JP5277551B2 - Deodorizing filter - Google Patents
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- JP5277551B2 JP5277551B2 JP2007070579A JP2007070579A JP5277551B2 JP 5277551 B2 JP5277551 B2 JP 5277551B2 JP 2007070579 A JP2007070579 A JP 2007070579A JP 2007070579 A JP2007070579 A JP 2007070579A JP 5277551 B2 JP5277551 B2 JP 5277551B2
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- 230000001877 deodorizing effect Effects 0.000 title claims description 19
- 229910052751 metal Inorganic materials 0.000 claims abstract description 58
- 239000002184 metal Substances 0.000 claims abstract description 58
- 239000011230 binding agent Substances 0.000 claims abstract description 44
- 239000000843 powder Substances 0.000 claims abstract description 26
- 239000001267 polyvinylpyrrolidone Substances 0.000 claims description 5
- 235000013855 polyvinylpyrrolidone Nutrition 0.000 claims description 5
- 229920000036 polyvinylpyrrolidone Polymers 0.000 claims description 5
- 239000001768 carboxy methyl cellulose Substances 0.000 claims description 3
- 229920002134 Carboxymethyl cellulose Polymers 0.000 claims description 2
- 235000010948 carboxy methyl cellulose Nutrition 0.000 claims description 2
- 239000008112 carboxymethyl-cellulose Substances 0.000 claims description 2
- 239000003960 organic solvent Substances 0.000 claims description 2
- 125000000623 heterocyclic group Chemical group 0.000 abstract description 11
- 238000004332 deodorization Methods 0.000 abstract description 3
- 239000002002 slurry Substances 0.000 description 42
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 34
- YXFVVABEGXRONW-UHFFFAOYSA-N Toluene Chemical compound CC1=CC=CC=C1 YXFVVABEGXRONW-UHFFFAOYSA-N 0.000 description 24
- 239000011888 foil Substances 0.000 description 17
- 239000010410 layer Substances 0.000 description 12
- 229910052782 aluminium Inorganic materials 0.000 description 11
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 11
- 239000003054 catalyst Substances 0.000 description 9
- 239000003795 chemical substances by application Substances 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- WNROFYMDJYEPJX-UHFFFAOYSA-K aluminium hydroxide Chemical compound [OH-].[OH-].[OH-].[Al+3] WNROFYMDJYEPJX-UHFFFAOYSA-K 0.000 description 6
- AMWRITDGCCNYAT-UHFFFAOYSA-L hydroxy(oxo)manganese;manganese Chemical compound [Mn].O[Mn]=O.O[Mn]=O AMWRITDGCCNYAT-UHFFFAOYSA-L 0.000 description 6
- 238000003756 stirring Methods 0.000 description 6
- 239000000919 ceramic Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 238000001035 drying Methods 0.000 description 5
- 239000007789 gas Substances 0.000 description 3
- 238000005227 gel permeation chromatography Methods 0.000 description 3
- 238000005470 impregnation Methods 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000000691 measurement method Methods 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 2
- 125000000129 anionic group Chemical group 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 238000001179 sorption measurement Methods 0.000 description 2
- 239000002335 surface treatment layer Substances 0.000 description 2
- IXPNQXFRVYWDDI-UHFFFAOYSA-N 1-methyl-2,4-dioxo-1,3-diazinane-5-carboximidamide Chemical compound CN1CC(C(N)=N)C(=O)NC1=O IXPNQXFRVYWDDI-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 239000004375 Dextrin Substances 0.000 description 1
- 229920001353 Dextrin Polymers 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229910021536 Zeolite Inorganic materials 0.000 description 1
- DPXJVFZANSGRMM-UHFFFAOYSA-N acetic acid;2,3,4,5,6-pentahydroxyhexanal;sodium Chemical compound [Na].CC(O)=O.OCC(O)C(O)C(O)C(O)C=O DPXJVFZANSGRMM-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000003463 adsorbent Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000005238 degreasing Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 235000019425 dextrin Nutrition 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000007429 general method Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 125000005842 heteroatom Chemical group 0.000 description 1
- 238000007654 immersion Methods 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 238000005342 ion exchange Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000007769 metal material Substances 0.000 description 1
- 229910044991 metal oxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 235000010981 methylcellulose Nutrition 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 235000014593 oils and fats Nutrition 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 239000000661 sodium alginate Substances 0.000 description 1
- 235000010413 sodium alginate Nutrition 0.000 description 1
- 229940005550 sodium alginate Drugs 0.000 description 1
- 235000019812 sodium carboxymethyl cellulose Nutrition 0.000 description 1
- 229920001027 sodium carboxymethylcellulose Polymers 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000010457 zeolite Substances 0.000 description 1
Landscapes
- Disinfection, Sterilisation Or Deodorisation Of Air (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Abstract
Description
本発明は、金属担体を構成する金属板表面に無機粉体が強固に担持された脱臭フィルタに関するものである。 The present invention relates to a deodorizing filter in which inorganic powder is firmly supported on the surface of a metal plate constituting a metal carrier.
