ１８０ｍｍ、長さ１０００ｍｍ、その内部に内径φ２．３ｍｍセルを２０７０個有する未焼成フィルタ成形体を得た。本実施例においては、原料粒度が０．２〜０．５ｍｍでアルミナ純度９９．８％の電融アルミナを乾式で所定の時間粉砕し、平均粒径がそれぞれ３０μｍ、５０μｍ、１００μｍのものをアルミナＡ、アルミナＢ、アルミナＣとした。
【００５３】
次に、各未焼成フィルタ成形体の、その側面の一の部位から所定のセルを貫通して他の部位まで連通する集水スリットを形成して集水スリット付き未焼成フィルタ成形体を得た。集水スリットの形状は長方形とした。
【００５４】
次に、得られた各集水スリット付き未焼成フィルタ成形体に、所定のセルのそれぞれの端面から、所定のセルを貫通する集水スリットに達するまでの空間内に目詰材を充填して目詰材充填未焼成フィルタ成形体を得た。各実施例においては、目詰材として、骨材粒子、無機結合材、バインダー、増粘剤及び保水剤を、表１及び表２に示す割合で混合したものを用いた。
【００５５】
【表１】

Figure 0003868391
【００５６】
【表２】
Figure 0003868391
【００５７】
各実施例におけにおける、目詰材充填未焼成フィルタ成形体を乾燥した状態での目詰材の引け欠陥の割合（％）を測定した。目詰材の引け欠陥とは、目詰材を充填した部分を乾燥した後、充填部分に水分が供給された際の目詰材充填部分の中央部の凹みの欠陥のことである。目詰材の引け欠陥の割合（％）は、目詰材を充填したセルの数に対する目詰材の引け欠陥の数の割合（％）を算出した値である。結果を表３及び表４に示す。
【００５８】
【表３】
Figure 0003868391
【００５９】
【表４】
Figure 0003868391
【００６０】
次に、得られた目詰材充填未焼成フィルタ成形体を焼成して目詰材充填フィルタ成形体を得、得られた目詰材充填フィルタ成形体を構成する所定のセルの内周面に濾過膜を成膜して乾燥した後に焼成し、その端面を所定の長さ切断した。この際、焼成した目詰材充填フィルタ成形体の乾式加工性について、各目詰材充填フィルタ成形体を切断する断刃から火花が飛ぶかを確認して評価した。結果を表３及び表４に示す。目詰材に含まれる無機結合材の量が多いと、焼成した目詰材充填フィルタ成形体の強度が上がり切断時に切断刃から火花が飛び切削性が悪くなることがあり、火花が飛ぶことがなく切断加工を良好に行うことができたものについては○とし、多少火花が飛ぶことがあったが切断加工を良好に行うことができたものについては△とし、火花が飛び散り切断加工が困難となったものについては×とした。結果を表３及び表４に示す。
【００６１】
実施例１〜１７のセラミックスハニカムフィルタの、目詰材を充填した部位における、クラックの発生率（％）を測定した。クラックの発生率（％）は、目詰材を充填したセルの数に対するクラックの発生したセルの数の割合（％）を算出した値である。結果を表３及び表４に示す。
【００６２】
また、目詰材を焼成することで形成された目詰部材の気孔径（μｍ）及び気孔率（％）を測定した。結果を表３及び表４に示す。
【００６３】
また、各セラミックスハニカムフィルタを形成する際に用いた目詰材をブロック状に鋳込み成形を行い、幅１０ｍｍ、厚さ５ｍｍ、長さ５０ｍｍの試験片を切り出し、支持間距離が３０ｍｍの３点曲げ強度測定を行った。結果を表３及び表４に示す。
【００６４】
各セラミックスハニカムフィルタを水中に浸漬させ、各セラミックスハニカムフィルタの一方の端面近傍に設けられた集水スリットを塞ぎ、他方の集水スリットから空気を送り込み、各セラミックスハニカムフィルタから発泡する際の圧力を計測して発泡検査を行った。結果を表３及び表４に示す。発泡検査の評価としては、８ｋＰａで加圧した際に目詰部材及び外壁から発泡が見られない場合は○とし、６ｋＰａで加圧した際に発泡が見られない場合は△とし、３ｋＰａで加圧した際に発泡が見られる場合は×とした。結果を表３及び表４に示す。
【００６５】
また、各セラミックスハニカムフィルタの一方の端面から被濾過流体を流入して浄化を行った際の、集水スリットと目詰部材との間に濾過流体が滞留するかについて測定した。滞留がない場合には○とし、滞留があった場合には×とした。結果を表３及び表４に示す。
【００６６】
（比較例１及び２）
集水スリット付き未焼成フィルタ成形体に、所定のセルのそれぞれの端面から、所定のセルを貫通する集水スリットに達するまでの空間内の所定の位置、比較例１においては、端面から４０ｍｍの位置（所定のセルの端面から集水スリットに達するまでの空間内の、所定のセルの端面から７３％の位置）まで、また、比較例２においては、端面から３５ｍｍの位置（所定のセルの端面から集水スリットに達するまでの空間内の、所定のセルの端面から６４％までの位置）まで、目詰材を充填して目詰材充填未焼成フィルタ成形体を得た以外は、上述した実施例と同様にしてセラミックスハニカムフィルタを製造し、同様の測定を行った。目詰材の構成及び各測定の結果を表５及び表６に示す。
【００６７】
【表５】
Figure 0003868391
【００６８】
【表６】
Figure 0003868391
【００６９】
表３、表４及び表６に示すように、実施例１〜１７のセラミックスハニカムフィルタは、所定のセルのそれぞれの端面から、所定のセルを貫通する集水スリットに達するまでの空間内に目詰材が充填されているために、上述した空間に濾過流体の滞留がなく、清浄度の高い濾過流体を供給することができるものであった。また、実施例１〜１７のセラミックスハニカムフィルタにおいては、目詰材の引け欠陥の割合（％）、乾式加工性、クラック発生率（％）及び発泡検査においていずれも優れた値を示すものであり、また、気孔径（μｍ）及び気孔率（％）についてもフィルタとして好適に用いることができるものであった。比較例１及び２のセラミックスハニカムフィルタは、集水スリットと目詰部材との間に液溜まりが形成されていることから、濾過流体の滞留があり、濾過流体の汚染を引き起こすものであった。また、発泡検査において、どちらも３ｋＰａで加圧した際に発泡が見られ、フィルタとして用いた場合には、被濾過流体が、発泡を生じた隙間を通過して濾過膜で濾過させることなく濾過流体に流入することとなり、フィルタとして用いることができないものであった。
【００７０】
【発明の効果】
以上説明したように、本発明によって、被濾過流体及び濾過流体が内部に滞留することを有効に防止し、清浄度の高い濾過流体を供給することが可能なセラミックスハニカムフィルタ及びその製造方法を提供することができる。
【図面の簡単な説明】
【図１】 図１（ａ）及び図１（ｂ）は、本発明のセラミックスハニカムフィルタの一の実施の形態を模式的に示す説明図であって、図１（ａ）はセラミックスハニカムフィルタの一部を切り欠いた斜視図、図１（ｂ）は中心軸を含む平面で切断した断面図である。
【図２】 図２（ａ）及び図２（ｂ）は、本発明のセラミックスハニカムフィルタの製造方法の一の実施の形態における、所定のセルに目詰材を充填する工程を工程順に示す断面図である。
【図３】 従来のセラミックスハニカムフィルタを模式的に示す断面図である。
【図４】 従来のセラミックスハニカムフィルタの製造方法における、所定のセルに目詰材を充填する工程を示す断面図である。
【符号の説明】
１…セラミックスハニカムフィルタ、２…隔壁、３…濾過膜、４…膜濾過セル、５…集水セル、６…外壁、７…集水スリット、８…目詰部材、９…シール部、１０…集水スリット付き未焼成フィルタ成形体、１１…フィルム、１２…所定のセル、１３…目詰材（目詰材スラリー）、１４…容器、２０…セラミックスハニカムフィルタ、２１…流通路（セル）、２１ａ…流通路（集水セル）、２１ｂ…流通路（膜濾過セル）、２２…濾過膜、２２ａ…固形成分、２２ｂ…水分、２３…空隙部（集水スリット）、２４…目詰部材、２５…濾過流体が滞留する部分（液溜まり）、２６…隔壁。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a ceramic honeycomb filter and a manufacturing method thereof. More specifically, the present invention relates to a ceramic honeycomb filter that can effectively prevent the fluid to be filtered and the filtration fluid from staying in the interior and supply a filtered fluid having a high cleanliness, and a method for manufacturing the ceramic honeycomb filter.
