JP3660940B2 - Recyclable filter and its regeneration method - Google Patents

Description

得られた不織布シートを、ポリプロピレン製多孔性芯筒（外形３０ｍｍ、長さ２５０ｍｍの多孔性円筒）に３０ｍｍの厚さで巻き付け、瀘過層の密度０．２５５ｇ／ｃｍ³のカートリッジフィルターを形成した。次に前記カートリッジフィルターを用いて瀘過試験を行った。瀘過試験は、濃度２００ｐｐｍに調整された試験用ダスト（関東ローム、平均粒子径８μｍ）の水懸濁液を均一に撹拌しながら、前記カートリッジフィルターの外側から内側に向かって１０リットル／分の速度で２００リットル流した。その結果、瀘過精度は５μｍ、初期瀘過効率は８１．５％であった。なお、瀘過精度と初期瀘過効率は次の測定法で算出した。
（１）瀘過精度：上記のようにして得られた清浄水を採取し、超遠心式自動粒度分布測定装置（掘場製作所製）で粒子の径を測定し、その最大粒子径（μｍ）で評価する。
（２）初期瀘過効率：上記懸濁液を１リットル採取し乾燥後のダスト重量をＡとし、瀘過開始１分経過後の清浄水を１リットル採取し、乾燥後のダスト重量をＢとして次式により算出する。初期瀘過効率（％）＝[(A-B)/A]×100
【００４３】
次に使用後のカートリッジフィルターを、キシロールを用いて洗浄し、捕集物をＳＥＢＳ樹脂とともに除去した。次いで前記配合条件１のスラリーに再度含浸し、同様な手段でＳＥＢＳ樹脂をカートリッジフィルターの構成繊維にコーティング付与し、再生した。再生したカートリッジフィルターを用いて再度前記の瀘過試験を行ったところ、瀘過精度は５μｍ、初期瀘過効率は８１．３％であり、初回の試験とほぼ同一であった。
【００４４】
【実施例２】
ポリエチレンとポリプロピレンとから成る分割型ポリオレフィン繊維（大和紡績製 商品名ＤＦ−７２，分割前繊度２ｄ，分割後繊度０．２ｄ）を用いて通常の抄造法でシート化した後、ウオータジェット加工して構成繊維を交絡させるとともに繊維を分割処理し、次いで熱カレンダー加工して、目付６０ｇ／ｍ²，厚み１ｍｍの不織布シートを作製した。
【００４５】
次に、上記不織布シートを、下記配合条件２のスラリーに含浸した後、８０℃×５分間熱風乾燥処理して溶剤を蒸発させた。下記配合物の固形分の付着量は１０ｇ／ｍ²，目付７０ｇ／ｍ²，厚み１ｍｍの不織布シートを作製した。

得られた不織布シートを、実施例１と同様な手段でカートリッジフィルターに形成し、実施例１と同様に瀘過試験を行ったところ、瀘過精度は４μｍ、初期瀘過効率は８３．５％であった。
次に使用後のカートリッジフィルターを、キシロールを用いて洗浄し、捕集物をＳＥＢＳ樹脂及びイオン交換樹脂微粉体とともに除去した。次いで前記配合条件２のスラリーに再度含浸し、同様な手段でＳＥＢＳ樹脂をカートリッジフィルターの構成繊維にコーティング付与し、再生した。再生したカートリッジフィルターを用いて再度前記の瀘過試験を行ったところ、瀘過精度は４μｍ、初期瀘過効率は８３．３％であり、初回の試験とほぼ同一であった。
【００４６】
【実施例３】
（参考例）
ポリエステル繊維（ユニチカ製）１５ｄ×８０重量％、６ナイロン（ユニチカ製）１４ｄ×２０重量％を混合しカード工程を経て目付１００ｇ／ｍ²のウェブ形成を行った。次に、一次結合処理剤として下記配合条件３の樹脂を用いて、付着量１００ｇ／ｍ²でスプレー加工し、１００〜１５０℃の乾燥工程を行い、目付２００ｇ／ｍ²、厚み１５ｍｍのフィルター基材を作製した。
【００４７】
次に、二次結合処理剤として下記配合条件３の樹脂にて付着量１５０ｇ／ｍ²で浸漬加工し、１００℃の乾燥工程を行い目付３５０ｇ／ｍ²、厚み１４ｍｍのフィルターを作製した。

上記フィルターを、粗塵用フィルターとして２ケ月間使用した後、回収処理工程としてキシロールを５０℃に加温しながら洗浄して、バインダー樹脂を溶解した後、フィルター基材を乾燥して回収したところ、二次結合処理工程に再利用できた。また、バインダー樹脂とろ過物質との混合物中のバインダー樹脂と有機溶媒は、二次結合処理工程にリサイクルし、ろ過物質は沈降除去された後乾燥して固形分としてコンパクト化した。これらコンパクト化した固形分には、１ｍ²当たり約７００ｇの砂塵、カーボンブラック、リンターの混合物が含まれていた。
【００４８】
【実施例４】
ポリプロピレン繊維（大和紡績製）３ｄ×１００重量％をカード工程を経て目付１５０ｇ／ｍ²のウェブ形成を行った後、１００Ｐ／ｃｍ²ニードルパンチにて加工した。次に、一次結合処理剤として下記配合条件５の樹脂にて付着量５０ｇ／ｍ²のスプレー加工、１００〜１５０℃の乾燥工程を行い、目付２００ｇ／ｍ²、厚み３．５ｍｍのフィルター基材を作製した。