従来、触媒、活性炭等の各種除去剤の担体として、セラミックペーパー等の無機繊維ペーパーをハニカム化したペーパーハニカム担体が広く用いられている（例えば特許文献１）。前記ハニカム担体は、構造上強度が高く、多くの除去剤を担持することができ、かつ、圧力損失が小さいという利点を有している。しかし、近年、装置の小型化、高性能化が進み、装置に組み込む脱臭フィルタの担体として、高強度、低圧力損失、かつ、小型の担体が望まれている。このため、セラミックペーパー等の代替材料が種々検討されている。中でも、アルミ箔等の金属箔はセラミックペーパーに比べて強度が高く、セラミックペーパーよりも厚みを薄くできるため、ハニカム化した場合、圧力損失を小さくすることができるという利点がある。そのため、アルミ箔等の金属箔をコルゲート加工して得られる金属ハニカム担体が種々検討されている（例えば特許文献２）。 Conventionally, as a carrier for various removing agents such as a catalyst and activated carbon, a paper honeycomb carrier obtained by honeycombing inorganic fiber paper such as ceramic paper has been widely used (for example, Patent Document 1). The honeycomb carrier is advantageous in that it has high structural strength, can carry a large amount of a remover, and has a small pressure loss. However, in recent years, downsizing and high performance of devices have progressed, and high strength, low pressure loss and a small size carrier are desired as a carrier for a deodorizing filter incorporated in the device. For this reason, various alternative materials such as ceramic paper have been studied. Among them, metal foils such as aluminum foil have higher strength than ceramic paper and can be made thinner than ceramic paper. Therefore, when honeycombed, there is an advantage that pressure loss can be reduced. Therefore, various metal honeycomb carriers obtained by corrugating metal foil such as aluminum foil have been studied (for example, Patent Document 2).
しかしながら、金属箔は、製造段階において、圧延する際に油脂等の有機物が付着するため、表面が撥水性を示す。一方で、ハニカム担体への各種除去剤の担持方法としては、一般的に、ハニカム担体を触媒、活性炭等の各種除去剤、および、バインダーを含有する水性スラリーに浸漬させた後に乾燥することが行われている。このため、金属箔の表面が撥水性であると、水性スラリーが担体に馴染まずハニカム担体への除去剤の担持量が少なくなるという問題がある。したがって、金属ハニカムを担体として用いる場合には、予め金属箔の表面を有機溶媒等で脱脂する等により清浄にする必要がある。しかしながら、このような作業を行うとコストがかさむと共にハニカム担体を接着しているバインダーが溶け出してハニカム担体の強度が低下するという問題がある。さらに、金属箔はセラミックペーパーと異なり繊維間の空隙がなく、平滑性に富むため、水性スラリー浸漬後に乾燥して除去剤を金属箔表面に担持させても、除去剤が表面から脱落し易いという問題がある。 However, the surface of the metal foil exhibits water repellency because organic substances such as oils and fats adhere to the metal foil during rolling in the manufacturing stage. On the other hand, as a method for supporting various removing agents on the honeycomb carrier, generally, the honeycomb carrier is dipped in an aqueous slurry containing various removing agents such as a catalyst and activated carbon and a binder and then dried. It has been broken. For this reason, if the surface of the metal foil is water-repellent, there is a problem that the aqueous slurry does not conform to the carrier and the amount of removal agent carried on the honeycomb carrier decreases. Therefore, when using a metal honeycomb as a carrier, it is necessary to clean the surface of the metal foil in advance by degreasing with an organic solvent or the like. However, when such an operation is performed, there is a problem that the cost is increased and the binder bonding the honeycomb carrier is melted and the strength of the honeycomb carrier is lowered. In addition, unlike ceramic paper, metal foil has no gap between fibers and is smooth, so even if it is dried after immersion in an aqueous slurry and the removal agent is supported on the surface of the metal foil, the removal agent is easily removed from the surface. There's a problem.
かかる問題を解決すべく、金属ハニカム担体の表面に、親水性樹脂及び無機バインダー固化物を含む表面処理層と、触媒、前記無機バインダー固化物及び有機バインダー固化物を含む触媒担持層とがこの順に形成されていることを特徴とする金属ハニカム触媒ユニットが開示されている（例えば、特許文献３）。しかしながら、触媒担持層の下に表面処理層が形成されているため、工程が多くコストが高くなるという問題と、金属ハニカム担体表面を少なくとも２層コートするため、圧力損失が高くなるという問題がある。また、触媒担持層に含有されるバインダー成分が多いため、触媒が被覆され十分な除去性能が得られないという問題がある。 In order to solve such a problem, a surface treatment layer containing a hydrophilic resin and an inorganic binder solidified product and a catalyst, a catalyst supporting layer containing the inorganic binder solidified product and an organic binder solidified product in this order on the surface of the metal honeycomb carrier. A metal honeycomb catalyst unit characterized by being formed is disclosed (for example, Patent Document 3). However, since the surface treatment layer is formed under the catalyst supporting layer, there are problems that the number of steps is high and the cost is high, and that at least two layers are coated on the surface of the metal honeycomb carrier, so that the pressure loss is high. . Moreover, since there are many binder components contained in a catalyst carrying layer, there exists a problem that a catalyst is coat | covered and sufficient removal performance is not obtained.