[0002]
[Prior art]
In recent years, a ceramic honeycomb filter having cells partitioned by porous partition walls has been used as a filter for solid-liquid separation or gas-solid separation. This ceramic honeycomb filter is superior in physical strength, durability, corrosion resistance, etc. compared to organic polymer membranes used in similar applications, and therefore has a wide range of applications in water treatment, exhaust gas treatment, pharmaceutical and food fields, etc. In such fields, it is suitably used for removing suspended substances, bacteria, dust, and the like in liquids and gases.
[0003]
In such a ceramic honeycomb filter, from the viewpoint of increasing the water flow rate and improving the filtration performance, as shown in FIG. 3, a large number of parallel flow passages formed in the longitudinal direction of the cylindrical porous body In order to form a filtration membrane 22 having a smaller pore diameter than the pores of the porous body on the inner peripheral surface of the (cell) 21 and to increase the amount of water flow from the flow passage near the center of the porous body, A slit-shaped gap (collection slit) 23 is provided in the longitudinal direction, and the edge of the flow passage (collection cell) 21 a communicating with the gap (collection slit) 23 is sealed with a clogging member 24. The fluid to be filtered supplied to the flow passage (membrane filtration cell) 21 b in which the filtration membrane 22 is formed is filtered by the filtration membrane 22, and the filtered fluid is flow passage (with the edge portion sealed by the clogging member 24 ( Cavity part (collection cell) 21a Ceramic honeycomb filter 20 capable of flowing out through the slit) 23 is proposed (e.g., see Patent Document 1).
[0004]
In the above-described ceramic honeycomb filter 20, the filtration performance is improved by forming the filtration membrane 22, and the water flow rate is increased by providing the gap portion (water collecting slit) 23.
[0005]
[Patent Document 1]
JP 2000-153117 A
[0006]
[Problems to be solved by the invention]
However, in the ceramic honeycomb filter described above, the clogging member 24 that seals the edge of the flow passage (water collection cell) 21a simply allows the fluid to be filtered to enter the flow passage (water collection cell) 21a. In other words, if the clogging member 24 is filled too deeply, the clogging member 24 filled in the flow passage (water collecting cell) 21a becomes the gap ( Since it protrudes from the (water collecting slit) 23 and causes a defect or troublesome correction, it has been filled only to the minimum necessary position that can prevent the infiltration of the fluid to be filtered. For this reason, in the flow passage (water collection cell) 21a, there is a portion (liquid reservoir) 25 in which the filtered fluid to be discharged is retained between the end of the clogging member 24 and the gap portion (water collection slit) 23. Was formed.
[0007]
For this reason, it has been a problem that a part of the filtration fluid stays in the liquid reservoir 25 described above, so that germs and the like propagate and contaminate the entire filtration fluid. In addition, the ceramic honeycomb filter 20 may be periodically cleaned with a chemical solution, but the chemical solution used for the cleaning stays in the liquid reservoir 25 and can be completely removed from the ceramic honeycomb filter 20. However, the accumulated chemical solution gradually diffuses and contaminates the filtered fluid. In addition, as shown in FIG. 4, in the film forming step of the filter membrane 22 constituting the ceramic honeycomb filter 20, the filter membrane slurry containing the solid component that becomes the filter membrane 22 is passed through a predetermined flow path (membrane filtration) under reduced pressure. Cell) 21b, and the solid component 22a contained in the poured filtration membrane slurry is attached to the inner surface of the flow passage (membrane filtration cell) 21b and then dried under atmospheric pressure. After the removal, the moisture 22b of the filtration membrane slurry stays in the liquid reservoir 25, and the moisture 22b of the filtration membrane slurry moves through the partition wall 26 along with the restoration to the atmospheric pressure after the film formation is completed. There has been a problem that the filtration membrane 22 just adhered to the inner surface of the passage (membrane filtration cell) 21b is lifted and peeled off.
[0008]
The present invention has been made in view of the above-described problems. A ceramic honeycomb filter capable of effectively preventing a fluid to be filtered and a filtering fluid from staying inside and supplying a filtering fluid having a high cleanliness, and a ceramic honeycomb filter therefor An object is to provide a manufacturing method.
[0009]
[Means for Solving the Problems]
In order to achieve the above object, the present invention provides the following ceramic honeycomb filter and a method for manufacturing the same.
[0010]
[1] A plurality of membrane filtration cells, which are partitioned by a porous partition wall made of ceramics and in which a filtration membrane is disposed, and which serve as a flow path for a fluid to be filtered; A plurality of water collection cells that are adjacent to the predetermined membrane filtration cell and serve as a flow path for the filtered fluid in which the fluid to be filtered is filtered by the filtration membrane, and an outer wall that surrounds the membrane filtration cell and the water collection cell And a portion of the outer wall at a predetermined length away from each end of the water collecting cell for flowing out the filtered fluid that has passed through the water collecting cell to the outside. A water collecting slit that passes through the water collecting cell and communicates with the other part of the outer wall, and a porous clogging member filled in a space from each end surface of the water collecting cell to the water collecting slit With this A ceramic honeycomb filter characterized by the above.
