WO2002100514A1 - Filter element and production method thereof - Google Patents
Filter element and production method thereof Download PDFInfo
- Publication number
- WO2002100514A1 WO2002100514A1 PCT/JP2001/004957 JP0104957W WO02100514A1 WO 2002100514 A1 WO2002100514 A1 WO 2002100514A1 JP 0104957 W JP0104957 W JP 0104957W WO 02100514 A1 WO02100514 A1 WO 02100514A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fluid passage
- plugging
- diameter fluid
- diameter
- small
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 30
- 239000012530 fluid Substances 0.000 claims abstract description 292
- 239000000463 material Substances 0.000 claims abstract description 185
- 238000000034 method Methods 0.000 claims description 56
- 238000001914 filtration Methods 0.000 claims description 50
- 239000007788 liquid Substances 0.000 claims description 34
- 238000011049 filling Methods 0.000 claims description 27
- 239000000758 substrate Substances 0.000 claims description 27
- 239000000945 filler Substances 0.000 claims description 13
- 239000000853 adhesive Substances 0.000 claims description 10
- 230000001070 adhesive effect Effects 0.000 claims description 10
- 229910010293 ceramic material Inorganic materials 0.000 claims description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 239000010419 fine particle Substances 0.000 claims description 6
- 238000002360 preparation method Methods 0.000 claims description 6
- 239000003501 hydroponics Substances 0.000 claims description 5
- 238000005498 polishing Methods 0.000 claims description 5
- 239000004065 semiconductor Substances 0.000 claims description 5
- 239000003795 chemical substances by application Substances 0.000 claims description 4
- 238000007599 discharging Methods 0.000 claims description 4
- 238000010304 firing Methods 0.000 claims description 2
- 239000000565 sealant Substances 0.000 abstract 1
- 239000007787 solid Substances 0.000 description 18
- 238000011144 upstream manufacturing Methods 0.000 description 18
- 239000002002 slurry Substances 0.000 description 10
- 239000000243 solution Substances 0.000 description 8
- 239000011148 porous material Substances 0.000 description 7
- 239000000919 ceramic Substances 0.000 description 6
- 239000002245 particle Substances 0.000 description 6
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 4
- 238000005520 cutting process Methods 0.000 description 4
- 239000010410 layer Substances 0.000 description 4
- 208000003443 Unconsciousness Diseases 0.000 description 3
- 238000011001 backwashing Methods 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 239000011247 coating layer Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 230000007547 defect Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 230000003287 optical effect Effects 0.000 description 3
- 238000007789 sealing Methods 0.000 description 3
- 239000003566 sealing material Substances 0.000 description 3
- 238000005245 sintering Methods 0.000 description 3
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 239000004927 clay Substances 0.000 description 2
- 230000007797 corrosion Effects 0.000 description 2
- 238000005260 corrosion Methods 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000011521 glass Substances 0.000 description 2
- 238000007654 immersion Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- MUHFRORXWCGZGE-KTKRTIGZSA-N 2-hydroxyethyl (z)-octadec-9-enoate Chemical compound CCCCCCCC\C=C/CCCCCCCC(=O)OCCO MUHFRORXWCGZGE-KTKRTIGZSA-N 0.000 description 1
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000001154 acute effect Effects 0.000 description 1
- DLHONNLASJQAHX-UHFFFAOYSA-N aluminum;potassium;oxygen(2-);silicon(4+) Chemical compound [O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[O-2].[Al+3].[Si+4].[Si+4].[Si+4].[K+] DLHONNLASJQAHX-UHFFFAOYSA-N 0.000 description 1
- 230000004323 axial length Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 1
- 229910052878 cordierite Inorganic materials 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 239000010433 feldspar Substances 0.000 description 1
- 229940095098 glycol oleate Drugs 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000005499 meniscus Effects 0.000 description 1
- 229920000609 methyl cellulose Polymers 0.000 description 1
- 239000001923 methylcellulose Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
- F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
- F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
- F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
- B01D29/11—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with bag, cage, hose, tube, sleeve or like filtering elements
- B01D29/111—Making filtering elements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
- B01D29/11—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with bag, cage, hose, tube, sleeve or like filtering elements
- B01D29/31—Self-supporting filtering elements
- B01D29/35—Self-supporting filtering elements arranged for outward flow filtration
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2459—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the plugs
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/247—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure of the cells
