JP6993944B2 - Manufacturing equipment and manufacturing method for filter molded products - Google Patents

Description

The present invention relates to a method for efficiently manufacturing a filter (a water purifier filter of a water purifier or a filter of an air purifier) for removing impurities in a liquid or gas, and a manufacturing apparatus thereof.

It is widely practiced to utilize the adsorptivity of activated carbon to selectively separate, remove and purify specific substances in gases and liquids, such as deodorization and water purification. Typical examples include water purifiers (pot type, faucet direct connection type, faucet integrated type, stationary type, etc.) and air purifiers. In particular, many replacement cartridge filters for water purifiers used in ordinary households use granular or fibrous activated carbon (purifying material) to adsorb and remove residual chlorine and organic substances. As a specific structure, a layer of granular or fibrous activated carbon is formed in a space partitioned by a membrane having small-diameter pores through which activated carbon does not pass and only water passes through, and this layer of activated carbon is formed. The water is purified by passing through.

However, in a replacement cartridge filter with such a structure, when water passes through the layer of activated carbon, it often naturally has a water path, and once the water path is formed, the flow of water concentrates on that part. Since activated carbon can only be used partially, the water purification function cannot be fully exerted. In addition, the membrane having small-diameter pores cannot completely prevent the passage of granular activated carbon, and there is also the inconvenience that the activated carbon particles are mixed in the water after passing through the filter.

Such a problem can be solved by molding a purifying material such as activated carbon into a porous body having a certain shape and using it. As a method of molding into a porous body, a powder of a polymer binder (thermoplastic resin, etc.) is added to the purifying material, and the polymer binder is melted by heating and pressurizing in a mold to melt the purifying material. A method of adhering and integrating them with each other is known. More specifically, for example, as disclosed in Patent Document 1 and Patent Document 2, the raw material for one filter molded body is put into a mold having a constant height, and the raw material is filled and heated for each one. , Pressurization, cooling, and mold release.

However, these methods require a lot of man-hours, and it is necessary to prepare a large number of molds in order to manufacture a large amount of filter molded products, which poses a problem in terms of productivity and cost.

As a method for increasing the productivity of a filter molded product, Patent Document 3 discloses a method to which an extrusion method is applied. After the main material (activated carbon) and the binder material (solid resin particles) are mixed, they are heated and cooled in the die to form a solid composite material (mixed raw material), and an extrusion screw is specified as the pressurization method. ing. Extrusion of the solid composite material (mixed raw material) by such a screw has an advantage that the main material (activated carbon) and the binder material (solid resin particles) can be easily mixed uniformly.

Japanese Unexamined Patent Publication No. 2001-187305 Japanese Patent Application Laid-Open No. 2003-266462 Japanese Patent No. 2927549

However, for example, when a large amount of mixed raw materials are input in order to continuously extrude a filter molded product for the purpose of improving productivity, the torque required to rotate the screw is required when the mixed raw materials are extruded by a screw. May become too large to rotate. In order to solve this problem, if the screw is shortened or the motor is made larger, the screw can be rotated, but due to the increased torque, the purifying material (activated carbon, etc.) may be excessively crushed. Since the voids are crushed, it may not be possible to obtain a porous body having sufficient voids as a filter for purification. Further, due to the rotational operation, the polymer binder is excessively stretched and covers the surface of the purifying material, so that sufficient performance as a filter for purifying may not be obtained.

Therefore, in the present invention, even when the filter molded product is continuously extruded, the purifying material is excessively crushed, and further, the polymer binder is excessively stretched to cover the surface of the purifying material. It is an object of the present invention to provide a manufacturing apparatus capable of forming a porous body having sufficient voids and manufacturing a filter molded body having excellent purification performance, and a manufacturing method thereof. ..

Means for Solving Problems and Effects of Invention

The present invention is a manufacturing apparatus for molding a filter molded product made of a porous body to which a purifying material is fixed by a polymer binder.
Cylindrical cylinder and
An input port provided on the outer peripheral surface of the one end side of the cylinder and into which a mixed raw material of the purifying material and the polymer binder is charged into the inside of the cylinder.
With a ram rod that is in sliding contact with the inner peripheral surface of the cylinder and is slidable in the axial direction of the cylinder,
It is characterized by including a heater that covers a heating zone formed of at least a part of the outer peripheral surface of the cylinder on the other end side of the charging port.

In the above configuration, the mixed raw material of the purifying material and the polymer binder, which is charged into the cylinder from the charging port, is pressed by the ram rod advancing and sliding on the inner peripheral surface of the cylinder. Then, the pressed mixed raw material is transferred to the heating zone by further pressing of the lamb rod, and is heated by the heater covering the heating zone to melt the polymer binder. After that, the mixed raw material leaves the heating zone by further pressing of the lamb rod, and the polymer binder is cooled below the melting point to form a filter molded product made of a porous body in which the purifying material is fixed by the polymer binder. It is formed. Further, after the ram rod is retracted to the charging port, the mixed raw material is further charged from the charging port, and the ram rod is advanced and pressed to bring the newly charged mixed raw material into the already charged mixed raw material. The already formed filter molded body can be pushed forward while being compacted between the and the ram rod.
In this way, the filter molded body can be continuously formed by repeating the forward movement, the backward movement of the ram rod, and the charging of the mixed raw material.
Here, in the above configuration, a ram rod that is slidably contacted with the inner peripheral surface of the cylinder and can slide linearly in the axial direction of the cylinder is used for pressing the mixed raw material without using a screw.
By extruding the mixed raw material with a screw, there is an advantage that the purifying material and the polymer binder can be easily mixed uniformly. However, for example, when a large amount of mixed raw materials are input in order to continuously extrude a filter molded product for the purpose of improving productivity, the torque required to rotate the screw is required when the mixed raw materials are extruded by a screw. May become too large to rotate. In order to solve this problem, if the screw is shortened or the motor is made larger, the screw can be rotated, but due to the increased torque, the purifying material (activated carbon, etc.) may be excessively crushed. Since the voids are crushed, it may not be possible to obtain a porous body having sufficient voids as a filter for purification. Further, due to the rotational operation, the polymer binder is excessively stretched and covers the surface of the purifying material, so that sufficient performance as a filter for purifying may not be obtained.
Therefore, by using a lamb rod to make the mixed raw material pressable linearly, it is possible to prevent the purifying material from being excessively crushed, and further, the polymer binder is excessively stretched to purify. It is possible to prevent the surface of the material from being covered. This makes it possible to provide a manufacturing apparatus capable of forming a porous body having sufficient voids as a filter for purification and manufacturing a filter molded body having excellent purification performance.

Further, the present invention is characterized in that, in the apparatus for manufacturing the filter molded product, the temperature of the heating zone of the cylinder is set to be 10 ° C. to 150 ° C. higher than the melting point of the polymer binder.

If the temperature of the heating zone is too low, it takes time for the polymer binder to melt, so that it is necessary to slow down the extrusion rate of the mixed raw material, which reduces productivity. On the other hand, if the temperature of the heating zone is too high, the fluidity of the molten polymer binder becomes too high, and the molten polymer binder covers the surface of the purifying material, which is sufficient as a filter for purification. You will not be able to obtain good performance. Therefore, by setting the temperature of the heating zone 10 ° C to 150 ° C higher than the melting point of the polymer binder, it is possible to prevent the productivity from decreasing and to form a filter having sufficient performance as a filter for purification. The body can be manufactured.