[0011]
[2] The ceramic honeycomb filter according to [1], wherein the plugging member is formed of a porous body in which a plurality of communication holes are formed.
[0012]
[3] The ceramic honeycomb according to [1] or [2], wherein the clogging member is formed of a porous material containing at least one material selected from the group consisting of alumina, mullite, selben, and cordierite. filter.
[0013]
[4] The ceramic honeycomb filter according to [2] or [3], wherein each of the plurality of communication holes formed in the clogging member has a portion having a hole diameter of 20 μm or less.
[0014]
[5] The ceramic honeycomb filter according to any one of [1] to [4], wherein the clogging member has a porosity of 25 to 50%.
[0015]
[6] The ceramic honeycomb filter according to any one of [1] to [5], wherein a thermal expansion coefficient of the plugging member is lower than or equal to a thermal expansion coefficient of the partition wall.
[0016]
[7] A group in which each of the cross-sections perpendicular to the flow direction of the fluid to be filtered of the plurality of membrane filtration cells is a circle, an ellipse, an oval, a triangle, a quadrangle, a pentagon, a hexagon, and a heptagon The ceramic honeycomb filter according to any one of [1] to [6], wherein the ceramic honeycomb filter has at least one shape selected from.
[0017]
[8] Each of the cross-sections perpendicular to the flow direction of the filtration fluid of the plurality of water collection cells is a group consisting of a circle, an ellipse, an oval, a triangle, a quadrangle, a pentagon, a hexagon, and a heptagon. The ceramic honeycomb filter according to any one of [1] to [7], which is at least one selected shape.
[0018]
[9] The raw material is extruded to obtain a green filter molded body having a predetermined shape having cells to be filtered and flow paths for the filtered fluid, and the obtained green filter molded body has one side surface of the green filter molded body. Forming a water collecting slit that penetrates the predetermined cell from the site to the other site to obtain a green filter molded body with a water collecting slit, to the obtained green filter molded body with the water collecting slit, A clogging material is filled into a space from each end face of the predetermined cell to reach the water collecting slit penetrating the predetermined cell to obtain a clogging material-filled unfired filter molded body. The clogging material-filled green filter molded body is fired to obtain a clogging material-filled filter molded body, and a filter membrane is formed on the inner peripheral surface of the predetermined cell constituting the obtained clogging material-filled filter molded body. It is characterized by firing after film formation A method for manufacturing a ceramic honeycomb filter.
[0019]
[10] The method for manufacturing a ceramic honeycomb filter according to [9], wherein the plugging material includes aggregate particles, an inorganic binder, a binder, a thickener, and a water retention agent.
[0020]
[11] The method for manufacturing a ceramic honeycomb filter according to [10], wherein the binder constituting the plugging material is included in an amount of 0.08 to 0.12 parts by mass with respect to 100 parts by mass of the aggregate particles.
[0021]
[12] The ceramic according to [10] or [11], wherein the thickener constituting the plugging material is included in an amount of 0.04 to 0.1 parts by mass with respect to 100 parts by mass of the aggregate particles. Manufacturing method of honeycomb filter.
[0022]
[13] The ceramic honeycomb filter according to any one of [10] to [12], wherein the water retention agent constituting the plugging material is included in 5 to 6 parts by mass with respect to 100 parts by mass of the aggregate particles. Manufacturing method.
[0023]
[14] Manufacturing the ceramic honeycomb filter according to any one of [9] to [13], wherein the filter membrane is formed on the plugging material-filled filter molded body, and then both end surfaces thereof are cut to a predetermined length. Method.
[0024]
[15] The above [10] to [14], wherein the aggregate particles constituting the plugging material are at least one compound selected from the group consisting of alumina, mullite, selben, and cordierite. Manufacturing method for ceramic honeycomb filter.
[0025]
[16] The above [10] to [15], wherein the inorganic binder constituting the plugging material is at least one compound selected from the group consisting of alumina, silica, zirconia, glass frit, feldspar, and cordierite. A method for producing a ceramic honeycomb filter according to any one of the above.
[0026]
[17] The binder according to any one of [10] to [16], wherein the binder constituting the plugging material is at least one compound selected from the group consisting of polyvinyl alcohol, polyethylene glycol, starch, and clay. Manufacturing method of ceramic honeycomb filter.
[0027]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of a ceramic honeycomb filter and a manufacturing method thereof according to the present invention will be specifically described with reference to the drawings.
[0028]
FIG. 1 (a) and FIG. 1 (b) are explanatory views schematically showing an embodiment of a ceramic honeycomb filter of the present invention, and FIG. 1 (a) is a perspective view with a part cut away. FIG. 1B is a cross-sectional view taken along a plane including the central axis. As shown in FIGS. 1 (a) and 1 (b), a ceramic honeycomb filter 1 of the present embodiment is partitioned by porous partition walls 2 made of ceramics, and a filtration membrane 3 is disposed therein. A plurality of membrane filtration cells 4 serving as flow paths for the fluid to be filtered and the partition wall 2 and adjacent to the predetermined membrane filtration cell 4 with the partition wall 2 interposed therebetween, and the fluid to be filtered is filtered by the filtration membrane 3 A plurality of water collection cells 5 that serve as flow paths for the filtration fluid, an outer wall 6 that surrounds the membrane filtration cell 4 and the water collection cell 5, and an outer wall 6 that flows out the filtered fluid that has passed through the water collection cell 5 to the outside. A water collection slit 7 that penetrates the water collection cell 5 from one part of the outer wall 6 to another part of the outer wall 6 at a position away from each end of each of the water collection cells 5 by a predetermined length; From each end of the water cell until it reaches the water collection slit 7 Characterized by comprising a Metsume member 8 of the porous filled in the space. In FIG. 1A, a cylindrical ceramic honeycomb filter 1 is shown. However, the shape of the ceramic honeycomb filter 1 of the present embodiment is not limited to a cylindrical shape, and is a plane perpendicular to the central axis. The shape of the cross-section in FIG.
[0029]
In the ceramic honeycomb filter 1 of the present embodiment, the fluid to be filtered flows into the membrane filtration cell 4 from the end face and passes through the filtration membrane 3 disposed inside the membrane filtration cell 4 to be filtered. The fluid is filtered, and the filtered fluid filtered by the filter membrane 3 flows into the water collection cell 5 through the porous partition wall 2 and enters the water collection slit 7 penetrating the water collection cell 5 from the water collection cell 5. It flows in and flows out from the opening of the water collecting slit 7 formed in the outer wall 6. Alternatively, a part of the filtered fluid filtered by the filter membrane 3 may flow out to the outside via the outer wall 6 as it is without flowing into the water collecting cell 5 from the partition wall 2. As described above, the ceramic honeycomb filter 1 of the present embodiment is configured to include the water collecting slit 7 so that the water flow resistance is reduced and the water permeability is excellent. Moreover, in the ceramic honeycomb filter provided with the conventional water collection cell, the part (liquid pool) in which the filtered fluid to flow out stays in the water collection cell between the end of the clogging member and the water collection slit When a part of the filtration fluid stays in the liquid reservoir, germs and other bacteria propagate to contaminate the entire filtration fluid, and the chemical used for cleaning the ceramic honeycomb filter stays in the liquid reservoir. However, in the ceramic honeycomb filter 1 of the present embodiment, the clogging member 8 is provided in each of the water collecting cells 5, although the staying chemical solution gradually diffuses and contaminates the filtered fluid. Since the space from the end surface to the water collecting slit 7 is filled, a portion where the filtration fluid, the chemical solution, or the like stays is not formed, and the filtration fluid is not contaminated.
