JPH11333234A - Active carbon filter - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase the strength of a fibrous active carbon filter which is applicable for cleaning air or water without deteriorating the filtration performance of a mat and improve the workability by stitching the fibrous active carbon mat which is carbonized and activated. SOLUTION: A fibrous active carbon filter which is applicable for cleaning air or water is constituted of a fibrous active carbon mat 31 obtained by carbonizing and activating an unwoven fabric mat made of phenol resin or the like. In this case, the fibrous active carbon mat 31 is sewn with a reinforcing yarn 32 such as a filament yarn or a spun yarn, preferably e.g. in a checker pattern using a stitching or a quilting process. The thread count in the wales direction of the reinforcing yarn 32 is set within the range of one pce/inch-28 pcs/inch. Further, the active carbon filter is constructed by integrally stitching the fibrous active carbon mat and a netlike tissue sheet laminated on one of the faces or both faces of the mat with the yarn.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an improvement of a fibrous activated carbon filter used for air purification or water purification.

[0002]

2. Description of the Related Art Fibrous activated carbon mats obtained by carbonizing a nonwoven fabric mat made of fibers such as phenolic resin, acrylic resin, rayon, and pitch have been used as various filters. This activated carbon mat, compared to powdered activated carbon,
The specific surface area and the cumulative pore volume are large, and the filter performance is excellent. Activated carbon mats have the advantage that they do not require secondary processing, such as kneading with a binder and processing them into granules or honeycombs, like powdered activated carbon when producing a filter. Has excellent characteristics as a filter such that there is no drift of the fluid to be purified, for example, since it can be produced uniformly at a desired density. However, activated carbon mats have the drawback that they are weak in strength and easily fall off or break when they are processed into filters or used filters are regenerated, and are difficult to handle.

[0003]

SUMMARY OF THE INVENTION In view of the above, it is an object of the present invention to reinforce the strength and improve the workability of a carbon activated carbon fibrous mat without deteriorating its performance as a filter. I do.

[0004]

The activated carbon filter of the present invention is characterized in that a reinforcing yarn such as a filament yarn or a spun yarn is sewn into a carbon activated fibrous activated carbon mat by stitching or quilting. And Here, the number of reinforcing yarns driven in the wale direction is
It is preferable that the ratio is more than 1 line / inch and less than 28 lines / inch. If the number of implants exceeds the above range, the reinforcing effect is excellent, but the pressure loss increases, which adversely affects the performance as a filter. On the other hand, when the amount is less than the above range, the activated carbon fibers are remarkably dropped at the time of processing or regeneration and the reinforcing effect is small. The present invention also provides an activated carbon filter obtained by stitching and integrating a fibrous activated carbon mat activated by carbonization and a sheet having a net-like structure laminated on one or both sides thereof.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The material of the reinforcing thread to be sewn into the fibrous activated carbon mat of the present invention can be appropriately selected depending on the purpose of use of the filter, such as synthetic fiber, inorganic fiber and metal fiber. For example, heat-resistant fibers such as phenol fibers, aramid fibers, glass fibers, and metal fibers are effective when heat treatment is performed in a regeneration treatment step or when the filter is used at a high temperature. When pleats are required to have shape retention during pleating, synthetic fibers such as polypropylene, polyethylene, and polyester are effective. However, in this case, the heat setting temperature of the pleats needs to be around the melting point of the fiber or higher.

[0006] When the fibrous activated carbon mat has a low basis weight, a low density, or is highly activated, and its strength is extremely weak, the mats or stitches of the thread to be sewn are sufficient. May not be able to maintain the shape. In that case, on one or both sides of the mat,
A similar effect can be obtained by laminating sheets having a net-like structure and stitching the laminated body with yarn. The net-like sheet used here may be any of a knitted fabric, a woven fabric, a non-woven fabric, and a plastic net as long as it is open so as not to adversely affect the pressure loss.

According to the present invention, the strength can be reinforced and the workability can be improved without lowering the performance of the carbonized fibrous activated carbon mat. For example, when pleating a fibrous activated carbon mat, deformation and breakage of the mat due to tension can be prevented, the pleats can be given shape retention properties, and workability can be further improved. In addition, workability during various operations such as punching and cutting can be improved. The used activated carbon mat may be subjected to a regenerating process and repeatedly reused as a filter. The activated carbon mat is regenerated by a heat treatment or a washing treatment. According to the present invention, it is possible to provide an activated carbon mat reinforced so as not to adversely affect such a regenerating treatment and to prevent deformation and breakage. it can.

FIGS. 1, 2 and 3 show yarns 12 and 2 on fibrous activated carbon mats 11, 21 and 31, respectively.
9 shows an example of a stitch pattern that appears on the surface of the mat by sewing Nos. 2 and 32. FIG. 1 shows a linear pattern, FIG. 2 shows a zigzag tricot pattern, and FIG. 3 shows a lattice pattern. When stitching, the seam pattern is formed by a horizontal stitch, such as a zigzag pattern as shown in FIG. 2 or a lattice pattern as shown in FIG. 3, rather than a linear chain stitch as shown in FIG. The moving pattern is preferable because the damage to the activated carbon fiber is small and the effect of reinforcing the surface is large. In particular, in the case of a linear chain stitch, a phenomenon in which the activated carbon fiber cuts along the stitch eyes was observed, but in the pattern in which the seam moved in the horizontal direction, no cutting by the activated carbon fiber thread was observed. .
FIG. 4 is a schematic diagram showing a cross section of the fibrous activated carbon mat, in which a thread 42 is sewn to the mat 41. Also,
FIG. 5 is a schematic view showing a cross section of a fibrous activated carbon mat 51 in which a cold gauze 53 is laminated on one side and a thread 52 is sewn.