上述のとおり、安いコストで製造可能で、金属担体表面に無機粉体が強固に担持されており、強度が高く、圧力損失が低く、かつ、高性能な脱臭フィルタは見当たらないのが現状である。 As described above, it is possible to manufacture at a low cost, the inorganic powder is firmly supported on the surface of the metal carrier, the strength is low, the pressure loss is low, and there is no high-performance deodorizing filter at present. .
本発明は上記従来技術の課題を背景になされたものであり、安いコストで製造可能で、金属担体表面に無機粉体が強固に担持されており、強度が高く、圧力損失が低く、かつ、高性能な脱臭フィルタを提供することを目的とする。 The present invention has been made against the background of the above-described prior art, can be manufactured at a low cost, the inorganic powder is firmly supported on the surface of the metal carrier, has high strength, low pressure loss, and An object is to provide a high-performance deodorizing filter.
本発明者は上記課題を解決するため、鋭意研究した結果、遂に本発明を完成するに到った。すなわち本発明は、以下の通りである。
１．金属担体を構成する金属板表面に、少なくとも無機粉体および有機バインダーからなる層が形成されている脱臭フィルタ。
２．前記有機バインダーが水溶性である上記１に記載の脱臭フィルタ。
３．前記有機バインダーの平均分子量が２×１０４〜２×１０６である上記１または２に記載の脱臭フィルタ。
４．前記有機バインダーの分子鎖中に少なくとも複素環構造を含有する上記１〜３のいずれかに記載の脱臭フィルタ。
５．前記金属担体の表面に形成されている層中の有機バインダー量が０．５〜１０ｗｔ％である上記１〜４のいずれかに記載の脱臭フィルタ。
As a result of intensive studies in order to solve the above problems, the present inventors have finally completed the present invention. That is, the present invention is as follows.
1. A deodorizing filter in which a layer comprising at least an inorganic powder and an organic binder is formed on the surface of a metal plate constituting a metal carrier.
2. 2. The deodorizing filter according to 1 above, wherein the organic binder is water-soluble.
3. 3. The deodorizing filter according to 1 or 2 above, wherein the organic binder has an average molecular weight of 2 × 10 4 to 2 × 10 6 .
4). 4. The deodorizing filter according to any one of 1 to 3 above, which contains at least a heterocyclic structure in the molecular chain of the organic binder.
5. 5. The deodorizing filter according to any one of 1 to 4 above, wherein the amount of the organic binder in the layer formed on the surface of the metal carrier is 0.5 to 10 wt%.
本発明による金属フィルタは、（１）金属担体を構成する金属板表面に、少なくとも無機粉体および有機バインダーからなる層が形成されており、（２）前記有機バインダーが水溶性であり、（３）平均分子量が２×１０４〜２×１０６であり、（４）分子鎖中に少なくとも複素環構造を含有し、（５）金属板表面に形成されている層中の有機バインダー量が０．５〜１０ｗｔ％であるため、安いコストで製造可能で、金属担体表面に無機粉体が強固に担持されており、強度が高く、圧力損失が低く、かつ、高性能という利点を有する。 In the metal filter according to the present invention, (1) a layer comprising at least an inorganic powder and an organic binder is formed on the surface of a metal plate constituting the metal carrier, (2) the organic binder is water-soluble, (3 ) The average molecular weight is 2 × 10 4 to 2 × 10 6 , (4) contains at least a heterocyclic structure in the molecular chain, and (5) the amount of organic binder in the layer formed on the metal plate surface is 0 Since it is 5 to 10 wt%, it can be produced at a low cost, the inorganic powder is firmly supported on the surface of the metal carrier, and has the advantages of high strength, low pressure loss, and high performance.
以下、本発明を詳細に説明する。本発明における脱臭フィルタは、金属担体を構成する金属板表面に少なくとも、無機粉体および有機バインダーからなる層が形成されていることが好ましい。本発明において金属板とは板状の金属材料全てを含んでおり、通常の金属板を含む他、より厚さの薄い金属箔をも含むものである。金属板の厚さとしては、０．１ｍｍ以下のものが好ましい。さらに、好ましくは０．０１ 〜０．０５ｍｍのものである。もし、金属板の厚みが０．１ｍｍより大きければ、ハニカム化した場合の圧力損失が高くなり好ましくない。また、金属板の厚みが０．０１ｍｍ未満であれば、金属板の強度が低いためハニカム化が困難になるため好ましくない。金属板の材質としては、特に限定されず、例えば、アルミニウム、白金、ステンレス、銅等が挙げられる。好ましくは、アルミニウムである。アルミニウムは、軽量で、加工性がよく、硬さ、厚さの種類が豊富で、且つ、安価であるからである。また、耐腐食性を付加する等の目的で、金属板表面がエポキシ、アクリル等の樹脂でコートされていてもよい。 Hereinafter, the present invention will be described in detail. In the deodorizing filter of the present invention, it is preferable that at least a layer made of an inorganic powder and an organic binder is formed on the surface of the metal plate constituting the metal carrier. In the present invention, the metal plate includes all plate-like metal materials, and includes a normal metal plate and a metal foil having a smaller thickness. The thickness of the metal plate is preferably 0.1 mm or less. Furthermore, it is preferably 0.01 to 0.05 mm. If the thickness of the metal plate is larger than 0.1 mm, the pressure loss is increased when it is made into a honeycomb, which is not preferable. Further, if the thickness of the metal plate is less than 0.01 mm, it is not preferable because the strength of the metal plate is low and it becomes difficult to form a honeycomb. The material of the metal plate is not particularly limited, and examples thereof include aluminum, platinum, stainless steel, and copper. Aluminum is preferable. This is because aluminum is lightweight, has good workability, has many types of hardness and thickness, and is inexpensive. Moreover, the metal plate surface may be coated with a resin such as epoxy or acrylic for the purpose of adding corrosion resistance or the like.