【００４９】
次に、二次結合処理剤として下記配合条件６の樹脂、イオン交換性材料にて付着量１００ｇ／ｍ²の浸漬加工、１００℃の乾燥工程を行い目付３５０ｇ／ｍ²、厚み３ｍｍのフィルターを作製した。

上記フィルターを、メッキ排水用フィルターとして１週間使用した後、回収処理工程としてキシロールを８０℃に加温しながら洗浄して、バインダー樹脂を溶解した後、フィルター基材は乾燥して回収したところ、二次結合処理工程に再利用できた。バインダー樹脂とイオン交換性材料、吸着物質の混合物中のバインダー樹脂と有機溶媒は、二次結合処理工程にリサイクルし、イオン交換性材料、吸着物質の混合物は沈降除去された後、乾燥して固形分としてコンパクト化した。これらコンパクト化した固形分には、吸着物質として通常ろ過される無機残査の他にイオン交換性材料にニッケル、クロム等の有害な重金属イオンが含まれていた。
【００５０】
【実施例５】
ポリプロピレン樹脂をスパンボンド法によりウェブ形成した後、熱ロール加工し目付５０ｇ／ｍ²、厚み０．３ｍｍのフィルター基材を作製した。
【００５１】
次に、二次結合処理剤として下記配合条件７の樹脂、消臭材にて付着量５０ｇ／ｍ²のコーティング加工、１００℃の乾燥工程を行い、目付１００ｇ／ｍ²、厚み０．５ｍｍのフィルターを作製した。

上記フィルターを、家庭用室内消臭フィルターとして１ケ月間使用した後、回収処理工程としてキシロールを８０℃に加温しながら洗浄し、バインダー樹脂を溶解した後、フィルター基材は乾燥して回収したところ、二次結合処理工程に再利用できた。バインダー樹脂とアンモニア、硫化水素、メルカプタンなどの悪臭成分を吸った消臭材料の混合物中のバインダー樹脂と有機溶媒は、二次結合処理工程にリサイクルし、消臭材料は沈降除去された後乾燥して固形分としてコンパクト化し、焼成加熱して再生した。
【００５２】
【発明の効果】
以上説明した通り、本発明のリサイクル性フィルターによれば、フィルター用基材に、有機溶媒に可溶なバインダー樹脂を用いて吸着性材料を結着して、吸着分離機能を向上させたフィルターであって、使用済みフィルターを有機溶媒を用いて前記バインダー樹脂を溶解除去するとともに、フィルター基材から吸着物と吸着性材料を分離可能としたことにより、さらに捕集効率を向上させ、使用済みフィルターから効率良く合理的に捕集物を除去することができ、かつ再利用が可能となる。
【００５３】
次に本発明の別のリサイクル性フィルターによれば、フィルター用基材に、有機溶媒に可溶なバインダー樹脂を塗布したフィルターであって、使用済みフィルターを有機溶媒を用いて前記バインダー樹脂を溶解除去するとともに、フィルター基材からろ過物質を分離可能としたフィルターに、ニッケル、銅、及び銀を含む金属または金属合金のめっき処理、またはカーボン塗布などの導電性処理をしたことにより、電磁波シールドフィルターとして好適なものとなる。
【００５４】
次に本発明のリサイクル性フィルターの再生方法によれば、耐熱性及び耐溶剤性を有する繊維からなるフィルター用基材に、有機溶媒に可溶でかつ耐熱性及び耐薬品性を有する熱可塑性エラストマーを主成分とするバインダー樹脂を固着した、使用済みフィルターを、前記バインダー樹脂を溶解する有機溶媒を用いてバインダー樹脂を溶解除去するとともに、フィルター基材からろ過物質を除去することにより、繰り返しフィルターを使用できる。
【図面の簡単な説明】
【図１】本発明に係るフィルターのリサイクル方法の一実施形態を示すフローチャート図である。
【符号の説明】
１ 繊維素材
２ フィルター基材
３ フィルター
Ａ ウェブ形成工程
Ｂ 一次結合処理
Ｃ 乾燥工程
Ｄ 二次結合処理
Ｅ 乾燥工程
Ｆ 吸着・ろ過使用
Ｇ 回収処理工程[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a filter excellent in recyclability and a method for regenerating the same. More specifically, the present invention relates to a recyclable filter that can efficiently and rationally remove collected matter from a used filter and can be reused, and a method for regenerating the same.