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2482—Thickness, height, width, length or diameter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2484—Cell density, area or aspect ratio
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
- B01D46/2492—Hexagonal
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
- B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
- B01D46/2418—Honeycomb filters
- B01D46/2451—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure
- B01D46/2486—Honeycomb filters characterized by the geometrical structure, shape, pattern or configuration or parameters related to the geometry of the structure characterised by the shapes or configurations
- B01D46/2496—Circular
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D63/00—Apparatus in general for separation processes using semi-permeable membranes
- B01D63/06—Tubular membrane modules
- B01D63/066—Tubular membrane modules with a porous block having membrane coated passages
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T10/00—Road transport of goods or passengers
- Y02T10/10—Internal combustion engine [ICE] based vehicles
- Y02T10/12—Improving ICE efficiencies
Definitions
- the present invention is used for filtration of household water purifiers, filtration of polishing liquid used in semiconductor manufacturing equipment, filtration of circulation baths, filtration of solutions in hydroponics, filtration of fine particles in a diesel particulate filter (DPF), etc. And a method of manufacturing the same.
- FIG. 5 is a diagram showing an end face configuration of an example of a conventional filter element. A black-out portion is plugged and used for filtering gas and liquid.
- Extrusion methods using a screw-type extruder or a cylinder-type extruder are widely used in the method of manufacturing a filter base material because it requires a large number of fluid passages in the axial direction of the filter base material.
- the cross-sectional shape of the fluid passage is rectangular, circular, hexagonal, etc., and is basically the same cross-sectional shape over the entire cross-section of the filter substrate due to the ease of manufacturing an extrusion die capable of forming such a fluid passage.
- a fluid passage having the same dimensions as that of the filter fluid is formed, so that both the inlet side of the filtered fluid and the outlet side of the clarified fluid are the same fluid passage.
- the plugging method is shown in Fig. 6 corresponding to the filter element shown in Fig. 5.
- a mask pattern appropriately selected from rubber, resin film, metal film, etc. in accordance with the material of the fill material is applied to the fill material, or placed on the end face of the fill material Later, plugging material is injected.
- This plugging material is injected, for example, by immersing the filter substrate with the mask pattern shown in FIG. 6 stuck in a slurry liquid made of the same material as the filter substrate, or when the diameter of the fluid passage is large. Since the drying shrinkage of the plugging material slurry was large, the plugging material prepared in a clay state was pressed with a spatula-shaped tool or squeegee.
- a filter is used to optically process the hole array at the end of the base material, and a nozzle that can inject a fixed amount of plugging material is filled. Then, a method of individually injecting slurry into plugged portions has also been adopted.
- the fluid passage of the filter base material is bounded by the plugging operation at the wall surface that is the filtration surface.
- Solids in the fluid to be filtered accumulate in the fluid passage on the upstream side, and are separated at the upstream and downstream sides.
- the solids in the fluid to be filtered are deposited on the upstream side, and the downstream side when the resistance of the fluid passing through the wall surface exceeds a predetermined value.
- the normal fluid flows from the fluid passage upstream to the so-called backwash.
- the life of the filter as a filtration element is determined when the solids that have entered the open pores of the filter base material cannot be removed beyond the limit even by the backwashing, so the upstream filtration area The larger the width, the lower the filtration resistance and the greater the amount of solids deposited.
- the inner diameter (d) of the fluid passage is reduced to secure a filtration area, the axial length (L) of the fluid passage will be reduced. LZd becomes large, and solid matter deposited on the bottom-side fluid passage on the upstream side, especially at the bottom, cannot be removed by backwashing, and the life of the filter is shortened. The following are considered good.
- Increasing the diameter of the fluid passage to facilitate removal of solids facilitates the discharge of solids, but reduces the filtration area per filter-element and increases the size of the filtration device. Becomes
- the filter element used for filtration of polishing liquid, filtration of circulation bath, filtration of solution in hydroponics, filtration of fine particles in diesel particulate filter (DPF), etc.
