JP3643083B2

JP3643083B2 - Mold for forming molded filter and method for producing molded filter

Info

Publication number: JP3643083B2
Application number: JP2002052516A
Authority: JP
Inventors: 俊夫松村; 正明山本; 洋二錦織
Original assignee: Mitsuboshi Belting Ltd
Current assignee: Mitsuboshi Belting Ltd
Priority date: 2002-02-28
Filing date: 2002-02-28
Publication date: 2005-04-27
Anticipated expiration: 2022-02-28
Also published as: JP2003251117A

Description

【０００１】
【発明の属する技術分野】
この発明は、活性炭と高分子量で低メルトインデックスの重合体結合材の混合原料を充填して、フィルター成形体を製造する成形金型とフィルター成形体の製造方法に関する。
【０００２】
【従来の技術】
この従来のフィルター成形体の製造方法については、本出願人から特開２００１−１８７３０５号公報が提案してある。これによれば、図５に示すように、先ず成形金型６は、図５（ａ）の様に底型１０と外型９と上型８から成り、中央部の中型は底型に固着した一体構造で構成されていた。
【０００３】
また前述の構成で形成された成形体の脱型方法は、成形金型６を十分に冷却した後に、底型１０を引き抜き、図（ｂ）の様に中実状の上型８にて押し抜きフィルター成形体１を脱型する事を特徴とするものであった。
【０００４】
【発明が解決しようとする課題】
しかし、この成形金型に充填した所定量の混合原料を加熱しながら重合体結合材を流動状態にし、上型自重でこれら混合原料を圧縮して成形金型内面で形成される。この加熱に当たって、成形金型６は均一に加熱昇温して均一に混合原料を加熱しないと成形体内のポーラス密度が不均一に成る不具合があった。
【０００５】
この事から内部混合原料を均一に加熱昇温させる上で、例えば図４に示す外型の内径とほぼ同じの外径を有した中実状のパイプ形状の上型では昇温時間がかかり温度分布差が大きくなる問題があった。
【０００６】
これに加えて上型嵌挿時の芯合わせの単純化や、混合原料を成形金型に充填する際に中空状の中型内に粉をこぼしてしまう改善や、成形後の型内の成形体脱型の際の作業性に優れて、且つ発生した成形バリの処理し易い等の金型改良が望まれていた。
【０００７】
本発明の目的は、以上のような成形金型の構造や成形金型の取扱に係わる諸問題を改善するものであり、製造されるフィルター成形体の高品質化と原価低減に結びつくフィルター成形体用の成形金型及びフィルター成形体の製造方法を提供することにある。
【０００８】
【課題を解決するための手段】
上記問題を解決する本願請求項１記載のフィルター成形体の製造金型の発明では、水から汚染物質を除去する水処理器に用いる活性炭を固化したフィルター成形体の製造金型において、その円筒状外面を形成する筒状の外型と、外型の内周面に嵌挿自在で成形体の上面を形成する上型と、外型の内周面に嵌挿自在で中心に組立穴を設けて成形体の下面を形成する底型と、その底型の組立穴に脱着自在に嵌入して成形体の中心に貫通穴を形成する筒状の中型とから成り前記中型が軸線方向に抜き勾配を備えていることを特徴とする。とりわけ成形金型組立や脱型作業性並びに成形品質向上への対応を可能とすることにある。
【０００９】
この請求項１の構成によれば、底型と中型が分割出来るから、とりわけ筒状の成形体の中心軸に埋め込んだ状態に形成されて、この成形体が成形収縮して食らいついた状態に成った中型を、先ずは底型から分離させて取り扱うことが出来るから脱型への対応がやりやすい。しかも、成形体が成形収縮してその中心軸に食らいついた状態の中型を脱型するに際して、打ち抜き距離が最小に出来るから最小の一撃で緩めることが出来る。
【００１０】
請求項２記載のフィルター成形体の製造金型の発明では、水から汚染物質を除去する水処理器に用いる活性炭を固化したフィルター成形体の製造金型において、その円筒状外面を形成する筒状の外型と、外型の内周面に嵌挿自在で成形体の上面を形成する上型と、外型の内周面に嵌挿自在で中心に組立穴を設けて成形体の下面を形成する底型と、その底型の組立穴に脱着自在に嵌入して成形体の中心に貫通穴を形成する筒状の中型とから成り、前記中型の上端部に脱着自在の入れ子を有している。これによれば、中型の上端に入れ子を装着することで、パイプ状の開孔した中型の頂部に密栓出来て、筒状の外型の中心に外型の上端から更に突き出した状態と出来るから、上型の嵌入に当たっては上型の中心穴をこの入れ子に串刺しする状態で落とし込めば筒状の外型の内周面との芯合わせが出来る。また取り外しができるから外型の上面から突き出さすこともなく上面からの加圧時や型収容時等の出っ張りが解消出来た。
【００１１】
請求項３記載のフィルター成形体の製造金型の発明では、請求項１または２の構成において、前記成形体の上面を形成する上型が、その加圧成型時の下降端で外型の上端面に当接する鍔をそなえてある。これによれば、成型時の金型閉め切り高さに狂いが発生しない。また閉め切り時の面倒れが阻止出来て成形体の仕上がり精度の向上に対応出来る。
【００１２】
【００１３】
請求項４記載のフィルター成形体の製造金型の発明では、請求項１又は２の構成において、前記成形体の上下面のそれぞれの外周縁を形成する前記上型並びに前記底型の外周部に、リング状の凸山を設けてある。これによれば外型内周面と上型の下面、並びに外型内周面と底型の上面に出現する型合わせ隙間部に、このリング状の凸山が位置して筒状のフィルター成形体の上下面のコーナーを切り欠いた成形が出来る。
【００１４】
