WO2013001942A1 - フィルター成形体の製造方法 - Google Patents

フィルター成形体の製造方法 Download PDF

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Publication number
WO2013001942A1
WO2013001942A1 PCT/JP2012/063024 JP2012063024W WO2013001942A1 WO 2013001942 A1 WO2013001942 A1 WO 2013001942A1 JP 2012063024 W JP2012063024 W JP 2012063024W WO 2013001942 A1 WO2013001942 A1 WO 2013001942A1
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WIPO (PCT)
Prior art keywords
mold
molded body
filter molded
mixture
surface mold
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PCT/JP2012/063024
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English (en)
French (fr)
Japanese (ja)
Inventor
田中　康裕
松尾　陽
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株式会社タカギ
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Publication of WO2013001942A1 publication Critical patent/WO2013001942A1/ja

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/3042—Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
    • B01J20/20—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising free carbon; comprising carbon obtained by carbonising processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/3007—Moulding, shaping or extruding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/3035—Compressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/52—Heating or cooling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • B29C35/08—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation
    • B29C35/0805—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation
    • B29C2035/0855—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould by wave energy or particle radiation using electromagnetic radiation using microwave

Definitions

  • the present invention relates to a method for forming a filter molded body that removes contaminants and impurities by permeating water or air.
  • the adsorbent material such as activated carbon that adsorbs contaminants and impurities is combined with the adsorbent material into the desired shape.
  • a method of filling a mold with a mixture containing a binder for molding and heating it is known.
  • a mold comprising a side mold that molds a filter side surface, an upper mold that is attached to the side mold from above, and a lower mold that is attached to the side mold from below.
  • the module is filled with a mixture composed of an adsorbent and a binder composed of a heat-meltable low melt index resin, and the upper surface mold is pushed downward to pressurize the mixture.
  • the binder is melted by heating in an oven at 130 to 300 ° C. for 30 to 120 minutes, and the binder is removed from the oven, the bottom mold is pushed upward to pressurize the mixture, and then cooled to room temperature.
  • the filter molded body was manufactured by releasing from the mold.
  • the present invention has been made to solve the above-mentioned problems, and provides a method for producing a filter molded body that can shorten the heating time, has few restrictions on the type of binder, and can reduce the production cost. Let it be an issue.
  • the first invention includes a first step of filling a mold module with a mixture containing an adsorbing material and a hot-melt binder, a second step of heating the hot-melt binder in the mold module, and the mixture. And a third step of releasing the mold from the mold module, wherein the second step heats the mixture by irradiating microwaves.
  • the adsorbing material includes one or both of fibrous activated carbon and granular activated carbon
  • the heat-meltable binder is made of a heat-meltable polymer resin powder.
  • the third invention is characterized in that the adsorbing material contains both fibrous activated carbon and granular activated carbon.
  • a fourth invention is a method of manufacturing a filter molded body for molding a cylindrical filter molded body, wherein the mold module includes a side mold that defines an outer peripheral side surface of the filter molded body, and an upper end of the side mold.
  • An upper surface mold that defines the axial upper end of the filter molded body, a lower surface mold that defines the axial lower end of the filter molded body, and the side mold.
  • a shaft mold that forms a central space portion of the filter molded body.
  • the side mold is formed of two side molds, and a mating surface of the two side molds is the filter molded model. It is characterized by extending in the axial direction.
  • a fifth invention is a method of manufacturing a filter molded body for forming a cylindrical filter molded body, wherein the mold module includes a side mold that defines a side surface of the filter molded body, and an upper end of the side mold.
  • An upper surface mold that defines the upper end in the axial direction of the filter molded body, a lower surface mold that defines the lower end in the axial direction of the filter molded body;
  • a shaft mold that forms a central space portion of the filter molded body.
  • the upper surface mold, the lower surface mold, and the shaft mold act, and the upper surface mold and the lower surface mold It is characterized by applying a force to compress the mixture by reducing the distance between the molds.
  • the mixture in the second step, can be directly heated by irradiating microwaves to heat the mixture, so that the heating time can be greatly shortened.
  • the amount of heat required can also be reduced. Since the heating time can be shortened, the hot melt binder melted by heating for a long time moves downward according to gravity, and the uniform dispersibility of the hot melt binder is not lowered. For this reason, a hot-melt binder having a high melt index can also be used, and the manufacturing cost can be reduced.
