JP4023023B2 - Manufacturing method of water softener - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a water softener. In particular, a method of manufacturing a water softener in which a resin container, a raw water tank portion, and a salt water tank portion are defined in a main body portion of the water softener when a plurality of divided bodies are joined and integrated by hot plate welding. About.
[0002]
[Prior art]
In recent years, household water softeners have been developed which remove hardness components from raw water and are used for domestic water such as drinking water, washing water and bathtub water. This home water softener mainly includes a resin cylinder filled with an ion exchange resin for removing hardness components, a raw water tank for storing raw water, and a salt water tank for storing salt water for regenerating the ion exchange resin. It consists of and.
[0003]
By the way, a filter for preventing and holding the ion exchange resin from flowing out, that is, a resin outflow preventing body is provided in the resin cylinder. The filter as the resin outflow prevention body is fixed with a screw or the like, but the material of the screw has to be made of SUS in order to solve the problem of corrosion. As described above, the number of assembling steps for the filter is large, and the material cost is high.
[0004]
Moreover, in the said salt water tank, the water-permeable member in which the salt for reproducing | regenerating the said ion exchange resin is mounted is provided. The water-permeable member includes a porous plate and a net bonded to the plate, and the plate and the net are bonded using an adhesive. And the means of mounting | wearing the water-permeable member comprised in this way in the said salt water tank via the suitable support member was performed. As described above, the number of steps for assembling the water-permeable member is increased, and labor is required for mounting the water-permeable member.
[0005]
[Problems to be solved by the invention]
In view of the above problems, an object of the present invention is to reduce the man-hours for assembling the filter and the water-permeable member in the production of a water softener.
[0006]
[Means for Solving the Problems]
The present invention has been made to solve the above-mentioned problems, and the invention according to claim 1 is an upper divided body made of a synthetic resin in which a main body portion of a water softener is divided in a transverse direction, a first intermediate divided portion. Each of the body, the second intermediate divided body and the lower divided body has a divided resin container, raw water tank and salt water tank, and when the divided bodies are joined and integrated, A water softener manufacturing method in which the resin container, the raw water tank part, and the salt water tank part are defined in a portion, wherein the resin container 6 in the second intermediate divided body 3 and the lower divided body 4 A slit-shaped lower plate 10 is interposed in the joint portion of the resin housing portion 6, and both joint surfaces of the second intermediate divided body 3 and the lower divided body 4 are joined by hot plate welding, and the first intermediate divided body 2 in the salt water A water-permeable member 12 having a structure in which a net 14 is sandwiched between porous plates 13 and 13 is interposed at a joint portion of the salt water tank portion 8 in the cup portion 8 and the second intermediate divided body 3, and the first intermediate portion Both joining surfaces of the divided body 2 and the second intermediate divided body 3 are joined by hot plate welding, and the resin accommodating portion 6 in the upper divided body 1 and the resin accommodating portion 6 in the first intermediate divided body 2 are joined. A slit-shaped upper plate 9 is interposed in the part, and both joint surfaces of the upper divided body 1 and the first intermediate divided body 2 are joined by hot plate welding .
[0008]
DETAILED DESCRIPTION OF THE INVENTION
Next, an embodiment of the present invention will be described. INDUSTRIAL APPLICABILITY The present invention can be suitably implemented in the manufacture of household water softeners for supplying soft water as domestic water, particularly home water softeners installed in relatively narrow bathrooms of apartment houses such as apartments.
