WO1996008303A1

WO1996008303A1 - Deodorizing filter

Info

Publication number: WO1996008303A1
Application number: PCT/JP1995/001800
Authority: WO
Inventors: Satoru Kadowaki; Ikuo Taguchi; Kunio Okamoto
Original assignee: Nippondenso Co., Ltd.
Priority date: 1994-09-14
Filing date: 1995-09-11
Publication date: 1996-03-21
Also published as: GB2299034A; DE19581244T1; JP3728753B2; GB9610033D0

Abstract

A flexible porous material formed into a flat plate is used as a porous material (2) carrying adsorbents for adsorbing foul-odor components in gas. Slits (2a, 2b) are alternately formed in front and back sides of this porous material such that the slits are formed to a midway along the thickness in a thickness direction and the porous material is then extended in a plane direction to be formed into pleats wherein a bottom portion of a slit becomes an angle portion thereof. When compared with a flat plate-like material, the pleated porous material formed as above has a filtering area remarkably increased to reduce the flow velocity of air passing through the filter, to thereby reduce remarkably the pressure loss. Therefore, since there is generated extra margin in attainment of a target pressure loss, it is possible to increase the volume of adsorbents carried by the porous material, thereby making it possible to improve deodorizing performance remarkably.

Description

Description Deodorizing filter Technical field

TECHNICAL FIELD The present invention relates to a deodorizing filter used for deodorizing odorous gas, and is suitable as, for example, a deodorizing filter for adsorbing and removing malodorous components in air introduced into a living space such as a cabin of an automobile. Background art

In recent years, the desire for comfort in living spaces has increased, and deodorizing filters have been used in various places to remove odorous components. As a conventional deodorizing filter, for example, there is a filter in which activated carbon is supported on a urethane foam having a three-dimensional network structure, which is obtained by a method disclosed in Japanese Patent Application Laid-Open No. 61-138511. In addition, there are deodorizing filters having various shapes such as honeycomb, pleated (folded).

These deodorizing filters have different characteristics such as pressure loss, service life, deodorizing performance, and cost depending on the shape, structure, type of adsorbent carried, and the like. For this reason, deodorizing filters are used according to the usage environment.

However, the conventional deodorizing filter has the following problems. That is, the deodorizing filter generally has a relationship in which the higher the deodorizing performance, the higher the pressure loss, and the lower the pressure loss, the lower the deodorizing performance. Therefore, for example, the deodorizing filter in which activated carbon is supported on urethane foam, which is disclosed in the above-mentioned Japanese Patent Application Laid-Open No. 61-138511, is excellent in cost, service life, and deodorizing performance. However, high pressure loss limits the usable environment. Also, Japanese Patent Application Laid-Open No. 62-2010 discloses that the filter body of the deodorizing filter is provided with a large number of small holes penetrating the front and back surfaces in the ventilation direction to suppress an increase in pressure loss. Something like that has been proposed. However, In the prior art, there is a problem that the air passing through the small holes and the adsorbent of the filter body are incompletely contacted with each other, and the deodorizing effect is reduced. The present invention has been made in view of the problems of the related art, and has as its object to provide a deodorizing filter having high deodorizing performance and low pressure loss.

Another object of the present invention is to enable such a deodorizing filter to be easily manufactured at low cost. Disclosure of the invention

The present invention employs the following technical means to achieve the above object. That is, in the present invention, firstly, in a deodorizing filter constituted by using a porous material carrying an adsorbent that adsorbs malodorous components in a gas, the flexibility formed in a flat plate shape as the porous material Using porous material with

Slits are alternately formed on both sides of this porous material from the thickness direction to the middle of the thickness,

By stretching this porous material in the plane direction, the slit is formed in a pleated shape in which the bottom of the slit becomes a peak. The upper porous material is a porous material having a large number of cells composed of micropores, and is subjected to a communication process for removing a cell membrane so that gas can be communicated between the cells. That is, the porous material has a structure through which gas can pass.

As such a porous material, a foamed plastic such as urethane foam is suitable. As the adsorbent, powdered activated carbon, activated carbon fiber, silica gel, zeolite, aluminum hydroxide, an impregnated adsorbent obtained by treating the adsorbent with an adsorbent, and the like can be used.

According to the first feature of the present invention, since the porous material supporting the adsorbent is formed into a pleated shape, the material area is greatly increased as compared with a flat plate-shaped porous material. The flow velocity of the passing gas decreases, resulting in a large pressure loss descend.

Therefore, by forming the porous material in a pleated shape, a sufficient margin is achieved for achieving the target pressure loss, so that the amount of adsorbent carried can also be increased. Combined with the decrease in the flow rate of the gas passing through the material, the deodorizing performance can be significantly improved.

Furthermore, focusing on the good workability of a porous material with high flexibility, a simple operation of inserting a slit in the porous material and stretching it into a pleated shape provides high performance and low pressure. It is possible to easily obtain a deodorized filter having no loss, which is extremely advantageous also in terms of reduction of filter manufacturing cost.

In order to achieve both the reduction of the filter pressure loss based on the first feature of the present invention and the improvement of the deodorizing performance, it is preferable to implement the following specific embodiments.

The pleat pitch, which is the width between the pleated peaks, is preferably in the range of 3 to 20 mm, and more preferably in the range of 10 to 15 mm.