本発明における脱臭フィルタの形状は、特に定めない。プリーツ状、ハニカム状等の一般的なフィルタの形状が用いられる。好ましくは、高強度、低圧力損失という特徴を有するハニカム形状である。 The shape of the deodorizing filter in the present invention is not particularly defined. Common filter shapes such as a pleated shape and a honeycomb shape are used. A honeycomb shape having characteristics of high strength and low pressure loss is preferable.
本発明における無機粉体は、特に定めない。例えば、活性炭、ゼオライト等の一般的な吸着剤、酸化マンガン等の金属酸化物等が挙げられる。好ましくは、活性炭、酸化マンガンである。活性炭は各種ガスに対する吸着能力が高く、また、酸化マンガンは各種ガスに対する分解能力が高いからである。 The inorganic powder in the present invention is not particularly defined. Examples thereof include general adsorbents such as activated carbon and zeolite, and metal oxides such as manganese oxide. Preferred are activated carbon and manganese oxide. This is because activated carbon has a high adsorption capacity for various gases, and manganese oxide has a high decomposition capacity for various gases.
本発明における有機バインダーは、水溶性であることが好ましい。前記バインダーが水溶性であれば、各種除去剤を含有する水性スラリー中に良分散させることができ金属板表面への無機粉体の担持が容易になるため、前記バインダーの添加量を少なくすることができるからである。もし、前記バインダーが水溶性でなければ、金属担体を構成する金属板表面に無機粉体を十分に強固に担持するためには、バインダー添加量を多くしなければならず、その結果、各種除去剤が有機バインダーにより被覆されてしまい、性能が低下するため好ましくない。 The organic binder in the present invention is preferably water-soluble. If the binder is water-soluble, it can be well dispersed in an aqueous slurry containing various removal agents, and it becomes easy to support inorganic powder on the surface of the metal plate, so the amount of the binder added should be reduced. Because you can. If the binder is not water-soluble, the amount of binder added must be increased in order to support the inorganic powder sufficiently and firmly on the surface of the metal plate constituting the metal carrier. Since the agent is covered with an organic binder and the performance is lowered, it is not preferable.
本発明における有機バインダーの平均分子量は２×１０４〜２×１０６であることが好ましい。より好ましくは、１×１０５〜２×１０６である。平均分子量が２×１０４〜２×１０６であれば、金属板表面に無機粉体を強固に担持することができることを本発明者は見出したからである。平均分子量が２×１０４未満であれば、十分に強固に担持するためにバインダー添加量を多くしなければならならず、その結果、各種除去剤が有機バインダーにより被覆されてしまい、性能が低下するため好ましくない。また、平均分子量が２×１０６より大きければ、水性スラリーの粘度が高くなり、無機粉体を均一に担持することができなくなり好ましくない。ここでいう平均分子量とは重量平均分子量のことを指す。重量平均分子量は、一般的に、ゲルパーミエーションクロマトグラフィー（ＧＰＣ）により測定することができる。 The average molecular weight of the organic binder in the present invention is preferably 2 × 10 4 to 2 × 10 6 . More preferably, it is 1 × 10 5 to 2 × 10 6 . This is because the inventor has found that when the average molecular weight is 2 × 10 4 to 2 × 10 6 , the inorganic powder can be firmly supported on the surface of the metal plate. If the average molecular weight is less than 2 × 10 4 , it is necessary to increase the amount of binder added in order to support it sufficiently firmly. As a result, various removal agents are coated with an organic binder, resulting in a decrease in performance. Therefore, it is not preferable. On the other hand, if the average molecular weight is larger than 2 × 10 6 , the viscosity of the aqueous slurry increases, and the inorganic powder cannot be uniformly supported, which is not preferable. The average molecular weight here refers to the weight average molecular weight. The weight average molecular weight can generally be measured by gel permeation chromatography (GPC).