- DPF diesel particulate filter
- the life of the filter element is determined by the total surface area and the total volume of the fluid passage on the upstream side. In either case, only the filtered clean fluid and fine solids of 5 to 10% of the maximum pore size of the filter element are permeated on the downstream side, so the downstream side has a larger fluid passage area than the upstream side.
- the fluid passage of the conventional filter element has the same cross-sectional area on both the upstream and downstream sides, so the size of the filter element becomes larger due to the excess cross-sectional area of the fluid passage on the downstream side. ing.
- the disposable filter element as described above needs to be inexpensive in order to ensure good filtration characteristics by replacing the filter element in a short period of time.
- the filter base material undergoes deformation such as twisting or bending during molding, the arrangement and shape of the fluid passages such as rectangles, circles, and hexagons are not constant. Later, it is necessary to correct the deviation between the mask pattern and the fluid passage of the filter substrate. Further, as the fluid passage becomes smaller, the wall thickness separating the fluid passage also decreases, so that the dimension of the joint between the openings of the mask pattern must be smaller than the wall thickness between the fluid passages. Also, the strength of the mask pattern itself is reduced, and the mask pattern is damaged when pasting.
- the method of attaching a mask pattern to an unfired ceramic filter base material is based on the fact that fine particles on the surface of the filter base material are easily peeled off, and the filter is sealed with one end face in advance. After that, it was necessary to bond the mask pattern. Therefore, the plugging method using a mask pattern was difficult for a filter base material formed in a fluid passage with an inscribed circle diameter of ⁇ 2 mm or less.
- the inner acute angle portion does not occur and the boundary portion has a smooth meniscus shape with respect to the plugging method by press-fitting the plugging material.
- This is a particularly advantageous and preferable plugging method in the case of an evening structure.
- the inner diameter of the fluid passage is small, the mask pattern and the filter-substrate are incompletely adhered to each other, and plugging is performed at a place other than the necessary place. Problems easily occur.
- the filter optically reads the hole array at the end of the substrate, processes the image, and interlocks a nozzle that can inject a fixed amount of plugging material.
- the method of individually injecting water has a problem that the equipment is expensive and the plugging process itself takes time.
- the above-described filter element has a problem that the dimensions are large, the yield related to plugging is particularly poor, and the product cost is high.
- An object of the present invention is to solve the above-mentioned problem and to make the total cross-sectional area of the fluid passage on the upstream side of the filtration wall the optimum cross-sectional area corresponding to the amount of solids in the fluid to be filtered. Also, since the total cross-sectional area on the downstream side can be minimized corresponding to the amount of the clarified liquid and the filtration application, the outer diameter of the filter element can be minimized, and the filter element that can reduce the size of the device can be reduced. It is something to offer. Another object of the present invention is that the occurrence of coating defects particularly in the case of a multilayer structure is remarkable.
- a filter element according to the present invention is a filter element comprising a plurality of parallel fluid passages partitioned by a porous wall, wherein the fluid passages have a large cross-section, a large-diameter fluid passage, and a large-diameter fluid passage.
- the large-diameter fluid passage is plugged on an end face opposite to the plugged end face.
- the fluid passage includes a large-diameter fluid passage and a small-diameter fluid passage, the large-diameter fluid passage is plugged on one end face, and the small-diameter fluid passage is sealed on the other end face.
- the total cross-sectional area of the fluid passage on the upstream side of the filtration wall can be set to an optimal cross-sectional area corresponding to the amount of solids in the fluid to be filtered, and the downstream side
- the total cross-sectional area of the filter element can be minimized in accordance with the amount of the clarified liquid and the purpose of filtration, so that the outer diameter of the filter element can be minimized and the size of the apparatus can be reduced.