  • the choice of the heat-meltable binder which can be used spreads, the freedom degree of design of a filter molded object improves, and it becomes easy to improve the performance of a filter molded object.
  • the adsorbing material includes one or both of fibrous activated carbon and granular activated carbon
  • the heat-meltable binder is made of a heat-meltable polymer resin powder.
  • the adsorbent material includes both fibrous activated carbon and granular activated carbon, thereby improving the initial purification performance by using the fibrous activated carbon having a large bulk volume and a small water passage resistance, and used.
  • the purification performance can be maintained for a long period of time with granular activated carbon whose degradation of purification performance with time is small.
  • the softening time in which the heat-meltable binder is melted can be shortened by heating with microwaves, the melt of the heat-meltable binder can be performed even when mixed with fibrous activated carbon and granular activated carbon. Both are not separated in the inside, and a uniformly dispersible filter molded body can be produced.
  • the mold module defines a side mold that defines the outer peripheral side surface of the filter molded body, and an axial upper end portion of the filter molded body that is assembled to the upper end of the side mold.
  • the side surface mold is formed of two side surface separation molds, and the mating surface of the two side surface separation molds extends in the axial direction of the filter molded body. The molded body can be easily released.
  • the softening time during which the heat-meltable binder is melted can be shortened by heating with microwaves, even if the side mold is formed with two side molds, the two side molds are combined. Burr is unlikely to occur on the surface.
  • the mold module defines a side surface that defines the side surface of the filter molded body, and an upper surface that is assembled to the upper end of the side surface mold and defines the axial upper end of the filter molded body.
  • the upper surface mold, the lower surface mold, and the shaft mold act to reduce the distance between the upper surface mold and the lower surface mold and apply a force to compress the mixture.
  • a compression process of the mixture can be performed at the time of assembling the mold module, and the manufacturing process can be simplified and the cost can be reduced.
  • the side mold is composed of two side molds and the distance between the two side molds is reduced and compressed, the mating surface of the side mold protrudes from the surface of the filter molded body.
  • the problem of generating burrs is likely to occur, particularly when the side mold is formed of a low dielectric constant material unsuitable for compression.
  • the fifth invention since the mixture is compressed by reducing the distance between the upper surface mold and the lower surface mold, an excellent filter molded body can be formed without generating burrs.
  • a method for producing a filter molded body according to an embodiment of the present invention will be described by taking as an example a method for producing a filter molded body used for a domestic water purifier for purifying tap water.
  • This filter molded body is obtained by heating a mixture of an adsorbent material that adsorbs and removes contaminants and impurities from water and air, and a hot-melt binder for bonding the adsorbent material into a desired shape. It is formed.
  • activated carbon or heavy metal adsorbing ceramic can be used as the adsorbing material.
  • activated carbon fibrous activated carbon and granular activated carbon can be used.
  • Fibrous activated carbon has a large bulk volume and low water flow resistance, and a large bulk volume increases the surface area per volume, resulting in excellent initial purification performance, but degradation in purification performance over time. large.
  • the fibrous activated carbon preferably has a length cut to 0.1 to 1 mm. If it is less than 0.1 mm, it is too small, and the binder cannot hold the activated carbon, causing black powder to be generated during use. Furthermore, 0.2 mm or more is preferable, and 0.3 mm or more is particularly preferable. On the other hand, if it is larger than 1 mm, an excessive gap tends to occur in the mixture, the density of the entire mixture becomes small, and the filling amount becomes insufficient. Furthermore, 0.8 mm or less is preferable, and 0.6 mm or less is particularly preferable.
  • the granular activated carbon has a small bulk volume and a high water flow resistance, so that the initial purification performance is inferior to the fibrous activated carbon, but the degradation of the purification performance with the passage of use time is small.
  • the particle size of the granular activated carbon is preferably between 40 mesh pass and 200 mesh pass. If it is less than 40 mesh pass, the granular activated carbon becomes large, the ratio of the surface area to the volume becomes small, and the contact efficiency with water decreases, so the purification performance is insufficient. Further, 50 mesh pass or more is preferable, and 60 mesh pass or more is particularly preferable.
  • the granular activated carbon is too small, and the binder cannot hold the activated carbon, which causes black powder to be generated during use.
  • 120 mesh path or less is preferable, and 140 mesh path or less is particularly preferable.
  • activated carbon When using activated carbon as an adsorbing material, only one of fibrous activated carbon and granular activated carbon may be used, or both may be mixed and used. When both are used, the initial purification ability is enhanced by the fibrous activated carbon, and the purification performance can be maintained for a long time by the granular activated carbon, which is desirable.