Further, the thickness of the pleated porous material is preferably in the range of 2 to 10 mm, and more preferably, in the range of 3 to 8 mm. The amount of the adsorbent supported on the pleated porous material per carrier volume is preferably in the range of 0.03 gZc c to 0.40 gZc c. The range of 0 g // cc to 0.20 gZc c is even more preferred. Further, the number of cells formed in the pleated porous material is preferably in the range of 6 to 20 per inch in length.

Secondly, in the present invention, in a deodorizing filter using a porous material having a deodorizing function, the porous material has a flat plate shape, and among the flat porous materials, an upstream side of a gas flow is provided. , There are many recesses,

It is characterized in that a low pressure loss portion is formed partially by the large number of recesses.

The low pressure loss part is for partially reducing the pressure loss when gas passes through the deodorizing filter, and is formed in a non-penetrating form on the upstream side of the gas flow. It has a concave shape.

The low pressure loss portion formed of the recess may be formed by a recess formed in a corrugated shape on the gas upstream side of the porous material.

The porous material preferably comprises a porous substrate and an adsorbent supported on the porous substrate. Thus, various porous materials and adsorbents can be freely combined.

Since the porous substrate has a flat plate shape, it is possible to use a porous glass, a binder having a porous structure, or the like, in addition to the foamed plastic.

In the deodorizing filter according to the second aspect of the present invention, since the flat porous material is provided with the low pressure loss portion formed of the recess, the gas passing through the low pressure loss portion receives much pressure loss. It can pass through the deodorizing filter without the need. Therefore, yet _c can be lower pressure loss of the entire filter, the low pressure drop section, from being formed into a concave shape in the form of non-through on the upstream side of gas flow, even at low pressure drop section, malodorous Since the gas containing the component always passes through the adsorbent-supporting portion and the malodorous component does not pass through the deodorizing filter, the deodorizing performance can be sufficiently secured.

Therefore, according to the present invention, a deodorizing filter having high deodorizing performance and low pressure loss can be provided.

Further, in the low pressure loss portion, the pressure loss reduction effect can be easily changed by adjusting the specific form such as the width and depth of the recess. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a porous material of a deodorizing filter according to Embodiment 1 of the present invention. FIG. 2 is a partially enlarged cross-sectional view of a porous substrate in the porous material of FIG. Fig. 3 (a) is an end view showing a state in which a slit is formed in the porous material in the first embodiment, and Fig. 3 (b) shows a state in which the slit-formed porous material is stretched in a pleated shape. It is an end elevation shown. FIG. 4 is an explanatory diagram showing a state in which the slit porous material of FIG. 3 is immersed in an adsorbent slurry. FIG. 5 is a partial cross-sectional view showing a state in which the deodorizing filter according to the first embodiment is mounted on the outer frame. It is. FIG. 6 (a) is a partial cross-sectional view showing another example of a state in which the deodorizing filter according to the first embodiment is mounted on the outer frame, and FIG. 6 (b) is a front view of the one-touch clamper alone. FIGS. 7A and 7B are partial cross-sectional views showing still another example of a state in which the deodorizing filter is assembled to the outer frame. FIG. 8 is a partial cross-sectional view showing still another example of a state in which the deodorizing filter is mounted on the outer frame. FIG. 9 is a graph showing the relationship between the thickness of a flat porous material and pressure loss as a comparative example of the present invention. FIG. 10 is a graph showing the relationship between flow velocity and pressure loss in a porous material. FIG. 11 is an explanatory diagram showing an example of specific dimensions of the pleated shape of the porous material in the first embodiment. FIG. 12 is a graph showing the toluene gas removal rates in Embodiment 1 and Comparative Example. FIG. 13 is a graph showing the relationship between the thickness of the urethane foam material as a porous material and the pressure loss. FIG. 14 is a graph showing the relationship between the pleated pitch of the pleated urethane foam and the amount of adsorbent carried and the pressure loss. FIG. 15 is a graph showing the relationship between the pressure loss and the thickness of the pleated urethane foam and the amount of adsorbent carried. FIG. 16 is a graph showing the relationship between the pleated pitch and thickness of the pleated urethane foam and the pressure loss. FIG. 17 is a graph showing the relationship between the pleat pitch and the amount of adsorbent carried on the pleated urethane foam and the toluene removal rate. FIG. 18 is a graph showing the relationship between the pitch and thickness of a pleated urethane foam and the toluene removal rate. FIG. 19 is a graph showing the relationship between the thickness of the pleated urethane foam, the amount of adsorbent carried, and the toluene removal rate. FIG. 20 is a partially enlarged cross-sectional view of the porous material of the deodorizing filter according to Embodiment 5 of the present invention. FIG. 21 is a perspective view of a porous material of a deodorizing filter according to Embodiment 5 of the present invention. FIG. 22 is a partially enlarged cross-sectional view of an example in which a through-hole is provided in a flat porous material as a comparative example of the present invention. FIG. 23 is a partially enlarged cross-sectional view of the porous material of the deodorizing filter according to Embodiment 6 of the present invention. FIG. 24 is a partially enlarged cross-sectional view of the porous substrate in the deodorizing filter according to the seventh embodiment. FIG. 25 is a partially enlarged cross-sectional view of the porous substrate in the deodorizing filter according to the eighth embodiment. BEST MODE FOR CARRYING OUT THE INVENTION

(Embodiment 1)

FIGS. 1 to 6 show a deodorizing filter according to Embodiment 1 of the present invention. As shown in FIGS. 1 and 2, a deodorizing filter 10 of this example is a porous material having a deodorizing function. The porous material 2 is composed of a porous base material 20 and an adsorbent supported on the porous base material 20 via a binder.