- Preferred examples of the filter element of the present invention include a configuration in which the cross section of the fluid passage is based on a circle, a configuration in which a small diameter fluid passage is arranged around a large diameter fluid passage, and the cross section of the fluid passage is based on a polygon, A configuration in which a small-diameter fluid passage is arranged around a large-diameter fluid passage; a configuration in which a polygon is a hexagon; a cross-section perpendicular to an axis of a filter element; When the configuration is more than 40% and less than or equal to 120% of the total cross-sectional area of the fluid passage, the large-diameter fluid passage is used as an inlet for a filtered fluid, and the small-diameter fluid passage is used as an outlet for a clarified fluid. To achieve the effects of the present invention more suitably. Can be.
- the first invention of the method for producing a filter element of the present invention comprises a plurality of parallel fluid passages partitioned by a porous wall, wherein the fluid passage has a large cross section.
- a preparation step of preparing a filter substrate comprising at least one small-diameter fluid passage having a cross-sectional size smaller than the diameter fluid passage; and one end face of the filter substrate prepared in the preparation step as a plugging material.
- the filling length of the plugging material of the small-diameter fluid passage is formed longer than the filling length of the plugging material of the large-diameter fluid passage, and then the small-diameter fluid passage is plugged.
- the second invention of the method for producing a filter element of the present invention comprises a large number of parallel fluid passages partitioned by a porous wall, wherein the fluid passage has a large-diameter fluid passage having a large cross section, and a large-diameter fluid passage.
- a preparatory step of preparing a filter base material comprising at least one small-diameter fluid passage having a cross-sectional size smaller than the fluid passage; and one end face of the filter base material prepared in the preparation step as a plugging material.
- a first plugging step of filling the plugging material into the plugging material, and an end face opposite to the end face plugged in the first plugging step is immersed in the plugging material to form a large-diameter fluid passage.
- the filling length of the plugging material is longer than the filling length of the plugging material in the small-diameter fluid passage.
- the fluid passage is composed of a large-diameter fluid passage and a small-diameter fluid passage, so that one filter, which is the most suitable plugging method, is immersed in the plugging material.
- This method can be used without using a mask pattern by utilizing the difference in cross-sectional size between the large-diameter fluid passage and the small-diameter fluid passage. Therefore, the occurrence of coating defects can be significantly reduced, especially in the case of a multi-layer structure, and since no mask pattern is used, it can be widely applied even when the fluid passage size is small. There is no sealing failure and plugging is possible even if the filler material is deformed, and the plugging time can be reduced, and a more expensive optical image processing device and plugging An inexpensive cost plugging method that does not require a material injection device can be achieved.
- the filter base is made of a ceramic material; the plugging material is made of a ceramic material; A structure in which a sealing step and a second plugging step are performed.
- the plugging material is any of a ceramic material and an organic adhesive.
- the first plugging step is performed.
- a second plugging step In the first plugging step, the filter base material is immersed in the plugging material, and then the filter base material is lifted upward to provide a large-diameter fluid passage and A structure in which a small-diameter fluid passage is filled with a plugging material.
- the large-diameter fluid passage or the small-diameter fluid passage is evacuated by vacuum suction from an upper portion of the filler substrate.
- Small-diameter fluid passage with sealing material filling length Is a structure in which the plugging material is selectively filled so as to be longer than the length of the plugging material in the large-diameter fluid passage.
- the base material of the filter is immersed in the plugging material. After the filling material is moved downward in the plugging material, the filling length of the plugging material in the large-diameter fluid passage or the small-diameter fluid passage becomes small-diameter fluid passage or large-diameter fluid passage.
- FIG. 1 is a view showing an end face structure of an example of the filter element of the present invention
- FIG. 2 is a view showing an end face structure of another example of the filter element of the present invention
- FIGS. 3 (a) to (1) are It is a diagram showing a method of first plugging the large diameter fluid passage in the method of manufacturing a filter element of the present invention in the order of steps,
- FIGS. 4 (a) to 4) are diagrams showing a method of plugging a small-diameter fluid passage first in a method of manufacturing a filter element of the present invention in the order of steps.
- FIG. 5 is a view showing an end face structure of an example of a conventional filter element
- FIG. 6 is a view showing an example of a mask pattern used for plugging an end face of the conventional filter element.
- FIG. 7 is a view showing an example of a shape of a plugging material at an end of a conventional fill element.
