Dehumidification member, dehumidification rotor, and method for manufacturing dehumidification member

Abstract

The present invention aims to provide a dehumidification component with high tensile strength. The problem can be solved by the following dehumidification component: a dehumidification component, which is a dehumidification component with a honeycomb structure, wherein the honeycomb structure includes: a flat substrate and a corrugated substrate; a contact portion formed by abutting between the peak portion of the corrugated substrate and the flat substrate; and a vent portion, the contact portion includes: a bonding portion bonded by an adhesive; and silica gel formed at a position closer to the vent portion than the bonding portion, and the components constituting the adhesive are different from the components of the silica gel formed at a position closer to the vent portion than the bonding portion.

Description

Technical Field

[0001] The disclosure of the present application relates to a dehumidification member, a dehumidification rotor, and a method for manufacturing the dehumidification member. Background Art

[0002] In a manufacturing site such as a factory, dry air is sometimes required after removing moisture. For example, in a semiconductor manufacturing plant, there is a growing demand for dry air after removing moisture, which is the main cause of oxidation, as much as possible. As a device for supplying dry air, a dehumidification device having a dehumidification rotor in which silica gel or zeolite is loaded on a honeycomb structure is known (see Patent Document 1).

[0003] A dehumidification device having a dehumidification rotor is disclosed in Patent Document 1. Figure 6 As shown in the figure, the dehumidification rotor is divided into a processing zone and a regeneration zone, and the dehumidification rotor rotates and moves at a predetermined speed in the order of processing zone, regeneration zone, processing zone, regeneration zone, etc. Then, the dehumidification rotor absorbs moisture from the high-humidity air when it is in the processing zone, and releases the moisture absorbed by the dehumidification rotor when it is in the regeneration zone, thereby regenerating the dehumidification function of the dehumidification rotor. By repeatedly absorbing moisture to the dehumidification rotor and removing moisture from the dehumidification rotor, continuous operation of the dehumidification device can be achieved.

[0004] As a method for manufacturing a dehumidification rotor, for example, Patent Document 1 describes a method including the following steps.

[0005] (1) Corrugated paper is formed by feeding paper between a pair of forming rotors having a desired tooth shape.

[0006] (2) After applying water glass adhesive to the peaks on one side of the corrugated paper, the corrugated paper is bonded to porous paper. Then, the corrugated paper is rolled up while applying water glass adhesive to the peaks on the other side, thereby obtaining a cylindrical molded body having a honeycomb structure.

[0007] (3) The molded body is immersed in an aqueous solution of water glass, followed by drying and acid treatment, thereby causing silica gel to adhere to the molded body.

[0008] In addition, Patent Document 2 describes another method for manufacturing a dehumidification rotor including the following steps.

[0009] (1) First, a honeycomb structure is produced.

[0010] (2) The honeycomb structured body produced is impregnated with a slurry containing silica gel, and then dried and fired to form a honeycomb structured body supporting silica gel.

[0011] Prior art literature

[0012] Patent Literature

[0013] Patent Document 1: Japanese Patent Application Laid-Open No. 61-252497

[0014] Patent Document 2: Japanese Patent No. 4958459 Summary of the invention

[0015] Problems to be solved by the invention

[0016] However, if the scale of the factory becomes larger or the required dehumidification capacity becomes higher, the dehumidification rotor may need to be enlarged. When the dehumidification rotor is enlarged, the compression force due to the weight of the dehumidification rotor acts on the upper side in the vertical direction from the rotation center of the dehumidification rotor. On the other hand, the force in the direction of peeling of the bonded part of the honeycomb structure due to the weight of the dehumidification rotor acts on the lower side in the vertical direction from the rotation center of the dehumidification rotor.

[0017] In addition, when the dehumidification rotor is installed in the dehumidification device, the dehumidification component is sometimes fixed by sheet metal. In this case, if the dehumidification rotor expands and contracts due to the adsorption and desorption of moisture, tensile stress is generated in the bonding part of the honeycomb structure, which may cause peeling. Therefore, it is desired to make the bonding part of the honeycomb structure more secure.

[0018] However, the dehumidification rotor described in Patent Document 1 is manufactured by the following steps in order to increase the amount of silica gel attached: (1) using paper having a very low density of inorganic fibers constituting a honeycomb structure and impregnating the paper with water glass to a depth of the paper; (2) using water glass as an adhesive for forming the honeycomb structure; and (3) silicating the water glass by acid treatment. Therefore, there is a problem that the amount of silica gel attached to the dehumidification rotor cannot be increased without changing the adhesive to an adhesive other than water glass.

[0019] On the other hand, the dehumidification rotor described in Patent Document 2 is manufactured by impregnating a honeycomb structure with silica gel slurry, drying it, and then heating and calcining it. However, as described in the comparative example below, the inventors of the present invention have newly discovered that in the manufacturing method of the dehumidification rotor described in Patent Document 2, the tensile strength of the honeycomb structure is very weak, in other words, interlayer delamination of the honeycomb structure is likely to occur.

[0020] The disclosure of the present application is completed in order to solve the above-mentioned problems. After intensive research, a new discovery is made: the abutment portion of the flat substrate and the corrugated substrate forming the honeycomb structure is formed by a bonding portion bonded by an adhesive and a silicone gel formed at a position closer to the vent portion than the bonding portion, thereby providing a dehumidification component with higher tensile strength.