[0002]
[Prior art]
  Various environmental filters that guarantee clean environments by removing clean water, clean air, and various pollutants are used not only in dust-free rooms (clean rooms) that handle advanced technologies such as semiconductors, but also in industrial wastewater and exhaust gas. It is an indispensable material for processing.
[0003]
  Conventionally, various environmental filter materials require 30% to 400% by weight of the adsorbed material, and a large amount of industrial waste is generated in order to obtain a clean environment. These filter materials generally have properties excellent in heat resistance and chemical resistance, and are subjected to processing such as flame retardant treatment due to safety and performance problems. As a result, incineration is not easy for disposal of used filters, and is generally discarded, which may become a new source of secondary contamination in the future. It was.
[0004]
[Problems to be solved by the invention]
  As described above, the conventional filter materials are not easy to process after use, and there is a problem in the processing. In addition, since the filter material after use has been discarded, there is a problem of wasting resources.
[0005]
  In order to solve the above-mentioned conventional problems, the present invention provides a recyclable filter that can efficiently and rationally remove collected matter from a used filter and that can be reused, and a method for regenerating the same. Objective.
[0006]
[Means for Solving the Problems]
  To achieve the above object, the present inventionNoA cycle filter is a filter in which an adsorptive material is bound to a filter base material using a binder resin soluble in an organic solvent to improve the adsorption separation function. The binder resin is used for dissolving and removing, and the adsorbate and the adsorbent material can be separated from the filter base material.
[0007]
  The present inventionNo fuIn the filter, the filter substrate is made of a fiber material having solvent resistance, and includes polyester fiber, polyolefin fiber, polyimide fiber, organic fiber containing fluorine fiber, glass fiber, carbon fiber, potassium titanate fiber, and alumina fiber. It is preferably at least one fiber selected from inorganic fibers containing, and metal fibers containing stainless steel and nickel.
[0008]
  Also, the present inventionNo fuIn the filter, the binder resin is preferably a resin having heat resistance and chemical resistance. In particular, binder resins with excellent heat resistance and chemical resistance include styrene thermoplastic elastomers, styrene-butadiene-styrene (SBS) block copolymers, and styrene-ethylene-butylene-styrene (SEBS) block copolymers. It is preferable that at least one polymer selected from the combination is a main component.
[0009]
  Also, the present inventionNo fuIn the filter, the organic solvent is preferably at least one solvent selected from xylene, toluene, methylcyclohexane, and tetrahydronaphthalene.
[0010]
  The present inventionNo fuIn the filter, the adsorptive material can be at least one material selected from a hygroscopic material, a deodorizing material, CO, and a hydrogen adsorbing material. In the case of a hygroscopic material or a dehumidifying material, the adsorptive material is preferably at least one selected from silica gel and calcium oxide. Moreover, when the adsorptive material is a deodorizing material, at least one selected from activated carbon, platinum-supported oxide, and zeolite can be used. Moreover, when the adsorptive material is a powder containing a hydrogen storage alloy, a hydrogen removal filter can be obtained. Furthermore, when a charged body is used as the adsorptive material, a charged particle removal filter can be used.
[0011]
  In the recyclable filter of the present invention, an inorganic powder is bound to a filter substrate using a binder resin soluble in an organic solvent, and the used filter is dissolved and removed from the used filter using an organic solvent. In addition, the adsorbate and the inorganic powder may be separated from the filter base material. The inorganic powder is a metal oxide provided with a catalyst, and is preferably an exhaust gas filter that catalytically oxidizes and removes hydrogen or CO from the exhaust gas.
[0012]
  The present inventionNo fuIn the filter, the adsorptive material is at least one selected from organic ion exchange resins, inorganic ion exchangers, and mixtures thereof, and the exchange groups are selected from cationic, anionic, and mixtures thereof. It is preferable that it is at least one. The adsorbate adsorbed on the adsorbent material is a metal ion and a complex thereof, and may be a metal ion separation filter that separates and solidifies the adsorbate.
[0013]
  Also, the present inventionNo fuIn the filter, the adsorptive material is a magnetic substance, and is preferably a magnetic powder removal filter. In addition, the magnetic material is alnico, ferrite, SmCo_FiveSystem, and Nd₂Fe₁₄It is preferably at least one selected from the B series.