  • the mixing ratio is preferably such that the weight of fibrous activated carbon / weight of granular activated carbon is 0.3 to 50. If the mixing ratio is less than 0.3, the initial purification performance tends to be insufficient, and if it exceeds 50, the purification performance tends to deteriorate due to long-term use.
  • the mixing ratio is preferably 1 or more, more preferably 5 or more, and particularly preferably 10 or more. Further, it is preferably 30 or less, particularly preferably 20 or less.
  • heating by microwaves is adopted as will be described later, and the heating time can be greatly shortened. Therefore, even if the weight ratio of the fibrous activated carbon is larger than the conventional one, the fibrous activated carbon and the granular activated carbon There is no fear that voids and the like are generated by melting and solidifying while being uniformly dispersed.
  • Heavy metal adsorbing ceramic is a powdery zeolite mainly composed of aluminosilicate, calcium phosphate, etc., which detoxifies the water quality by taking in metal ions such as lead ions in water and releasing sodium ions and calcium ions. is there. In particular, it is preferable to use an aluminosilicate because of its excellent heavy metal adsorption performance.
  • the heavy metal adsorbing ceramic is processed into a granular shape, and the particle size is preferably in the range of 10 to 100 ⁇ m. If it is less than 10 ⁇ m, dust is generated when the mold is filled with the mixture, and the uniform dispersibility of the material is lost due to inevitable vibration in each work process.
  • it is preferably 20 ⁇ m or more, particularly preferably 30 ⁇ m or more. If it is larger than 100 ⁇ m, the ratio of the surface area to the volume becomes small, and the contact efficiency with water decreases, so that the purification performance is insufficient. Further, it is preferably 80 ⁇ m or less, more preferably 60 ⁇ m or less, and particularly preferably 50 ⁇ m or less.
  • the weight ratio of activated carbon to 100 parts by weight of the mixture is preferably 50 to 85 parts by weight. If it is less than 50 parts by weight, the purification performance of the filter molded body will be insufficient. Further, 55 parts by weight or more is preferable, and 65 parts by weight or more is particularly preferable. Moreover, when it becomes larger than 85 weight part, there exists a possibility that the ratio of a heat-meltable binder may fall, the intensity
  • the weight ratio of the heavy metal adsorbing ceramic to 100 parts by weight of the mixture is preferably 10 to 30 parts by weight. If it is less than 10 parts by weight, the purification performance of the filter molded body will be insufficient. Furthermore, 15 parts by weight or more is preferable, and 18 parts by weight or more is particularly preferable. Moreover, when it becomes larger than 30 weight part, the ratio of adsorption materials other than heavy metal adsorption ceramics, such as activated carbon, will fall, and purification performance will fall. Further, it is preferably 25 parts by weight or less, particularly preferably 23 parts by weight or less.
  • the heat-meltable binder polyethylene, polypropylene, polystyrene, polyester, and a mixed material thereof can be used, and those having a softening point higher than the use temperature of the filter molded body are preferable.
  • the melt index of the hot-melt binder is not particularly limited.
  • the weight ratio of the hot-melt binder to 100 parts by weight of the mixture is preferably 5 to 30 parts by weight. If it is less than 5 parts by weight, the strength of the filter molded body may be insufficient and collapse. Furthermore, 10 parts by weight or more is preferable, and 12 parts by weight or more is particularly preferable. On the other hand, if it exceeds 30 parts by weight, the passage in the filter molded body is blocked by the hot-melt binder, so that the water flow resistance becomes high. Furthermore, 20 parts by weight or less is preferable, and 17 parts by weight or less is particularly preferable.
  • the adsorbing material and the heat-meltable binder are mixed so as to be in a uniformly dispersed state.
  • Mixing can be performed, for example, by dry mixing using a mixer.
  • a mold is filled with a mixture in which the adsorbent material and the hot-melt binder are uniformly mixed.
  • a mold module 1 shown in FIG. 1 is used to form a cylindrical filter molded body.
  • the mold module 1 includes a side surface mold 2 that defines the outer peripheral side surface of the filter molded body, an upper surface mold 3 that is assembled to the upper end of the side surface mold 2 to define the upper end in the axial direction of the filter molded body, and the side surface
  • An upper spacer 6 includes a lower surface mold 4 that is assembled to the lower end of the mold 2 to define the lower end in the axial direction of the filter molded body, and a shaft mold 5 that is inserted into the side mold 2 to form the central space of the filter.