[0021] That is, an object of the disclosure of the present application is to provide a dehumidification member having high tensile strength, a dehumidification rotor, and a method for manufacturing a dehumidification member.

[0022] Means used to solve problems

[0023] The disclosure of the present application relates to a dehumidification member, a dehumidification rotor, and a method for manufacturing the dehumidification member as shown below.

[0024] (1) A dehumidification member comprising a honeycomb structure, wherein:

[0025] The honeycomb structure comprises:

[0026] Flat substrate and corrugated substrate;

[0027] A contact portion formed by a contact between a peak portion of the corrugated substrate and the flat substrate; and

[0028] Ventilation hole,

[0029] The abutting portion comprises:

[0030] A bonding portion bonded by an adhesive; and

[0031] Silicone rubber formed at a position closer to the vent portion than the bonding portion,

[0032] The adhesive has a component different from a component of the silicone rubber formed on the vent hole side relative to the bonding portion.

[0033] (2) In addition to the dehumidification component described in (1),

[0034] The flat substrate and / or the corrugated substrate is mixed paper.

[0035] (3) In addition to the dehumidification component described in (2),

[0036] The mixed paper contains silica gel in the gaps between fibers.

[0037] The amount of voids in the silica gel contained in the mixed paper is larger than the amount of voids in the silica gel formed at a position closer to the vent portion than the adhesive portion.

[0038] (4) In the dehumidification member described in any one of (1) to (3) above,

[0039] The adhesive contains an organic component.

[0040] (5) A dehumidification rotor comprising the dehumidification member described in any one of (1) to (4) above.

[0041] (6) A manufacturing method, which is a manufacturing method of a dehumidification member, wherein:

[0042] The manufacturing method comprises:

[0043] a loading step in which a sodium silicate solution is loaded on the honeycomb structure; and

[0044] a silica gel synthesis step in which the sodium silicate supported on the honeycomb structure in the supporting step is subjected to an acid treatment to synthesize silica gel,

[0045] The honeycomb structure comprises:

[0046] Flat substrate and corrugated substrate;

[0047] A bonding portion bonding the peak portion of the corrugated substrate and the flat substrate; and

[0048] Vent section.

[0049] (7) Based on the manufacturing method described in (6),

[0050] The flat substrate and / or the corrugated substrate is mixed paper.

[0051] (8) Based on the manufacturing method described in (6) or (7),

[0052] The adhesive contains an organic component.

[0053] Effects of the Invention

[0054] According to the disclosure of the present application, it is possible to provide a dehumidification member having higher tensile strength than conventional dehumidification members. BRIEF DESCRIPTION OF THE DRAWINGS

[0055] Figure 1 It is a perspective view schematically showing a dehumidification rotor and a dehumidification member according to the first embodiment.

[0056] Figure 2 It means in Figure 1 This is a diagram showing an overview of the honeycomb structure when the dehumidification member is viewed in the direction of the rotation center axis of the dehumidification rotor.

[0057] Figure 3 This is an enlarged schematic cross-sectional view of a contact portion of the honeycomb structure.

[0058] Figure 4 It is a perspective view schematically showing a dehumidification member according to a third embodiment.

[0059] Figure 5 This is a schematic diagram for explaining a method for evaluating the tensile strength of a dehumidification member.

[0060] Figure 6This is a graph showing the measurement results of the tensile strength of the dehumidification members produced in Example 1 and Comparative Example 1 and the honeycomb structure produced in Comparative Example 2.

[0061] Figure 7 This is a graph showing the measurement results of the tensile strength of the dehumidification members produced in Example 2 and Comparative Example 3 and the honeycomb structure produced in Comparative Example 4.

[0062] Figure 8 This is a photograph used in place of a drawing, and is a SEM photograph of the surface of a mixed paper.

[0063] Fig. 9 It is a photo used in place of the attached picture. Fig. 9 (A) is a SEM photograph of the surface and cross section of the mixed paper constituting the honeycomb structure of the dehumidification member prepared in Example 2. Fig. 9 (B) is a SEM photograph of a cross section of the cellophane constituting the honeycomb structure of the dehumidification member prepared in Example 1. DETAILED DESCRIPTION

[0064] Hereinafter, the dehumidification member, the dehumidification rotor, and the method for manufacturing the dehumidification member disclosed in the present application will be described in detail.

[0065] (First embodiment of the dehumidification member)

[0066] Reference Figures 1 to 3 , the dehumidification component involved in the first embodiment is described. Figure 1 It is a perspective view schematically showing the dehumidification rotor 10 and the dehumidification member 1 . Figure 2 It means along Figure 1 FIG. 1 is a schematic diagram of the honeycomb structure 2 when the dehumidification member 1 is viewed in the direction of the rotation center axis Z of the dehumidification rotor 10 . Figure 3 It is a schematic cross-sectional view in which the contact portion 23 of the honeycomb structure 2 is enlarged.

[0067] The dehumidification member 1 according to the first embodiment is a divided body obtained by dividing the dehumidification rotor 10 into one or more components. Figure 1 In the example shown, the dehumidification rotor 10 is formed by combining three dehumidification members 1, but the number of dehumidification members 1 constituting the dehumidification rotor 10 may be arbitrary. Alternatively, the dehumidification rotor 10 may be formed by a single dehumidification member 1.