Further, the present invention is characterized in that, in the apparatus for manufacturing the filter-molded body, the axial length of the heating zone in the cylinder is in the range of 3 to 20 times the diameter length of the filter-molded body. It is supposed to be.

If the axial length of the heating zone is less than 3 times the diameter length of the filter molded product to be molded, it is necessary to extremely slow the extrusion rate of the mixed raw material in order to melt the polymer binder in the mixed raw material. There is a significant decrease in productivity. On the other hand, if the axial length of the heating zone is longer than 20 times the diameter length of the filter molded body to be molded, the extrusion resistance due to the friction between the mixed raw material and the inner peripheral surface of the cylinder becomes too large, and the mixed raw material is stabilized. It may not be possible to extrude. Therefore, by setting the length of the heating zone in the range of 3 to 20 times the diameter length of the filter molded product, it is possible to prevent the productivity from decreasing and to stably and efficiently manufacture the filter molded product. be able to.

Further, the present invention is characterized in that the apparatus for manufacturing the filter molded product includes a cooler that covers a cooling zone formed of at least a part of the outer peripheral surface of the cylinder on the other end side of the heating zone. There is.

By providing the above-mentioned cooler, the mixed raw material containing the polymer binder melted in the heating zone leaves the heating zone and shifts to the cooling zone by further pressing of the lamb rod. The cooler in this cooling zone rapidly cools the polymer binder below the melting point to form a filter molded product made of a porous body to which the purifying material is fixed by the polymer binder in a short time. be able to.

Further, in the present invention, in the apparatus for manufacturing the filter-molded article, the axial length of the cooling zone in the cylinder is in the range of 0.5 to 10 times the diameter length of the filter-molded article. It is characterized by.

When the axial length of the cooling zone is shorter than 0.5 times the diameter length of the filter molded body to be molded, the purifying material is sufficiently cooled and solidified to form a porous body to which the purifying material is fixed by the polymer binder. In order to form the mixture, it is necessary to extremely slow the extrusion rate of the mixed raw material, which significantly reduces the productivity. On the other hand, if the axial length of the cooling zone is longer than 10 times, the extrusion resistance due to the friction between the mixed raw material and the inner peripheral surface of the cylinder becomes too large, and the mixed raw material may not be stably extruded. .. Therefore, by setting the length of the cooling zone in the range of 0.5 to 10 times the diameter length of the filter molded product, it is possible to prevent the productivity from decreasing, and to stably and efficiently produce the filter molded product. Can be manufactured.

Further, the present invention relates to the above-mentioned apparatus for manufacturing a filter molded product.
With a hopper that can put the stored mixed raw material into the inlet,
A reciprocating drive that enables reciprocating movement of the ram rod forward and backward,
(1) Raw material charging operation in which a predetermined amount of the mixed raw material is charged into the inside of the cylinder from the hopper via the charging port.
(2) A pressing operation in which the reciprocating drive advances the ram rod and slides the inner peripheral surface of the cylinder to press the charged raw material.
(3) A retreat operation in which the reciprocating drive retracts the ram rod.
It is characterized by being provided with a control device for controlling the operations (1) to (3) to be repeatedly executed.

According to the above configuration, the control device inputs the mixed raw material from the hopper into the cylinder, drives the reciprocating drive, and advances the ram rod to press the charged mixed material to press the reciprocating drive. Drive and retract the ram bar. By controlling a series of operations by the control device, it is possible to efficiently manufacture a filter molded product having excellent purification performance.

Further, the present invention relates to the above-mentioned apparatus for manufacturing a filter molded product.
Further equipped with a cutting device provided near the other end of the cylinder,
The control device cuts the porous body extruded from the other end of the cylinder by the pressing operation of the cutting device (2) while the retracting operation of the (3) is being performed. , It is characterized in that it is controlled to be processed into the filter molded body.

While the ram rod is retracting, the porous body to which the purifying material is fixed by the polymer binder is stationary in a state of being extruded from the other end of the cylinder, so that even a fixed cutting device can accurately filter. Can be cut into the body.
Further, in a series of operations of (1) raw material feeding operation, (2) pressing operation, and (3) retreating operation, the operation of cutting the porous body by the cutting device can be executed in parallel with the retreating operation. Therefore, productivity can be improved.
Further, by cutting the continuously extruded porous body and processing it into a filter molded body, it becomes possible to manufacture a long filter molded body, which was difficult with the mold batch production method.

Further, the present invention may be characterized in that the hopper of the apparatus for manufacturing the filter molded product is provided with a temperature controller for preheating the stored mixed raw materials.

According to the above configuration, by attaching a temperature controller to the hopper and preheating the mixed raw material, the mixed raw material can be melted in a short time to form a porous body. As a result, the amount of the mixed raw material charged into the cylinder can be increased as compared with the case where the mixed raw material is not preheated. As a result, the extrusion speed of the mixed raw material (porous material) is increased, and the productivity of the filter molded product can be improved.

Further, in the present invention, it is preferable that the preheating temperature of the mixed raw material by the temperature controller is set to be 50 ° C. to 20 ° C. lower than the melting point of the polymer binder in the mixed raw material.

By setting the preheating temperature, it is not necessary to raise the heating temperature in the heating zone excessively, and the mixed raw material is melted in a short time without making the length of the heating zone excessively long, and the mixture is porous. Can be a body.

Further, the present invention is characterized in that, in the ram rod of the apparatus for manufacturing the filter molded product, a resin ram chip is attached to a portion in contact with the mixed raw material.

By arranging the resin ram chips at the portions of the ram rods that come into contact with the mixed raw materials, it is possible to form a structure having excellent heat resistance and wear resistance.

Further, the present invention is a method for producing a filter molded body made of a porous body in which a purifying material is fixed by a polymer binder.
A raw material charging step of charging a predetermined amount of a mixed raw material of the purifying material and the polymer binder into the inside of the cylinder through a charging port provided in the tubular cylinder.
By advancing the ram rod slidable in the axial direction on the inner peripheral surface of the cylinder and sliding the inner peripheral surface of the cylinder, the outer peripheral surface of the cylinder is pressed while the charged raw material is pressed. A pressing process, which transfers at least part of the cylinder to a heating zone covered by a heater,
It is characterized in that the above-mentioned process including the retreating step of retracting the ram rod is repeated.