  • the lower spacer 7, the upper stop ring 8, and the lower stop ring 9 are integrally assembled.
  • the side surface mold 2 has a cylindrical inner peripheral surface, and defines the outer peripheral side surface of the filter molded body. Further, recessed portions 10 for preventing the upper spacer 6 and the lower spacer 7 from coming off are formed on the upper and lower portions of the inner peripheral surface of the side mold 2, respectively.
  • the side surface mold 2 is composed of two side surface separation molds 2a and 2b.
  • the two side surface separation molds 2a and 2b are in contact with a mating surface extending in the axial direction of the filter molded body (FIG. 1), and are clamped and held together by an annular upper stop ring 8 and lower stop ring 9.
  • the two side surface separation molds 2a and 2b are formed of a low dielectric constant material having a low dielectric loss coefficient in order to efficiently heat the mixture by microwaves.
  • the dielectric loss coefficient of the low dielectric constant material is preferably 0.015 or less.
  • the side surface mold absorbs the microwave and converts it into heat. Cause damage. Furthermore, it is preferably 0.010 or less, and particularly preferably 0.005 or less.
  • the lower limit of the dielectric loss coefficient is not particularly limited in terms of the technical idea of the present invention, but a material having a very small dielectric loss coefficient is expensive and increases the material cost. .
  • Such a low dielectric constant material must satisfy the dielectric loss coefficient and have sufficient use resistance at the softening point of the heat-meltable binder.
  • a fluororesin such as PTFE (polytetrafluoroethylene), Polyolefin resins such as polymethylpentene, polyphenyl sulfide resins, PET (polyethylene terephthalate), and mixtures thereof can be used. It is particularly preferable to use a fluororesin such as PTFE or a polyphenylsulfide resin because it has a low dielectric loss coefficient and is easy to release the filter molded body.
  • a fiber material such as a short fiber may be mixed in the low dielectric constant material. For example, glass fiber or the like can be used.
  • the upper surface mold 3 is a member that is assembled to the upper end of the side surface mold via an upper spacer 6 to be described later, and has an upper large diameter portion 3a and a lower small diameter portion 3b.
  • the small diameter portion 3b is formed to have an outer diameter inscribed in the upper spacer 6 and the side surface mold 2, and enters the side surface mold 2 from above to pressurize the mixture filled in the side surface mold 2.
  • the large-diameter portion 3a is placed on the upper spacer 6 and screwed with a female screw formed on the inner peripheral surface of the upper spacer 6 by a male screw formed on the outer peripheral surface.
  • a through-hole for inserting and holding the shaft mold 5 is formed in the center of the upper mold 3.
  • the lower surface mold 4 is a member that is assembled to the lower end of the side surface mold via a lower spacer 7 to be described later, and has a lower large diameter portion 4a and an upper small diameter portion 4b.
  • the small diameter portion 4b is formed to have a diameter inscribed in the lower spacer 7 and the side surface mold 2, and enters the side surface mold 2 from below to become a plug of the side surface mold 2.
  • the large diameter portion 4a abuts on the lower spacer 7 and is screwed with a female screw formed on the inner peripheral surface of the lower spacer 7 by a male screw formed on the outer peripheral surface.
  • a through hole is formed through which the shaft mold 5 is inserted and held.
  • a bottomed recessed hole is formed instead of the through hole, and the shaft is inserted into the recessed hole.
  • the mold 5 may be fitted and held.
  • the lower surface mold 4 is provided with a screw hole 11 that horizontally penetrates the large diameter portion from the outer peripheral surface to the through hole.
  • the screw hole 11 and the set screw 12 may be provided only on the upper surface die 3 in addition to the lower surface die 4, or may be provided on both the upper surface die 3 and the lower surface die 4.
  • the upper surface mold 3 and the lower surface mold 4 are preferably formed of a low dielectric constant material in the same manner as the side surface mold 2.
  • the upper spacer 6 is a cylindrical member, and is attached to the side surface mold 2 from above and places the upper surface mold 3 in order to hold the upper surface mold 3 in an appropriate position with respect to the side surface mold 2.
  • a convex portion 13 projects from the lower outer peripheral surface inserted into the side surface mold 2, and is prevented from coming off by fitting into the concave portion 10 of the side surface mold 2.