As the porous substrate 20, as shown in FIG. 2, a foamed plastic having a skeleton portion 23 and a large number of cells 25 formed of micropores formed therein, specifically a polyurethane foam, is used. Using. The number of the cells 25 may be any number from 6 to 20 per inch of length, but in this example, the number of cells 25 is 13 per inch (cell diameter 2.0 mm). Was used. The porous substrate 20 is subjected to a communication process for eliminating film adhesion between the cells 25 so that gas can pass between the cells 25.

The adsorbent adsorbs malodorous components in the gas. In this example, powdered activated carbon having a particle size of 5 to 30 m and a specific surface area of 1200 m ² / g was used. Therefore, the gas (gas) passes between the cells 25, during which time the odor in the gas is adsorbed by the adsorbent carried on the porous substrate 20.

Here, the specific surface area of the adsorbent is preferably 8 0 0~ 2 0 0 0 m 2 Z g. When the specific surface area exceeds ² 0 0 0 m 2, pore volume becomes excessively large, and decreases the density of the adsorbents themselves, the loading density when supported on the carrier there is a problem that are too low. On the other hand, if the specific surface area is less than 80 Om ² , there is a problem that the adsorption performance is too low.

The foamed plastic used as the porous base material 20 of the porous material 2 includes polyether polyurethane foam, polyester polyurethane foam, rubber foam, vinyl foam, polystyrene foam, acrylic foam, polyacetal foam, Nylon foam or the like can be used.

Next, a method for manufacturing the deodorizing filter according to the first embodiment will be described in detail. First, a porous material 2 formed in a flat plate shape as shown in FIG. 3 is prepared. FIG. 3 shows the shape of the end face of the flat porous material 2. In the figure, h indicates the material thickness of the porous material 2, and the material thickness h is, for example, 2 O mm.

Next, slits 2a and 2b are alternately formed on both the front and back surfaces of the porous material 2 from the thickness h direction to the middle of the thickness (plate thickness). As a method for forming the slits 2a and 2b, a method such as cutting with a metal cutter or cutting with a laser beam can be used. Here, the width (interval) t of the slits 2a and 2b is a dimension to be a filter thickness described later, and is, for example, 3 mm. The depth d of each of the slits 2a and 2b is, for example, 17 mm.

Next, as shown in FIG. 4, the porous material 2 with the slits 2a and 2b was placed in the adsorbent slurry A, which is a suspension containing the adsorbent (specifically, the powdered activated carbon). And the porous material 2 carries an adsorbent. Here, B is a container containing the adsorbent slurry A.

In preparing adsorbent slurry A, 100 parts by weight of powdered activated carbon (parts by weight, the same applies hereinafter) are mixed with 5 parts of ethylene vinyl dibenzoate copolymer emulsion as an activated carbon binder (binder) after slurry drying. 4400 parts, and water is preferably 200-500 parts.

If the ethylene-vinyl acetate copolymer emulsion (polyvinyl alcohol) is less than 5 parts, the dry strength of the ethylene-vinyl acetate copolymer emulsion (polyvinyl alcohol) is weak, and there is a problem that the activated carbon powder falls off. On the other hand, if it exceeds 40 parts, the pore coverage of the powdered activated carbon increases, and there is a problem that the adsorption capacity of the powdered activated carbon is deteriorated.

If the amount of water is less than 200 parts, the slurry concentration is too high.Therefore, there is a problem that the slurry does not uniformly penetrate into the urethane foam during the impregnation process. However, there is a problem that the slurry concentration is too low and the amount of the powdered activated carbon carried on the porous substrate 20 is reduced. Therefore, in this example, 35 parts of ethylene Z vinyl acetate copolymer emulsion (polyvinyl alcohol) and 400 parts of water were prepared based on 100 parts of powdered activated carbon. Examples of the binder include acrylemulsion, polyvinyl alcohol, polyvinyl acetal, vinyl chloride, acrylic ethylene copolymer, and acryl-styrene, in addition to the ethylene-vinyl alcohol copolymer emulsion. Copolymer, ether polyurethane resin, ether-ester polyurethane resin, polyester-urethane, urethane-based resin, methylcellulose, hydroxypropylmethylcellulose (NH, salt, Na salt), hot melt polyester, or An acid vinyl emulsion can be used, and all of these binders (binders) satisfy the required characteristics in that the powdered activated carbon is bonded (supported) to the porous substrate 20. Next, the porous material 2 impregnated with the slurry A is passed between two rollers to squeeze out excess slurry. Then, the porous material 2 is obtained by drying at 120 for 5 hours. In this porous material 2, the amount of adsorbent carried after drying (the amount of powdered activated carbon carried per carrier volume) is preferably in the range of 0.03 g Zcc to 0.40 g Zcc. If the amount of adsorbent carried is less than 0.3 g Zcc, the adsorption performance of malodorous components will be reduced, and if the amount of adsorbent exceeds 0.4 g / cc, the pressure loss of the Jfe odor filter will decrease. Has the problem of rising excessively.