In the above method, the mixed raw material of the purifying material and the polymer binder, which is charged into the cylinder from the charging port, is pressed by the ram rod advancing and sliding on the inner peripheral surface of the cylinder. Then, the pressed mixed raw material is transferred to the heating zone by further pressing of the lamb rod, and is heated by the heater covering the heating zone to melt the polymer binder. After that, the mixed raw material leaves the heating zone by further pressing of the lamb rod, and the polymer binder is cooled below the melting point, so that a filter molded product made of a porous body in which the purifying material is fixed by the polymer binder is formed. Manufactured. Further, after the ram rod is retracted to the charging port, the mixed raw material is further charged from the charging port, and the ram rod is advanced and pressed to bring the newly charged mixed raw material into the already charged mixed raw material. The already formed filter molded body can be pushed forward while being compacted between the and the ram rod.
In this way, by repeating the forward movement, the backward movement of the ram rod, and the charging of the mixed raw material, the filter molded product can be continuously manufactured.
Here, in the above method, a ram rod that is slidably contacted with the inner peripheral surface of the cylinder and can be slid linearly in the axial direction of the cylinder is used for pressing the mixed raw material without using a screw.
By extruding the mixed raw material with a screw, there is an advantage that the purifying material and the polymer binder can be easily mixed uniformly. However, for example, when a large amount of mixed raw materials are input in order to continuously extrude a filter molded product for the purpose of improving productivity, the torque required to rotate the screw is required when the mixed raw materials are extruded by a screw. May become too large to rotate. In order to solve this problem, if the screw is shortened or the motor is made larger, the screw can be rotated, but due to the increased torque, the purifying material (activated carbon, etc.) may be excessively crushed. Since the voids are crushed, it may not be possible to obtain a porous body having sufficient voids as a filter for purification. Further, due to the rotational operation, the polymer binder is excessively stretched and covers the surface of the purifying material, so that sufficient performance as a filter for purifying may not be obtained.
Therefore, by using a lamb rod to make the mixed raw material pressable linearly, it is possible to prevent the purifying material from being excessively crushed, and further, the polymer binder is excessively stretched to purify. It is possible to prevent the surface of the material from being covered. As a result, it is possible to form a porous body having sufficient voids as a filter for purification, and to manufacture a filter molded body having excellent purification performance.

Further, in the above manufacturing method, the present invention is a cutting step of cutting the porous body extruded from the cylinder by the pressing step while the retreating step is being performed, and processing the porous body into the filter molded body. Is further included.

While the ram rod is retracting, the porous body to which the purifying material is fixed by the polymer binder is stationary in a state of being extruded from the other end of the cylinder, so that it can be accurately cut into a filter molded body. can.
Further, in the series of operations of the raw material charging step, the pressing step, and the retreating step, the cutting step of cutting the porous body can be executed in parallel with the retreating step, so that the productivity can be improved. ..
Further, by cutting the continuously extruded porous body and processing it into a filter molded body, it becomes possible to manufacture a long filter molded body, which was difficult with the mold batch production method.

Even when the filter molded product is continuously extruded, it is possible to prevent the purifying material from being excessively crushed and further, preventing the polymer binder from being excessively stretched and covering the surface of the purifying material. It is possible to provide a manufacturing apparatus capable of forming a porous body having sufficient voids and manufacturing a filter-molded body having excellent purification performance, and a manufacturing method thereof.

It is sectional drawing of the faucet direct connection type water treatment apparatus using the filter molded body obtained by the manufacturing apparatus and manufacturing method which concerns on this embodiment. It is sectional drawing in the vertical direction of the manufacturing apparatus which concerns on this embodiment (the explanatory view of the raw material input process). It is a block diagram of the computer of the manufacturing apparatus which concerns on this embodiment. It is explanatory drawing of the pressing process of the manufacturing method which concerns on this embodiment. It is explanatory drawing of the retreat process and the cutting process of the manufacturing method which concerns on this embodiment.

(Embodiment)
Hereinafter, embodiments of the present invention will be described.

(Filter molded body 1)
The filter molded body 1 obtained by the manufacturing apparatus 10 and the manufacturing method of the present embodiment is typically cylindrical, and is, for example, a filter for a water treatment device of a water treatment device 100 directly connected to a faucet as shown in FIG. Used for 101. The filter 101 for a water treatment device is housed in a filter storage chamber 100a formed in the water treatment device 100. The filter 101 for a water treatment device is composed of a filter molded body 1, a filtration layer 102 that covers the outer peripheral surface of the filter molded body 1, and a pair of caps 103 that are attached to the upper surface and the lower surface of the filter molded body 1. The cap 103 is attached (with watertightness) in close contact with the filter molded body 1. A switching plate 104 for switching the flow of water supplied from the faucet 106 is arranged in the water treatment device 100, and is supplied from the faucet 106 in a state where the switching plate 104 is arranged at the position shown in FIG. The fresh water passes through the water treatment device filter 101. Specifically, the flow of water passing through the filter 101 for a water treatment device first passes through the filtration layer 102 to remove relatively large dust and the like, and then passes through the filter molded body 1 to obtain residual chlorine and the like. Organic substances and the like are removed, and then the water flows out from the water purification port 105.

The filter molded body 1 is a solid activated carbon molded body obtained by solidifying a purifying material made of granular or powdered activated carbon with a polymer binder having a high molecular weight and a low melt index as a binder. As the polymer binder, for example, ultra-high molecular weight polyethylene having an average molecular weight of about several hundred thousand to several million is used. The filter molded body 1 is a porous body containing a large number of voids. The purifying material is fixed to the polymer binder so as to be exposed in the voids, and can adsorb harmful substances (residual chlorine, organic substances, etc.) contained in water passing through the voids.

(Manufacturing device 10 of filter molded body 1)
As shown in FIG. 2, the manufacturing apparatus 10 of the filter molded body 1 includes a cylinder 11 having a charging port 12 on the outer peripheral surface 11a, a raw material charging hopper 13 connected to the charging port 12, and a cylinder 11. A ram rod 14 that is in sliding contact with the peripheral surface 11b and can slide in the axial direction of the cylinder 11, a hydraulic cylinder 15 (reciprocating drive), a heater 16 (heater) that covers the outer peripheral surface 11a of the cylinder 11, and a cylinder 11. A water-cooled jacket 17 (cooler) that covers the outer peripheral surface 11a of the cylinder 11, a cutting device 18 provided near the end portion 11d on the outlet side of the cylinder 11, and a computer 19 (control device) are provided. ..

In the manufacturing apparatus 10, the control system by the computer 19 is not an indispensable element, and the system may not be controlled by the computer 19.

The cylinder 11 has a cylindrical shape and is made of steel. The charging port 12 is formed on the outer peripheral surface 11a of the cylinder 11 on the end portion 11c side (inlet side) of the cylinder 11.

The raw material input hopper 13 stores a mixed raw material 2 of a purifying material made of granular or powdered activated carbon and a polymer binder such as a thermoplastic resin, and a predetermined amount is stored at an appropriate timing according to a control command from the computer 19. The mixed raw material 2 can be charged into the cylinder 11 via the charging port 12.

As the raw material input hopper 13, one that is not controlled by the computer 19 may be used. In this case, the mixed raw material 2 is separately weighed by a weighing device and then charged into the raw material charging hopper 13. Then, the mixed raw material 2 charged into the raw material charging hopper 13 is charged into the inside of the cylinder 11 through the charging port 12 by spontaneously falling into the gap in the cylinder 11 generated by the ram rod 14 retracting. ..

Further, the raw material input hopper 13 may be equipped with a temperature controller 20 for preheating the mixed raw material 2 stored in the raw material input hopper 13. In this case, the preheating temperature for the mixed raw material 2 is preferably set to be 50 ° C. to 20 ° C. lower than the melting point of the polymer binder in the mixed raw material 2 (“melting point −50 ° C.” to “melting point −20”). ℃ "). In this way, by attaching the temperature controller 20 to the raw material input hopper 13 to preheat the mixed raw material 2, it is not necessary to excessively raise the heating temperature in the heating zone 161 by the heater 16 described later, and the heating zone The mixed raw material 2 can be melted in a short time to form a porous body without making the length of 161 excessively long. As a result, the amount of the mixed raw material 2 charged into the cylinder 11 can be increased as compared with the case where the mixed raw material 2 is not preheated. As a result, the extrusion speed of the porous body can be increased, and the productivity can be improved.