[0030]
In the ceramic honeycomb filter 1 of the present embodiment, the fluid to be filtered flows directly from the partition wall 2 portion on the end face of the ceramic honeycomb filter 1 and is filtered by the filtration membrane 3 on the inner surface of the membrane filtration cell 4. In order to prevent the liquid from flowing out to the outside, a seal portion 9 is formed so as to cover the partition wall 2 on the end face of the ceramic honeycomb filter 1. The seal portion 9 is formed by applying a glaze such as silica glass on the end face of the ceramic honeycomb filter 1 and firing it.
[0031]
In the present embodiment, the position where the water collecting slit 7 is formed and the shape of the opening thereof are preferably set as appropriate depending on the size of the ceramic honeycomb filter 1. For example, the shape of the ceramic honeycomb filter 1 is cylindrical. When the end face has a diameter of 180 mm and an axial length of 1000 mm, the shape of the opening of the water collecting slit 7 formed in the outer wall 6 is an oval or square with a side length of 20 to 80 mm. Or it is preferable that it is a rectangle.
[0032]
The ceramic honeycomb filter 1 of the present embodiment is such that the clogging member 8 is filled in the space from each end face of the water collection cell 5 to the water collection slit 7. From the viewpoint of accuracy when filling the clogging member 8, “filled in the space from each end face of the water collection cell 5 to the water collection slit 7” means It means that the clogging member 8 is filled in a range of 80 to 100% from each end face of the water collection cell 5 in the space from each end face to the water collection slit 7. By comprising in this way, it becomes the ceramic honeycomb filter 1 which can prevent effectively that a to-be-filtered fluid and a filtration fluid remain in an inside, and can supply the filtration fluid with a high cleanliness.
[0033]
The partition walls 2 of the ceramic honeycomb filter 1 according to the present embodiment are, for example, a known honeycomb molding made of kneaded clay obtained by kneading an aggregated particle and an inorganic binder with an organic binder such as methylcellulose, a dispersing agent and water. It can be formed by extrusion molding with a machine. As the aggregate particles, at least one compound selected from the group consisting of alumina, mullite, selben, and cordierite can be suitably used. As the inorganic binder, at least one compound selected from the group consisting of alumina, silica, zirconia, titania, glass frit, feldspar, and cordierite can be suitably used.
[0034]
The clogging member 8 used in the present embodiment can preferably use the same material as that of the partition wall 2 described above. For example, at least one material selected from the group consisting of alumina, mullite, selben, and cordierite. It is preferable that it is formed from the porous material containing this. The clogging material (clogging material slurry) used in the manufacturing process is filled with the clogging member 8 from the respective end faces of the water collection cell 5 to the water collection slit 7 in the obtained ceramic honeycomb filter 1. As shown, it is preferable to use a binder, a thickener and a water retention agent. The configuration of the clogging material (clogging material slurry) will be specifically described when the method for manufacturing the ceramic honeycomb filter is described.
[0035]
The clogging member 8 is preferably rough enough to drain water contained in the filtration membrane slurry used when the filtration membrane 3 is formed. Specifically, a plurality of communication holes are provided. It is preferable that it is comprised from the formed porous body. Furthermore, when the clogging member 8 is composed of a porous body in which a plurality of communication holes are formed, each of the plurality of communication holes preferably has a portion having a hole diameter of 20 μm or less. Moreover, in this Embodiment, it is preferable that the porosity of the clogging member 8 is 25 to 50%. Each of the plurality of communication holes is used for forming the filtration membrane 3 when the pore diameter does not have a portion of 20 μm or less and / or when the porosity of the clogging member 8 exceeds 50%. The solid component contained in the filtration membrane slurry may pass through the clogging member 8 and enter the water collection cell 5. Further, when the porosity is less than 25%, it may be difficult to discharge moisture contained in the filtration membrane slurry used when the filtration membrane 3 is formed. The communication hole in the present embodiment is a pore communicating from one part of the surface of the clogging member 8 to another part. The clogging member 8 has a volume of 0.065 mm inside. Three It is preferable that it is uniformly filled so that there are no voids exceeding. Volume is 0.065mm Three In the case where there is an air gap exceeding 1, when the defective portion at the end of the ceramic honeycomb filter 1 is cut, irregularities may be formed on the cut surface. When irregularities are formed on the end face of the ceramic honeycomb filter 1, it may be difficult to uniformly apply glaze or the like when forming the seal portion 9. The porosity can be measured by a mercury intrusion method.
[0036]
Moreover, it is preferable that the thermal expansion coefficient of the clogging member 8 is lower than or equal to the thermal expansion coefficient of the partition wall 2. If the thermal expansion coefficient of the clogging member 8 is larger than the thermal expansion coefficient of the partition wall 2, the clogging member 8 may expand during firing and damage the partition wall 2.
[0037]
Moreover, in this Embodiment, although the case where each shape of the cross section perpendicular | vertical to the flow direction of the to-be-filtered fluid of the some membrane filtration cell 4 is a circle is shown, the shape of the membrane filtration cell 4 is this. For example, it is preferably at least one shape selected from the group consisting of a circle, an ellipse, an oval, a triangle, a quadrangle, a pentagon, a hexagon, and a heptagon. Further, the shape of each of the water collecting cells 5 is not limited to this, and the shape of each of the cross sections perpendicular to the flow direction of the fluid to be filtered is a circle. It is preferably at least one shape selected from the group consisting of a circle, an ellipse, an oval, a triangle, a quadrangle, a pentagon, a hexagon, and a heptagon.
[0038]
Moreover, it is preferable that the filtration membrane 3 arrange | positioned inside the membrane filtration cell 4 contains a titania, an alumina, or both. The filtration membrane 3 has an average pore size smaller than the average pore size of the partition wall 2, and for example, the average pore size is preferably 0.1 to 1.0 μm. Although not shown in the drawings, in the present embodiment, the filtration membrane is the above-described filtration membrane as an upper-layer filtration membrane, and an intermediate membrane having an average pore diameter in the middle between the partition wall and the upper-layer filtration membrane is provided. Furthermore, the structure provided may be sufficient.