請求項５記載のフィルター成形体の製造方法の発明では、水から汚染物質を除去する水処理器に用いる活性炭を固化したフィルター成形体を分割型を用いて成形する製造方法において、外型と底型と中型とを組み立てて中型の上端部に入れ子を装着して型内に混合原料を投入し加震し充填した後に、上型を被せて入れ子を外して加熱し上型の鍔が外型の上端面に当接するように加圧をし、冷却した後、少なくとも成形体を串刺しにした中型と一体で外型から抜き取る事を特徴としている。
【００１５】
この製造方法によれば、先ず底型と中型が分割出来るから、少なくとも中型に串刺しにされた成形体と一体で外型から抜き外せるし、中型には抜き勾配を設けたことから成形体の軸芯に位置する中型の脱型が容易になった。また中型上端部に入れ子を別体で取り外し可能に設けたことから混合原料を投入時に中空のパイプ状の中型に密栓が出来て、且つ中心に貫通穴を有して中型に嵌挿する上型を、外型に嵌込みの際に芯出し案内が出来る。更に上型に鍔を設けて外型の上端面に突き当てて加圧下降限に設定出来るから、加圧終了位置のバラツキを阻止する対応が出来る。
【００１６】
【発明の実施の形態】
本発明のフィルター成形体用の成形金型及びフィルター成形体の製造方法の一実施形態について、図１〜図７を参照して説明する。これに先立ち、先ずフィルター成形体１そのものに関して図６、７を用いて概説する。
【００１７】
本発明の製造方法によって得られる活性炭を固化したフィルター成形体１は、例えば図７に示すような蛇口直結型の水処理器Ｓに水処理器用フィルター２のフィルターとして使用するものである。水処理器用フィルター２の構造としては、例えば図６（ｂ）、図６（ｃ）に示すように円筒形のフィルター成形体１の外周に濾過層３を被覆して、円筒形のフィルター成形体１の頂面及び底面部分には、キャップ４がかぶさっており、キャップ４は前記フィルター成形体１とは、汚れを含んだ水が通過しないように接着剤で水密性をもって接続されている。
【００１８】
また、円筒形のフィルター成形体１は円筒の中心軸に孔５を有している。この水処理器用フィルター２を水処理器Ｓに取りつけたときの水の流れは、濾過層３側から、水を取り込み、濾過層３で大きなサイズのごみなどの汚れを取った後、フィルター成形体１の円筒断面を通過して残留塩素や有機物を吸着除去し、孔５内に湧き出して水処理器Ｓの浄水口Ｊから流出する行程で処理が行われる。
【００１９】
本発明の製造方法により得られるフィルター成形体１は、活性炭を高分子量で低メルトインデックスの重合体結合材で固化した多孔質の固体活性炭成形体であり、このフィルター成形体１に水を通すことによって水処理を行うよう構成されたものである。
【００２０】
先ずフィルタ成形体１の成形金型６については、熱伝導率の高いアルミやステンレス材を含む鉄等が好適に用いられて耐蝕・耐摩耗処理が施してある。図１にその型割構造と組立状態を表しており、型割は底型１０と外型９と中型１１と上型８の４点に分割して構成されて、製造ライン上のパレット５１上面に配してあるセンタリングピン５２上に、中型１１の下端穴を嵌挿して位置決めを行っている。
【００２１】
この時、図中の入れ子１４は作業治具として用いてあり、図３（ａ）（ｂ）に示す様に、原料Ｐの投入時並びに上型８の組み付け時に中型１１の頂部に着装し、上型８の組み付け後に取り外している。これによってパイプ状の中型１１内部への原料Ｐの侵入が無くなり、上型８の外型９への嵌挿に当たって芯出しに苦労せず楽に組み付けられ、組み付け後の加熱工程では中空状の中型１１の頂部から入れ子１４が外されて開放されるから、中型１１の軸線方向の熱回りが確保出来る事になる。
【００２２】
次に成形金型６の組立状態については、図１のように底型１０に中型１１を挿通してパレット５１上に位置決めし、これに外型９をはめ込み、後述の一連の作業工程を経て、上型８を組み付けて図２（ｂ）の様に組立が完結する。
【００２３】
続いて、前述の分割された底型１０と外型９と中型１１と上型８のそれぞれの型の中から、とりわけ本発明に係わる底型１０と中型１１と上型８について詳述する。
【００２４】
先ず底型１０については、その最大外径を外型９の内径以内に抑えて、中型１１に串刺し状態となって一体化した底型１０とフィルター成形体１と上型８を、外型９から上型８の鍔方向に容易に引き抜ける構成にしてある。
【００２５】
この中型１１に串刺しにされて一体化したフィルター成形体１は、取り出しの際には成形して収縮しているから外径や成形長さが、若干小さくなって隙間が出来て外型９内面や底型１０と上型８の成形面での離型が比較的容易に出来る。尚、凸リング状の山１８については後述する。
【００２６】
次に中型１１は、図３（ｄ）に示す様に、底型１０に嵌挿する軸方向に向かって、その軸径が緩やかなラッパ状に大きくなる抜き勾配１５が設けてある。これによって、軸抜け量とともに軸径方向での嵌合隙間が大きくなり嵌合長さが長くて食らいついた本成形体の脱型には好適に対応出来るものである。また中型１１は、中空状の軸体形状にすることによって熱回りが良く成るようにしてある。
【００２７】
続いて上型８は、図１に示す様に中抜きして中空形状にして下面には中型１１を貫通する開口を持った底板を備え、上面には外周周縁部に鍔１３を備えた構成にしてある。これによって、成形面の温度分布や昇温速度等の熱回りが改善されて、且つ上型８の重量も肉厚で微調整出来るから、加熱加圧時の上蓋自重による押し蓋作用が好適に与えられる。
【００２８】
次に底型１０と上型８の成形面の外周縁に設けた本発明に係わる凸リング状の山１８について説明する。図４（ａ）成形金型６での凸リング形状、に示す様に、先ず上型８の底面と外型９の内面で構成するリング状のコーナー部に上型８の底面にリング状に突き出した山１８を設けてあり、その大きさは、後述の接着剤のはみ出しと成形バリのはみ出しが吸収できる予め求めた寸法で、概ね三角形状の断面をした山である。同様に底型１０の上面と外型９の内面で構成するリング状のコーナー部にも底型８の上面に突き出した山１８を設けてある。
【００２９】