The ram rod 14 is provided at the center of the side surface of the ram chip 141 on the end portion 11d side of the ram chip 141 that comes into contact with the mixed raw material charged from the charging port 12 and actually slides into the inner peripheral surface 11b of the cylinder 11. It includes a mandrel 142 extending along the axial direction of the cylinder 11 and a support rod 143 provided at the center of the side surface of the end portion 11c side of the ram chip 141 and extending along the axial direction of the cylinder 11.

The ram chip 141 reduces the gap between the inner peripheral surface 11b of the cylinder 11 and prevents leakage of the mixed raw material 2 to the end portion 11c side, and the metal powder is caused by the interference between the support rod 143 and the inner peripheral surface 11b of the cylinder 11. Is slightly thicker than the support rod 143 and has a cylindrical shape having approximately the same dimensions as the inner diameter of the cylinder 11 in order to prevent the mixed raw material 2 from being contaminated. The material of the ram chip 141 is preferably a resin having excellent heat resistance and abrasion resistance, and examples thereof include phenol resin, epoxy resin, fluororesin, and polypropylene resin. Further, these resins may contain a reinforcing material, and examples of the reinforcing material include wood flour, cotton, and glass fiber. Of these, a phenol resin containing a cloth can be preferably used in consideration of strength and heat resistance.

The mandrel 142 has a cylindrical shape, and its outer diameter corresponds to the inner diameter of the filter molded body 1 to be molded. That is, the mandrel 142 plays a role of regulating the inner diameter of the filter molded body 1 to be molded. Further, the mandrel 142 preferably has a length such that the tip end portion 11d of the mandrel 142 and the end portion 11d of the cylinder 11 are substantially at the same position when the ram rod 14 advances in the cylinder 11 (see FIG. 4). The support rod 143 serves to support the ram chip 141. The outer diameter of the support rod 143 is made smaller than the outer diameter of the ram tip 141 so as not to slide on the inner peripheral surface 11b of the cylinder 11. As a result, the frictional resistance generated during the axial reciprocating operation of the ram rod 14 is reduced.

The hydraulic cylinder 15 enables the support rod 143 to reciprocate in the axial direction of the cylinder 11 at an appropriate timing by a control command from the computer 19. As a result, the ram rod 14 in the cylinder 11 is subjected to either a forward operation of moving to the end 11d side (outlet side) or a backward operation of moving to the end 11c side (inlet side). be able to.

As the hydraulic cylinder 15, a hydraulic cylinder 15 that is not controlled by the computer 19 may be used. In this case, the hydraulic cylinder 15 is operated by switching the operating direction with a limit switch. The operation direction of the hydraulic cylinder 15 is switched by switching with this limit switch, and the forward operation of moving the ram rod 14 in the cylinder 11 to the end 11d side (outlet side) and the end 11c side (inlet side). ) Is switched between the backward movement and the backward movement.

The heater 16 covers the heating zone 161 set on the outer peripheral surface 11a on the end 11d side of the input port 12 of the cylinder 11. The axial length of the heating zone 161 in the cylinder 11 is preferably in the range of 3 to 20 times (more preferably in the range of 5 to 15 times) the outer diameter (diameter length) of the filter molded body 1 to be molded. ). When the axial length of the heating zone 161 is shorter than 3 times the outer diameter of the filter molded body 1 to be molded, the extrusion speed of the mixed raw material is extremely slowed down in order to melt the polymer binder in the mixed raw material. This is necessary, and productivity is significantly reduced. On the other hand, when the axial length of the heating zone 161 is longer than 20 times the outer diameter of the filter molded body 1 to be molded, the extrusion resistance due to the friction between the mixed raw material and the inner peripheral surface 11b of the cylinder 11 becomes too large. , It may not be possible to extrude the mixed raw material in a stable manner. For this reason, by setting the length of the heating zone 161 in the range of 3 to 20 times the outer diameter of the filter molded body 1, it is possible to prevent the productivity from decreasing, and to stabilize and efficiently. The filter molded body 1 can be manufactured.

Further, in the present embodiment, the heater 16 is provided so as to cover the entire outer peripheral surface 11a of the cylinder 11 in the heating zone 161. However, at least a part of the outer peripheral surface 11a of the cylinder 11 in the heating zone 161 is covered. It may be provided so as to cover it.

The temperature of the heating zone 161 heated by the heater 16 is determined by the melting point or softening point of the polymer binder in the mixed raw material 2, but is preferably 10 ° C to 150 ° C higher than the melting point of the polymer binder. It is better to be set (more preferably 30 ° C to 100 ° C higher, still more preferably 50 to 80 ° C higher). If the temperature of the heating zone 161 is too low, it takes time for the polymer binder to melt, so that it is necessary to slow down the extrusion speed of the mixed raw material 2, which lowers the productivity. On the other hand, if the temperature of the heating zone 161 is too high, the fluidity of the molten polymer binder becomes too high, and the molten polymer binder covers the surface of the purifying material. Sufficient performance cannot be obtained. For this reason, by setting the temperature of the heating zone 161 to be 10 ° C. to 150 ° C. higher than the melting point of the polymer binder as described above, it is possible to prevent a decrease in productivity and purify the mixture. It is possible to manufacture a filter molded body 1 having sufficient performance as a filter. The temperature of the heating zone 161 may be constant or may be changed depending on the location.

The water-cooled jacket 17 covers the cooling zone 171 set on the outer peripheral surface 11a on the end 11d side of the heating zone 161. The axial length of the cooling zone 171 in the cylinder 11 is preferably in the range of 0.5 to 10 times (more preferably 1 to 5 times) the outer diameter (diameter length) of the filter molded body 1 to be molded. Range). When the axial length of the cooling zone 171 is shorter than 0.5 times the outer diameter of the filter molded body 1 to be molded, the purifying material is porous with the purifying material fixed by the polymer binder due to sufficient cooling and solidification. In order to form a body, it is necessary to extremely slow the extrusion rate of the mixed raw material 2, which significantly reduces the productivity. On the other hand, when the axial length of the cooling zone 171 becomes longer than 10 times, the extrusion resistance due to the friction between the mixed raw material 2 and the inner peripheral surface 11b of the cylinder 11 becomes too large, and the mixed raw material 2 is stably extruded. When the ram rod 14 is extruded, the mixed raw material 2 clings to the mandrel 142, and when the ram rod 14 is retracted, the hugged mixed raw material 2 retracts together with the mandrel 142 and is charged inside the cylinder 11. There may be cases where a new mixed raw material 2 cannot be added due to the lack of voids. For this reason, by setting the length of the cooling zone 171 in the range of 0.5 to 10 times the outer diameter of the filter molded body 1, it is possible to prevent a decrease in productivity and to stabilize it. The filter molded body 1 can be efficiently manufactured.