[0039]
Next, a method for manufacturing the ceramic honeycomb filter of the present embodiment will be described. First, the raw material is extruded using, for example, a vacuum extrusion molding machine to obtain a green filter molded body having a predetermined shape having cells to be filtered and flow paths for the filtered fluid. The raw material is a kneader obtained by adding an organic binder such as methylcellulose, a dispersing agent and water to the aggregate particles and the inorganic binder described as a preferable material for the partition walls 2 of the ceramic honeycomb filter 1 shown in FIG. A clay kneaded using a kneader or the like can be suitably used.
[0040]
Next, on the obtained green filter molded body, a water collecting slit that penetrates a predetermined cell from one part of its side surface to communicate with another part is formed to form an unfired filter molded body with a water collecting slit. obtain. For example, the water collecting slit is formed by grooving the outer wall of the water collecting slit forming portion at the time of molding, breaking the outer water collecting cell wall with a grindstone or the like, and then breaking through the water collecting cell with a jig having a sharp tip. A slit can be formed. The water collecting slit secures about 25 mm as a part for disposing a sealing member that separates the fluid to be filtered and the filtering fluid at the end when the ceramic honeycomb filter as the final product is installed in a water purification facility or the like. In addition, in the film forming process of the filtration membrane described later, a failure occurs in the grip portion that grips the end face, and it is necessary to remove the portion where the failure has occurred by about 30 mm at the maximum, It is preferable to form it on the side surface of the unfired filter molded body with a water collecting slit that is about 55 mm away from the end surface. The process so far can be performed according to the conventional method for manufacturing a ceramic honeycomb filter.
[0041]
Next, as shown in FIGS. 2 (a) and 2 (b), the obtained unfired filter molded body 10 with water collecting slits penetrates the predetermined cell 12 from each end face of the predetermined cell 12. A clogging material (clogging material slurry) 13 is filled in the space up to the water collecting slit 7 to obtain a clogging material filled unfired filter molded body. Specifically, films 11 (masking) such as polyester are attached to both end faces of the unfired filter molded body 10 with water collecting slits, and holes are formed in portions corresponding to predetermined cells 12. After that, the end face to which the film 11 of the unfired filter molded body 10 with a water collecting slit is attached is pressed into the container 14 filled with the clogging material 13, and further pressurized with an air cylinder or the like, for example, 200 kg. A predetermined cell 12 is filled with a plugging material.
[0042]
As the clogging material 13 used in the present embodiment, the clogging material 13 can be filled in predetermined cells 12 until reaching the water collecting slit, so that the aggregate particles, the inorganic binder, the binder, It is preferable that it contains a thickener and a water retention agent. As the aggregate particles and the inorganic binder, those similar to the aggregate particles and the inorganic binder used when the green filter molded body is manufactured can be suitably used.
[0043]
The binder constituting the plugging material 13 has a function of giving dry strength at the time of drying the plugging material 13 and preventing the occurrence of cracks during drying, and is made of polyvinyl alcohol, polyethylene glycol, starch, and clay. It is preferably at least one compound selected from Moreover, it is preferable that 0.08-0.12 mass part of this binder is contained in the plugging material 13 with respect to 100 mass parts of aggregate particles. If the binder is less than 0.08 parts by mass, cracks may occur when the plugging material 13 is dried. Moreover, when a binder exceeds 0.12 mass part, the intensity | strength of the plugging material 13 will become high and a crack may generate | occur | produce in the unbaking filter molded object 10 with a water collection slit.
[0044]
The thickener constituting the plugging material 13 has an appropriate viscosity for the plugging material 13 so that the plugging material 13 can easily enter the predetermined cells 12 of the green filter molded body 10 with water collecting slits. It has a function of expression, and methylcellulose, carboxymethylcellulose and the like can be suitably used. Moreover, it is preferable that 0.04-0.1 mass part of this thickener is contained in the plugging material 13 with respect to 100 mass parts of aggregate particle | grains. If the thickener is less than 0.04 parts by mass, the clogging material 13 does not enter the predetermined cell 12 smoothly, and it may be difficult to fill the clogging material 13 to a predetermined depth. . Further, when the thickener exceeds 0.1 parts by mass, the depth of the plugging material 13 filled in each cell 12 is different, and it becomes difficult to uniformly fill the plugging material 13 to a predetermined depth. Sometimes.
[0045]
The water retention agent constituting the plugging material 13 prevents the moisture of the plugging material 13 from being absorbed and solidified by the dry green filter molded body 10 with a water collecting slit when the plugging material 13 is filled. In addition, the clogging material 13 has a function of uniformly entering the predetermined depth. As this water retention agent, starch, glycerin and the like can be suitably used. Moreover, it is preferable that 5-6 mass parts of this water retention agent is contained in the plugging material 13 with respect to 100 mass parts of aggregate particles. When the water retention agent is less than 5 parts by mass, when filling the plugging material 13, the moisture of the plugging material 13 is instantaneously absorbed by the unfired filter molded body 10 with a water collection slit, It may not be possible to fill to a predetermined depth. Moreover, when a water retention agent exceeds 6 mass parts, the clogging material 13 may not fully dry by drying before baking, and a crack may generate | occur | produce at the time of baking.
[0046]
Next, the obtained plug-filled unfired filter molded body is fired at, for example, 900 to 1400 ° C. to obtain a plug-filled filter molded body.
[0047]
Next, a filtration membrane is formed on the inner peripheral surface of a predetermined cell constituting the obtained plugging material-filled filter molded body, and then fired. As a method for forming a filtration membrane, for example, in the case of forming a filtration membrane composed of an intermediate membrane and an upper filtration membrane having a pore size smaller than that of the intermediate membrane, the first step is to form the intermediate membrane. An intermediate film slurry is formed. The intermediate film slurry is obtained by adding 400 parts by mass of water to 100 parts by mass of a ceramic raw material such as alumina, mullite, titania, cordierite, etc. having the same material as that of the unfired filter molded body, for example, having an average particle size of 3.2 μm Can be formed. In addition, an inorganic binder for a film may be added to the intermediate film slurry in order to increase the film strength after firing. As the inorganic binder for the film, clay, kaolin, titania sol, silica sol, glass frit and the like can be used, and the addition amount is preferably 5 to 20 parts by mass from the viewpoint of film strength. Further, when the film strength is obtained by sintering only with the ceramic raw material, it is not necessary to add the inorganic binder for the film. This intermediate film slurry is formed on the surface of each cell using the apparatus disclosed in JP-A-61-238315, dried, and then sintered at a predetermined firing temperature, for example, 900 to 1050 ° C. The intermediate film can be formed by being fixed to the clogging material-filled filter molded body.