- the filter is constituted by a combination of at least two or more fluid passages having different internal dimensions in the cross-sectional direction of the fluid passage of the base material.
- Fig. 1 shows the end face configuration of a fill element composed of a ⁇ -shaped fluid passage, and the black-out portion is plugged.
- FIG. 2 shows an end face configuration of a filter element composed of hexagonal fluid passages. Similarly, a black-out portion shows a plugged state.
- the mold is inexpensive. Also, based on the cross-sectional area of the large-diameter fluid passage with the largest cross-sectional area, the small-diameter fluid passage on the downstream side, which is easy to design, can be appropriately arranged and a fine arrangement can be suitably configured. The design of the cross-sectional area ratio on the downstream side It will be easier.
- two types of small-diameter fluid passages are arranged for one type of large-diameter fluid passage, but the plugging method described later can of course be employed.
- the plugging method described later can of course be employed.
- the outer diameter portion of the filter base material and the large-diameter fluid passage intersect, it is preferable to dispose the large-diameter fluid passage appropriately instead of omitting it.
- the inscribed circle of the deformed large-diameter fluid passage needs to be larger than the inscribed circle of the small-diameter fluid passage.
- the hexagonal hole type shown in Fig. 2 minimizes the volume of the wall, which is the filtration layer, has no sharp corners inside and is easy to arrange finely, so the outer diameter of the filter element is minimized. And most preferred.
- the cross section of the fluid passage may be triangular, square, trapezoidal, octagonal, star-shaped, etc., and may be of any combination including any of the deformed types and the ⁇ -shaped shapes.
- the deformation mode of the large-diameter fluid passage at the outer diameter portion of the filter element is the same as that of the above-mentioned ⁇ type element.
- the large-diameter fluid passage and the small-diameter fluid passage use the wall of the fluid passage as a filtration portion, it is necessary that both fluid passages are close to each other to reduce filtration resistance. It is preferable that a small-diameter fluid passage is disposed in the first fluid passage, and one small-diameter fluid passage is shared by a plurality of large-diameter fluid passages.
- the large-diameter fluid passage is preferably the upstream side where solids in the fluid are separated and deposited, and the downstream side is preferably 40% or more and 120% or less of the total cross-sectional area of the upstream side. .
- the content is preferably up to 120%.
- the large-diameter fluid passage side is set as the upstream side of the filtration. If it is necessary to reduce the exposed area per filter fluid and improve the durability of the plugged portion, of course, the downstream side may be a large-diameter fluid passage.
- a method of plugging the fluid passage will be described.
- the method can be used in any of the two modes of plugging a small-diameter fluid passage other than the large-diameter fluid passage. It is preferable to select similar materials and properties for the filter base material and the plugging slurry liquid.
- a sintering aid made of clay such as feldspar and force orinite is used for fused alumina with a particle size of # 800.
- a mixture of material and methylcellulose and polyethylene glycol oleate as a binder is extruded into the shape shown in Fig. 2 and then calcined at 150. I do.
- a ceramic emergent which is the most preferable embodiment, is described.
- a porous plastic if an organic adhesive described later is used, a porous plastic,
- the present invention can be applied to a filter made of a sintered metal and a substrate.
- alumina is used as a ceramic material because both low cost and strength can be achieved.
- a filter such as a filter element used for filtering fine particles in a diesel particulate filter (DPF) is used.
- DPF diesel particulate filter
- Plugging can be performed by the method according to the invention.
- the outer diameter of the fill material base material shown in the example is ⁇ 80 mm
- the diameter of the inscribed circle of the large diameter fluid passage is ⁇ 3 mm
- the diameter of the inscribed circle of the small diameter fluid passage is ⁇ 1 mm. 4 mm.
- the plugging slurry (plugging liquid) is prepared by adding fused alumina particles of # 150 particle size to fused alumina of the above particle size to minimize shrinkage during plugging.
- Amonium acrylate is also used as a sintering aid, and the force-oliginate and potassium feldspar are well kneaded with water to form a plugging material slurry, which will be used in subsequent steps.