[0009]
In the method of manufacturing a water softener according to the present invention, an upper divided body, a first intermediate divided body, a second intermediate divided body, and a lower divided body obtained by dividing the main body portion of the water softener in the transverse direction are used. Each of the divided bodies has a resin housing portion that is filled with an ion exchange resin, a raw water tank portion that stores raw water, and a salt water tank portion that regenerates the ion exchange resin in a divided state. And the said resin accommodating part, the said raw | natural water tank part, and the said salt water tank part are defined in the said main-body part by joining and integrating each said division body. Similarly, a slit-like lower plate that prevents the ion exchange resin from flowing out of the system is interposed at the joint between the resin housing portion in the second intermediate divided body and the resin housing portion in the lower divided body. Then, both joint surfaces of the second intermediate divided body and the lower divided body are joined by hot plate welding. On the other hand, a slit-like upper plate that similarly prevents outflow of the ion exchange resin out of the system is provided at the joint of the resin container in the upper divided body and the resin container in the first intermediate divided body. The both joint surfaces of the upper divided body and the first intermediate divided body are joined.
[0010]
Further, a water- permeable member for supporting salt is interposed at the joint of the salt water tank portion in the first intermediate divided body and the salt water tank portion in the second intermediate divided body , and the first intermediate divided body And both the joint surfaces of said 2nd intermediate division body are joined. The water-permeable member has a structure in which a net is sandwiched between two porous plates.
[0011]
By the way, a synthetic resin is used as the material of each of the divided bodies. As a method for joining the respective divided bodies, a method in which heat bonding is performed by hot plate welding is applied. The method of thermocompression bonding by hot plate welding is another bonding method, for example, a method using an adhesive, a method of forming a flange portion on each divided body and fixing with a bolt, and reciprocating the divided bodies in opposite directions. The size of the main body part is not limited compared to the method of performing friction welding to move and weld, the method of spin welding to contact each of the divided bodies while rotating them, the method of ultrasonic welding, etc. The adhesive strength is high, and the formation of fine gaps at the joints can be reliably prevented, so there is no fear of water leakage and the like, which is preferable.
[0012]
【Example】
Hereinafter, specific embodiments of the present invention will be described in detail with reference to the drawings. First, FIG. 1 showing one embodiment of the present invention will be described. FIG. 1 is a cross-sectional explanatory view schematically showing the structure of an embodiment of a water softener manufactured according to the present invention.
[0013]
As shown in FIG. 1, in this embodiment, first, a space portion (reference numeral omitted) for forming a component forming portion is formed inside, and the entire body portion of the water softener is linearly divided in the transverse direction. The upper divided body 1, the first intermediate divided body 2, the second intermediate divided body 3, and the lower divided body 4 are respectively formed. Then, the whole component apparatus formation part is comprised in one container by joining each said division bodies 1-4. Specifically, the component device forming unit includes a resin container 6 filled with an ion exchange resin 5, a raw water tank unit 7 for storing raw water, and salt water for storing salt water for regenerating the ion exchange resin 5. This is a tank unit 8. Each of these parts is formed by partition walls (reference numerals omitted) that define these parts. Therefore, the resin container 6, the raw water tank 7, and the salt water tank 8 are in close contact with each other only through the partition wall. In the embodiment shown in FIG. 1, a specific example is shown in which the respective parts are closely arranged in a straight line in a plan view. However, the close arrangement is not limited to the arrangement in a straight line, and various close arrangements such as a triangular shape and a trapezoidal shape are possible.
[0014]
Now, at the time of the joining, a resin-made upper plate 9 is interposed in a slit shape at the joining part of the resin accommodating part 6 in the upper divided body 1 and the resin accommodating part 6 in the first intermediate divided body 2. The upper plate 9 is for preventing the ion exchange resin 5 from flowing out of the system, and functions as a resin outflow prevention body. A portion (reference numeral omitted) for fitting the upper plate 9 is provided on the upper surface of the partition wall defining the resin housing portion 6 in the first intermediate divided body 2. Further, a lower plate 10 is interposed at a joint portion between the resin housing portion 6 in the second intermediate divided body 3 and the resin housing portion 6 in the lower divided body 4. The shape, material and function of the lower plate 10 are the same as those of the upper plate 9. Furthermore, a portion (reference numeral omitted) for fitting the lower plate 10 is provided on the lower surface of the partition wall defining the resin accommodating portion 6 in the second intermediate divided body 3.