本発明における有機バインダーは、分子鎖中に少なくとも複素環構造を含有することが好ましい。分子鎖中に少なくとも複素環構造を含有することにより、複素環構造の電子的な効果により、金属板表面と水性スラリーとの親和性、および、無機粉体と有機バインダーとの親和性が増し、金属板表面に無機粉体を強固に、かつ、均一に担持することができることを本発明者は見出した。もし、複素環構造がなければ、金属板表面と水性スラリー、および、無機粉体と有機バインダーとの親和性が低下するため、強固、かつ、均一に担持することが困難になるため好ましくない。複素環構造の環員数については特に定めないが、３〜６員環が好ましい。複素環構造に含有されるヘテロ原子については特に定めないが、酸素、窒素が好ましい。例えば、ポリビニルピロリドン、カルボキシメチルセルロース、メチルセルロース、アルギン酸ナトリウム、デキストリン等が挙げられる。 The organic binder in the present invention preferably contains at least a heterocyclic structure in the molecular chain. By containing at least a heterocyclic structure in the molecular chain, the electronic effect of the heterocyclic structure increases the affinity between the metal plate surface and the aqueous slurry, and the affinity between the inorganic powder and the organic binder, The inventor has found that the inorganic powder can be firmly and uniformly supported on the surface of the metal plate. If there is no heterocyclic structure, the affinity between the metal plate surface and the aqueous slurry, and between the inorganic powder and the organic binder is lowered, so that it is difficult to carry it firmly and uniformly, which is not preferable. The number of ring members in the heterocyclic structure is not particularly defined, but a 3-6 membered ring is preferable. The heteroatom contained in the heterocyclic structure is not particularly defined, but oxygen and nitrogen are preferred. For example, polyvinylpyrrolidone, carboxymethylcellulose, methylcellulose, sodium alginate, dextrin and the like can be mentioned.
本発明における金属板表面に形成されている層中の有機バインダー量は、０．５〜１０ｗｔ％であることが好ましい。１０ｗｔ％より多いと無機粉体が有機バインダーにより被覆され、無機粉体の特徴、例えば、吸着能力、触媒分解能力が低下してしまうため、好ましくない。また、０．５ｗｔ％より少ないと、金属板表面に十分に無機粉体を担持することができないため、好ましくない。 The amount of the organic binder in the layer formed on the metal plate surface in the present invention is preferably 0.5 to 10 wt%. If it is more than 10 wt%, the inorganic powder is coated with an organic binder, and the characteristics of the inorganic powder, for example, the adsorption ability and the ability to decompose the catalyst are deteriorated. On the other hand, if it is less than 0.5 wt%, it is not preferable because the inorganic powder cannot be sufficiently supported on the surface of the metal plate.
本発明における有機バインダーは、少なくとも非イオン性、アニオン性のいずれかを含有することが好ましい。有機バインダーが少なくとも非イオン性、アニオン性のいずれかを含有することにより、金属板表面と水性スラリーとの親和性、および、無機粉体と有機バインダーとの親和性が増し、強固に担持した均一な層を形成できることを本発明者は見出した。もし、有機バインダーがカチオン性であれば、金属板表面と水性スラリーとの親和性、および、無機粉体と有機バインダーとの親和性が低下し、強固に担持した均一な層を形成できなくなるため、好ましくない。 The organic binder in the present invention preferably contains at least either nonionic or anionic. When the organic binder contains at least nonionic or anionic, the affinity between the metal plate surface and the aqueous slurry and the affinity between the inorganic powder and the organic binder are increased, and the support is firmly supported. The present inventors have found that a simple layer can be formed. If the organic binder is cationic, the affinity between the metal plate surface and the aqueous slurry and the affinity between the inorganic powder and the organic binder will be reduced, and it will not be possible to form a strongly supported uniform layer. It is not preferable.
本発明における脱臭フィルタの製造方法については特に定めない。金属担体を、無機粉体、および、有機バインダーを含む水性スラリーと接触させた後に乾燥するといった一般的な方法を用いることができる。前記水性スラリーの固形分比率は、１０〜５０％、好ましくは２５〜５０％である。固形分比率が１０％未満であると金属板表面に無機粉体が十分に担持されなくなるため好ましくない。また、固形分比率が５０％を越えると増粘して水性スラリーの流動性が低下して含浸できなくなるため好ましくない。乾燥する際の温度は、通常６０〜２００℃、好ましくは１００〜１５０℃である。乾燥温度が２００℃を越えると、有機バインダーが劣化するため好ましくない。また、乾燥温度が６０℃より低いと、乾燥時間が長くなるため、コストが高くなり好ましくない。 The manufacturing method of the deodorizing filter in this invention is not specifically defined. A general method of drying after contacting a metal carrier with an aqueous slurry containing an inorganic powder and an organic binder can be used. The solid content ratio of the aqueous slurry is 10 to 50%, preferably 25 to 50%. When the solid content ratio is less than 10%, the inorganic powder is not sufficiently supported on the surface of the metal plate, which is not preferable. On the other hand, if the solid content ratio exceeds 50%, the viscosity is increased, the fluidity of the aqueous slurry is lowered, and impregnation is not possible. The temperature at the time of drying is 60-200 degreeC normally, Preferably it is 100-150 degreeC. When the drying temperature exceeds 200 ° C., the organic binder deteriorates, which is not preferable. On the other hand, if the drying temperature is lower than 60 ° C., the drying time becomes longer, which increases the cost and is not preferable.
本発明における脱臭フィルタは、コピー機等に用いられるオゾンフィルタ、ＶＯＣ除去フィルタ、冷蔵庫やトイレ脱臭機などに用いられる脱臭フィルタ等に使用できる。 The deodorizing filter of the present invention can be used for an ozone filter used for a copy machine or the like, a VOC removal filter, a deodorizing filter used for a refrigerator or a toilet deodorizer, and the like.
以下、実施例によって本発明の作用効果をより具体的に示す。下記実施例は本発明方法を限定する性質のものではなく、前・後記の趣旨に沿って設計変更することはいずれも本発明の技術的範囲に含まれるものである。 Hereinafter, the effects of the present invention will be described more specifically by way of examples. The following examples are not intended to limit the method of the present invention, and any design changes in accordance with the gist of the preceding and following descriptions are included in the technical scope of the present invention.