続いて図４（ｂ）には、前述の成形型５の突き出した山１８で成形され上下面にコーナー溝２１を有したフィルター成形体１の部分断面形状と、その上下面に付属キャップ４が接着剤２５によって成形体１に一体化された状態を部分断面で表している。このように凸リング状の山１８によって成形されたコーナー溝２１は、成型時に発生した円周上の成形バリ２３と外周部に溢れる余剰の接着剤２５を、このコーナー溝２１に収容する事により、仕上げが不要な工程造りが出来るようにしてある。
【００３０】
次に本発明に係わるフィルター成形体の製造方法について、図３（ａ）混合原料投入、（ｂ）上型嵌挿・落とし蓋にして加熱、（ｃ）加熱・加圧・冷却して成形完了、（ｄ）内型脱型、を用いて所定の密度、均一な粒度を有する円筒形状の成形体を成形する手順について詳述する。
【００３１】
まず混合原料Ｐは、活性炭と高分子量で低メルトインデックスの重合体結合材を所定比率で混合攪拌して両者が均質に分散したものである。この時、フィルター成形体１の全域に活性炭が分散して水処理の効果を十分に発揮できるように、活性炭は６０メッシュより細かい粒状もしくは粉末ものを、重合体結合材は粒径が約１００μｍ程度のものを用いている。
【００３２】
次に図３（ａ）に示す様に、底型１０に中型１１を挿入しその底型１１の外周に外型９を装着して成形金型６の容器部を組み立て、中型１１頂部に先端を細くした入れ子１４を装着して、外型９の上部開口面に漏斗４２を装着して、計量済の前記混合原料Ｐを投入する。この際には、中央部の中型頂部には入れ子で密栓してある。
【００３３】
所定量充填すると成形後のフィルター成形体高さの１５０〜２００％になる。そして混合原料Ｐを含む成形金型６を振動装置にて振幅１〜３ｍｍ、振動数５〜１０回／秒にて５〜１０秒振動をおこなって、所定高さの５〜１５％増になるまで原料の嵩高さを減少させる。ここで前記の成形後のフィルター成形体高さは、フィルター成形体１のできあがりの高さであり、成形後の冷却時の成形収縮をも勘案したものである。
【００３４】
成形金型６を振動させる際に振幅が大きすぎたり、振動数が大きくすぎたりして振動を与えすぎると、混合原料Ｐが詰まりすぎ所定の密度が得られなくなる。またそれぞれの粒径の違いまた重さの違いにより混合原料Ｐが分離し均一な成形体１が得られない場合があるので好ましくない。
【００３５】
また、逆に振動が不十分であると加熱成形後にて加圧し成形後のフィルター成形体１の高さに調整する際、加圧による調整量が多く成るため加圧時の圧力損失により成形体上下に密度差が生じるばかりでなく、成形金型５内面と原料界面がこすれ目詰まりをおこし、フィルターとしての機能を損なうことになる。
【００３６】
次に図３（ｂ）に示す様に、上型８底面の組立穴部を先端が細くなった入れ子に差し込んで挿入してやれば、外型９と内型１１との嵌挿時の芯出しが自ずと簡単に出来て型合わせが容易でスムースに下降出来る。
【００３７】
続いてオーブン内で１８０〜２６０℃にて３０〜９０ｍｉｎ程度加熱し、混合原料Ｐ中の重合体結合材を流動状態にする。重合体結合材が流動状態になったところで、成形金型６をオーブンから取り出し、ほぼ下降した上型８の最後をもう一押し下げて加圧し、図２（ａ）上型落とし蓋状態（ｂ）加熱成形完了状態、に示す様に加圧密着して上型８の鍔１３面を外型９の上面に当接させて、図３（ｃ）に示す成形完了状態に至る。
【００３８】
次いで成形金型６を十分に冷却し、外型９の成形面では成形収縮し隙間も出来て、引き出しやすくなって、中型１１に串刺しされた底型１０、フィルター成形体１、上型８を外型９から一体で脱型して成形体１の両側にある底型１０と上型８を取り外す。
【００３９】
図３（ｄ）に示す様に、中型１１に串刺しされて、成形収縮したフィルター成形体１が食らいついた中型１１をプレスの固定テーブル上の貫通穴に軸径の大きな側を下にしてセットし、上方から中型１１の上部を突き押して脱型を行い離型するものである。
【００４０】
この様にして所定量の活性炭と重合体結合材を混合し、成形金型６に充填し、加震して嵩高さを均一に調整後、２００℃前後の温度にて所定時間加熱した後に、上型８を密着させて、冷却し、脱型することによって粒度が均一で密度を上記のような０．５〜０．６５ｇ／ｃｍ³の範囲内に調整されたフィルター成形体１を作成することができる。
【００４１】
尚、本発明のフィルター成形体の成形金型及びフィルター成形体の製造方法では、図１〜図７に示すものに限定されず、例えば次の様な形態をとることが出来る。
１）底型１０の中心部への中型１１の嵌挿に当たって、上図においては全て貫通方式としているが、中型１１を貫通させず途中の深さで突き当て位置決めする形態も可能である。
【００４２】
【発明の効果】
請求項１に記載のフィルター成形体の成形金型では、筒状のフィルター成形体が成形収縮して食らいついた中型の脱型の前に、先ずは底型から分離出来るから脱型への対応がしやすくなったことから、脱型工数が低減でき少なからず製造原価を低減できた。また型製作に置いて一体加工するロスが省けて、型製作費と保全費が割安に対応できた。更には、中型を脱型するに際して、打ち抜き距離を最小にして最小の一撃で緩めることが出来るから、成形体への脱型時の衝撃を遙かに緩和できて、損傷の心配が排除でき、機械での対応が簡便になった。また中型の損傷も無く成った。
【００４３】
請求項２に記載のフィルター成形体の成形金型では、パイプ状の開孔した中型の頂部に密栓出来るから外型に混合原料を投入時にパイプ状の中型に侵入することが無い。また上型を串刺しする状態で落とし込めて筒状の外型の内周面との芯合わせが出来るから、作業性を損なうことなく嵌合隙間を少なくできて成形品質が向上し、作業時間も低減出来た。
【００４４】
請求項３に記載のフィルター成形体の成形金型では、成型時の金型閉め切り高さに狂いが発生せず、また閉め切り時の面倒れが阻止出来て成形体の仕上がり精度が向上するから、水処理器への組立嵌合性等の品質の向上が図れた。
【００４５】
【００４６】
請求項４に記載のフィルター成形体の成形金型では、リング状の凸山によって筒状のフィルター成形体の上下面のコーナーを切り欠いた成形が出来から、このリング状のコーナー空隙に発生する円周バリがコーナー内面側に収容できるから、後工程でのキャップ嵌着作業の障害も無く仕上げのロスが排除できた。