[0068] The dehumidification member 1 includes a honeycomb structure 2. The honeycomb structure 2 includes a flat substrate 21, a corrugated substrate 22, a contact portion 23 formed by contact between a peak portion 22a of the corrugated substrate 22 and the flat substrate 21, and a vent portion 24. The contact portion 23 includes a bonding portion 23a bonded by an adhesive, and a silica gel 23b formed at a position closer to the vent portion side than the bonding portion 23a.

[0069] As described in detail in the manufacturing method to be described later, with respect to the dehumidification component 1, a honeycomb structure 2 including an adhesive portion 23a is first manufactured, and then a sodium silicate solution is loaded on the honeycomb structure 2. Then, silica gel 23b is synthesized from sodium silicate by acid treatment (hereinafter, silica gel synthesized from sodium silicate is sometimes described as "synthetic silica gel"). If the honeycomb structure 2 is immersed in the sodium silicate solution, the sodium silicate solution fills the gap S formed by the adhesive portion 23a, the flat substrate 21, and the corrugated substrate 22. Thus, the adhesive portion 23a is covered with the synthetic silica gel 23b. In addition, in the manufacturing method disclosed in the present specification, the synthetic silica gel 23b is formed around the entire flat substrate 21 and the corrugated substrate 22 constituting the honeycomb structure 2. In the present specification, the silica gel 23b contained in the abutting portion 23 refers to, for example Figure 3 As shown in FIG. 1 , the synthetic silicone rubber 23b is closer to the bonding portion 23a than the boundary B between the synthetic silicone rubber 23b formed around the flat substrate 21 and the synthetic silicone rubber 23b formed around the corrugated substrate 22. In other words, it can be said that it is a portion in the synthetic silicone rubber 23b that contacts both the flat substrate 21 and the corrugated substrate 22.

[0070] The flat substrate 21 and the corrugated substrate 22 of the dehumidification component 1 involved in the first embodiment can use fibrous substrates known in the technical field. Specific examples of fibrous substrates include inorganic fibers such as silica-alumina fibers, silica fibers, alumina fibers, mullite fibers, glass fibers, asbestos fibers, and carbon fibers; organic fibers such as polyethylene fibers, polypropylene fibers, nylon fibers, polyester fibers, polyvinyl alcohol fibers, polyethylene terephthalate fibers, aramid fibers, pulp fibers, and rayon fibers. In addition, these fibers can be a single type or a combination of two or more. In addition, the above-mentioned fibers are merely examples and are not limited to these fibers. In addition, the flat substrate 21 and the corrugated substrate 22 can use the same fibers or different fibers.

[0071] If the fiber density of the dehumidification component 1 involved in the first embodiment is too low, the strength of the honeycomb structure will be weakened. If the density is too high, the amount of silica gel loaded between the fibers will be reduced. Therefore, the fiber density can be appropriately selected by considering the strength and the amount of the honeycomb structure (moisture absorption). The fiber density of the dehumidification component 1 involved in the first embodiment can be, for example, 0.05 to 0.5 g / cm 3 , preferably 0.08 to 0.3 g / cm 3 , more preferably 0.1 to 0.2 g / cm 3 wait.

[0072] The adhesive forming the bonding portion 23a is not particularly limited as long as it can bond the flat substrate 21 to the peak portion 22a of the corrugated substrate 22. For example, an inorganic adhesive or an organic adhesive can be cited. Examples of inorganic adhesives include silica-based adhesives, water glass, and the like. In addition, examples of organic adhesives include acrylic resin adhesives, acrylic resin emulsion adhesives, α-olefin adhesives, polyurethane resin adhesives, polyurethane resin emulsion adhesives, ether cellulose, ethylene-vinyl acetate resin emulsion adhesives, epoxy resin adhesives, epoxy resin emulsion adhesives, vinyl chloride resin solvent adhesives, chloroprene rubber adhesives, vinyl acetate resin emulsion adhesives, cyanoacrylate adhesives, silicone adhesives, aqueous polymer-isocyanate adhesives, styrene-butadiene rubber solution adhesives, styrene-butadiene rubber latex adhesives, nitrile rubber adhesives, polyimide adhesives, polyvinyl alcohol adhesives, starch adhesives, natural rubber adhesives, and the like.

[0073] The adhesive may be appropriately selected according to the materials of the flat substrate 21 and the corrugated substrate 22. In addition, the adhesive may be a combination of two or more selected from inorganic adhesives and organic adhesives. In addition, the adhesive may contain a tackifier, a plasticizer, a curing agent, a cross-linking agent, a diluent, a filler, a thickener, a pigment, an anti-aging agent, an antioxidant, a defoaming agent, a flame retardant, a preservative, a dispersant, a wetting agent, a hydrophilizing agent, etc. as needed.

[0074] The sodium silicate solution used for synthesizing silica gel 23b is a solution obtained by dissolving sodium silicate in water, and is also called "water glass". The sodium silicate solution can be made by dissolving commercially available sodium silicate in water. If the concentration of the sodium silicate solution is too dilute, the amount that can be loaded on the honeycomb structure 2 through a single loading process becomes less. On the other hand, if it is too concentrated, the air vents 24 of the honeycomb structure 2 may be clogged. Therefore, the concentration of sodium silicate is appropriately set so that the desired amount can be loaded without clogging the air vents 24. The concentration of the sodium silicate solution can be, for example, 20 to 50% by mass, preferably 25 to 45% by mass, and more preferably 30 to 40% by mass.