  • the upper part is formed in a large diameter, and the upper surface mold 3 is placed and surrounds the outer peripheral surface thereof.
  • a female screw is formed on the inner peripheral surface of the upper part, and is screwed with the male screw of the large-diameter portion 3a of the upper surface mold 3 (screw coupling 14).
  • the lower spacer 7 is formed in the same shape as the upper spacer 6, and is attached to the side surface mold 2 from below and attached to the upper side of the lower surface mold 4 in order to hold the lower surface mold 4 in an appropriate position with respect to the side surface mold 2. .
  • Protruding portions 13 project from the upper outer peripheral surface inserted into the side surface mold 2, and are prevented from coming out by fitting into the concave portions 10 of the side surface mold 2.
  • the lower part is formed in a large diameter, abuts on the upper side of the lower surface mold 4 and surrounds the outer peripheral surface thereof.
  • a female screw is formed on the inner peripheral surface of the lower portion, and is screwed with the male screw of the large-diameter portion 4a of the lower surface mold 4 (screw coupling 15).
  • the upper spacer 6 and the lower spacer 7 may be omitted, and the upper surface mold 3 and the lower surface mold 4 may be formed so as to be screwed directly with the side surface mold 2, but in the present invention, the mating surfaces extend in the axial direction. Since the side surface mold 2 is formed by the side surface separation molds 2a and 2b, it is difficult to provide an accurate female screw on the side surface mold 2, and compression failure is likely to occur. Therefore, it is preferable to provide the upper spacer 6 and the lower spacer 7. .
  • the upper spacer 6 and the lower spacer 7 are desirably formed of a low dielectric constant material as in the case of the side surface mold 2.
  • the shaft mold 5 is a rod-shaped member inserted into the side mold 2 and forms a central space portion of the filter molded body.
  • the shaft mold 5 is preferably formed of metal. By forming the shaft mold 5 from metal, it is possible to prevent the shaft mold 5 from being deformed in the direction of the side mold 2 when the mold module 1 is assembled or heated by microwaves. Dimensional accuracy can be improved. Moreover, the surrounding mixture can be heated by reflecting the microwave irradiated at the time of a heating.
  • the process of filling the mold module 1 with the mixture is as follows. First, the two side surface separation molds 2a and 2b are attached to the upper spacer 6 and the lower spacer 7, and fixed with the upper stop ring 8 and the lower stop ring 9 so that the side surface mold 2 is not detached. Next, the lower surface mold 4 is inserted below the fixed lower spacer 7 and attached by screwing. Next, the shaft mold 5 is inserted through the through hole of the lower surface mold 4. At this time, the lower end of the lower surface mold 4 and the lower end of the shaft mold 5 are coincident with each other at the same height, and the set screw 12 is screwed into the screw hole 11 so that the shaft mold 5 is positioned in the side surface mold 2. Then, the shaft mold 5 is fixed.
  • the mixture is filled into the side mold 2 from above the upper spacer 6 using a funnel-shaped instrument or an automatic supply device having a cylindrical tip. At this time, the mixture is filled up to a position higher than the height of the completed filter molded body.
  • the upper surface mold 3 is attached to the upper spacer 6 and the shaft mold 5 and screwed together, and the mixture is pressed by the upper surface mold 3 to reduce the bulk volume. Thereby, as shown in FIG. 2, the mixture can be filled into the cylindrical space in the mold module 1.
  • the mixture may be compressed only by the upper surface mold 3, but when the lower surface mold 4 is screwed to the lower spacer, only a part is screwed with a margin, the mixture is filled, and the upper surface mold is filled. At the same time as or before or after compressing the mixture by 3, the lower surface mold 4 may be further screwed and compressed.
  • the lower end of the shaft mold 5 and the lower end of the lower surface mold 4 are matched, and the upper end of the shaft mold 5 is positioned below the upper end of the upper surface mold 3.
  • the upper end of the shaft mold 5 and the upper end of the upper surface mold 3 may coincide with each other, and the lower end of the shaft mold 5 may be positioned above the lower end of the lower surface mold 4.
  • the shaft mold 5 may be formed longer, so that the lower end of the shaft mold 5 and the lower end of the lower surface mold 4 coincide with each other, and the upper end of the shaft mold 5 and the upper end of the upper surface mold 3 may coincide with each other.
  • the shaft mold 5 may be formed longer and the shaft mold 5 may be formed so as to partially protrude from the tip of the upper surface mold 3 or the lower surface mold 4.