【００４７】
請求項５に記載のフィルター成形体の製造方法では、底型と成形体と上型を中型で串刺し状になった一体で外型から抜き外せるから、型高さのある上型を外型の内面中を嵌挿させることがなく、また中型に成形収縮して食らいついたフィルター成形体は抜き勾配方向に容易にはずれるから型バラシと成形体の離型に要する時間が短縮でき、更に入れ子による中型の密栓と上型の芯出しにより型合わせ時間の短縮、また加圧終了位置のバラツキが無くなったことから成形バラツキが低減できた。従ってこれら型合わせや脱型作業性が向上し、成形バラツキも改善されて製造原価が削減出来た。
【００４８】
以上の様に、本願の請求項１〜５記載のフィルター成形体用の成形金型及びフィルター成形体用の製造装置に係わる発明ではその機能を充分に発揮する事が出来る。
【図面の簡単な説明】
【図１】本発明のフィルター成形体用の成形金型をパレット上に組み付けたその中央縦断面で全体正面図である。
【図２】本発明のフィルター成形体用の成形金型で、上型の鍔の機能を表す中央縦断面である。
【図３】本発明のフィルター成形体の製造方法を説明する工程流れを表す説明図である。
【図４】本発明のフィルター成形体用の成形金型で、上型と底型の成形面に設けた凸リング状の山の説明図である。
【図５】従来のフィルター成形体の製造方法の説明図であり、（ａ）上型の自重で加圧し成形している状態、（ｂ）成形体の脱型状態を表している。
【図６】本発明の製造方法によって得られたフィルター成形体とこれを用いた水処理器用フィルターの説明図、（ａ）本発明の製造方法によって得られたフィルター成形体の例を示す斜視図、（ｂ）フィルター成形体を用いた水処理器用フィルターの斜視図、（ｃ）前図（ｂ）におけるＡ−Ａ断面図である。
【図７】水処理器の断面図である。
【符号の説明】
１フィルター成形体
６成形金型
８上型
９外型
１０底型
１１中型
１３鍔
１４入れ子
１８凸リング状の山
Ｐ混合原料[0001]
BACKGROUND OF THE INVENTION
The present invention, in activated carbon and molecular weight by filling a mixed material of the polymer binder of the low melt index, a method for manufacturing a molding die and filter over molded body to manufacture a filter over molding.
[0002]
[Prior art]
The method for producing the conventional filter over the molded body, are proposed by JP 2001-187305 from the present applicant. According to this, as shown in FIG. 5, first, the molding die 6 is composed of a bottom mold 10, an outer mold 9 and an upper mold 8 as shown in FIG. 5A, and the middle mold in the center is fixed to the bottom mold. It was composed of an integral structure.
[0003]
Further, in the method of removing the molded body formed in the above-described configuration, after the molding die 6 is sufficiently cooled, the bottom die 10 is pulled out and is punched out by the solid upper die 8 as shown in FIG. The filter molded body 1 was demolded.
[0004]
[Problems to be solved by the invention]
However, the polymer binder is fluidized while heating a predetermined amount of the mixed raw material filled in the molding die, and the mixed raw material is compressed by the upper mold weight to form the inner surface of the molding die. In this heating, the molding die 6 has a problem that the porous density in the molded body becomes non-uniform unless the temperature is raised uniformly and the mixed raw material is not heated uniformly.
[0005]
For this reason, in order to uniformly heat the temperature of the internal mixed raw material, for example, a solid pipe-shaped upper mold having an outer diameter substantially the same as the inner diameter of the outer mold shown in FIG. There was a problem that the difference became large.