[0048]
Next, an upper filtration membrane slurry for forming an upper filtration membrane is formed. The upper layer filtration membrane slurry is, for example, the same material as the green filter molded body having an average particle size of 0.4 μm, for example, a ceramic raw material such as alumina, mullite, titania, cordierite, or the thermal expansion coefficient of these ceramic raw materials. Can be formed by adding 1000 parts by mass of water to 100 parts by mass of a small material. In addition, an inorganic binder for membrane may be added to the upper filtration membrane slurry in order to increase the membrane strength after firing. As the inorganic binder for the film, clay, kaolin, titania sol, silica sol, glass frit and the like can be used, and the addition amount is preferably 5 to 20 parts by mass from the viewpoint of film strength. This upper layer filtration membrane slurry is formed on the surface of the intermediate film using an apparatus disclosed in JP-A-61-238315, dried and then sintered at a predetermined firing temperature of 900 to 1050 ° C. The filtration membrane can be formed by adhering to the intermediate film formed on the filler-filled filter molded body. In the present embodiment, since the clogging material configured as described above is filled in the space up to the water collection slit, the filtration membrane slurry (intermediate membrane slurry and upper filtration membrane slurry) It is possible to normally form the filtration membrane over the entire area of the predetermined cell without floating and peeling off the filtration membrane that has just been deposited and adhered to the liquid reservoir.
[0049]
In addition, as described above, when forming a filtration membrane, a defect may occur in the gripping portion that grips the end surface. Therefore, the end surface of the formed filter material-filled filter molded body is cut by about 30 mm. To do. Next, a glaze such as glass frit is applied to the end face of the clogging material-filled filter molded body that has been cut and newly formed, once dried, and then fired at 900 to 1400 ° C. to produce a ceramic honeycomb filter. . The glaze application and firing conditions and the like can be performed in accordance with conventional ceramic honeycomb filter manufacturing methods.
[0050]
The ceramic honeycomb filter thus obtained can effectively prevent the fluid to be filtered and the filtered fluid from staying inside, and can supply a filtered fluid with high cleanliness.
[0051]
【Example】
EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to these examples.
[0052]
(Examples 1-17)
Throughout all the examples, alumina having an average particle size of a predetermined size as aggregate particles and glass frit as an inorganic binder were mixed at a mass ratio of 9: 1, and with respect to 100 parts by mass of the obtained mixed powder Then, 15 parts by weight of water, 4.5 parts by weight of methylcellulose as an organic binder, and 1 part by weight of a dispersing agent were added and kneaded to obtain a clay. The obtained clay was extruded and formed by a honeycomb molding machine and then dried. Thus, an unfired filter molded body having an outer diameter of 180 mm, a length of 1000 mm, and 2070 inner diameter of 2.3 mm cells therein was obtained. In this embodiment, fused alumina having a raw material particle size of 0.2 to 0.5 mm and an alumina purity of 99.8% is pulverized in a dry process for a predetermined time, and those having an average particle size of 30 μm, 50 μm, and 100 μm are alumina. A, alumina B, and alumina C were used.
[0053]
Next, a water collecting slit that penetrates a predetermined cell from one part of the side surface of each green filter molded body and communicates with another part is formed to obtain a green filter molded body with a water collecting slit. . The shape of the water collecting slit was a rectangle.
[0054]
Next, the obtained unfired filter molded body with water collecting slits is filled with a clogging material in the space from each end face of the predetermined cell to the water collecting slit penetrating the predetermined cell. An unfired filter molded body filled with a plugging material was obtained. In each Example, what mixed aggregate particle | grains, the inorganic binder, the binder, the thickener, and the water retention agent in the ratio shown in Table 1 and Table 2 was used as a clogging material.
[0055]
[Table 1]
Figure 0003868391
[0056]
[Table 2]
Figure 0003868391
[0057]
In each Example, the ratio (%) of the closing defect of the clogging material in a state where the clogging material-filled unfired filter molded body was dried was measured. The closing defect of the clogging material is a defect in the dent at the center of the clogging material filling portion when moisture is supplied to the filling portion after the portion filled with the clogging material is dried. The ratio (%) of the closing defect of the plugging material is a value obtained by calculating the ratio (%) of the number of closing defects of the plugging material with respect to the number of cells filled with the plugging material. The results are shown in Tables 3 and 4.
[0058]
[Table 3]
Figure 0003868391
[0059]
[Table 4]
Figure 0003868391
[0060]
Next, the obtained clogging material-filled unfired filter molded body is fired to obtain a clogging material-filled filter molded body, and on the inner peripheral surface of a predetermined cell constituting the obtained clogging material-filled filter molded body The filter membrane was formed, dried and fired, and the end face was cut to a predetermined length. At this time, the dry processability of the fired clogging material-filled filter molded body was evaluated by confirming whether or not a spark would fly from the cutting blade that cuts each clogging material-filled filter molded body. The results are shown in Tables 3 and 4. If the amount of the inorganic binder contained in the plugging material is large, the strength of the fired plugging material-filled filter molded body will increase, and a spark may fly from the cutting blade during cutting, resulting in poor cutting performance. If it was able to cut well, it was marked as ◯, and some sparks were scattered, but if it was able to be cut well, it was marked as △. For those that became, ×. The results are shown in Tables 3 and 4.
[0061]
The occurrence rate (%) of cracks in the portions filled with the plugging material of the ceramic honeycomb filters of Examples 1 to 17 was measured. The crack generation rate (%) is a value obtained by calculating the ratio (%) of the number of cells in which cracks occur to the number of cells filled with the plugging material. The results are shown in Tables 3 and 4.
[0062]
Further, the pore diameter (μm) and the porosity (%) of the clogging member formed by firing the clogging material were measured. The results are shown in Tables 3 and 4.
[0063]
Also, the clogging material used for forming each ceramic honeycomb filter was cast into a block shape, cut out a test piece having a width of 10 mm, a thickness of 5 mm, and a length of 50 mm, and a three-point bending with a support distance of 30 mm. Strength measurements were made. The results are shown in Tables 3 and 4.
[0064]
Each ceramic honeycomb filter is immersed in water, the water collecting slit provided in the vicinity of one end face of each ceramic honeycomb filter is closed, air is sent from the other water collecting slit, and the pressure when foaming from each ceramic honeycomb filter is set. Measurement and foaming inspection were performed. The results are shown in Tables 3 and 4. The evaluation of the foaming test is as follows: when foaming is not seen from the clogging member and the outer wall when pressurized at 8 kPa, △ when foaming is not seen when pressurized at 6 kPa, and adding at 3 kPa. When foaming was observed when pressed, it was marked as x. The results are shown in Tables 3 and 4.
[0065]
Further, it was measured whether the filtered fluid stayed between the water collecting slit and the clogging member when the filtered fluid was introduced from one end face of each ceramic honeycomb filter for purification. When there was no retention, it was marked with ◯, and when there was retention, it was marked with ×. The results are shown in Tables 3 and 4.