Further, in the present embodiment, the water-cooled jacket 17 is provided so as to cover the entire outer peripheral surface 11a of the cylinder 11 in the cooling zone 171 but at least a part of the outer peripheral surface 11a of the cylinder 11 in the cooling zone 171. It may be provided so as to cover the. Further, examples of the refrigerant of the water-cooled jacket 17 include water and oil, and in the present embodiment, a method of winding the water-cooled jacket 17 around the outer peripheral surface 11a of the cylinder 11 is adopted for the sake of simplicity. As a cooling method, in the present embodiment, a cooling zone 171 is provided in order to accelerate the cooling rate, and the water-cooled jacket 17 is forcibly cooled. However, natural cooling is performed without using the water-cooled jacket 17 or the like. The mixed raw material 2 may be cooled by air cooling or air cooling.

The cutting device 18 includes a round blade that can be rotationally driven by driving a motor, and cuts the porous body extruded from the end portion 11d of the cylinder 11 at an appropriate timing by a control command from the computer 19. It is processed into a filter molded body 1.

As the cutting device 18, a cutting device 18 that is not controlled by the computer 19 may be used.

As shown in FIG. 3, the computer 19 includes an input unit 191 (operation buttons, keyboard, touch panel, etc.), a CPU 192, a storage device 193, and the like, and information is input from the input unit 191 and stored in the storage device 193. Based on the information, the input amount and input timing of the mixed raw material 2 by the raw material input hopper 13, the reciprocating operation of the ram rod 14 by the hydraulic cylinder 15, the temperature control of the heater 16 and the water cooling jacket 17, the cutting operation of the cutting device 18, etc. Is program controlled. It should be noted that the control by the computer 19 is not an indispensable element, and the configuration may not include the computer 19.

(Mixed raw material 2)
The mixed raw material 2 is a mixture of a purifying material made of granular or powdered activated carbon and a polymer binder such as a thermoplastic resin.

As the purifying material, a mixture of activated carbons having different particle sizes may be used. For example, it is preferable to use a mixture of granular activated carbon of 60 to 200 mesh passes and powdered activated carbon of 200 mesh passes at a ratio of 2: 1. The "mesh" is a scale indicating the size of the mesh. "Mesh path" means all particles that pass through the mesh, and the larger the mesh path, the smaller the particle size. For example, a 60 mesh path means all particles that pass through a 60 mesh (60 vertical and 60 horizontal meshes in a 1 inch (= 25.4 mm) square) sieve. If granular activated carbon with a relatively large diameter of less than 60 mesh paths is used, it becomes difficult to solidify the activated carbon with the polymer binder, and the voids of the filter molded body 1 become too large to come into contact with the activated carbon. It is not preferable because a large amount of water passes through the filter molded body 1 and the purification performance deteriorates. On the other hand, if powdered activated carbon having a relatively small diameter exceeding 200 mesh paths is used, the void portion in the filter molded body 1 is reduced, and a sufficient allowable flow rate cannot be secured, which is not preferable.

The purifying material is not limited to using a mixture of activated carbons having different particle sizes, and activated carbons having the same particle size may be used. Further, as the purifying material, fibrous activated carbon may be used, or granular or powdered activated carbon and fibrous activated carbon may be mixed and used. Further, as the purifying material, a material other than activated carbon (for example, zeolite, silica gel, etc.) may be used.

The polymer binder is in the form of a powder having an average particle size of about 100 μm, a bulk density of less than 0.3 g / cm ³ , and a melt index of 1.1 to 2.3 g / 10 min (ASTM D1238, 190 ° C., 15 kg Road). It is preferable to use ultra-high molecular weight polyethylene. The "melt index" is a measure of the fluidity of a polymer material at the time of melting, and the smaller this value is, the lower the fluidity is. If the melt index of the polymer binder is less than 1.1 g / 10 min, the proportion of the polymer binder must be increased in order to solidify the activated carbon into a block. Then, the amount of activated carbon in the filter molded body 1 becomes small and the purification performance deteriorates, which is not preferable. On the other hand, if the melt index of the polymer binder exceeds 2.3 g / 10 min, the polymer melted during molding of the filter molded body 1 covers the pores of the activated carbon, and water cannot pass through the activated carbon. Not preferred.

The polymer binder is not limited to ultra-high molecular weight polyethylene, and any material having a function of binding a purifying material may be used (a thermoplastic resin other than ultra-high molecular weight polyethylene may be used). Further, a thermosetting resin such as a phenol resin may be used. Further, the content of the polymer binder in the entire mixed raw material 2 is not particularly limited.

(Manufacturing method of filter molded body 1: controlled by computer 19)
Next, a method of manufacturing the filter molded body 1 using the manufacturing apparatus 10 will be described.

[Mixed raw material stirring process]
First, the mixed raw material 2 (purifying material and the polymer binder) which is the raw material of the filter molded body 1 is adjusted so that the content of the polymer binder in the entire mixed raw material 2 is a predetermined ratio (for example, 10% by mass). Mix. Then, the purifying material and the polymer binder are stirred so as to be uniformly dispersed.

[Raw material input process]
Next, as shown in FIG. 2, the stirred mixed raw material 2 is filled in the raw material charging hopper 13 provided on the charging port 12, and the ram rod 14 moves to the end 11c side (inlet side). A predetermined amount of the mixed raw material 2 is charged into the gap in the cylinder 11 generated by the retracting operation at an appropriate timing according to a control command from the computer 19. The mixed raw material 2 may be weighed by a weighing device outside the raw material input hopper 13 and charged in a predetermined amount. As a result, a predetermined amount of the mixed raw material 2 is charged into the inside of the cylinder 11 from the raw material charging hopper 13 via the charging port 12 (raw material charging operation).

[Pressing process]
Next, after the raw material charging step, as shown in FIG. 4, the hydraulic cylinder 15 is operated and the ram rod 14 in the cylinder 11 is advanced by a control command from the computer 19. As a result, while pressing the mixed raw material 2 charged inside the cylinder 11 (while compacting the mixed raw material 2), the mixed raw material 2 is transferred to the heating zone 161 (pressing operation). Then, the polymer binder in the mixed raw material 2 that has been transferred to the heating zone 161 set to be 10 ° C. to 150 ° C. higher than the melting point of the polymer binder by the heater 16 is melted.

Next, by further pressing the mixed raw material 2 with the lamb rod 14, the mixed raw material 2 in which the polymer binder is melted is transferred to the cooling zone 171 while being compacted. Then, in the mixed raw material 2 that has moved to the cooling zone 171 cooled by the water-cooled jacket 17, the cooled polymer binder is solidified and the purifying material is fixed by the polymer binder (filter molded body precursor). Become a body). As a result, the mixed raw material 2 that has passed through the cooling zone 171 becomes a porous body that maintains a constant shape.

Next, the porous body that has passed through the cooling zone 171 is pushed out by a certain amount (a certain length) from the end portion 11d of the cylinder 11 by further pressing by the ram rod 14.

The extrusion speed of the porous body in the cylinder 11 is the amount of the mixed raw material 2 charged each time the ram rod 14 reciprocates in the cylinder 11 and the cycle time required for the ram rod 14 to reciprocate once. Although determined, this extrusion rate is such that the polymer binder in the mixed raw material 2 is sufficiently melted in the heating zone 161 and the porous body extruded from the end portion 11d of the cylinder 11 retains sufficient strength. It is determined in consideration of productivity as long as it is guaranteed to be cooled in the cooling zone 171 to the temperature at which the cylinder is cooled.