［トルエン除去性能の測定方法］
６０ｍｍφのガラス製カラムにハニカムサンプル（６０ｍｍφ、厚み２０ｍｍ）をセットし、そのカラム中にトルエン５ｐｐｍを含む温度２５℃、湿度５０ＲＨ％の空気を２ｍ／ｓの速度で通過させた。ハニカムサンプル通過前後のトルエン濃度をＦＩＤ付きガスクロマトグラフにて、１分毎に測定し、その通過前後の濃度変化からトルエン除去率を算出した。トルエン除去率が２０％になるまで、測定を続け、その経過時間、トルエン除去率よりトルエン総除去容量（ｇ）を算出し、それをハニカムサンプルの体積で割ることにより除去容量（ｇ／Ｌ）を算出した。
[Measurement method of toluene removal performance]
A honeycomb sample (60 mmφ, thickness 20 mm) was set on a glass column of 60 mmφ, and air having a temperature of 25 ° C. and a humidity of 50 RH% containing 5 ppm of toluene was passed through the column at a speed of 2 m / s. The toluene concentration before and after passing through the honeycomb sample was measured every minute with a gas chromatograph with FID, and the toluene removal rate was calculated from the change in concentration before and after passing through the honeycomb sample. The measurement is continued until the toluene removal rate reaches 20%, and the total removal capacity (g) of toluene is calculated from the elapsed time and toluene removal rate, and the removal capacity (g / L) is divided by the volume of the honeycomb sample. Was calculated.
［金属板の厚さの測定方法］
リニアゲージ（Ｄ−１０ＨＳ、尾崎製作所製）、および、デジタルカウンタ（Ｃ−７ＨＳ、尾崎製作所製）を用いて、金属板の厚みを測定した。
[Measurement method of metal plate thickness]
The thickness of the metal plate was measured using a linear gauge (D-10HS, manufactured by Ozaki Seisakusho) and a digital counter (C-7HS, manufactured by Ozaki Seisakusho).
［平均分子量の測定方法］
ＧＰＣ装置（ＨＬＣ−８１２０ＧＰＣ、東ソー株式会社製）、カラム（ＴＳＫｇｅｌシリーズ、東ソー株式会社製）を使用し、有機バインダーの重量平均分子量を求めた。
[Measurement method of average molecular weight]
The weight average molecular weight of the organic binder was determined using a GPC device (HLC-8120GPC, manufactured by Tosoh Corporation) and a column (TSKgel series, manufactured by Tosoh Corporation).
（実施例１）
厚さ０．０３ｍｍのアルミ箔を用いてハニカム（５００セル／ｉｎｃｈ２）を作製した。活性炭２５０ｇ（乾燥重量１２５ｇ）、水酸化アルミ９．５ｇ（乾燥重量９．５ｇ）、ポリビニルピロリドン（平均分子量４０，０００）２．９ｇ（乾燥重量２．７５ｇ）を１９５ｇのイオン交換水中に添加し、終夜撹拌し、十分に分散させることにより、水性スラリーを調整した。引き続いて、前記ハニカムを前記水性スラリーに浸漬し、水性スラリーがハニカム内部に十分に浸透したことを確認してから、ハニカムを引き上げた。エアーブローでハニカムから余分なスラリーを吹き落とした後、乾燥機内（１２０℃）で３時間乾燥させた。ハニカムサンプルの活性炭添着量は４９ｇ／Ｌであった。
Example 1
A honeycomb (500 cells / inch 2 ) was manufactured using an aluminum foil having a thickness of 0.03 mm. Activated carbon 250g (dry weight 125g), aluminum hydroxide 9.5g (dry weight 9.5g), polyvinylpyrrolidone (average molecular weight 40,000) 2.9g (dry weight 2.75g) was added to 195g ion-exchanged water. The aqueous slurry was prepared by stirring overnight and fully dispersing. Subsequently, the honeycomb was dipped in the aqueous slurry, and after confirming that the aqueous slurry had sufficiently penetrated into the honeycomb, the honeycomb was pulled up. After excess slurry was blown off from the honeycomb by air blow, the slurry was dried in a dryer (120 ° C.) for 3 hours. The amount of activated carbon attached to the honeycomb sample was 49 g / L.