[0006]
In addition to this, simplification of centering when the upper mold is inserted, improvement of spilling powder into the hollow middle mold when filling the mixed mold with the molding material, and molding in the mold after molding There has been a demand for mold improvement such as excellent workability at the time of demolding and easy processing of formed burrs.
[0007]
An object of the present invention is to improve the problems related to the handling of the structure and the molding die of the molding die as described above, the filter over leading to higher quality and cost reduction of the filter over moldings produced It is to provide a method for manufacturing a molding die and filter over molding of the molded articles.
[0008]
[Means for Solving the Problems]
In the invention of a mold for manufacturing the filter over the molded body of the present claim 1 to solve the above problems, in the manufacturing mold of the filter over molded body solidifying the activated carbon used in water treatment device for removing contaminants from water, the A cylindrical outer mold that forms a cylindrical outer surface, an upper mold that can be inserted into the inner peripheral surface of the outer mold to form the upper surface of the molded body, and an assembly hole that can be inserted into the inner peripheral surface of the outer mold and centered A bottom mold that forms a lower surface of the molded body, and a cylindrical middle mold that is detachably inserted into an assembly hole of the bottom mold to form a through hole at the center of the molded body, and the middle mold is in the axial direction. It has a draft angle . In particular, it is possible to cope with molding die assembly, demolding workability and molding quality improvement.
[0009]
According to the structure of this first aspect, since the bottom mold and the middle mold can be divided, they are formed so as to be embedded in the central axis of the cylindrical molded body, and the molded body is in a state where it has been shrunk after being molded and contracted. Since the middle mold can be handled separately from the bottom mold, it is easy to deal with demolding. In addition, when the mold is shrunk and removed from the middle mold in the state where the molded body has bitten on its central axis, the punching distance can be minimized, so that it can be loosened with a minimum stroke.
[0010]
In the invention of the filter mold manufacturing mold according to claim 2, in the filter mold manufacturing mold for solidifying activated carbon used in a water treatment device for removing contaminants from water, a cylindrical shape forming the cylindrical outer surface thereof An outer mold, an upper mold that can be inserted into the inner peripheral surface of the outer mold to form the upper surface of the molded body, and an assembly hole that can be inserted into the inner peripheral surface of the outer mold and provided in the center to provide a lower surface of the molded body. It consists of a bottom mold to be formed and a cylindrical middle mold that is removably fitted into an assembly hole of the bottom mold to form a through hole at the center of the molded body, and has a removable insert at the upper end of the middle mold ing. According to this, by attaching the insert to the upper end of the middle mold, it can be sealed at the top of the pipe-shaped middle mold, and can be in a state of further protruding from the upper end of the outer mold to the center of the cylindrical outer mold When the upper mold is inserted, the center hole of the upper mold can be aligned with the inner peripheral surface of the cylindrical outer mold by dropping the center hole of the upper mold in a state of being inserted into the insert. In addition, since it can be removed, it can be prevented from protruding from the upper surface of the outer mold, and the protrusion at the time of pressurization from the upper surface or when the mold is accommodated can be eliminated.
[0011]
According to a third aspect of the invention of the mold for producing a filter molded body according to the first or second aspect of the present invention, the upper mold for forming the upper surface of the molded body is the lower end of the pressure molding at the lower end of the outer mold. It is equipped with a ridge that contacts the end face. According to this, there is no deviation in the die closing height at the time of molding. In addition, it is possible to prevent the tilting of the face at the time of closing and improve the finished precision of the molded body.
[0012]
[0013]
In the invention of the filter mold manufacturing die according to claim 4, in the configuration of claim 1 or 2, the upper mold that forms the outer peripheral edges of the upper and lower surfaces of the molded body and the outer periphery of the bottom mold are formed. A ring-shaped convex mountain is provided. According to this, the ring-shaped convex ridge is located in the mold alignment gap portion appearing on the inner peripheral surface of the outer mold and the lower surface of the upper mold, and on the upper surface of the outer peripheral surface of the inner mold and the bottom mold. Can be molded by cutting out the corners on the upper and lower surfaces of the body.
[0014]
The present invention provides a method for preparing a filter over the molded body according to claim 5, wherein, in the production method of molding using a split-type filter formed body solidifying the activated carbon used in water treatment device for removing contaminants from water, and the outer mold After assembling the bottom mold and the middle mold, attaching the insert to the upper end of the middle mold, putting the mixed raw material into the mold and shaking and filling it, put the upper mold on and remove the nest and heat to remove the upper mold cage It is characterized in that after pressurizing so as to abut on the upper end surface of the mold and cooling, it is extracted from the outer mold integrally with at least the intermediate mold in which the molded body is skewered.
[0015]
According to this manufacturing method, since the bottom mold and the middle mold can be divided first, it can be removed from the outer mold integrally with at least the molded body skewed into the middle mold, and since the draft is provided in the middle mold, the shaft of the molded body The middle mold located in the core can be easily removed. In addition, since the nest is provided separately and removable at the upper end of the middle mold, when the mixed raw material is charged, the hollow pipe-shaped middle mold can be sealed, and the upper mold has a through hole in the center and is inserted into the middle mold Can be centered and guided when fitted into the outer mold. Furthermore, since the upper die is provided with a flange and abuts against the upper end surface of the outer die to set the pressure lowering limit, it is possible to prevent variations in the pressurization end position.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of a method for manufacturing a molding die and filter over molding of the filter over the molded body of the present invention will be described with reference to FIGS. Prior to this, first outlined with reference to FIGS respect the filter over the molded body 1 itself.