[0009]

The present invention will be described below in more detail with reference to examples. << Example 1 >> A needle-punched nonwoven fabric mat (30%) of 100% novoloid fiber having a fiber diameter of 14 μm and a fiber length of 70 mm
0 g / m ² ) in a nitrogen atmosphere at 1000 ° C. while supplying steam to carry out a carbonization activation treatment to give a basis weight of 160 g / m ² ).
A mat of activated carbon fibers of g / m ² was obtained. The specific surface area of the activated carbon mat was 2000 m ² / g. The mat has a nylon denier of 150 denier. Forty-eight filament yarns were woven using a stitch bond machine. The stitch pattern was a tricot pattern, the driving density in the wale direction was 14 / inch, and the stitch length in the flow direction was 2.0 mm. As a result, a stitch-bonded nonwoven fabric of activated carbon fibers having a configuration as shown in FIG. 4 reinforced with nylon yarn was obtained.

Example 2 Fiber diameter 14 μm, fiber length 70
mm of novoloid fiber 100% mat is carbonized and activated in the same manner as in Example 1 to obtain a basis weight of 160 g / m ^2.
Activated carbon fiber mat, polypropylene cold gauze (30
The number of 0 denier monofilaments to be driven is
10 wefts / inch) were laminated. Filament yarn was knitted into this laminate under the same conditions as in Example 1. That is, the stitch pattern is a tricot pattern, the driving density in the wale direction is 14 / inch, and the stitch length in the flow direction is 2.0 mm. As a result, a stitch-bonded nonwoven fabric having a configuration as shown in FIG. 5 was obtained in which the cold gauze was laminated on one side and further reinforced with nylon yarn.

<< Embodiment 3 >> A basis weight 16 similar to that of Embodiment 1
On both surfaces of the mat of the activated carbon fibers of 0 g / m @ 2, were laminated polyester spunbonded nonwoven fabric of basis weight 30 g / m ^2, respectively. Filament yarn was knitted into this laminate under the same conditions as in Example 1. As a result, a nonwoven fabric was laminated on both sides of the activated carbon fiber mat, and a stitch-bonded nonwoven fabric reinforced with nylon yarn was obtained.

Comparative Example 1 Fiber diameter 14 μm, fiber length 70
mm novoloid fiber 100% needle-punched nonwoven fabric mat (300 g / m ² ) in a nitrogen atmosphere.
Carbonization activation treatment was performed while supplying steam at 00 ° C. to obtain an activated carbon fiber mat having a basis weight of 160 g / m ² . The specific surface area of this activated carbon mat was 2000 m ² / g.

Comparative Example 2 Fiber diameter 14 μm, fiber length 70
The activated carbon fiber mat having a basis weight of 160 g / m ² was obtained by activating a 100% mm novoloid fiber mat. The mat has a nylon denier of 150 denier. Forty-eight filament yarns were woven using a stitch bond machine. The stitch pattern is a chain stitch pattern and the driving density in the wale direction is 1 strand / inc.
h, the stitch length in the flow direction was 2.0 mm. As a result, a stitch-bonded nonwoven fabric reinforced with nylon yarn was obtained.

Comparative Example 3 The stitch pattern is a tricot pattern, and the driving density in the wale direction is 28
Stitch processing was performed in the same manner as in Comparative Example 2 except that the thickness was changed to inch, and a stitch-bonded nonwoven fabric reinforced with nylon yarn was obtained.

Table 1 shows a comparison of the physical property values of the fibrous activated carbon nonwoven fabrics of the above Examples and Comparative Examples.

[0016]

[Table 1]

* 1: JIS L1096 A method (cut strip method), sample width 5 cm, chuck interval 20 cm,
The measurement was performed under the condition of a pulling speed of 15 cm / min. * 2: Measured under a flow rate of 3.0 m ³ / min. * 3: Measured under a flow rate of 6.0 m ³ / min. * 4: Judgment was made based on whether the activated carbon nonwoven fabric was broken by the reinforcing yarn.

[0018]

As described above, according to the present invention, a moderate strength filter is used, except that it is difficult to process the filter due to its low strength, and it is very difficult to handle the filter when it is to be regenerated. A fibrous activated carbon mat having strength can be obtained. As a result, the filter can be easily processed without deteriorating the performance as a filter, and the used filter can be regenerated.

[Brief description of the drawings]

FIG. 1 is a plan view of a fibrous activated carbon mat having a linear stitch pattern.

FIG. 2 is a plan view of a fibrous activated carbon mat having stitches in a zigzag tricot pattern.

FIG. 3 is a plan view of a fibrous activated carbon mat having stitches in a lattice-like atlas two reed pattern.

FIG. 4 is a schematic view showing a cross section of a fibrous activated carbon mat stitched.

FIG. 5 is a schematic view showing a cross section of a fibrous activated carbon mat in which a cold gauze is laminated on one side.

[Explanation of symbols]

 11, 21, 31, 41, 51 Fibrous activated carbon mat 12, 22, 32, 42, 52 Reinforcing yarn 53 Cold gauze

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Yohei Kawaguchi 2-6-10 Komyobashi, Chuo-ku, Osaka Dynic Corporation Osaka Branch

Claims (3)

[Claims] 1. An activated carbon filter characterized by stitching a carbon activated fibrous activated carbon mat with a yarn. 2. The wale direction driving density of the yarn on the fibrous activated carbon mat is more than 1 yarn / inch, and
2. The activated carbon filter according to claim 1, wherein the ratio is less than book / inch. 3. An activated carbon filter comprising a carbonized activated fibrous activated carbon mat and a sheet having a net-like structure laminated on one or both surfaces thereof, which are integrated by stitching with a thread.