Next, the porous material 2 supporting the adsorbent is lightly stretched in its plane direction C (see FIG. 3 (a), a direction perpendicular to the thickness direction h) to thereby obtain the porous material 2 as shown in FIG. 3 (b). A pleat shape in which the bottom 2c of the slits 2a and 2b becomes the peak 2d can be formed. Here, the pleated pitch p refers to the width between the ridges 2d of the pleated shape.

By adjusting the material thickness h, slit width t, and pleat pitch p, pressure loss and deodorization performance that meets the required specifications described below can be obtained within the product specification space (spec space). it can. Next, as shown in FIG. 5, the porous material 2 is housed and fixed in the filter outer frame 2e while keeping its pleated shape. The filter outer frame 2 e is formed of resin into a rectangular frame shape (opening shape), and the inner wall surface of the outer frame 2 e has a pleat direction (porous material 2) of the porous material 2 carrying the adsorbent. The end 2 f of FIG. 5 (in the left-right direction) and the pleated end surface of the porous material 2 (the end surface in the direction perpendicular to the paper surface of FIG. 5) are fixed by fixing means such as bonding. Thus, the deodorizing filter 10 is completed. This deodorizing filter 10 is detachably mounted in a ventilation path (ventilation duct) of an air conditioner for an automobile, an air cleaner for an automobile, or the like, and a gas containing an odorous component (in the direction of arrow D in FIG. 5). Air) is ventilated.

As means for fixing the pleated porous material 2 to the filter outer frame 2e, besides the bonding method as shown in FIG. 5 above, as shown in FIG. 6, an elastic material (resin, metal, etc.) as shown in FIG. Using the molded one-touch clamper 2 g, insert the elastically deformable mounting leg 2 h of the clamper 2 g into the end 2 f of the porous material 2 and the hole of the filter outer frame 2 e. The end 2f of the porous material 2 may be fixed to the filter outer frame 2e by locking the clamper 2g to the filter outer frame 2e.

As shown in FIG. 7, a support wall 2i is integrally formed adjacent to the inner wall surface of the outer frame 2e of the filter, and an end 2f of the pleated porous material 2 is formed on the support wall 2i. Fit the inside of the mountain. Then, an auxiliary frame 2 j for suppressing the peak of the end 2 f of the porous material 2 is provided, and both ends 2 k of the auxiliary frame 2 j are bonded and fixed to the outer frame 2 e of the film. Is also good. Further, as shown in FIG. 8, a support wall 2i is integrally formed adjacent to the inner wall surface of the filter outer frame 2e, and a locking claw 2m is integrally formed at a tip of the support wall 2i. Insert the end 2 f of the pleated porous material 2 between the filter outer frame 2 e and the support wall 2 i and lock the end 2 f with the locking claw 2 m at the tip of the support wall 2 i. Thereby, the end 2 f of the porous material 2 may be fixed to the outer frame 2 e of the filter.

Next, the operation and effect of the deodorizing filter of the present invention manufactured by the above manufacturing method will be described. Now, as the product specification space, in the case of vertical (200 mm) x horizontal (200 mm) x thickness (20 mm), the permissible pressure loss is calculated as follows: The gas flow rate = 3 m / s Now, consider the case where the pressure is suppressed to 65 Pa or less. This required specification is a very reasonable level for a vehicle air purifier. is there.

If this required specification is to be achieved with a flat porous material (flat urethane foam), the thickness will be as shown in Fig. 9. That is, Fig. 9 shows the pressure loss Pa on the vertical axis and the thickness of the porous material (urethane foam) on the horizontal axis, and the allowable pressure under the condition that the adsorbent loading amount is 0.065 gZc c. In order to achieve the target of loss ≤ 65 Pa, the number of cells should be 8.5 mm or less for 10 cells, the thickness should be 6.5 mm or less for 13 cells, and the number of cells should be 20 In this case, the thickness must be 3.5 mm or less.

As described above, when a flat porous material is used, the thickness must be set to a value sufficiently smaller than the thickness of the product specification space (20 mm) due to pressure loss. As a result, the product specification space cannot be fully utilized for improving the deodorizing performance, and the deodorizing performance is reduced.

On the other hand, in the present invention, by forming the porous material 2 carrying the adsorbent in a pleated shape, the area of the filter medium is greatly increased, and the flow velocity of the gas passing through the »medium is reduced, The pressure drop is greatly reduced.

FIG. 10 shows the effect of reducing the pressure loss according to the present invention. The horizontal axis shows the flow rate of the gas passing through the lagging material. When a flat porous material is used, the amount of adsorbent carried: 0. Under the conditions of 065 gZc c, the number of cells: 13, and the thickness: 5.0 mm, as shown by the solid line in ①, 圧力 Pressure loss increases in a substantially proportional relationship with the flow velocity of gas passing through the material. When the flow velocity is 3 m / s, the pressure loss becomes 50 Pa.

On the other hand, in the product of the present invention, when the porous material 2 supporting the adsorbent is formed into a pleated shape and the material area is increased, for example, three times as compared with the flat plate shape, the flow velocity of the gas passing through the material is increased. Is 3 times, that is, 1 mZs, and the pressure loss is 1 OPa, so that there is sufficient margin for the target pressure loss (65 Pa).