[0075] In the dehumidification member 1 according to the first embodiment, first, the flat substrate 21 and the peak portion 22a of the corrugated substrate 22 are bonded together by an adhesive to form a honeycomb structure 2. Unlike Patent Document 2, the dehumidification member 1 according to the first embodiment does not require firing. Therefore, a relatively heat-resistant adhesive can be used, and the options for the type of adhesive used are increased.

[0076] In addition, as described in Patent Document 1, sodium silicate (water glass) can also be used as an adhesive. However, the dehumidification component 1 involved in the first embodiment can select an adhesive with a better bonding effect to the bonding portion 23a. Therefore, the components of the bonding portion 23a bonded by the adhesive and the synthetic silica gel 23b formed at a position closer to the vent portion than the bonding portion 23a are different. In addition, in this specification, different components means that the overall composition of the adhesive is different from the composition of the synthetic silica gel 23b, and does not prevent part of the composition of the adhesive from being the same as the composition of the synthetic silica gel.

[0077] As the effects of the different components of the bonding portion 23a bonded by the adhesive and the synthetic silica gel 23b formed at a position closer to the vent portion than the bonding portion 23a, there are the effects of improving the bonding strength by the anchoring effect brought about by different types of adhesives, thereby improving the strength of the honeycomb structure, and reducing costs and imparting functionality due to the increase in design freedom brought about by the use of different types of adhesives. On the other hand, it is believed that, for example, in the case of using sodium silicate as an adhesive, the adhesive attached and cured to the bonding portion 23a is dissolved in the loading process of the sodium silicate solution, and the molded body as a dehumidification component cannot be maintained. In this case, it can be considered that if a different adhesive that is poorly soluble in the sodium silicate solution is used as the adhesive, the effect of preventing such a phenomenon can be prevented. As adhesives that are poorly soluble in the sodium silicate solution, for example, acrylic resin emulsion adhesives, ethylene-vinyl acetate resin emulsion adhesives, etc. can be cited.

[0078] In addition, as another effect of the different compositions of the bonding portion 23a bonded by the adhesive and the synthetic silicone 23b formed at a position closer to the vent portion than the bonding portion 23a, it can be listed that it helps to clarify the cause of product failure by investigating the distribution and adhesion amount of the adhesive.

[0079] (Second embodiment of dehumidification member)

[0080] A second embodiment of the dehumidification component 1 is described. The dehumidification component 1 involved in the second embodiment is different from the dehumidification component 1 involved in the first embodiment in that the flat substrate 21 and / or the corrugated substrate 22 is mixed paper, and the other points are the same as the dehumidification component 1 involved in the first embodiment. Therefore, in the second embodiment, the description will focus on the points that are different from the first embodiment, and the repeated description of the matters explained in the first embodiment will be omitted. Therefore, of course, even if it is not clearly described in the second embodiment, the matters explained in the first embodiment can be adopted in the second embodiment.

[0081] In this specification, mixed paper refers to a paper-like substrate formed by inserting hygroscopic particles such as silica gel, zeolite, silica alumina amorphous porous body, mesoporous silica, ion exchange resin, polyacrylate resin, and alkylene oxide resin into the gaps between the fibers of the fibrous substrate constituting the flat substrate 21 and the corrugated substrate 22 exemplified in the first embodiment. Mixed paper is made by forming a fiber solution in which hygroscopic particles are dispersed into a paper shape. The type of silica gel can be appropriately selected according to the purpose. For example, type A with excellent hygroscopicity at low humidity and type B with excellent hygroscopicity at high humidity can be selected according to the purpose. Alternatively, type A and type B silica gel can be mixed.

[0082] In addition, the hygroscopic particles contained in the mixed paper become the form of particles agglomerated in the gaps of the fibers during the manufacturing process. On the other hand, the synthetic silica gel 23b formed at a position closer to the vent portion than the bonding portion 23a is made by acid treatment of the sodium silicate impregnated in the honeycomb structure 2. Therefore, the amount of voids in the hygroscopic particles contained in the mixed paper is more than the amount of voids in the synthetic silica gel 23b formed at a position closer to the vent portion than the bonding portion 23a. In addition, in this specification, "the amount of voids" refers to the amount of unit volume of the gaps formed in the gaps between the particles and the particles, which is different from the specific surface area of ​​the pore surface area inside the hygroscopic particles. The "amount of voids" can be compared from the roughness of the appearance by photographing the particles with SEM or the like. The more irregularly the particles aggregate, the more "the amount of voids" there are, and the rougher the appearance of the SEM image (fine concave and convex shapes are observed). On the other hand, the less "the amount of voids", the more densely the particles are formed, so the appearance of the SEM image is smooth.

[0083] In addition, the "amount of voids" is not the amount of gaps between individual particles and particles, but the amount of voids in the region where a predetermined amount of particles are aggregated (roughness or smoothness of appearance). The region where a predetermined amount of particles are aggregated refers to any region where particles are aggregated as seen from the SEM image. Therefore, the region does not include cracks formed on the surface. In other words, the region does not refer to the entire surface observed through the SEM image, but only refers to the part where the particles are aggregated.