[0017]
A filter molded body 1 obtained by solidifying activated carbon obtained by the production method of the present invention is used, for example, as a filter for a water treatment filter 2 in a faucet direct connection type water treatment device S as shown in FIG. As the structure of the filter 2 for water treatment device, for example, as shown in FIGS. 6 (b) and 6 (c), the outer periphery of the cylindrical filter molded body 1 is coated with a filtration layer 3 to form a cylindrical filter molded body. A cap 4 covers the top surface and the bottom surface portion of 1, and the cap 4 is connected to the filter molded body 1 with an adhesive so as to prevent water containing dirt from passing therethrough.
[0018]
The cylindrical filter molded body 1 has a hole 5 in the central axis of the cylinder. When the water treatment device filter 2 is attached to the water treatment device S, the flow of water takes in water from the filtration layer 3 side, removes dirt such as large-sized dust from the filtration layer 3, and then forms a filter. The residual chlorine and organic substances are adsorbed and removed by passing through the cylindrical section of 1, and the process is performed in a process of flowing out into the hole 5 and flowing out from the water purification port J of the water treatment device S.
[0019]
A filter molded body 1 obtained by the production method of the present invention is a porous solid activated carbon molded body obtained by solidifying activated carbon with a polymer binder having a high molecular weight and a low melt index, and water is passed through the filter molded body 1. Is configured to perform water treatment.
[0020]
First, the molding die 6 of the filter molded body 1 is subjected to corrosion resistance and wear resistance treatment by suitably using aluminum having high thermal conductivity, iron containing stainless steel, or the like. FIG. 1 shows the parting structure and the assembled state. The parting is divided into four parts of a bottom mold 10, an outer mold 9, a middle mold 11 and an upper mold 8, and the upper surface of the pallet 51 on the production line. Positioning is performed by inserting a lower end hole of the middle mold 11 on the centering pin 52 disposed in the center.
[0021]
At this time, the insert 14 in the drawing is used as a work jig, and as shown in FIGS. 3A and 3B, when the raw material P is charged and the upper die 8 is assembled, it is attached to the top of the middle die 11, It is removed after the upper mold 8 is assembled. This eliminates the intrusion of the raw material P into the pipe-shaped middle mold 11, so that it can be easily assembled without difficulty in centering when the upper mold 8 is inserted into the outer mold 9. Since the insert 14 is removed from the top of the mold and opened, the heat around the axial direction of the middle mold 11 can be secured.
[0022]
Next, as for the assembled state of the molding die 6, as shown in FIG. 1, the middle die 11 is inserted into the bottom die 10 and positioned on the pallet 51, and the outer die 9 is fitted into this, followed by a series of work steps described later. The upper die 8 is assembled, and the assembly is completed as shown in FIG.
[0023]
Next, the bottom mold 10, the middle mold 11 and the upper mold 8 according to the present invention will be described in detail from among the divided molds of the bottom mold 10, the outer mold 9, the middle mold 11 and the upper mold 8.
[0024]
First, the bottom mold 10 is suppressed and the maximum outer diameter within an inner diameter of the outer mold 9, the bottom mold 10 and the filter over the molded body 1 and the upper die 8 that is integrated in a skewered state medium-sized 11, the outer mold 9 is configured to be easily pulled out in the heel direction of the upper mold 8.
[0025]
The medium-sized 11 filter over molding 1 obtained by integrating been skewered, the molded to contract and the outer diameter and forming length because the time of extraction is, the outer mold by a gap slightly smaller 9 Mold release on the inner surface and the molding surfaces of the bottom mold 10 and the upper mold 8 can be performed relatively easily. The convex ring-shaped peak 18 will be described later.
[0026]
Next, as shown in FIG. 3 (d), the middle mold 11 is provided with a draft angle 15 that increases in a trumpet shape with a gentle shaft diameter in the axial direction to be inserted into the bottom mold 10. As a result, the fitting gap in the shaft radial direction is increased along with the amount of shaft slip, so that it is possible to cope with the demolding of the molded body that has been eaten because the fitting length is long. Further, the middle mold 11 has a hollow shaft body shape so that the hot rotation is improved.
[0027]
Subsequently, as shown in FIG. 1, the upper die 8 is hollowed out to have a hollow shape, and a bottom plate having an opening penetrating the middle die 11 on the lower surface and a flange 13 on the outer peripheral edge portion on the upper surface. It is. As a result, the heat circulation such as the temperature distribution on the molding surface and the heating rate can be improved, and the weight of the upper mold 8 can be finely adjusted by the thickness. Given.
[0028]
Next, the convex ring-shaped peak 18 according to the present invention provided on the outer peripheral edge of the molding surface of the bottom mold 10 and the upper mold 8 will be described. As shown in FIG. 4A, a convex ring shape in the molding die 6, first, a ring-shaped corner portion constituted by a bottom surface of the upper die 8 and an inner surface of the outer die 9 is formed in a ring shape on the bottom surface of the upper die 8. A protruding peak 18 is provided, the size of which is a dimension determined in advance that can absorb the protrusion of the adhesive and the protrusion of the molding burr, which will be described later, and has a substantially triangular cross section. Similarly, a crest 18 protruding from the upper surface of the bottom mold 8 is also provided at a ring-shaped corner formed by the upper surface of the bottom mold 10 and the inner surface of the outer mold 9.