[0014]
  Moreover, in the said structure, it is preferable that an inorganic powder is a sterilization filter which is a titanium oxide with a photocatalytic action. As the inorganic powder, it is preferable to use a functional fiber material which is a ceramic powder having infrared absorption ability and heat retention characteristics.
[0015]
  Next, the present inventionanotherA recyclable filter is a filter in which a binder resin that is soluble in an organic solvent is applied to a filter substrate. The used filter is dissolved and removed using an organic solvent, and the filter is filtered from the filter substrate. An electromagnetic wave shielding filter is formed by applying at least one conductive treatment selected from plating, vapor deposition, sputtering, and carbon coating to metals or metal alloys containing nickel, copper, and silver on a filter that can separate substances. It is what you did.
[0016]
  Next, the recycling method of the recyclable filter of the present invention is applied to a filter substrate made of fibers having heat resistance and solvent resistance.At least one selected from xylene, toluene, methylcyclohexane, and tetrahydronaphthaleneDissolve the binder resin with a used filter, to which a binder resin mainly composed of a thermoplastic elastomer that is soluble in an organic solvent and has heat resistance and chemical resistance is fixed.SaidThe binder resin is dissolved and removed using an organic solvent, and the filtering substance is removed from the filter base material.
[0017]
  In the above method, after removing the binder resin and the filtering substance from the filter substrate, the binder resin mainly composed of a thermoplastic elastomer that is soluble in an organic solvent and has heat resistance and chemical resistance is fixed. It is preferable.
[0018]
  Next, the recyclable filter of the present invention may be formed by integrally molding any one of the above-described filters using the thermoplasticity of the binder resin.
[0019]
DETAILED DESCRIPTION OF THE INVENTION
  According to the configuration of the present invention described above, a new concept environmentally friendly high-performance filter (super eco-friendly) that can be used by treating a used filter with an organic solvent to completely separate and recover the filter base material from the adsorbed material and reuse it. Filter). In addition, since all materials are recycled, there is no environmental burden due to industrial waste, and a completely closed system in which only adsorbed substances are removed as solids has been realized. In addition, since this filter is made by binding the filter material with a thermoplastic elastomer, it has become possible to perform thermoforming integrated processing into any complicated shape.
[0020]
  The filter of the present invention has the following advantages.
(1) In the field of liquid filtration filters and gas filtration filters that remove all solid matter from micro to macro, without sacrificing conventional performance, from the production of clean air and water, to industrial and household exhaust gas and waste water It can be used in a wide range of treatments, biofilters for separating microorganisms.
(2) Metal ion adsorption filters that selectively adsorb and remove metal ions in liquids by supporting ion exchange materials, separation and recovery of metal resources, removal of heavy metals from mines and industrial wastewater, and separation and removal of radioactive metal ions Can also be used.
(3) A chemical adsorption filter that adsorbs and removes a specific gas component can be used as a dehumidifying filter carrying a hygroscopic material, a deodorizing filter carrying a odor adsorbing material, a poisoning filter carrying a toxic gas adsorbing material, and the like.
(4) The conductive treatment filter having nickel or silver plating on the surface can be used for a protective package of an electronic circuit as a breathable electromagnetic wave filter that prevents intrusion of electromagnetic waves and dust and does not hinder heat dissipation. It is effective in preventing malfunction of electronic devices from electromagnetic pollution caused by the spread of portable communication devices and improving reliability.
(5) A heat-resistant filter mainly composed of inorganic materials is a heat-resistant soundproof filter that removes carbon particles and noise from combustion exhaust gas, and supports an oxidation catalyst to remove unburned hydrocarbons, hydrogen, and carbon monoxide. It can be used as an exhaust gas filter to prevent poisoning accidents.
(6) The ceramic-carrying filter absorbs infrared rays and retains heat, and maintains moisture permeability, so that it is an antibacterial cloth that functions as a functional clothing material and absorbs ultraviolet rays to exhibit a bactericidal action. Available as
(7) A magnetic powder removal filter carrying a magnetic material can be used to remove magnetic fine powder such as iron powder from gas or liquid.
(8) A hydrogen removal filter carrying a hydrogen storage alloy is effective for removing a trace amount of hydrogen from a gas or liquid.
[0021]
  As described above, the filter of the present invention can be used for cleaning all fluid environments other than organic solvent systems, and can separate and remove adsorbate from the used filter. It can make a significant contribution to conservation and energy and resource savings.