Thus, by forming the porous material 2 in a pleated shape, there is a margin for achieving the target pressure loss, so that the amount of adsorbent carried can be increased. Therefore, the increase in the amount of adsorbent carried and the low flow velocity of the gas passing through the base material In combination with the following, the deodorizing performance can be significantly improved.

The deodorizing performance of the product of the present invention will be described quantitatively based on experimental data. FIG. 11 shows an example of the pleated condition of the porous material 2. The multiplication factor of the base material area in Fig. 11 is the multiplication factor for a flat plate, and the porosity and urethane ratio are the ratios of the space and urethane foam in the product specification space.

In a deodorization performance experiment, a pleated shape having a urethane foam thickness t: 5 mm and a pleated pitch P: 10 mm was used as a representative example. On the other hand, as a comparative product, a plate-like foam with the number of cells: 10, the thickness t: 8.5 mm, the amount of activated carbon carried: 0.06 g Zcc was used, and the pressure loss was at the target level. 65 Pa was used.

The product of the present invention has a pleat shape as described above, and the conditions for matching the pressure loss with the comparative product are to increase the number of cells to 10 and the amount of activated carbon carried to 0.15 g Zcc. Was completed.

Referring next to pass gas removal rate measurements for evaluating deodorization performance, using a concentration 9 0 ppm toluene gas as a measurement gas, the gas flow rate: 1 at 5 0 m ^3, the present invention product measurement gas The sample gas was continuously passed through the sample and a comparative product, and the measured gas vagueness after the passage was measured over time using a gas chromatograph (manufactured by Hitachi, Ltd.).

From the measured values, the toluene removal rate is calculated using the following formula. Toluene removal rate-(toluene concentration before passing one toluene concentration after passing) Z concentration after passing X 100 (%)

The results are shown in Fig. 12 with the gas passage time (min) on the horizontal axis and the toluene removal rate (%) on the vertical axis. As can be understood from FIG. 12, it was confirmed that the toluene removal rate of the product of the present invention can be significantly improved as compared with the comparative product. As described above, in the present invention, it is possible to effectively utilize the given product specification space and to improve the deodorizing performance while satisfying the low pressure loss requirement.

Further, in the manufacturing method of the present embodiment, the characteristics and In other words, it takes advantage of good workability, flexibility, three-dimensional network structure, and good adsorbent loading, so it has good gas collision efficiency and excellent deodorization performance. Then, a simple operation of putting a slit into urethane foam and stretching it into a pleated shape makes it possible to easily obtain a high-performance, low-pressure-drop deodorizing filter.

Next, a preferred numerical range of the pleated shape of the porous material 2 which is a feature of the present invention will be described. First, Fig. 13 shows the relationship between the pressure loss of urethane foam material and the material thickness as a parameter of the number of cells. In the practical range of material thickness (thickness t 1 Omm), the number of cells is 8, 1 Since 0 and 13 show the same level of pressure loss, it can be seen that any number of cells may be used. The experimental conditions in Fig. 13 are that the flow velocity of the gas passing through the urethane foam material is 3 m / s.

Next, Fig. 14 shows the relationship between the pleat pitch p and the adsorbent load and the pressure loss. The experimental conditions in Fig. 14 were fixed at a thickness (slit width) t = 5 mm and the number of cells-10 cells. The gas flow rate is 3mZs.

In Fig. 14, the appropriate range of the pleat pitch p and the adsorbent load that satisfies the target pressure loss 65 Pa is p = 10 to 15 mm, and the adsorbent load-0.15 g / cc or less. I understand.

Next, Fig. 15 shows the relationship between the pleat-shaped thickness t and the amount of adsorbent carried, and the pressure loss.The experimental conditions in Fig. 15 are fixed at a pleat pitch p = 10 mm and the number of cells = 10 cells The gas flow rate is 3 mZs.

In Fig. 15, it can be seen that in order to satisfy the target pressure loss (65 Pa or less), it is appropriate to set the thickness t = 5 mm or less and the adsorbent load = 0.15 g / cc or less. .

Next, Fig. 16 shows the relationship between the thickness t of the pleated shape, the pleated pitch p, and the pressure loss.The experimental conditions in Fig. 16 are as follows: the number of cells-10 cells, the adsorbent carrying amount = 0.15 g / The flow rate of the gas is 3 m "s. In Fig. 16, in order to satisfy the target pressure loss (65 Pa or less), the thickness t = 5 mm or less, and the pleated pitch p == 10 to 15 mm is an appropriate range It turns out that it is an enclosure.

Although the experimental data in FIGS. 14 to 16 described above described the case where the target pressure loss was set to 65 Pa or less, if the target pressure loss changed, the thickness (thickness) was changed accordingly. Of course, the proper range of the t), the pleated pitch p, and the amount of adsorbent carried varies, and the deodorizing performance also changes according to the change of the proper range.

Next, the change in deodorization performance due to the change in the shape of the pliers and the amount of adsorbent carried will be described with reference to FIGS. 17 to 19. FIG. 17 shows the passage time of the pleated porous material (urethane foam) 2. It shows the one-pass removal rate after 15 minutes, and shows the change in toluene removal performance depending on the pleated pitch p and the amount of adsorbent carried. The experimental conditions were as follows: thickness t = 5 mm, number of cells −10, and gas flow rate 1 mZ s.