[0015]
At the time of joining, a water-permeable member 12 for holding the salt 11 is interposed at the joint of the salt water tank portion 8 in the first intermediate divided body 2 and the salt water tank portion 8 in the second intermediate divided body 3. Let The salt 11 is placed on the water-permeable member 12. Here, a portion (reference numeral omitted) for fitting the water-permeable member 12 is provided on the upper surface of the partition wall defining the second intermediate divided body 3. The water-permeable member 12 has a structure in which a resin net 14 is sandwiched between two porous resin plates 13 and 13.
[0016]
Next, the lines connected to the component device forming unit will be described. First, a raw water inlet 15 is provided at the lower part of the resin container 6, and a soft water outlet 16 is provided at the upper part of the resin container 6. A raw water line 17 is connected to the raw water inlet 15, and a soft water line 18 is connected to the soft water outlet 16. Further, a water supply inlet 19 is provided at the lower part of the raw water tank section 7, and the water supply inlet 19 and the raw water line 17 are connected by a water supply line 20.
[0017]
A replenishment water outlet 21 is provided at the lower part of the raw water tank unit 7, and a replenishment water inlet 22 is provided at the lower part of the salt water tank part 8. The makeup water outlet 21 and the makeup water inlet 22 are connected by a makeup water line 23.
[0018]
A raw water outlet 24 is provided at the lower part of the raw water tank unit 7, and a salt water outlet 25 is provided at the lower part of the salt water tank part 8. In addition, a salt water inlet 26 is provided on the upper portion of the resin housing portion 6. The salt water outlet 25 and the salt water inlet 26 are connected by a salt water flow line 27. Further, the salt water flow line 27 and the raw water outlet 24 are connected by a raw water flow line 28.
[0019]
On the other hand, a drain outlet 29 for discharging waste water generated during regeneration of the ion exchange resin 5 to the outside of the system is provided at the lower part of the resin container 6, and a drain line 30 is connected to the drain outlet 29. The
[0020]
Further, an overflow part 31 is provided in the upper part of the raw water tank part 7, and an overflow line 32 is connected to the overflow part 31. In addition, a salt charging port 33 is provided at the upper part of the salt water tank unit 8, and the salt 11 is appropriately charged from here.
[0021]
By the way, a synthetic resin is used as the material of each of the divided bodies. Hot plate welding is applied as a method for joining the divided bodies. This hot plate welding will be described in detail with reference to FIGS. In FIG. 2 and FIG. 3, the illustration of the respective entrances and the respective lines is omitted for the sake of simplification of the drawings. FIG. 2 is a schematic explanatory view showing a first step of hot plate welding of the upper divided body 1 and the first intermediate divided body 2, and FIG. It is a schematic explanatory drawing which shows two processes.
[0022]
In FIG. 2, a plurality of welding allowances 34, 34,... Are provided on the joint surfaces (that is, the upper surface and the lower surface of each partition wall) of both the divided bodies 1, 2. Each of these welding allowances 34 is for preventing the upper plate 9 from being directly heated. As shown in FIG. 2, first, a plate-like heater 35 is inserted between the joint surfaces of the two divided bodies 1 and 2. Each welding allowance 34 is brought into contact with a plate heater 35 and heated until the melting temperature of the synthetic resin is reached. Thereafter, as shown in FIG. 3, the heater 35 is removed, and both the joint surfaces are welded while applying pressure to the two divided bodies 1 and 2 from above and below. As a result, the welding allowances 34 are crushed and the two divided bodies 1 and 2 are firmly joined. Here, the upper plate 9 is not bonded to the two divided bodies 1 and 2 and is sandwiched between the divided opening portions of the resin housing portion 6 . That is, the upper plate 9 can be interposed by a simple method of only being loaded into the divided opening of the resin accommodating portion 6 at the time of joining, and after the interposition, there is no dropout or the like.