[0022]
  In the filter of the present invention, the filter substrate is firmly bonded with a thermoplastic elastomer that is soluble in an organic solvent and has excellent heat resistance and chemical resistance, and the porous substrate is formed by arbitrarily controlling the filter aperture. Formed. Since a thermoplastic elastomer is used, there are advantages that it is rich in stretchability and superior in mechanical strength as compared with conventional nonwoven fabrics. In addition, various function-expressing materials such as ion exchangers, adsorbents, and oxides can be simultaneously applied or electroless plating can be easily performed, and high functionality and intelligentization can be achieved. In particular, since an organic solvent is used, it is optimal for supporting a hygroscopic agent or a metal material that easily oxidizes. Furthermore, the integral molding process using thermoplasticity can be easily performed, and a filter having a complicated shape can be manufactured.
[0023]
  In the filter of the present invention, the used filter is treated again with an organic solvent to dissolve the thermoplastic elastomer to which the adsorbed material adheres, and is separated from the filter base material. The filter base material can be separated as a solid content, and the filter base material can be separated into a fiber material, or a fiber material and a binding resin, if necessary. By this method, the volume of waste can be greatly reduced, and hazardous substances can be stored in a compact size.
[0024]
  Any fiber material with excellent solvent resistance can be used as the fiber material, but depending on the application such as temperature and environment, organic fibers such as polyester fiber, polyethylene fiber, polyimide fiber, fluororesin, glass, etc. Inorganic fibers such as fibers, carbon fibers, potassium titanate fibers, and alumina fibers, and metal fibers such as stainless steel and nickel can be used.
[0025]
  The thermoplastic elastomer is mainly composed of styrene-based styrene-butadiene-styrene (SBS) or styrene-ethylene-butylene-styrene (SEBS) from the viewpoint of chemical resistance, heat resistance, mechanical strength, and the like. Things are optimal.
[0026]
  As the solvent, xylene, toluene, methylcyclohexane, tetrahydronaphthalene, or the like can be used. Since an organic solvent is used, an oxidizable material such as moisture or gas adsorbing material or metal can be supported on the filter base.
[0027]
  Various materials can be used as the function-expressing material to be imparted. As the ion exchange material, an inorganic ion exchanger such as an ion exchange resin or potassium titanate, silica gel or calcium oxide as a dehumidifier, and activated carbon or zeolite as a deodorant can be used. Those carrying powders such as titanium oxide and aluminum oxide with platinum-based catalyst catalytically oxidize and remove hydrogen and CO from exhaust gas, and those carrying active titanium oxide exhibit antibacterial action by photocatalytic action. In addition, those added with ceramics such as titanium oxide are excellent in infrared absorption ability and heat retention characteristics. When the molded body is subjected to a conductive treatment such as electroless plating such as nickel, copper or silver, vapor deposition, sputtering, or carbon coating, it will have excellent electromagnetic shielding properties. Magnetic materials include alnico, ferrite, and SmCo_FiveSystem, Nd₂Fe₁₄Various pre-magnetization powders such as B-type can be supported and magnetized for use.
[0028]
  The filter of the present invention is used as a functional separation material that guarantees a comfortable and safe living environment from the field of conventional industrial water and gas filtration filters, and also improves the reliability of electronic equipment. As a material, it is used extensively in close contact with daily life as an apparel-related comfort cloth and a medical antibacterial cloth. Since used materials are collected and reused, it is possible to minimize the burden on the environment, and it is possible to achieve both convenience of living and environmental / resource problems. In other words, it aims to fundamentally reform the production / consumption cycle based on conventional mass consumption of petroleum resources.
[0029]
  This will be described below with reference to the drawings. FIG. 1 is a flowchart showing an embodiment of a filter recycling method according to the present invention. In FIG. 1, 1 is a fiber material having water resistance and solvent resistance selected according to the use temperature, use environment, application, etc., and this fiber material 1 is a dry method by indirect spinning using a card, land webber, melt blow, The web is formed through a web type process A such as a dry method by direct spinning such as spunbond or a wet method in which short fibers are dispersed in water to make paper.
[0030]
  Next, the web is heat-bonded (hot roll, hot air passage device, etc.), mechanically bonded (needle punch, water needle, etc.), and chemically bonded with a solvent-resistant resin (PVA, epoxy resin, etc.). After performing the primary bonding treatment step B appropriately combined as necessary, the filter substrate 2 is produced through the drying treatment step C.
[0031]
  Next, the filter substrate 2 is obtained by adjusting the density of a thermoplastic elastomer binder resin dissolved in an organic solvent in a secondary bonding treatment step D such as a spray method, a dipping method, a coating method, etc. After coating a predetermined amount of the binder resin, a desired filter 3 in which the binder resin was firmly fixed between the surface of the filter substrate and the entangled fibers was produced through a drying step E.