[Retreat process]
Next, as shown in FIG. 5, the hydraulic cylinder 15 is operated and the ram rod 14 in the cylinder 11 is retracted (retracted operation) by a control command from the computer 19. As a result, the ram rod 14 moves to the end portion 11c side (inlet side), and a gap is created under the input port 12 of the cylinder 11.

[Cut process]
Next, as shown in FIG. 5, by a control command from the computer 19, while the ram rod 14 in the cylinder 11 is retracted by the retracting step, the ram rod 14 is extruded from the end portion 11d of the cylinder 11 in the extrusion process. The porous body is cut by the cutting device 18 and processed into a filter molded body 1 having a specified length (height).

As for the timing of cutting the porous body extruded from the end portion 11d of the cylinder 11 in the extrusion step, it is difficult to cut the porous body because the porous body also moves while the ram rod 14 is advancing. Therefore, by cutting while the ram rod 14 is retracting, the stationary porous body can be accurately cut into the filter molded body 1. Further, by continuously cutting the extruded porous body, it becomes easy to manufacture a long filter molded body 1 which was difficult in the conventional mold batch production method. Further, in a series of operations of the raw material charging process, the pressing process, and the retreating process, the operation of cutting the porous body by the cutting device 18 can be executed in parallel with the retreating process, so that the productivity is improved. Can be done (efficiency). Further, in the case of manufacturing with a conventional mold, when the input amount of the mixed raw material and the pressing are varied, the length of the filter molded body is likely to be varied, but it is continuous as in the present embodiment. In the method of manufacturing the filter-molded body 1 by cutting the extruded porous body to a predetermined length, the length accuracy of the filter-molded body 1 can be improved.

The filter molded body 1 is continuously manufactured by repeatedly executing the raw material charging step, the pressing step, the retreating step, and the cutting step.

In the manufacturing apparatus 10 and the manufacturing method, the ram rod 14 advances in the mixed raw material 2 of the purifying material and the polymer binder, which is charged into the cylinder 11 from the charging port 12, and the inner peripheral surface 11b of the cylinder 11 Is pressed by sliding. Then, the pressed mixed raw material 2 is further pressed by the ram rod 14 to move to the heating zone 161 and is heated by the heater 16 covering the heating zone 161 to melt the polymer binder. After that, by further pressing the lamb rod 14, the mixed raw material 2 leaves the heating zone 161 and shifts to the cooling zone 171. The polymer binder is cooled below the melting point, so that the purifying material is made of the polymer binder. A fixed porous body (filter molded body 1) is formed. Further, after the ram rod 14 is retracted to the charging port 12, the mixing raw material 2 is further charged from the charging port 12, and the ram rod 14 is advanced and pressed to already feed the newly charged mixed raw material 2. The already formed porous body can be pushed forward while being compacted between the mixed raw material 2 and the lamb rod 14 that have been charged. Then, the extruded porous body is cut by the cutting device 18 to be processed into the filter molded body 1. In this way, the filter molded body 1 can be continuously formed by repeating the forward movement, the backward movement of the ram rod 14, and the charging of the mixed raw material 2.

Here, in the above configuration, a ram rod 14 that is slidably contacted with the inner peripheral surface 11b of the cylinder 11 and can be linearly slid in the axial direction of the cylinder 11 is used for pressing the mixed raw material 2 without using a screw. is doing. In this way, by using the lamb rod 14 to make the mixed raw material 2 linearly pressable, it is possible to prevent the purifying material from being excessively crushed, and further, the polymer binder is excessive. It can be prevented from being stretched to cover the surface of the purifying material. As a result, it is possible to form a porous body having sufficient voids as a filter for purification, and to manufacture a filter molded body 1 having excellent purification performance.

Further, by providing the cooling zone 171 provided with the water-cooled jacket 17 in the manufacturing apparatus 10, the mixed raw material 2 containing the polymer binder melted in the heating zone 161 is further pressed by the lamb rod 14 to heat the heating zone 161. And move to the cooling zone 171. The water-cooled jacket 17 in the cooling zone 171 rapidly cools the polymer binder below the melting point, so that a porous body in which the purifying material is fixed by the polymer binder can be formed in a short time. ..

Further, in the manufacturing apparatus 10, the computer 19 controls the repetition of a series of operations of the raw material charging process (raw material charging operation), the pressing process (pressing operation), the retreating process (retracting operation), and the cutting process (cutting operation). As a result, it is possible to efficiently manufacture a filter molded product having excellent purification performance.

(Manufacturing method of filter molded body 1: without control by computer 19)
Next, a method of manufacturing the filter molded body 1 by the manufacturing apparatus 10 having no system control function by the computer 19 will be described. It should be noted that the description of the operation / effect that overlaps with the description of the manufacturing method of the filter molded body 1 using the system control by the computer 19 will be omitted.

[Mixed raw material stirring process]
First, the mixed raw material 2 (purifying material and the polymer binder) which is the raw material of the filter molded body 1 is adjusted so that the content of the polymer binder in the entire mixed raw material 2 is a predetermined ratio (for example, 10% by mass). Mix. Then, the purifying material and the polymer binder are stirred so as to be uniformly dispersed.

[Raw material input process]
Next, the mixed raw material 2 is charged into the raw material input hopper 13 and stored. Then, the mixed raw material 2 stored in the raw material charging hopper 13 naturally falls into the gap in the cylinder 11 generated by the retracting operation in which the ram rod 14 moves to the end portion 11c side (inlet side), so that the charging port 12 It is automatically charged into the cylinder 11 via the (raw material charging operation).

[Pressing process]
Next, after the raw material charging step, the hydraulic cylinder 15 is operated by the signal of the limit switch, and the ram rod 14 in the cylinder 11 is advanced. As a result, while pressing the mixed raw material 2 charged inside the cylinder 11 (while compacting the mixed raw material 2), the mixed raw material 2 is transferred to the heating zone 161 (pressing operation).

Next, by further pressing the mixed raw material 2 with the lamb rod 14, the mixed raw material 2 in which the polymer binder is melted is transferred to the cooling zone 171 while being compacted. Then, in the mixed raw material 2 that has moved to the cooling zone 171 cooled by the water-cooled jacket 17, the cooled polymer binder is solidified and the purifying material is fixed by the polymer binder (filter molded body precursor). Become a body).

Next, the porous body that has passed through the cooling zone 171 is pushed out by a certain amount (a certain length) from the end portion 11d of the cylinder 11 by further pressing by the ram rod 14.

[Retreat process]
Next, the operating direction of the hydraulic cylinder 15 is switched by the signal of the limit switch, and the ram rod 14 in the cylinder 11 is retracted (retracting operation). As a result, the ram rod 14 moves to the end portion 11c side (inlet side), and a gap is created under the input port 12 of the cylinder 11.

[Cut process]
Next, while the ram rod 14 in the cylinder 11 is retracted by the retracting step, the porous body extruded from the end portion 11d of the cylinder 11 in the extrusion process is rotationally driven by the round blade of the cutting device 18. It is cut and processed into a filter molded body 1 having a specified length (height). The timing for cutting the porous body by the cutting device 18 is not limited to the time when the ram rod 14 in the cylinder 11 is retracted by the retracting step, and the ram rod 14 is retracted even before the ram rod 14 is retracted. It may be after letting it.