[0084] In addition, the difference between the hygroscopic particles contained in the mixed paper and the synthetic silica gel 23b can also be distinguished by using the terms "surface smoothness", "surface properties" or "surface roughness" instead of "the amount of voids". In addition, the difference between the hygroscopic particles contained in the mixed paper and the synthetic silica gel 23b seen from the SEM image can also be expressed as follows.

[0085] Hygroscopic fine particles with an uneven surface formed by the aggregation of particles, and block-shaped synthetic silica gel with a relatively flat surface.

[0086] • Hygroscopic microparticles with a rough surface and synthetic silica with a smooth surface.

[0087] (Third Embodiment of Dehumidification Member)

[0088] Reference Figure 4 The third embodiment of the dehumidification component 1 is described. The dehumidification component 1 involved in the third embodiment is different from the dehumidification component 1 involved in the first and second embodiments in that the honeycomb structure 2 is formed so that the peak portion 22a of the corrugated substrate 22 is adhered to the flat substrate 21 while being stacked, in other words, the flat substrate 21 is made roughly parallel. The other points are the same as the dehumidification component 1 involved in the first and second embodiments. Therefore, in the third embodiment, the description will focus on the points that are different from the first and second embodiments, and the repeated description of the matters already described in the first and second embodiments will be omitted. Therefore, of course, even if it is not clearly described in the third embodiment, the matters already described in the first and second embodiments can be adopted in the third embodiment.

[0089] In the dehumidification component 1 involved in the third embodiment, the peak portion 22a of the corrugated substrate 22 is bonded to the flat substrate 21, and the flat substrate 21 and the corrugated substrate 22 are cut into predetermined lengths and stacked in sequence. As a stacking form, the flat substrate 21 → corrugated substrate 22 → flat substrate 21 → corrugated substrate 22 can be stacked alternately. Alternatively, an assembly of flat substrate 21 → corrugated substrate 22 → flat substrate 21 can be made, and the flat substrate 21 of the assembly can be bonded. In addition, in Figure 4 , an example of the honeycomb structure 2 is shown in which the vent holes 24 are alternately stacked in a direction staggered by 90 degrees, but the vent holes 24 may be formed in the same direction. In addition, the first embodiment and the second embodiment are also the same in terms of the stacking form.

[0090] (Embodiment of Dehumidification Rotor)

[0091] Reference Figure 1 as well as Figure 4 , the embodiment of the dehumidification rotor 10 is described. The dehumidification rotor 10 can be manufactured by combining the dehumidification components 1 involved in the first embodiment and the second embodiment. If the dehumidification components 1 involved in the first embodiment and the second embodiment are used, the manufacturing steps of the dehumidification rotor 10 are not particularly limited. For example, in Figure 1 , the following examples are shown: (1) a rotor is manufactured by rolling up a corrugated substrate 22 into a roll while bonding the peak portion 22a of the corrugated substrate 22 to a flat substrate 21; (2) the rotor is divided and a sodium silicate solution is loaded on each of the divided rotors; (3) a dehumidification member 1 is manufactured by synthesizing silica gel 23b by subjecting sodium silicate to an acid treatment; (4) a dehumidification rotor 10 is manufactured by combining the manufactured dehumidification members 1. Alternatively, in the above step (2), the rotor may be used directly without being divided.

[0092] In addition, when using Figure 4 When the dehumidifying member 1 according to the third embodiment shown is made into the dehumidifying rotor 10 , the dehumidifying member 1 may be cut into a suitable shape and assembled.

[0093] (Embodiment of the method for manufacturing a dehumidifying member)

[0094] The manufacturing method of the dehumidification component comprises:

[0095] a loading step in which a sodium silicate solution is loaded on the honeycomb structure; and

[0096] A silica gel synthesis step in which the sodium silicate supported on the honeycomb structure in the supporting step is subjected to an acid treatment to synthesize silica gel.

[0097] Since the honeycomb structure and the sodium silicate solution have been explained, detailed description is omitted. The acid used in the silica gel synthesis process is not particularly limited as long as it can synthesize silica gel from the sodium silicate solution. As the acid, for example, sulfuric acid, phosphoric acid, nitric acid, hydrochloric acid, and metal salts of these acids, such as aluminum salts such as aluminum sulfate and aluminum nitrate, calcium salts such as calcium nitrate and calcium chloride, magnesium salts such as magnesium sulfate and magnesium chloride, and iron salts such as iron sulfate and iron nitrate. The above-mentioned acids and metal salts of acids can be used alone or in combination. In addition, the synthetic silica gel 23b can be type A or type B. By changing the concentration of the acid treatment, the synthesis can be performed according to the purpose to become the desired type. In addition, when synthesizing silica gel from a sodium silicate solution, when aluminum salts are used as acids, silica-alumina gel can be obtained. When described as "synthetic silica gel" in this specification, silica gel containing metal salts derived from acids is also included in "synthetic silica gel".

[0098] The following examples are given to specifically describe the embodiments disclosed in the present application, but these examples are only for describing the embodiments and are not intended to limit or restrict the scope of the invention disclosed in the present application.