Figure 18 shows the change in toluene removal performance with pleated pitch p and thickness t. The experimental conditions were as follows: adsorbent load-0.15 g Z cc, number of cells-10, and gas flow rate of 1 mZ s.

Figure 19 shows the change in toluene removal performance depending on the amount of adsorbent carried and the thickness t. The experimental conditions were a pleat pitch p = 10 mm, the number of cells-10 and the gas flow rate was 1 s.

The preferred form of the pleated deodorizing filter according to the present invention is summarized as follows according to a specific numerical range.

(1) The number of cells per inch is preferably in the range of 6 to 20 cells. That is, the upper limit of the number of cells is preferably set to 20 or less in order to suppress an increase in pressure loss as shown in FIG. Also, if the lower limit of the number of cells is less than 6, there is a problem because the outer surface of the polyurethane foam material is too small, which leads to a decrease in deodorizing performance.

(2) The pleat pitch p is preferably in the range of 3 to 20 mm. In other words, the upper limit of the pre-pitch p is determined by suppressing the increase in pressure loss shown in Figs.

From the viewpoint of the deodorizing performance shown in 17 and 18, the thickness is preferably 20 mm or less. In addition, the lower limit of the pleated pitch p suppresses the rise in pressure loss shown in Figs. 14 and 16. In practice, it is preferable that the thickness be 3 mm or more.

More preferably, the pleated pitch p should be in the range of 10 to 15 mm based on the experimental results shown in FIGS.

(3) The thickness t is preferably in the range of 2 to 10 mm. In other words, the upper limit of the thickness t is preferably set to 10 mm or less for practical use in order to suppress an increase in pressure loss as shown in FIG. From the experimental results of the toluene removal performance shown in FIG. 19, the lower limit of the thickness t is preferably 2 mm or more for practical use.

More preferably, the thickness t is set to 8 mm or less based on the experimental results shown in FIG. Further, the lower limit of the thickness t is preferably 3 mm or more in order to secure the toluene removal performance shown in FIGS.

(4) The amount of adsorbent carried per carrier volume can be practically used in the range of 0.03 gZc c to 0.40 g / cc, but within that range, especially 0.10 g / cc to 0. A range of 20 g / cc is preferred. In other words, the upper limit of the amount of adsorbent carried is preferably practically 0.40 gZc c or less in order to suppress an increase in pressure loss. More preferably, the upper limit of the amount of adsorbent carried is determined to be 0.20 gZc c or less based on the experimental results of FIGS. 14 and 15 described above.

In addition, the lower limit of the amount of adsorbent carried is preferably practically not less than 0.03 g / cc in order to ensure deodorizing performance. More preferably, the lower limit of the amount of adsorbent carried is determined to be 0.10 OgZc c or more based on the experimental results of FIGS. 17 and 19 described above.

(Embodiment 2)

In Embodiment 1, the activated carbon used as the adsorbent was non-impregnated normal activated carbon to which no impregnating agent was added.In Embodiment 2, instead of this non-impregnated normal activated carbon, an impregnating agent was added. This impregnated activated carbon is used to support the impregnated activated carbon on the porous member 2, and thereafter, the porous member 2 is formed into a pleated shape by the same method as in the first embodiment. Among the above impregnating agents, the acidic gas-adaptive impregnating agents include 3-aminopropyltrihydrosilane, 7-aminopropyltriethoxysilane, argysidoxypropyltrimethoxysilane and N- (aminoethyl). Organic gay compounds such as aminopropyltrimethoxysilane, dimethyltrimethyl-silylamine, N- (yS-aminoethyl) -1-aminopropyl-1-trimethoxysilane;

Alternatively, an aniline compound such as aniline phosphate or aniline hydrochloride,

Alternatively, any of pyridine, toluidine, benzenamine light, and anthranilic acid was used.

In addition, basic gas-adaptive impregnating agents include L-tartaric acid, salicylic acid, picolinic acid, benzoic acid, phthalic acid, L-glutamic acid, succinic acid, maleic acid, cunic acid, gluconic acid, malic acid, fumaric acid, One of glutaric acid, itaconic acid, pimelic acid, adipic acid, glyceric acid and gallic acid was used. In addition, other metal salt compounds such as cobanolate, copper, manganese, chromium, iron, nickel, and titanium can be used as the adsorbent.

Otherwise, a deodorizing filter 1 was manufactured in the same manner as in the first embodiment. According to this example, the deodorant performance of the odorous gas such as hydrogen sulfide and acetoaldehyde was remarkably improved in the one using the acidic gas-adaptive impregnating agent. In addition, those using the basic gas-adaptive impregnant significantly improved the deodorizing performance of odorous gases such as ammonia. In addition, the same effects as in the first embodiment can be obtained.

(Embodiment 3)

Instead of the powdered activated carbon used in Embodiment 1, activated carbon fiber, silica gel, zeolite, aluminum hydroxide, sepiolite, or the like is used as an adsorbent.