[0029]
The subsequently FIG. 4 (b), has a filter over the molded body 1 of the partial cross-sectional shape that is molded in the mountains 18 protruding mold 5 having a corner groove 21 in the upper and lower surfaces of the above, comes the cap 4 on the upper and lower surfaces Is shown in a partial cross-section in a state where is integrated into the molded body 1 by the adhesive 25. In this way, the corner groove 21 formed by the convex ring-shaped ridges 18 accommodates the molding burr 23 on the circumference generated at the time of molding and the excess adhesive 25 overflowing the outer peripheral portion in the corner groove 21. The process can be made without the need for finishing.
[0030]
Next a manufacturing method of the filter over the molded body according to the present invention, FIGS. 3 (a) mixing raw material input, (b) heating the upper die fitted-down lid, to heat and pressure and cooling (c) molding A procedure for forming a cylindrical molded body having a predetermined density and a uniform particle size by using completion and (d) inner mold release will be described in detail.
[0031]
First, the mixed raw material P is obtained by mixing and stirring activated carbon and a polymer binder having a high molecular weight and a low melt index at a predetermined ratio, and both are uniformly dispersed. At this time, the activated carbon is granular or powdered finer than 60 mesh, and the polymer binder has a particle size of about 100 μm so that the activated carbon is dispersed throughout the filter molded body 1 and the effect of water treatment can be sufficiently exhibited. Is used.
[0032]
Next, as shown in FIG. 3A, the middle mold 11 is inserted into the bottom mold 10, the outer mold 9 is attached to the outer periphery of the bottom mold 11, and the container part of the molding die 6 is assembled. A thin insert 14 is attached, a funnel 42 is attached to the upper opening surface of the outer mold 9, and the mixed raw material P that has been weighed is introduced. In this case, the middle mold top of the central part is sealed with a nest.
[0033]
When a predetermined amount is filled, it becomes 150 to 200% of the height of the formed filter body. Then, the molding die 6 containing the mixed raw material P is vibrated for 5 to 10 seconds at an amplitude of 1 to 3 mm and a frequency of 5 to 10 times / second by a vibration device, thereby increasing 5 to 15% of a predetermined height. Until the bulk of the raw material is reduced. Here, the height of the molded filter body after molding is the height of the completed filter molded body 1 and also takes into account molding shrinkage during cooling after molding.
[0034]
When the molding die 6 is vibrated, if the amplitude is too large or the vibration frequency is too large to give too much vibration, the mixed raw material P is too clogged and a predetermined density cannot be obtained. Further, the mixed raw material P is separated due to the difference in the particle diameter and the weight, and the uniform molded body 1 may not be obtained.
[0035]
On the other hand, if the vibration is insufficient, when the pressure is applied after the heat forming and the height of the filter formed body 1 after the forming is adjusted, the amount of adjustment due to the pressurization increases. Not only does the density difference rise and fall, but the inner surface of the molding die 5 and the material interface are rubbed and clogged, impairing the function as a filter.
[0036]
Next, as shown in FIG. 3 (b), if the assembly hole on the bottom surface of the upper die 8 is inserted into a nest with a narrow tip, the outer die 9 and the inner die 11 can be centered during insertion. It can be done easily, mold matching is easy and it can move down smoothly.
[0037]
Then, it heats at 180-260 degreeC in an oven for about 30-90 minutes, and makes the polymer binder in the mixed raw material P a fluid state. When the polymer binder is in a fluidized state, the molding die 6 is taken out of the oven, and the lower end of the upper die 8 that has been substantially lowered is pushed down and pressurized again, and FIG. 2 (a) upper die dropping lid state (b) As shown in FIG. 3 (c), the mold 13 is pressed and brought into close contact with the upper surface of the outer mold 9 as shown in FIG. 3 (c).
[0038]
Then sufficiently cool the molding die 6, the molding surface of the outer mold 9 can also gaps and mold shrinkage, making it easier drawer, skewered by bottom mold 10 to mid-size 11, filter over the molded body 1, the upper die 8 Are integrally removed from the outer mold 9 to remove the bottom mold 10 and the upper mold 8 on both sides of the molded body 1.
[0039]
As shown in FIG. 3 (d), is skewered in medium-sized 11, set on the large end of the shaft diameter of the medium-sized 11 filter over the molded body 1 is Kuraitsui that molding shrinkage in the through holes on a press of the stationary table in the lower Then, the upper part of the middle mold 11 is pushed from above to remove the mold and release it.
[0040]
In this way, a predetermined amount of activated carbon and a polymer binder are mixed, filled in the molding die 6, and after shaking to uniformly adjust the bulk, heated at a temperature of around 200 ° C. for a predetermined time, The upper mold 8 is brought into close contact, cooled, and demolded to produce a filter molded body 1 having a uniform particle size and a density adjusted in the range of 0.5 to 0.65 g / cm ³ as described above. be able to.
[0041]
In the manufacturing method of the molding die and filter over molding of the filter over the molded body of the present invention is not limited to those shown in FIGS. 1-7, for example, can take the following such forms.
1) In inserting the middle mold 11 into the center of the bottom mold 10, all the penetrations are shown in the above figure. However, a configuration in which the middle mold 11 is abutted and positioned at a midway depth without penetrating the middle mold 11 is also possible.
[0042]
【The invention's effect】
The molding die of the filter over the molded body according to claim 1, prior to demolding medium sized cylindrical filter over molded body Kuraitsui to molding shrinkage, first, to demolding because it separated from the bottom mold Since it became easier to handle, it was possible to reduce the number of demolding steps, and not only to reduce the manufacturing cost. In addition, the loss of integral processing in mold production was eliminated, and mold production costs and maintenance costs could be reduced. Furthermore, when removing the middle mold, the punching distance is minimized and can be loosened with a minimum stroke, so the impact at the time of demolding to the molded body can be greatly reduced, and the worry of damage can be eliminated, The machine response has been simplified. It was also free from medium damage.