[0066]
(Comparative Examples 1 and 2)
A predetermined position in the space from each end face of the predetermined cell to the water collecting slit penetrating the predetermined cell in the green filter molded body with the water collecting slit, in Comparative Example 1, 40 mm from the end face Up to the position (73% of the end face of the predetermined cell in the space from the end face of the predetermined cell to the water collecting slit), and in Comparative Example 2, the position of 35 mm from the end face (of the predetermined cell) Except that the clogging material is filled up to 64% from the end surface of the predetermined cell in the space from the end surface to the water collecting slit to obtain a clogging material-filled unfired filter molded body. A ceramic honeycomb filter was manufactured in the same manner as in the above example, and the same measurement was performed. Table 5 and Table 6 show the configuration of the plugging material and the results of each measurement.
[0067]
[Table 5]
Figure 0003868391
[0068]
[Table 6]
Figure 0003868391
[0069]
As shown in Table 3, Table 4, and Table 6, the ceramic honeycomb filters of Examples 1 to 17 have eyes in the space from each end surface of the predetermined cell to the water collecting slit that penetrates the predetermined cell. Since the filling material is filled, the filtration fluid does not stay in the above-described space, and the filtration fluid with high cleanliness can be supplied. Moreover, in the ceramic honeycomb filters of Examples 1 to 17, all of the excellent values were obtained in the ratio (%) of the closing defect of the plugging material, the dry processability, the crack generation rate (%), and the foaming inspection. Also, the pore diameter (μm) and the porosity (%) can be suitably used as a filter. In the ceramic honeycomb filters of Comparative Examples 1 and 2, since a liquid pool is formed between the water collecting slit and the clogging member, there is a retention of the filtration fluid, which causes contamination of the filtration fluid. Also, in the foaming inspection, foaming is observed when both are pressurized at 3 kPa, and when used as a filter, the fluid to be filtered passes through the foamed gap without being filtered through the filtration membrane. It would flow into the fluid and could not be used as a filter.
[0070]
【The invention's effect】
As described above, according to the present invention, a ceramic honeycomb filter capable of effectively preventing the fluid to be filtered and the filtered fluid from staying in the interior and supplying a filtered fluid with high cleanliness and a method for manufacturing the ceramic honeycomb filter are provided. can do.
[Brief description of the drawings]
FIG. 1 (a) and FIG. 1 (b) are explanatory views schematically showing an embodiment of a ceramic honeycomb filter of the present invention. FIG. 1 (a) is a diagram of a ceramic honeycomb filter. FIG. 1B is a cross-sectional view cut along a plane including the central axis.
FIGS. 2 (a) and 2 (b) are cross-sectional views showing, in order of steps, a process of filling a predetermined cell with a plugging material in an embodiment of a method for manufacturing a ceramic honeycomb filter of the present invention. FIG.
FIG. 3 is a cross-sectional view schematically showing a conventional ceramic honeycomb filter.
FIG. 4 is a cross-sectional view showing a process of filling a predetermined cell with a plugging material in a conventional method for manufacturing a ceramic honeycomb filter.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 ... Ceramic honeycomb filter, 2 ... Partition wall, 3 ... Filtration membrane, 4 ... Membrane filtration cell, 5 ... Water collection cell, 6 ... Outer wall, 7 ... Water collection slit, 8 ... Clogging member, 9 ... Sealing part, 10 ... Unfired filter molded body with water collecting slit, 11 ... film, 12 ... predetermined cell, 13 ... clogging material (clogging material slurry), 14 ... container, 20 ... ceramic honeycomb filter, 21 ... flow passage (cell), 21a ... flow passage (collection cell), 21b ... flow passage (membrane filtration cell), 22 ... filtration membrane, 22a ... solid component, 22b ... moisture, 23 ... void portion (collection slit), 24 ... clogging member, 25: A portion where the filtered fluid stays (liquid pool), 26: a partition wall.

Claims (17)

セラミックスからなる多孔質の隔壁によって区画され、その内部に濾過膜が配設された、被濾過流体の流路となる複数の膜濾過セルと、前記隔壁によって区画されるとともに前記隔壁を挟んで所定の前記膜濾過セルに隣接し、前記被濾過流体が前記濾過膜によって濾過された濾過流体の流路となる複数の集水セルと、前記膜濾過セル及び前記集水セルを取り囲む外壁と、前記集水セルを通過した前記濾過流体を外部に流出するための、前記外壁の前記集水セルのそれぞれの両端部から所定の長さ離れた箇所で、前記外壁の一の部位から前記集水セルを貫通して前記外壁の他の部位まで連通する集水スリットと、前記集水セルのそれぞれの端面から前記集水スリットに達するまでの空間内に充填された多孔質の目詰部材とを備えてなることを特徴とするセラミックスハニカムフィルタ。A plurality of membrane filtration cells that serve as a flow path for the fluid to be filtered, which are partitioned by a porous partition wall made of ceramics, and in which a filtration membrane is disposed, and are defined by the partition and sandwiching the partition A plurality of water collection cells which are adjacent to the membrane filtration cell and serve as a flow path for the filtered fluid in which the fluid to be filtered is filtered by the filtration membrane, an outer wall surrounding the membrane filtration cell and the water collection cell, and The water collection cell from one part of the outer wall at a location a predetermined length away from both ends of the water collection cell of the outer wall for flowing out the filtered fluid that has passed through the water collection cell to the outside A water collecting slit that penetrates through to the other part of the outer wall, and a porous clogging member filled in a space from each end face of the water collecting cell to the water collecting slit. Specially Ceramic honeycomb filter to. 前記目詰部材が、複数の連通孔が形成された多孔質体から構成された請求項１に記載のセラミックスハニカムフィルタ。The ceramic honeycomb filter according to claim 1, wherein the clogging member is composed of a porous body in which a plurality of communication holes are formed. 前記目詰部材が、アルミナ、ムライト、セルベン、及びコージェライトからなる群から選ばれる少なくとも一つの材料を含む多孔質材料から形成された請求項１又は２に記載のセラミックスハニカムフィルタ。