- a method of first plugging a large-diameter fluid passage will be described with reference to FIGS. 3 (a) to (1) showing a plugging procedure according to the present invention.
- the filter base material prepared by the above method is immersed in the plugging liquid prepared by the same method as shown in Fig. 3 (b) to a length of 4 mm.
- the plugging liquid that has entered the small-diameter fluid passage absorbs moisture by the base material, and solids adhere to the inner diameter of the small-diameter fluid passage to close the small-diameter fluid passage.
- the plugging liquid adheres to the inner diameter of the small-diameter fluid passage as well as the small-diameter fluid passage.
- the filter base material is removed from the plugging liquid.
- the base material of the filter is made of the same material as the plugging material in order to minimize distortion due to firing of the plugged portion.
- other ceramic materials may be used to match the thermal expansion difference with the plugging portion.
- the filter base material In order to reduce the sintering cost, it is preferable to plug in the unsintered state. Is also good. Further, if the filter base material is easily deformed or damaged due to the penetration of a dissolving material such as water in the slurry plugging material, the filter base material should be fired before plugging. Is preferred.
- the plugging liquid is discharged from the large-diameter fluid passage, and an opening is formed in the central portion.
- the large-diameter fluid passage side must be open at the center, so as the plugging liquid adheres to the small-diameter fluid passage of the base material, pulling it upward raises the large-diameter fluid passage.
- the center of the fluid passage always moves upward in an open state, which is the most preferable.
- the filter substrate may be rotated in such a manner that the axial direction of the filter substrate becomes radial, and the plugging liquid in the large-diameter fluid passage may be discharged by centrifugal force.
- the filler is removed from the plugging liquid and dried as shown in Fig. 3 (f).
- Fig. 3 (g) the filter base material is cut at the position where the plugged portion of the large-diameter fluid passage is left and the plugged portion of the small-diameter fluid passage is removed, and the large-diameter fluid passage is targeted.
- the first plugging step is completed. In this cutting, the processing load imposed on the base material and the plugged portion by the cutting with the diamond whetstone is small and good.
- the large-diameter fluid passage of the filter base material can be plugged at one end as shown in FIG. 3 (h).
- plugging is performed in the same process as above. Is performed.
- vacuum suction is performed from the upper end of the filter base material, or the small-diameter fluid passage and the large-diameter fluid passage are plugged by a capillary phenomenon.
- the length of the stopper in the axial direction may be increased, or the stopper may be pulled upward while attaching the plugging liquid to the small-diameter fluid passage side as in FIG. 3 (b).
- the plugged portion of the large-diameter fluid passage can be removed as shown in Fig. 3 (k) and the small-diameter fluid can be removed.
- the filter base material is cut at a position where the plugged portion on the passage side remains, and the second plugging step is completed.
- the second plugging step is completed, the large-diameter fluid passage is plugged on one end face and the small-diameter fluid passage is plugged on the other end face, as shown in Fig. 3 (1). You can get a filled element.
- the plugging material was the same ceramic material as the base material of the filter.
- the filter material for domestic water purifiers and the CMP polisher for semiconductor wafer manufacturing were used as plugging materials.
- the polishing fluid filtration filter to be stored, the filtration filter for the circulation bath, and the filtration filter for the solution in hydroponics The fluid temperature of the Yuichi water purifier is 80 or less, and the plugging material is an organic type that can be easily filled. Are preferred.
- the process in this case is the same as that of the ceramics-based plugging material described above, but the same operation and effect can be obtained by curing the adhesive instead of attaching the plugging material to the filler.
- the adhesive it is preferable to mix ceramic powder or resin particles having a particle size of about # 150 into the adhesive in order to prevent the film from being pulled and damaged by the curing shrinkage of the adhesive. If heat is applied to further cure by heating, the adhesive that has a higher coefficient of thermal expansion than the filter substrate during cooling will tensilely damage the filter substrate, so the adhesive is a main agent that can be effective at room temperature. Select a hardening agent that has a long pot life, use a material diluted with a solvent such as acetate, and perform immersion and removal several times to coat the inner surface of the filter substrate. It is preferable to use a method in which an adhesive is adhered.