The filter molded body 1 is continuously manufactured by repeatedly executing the raw material charging step, the pressing step, the retreating step, and the cutting step.

(Other embodiments)
Although the preferred embodiment of the present invention has been shown above, the above embodiment can be further modified as follows.

In the manufacturing apparatus 10 of the filter molded body 1 of the above embodiment, it is necessary to solidify into a porous body depending on the type of the mixed raw material 2, the shape of the cylinder 11, and the temperature and length of the heating zone 161 and the cooling zone 171. Back pressure may not be applied sufficiently. In such a case, in order to solidify the porous body more firmly or to keep the density of the porous body constant, a porous body is placed between the end portion 11d of the cylinder 11 and the cutting device 18. A brake device may be provided to hold the brake. As the brake device, a method of pressing a plate-shaped brake plate against the porous body with a constant force or a method of sandwiching the porous body with a roller or a caterpillar can be adopted. Needless to say, if sufficient back pressure can be obtained, it is not necessary to provide a brake device.

Further, in the above embodiment, the cross-sectional shape of the filter molded body 1 to be molded in the direction orthogonal to the axial direction is substantially the same as the cross-sectional shape in the direction orthogonal to the axial direction of the cylinder 11. Therefore, by changing the cross-sectional shape of the cylinder 11, the cross-sectional shape of the filter molded body 1 can be formed into a desired shape such as an ellipse, a polygon such as a triangle or a square, as well as a circular shape in the present embodiment. .. Further, the filter molded body 1 is not limited to the tubular shape, and may have a shape without a hole in the center.

Further, the filter molded body 1 manufactured by the manufacturing apparatus / manufacturing method of the present invention can be used for various types of water treatment devices in addition to the water treatment device directly connected to the faucet. For example, the filter molded body 1 may be used for a water purifier arranged in a sink and connected to a faucet via a hose, or may be used for a water purifier that also serves as a shower handle. good. Further, it may be used for a pot pitcher type water purifier.

Further, the filter molded body 1 manufactured by the manufacturing apparatus / manufacturing method of the present invention may be used for an air purifier that removes harmful substances from air.

A filter molded product was produced using the "equipment for producing a filter molded product" according to Examples 1 to 5 and Comparative Examples 1 to 3 below, and the quality and productivity (extrusion speed) of the produced filter molded product were improved. The effects were compared.

(Example 1)
As the manufacturing apparatus 10 for the filter molded body according to the first embodiment, a cylinder 11 and a ram rod 14 having a circular cross section are attached to a horizontal ram extruder (manufactured by Tabata Machinery Co., Ltd.) to manufacture a pipe-shaped filter molded body 1. did.

Specific dimensions and conditions are described below.
Inner diameter of cylinder 11: φ48.5 mm
A band heater was wound around a heating zone 161 of the cylinder 11 in a range of an axial length of 400 mm (about 8 times the outer diameter of the filter molded body 1) to control the temperature.
A water-cooled jacket was attached to the cooling zone 171 of the cylinder 11 within a range of an axial length of 100 mm (about twice the outer diameter of the filter molded body 1), and water-cooled.
A ram tip 141 made of a cloth-containing phenol resin having an outer diameter of φ48.1 mm was attached to the tip of the ram rod 14.
A mandrel 142 having an outer diameter of φ27 mm was attached to the tip of the ram tip 141. The mandrel 142 was attached so as to be concentric with the ram tip 141, and the length was such that the tip of the mandrel 142 was in the same position as the tip (end 11d) of the cylinder 11 when the ram rod 14 was advanced. Specifically, the length of the mandrel 142 was set to 500 mm.
As the mixed raw material 2, a mixture of the following powders was used.
Purifying material: Powdered coconut shell activated carbon with an average particle diameter of about 170 μm, 88 parts by mass Polymer binder: Powdered ultra-high molecular weight polyethylene with an average particle diameter of about 30 μm (Miperon XM-220 manufactured by Mitsui Kagaku Co., Ltd., melting point about 136) ℃), 12 parts by mass The extrusion conditions were as follows.
Temperature of heating zone 161: 210 ° C
Cooling zone 171 temperature: 20 ° C (20 ° C cooling water continued to flow through the water cooling jacket)
Mixed raw material input amount: 6 g / cycle (1 cycle is until the ram rod 14 moves forward and backward and then starts moving forward)
Cycle time: 10 seconds

In Example 1, a good product of the filter molded body 1 having an outer diameter substantially the same as the inner diameter of the cylinder 11, an inner diameter substantially the same as the outer diameter of the mandrel 142, and a smooth surface was obtained. The extrusion speed of the extruded porous body was 50 mm / min.

(Example 2)
In the apparatus for manufacturing the filter molded body according to Example 2, an attempt was made to manufacture the filter molded body 1 under the same equipment configuration and conditions as in Example 1 except that the temperature of the heating zone 161 was lowered to 170 ° C.

Also in Example 2, a good product of the filter molded product 1 having a smooth surface was obtained. Further, since the temperature in the heating zone 161 is lower than that in Example 1, it is necessary to reduce the input amount of the mixed raw material in order to sufficiently dissolve the polymer binder in the mixed raw material. The input amount of the mixed raw material was 3 g / cycle, and the extrusion speed of the extruded porous body was 25 mm / min.

(Example 3)
In the apparatus for manufacturing the filter molded body according to the third embodiment, the filter molding is performed under the same equipment configuration and conditions as in the first embodiment except that the length of the heating zone 161 is 200 mm (about 4 times the outer diameter of the filter molded body 1). Attempt to manufacture body 1.

Also in Example 3, a good product of the filter molded product 1 having a smooth surface was obtained. Further, since the length of the heating zone 161 is shorter than that of the first embodiment, it is necessary to reduce the input amount of the mixed raw material in order to sufficiently dissolve the polymer binder in the mixed raw material. The input amount of the mixed raw material was 3 g / cycle, and the extrusion speed of the extruded porous body was 25 mm / min.

(Example 4)
In the apparatus for manufacturing the filter molded body according to the fourth embodiment, the filter molding is performed under the same equipment configuration and conditions as in the first embodiment except that the length of the heating zone 161 is 800 mm (about 16 times the outer diameter of the filter molded body 1). Attempt to manufacture body 1.

Also in Example 4, a good product of the filter molded product 1 having a smooth surface was obtained. Further, since the length of the heating zone 161 is longer than that of the first embodiment, the polymer binder in the mixed raw material can be sufficiently dissolved, so that the input amount of the mixed raw material can be increased. The mixed raw material input amount was 9 g / cycle, and the extrusion speed of the extruded porous material was 75 mm / min.

(Example 5)
In the apparatus for manufacturing the filter molded product according to the fifth embodiment, the temperature controller 20 is attached to the raw material input hopper 13, the raw material input hopper 13 is heated to 100 ° C., and the mixed raw material is preheated in the raw material input hopper 13. An attempt was made to manufacture the filter molded body 1 under the same equipment configuration and conditions as in Example 4.

Also in Example 5, a good product of the filter molded product 1 having a smooth surface was obtained. Further, since the mixed raw material is preheated in the raw material input hopper 13, the mixed raw material 2 can be melted in a short time in the heating zone 161 to form a porous body. As a result, the input amount of the mixed raw material can be increased as compared with the case where the mixed raw material is not preheated, the input amount of the mixed raw material is 12 g / cycle, and the extrusion speed of the extruded porous body is 100 mm / min. rice field.