[0032]
  By the way, in the binder resin dissolved in the organic solvent, an ion exchange material, a dehumidifying agent, a deodorant, a magnetic substance, an inorganic powder, and the like are given as a function-expressing material depending on the application.The
[0033]
  As the binder resin, in particular, styrene-butadiene-styrene (SBS) or styrene-ethylene-butylene-styrene (SEBS), which is a styrene copolymer, is mainly composed of fibers and adsorptive substances. Optimal for adhesion and excellent chemical resistance.
[0034]
  As the organic solvent, one or more selected from xylene, toluene, methylcyclohexane, tetrahydronaphthalene, and the like can be used.
[0035]
  Next, the filter 3 that has been used for a certain period of time and subjected to adsorption / filtration is exchanged with an organic solvent similar to the organic solvent used in the primary bonding treatment step B. The recovery treatment step G (cleaning or heat treatment as necessary) ) To obtain a filter substrate 2 from which the binder resin was dissolved and the adsorbed and filtered substance was removed. The filter substrate 2 is then washed / dried and recycled to the secondary bonding process D.
[0036]
  By the way, although the illustration of the adsorbed / filtered substance in the mixture of the binder resin and the adsorbed / filtered substance is omitted, it is settled and removed in the recovery processing step G, and then dried to be compacted as a solid content and subjected to an analysis step. Separated into reusable and waste. Further, the binder resin and the organic solvent are subjected to concentration analysis / drying treatment and recycled to the secondary binding treatment step D. At this time, the adsorbed / filtered substance that dissolves in the organic solvent may be separated and recovered by evaporating and recovering the organic solvent, or the function-expressing material and the adsorbed / filtered substance are separated and recovered in a separate process. It is also possible to increase the purity of the adsorbate while regenerating the material and reuse it.
[0037]
  Furthermore, if the filter base material cannot be used after being recycled several times after being recycled several times, it is separated into the fiber material alone or the fiber material and the resin used in the primary bonding process, and the fiber material is melted pellets. It is possible to melt and spin, or to recycle and reuse as the fiber material 1, or to wash and dry the resin for reuse.
[0038]
  By the way, as another embodiment of the present invention, it is possible to omit the primary bonding process and perform only the secondary bonding process on the web.
[0039]
【Example】
  Hereinafter, the present invention will be described more specifically with reference to examples.
[0040]
[Example 1]
(Reference example)
  After forming into a sheet by a normal papermaking method using split-type polyolefin fibers (trade name DF-72, manufactured by Daiwa Boseki Co., Ltd., fineness 2d before splitting, fineness 0.2d after splitting) made of polyethylene and polypropylene, water jet processing is performed. The constituent fibers are entangled and the fibers are divided and then heat calendered to a basis weight of 60 g / m²A nonwoven sheet having a thickness of 1 mm was produced.
[0041]
  Next, after impregnating the nonwoven fabric sheet with a slurry having the following blending condition 1, the solvent was evaporated by drying with hot air at 80 ° C. for 5 minutes. The adhesion amount of the solid content of the following composition is 10 g / m.², Weight per unit 70g / m²A nonwoven sheet having a thickness of 1 mm was produced.
[0042]

  The obtained non-woven sheet was wound around a polypropylene porous core (a porous cylinder having an outer diameter of 30 mm and a length of 250 mm) at a thickness of 30 mm, and the density of the filter layer was 0.255 g / cm.^ThreeA cartridge filter was formed. Next, a filtration test was performed using the cartridge filter. In the filtration test, a water suspension of test dust (Kanto loam, average particle diameter of 8 μm) adjusted to a concentration of 200 ppm was stirred uniformly, and 10 liters / minute from the outside to the inside of the cartridge filter. Flowed 200 liters at a speed. As a result, the filtration accuracy was 5 μm, and the initial filtration efficiency was 81.5%. The filtration accuracy and initial filtration efficiency were calculated by the following measurement methods.
(1) Filtering accuracy: The clean water obtained as described above is collected, and the particle diameter is measured with an ultracentrifugal automatic particle size distribution measuring device (manufactured by Minato Seisakusho). The maximum particle diameter (μm) Evaluate with.
(2) Initial filtration efficiency: 1 liter of the above suspension is collected, the dust weight after drying is A, 1 liter of clean water is collected after 1 minute of filtration, and the dust weight after drying is B Calculated by the following formula. Initial filtration efficiency (%) = [(A-B) / A] x 100
[0043]
  Next, the used cartridge filter was washed with xylol, and the collected matter was removed together with the SEBS resin. Next, the slurry of the above blending condition 1 was impregnated again, and the SEBS resin was coated on the constituent fibers of the cartridge filter by the same means and regenerated. When the above-described filter test was performed again using the regenerated cartridge filter, the filter accuracy was 5 μm and the initial filter efficiency was 81.3%, which was almost the same as the first test.