[0099] 〔Manufacture of dehumidification components〕

[0100] <Raw Materials>

[0101] The following products were used as raw materials. The ratios are in mass %.

[0102] <Base Material>

[0103] Table 1

[0104] Material cellophane Mixed paper Silicone 65％ Fiberglass 75％ 15％ Organic Fiber 25％ 20％

[0105] In addition, SYLYSIA740 (A-type silica gel, manufactured by Fuji Silysia Chemical Co., Ltd.) was used as the silica gel. 2 ), the glass paper is 20, the mixed paper is 83, and the thickness (μm) is 101 for the glass paper and 197 for the mixed paper.

[0106] <Adhesive>

[0107] Table 2

[0108] Material For cellophane For mixed paper Colloidal silicon dioxide (solid content) 40％ 32％ Vinyl acetate emulsion (solid content) 8％ Acrylic emulsion (solid content) 13％ Ion exchange water 52％ 55％

[0109] <Sodium silicate solution>

[0110] Table 3

[0111] Material ratio Sodium silicate No. 2 89％ Ion exchange water 11％

[0112] <Acid treatment liquid>

[0113] Table 4

[0114] Material ratio Aluminum sulfate 18％ Ion exchange water 82％

[0115] <Silica gel slurry solution>

[0116] Table 5

[0117] Material ratio Type A Silicone 24％ Colloidal silicon dioxide (solid content) 7％ Ion exchange water 69％

[0118] <Example 1>

[0119] [Manufacturing of dehumidification components]

[0120] The dehumidification component is manufactured through the following steps.

[0121] (1) Cellophane was used as a flat substrate and a corrugated substrate. The cellophane was corrugated using an adhesive, and the corrugated paper was spirally wound using an adhesive to produce a rotor-type honeycomb structure having a diameter of 450 mm, a flute length of 210 mm, and a flute peak height of 1.9 mm. The flute length refers to the length of the peak portion 22a of the corrugated substrate 22 (the thickness of the dehumidification rotor) (see Figure 1 as well as Figure 2 The height of the peak refers to the distance between the peak portion 22a and the flat substrate 21 (refer to Figure 2 H).

[0122] (2) After the manufactured honeycomb structure is immersed in a sodium silicate solution (the method for supporting the sodium silicate may be a method based on spraying or scattering such as spraying or sprinkling), the honeycomb structure is lifted out of the sodium silicate solution.

[0123] (3) After blowing air on the honeycomb structure loaded with the sodium silicate solution, the honeycomb structure is immersed in an acid treatment solution to generate aluminum silicate hydrogel through a chemical reaction between the sodium silicate and aluminum sulfate in the honeycomb structure.

[0124] (4) The honeycomb structure is heated and dried to obtain a dehumidification member reinforced with silica gel.

[0125] [Evaluation method of tensile strength of dehumidification member]

[0126] One side reference Figure 5 , while explaining the evaluation method of the tensile strength of the dehumidification member. The tensile strength was evaluated by the following steps.

[0127] (1) Cut the dehumidification member into 5 cm pieces parallel to the stacking direction. 3 The cube shape is used as the experimental body for tensile strength measurement.

[0128] (2) The test body was dried at 110° C. for 1 hour, and its weight was measured with an electronic balance and the lengths of its three sides were measured with a vernier caliper.

[0129] (3) A jig for a tensile test was bonded to the upper and lower sides of the honeycomb structure of the test body in the lamination direction using an epoxy adhesive.

[0130] (4) The test specimen was mounted on a tensile testing machine (Shimadzu Corporation, Shimadzu Corporation / Small Desktop Testing Machine Ez-LX), and a tensile load was continuously applied to the test specimen at a rate of 1 mm / min. The load at fracture was determined to the nearest 1 N.

[0131] (5) The tensile strength in the lamination direction is calculated by the following formula.

[0132] σ=F / (A×B)

[0133] (Wherein, σ: tensile strength [N / cm 2 ], F: load when the test object breaks [N], A dimension of the test object [cm], B dimension of the test object [cm])

[0134] The tensile strength was evaluated using three test specimens. The evaluation results are shown in Figure 6 The average value of tensile strength is 24.3 kPa.

[0135] <Comparative Example 1>

[0136] A silica gel slurry solution was used instead of the sodium silicate solution of Example 1. After being immersed in a silica gel slurry solution whose solid content concentration was adjusted so that the density of the dehumidifying component was almost the same as that of Example 1, it was dried at 150°C and then calcined at 500°C for 1 hour to produce a dehumidifying component of Comparative Example 1. The tensile strength of the dehumidifying component was evaluated by the same procedure as in Example 1. The evaluation results are shown in Figure 6 The average value of tensile strength is 9.6 kPa.

[0137] <Comparative Example 2>

[0138] The honeycomb structure prepared in Example 1 (not immersed in the sodium silicate solution) was used as Comparative Example 2. The tensile strength of Comparative Example 2 was evaluated by the same procedure as in Example 1. The evaluation results are shown in Figure 6 The average value of tensile strength is 18.6 kPa.