Since the activated carbon fiber is a long fiber and does not uniformly enter the inside of the porous material 2 as it is, it is preferable to use a pulverized powder. According to this example, the activated carbon fibers have more fine pores than the powdered activated carbon, and accordingly, the toluene removal rate shown in the first embodiment is improved by about 20%. Otherwise, the same effect as in the first embodiment can be obtained.

(Embodiment 4)

In the first embodiment, the adsorbent is made into a slurry to be supported on a porous material (urethane foam) 2. Instead of this supporting method, a porous material is used. It is also possible to use a “dry supporting method” in which a binder is previously attached to the skeleton portion 23 of the material (urethane foam) 2 and the adsorbent is attached to the surface of the porous material by the binder.

Embodiment 4 will be specifically described below.

①Binder adhesion process

As the binder material, the same material as in the first embodiment can be used, but not limited to a water-soluble material, and an oil-based material such as a specially modified polymer can also be used. In this example, an ethylene Z vinyl acetate copolymer emulsion was used as the binder material.

The binder can be attached to a pleated porous material (urethane foam) 2 by using a spray method in which a binder spray liquid is applied by a sprayer, or a pleated porous material 2 by a sprayer. Roller method in which binder liquid is adhered by mouth, impregnation method in which pleated stretched porous material 2 is immersed in a container containing binder slurry, and porous material 2 is impregnated with binder Can be used.

In the impregnation method, as in FIG. 4, the porous material 2 may be impregnated with the binder slurry in a flat plate state before being pleated. In the impregnation method, unnecessary binder is squeezed out after the impregnation, and then air blow is performed to prevent clogging of the porous material 2.

② Adsorbent loading process

The particle size of the powdered activated carbon as the adsorbent is preferably in the range of 20 to 50 mesh. If the particle size is less than 20 mesh, the pressure loss increases, which is not preferable. On the other hand, when the particle size is 50 mesh or more, the amount of activated carbon carried becomes small, and the deodorizing performance is undesirably reduced.

As a method for supporting the adsorbent, the porous material 2 to which the binder is adhered is fixed in a state where the porous material 2 is stretched in a pleated shape, and powdered activated carbon is sprayed on the upper surface of the pleated porous material 2 and this The powdered activated carbon thus pressed is pushed into the inside of the porous material 2 by a stirrer. The loading amount of the adsorbent can be practically used in the range of 0.03 gZc c to 0.AO gZc c, but within that range, the range of 0.10 gZc c to 0.20 g / cc is the pressure. It is preferable from the viewpoint of suppressing loss and improving deodorizing performance. (Embodiment 5)

In all of Embodiments 1 to 4 described above, the porous material 2 is formed in a pleated shape to reduce the pressure loss and improve the deodorizing performance.'In Embodiment 5, as shown in FIGS. In the plate-shaped porous material 2, a large number of concave portions 32 formed in a concave shape such as a cylindrical shape are provided on the surface on the upstream side in the gas flow direction. To reduce the pressure loss of the deodorizing filter.

The porous material 2 in this example also includes a porous substrate 20 and an adsorbent supported thereon via a binder, as in the first to fourth embodiments. The materials of the binder and the adsorbent, and the support of the adsorbent The method and the like may be the same as those of the first to fourth embodiments.

As shown in FIG. 2, a urethane foam having a skeleton portion 23 and a number of cells 25 formed therein was used as the porous substrate 20. In this example, the number of the cells 25 is 13 per inch (cell diameter is about 2.0 mm). Communication processing is performed to eliminate film tension between cells. Therefore, the gas passes between the cells 25, during which time the odor in the gas is adsorbed on the porous substrate 20.

As shown in FIG. 21, the recess 32 has a diameter D that is approximately twice that of the cell 25, that is, 5 mm, and the recess 32 has a vertical interval P of 6 mm, as shown in FIG. 21. The horizontal spacing Q was 9 mm, and they were arranged regularly in the vertical and horizontal directions. The plate-shaped porous material 2 having the recesses 32 formed therein is immersed in an adsorbent slurry to support the adsorbent (powder activated carbon) on the porous material 2. In this porous material 2, the amount of powdered activated carbon supported per carrier volume was 0.05 gZc c.

In the deodorizing filter 110 of the present example, the gas passing through the recess 32 provided as the low pressure loss portion passes through the deodorizing filter without receiving much pressure loss. Therefore, the overall pressure loss can be reduced. The above recess 3 The gas passing through 2 does not pass through, but passes through the bottom wall portion of the recess 32 and is deodorized by the powdered activated carbon carried therein. Therefore, the deodorizing filter 10 of the present example can achieve low pressure loss while maintaining high deodorizing performance.

Incidentally, when the through-hole 3 is formed in the flat porous material 2 as in the comparative example shown in FIG. 22, a part of the offensive odor gas passes through the through-hole 3 without being adsorbed by the adsorbent. Therefore, the deodorizing performance tends to decrease.

In addition, since the low pressure loss portion in this example is concave, there is an effect that the pressure loss and the deodorizing performance can be easily adjusted depending on the degree of the concave shape (depth, diameter, cross-sectional shape, etc. of the concave shape).

As a method of forming the recess 32 as a low pressure loss portion in the fifth embodiment, in FIG. 20, a hole is formed halfway through the thickness method of the porous material 2 to form the recess 32. However, a hole is formed in the porous material 2 so as to penetrate the porous material 2 in a thickness manner, and a thin plate-shaped porous material is disposed on one surface of the porous material 2 to close one end of the through hole. The structure may be such that: It is a matter of course that the adsorbent is similarly carried on the thin flat porous material.