[0044]
[Example 2]
  After forming into a sheet by a normal papermaking method using split-type polyolefin fibers (trade name DF-72, manufactured by Daiwa Boseki Co., Ltd., fineness 2d before splitting, fineness 0.2d after splitting) made of polyethylene and polypropylene, water jet processing is performed. The constituent fibers are entangled and the fibers are divided and then heat calendered to a basis weight of 60 g / m²A nonwoven sheet having a thickness of 1 mm was produced.
[0045]
  Next, after impregnating the nonwoven fabric sheet in a slurry having the following blending condition 2, the solvent was evaporated by drying with hot air at 80 ° C. for 5 minutes. The adhesion amount of the solid content of the following composition is 10 g / m.², Weight per unit 70g / m²A nonwoven sheet having a thickness of 1 mm was produced.

  The obtained nonwoven fabric sheet was formed on a cartridge filter by the same means as in Example 1, and a filtration test was conducted in the same manner as in Example 1. As a result, the filtration accuracy was 4 μm and the initial filtration efficiency was 83.5%. sothere were.
  Next, the used cartridge filter was washed with xylol, and the collected product was removed together with the SEBS resin and ion-exchange resin fine powder. Next, the slurry of the above blending condition 2 was impregnated again, and the SEBS resin was coated on the constituent fibers of the cartridge filter by the same means and regenerated. When the above-described filter test was performed again using the regenerated cartridge filter, the filter accuracy was 4 μm and the initial filter efficiency was 83.3%, which was almost the same as the first test.
[0046]
[Example 3]
(Reference example)
  Polyester fiber (made by Unitika) 15d x 80 wt%, 6 nylon (made by Unitika) 14d x 20 wt% are mixed, and the basis weight is 100 g / m through the card process.²The web was formed. Next, using a resin having the following compounding condition 3 as a primary binding treatment agent, the adhesion amount is 100 g / m.²Spraying process, 100 ~ 150 ℃ drying process, 200g / m²A filter substrate having a thickness of 15 mm was prepared.
[0047]
  Next, the adhesion amount 150 g / m with the resin of the following compounding condition 3 as a secondary bond treating agent²Immersion process, and a drying process at 100 ° C. is performed to have a basis weight of 350 g / m²A filter having a thickness of 14 mm was produced.

  After the above filter has been used as a coarse dust filter for 2 months, the xylol was washed while warming to 50 ° C. as a recovery treatment step, and after the binder resin was dissolved, the filter substrate was dried and recovered. And could be reused in the secondary bonding process. Further, the binder resin and the organic solvent in the mixture of the binder resin and the filtration substance were recycled to the secondary bonding treatment step, and the filtration substance was settled and removed, and then dried to be compacted as a solid content. These compact solids contain 1m²About 700 g of dust, carbon black, and linter mixture were included.
[0048]
[Example 4]
  Polypropylene fiber (manufactured by Daiwabo) 3d x 100% by weight through the card process 150g / m²After forming the web, 100 P / cm²Processed with a needle punch. Next, an adhesion amount of 50 g / m with a resin having the following blending condition 5 as a primary binding treatment agent.²Spray processing, drying process at 100-150 ° C., basis weight 200 g / m²A filter substrate having a thickness of 3.5 mm was produced.
[0049]
  Next, the amount of adhesion is 100 g / m with the resin and ion exchange material of the following blending condition 6 as the secondary bond treating agent.²350g / m²A filter having a thickness of 3 mm was produced.

  After using the above filter as a plating drainage filter for a week, the xylol was washed while heating to 80 ° C. as a recovery treatment step, and after dissolving the binder resin, the filter substrate was dried and recovered. It could be reused in the secondary bonding process. The binder resin and organic solvent in the mixture of binder resin and ion exchange material and adsorbent are recycled to the secondary binding treatment process, and the mixture of ion exchange material and adsorbent is settled and removed, and then dried and solidified. Compacted as minutes. These compacted solids contained harmful heavy metal ions such as nickel and chromium in the ion-exchange material in addition to the inorganic residue usually filtered as an adsorbent.
[0050]
[Example 5]
  After forming a web of polypropylene resin by the spunbond method, it is hot-rolled to have a basis weight of 50 g / m²A filter substrate having a thickness of 0.3 mm was produced.
[0051]
  Next, the amount of adhesion is 50 g / m with a resin and deodorant as shown in the following blending condition 7 as a secondary binding treatment agent.²Coating process, drying process at 100 ° C., basis weight 100 g / m²A filter with a thickness of 0.5 mm was produced.