[0139] like Figure 6 As shown, it was confirmed that the tensile strength was improved by covering the surrounding of the adhesive of the honeycomb structure with synthetic silica gel. As a reason for this, it can be considered that the synthetic silica gel formed at a position closer to the vent portion than the bonding portion of the honeycomb structure increases the bonding area of ​​the abutment portion, thereby exerting a bonding effect. On the other hand, the dehumidification component manufactured by the manufacturing method described in Patent Document 2, which is to immerse the honeycomb structure in silica gel slurry, has a lower tensile strength than the honeycomb structure. In the manufacturing method described in Patent Document 2, it is difficult to increase the load of silica gel. Therefore, by implementing a firing process, the dehumidification performance of the manufactured dehumidification component is improved. However, through the disclosure of the present application, it is newly discovered that in the manufacturing method of Patent Document 2, based on the viewpoint of tensile strength, the tensile strength of the honeycomb structure is significantly reduced due to the firing process. As a reason for the reduction in tensile strength, it can be considered that organic components such as adhesives are burned out due to the firing process.

[0140] In addition, the manufacturing method described in Patent Document 2 requires adding colloidal silica without dehumidification function to the silica gel slurry in order to load silica gel on the honeycomb structure. Therefore, it is not possible to make all the particles loaded on the honeycomb structure have dehumidification function. On the other hand, since the dehumidification component disclosed in the present application synthesizes silica gel from a sodium silicate solution, all the particles (synthetic silica gel) loaded on the honeycomb structure have dehumidification function. Therefore, the dehumidification capacity per unit weight can be improved.

[0141] <Example 2>

[0142] A dehumidification member was prepared by the same procedure as in Example 1 except that mixed paper was used instead of glassine paper, and the tensile strength was evaluated. The evaluation results are shown in FIG. Figure 7 The average value of tensile strength is 46.8 kPa.

[0143] <Comparative Example 3>

[0144] A dehumidification member was prepared by the same procedure as in Comparative Example 1 except that mixed paper was used instead of glassine paper, and the tensile strength was evaluated. The evaluation results are shown in FIG. Figure 7 The average value of tensile strength is 2.1 kPa.

[0145] <Comparative Example 4>

[0146] The honeycomb structure using mixed paper prepared in Example 2 (not immersed in a sodium silicate solution) was used as Comparative Example 4. The tensile strength of Comparative Example 4 was evaluated by the same procedure as in Example 1. The evaluation results are shown in FIG. Figure 7 The average value of tensile strength is 8.7 kPa.

[0147] like Figure 7 As shown, it was confirmed that the tensile strength was improved by covering the periphery of the adhesive of the honeycomb structure with synthetic silica gel. In addition, in the case of Comparative Example 1 and Comparative Example 2, the tensile strength was increased by about 1.3 times by covering the periphery of the adhesive with silica gel. On the other hand, in the case of Comparative Example 2 and Comparative Example 4, the tensile strength was increased by about 5.4 times by covering the periphery of the adhesive with silica gel. In other words, when mixed paper was used, the tensile strength was greatly increased by means of the honeycomb structure made of the adhesive compared to when glass paper was used as the substrate.

[0148] In order to clarify why the tensile strength of the mixed paper substrate was significantly increased compared to the honeycomb structure, the surface and cross-section of the substrate were photographed using SEM. Figure 8 The SEM photo of the surface of the mixed paper is shown. Figure 8 As shown, it was confirmed that silica gel was porously supported in the gaps between the fibers in the mixed paper.

[0149] Next, SEM photographs of the surface and cross section of the mixed paper constituting the honeycomb structure of the dehumidification member prepared in Example 2 are shown ( Fig. 9 (A) in Example 1), a SEM photograph of a cross section of the cellophane constituting the honeycomb structure of the dehumidification member prepared in Example 1 ( Fig. 9 (B) in the figure.

[0150] like Fig. 9 As shown in the SEM photograph of the surface of (A) in FIG. , it was confirmed that the synthetic silica gel formed a very smooth surface (with few voids). Fig. 9 As shown in the SEM photograph of the cross section of (A) in the example 2, it was confirmed that in the dehumidification member prepared in Example 2, the porous silica gel ( Fig. 9 The surface of the portion (enclosed by a circle in the photo (A)) is laminated with a synthetic silicone layer ( Fig. 9 (arrow part in the photo of (A)).

[0151] On the other hand, Fig. 9 As shown in the SEM photograph of the cross section in (B), it was confirmed that in the dehumidification member prepared in Example 1, silica gel synthesized by acid-treating a sodium silicate solution was synthesized integrally from the surface to the inside of the cellophane.

[0152] The reason why the tensile strength of the dehumidification member produced in Example 2 is significantly higher than that of the dehumidification member in Example 1 is considered to be as follows.

[0153] (1) First, the vicinity of the abutting portion of the honeycomb structure is discussed. As described above, the synthetic silica gel formed at a position closer to the vent portion than the bonding portion increases the bonding area of ​​the abutting portion. However, the silica gel inside the mixed paper is porous (with many bumps). Therefore, the sodium silicate solution penetrates into the gaps in the porous silica gel, and through the synthesis process, a portion of the synthetic silica gel is entangled in the porous silica gel, thereby increasing the integrity of the porous silica gel inside the mixed paper and the synthetic silica gel on the outside, in other words, the adhesion between the porous silica gel and the synthetic silica gel on the outside. Therefore, it can be considered that in addition to the increase in the bonding area of ​​the abutting portion, Figure 3 The synthetic silica gel in the gap S also works together with the porous silica gel contained in the flat substrate 21 and the corrugated substrate 22 to enhance the adhesive force.