  • the shaft mold 5 may be fixed to the mold module 1 by the set screw 12 immediately after the shaft mold 5 is arranged, after filling the mixture, or after the upper surface mold 3 is assembled. Further, instead of fixing the shaft mold 5 with the set screw 12, a recess (not shown) is provided on one of the inner peripheral surface of the upper surface mold 3 and / or the lower surface mold 4 and the outer peripheral surface of the shaft mold 5, and the other A projecting amount variable mechanism (not shown) whose projecting amount can be changed by a spring may be provided, and the shaft type 5 may be held and fixed by the projecting amount varying mechanism coming into contact with the recess by the biasing force of the spring.
  • the mixture filled in the mold module 1 is heated by being irradiated with microwaves.
  • the mixture since the mixture is heated by microwaves, it is not necessary to heat the furnace (heating device) body, the furnace atmosphere, and the mold module as compared with the case of heating with an oven or the like, and the mixture is directly heated.
  • the inside of the mixture can be heated at the same time, so that the amount of heat and time required for heating can be greatly reduced, and the manufacturing cost can be reduced. Heating with the oven required 30 to 120 minutes, whereas heating with the microwave completed the heating of the mixture (second step) in 1.5 to 4 minutes.
  • usable heat-meltable binders are not limited to those having a high viscosity and a low melt index, thereby reducing manufacturing costs. Can be made.
  • the heating device used for heating has a heating chamber inside, and a belt conveyor passing through the heating chamber is laid so that the mold module 1 is transported through the heating chamber by the belt conveyor. Further, a plurality of microwave irradiation devices are arranged in the heating chamber along the traveling direction of the belt conveyor, and the microwaves irradiated from each microwave irradiation device are irradiated to the mold module 1 passing through the heating chamber, Heat the mixture.
  • the inner wall of the heating chamber is made of metal, when the irradiated microwave hits the inner wall of the heating chamber, it is irregularly reflected in multiple directions and used for heating the mixture. As a result, the output of the microwave irradiation apparatus can be reduced, and the microwave can heat the mixture from multiple directions to uniformly heat the entire mixture, and the apparatus can be miniaturized.
  • the mold module 1 is preferably placed on the belt conveyor so that the axial direction of the shaft mold 5 and the mixture intersects perpendicularly to the traveling direction of the belt conveyor.
  • the microwave irradiation direction of the microwave irradiation apparatus is preferably set so as to substantially coincide with the axial direction of the axial mold 5 and the mixture.
  • the shaft type 5 made of metal shields the microwave and does not cause insufficient heating of the mixture behind it, and the entire mixture can be heated uniformly.
  • the frequency of the microwave used for heating can be 200 MHz (wavelength 1500 mm) to 10 GHz (wavelength 30 mm). Furthermore, those of 500 MHz (wavelength 600 mm) to 5 GHz (wavelength 60 mm) are preferable.
  • the microwave output is preferably 0.4 to 1.5 kw. If it is less than 0.4 kW, the output is insufficient and the time required for heating becomes long. Furthermore, 0.5 kw or more is preferable, and 0.7 kw or more is particularly preferable. Moreover, when it becomes larger than 1.5 kw, a mixture will be in a superheated state, and while a hot-melt binder is degreased, there exists a possibility that a type
  • the microwave In heating with microwaves, it is preferable to perform intermittent irradiation by repeating irradiation for a certain period of time after repeating irradiation for a certain period of time.
  • the microwave When the microwave is continuously irradiated, the heat-meltable binder is heated rapidly and deteriorates before being melted and bonded to the adsorbing material, thereby causing a molding defect or a reduction in strength of the filter molded body. Also, the mold module may be damaged by rapid heating.
  • the irradiation is continued in the range of 0.1 to 5 seconds and stopped in the range of 0.1 to 5 seconds.
  • the irradiation time and the stop time may be the same length or different.
  • the lower limits of the irradiation time and the stop time are each preferably 0.5 seconds or more, particularly preferably 1 second or more. Further, the upper limit is preferably further 4 seconds or less, and particularly preferably 3 seconds or less.
  • the total of only the irradiation time excluding the stop time is preferably 75 to 120 seconds.
  • the irradiation time of intermittent irradiation is less than 75 seconds, the heat melting property cannot be uniformly and sufficiently melted.
  • it is preferably 80 seconds or more, particularly preferably 85 seconds or more.