  After using the above filter as a household indoor deodorizing filter for one month, the xylol was washed while heating to 80 ° C. as a recovery treatment step, and after dissolving the binder resin, the filter substrate was dried and recovered. However, it could be reused in the secondary bonding process. The binder resin and organic solvent in the mixture of the binder resin and the deodorant material that absorbs malodorous components such as ammonia, hydrogen sulfide, and mercaptan are recycled to the secondary bonding treatment process. It was compacted as a solid content and regenerated by baking and heating.
[0052]
【The invention's effect】
  As explained above,Of the present inventionAccording to the recyclable filter, an adsorbent material is bound to a filter base material using a binder resin soluble in an organic solvent to improve the adsorption separation function. The binder resin is dissolved and removed using a solvent, and the adsorbate and adsorbent material can be separated from the filter base material to further improve the collection efficiency and efficiently and rationally collect from the used filter. Objects can be removed and reused.
[0053]
  Next, the present inventionanotherAccording to the recyclable filter, a filter base material is coated with a binder resin soluble in an organic solvent, the used filter is dissolved and removed using an organic solvent, and the filter base material is used. By applying a conductive treatment such as plating with a metal or metal alloy containing nickel, copper, and silver, or carbon coating to a filter that enables separation of the filtration material from the filter, the filter becomes suitable.
[0054]
  Next, according to the recycling method of the recyclable filter of the present invention, a thermoplastic elastomer which is soluble in an organic solvent and has heat resistance and chemical resistance on a filter substrate made of fibers having heat resistance and solvent resistance. The used filter having the binder resin as a main component fixed thereon is dissolved and removed with an organic solvent that dissolves the binder resin, and the filter material is removed from the filter base material, thereby repeatedly removing the filter. Can be used.
[Brief description of the drawings]
FIG. 1 is a flowchart showing an embodiment of a filter recycling method according to the present invention.
[Explanation of symbols]
1 Textile material
2 Filter base material
3 Filter
A web formation process
B Primary join processing
C Drying process
D Secondary bond processing
E Drying process
F Adsorption / filtration use
G Recovery process

Claims (10)

  An adsorbent material is bound to a filter base material using a binder resin that is soluble in an organic solvent, thereby improving the adsorption separation function. A recyclable filter characterized in that the adsorbate and adsorbent material can be separated from the filter substrate while dissolving and removing the filter. The filter substrate is made of a fiber material having solvent resistance, polyester fiber, polyolefin fiber, polyimide fiber, organic fiber containing fluorine fiber, glass fiber, carbon fiber, potassium titanate fiber, inorganic fiber containing alumina fiber, The recyclable filter according to claim 1 , which is at least one fiber selected from metal fibers containing stainless steel and nickel. The recyclable filter according to claim 1 , wherein the binder resin is a resin having heat resistance and chemical resistance. Binder resin having heat resistance and chemical resistance is obtained from styrene thermoplastic elastomer, styrene-butadiene-styrene (SBS) block copolymer, and styrene-ethylene-butylene-styrene (SEBS) block copolymer. The recyclable filter according to claim 3 , comprising at least one selected polymer as a main component. The recyclable filter according to claim 1 , wherein the adsorptive material is at least one material selected from a hygroscopic material, a deodorizing material, CO, and a hydrogen adsorbing material. The adsorptive material is at least one selected from an organic ion exchange resin, an inorganic ion exchanger, and a mixture thereof, and the exchange group is at least one selected from cationic, anionic, and a mixture thereof. The recyclable filter according to claim 1 , wherein the adsorbate adsorbed on the adsorbent material is a metal ion and a complex thereof, and is a metal ion separation filter that separates the adsorbate and solidifies. The adsorptive material is a magnetic substance, and is a magnetic powder removal filter that is magnetized after being bonded to a filter substrate by binding magnetic powder before magnetization with a binder resin. The recyclable filter according to claim 1 , wherein the recyclable filter is aggregated and solidified.   Recycle wherein the filter according to claim 1 is subjected to at least one conductive treatment selected from plating treatment, vapor deposition treatment, sputtering treatment and carbon coating of a metal or metal alloy containing nickel, copper and silver to form an electromagnetic shielding filter. Sex filter. Thermoplastic elastomer which is soluble in at least one organic solvent selected from xylene, toluene, methylcyclohexane and tetrahydronaphthalene and has heat resistance and chemical resistance on a filter substrate made of fibers having heat resistance and solvent resistance was fixed to a binder resin composed mainly, the used filter, with dissolution to remove the binder resin using the organic solvent for dissolving the binder resin, regeneration of recyclability filter for removing filtered material from the filter substrate Method. From the filter base material, after removal of the binder resin and the filtration material, according to claim 9 for fixing the binder resin as a main component a thermoplastic elastomer having a soluble in and heat resistance and chemical resistance again in an organic solvent To recycle recyclable filters.

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