(Comparative Example 1)
In the apparatus for manufacturing the filter molded product according to Comparative Example 1, an attempt was made to manufacture the filter molded product 1 under the same equipment configuration and extrusion conditions as in Example 1 except that the cooling zone was not provided (the water cooling jacket was not attached).

In Comparative Example 1, the porous body could be continuously extruded, but the porous body extruded from the tip of the cylinder was soft and could not maintain a constant pipe shape (the quality of the filter molded body was poor). there were). Therefore, when a cooling zone is not provided by a water-cooled jacket or the like, a mixed raw material in which the polymer binder is melted by natural cooling can be obtained by using a cylinder in which the distance from the end of the heating zone to the tip of the cylinder is long. Needs to be cooled.

(Comparative Example 2)
In the apparatus for manufacturing the filter molded product according to Comparative Example 2, the same equipment configuration and extrusion conditions as in Example 1 were used except that the length of the heating zone was 1200 mm (about 25 times the outer diameter of the molded filter molded product). An attempt was made to manufacture a filter molded product. The length of the mandrel was set to 500 mm as in Example 1.

In Comparative Example 2, the extrusion resistance due to the friction between the mixed raw material and the inner peripheral surface of the cylinder was large, and the extrusion force of the ram rod required for extrusion exceeded 70 kN, so the extrusion was stopped (manufacturing not possible). Therefore, when the length of the heating zone is made larger than 20 times the outer diameter of the filter molded body to be molded, a large hydraulic cylinder or the like having a larger pushing force is required in order to increase the pushing force of the ram rod. become.

(Comparative Example 3)
In the apparatus for manufacturing the filter molded product according to Comparative Example 3, an attempt was made to manufacture the filter molded product under the same equipment configuration and conditions as in Example 4 except that the mixed raw material input amount was increased to 12 g / cycle.

In Comparative Example 3, since the input amount of the mixed raw material was increased, the polymer binder in the mixed raw material was not sufficiently melted in the heating zone, so that the porous body could not be formed (cannot be produced).

Table 1 below summarizes the quality (filter shape) and extrusion speed of the filter molded product produced by using the "filter molded product manufacturing apparatus" according to Examples 1 to 5 and Comparative Examples 1 to 3.

In the manufacturing process of the filter molded body 1, the extrusion speed of the porous body in the cylinder 11 is determined by the input amount of the mixed raw material 2 and the cycle time required for the ram rod 14 to make one reciprocation. However, as the input amount of the mixed raw material 2 is increased, the extrusion speed of the porous body becomes faster, and the productivity can be improved. However, if the input amount of the mixed raw material 2 is too large, the polymer binder may not be sufficiently melted in the heating zone 161 and the porous body may not be formed (see Comparative Example 3). In order to solve this problem, it is possible to take measures to raise the temperature of the heating zone 161. However, as described above, the fluidity of the molten polymer binder becomes too high, and the molten polymer binder becomes a purifying material. Since it covers the surface of the polymer, it is not possible to obtain sufficient performance as a purifying filter. Further, a measure to lengthen the heating zone 161 can be considered, but in that case, as described above, the extrusion resistance due to the friction between the mixed raw material 2 and the inner peripheral surface 11b of the cylinder 11 becomes too large, and the mixed raw material 2 is used. It becomes impossible to extrude stably (see Comparative Example 2).

Therefore, when the temperature controller 20 is attached to the raw material input hopper 13 and the mixed raw material 2 is preheated as in the fifth embodiment, it is not necessary to excessively raise the heating temperature in the heating zone 161 and the heating zone 161 The mixed raw material 2 can be melted in a short time to form a porous body without making the length of the mixed raw material 2 excessively long. Therefore, the amount of the mixed raw material 2 charged into the cylinder 11 can be increased as compared with the case where the mixed raw material 2 is not preheated, and as a result, the extrusion speed of the porous body is improved and the productivity is further improved. I understood.

1 Filter molded body 2 Mixed raw material 10 Manufacturing equipment 11 Cylinder 11a Outer peripheral surface 11b Inner peripheral surface 11c End 11d End 12 Input port 13 Raw material input hopper 14 Lamb rod 141 Lamb chip 142 Mandrel 143 Support rod 15 Hydraulic cylinder 16 Heater 161 Heating zone 17 Water cooling jacket 171 Cooling zone 18 Cutting device 19 Computer 20 Temperature controller

Claims (9)

A manufacturing device for molding a filter molded product made of a porous body to which a purifying material is fixed by a polymer binder.
Cylindrical cylinder and
An input port provided on the outer peripheral surface of the one end side of the cylinder and into which a mixed raw material of the purifying material and the polymer binder is charged into the inside of the cylinder.
With a ram rod that is in sliding contact with the inner peripheral surface of the cylinder and is slidable in the axial direction of the cylinder,
A heater is provided, which covers a heating zone formed of at least a part of the outer peripheral surface of the cylinder on the other end side of the charging port.
An apparatus for manufacturing a filter molded product, characterized in that a resin ram chip is attached to a portion of the ram rod that comes into contact with the mixed raw material . The apparatus for manufacturing a filter molded product according to claim 1, wherein the temperature of the heating zone of the cylinder is set to be 10 ° C. to 150 ° C. higher than the melting point of the polymer binder. The filter molded product according to claim 1 or 2, wherein the axial length of the heating zone in the cylinder is in the range of 3 to 20 times the diameter length of the filter molded product. Manufacturing equipment. The filter molding according to any one of claims 1 to 3, wherein the cylinder is provided with a cooler that covers a cooling zone formed of at least a part of an outer peripheral surface on the other end side of the heating zone. Body manufacturing equipment. The filter molded product according to claim 4, wherein the axial length of the cooling zone in the cylinder is in the range of 0.5 to 10 times the diameter length of the filter molded product. Manufacturing equipment. With a hopper that can put the stored mixed raw material into the inlet,
A reciprocating drive that enables reciprocating movement of the ram rod forward and backward,
(1) Raw material charging operation in which a predetermined amount of the mixed raw material is charged into the inside of the cylinder from the hopper via the charging port.
(2) A pressing operation in which the reciprocating drive advances the ram rod and slides the inner peripheral surface of the cylinder to press the charged raw material.
(3) A retreat operation in which the reciprocating drive retracts the ram rod.
The apparatus for manufacturing a filter molded product according to any one of claims 1 to 5, further comprising a control device for controlling the operation of the above (1) to (3) to be repeatedly executed. Further equipped with a cutting device provided near the other end of the cylinder,
The control device cuts the porous body extruded from the other end of the cylinder by the pressing operation of the cutting device (2) while the retracting operation of the (3) is being performed. The apparatus for manufacturing a filter-molded body according to claim 6, wherein the filter-molded body is controlled to be processed. The apparatus for manufacturing a filter molded product according to claim 6 or 7, wherein the hopper is provided with a temperature controller for preheating the stored mixed raw materials. The eighth aspect of the present invention, wherein the preheating temperature of the mixed raw material by the temperature controller is set to be 50 ° C. to 20 ° C. lower than the melting point of the polymer binder in the mixed raw material. Equipment for manufacturing filter molded products.

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