[0154] (2) Next, the flat substrate and the corrugated substrate as a whole are discussed. In the honeycomb structure of Example 2, only the surface of the mixed paper is covered with dense synthetic silica gel while maintaining the porous portion inside the mixed paper. Therefore, the rigidity of the outer and inner sides of the mixed paper serving as the substrate constituting the honeycomb structure is different, so when a tensile force is applied, the force is easily dispersed. In other words, when a tensile force is applied to the honeycomb structure, the flat substrate and the corrugated substrate of the honeycomb structure are easy to disperse the tensile force, resulting in that deformation is difficult to concentrate on the abutment portion 23. On the other hand, in Example 1, as Fig. 9 As shown in (B) in FIG. 1 , since the glass paper is integrally formed from the surface to the inside by synthetic silicone, it is difficult to disperse the force when a tensile force is applied. Therefore, it is believed that since the applied tensile force is concentrated on the abutment portion 23, the tensile strength is weaker than that of mixed paper.

[0155] According to the above results, when manufacturing a dehumidification component by the manufacturing method of the dehumidification component disclosed in the present application, a honeycomb structure is first formed, and then silica gel is synthesized, so the options of adhesives for forming the honeycomb structure increase. In particular, since the dehumidification component described in Patent Document 2 achieves improved dehumidification performance through a sintering process at about 500°C, an adhesive with a combustion temperature lower than 500°C cannot be used. On the other hand, for the dehumidification component disclosed in the present application, even an adhesive with a lower combustion temperature can be used.

[0156] In addition, in addition to the dehumidification function of silica gel, synthetic silica gel also has the effect of significantly improving the bonding function of the abutting part of the honeycomb structure. In other words, two different effects were confirmed. The tensile strength of the honeycomb structure formed by mixed paper is lower than the tensile strength of the honeycomb structure formed by cellophane (refer to Comparative Examples 2 and 4). However, because synthetic silica gel exhibits a bonding effect on both the porous silica gel and the fibers contained in the mixed paper, when mixed paper is used as the substrate for forming the honeycomb structure, it is also confirmed that the bonding function of synthetic silica gel is very excellent.

[0157] Industrial Applicability

[0158] According to the disclosure of the present application, the tensile strength of the dehumidification member is improved, and thus, it is useful for manufacturers of dehumidification devices and manufacturing industries that require dehumidified air.

[0159] Description of Reference Numerals

[0160] 1: Dehumidification component; 2: Honeycomb structure; 21: Flat substrate; 22: Corrugated substrate; 22a: Peak portion; 23: Abutment portion; 23a: Adhesive portion; 23b: Synthetic silica gel; 24: Vent portion; 10: Dehumidification rotor; B: Boundary; H: Peak height; L: Ridge length; S: Gap; Z: Rotation center axis of the dehumidification rotor.

Claims

1. A dehumidification member comprising a honeycomb structure, wherein: The honeycomb structure comprises: Flat substrate and corrugated substrate; A contact portion formed by a contact between a peak portion of the corrugated substrate and the flat substrate; and Ventilation hole, The abutting portion comprises: A bonding portion bonded by an adhesive; and a synthetic silica gel synthesized from sodium silicate and formed at a position closer to the vent portion than the bonding portion, The adhesive has a component different from the component of the synthetic silicone formed at a position closer to the vent portion than the bonding portion. The flat substrate and / or the corrugated substrate is mixed paper, The mixed paper contains porous silica gel inside, and a part of the synthetic silica gel is entangled in the porous silica gel, so that the porous silica gel and the synthetic silica gel inside the mixed paper are integrated.

2. The dehumidification member according to claim 1, wherein: The mixed paper contains silica gel in the gaps between fibers. The amount of voids in the silica gel contained in the mixed paper is greater than the amount of voids in the synthetic silica gel formed at a position closer to the vent portion than the adhesive portion.

3. The dehumidification member according to claim 1 or 2, wherein: The adhesive contains an organic component.

4. A dehumidification rotor, wherein: The dehumidification rotor includes the dehumidification member according to any one of claims 1 to 3.

5. A manufacturing method, which is a manufacturing method of a dehumidification member, wherein: The manufacturing method comprises: a loading step in which a sodium silicate solution is loaded on the honeycomb structure; and a silica gel synthesis step in which the sodium silicate supported on the honeycomb structure in the supporting step is subjected to an acid treatment to synthesize silica gel, The honeycomb structure comprises: Flat substrate and corrugated substrate; A bonding portion where the peak portion of the corrugated substrate and the flat substrate are bonded together by an adhesive; and Ventilation hole, The flat substrate and / or the corrugated substrate is mixed paper, The synthetic silicone synthesized in the silicone synthesis step is formed at a position closer to the vent portion than the bonding portion, and together with the bonding portion, forms a contact portion where the peak portion of the corrugated substrate contacts the flat substrate. The mixed paper contains porous silica gel inside, and a part of the synthetic silica gel is entangled in the porous silica gel, so that the porous silica gel inside the mixed paper and the synthetic silica gel have integrity. The adhesive has a component different from a component of the silicone rubber formed on the vent hole side relative to the bonding portion.

6. The manufacturing method according to claim 5, wherein: The adhesive contains an organic component.

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