[0023]
And the joining of each divided body 1 to 4 is performed by first performing hot plate welding of the second intermediate divided body 3 and the lower divided body 4, and then joining the divided bodies 3 and 4 with the first one. It is carried out in the order of performing hot plate welding of one intermediate divided body and 2 and further performing hot plate welding of the above-mentioned divided bodies 2 to 4 and the upper divided body 1. The process is performed in the same manner as the two divided bodies 1 and 2.
[0024]
Further, the lower plate 10 was sandwiched between the divided opening portions of the resin housing portion 6 in the same manner as the upper plate 9 when the second intermediate divided body 3 and the lower divided body 4 were welded together. Intervened in state. Further, the water-permeable member 12 includes the second intermediate divided body 3 (that is, the upper joint surface of the second intermediate divided body 3 after the second intermediate divided body 3 and the lower divided body 4 are joined). When the hot plate is welded to the first intermediate divided body 2, it is interposed in the state of being sandwiched between the divided opening portions of the salt water tank portion 8, like the upper plate 9. Accordingly, the lower plate 10 and the water-permeable member 12 are also divided into the opening portion of the resin housing portion 6 and the divided salt water tank , as in the upper plate 9, without requiring any special assembly man-hours. It will be interposed by a simple method of only loading into the opening portion of the portion 8 .
[0025]
The water softener manufactured by the method described above contains the water containing step of passing raw water from the bottom of the resin containing portion 6 as an upward flow, and salt water having a predetermined concentration obtained by mixing saturated salt water and raw water. A water softening process is performed, which includes a regeneration process for flowing down into the section 6 and a water washing process for stopping the flow of salt water and flowing down only the raw water into the resin housing section 6.
[0026]
【The invention's effect】
As described above, according to the present invention, in the production of the water softener, the upper plate, it is possible to reduce the assembly steps of the lower plate and the water-permeable member, said upper plate, the lower plate and the water permeability The mounting strength of the members is increased, and the falling off of these parts can be prevented. Further, by performing hot plate welding , the joining strength of the divided body is increased, and thus the mounting strength of the component is further increased.
[Brief description of the drawings]
FIG. 1 is an explanatory cross-sectional view schematically showing the structure of an embodiment of a water softener embodying the present invention.
FIG. 2 is a schematic explanatory view showing a first step of hot plate welding of an upper divided body and a first intermediate divided body.
FIG. 3 is a schematic explanatory view showing a second step of hot plate welding of the upper divided body and the first intermediate divided body.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Upper division body 2 1st intermediate division body 3 2nd intermediate division body 4 Lower division body 6 Resin accommodating part 7 Raw water tank part 8 Salt water tank part 9 Upper plate 10 Lower plate 12 Water-permeable member

Claims (1)

Each of the upper divided body 1, the first intermediate divided body 2, the second intermediate divided body 3 and the lower divided body 4 made of synthetic resin obtained by dividing the main body portion of the water softener in the transverse direction is divided into resin housing parts 6, It has the raw water tank part 7 and the salt water tank part 8, and when the said division bodies 1-4 are joined and integrated, the said resin container part 6, the said raw water tank part 7, and the said salt water tank are integrated in the said main-body part. A method of manufacturing a water softener in which a portion 8 is defined, wherein a slit-like lower plate is formed at a joint portion of the resin housing portion 6 in the second intermediate divided body 3 and the resin housing portion 6 in the lower divided body 4. 10, both joint surfaces of the second intermediate divided body 3 and the lower divided body 4 are joined by hot plate welding, and the salt water tank portion 8 and the second intermediate divided body in the first intermediate divided body 2 are joined. Said salt water tank in 3 A water-permeable member 12 having a structure in which a net 14 is sandwiched between porous plates 13 and 13 is interposed at a joint portion of 8 and both joint surfaces of the first intermediate divided body 2 and the second intermediate divided body 3 are formed. The upper divided body is joined by hot plate welding, and a slit-like upper plate 9 is interposed between the resin accommodating portion 6 in the upper divided body 1 and the resin accommodating portion 6 in the first intermediate divided body 2. 1 and the first intermediate divided body 2 are joined to each other by hot plate welding.

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