The ceramic honeycomb filter according to claim 1 or 2, wherein the clogging member is formed of a porous material containing at least one material selected from the group consisting of alumina, mullite, selben, and cordierite. 前記目詰部材に形成された複数の前記連通孔のそれぞれが、孔径が２０μｍ以下の部位を有する請求項２又は３に記載のセラミックスハニカムフィルタ。4. The ceramic honeycomb filter according to claim 2, wherein each of the plurality of communication holes formed in the clogging member has a portion having a hole diameter of 20 μm or less. 前記目詰部材の気孔率が、２５〜５０％である請求項２〜４のいずれかに記載のセラミックスハニカムフィルタ。The ceramic honeycomb filter according to any one of claims 2 to 4, wherein the clogging member has a porosity of 25 to 50%. 前記目詰部材の熱膨張率が、前記隔壁の熱膨張率より低いか又は同一である請求項１〜５のいずれかに記載のセラミックスハニカムフィルタ。The ceramic honeycomb filter according to any one of claims 1 to 5, wherein a thermal expansion coefficient of the clogging member is lower than or equal to a thermal expansion coefficient of the partition wall. 複数の前記膜濾過セルの、前記被濾過流体の流れ方向に垂直な断面のそれぞれの形状が、円形、楕円形、長円形、三角形、四角形、五角形、六角形及び七角形からなる群から選ばれる少なくとも一つの形状である請求項１〜６のいずれかに記載のセラミックスハニカムフィルタ。Each of the plurality of membrane filtration cells having a cross-sectional shape perpendicular to the flow direction of the fluid to be filtered is selected from the group consisting of a circle, an ellipse, an oval, a triangle, a quadrangle, a pentagon, a hexagon, and a heptagon. The ceramic honeycomb filter according to any one of claims 1 to 6, wherein the ceramic honeycomb filter has at least one shape. 複数の前記集水セルの、前記濾過流体の流れ方向に垂直な断面のそれぞれの形状が、円形、楕円形、長円形、三角形、四角形、五角形、六角形及び七角形からなる群から選ばれる少なくとも一つの形状である請求項１〜７のいずれかに記載のセラミックスハニカムフィルタ。Each of the cross-sections perpendicular to the flow direction of the filtration fluid of the plurality of water collection cells has at least a shape selected from the group consisting of a circle, an ellipse, an oval, a triangle, a quadrangle, a pentagon, a hexagon, and a heptagon. The ceramic honeycomb filter according to any one of claims 1 to 7, wherein the ceramic honeycomb filter has one shape. 原材料を押出し成形して被濾過流体及び濾過流体の流路となるセルを有する所定形状の未焼成フィルタ成形体を得、
得られた前記未焼成フィルタ成形体に、その側面の一の部位から所定の前記セルを貫通して他の部位まで連通する集水スリットを形成して集水スリット付き未焼成フィルタ成形体を得、
得られた前記集水スリット付き未焼成フィルタ成形体に、所定の前記セルのそれぞれの端面から、所定の前記セルを貫通する前記集水スリットに達するまでの空間内に目詰材を充填して目詰材充填未焼成フィルタ成形体を得、
得られた前記目詰材充填未焼成フィルタ成形体を焼成して目詰材充填フィルタ成形体を得、
得られた前記目詰材充填フィルタ成形体を構成する所定の前記セルの内周面に濾過膜を成膜した後に焼成することを特徴とするセラミックスハニカムフィルタの製造方法。Extruding the raw material to obtain an unfired filter molded body having a predetermined shape having cells to be filtered and flow paths for the filtered fluid,
In the obtained green filter molded body, a water collecting slit that penetrates the predetermined cell from one part of its side surface to the other part is formed to obtain a green filter molded body with a water collecting slit. ,
Filling the obtained unfired filter molded body with the water collecting slit into a space from each end face of the predetermined cell to the water collecting slit penetrating the predetermined cell. Obtaining an unfired filter molded body filled with a clogging material,
Firing the obtained filler-filled green filter molded body to obtain a plug-filled filter molded body,
A method for producing a ceramic honeycomb filter, comprising: forming a filter membrane on an inner peripheral surface of a predetermined cell constituting the obtained filter material-filled filter molded body and firing the filter membrane. 前記目詰材が、骨材粒子、無機結合材、バインダー、増粘剤及び保水剤を含んだものである請求項９に記載のセラミックスハニカムフィルタの製造方法。The method for manufacturing a ceramic honeycomb filter according to claim 9, wherein the plugging material includes aggregate particles, an inorganic binder, a binder, a thickener, and a water retention agent. 前記目詰材を構成する前記バインダーが、前記骨材粒子１００質量部に対して、０．０８〜０．１２質量部含まれる請求項１０に記載のセラミックスハニカムフィルタの製造方法。The method for manufacturing a ceramic honeycomb filter according to claim 10, wherein the binder constituting the plugging material is included in an amount of 0.08 to 0.12 parts by mass with respect to 100 parts by mass of the aggregate particles. 前記目詰材を構成する前記増粘剤が、前記骨材粒子１００質量部に対して、０．０４〜０．１質量部含まれる請求項１０又は１１に記載のセラミックスハニカムフィルタの製造方法。The method for manufacturing a ceramic honeycomb filter according to claim 10 or 11, wherein the thickening agent constituting the plugging material is contained in an amount of 0.04 to 0.1 parts by mass with respect to 100 parts by mass of the aggregate particles. 前記目詰材を構成する前記保水剤が、前記骨材粒子１００質量部に対して、５〜６質量部含まれる請求項１０〜１２のいずれかに記載のセラミックスハニカムフィルタの製造方法。The method for producing a ceramic honeycomb filter according to any one of claims 10 to 12, wherein the water retention agent constituting the plugging material is contained in an amount of 5 to 6 parts by mass with respect to 100 parts by mass of the aggregate particles. 前記目詰材充填フィルタ成形体に前記濾過膜を成膜した後に、その両端面を所定の長さ切断する請求項９〜１３のいずれかに記載のセラミックスハニカムフィルタの製造方法。The method for manufacturing a ceramic honeycomb filter according to any one of claims 9 to 13, wherein both end surfaces of the filter membrane are cut to a predetermined length after the filter membrane is formed on the plugging material-filled filter molded body. 前記目詰材を構成する前記骨材粒子が、アルミナ、ムライト、セルベン、及びコージェライトからなる群から選ばれる少なくとも一つの化合物である請求項１０〜１４のいずれかに記載のセラミックスハニカムフィルタの製造方法。The ceramic honeycomb filter production according to any one of claims 10 to 14, wherein the aggregate particles constituting the plugging material are at least one compound selected from the group consisting of alumina, mullite, selben, and cordierite. Method. 前記目詰材を構成する前記無機結合材が、アルミナ、シリカ、ジルコニア、ガラスフリット、長石、及びコージェライトからなる群から選ばれる少なくとも一つの化合物である請求項１０〜１５のいずれかに記載のセラミックスハニカムフィルタの製造方法。The inorganic binder constituting the plugging material is at least one compound selected from the group consisting of alumina, silica, zirconia, glass frit, feldspar, and cordierite. Manufacturing method of ceramic honeycomb filter. 前記目詰材を構成する前記バインダーが、ポリビニルアルコール、ポリエチレングリコール、澱粉、及び粘土からなる群から選ばれる少なくとも一つの化合物である請求項１０〜１６のいずれかに記載のセラミックスハニカムフィルタの製造方法。The method for producing a ceramic honeycomb filter according to any one of claims 10 to 16, wherein the binder constituting the plugging material is at least one compound selected from the group consisting of polyvinyl alcohol, polyethylene glycol, starch, and clay. .
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