（実施例２）
厚さ０．０３ｍｍのアルミ箔を用いてハニカム（５００セル／ｉｎｃｈ２）を作製した。活性炭２５０ｇ（乾燥重量１２５ｇ）、水酸化アルミ９．５ｇ（乾燥重量９．５ｇ）、ポリビニルピロリドン（平均分子量１，２００，０００）２．９ｇ（乾燥重量２．７５ｇ）を１９５ｇのイオン交換水中に添加し、終夜撹拌し、十分に分散させることにより、水性スラリーを調整した。引き続いて、前記ハニカムを前記水性スラリーに浸漬し、水性スラリーがハニカム内部に十分に浸透したことを確認してから、ハニカムを引き上げた。エアーブローでハニカムから余分なスラリーを吹き落とした後、乾燥機内（１２０℃）で３時間乾燥させた。ハニカムサンプルの活性炭添着量は５１ｇ／Ｌであった。
(Example 2)
A honeycomb (500 cells / inch 2 ) was manufactured using an aluminum foil having a thickness of 0.03 mm. Activated carbon 250g (dry weight 125g), aluminum hydroxide 9.5g (dry weight 9.5g), polyvinylpyrrolidone (average molecular weight 1,200,000) 2.9g (dry weight 2.75g) in 195g ion-exchanged water. The aqueous slurry was prepared by adding, stirring overnight and fully dispersing. Subsequently, the honeycomb was dipped in the aqueous slurry, and after confirming that the aqueous slurry had sufficiently penetrated into the honeycomb, the honeycomb was pulled up. After excess slurry was blown off from the honeycomb by air blow, the slurry was dried in a dryer (120 ° C.) for 3 hours. The activated carbon impregnation amount of the honeycomb sample was 51 g / L.
（実施例３）
厚さ０．０３ｍｍのアルミ箔を用いてハニカム（５００セル／ｉｎｃｈ２）を作製した。活性炭２５０ｇ（乾燥重量１２５ｇ）、水酸化アルミ９．５ｇ（乾燥重量９．５ｇ）、カルボキシメチルセルロースナトリウム（平均分子量２００，０００）２．９ｇ（乾燥重量２．７５ｇ）を１９５ｇのイオン交換水中に添加し、終夜撹拌し、十分に分散させることにより、水性スラリーを調整した。引き続いて、前記ハニカムを前記水性スラリーに浸漬し、水性スラリーがハニカム内部に十分に浸透したことを確認してから、ハニカムを引き上げた。エアーブローでハニカムから余分なスラリーを吹き落とした後、乾燥機内（１２０℃）で３時間乾燥させた。ハニカムサンプルの活性炭添着量は５５ｇ／Ｌであった。
(Example 3)
A honeycomb (500 cells / inch 2 ) was manufactured using an aluminum foil having a thickness of 0.03 mm. Activated carbon 250g (dry weight 125g), aluminum hydroxide 9.5g (dry weight 9.5g), sodium carboxymethylcellulose (average molecular weight 200,000) 2.9g (dry weight 2.75g) was added to 195g ion-exchange water. The aqueous slurry was prepared by stirring overnight and thoroughly dispersing. Subsequently, the honeycomb was dipped in the aqueous slurry, and after confirming that the aqueous slurry had sufficiently penetrated into the honeycomb, the honeycomb was pulled up. After excess slurry was blown off from the honeycomb by air blow, the slurry was dried in a dryer (120 ° C.) for 3 hours. The activated carbon impregnation amount of the honeycomb sample was 55 g / L.
（実施例４）
厚さ０．０３ｍｍのアルミ箔を用いてハニカム（５００セル／ｉｎｃｈ２）を作製した。活性炭２５０ｇ（乾燥重量１２５ｇ）、水酸化アルミ９．５ｇ（乾燥重量９．５ｇ）、ポリビニルピロリドン（平均分子量１，２００，０００）１１．６ｇ（乾燥重量１１ｇ）を２１５ｇのイオン交換水中に添加し、終夜撹拌し、十分に分散させることにより、水性スラリーを調整した。引き続いて、前記ハニカムを前記水性スラリーに浸漬し、水性スラリーがハニカム内部に十分に浸透したことを確認してから、ハニカムを引き上げた。エアーブローでハニカムから余分なスラリーを吹き落とした後、乾燥機内（１２０℃）で３時間乾燥させた。ハニカムサンプルの活性炭添着量は５２ｇ／Ｌであった。
Example 4
A honeycomb (500 cells / inch 2 ) was manufactured using an aluminum foil having a thickness of 0.03 mm. Activated carbon 250g (dry weight 125g), aluminum hydroxide 9.5g (dry weight 9.5g), polyvinylpyrrolidone (average molecular weight 1,200,000) 11.6g (dry weight 11g) were added to 215g ion-exchanged water. The aqueous slurry was prepared by stirring overnight and fully dispersing. Subsequently, the honeycomb was dipped in the aqueous slurry, and after confirming that the aqueous slurry had sufficiently penetrated into the honeycomb, the honeycomb was pulled up. After excess slurry was blown off from the honeycomb by air blow, the slurry was dried in a dryer (120 ° C.) for 3 hours. The amount of activated carbon attached to the honeycomb sample was 52 g / L.