(Embodiment 6)

The present embodiment is characterized in that, as shown in FIG. 23, instead of the recesses 32 in the fifth embodiment, a corrugated recess 33 having a corrugated cross-sectional shape is provided in the porous material 2. . According to the present example, the same effect as in the fifth embodiment can be obtained by providing the low pressure loss portion by the corrugated recess 33. Further, the pressure loss and the deodorizing performance can be easily adjusted by selecting the shape degree of the corrugated recess 33.

(Embodiment 7)

In this example, instead of urethane foam as the porous base material 20 in Embodiments 1 to 6, as shown in FIG. 24, a bonded body 204 having a porous structure made of a porous ceramic was used. I have. The bonded body 204 having a porous structure has a number of voids 242 through which gas can flow between the bonded particles 241. The porous structure of the bonded body 204 is formed in a flat plate shape. By providing the cylindrical recessed portion 32 and the corrugated recessed portion 33 of the fifth and sixth embodiments in the combined structure 204 having the porous structure, the same effects as those of the fifth and sixth embodiments can be obtained. . If a material having an adsorbing effect (for example, a metal oxide) is used as the material of the binder 204, the deodorizing ability is further increased, and the effect of extending the life is obtained. In addition, the effect of improving filter strength and heat resistance can be obtained.

Further, when a binder obtained by binding a granular substance with a binder was used as the binder 204 having a porous structure, the same effect was obtained.

(Embodiment 8)

In this example, as shown in FIG. 25, a porous glass 205 was used as the porous substrate 20 in the seventh embodiment instead of the bonded body 204 having a porous structure. The porous glass 205 has a large number of pores 251 through which gas can be communicated. Others are the same as the seventh embodiment.

According to this example, as in the seventh embodiment, the porous glass itself has an adsorption effect, so that an effect of improving the deodorizing performance can be obtained. In addition, the effect of improving filter strength and heat resistance can be obtained. Industrial applicability

According to the present invention, a filter having a deodorizing ability for deodorizing odorous gas is constituted by a low pressure drop structure. It is suitable for use in deodorizing air conditioning air.

Claims

The scope of the claims

1. In a deodorizing filter composed of a porous material carrying an adsorbent that adsorbs malodorous components in gas,

A flexible porous material formed in a flat plate shape is used as the porous material,

A deodorizing filter characterized in that a bottom portion of the slit is formed into a pleated shape in which a bottom portion of the slit is formed as a mountain by stretching the porous material in a plane direction.

2. The deodorizing filter according to claim 1, wherein the porous material is made of foamed plastic.

3. The deodorizing filter according to claim 2, wherein the foamed plastic is polyurethane foam.

4. The pleated pitch, which is the width between the peaks of the pleated shape, is in a range of 3 to 20 mm, according to any one of claims 1 to 3, wherein Deodorizing filter.

5. The pleated pitch, which is the width between the peaks of the pleated shape, is in the range of 10 to 15 mm, according to any one of claims 1 to 3, wherein Deodorizing filter.

6. The deodorizing filter according to any one of claims 1 to 5, wherein a thickness of the pleated porous material is in a range of 2 to 10 mm.

7. The deodorizing filter according to any one of claims 1 to 5, wherein the thickness of the pleated porous material is in a range of 3 to 8 mm.

8. The amount of the adsorbent supported on the pleated porous material per carrier volume is in the range of 0.03 g / c; to 0.40 g / cc. The deodorizing filter according to any one of claims 1 to 7, characterized in that:

9. The loading amount of the adsorbent supported on the pleated porous material per carrier volume is in the range of 0.10 g / cc to 0.20 cc. 7. The deodorizing filter according to any one of Items 1 to 7.

10. The method according to any one of claims 1 to 9, wherein the number of cells formed in the pleated porous material is in a range of 8 to 20 cells per inch. Or 1 deodorizing filter Yuichi.

1 1. Form a flexible porous material into a flat plate,

Next, an adsorbent for adsorbing malodorous components in the gas is supported on the slit-attached porous material,

Next, a method for manufacturing a deodorizing filter, characterized in that the porous material is stretched in the plane direction to form a pleated shape in which the bottom of the slit is a mountain.

1 2. Form a flexible porous material into a flat plate,

Slits are alternately formed on both sides of this porous material from the thickness direction to the middle of the thickness.

Next, the porous material is stretched in the plane direction to form a pleated shape in which the bottom of the slit is a peak,

Next, a method for producing a deodorizing filter, wherein an adsorbent for adsorbing malodorous components in a gas is supported on the pleated porous material.

13. In a deodorizing filter using a porous material having a deodorizing function, the porous material has a plate shape, and among the plate-shaped porous material, a large number of concave portions are formed on the upstream side of the gas flow. Place is established,

A deodorizing filter characterized in that a low pressure loss part is partially formed by the plurality of recesses.

14. The deodorizing filter according to claim 13, wherein the porous material comprises a porous base material and an adsorbent supported on the porous base material.

15. The deodorizing filter according to claim 14, wherein the porous base material is any one of a foamed plastic, a porous glass, and a combination of porous structures.