  • it will be in a superheated state for 120 seconds or more, and it will cause damage to the mold module 1 and degreasing of the hot-melt binder.
  • it is preferably 100 seconds or shorter, particularly preferably 90 seconds or shorter.
  • microwave irradiation devices In the present embodiment in which a plurality of microwave irradiation devices are arranged in the heating device, it is preferable to synchronize intermittent irradiation of each microwave irradiation device (simultaneous irradiation is started and stopped simultaneously). Since one microwave irradiation device applies microwaves to a certain wide range and heats it, if the intermittent irradiation of each microwave irradiation device is not synchronized, another microwave irradiation device is stopped even when a certain microwave irradiation device is stopped. This is because the microwave irradiation device will irradiate the microwave, and the mixture will not be different from the continuous irradiation.
  • compression process A which presses a mixture between a 1st process and a 2nd process and reduces a bulk volume
  • compression process B which presses the said mixture and reduces a bulk volume
  • a compression step C for reducing the bulk volume can also be performed.
  • a load mechanism (not shown) using a spring or the like, or a pressurizing mechanism using hydraulic pressure ( (Not shown) is set on the upper surface mold 3 and / or the lower surface mold 4, and in the case of the upper surface mold 3, the load is applied in the direction of the lower surface mold 4, and in the case of the lower surface mold 4, the load is applied in the direction of the upper surface mold 3.
  • the pressure of the load mechanism or the pressure mechanism is set in consideration of the pressure time in the molten state, the reaction force of the mixture at the time of pressure, the degree of compression, and the like.
  • the mixture is compressed using a load mechanism or a hydraulic mechanism.
  • the pressure of the load mechanism or the pressure mechanism is set in consideration of the pressure time in the molten state, the reaction force of the mixture at the time of pressure, the degree of compression, and the like.
  • the manufacturing equipment can be relatively simplified and the manufacturing cost can be reduced.
  • the compression step B and the compression step C the mixture can be more reliably compressed, and it is particularly preferable to employ the compression step C.
  • ⁇ Third step> Thereafter, after the mold module 1 and the mixture (filter molded body) are naturally cooled, first, the upper surface mold 3 and the lower surface mold 4 are removed, and then the upper stop ring 8 and the lower stop ring 9 are removed, and two side surface molds are removed. 2a, 2b, the upper spacer 6 and the lower spacer 7 are disassembled, and finally the shaft mold 5 is extracted to release the filter molded body.
  • forced cooling may be performed by a method such as air cooling by air blowing.
  • the mold By configuring the side surface mold 2 with the two side surface separation molds 2a and 2b having the mating surfaces extending in the axial direction, the mold can be easily released by the procedure as described above after forming the filter molded body.
  • the side surface mold 2 when the side surface mold 2 is composed of two divided side surface molds 2a and 2b, burrs are generated on the side surfaces of the filter molded body along the mating surfaces, and post-processing may be required.
  • the heating time can be shortened by the microwave, the softening time due to the melting of the heat-meltable binder is shortened, and the possibility that burrs are generated on the mating surfaces can be greatly reduced.
  • burrs are generated, they are extremely small, so that the finishing process can be facilitated, the cost can be reduced, and the quality of the filter molded body can be improved.
  • Compressing is preferably performed so that the ratio of the bulk volume of the mixture immediately after filling the mold module 1 to the volume of the completed filter molded body is 1 to 1.5.
  • the heat-meltable binder binds the adsorbent material like a mesh to form the filter molded body with good strength, and fine water that passes between the adsorbent materials while being purified.
  • a passage can be formed.
  • the volume ratio When the volume ratio is less than 1, the compression is insufficient and the moldability and strength of the filter molded body are insufficient. Further, it is preferably 1.1 or more, particularly preferably 1.15 or more. When the volume ratio is larger than 1.5, an excessively compressed state is formed, and a restoring force is exerted on the released filter molded body. The restoring force cannot be bonded by a hot-melt binder, and the filter The molded body will be damaged. Further, it is preferably 1.4 or less, and particularly preferably 1.3 or less. In general, when the volume ratio is increased in the filter molded body, the compactness and purification ability are improved instead of decreasing the water flow rate per hour. According to the present invention, a good filter molded body can be realized even if the volume ratio is set high.
  • Example> A cylindrical filter molded body was manufactured according to an embodiment of the present invention, and a property test was performed.