（比較例１）
厚さ０．０３ｍｍのアルミ箔を用いてハニカム（５００セル／ｉｎｃｈ２）を作製した。活性炭２５０ｇ（乾燥重量１２５ｇ）、水酸化アルミ９．５ｇ（乾燥重量９．５ｇ）、ポリ酢酸ビニルエマルジョン（平均分子量１０，０００）５５ｇ（乾燥重量２７．５ｇ）を１８５ｇのイオン交換水中に添加し、終夜撹拌し、十分に分散させることにより、水性スラリーを調整した。引き続いて、前記ハニカムを前記水性スラリーに浸漬し、水性スラリーがハニカム内部に十分に浸透したことを確認してから、ハニカムを引き上げた。エアーブローでハニカムから余分なスラリーを吹き落とした後、乾燥機内（１２０℃）で３時間乾燥させた。ハニカムサンプルの活性炭添着量は４５ｇ／Ｌであった。
(Comparative Example 1)
A honeycomb (500 cells / inch 2 ) was manufactured using an aluminum foil having a thickness of 0.03 mm. Activated carbon 250g (dry weight 125g), aluminum hydroxide 9.5g (dry weight 9.5g), polyvinyl acetate emulsion (average molecular weight 10,000) 55g (dry weight 27.5g) were added to 185g ion-exchanged water. The aqueous slurry was prepared by stirring overnight and fully dispersing. Subsequently, the honeycomb was dipped in the aqueous slurry, and after confirming that the aqueous slurry had sufficiently penetrated into the honeycomb, the honeycomb was pulled up. After excess slurry was blown off from the honeycomb by air blow, the slurry was dried in a dryer (120 ° C.) for 3 hours. The amount of activated carbon attached to the honeycomb sample was 45 g / L.
（比較例２）
厚さ０．０３ｍｍのアルミ箔を用いてハニカム（５００セル／ｉｎｃｈ２）を作製した。活性炭２５０ｇ（乾燥重量１２５ｇ）、水酸化アルミ９．５ｇ（乾燥重量９．５ｇ）、ポリエチレン（平均分子量２，５００，０００）２７．５ｇ（乾燥重量２７．５ｇ）を２５０ｇのイオン交換水中に添加し、終夜撹拌し、十分に分散させることにより、水性スラリーを調整した。引き続いて、前記ハニカムを前記水性スラリーに浸漬し、水性スラリーがハニカム内部に十分に浸透したことを確認してから、ハニカムを引き上げた。エアーブローでハニカムから余分なスラリーを吹き落とした後、乾燥機内（１２０℃）で３時間乾燥させた。ハニカムサンプルの活性炭添着量は０ｇ／Ｌであった。
(Comparative Example 2)
A honeycomb (500 cells / inch 2 ) was manufactured using an aluminum foil having a thickness of 0.03 mm. 250 g of activated carbon (dry weight 125 g), aluminum hydroxide 9.5 g (dry weight 9.5 g), polyethylene (average molecular weight 2,500,000) 27.5 g (dry weight 27.5 g) were added to 250 g of ion-exchanged water. The aqueous slurry was prepared by stirring overnight and thoroughly dispersing. Subsequently, the honeycomb was dipped in the aqueous slurry, and after confirming that the aqueous slurry had sufficiently penetrated into the honeycomb, the honeycomb was pulled up. After excess slurry was blown off from the honeycomb by air blow, the slurry was dried in a dryer (120 ° C.) for 3 hours. The amount of activated carbon attached to the honeycomb sample was 0 g / L.
実施例１〜４、比較例１、２のハニカムサンプルを用いてトルエン除去性能測定を実施した。結果を表１に示す。表１より明らかなように、本発明である実施例１〜４は、非水溶性で、分子鎖内に複素環構造を有しておらず、平均分子量２０，０００未満の有機バインダーの場合（比較例１）、および、非水溶性で、分子鎖内に複素環構造を有しておらず、平均分子量２，０００，０００より大きい有機バインダーの場合（比較例２）と比較して除去容量が高いことが分かる。 Using the honeycomb samples of Examples 1 to 4 and Comparative Examples 1 and 2, toluene removal performance was measured. The results are shown in Table 1. As is clear from Table 1, Examples 1-4 according to the present invention are water-insoluble, have no heterocyclic structure in the molecular chain, and are organic binders having an average molecular weight of less than 20,000 ( Comparative Example 1) and removal capacity compared with the case of an organic binder that is water-insoluble, does not have a heterocyclic structure in the molecular chain, and has an average molecular weight of more than 2,000,000 (Comparative Example 2) Is high.
本発明における脱臭フィルタは、安いコストで製造可能で、金属担体表面に無機粉体が強固に担持されており、強度が高く、圧力損失が低く、かつ、高性能であり、コピー機等に用いられるオゾンフィルタ、ＶＯＣ除去フィルタ、冷蔵庫やトイレ脱臭機などに用いられる脱臭フィルタ等に使用できる。
The deodorizing filter according to the present invention can be manufactured at a low cost, the inorganic powder is firmly supported on the surface of the metal carrier, the strength is high, the pressure loss is low, and the performance is high. It can be used for an ozone filter, a VOC removal filter, a deodorization filter used for a refrigerator, a toilet deodorizer, and the like.
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| JPH02180644A (en) * | 1988-12-28 | 1990-07-13 | Aichi Steel Works Ltd | Catalyst and its preparation |
| JPH05103998A (en) * | 1991-10-15 | 1993-04-27 | Tanaka Kikinzoku Kogyo Kk | Formation of carrier layer on metal substrate |
| JPH0741748A (en) * | 1993-07-29 | 1995-02-10 | Mitsui Petrochem Ind Ltd | Water-dispersed adhesive |
| JPH07247400A (en) * | 1994-03-10 | 1995-09-26 | Kuraray Co Ltd | Aqueous emulsion |
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| JP2003160621A (en) * | 2001-08-08 | 2003-06-03 | Sumitomo Chem Co Ltd | Modified olefin-based copolymer |
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