- the method of first plugging the small-diameter fluid passage is basically the same as the above-described method of first plugging the large-diameter fluid passage.
- the outline is described with reference to FIGS. 4 (a) to 4 (i).
- the filter substrate prepared by the above method is shown in FIG. 4 (b).
- immerse in the plugging solution prepared by the above method to a length of 4 mm.
- the filler substrate is removed from the plugging liquid.
- FIG. 4 (d) since the central portion is in a soft state, the plugging liquid is discharged from the large-diameter fluid passage, and an opening is formed in the central portion.
- the filter material is placed in a dryer, and the plugged portion of the small-diameter fluid passage is fixed to the filter material.
- the first step is completed, and as shown in FIG. 4 (e), the small-diameter fluid passage of the filler can be plugged at one end.
- the filter base material is cut at the position where the plugged portion on the radial fluid passage side remains, and the second plugging step is completed.
- the second plugging step is completed, the large-diameter fluid passage is plugged on one end face and the small-diameter fluid passage is plugged on the other end face, as shown in FIG. 4 (i).
- a filtered element can be obtained.
- the plugging process of the filter element according to the present invention includes two methods, a method of first plugging a large-diameter fluid passage and a method of first plugging a small-diameter fluid passage.
- the method of first plugging the small-diameter fluid passage is preferable because the number of processes is small, but the large-diameter fluid passage is large in the point that the large-diameter fluid passage side having a large plugging volume can be reliably plugged first.
- the method of first plugging the passage is preferable. Either of these two methods can be appropriately selected depending on the material of the ceramic base, the internal dimensions of the fluid passage, and the material of the plugging material.
- the plugging portion of the small-diameter fluid passage is first plugged, so that the small-diameter fluid passage that comes into contact with the fluid containing the solid is removed.
- a glass glaze is applied to the end face of the filter base material of the plugged small-diameter fluid passage, the adhesion of the plugged portion to the filter base material can be strengthened, and the abrasion resistance can be improved.
- a large-diameter fluid passage and a small-diameter fluid passage are selected between inscribed circle dimensions of ⁇ 1 to ⁇ 2.5 mm.
- the slurry plugging material is also preferably used as a glass glaze.
- the fluid passage is composed of the large-diameter fluid passage and the small-diameter fluid passage, and the large-diameter fluid passage is plugged with one end face, Since the small-diameter fluid passage is configured to be plugged with the other end face, the total cross-sectional area of the fluid passage on the upstream side of the filtration wall is optimized for the solid matter in the fluid to be filtered.
- the cross-sectional area can be reduced, and the total cross-sectional area on the downstream side can be minimized according to the amount of the clarified liquid and the filtration application, so the outer diameter of the filter element can be minimized. Can also be reduced.
- the filter base material which is the most suitable plugging method
- the method of immersion in the sealing material can be used without using a mask pattern by utilizing the difference in cross-sectional size between the large-diameter fluid passage and the small-diameter fluid passage. Therefore, the occurrence of coating defects can be significantly reduced, especially in the case of a multi-layer structure, and since no mask pattern is used, it can be widely applied even when the fluid passage dimension is small. Plugging is possible even if there is no deformation of the filter base material, and the plugging time can be reduced. Furthermore, expensive optical image processing equipment and injection equipment for plugging material can be used. An unnecessary and inexpensive cost plugging method can be achieved.