  • a property test was performed in 100 parts by weight of the mixture, 61 parts by weight of fibrous activated carbon cut to 0.1 to 0.5 mm as an adsorbing material, 4 parts by weight of granular activated carbon having a 60-140 mesh pass, and 40 ⁇ m particle diameter aluminosilicate.
  • This mixture is composed of a PTFE (Teflon (registered trademark)) side mold 2, an upper mold 3, a lower mold 4, an upper spacer 6 and a lower spacer 7 having a dielectric loss of 0.003, and a shaft mold 5 made of stainless steel.
  • a PTFE Teflon (registered trademark)
  • the upper surface mold 3 was screwed to the upper spacer 6, or the lower surface mold 4 was screwed to the lower spacer 7 to compress the mixture.
  • the mixture was heated by irradiating the mixture with microwaves in a heating device in which four microwave irradiation devices were arranged along the belt conveyor in the heating chamber.
  • the inner wall of the heating chamber was made of metal.
  • the mold module 1 was placed on the belt conveyor so that the axial direction of the shaft mold 5 and the mixture was perpendicular to the traveling direction of the belt conveyor.
  • the irradiation direction of each microwave irradiation apparatus was made to correspond to the axial direction of the shaft mold 5 and the mixture.
  • Each microwave irradiation device has a microwave frequency of 2.45 GHz, an output of 0.7 kW (instant maximum electric field density of 4.99 ⁇ m / cm 3 ), and intermittent irradiation that alternately repeats irradiation for 2 seconds and stopping for 2 seconds.
  • the total time of irradiation time and stop time was 180 seconds (irradiation time 90 seconds, stop time 90 seconds). At that time, the period of intermittent irradiation was synchronized in the four microwave irradiation apparatuses.
  • the mold module 1 was cooled for 180 seconds and then released to obtain a cylindrical filter molded body having an outer diameter of 22 mm, an inner diameter of 7 mm, a height of 108 mm, and a weight of 16 g.
  • the ratio of the volume of the mixture immediately after filling the mold module to the volume of the completed filter molded body was 1.18.
  • the filtration flow rate test is to measure the flow rate permeating the filter molded body per unit time when the dynamic water pressure is set to 0.1 MPa after the initial flow of water through the filter molded body and further continuous water passage for 10 minutes.
  • the free residual chlorine filtration capacity test water whose free residual chlorine concentration was adjusted to 2.0 ⁇ 0.2 mg / L was continuously filtered with a filter molded body, and total filtration until the chlorine removal rate decreased to a predetermined value. It measures the amount of water. In this test, the total amount of filtered water until the chlorine removal rate was reduced to 80% was measured. The results are shown in Table 1.
  • the filter molded body used in the water purifier is desirably a flow rate of 2.5 L / min or more in the filtration flow rate test, but in the examples, it was 2.9 L / min.
  • a filter molded object used for a water purifier although it is preferable that 1200 L or more of water can be filtered in the free residual chlorine filtration ability test, it was 2100 L in the Example.
  • the manufacturing method of the filter molded object of an Example can shorten heating time, the melt index of a heat-meltable binder is not limited, can reduce manufacturing cost, and is sufficient as a filter molded object It was found that it has a good purification ability.

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  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Solid-Sorbent Or Filter-Aiding Compositions (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
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JP2019018154A (ja) * 2017-07-18 2019-02-07 フタムラ化学株式会社 浄水用フィルター体及び浄水器
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JPH03151012A (ja) * 1989-11-02 1991-06-27 Kuraray Chem Corp 吸着性フィルター
JPH0542554A (ja) * 1991-08-09 1993-02-23 Showa Electric Wire & Cable Co Ltd ゴムの成形方法
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JP3164470U (ja) * 2010-09-17 2010-12-02 Ｇｅテクノ株式会社 浄水器用フィルター、及びこれを用いた浄水器

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JPS5624151A (en) * 1979-07-26 1981-03-07 Jiyobu Anshian Ets Barudou Jiy Manufacture of filter structure
JPH03151012A (ja) * 1989-11-02 1991-06-27 Kuraray Chem Corp 吸着性フィルター
JPH0542554A (ja) * 1991-08-09 1993-02-23 Showa Electric Wire & Cable Co Ltd ゴムの成形方法
JP2001187305A (ja) * 1999-12-28 2001-07-10 Mitsuboshi Belting Ltd フィルター成形体の製造方法
JP3164470U (ja) * 2010-09-17 2010-12-02 Ｇｅテクノ株式会社 浄水器用フィルター、及びこれを用いた浄水器

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