[0043]
In the molding die for the filter molded body according to claim 2, since it can be sealed at the top of the pipe-shaped medium mold, it does not enter the pipe-shaped medium mold when the mixed raw material is charged into the outer mold. In addition, the upper die can be dropped in the state of being skewered and can be aligned with the inner peripheral surface of the cylindrical outer die, so that the fitting gap can be reduced without sacrificing workability, the molding quality is improved, and the working time is also shortened Reduced.
[0044]
In the molding die of the filter molded body according to claim 3, there is no deviation in the mold closing height at the time of molding, and the surface tilt at the time of closing can be prevented and the finished product accuracy is improved. The quality of the assembly fit to the water treatment device was improved.
[0045]
[0046]
The molding die of the filter over the molded body according to claim 4, the can forming by cutting out a corner of the upper and lower surface of the cylindrical filter over the molded body by a ring-shaped Totsuyama, in the ring-shaped corner gaps Since the generated circumferential burrs can be accommodated on the inner side of the corner, there was no hindrance to the cap fitting work in the subsequent process and the finishing loss could be eliminated.
[0047]
In the manufacturing method of the filter over the molded body according to claim 5, the bottom mold and the molded body and the upper mold from Hazuseru vent from the outer mold integral became skewered state by medium-sized, the outer mold an upper mold with a mold height of without causing fitted through the inner surface, also the filter over molded body Kuraitsui in molding shrinkage to medium size can reduce the time required for the release of the mold Balazs and moldings from outside to easily draft direction, further nested Due to the middle cap and the centering of the upper mold, the mold alignment time was shortened, and the variation in the pressing end position was eliminated. Therefore, the mold matching and mold removal workability has been improved, the molding variation has been improved, and the manufacturing cost has been reduced.
[0048]
As described above, in the invention according to the following claims 1-5 manufacturing apparatus filter over molding die for molding body and filter over a molded product according it is possible to sufficiently exhibit its function.
[Brief description of the drawings]
1 is an overall front view with its center longitudinal section assembled on a pallet a molding die for the filter over the molded body of the present invention.
[2] In the molding die of the filter over the molded body of the present invention is a central longitudinal sectional view representing the functionality of the collar of the upper die.
Figure 3 is a schematic diagram of a process flow illustrating a method of manufacturing the filter over the molded body of the present invention.
[4] In the molding die of the filter over the molded body of the present invention, it is an explanatory view of a convex-ring shaped mountain provided on the molding surface of the upper mold and the bottom mold.
[Figure 5] is an explanatory view of a conventional method of manufacturing a filter over the molded body, represents the demolding state condition, (b) the molded body being pressed molded by the weight of the upper mold (a).
6 is an explanatory view of a filter molded body obtained by the production method of the present invention and a filter for a water treatment device using the filter molded body, and (a) a perspective view showing an example of the filter molded body obtained by the production method of the present invention. FIG. 2B is a perspective view of a filter for a water treatment device using a filter molded body, and FIG. 3C is a cross-sectional view taken along line AA in FIG.
FIG. 7 is a cross-sectional view of a water treatment device.
[Explanation of symbols]
1 filter over molded body 6 forming mold 8 upper mold 9 outer mold 10 bottom mold 11 Medium 13 collar 14 nested 18 projecting annular mountain P mixed material

Claims

In a mold for manufacturing the filter over molded body solidifying the activated carbon used in water treatment device for removing contaminants from water,挿自standing fit and outer die cylindrical forming the outer cylindrical surface, the inner peripheral surface of the outer mold The upper mold that forms the upper surface of the molded body, the bottom mold that can be inserted into the inner peripheral surface of the outer mold and has an assembly hole in the center to form the lower surface of the molded body, and the assembly hole in the bottom mold is removable. consists of a tubular medium-sized forming a through hole in the center of the molded body fitted to the molding die of the filter over molded the medium size is characterized by comprising a draft in the axial direction.

In a mold for manufacturing a filter molded body in which activated carbon is solidified used in a water treatment device that removes contaminants from water, it can be freely inserted into the cylindrical outer mold that forms the cylindrical outer surface and the inner peripheral surface of the outer mold. An upper mold that forms the upper surface of the molded body, a bottom mold that can be fitted into the inner peripheral surface of the outer mold and has an assembly hole in the center to form the lower surface of the molded body, and can be freely attached to and detached from the assembly hole of the bottom mold consists of a tubular medium-sized forming a through hole in the center of the fitting to the molded body, the molding die of the filter over the molded body, characterized in that it has a nested detachably to the upper end of the middle size.

Upper die for forming the upper surface of the shaped body, forming metal filter over molded body according to claim 1 or 2 in the outer mold upper face of which has a flange abutting the falling edge at the time of compacting Type.

Wherein the outer peripheral portion of the upper mold and said bottom mold, molding die of the filter over the molded body according to claim 1 or 2 is provided with a ring-shaped Totsuyama form respective outer peripheral edges of the upper and lower surfaces of the green body Type.

In a manufacturing method that uses a split mold to mold a filter molded body that has solidified activated carbon used in a water treatment device that removes contaminants from water, the outer mold, bottom mold, and middle mold are assembled and a nest is attached to the upper end of the middle mold Then, after mixing the raw material into the mold, shaking and filling, the upper mold was put on and the nest was removed and heated to pressurize and cool the upper mold so that the upper mold was in contact with the upper end surface of the outer mold. after manufacturing method of the filter over molded body characterized by extracting from the outer mold integrally with the mid-size that at least the molded body skewered.