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- Physics & Mathematics (AREA)
- Geometry (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Combustion & Propulsion (AREA)
- General Engineering & Computer Science (AREA)
- Filtering Materials (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
- Hydroponics (AREA)
- Details Of Fluid Heaters (AREA)
- Filtering Of Dispersed Particles In Gases (AREA)
- Filtration Of Liquid (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
Description
Claims
Priority Applications (2)
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JP2000158206A JP4471452B2 (ja) | 2000-05-29 | 2000-05-29 | フィルターエレメントの製造方法 |
PCT/JP2001/004957 WO2002100514A1 (en) | 2000-05-29 | 2001-06-12 | Filter element and production method thereof |
Applications Claiming Priority (2)
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JP2000158206A JP4471452B2 (ja) | 2000-05-29 | 2000-05-29 | フィルターエレメントの製造方法 |
PCT/JP2001/004957 WO2002100514A1 (en) | 2000-05-29 | 2001-06-12 | Filter element and production method thereof |
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WO2002100514A1 true WO2002100514A1 (en) | 2002-12-19 |
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PCT/JP2001/004957 WO2002100514A1 (en) | 2000-05-29 | 2001-06-12 | Filter element and production method thereof |
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WO (1) | WO2002100514A1 (ja) |
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FR2902348A1 (fr) * | 2006-06-19 | 2007-12-21 | Ceramiques Tech Ind Sa Sa | Corps poreux monolithique a structure en nid d'abeille, notamment filtre a particules pour gaz d'echappement |
US7314496B2 (en) | 2002-09-13 | 2008-01-01 | Ibiden Co., Ltd. | Honeycomb structure |
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JP4600826B2 (ja) * | 2005-10-18 | 2010-12-22 | 日立金属株式会社 | セラミックハニカムフィルタ |
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JP2009195905A (ja) * | 2009-04-13 | 2009-09-03 | Hitachi Metals Ltd | セラミックハニカムフィルタの製造方法 |
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JP6068067B2 (ja) | 2012-09-06 | 2017-01-25 | 日本碍子株式会社 | 目封止ハニカム構造体 |
JP2016055231A (ja) * | 2014-09-08 | 2016-04-21 | イビデン株式会社 | ハニカム焼成体及びハニカムフィルタ |
JP6898513B2 (ja) * | 2018-03-30 | 2021-07-07 | 日本碍子株式会社 | 目封止ハニカムセグメント、及び目封止ハニカム構造体 |
DE102020131637A1 (de) * | 2020-05-22 | 2021-11-25 | Taiwan Semiconductor Manufacturing Co., Ltd. | Filtervorrichtung für prozess zur herstellung von halbleitervorrichtungen |
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Cited By (13)
Publication number | Priority date | Publication date | Assignee | Title |
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US7766991B2 (en) | 2002-09-13 | 2010-08-03 | Ibiden Co., Ltd. | Honeycomb structural body |
US7314496B2 (en) | 2002-09-13 | 2008-01-01 | Ibiden Co., Ltd. | Honeycomb structure |
US7316722B2 (en) | 2002-09-13 | 2008-01-08 | Ibiden Co., Ltd. | Honeycomb structure |
US7326270B2 (en) | 2002-09-13 | 2008-02-05 | Ibiden Co., Ltd. | Filter |
US8012234B2 (en) | 2002-09-13 | 2011-09-06 | Ibiden Co., Ltd. | Honeycomb structural body |
US8246710B2 (en) | 2003-06-05 | 2012-08-21 | Ibiden Co., Ltd. | Honeycomb structural body |
US8062603B2 (en) | 2003-06-23 | 2011-11-22 | Ibiden Co., Ltd. | Honeycomb structural body |
US8361400B2 (en) | 2003-06-23 | 2013-01-29 | Ibiden Co., Ltd. | Honeycomb structural body |
US7517502B2 (en) | 2003-10-23 | 2009-04-14 | Ibiden Co., Ltd. | Honeycomb structural body |
US7585471B2 (en) | 2004-02-23 | 2009-09-08 | Ibiden Co., Ltd. | Honeycomb structured body and exhaust gas purifying device |
FR2902348A1 (fr) * | 2006-06-19 | 2007-12-21 | Ceramiques Tech Ind Sa Sa | Corps poreux monolithique a structure en nid d'abeille, notamment filtre a particules pour gaz d'echappement |
EP2939808A4 (en) * | 2012-12-27 | 2016-08-17 | Sumitomo Chemical Co | METHOD FOR MANUFACTURING HONEYCOMB STRUCTURE |
EP3173139B1 (en) * | 2014-07-23 | 2024-04-03 | Ibiden Co., Ltd. | Honeycomb filter |
Also Published As
Publication number | Publication date |
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JP4471452B2 (ja) | 2010-06-02 |
JP2001334114A (ja) | 2001-12-04 |
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