Method of manufacturing ion exchanger cartridge

Abstract

To provide a method for manufacturing a cartridge for an ion exchanger capable of suppressing deterioration of an ion exchange resin.SOLUTION: The manufacturing method of the cartridge for the ion exchanger includes a charging step of charging the ion exchange resin R into the cap 31 opened upward, and a fixing step of fixing the cap 31 charged with the ion exchange resin R and the lid member 45 by thermal caulking. In the charging step, a first ion exchange R1 is charged into the cap 31 to form a first R1 layer made of the first ion exchange L1, and then a second ion exchange L1 is charged onto the first R2 layer to form a second R2 layer made of the second ion exchange L2 as an uppermost layer.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a cartridge for an ion exchanger. [Background technology]

[0002] The ion exchanger described in Patent Document 1 includes a case provided with an inlet pipe and an outlet pipe through which a coolant flows, and a cartridge detachably attached to the case. The cartridge includes a cylindrical cap having an opening, and a lid member (referred to as a support member in Patent Document 1) that closes the opening.

[0003] Patent Document 1 discloses a method for filling the inside of a cap with ion exchange resin. In this method, the ion exchange resin is poured into the inside of the cap through an opening, and then the ion exchange resin is pressed toward the back of the cap with a pressing jig, thereby filling the inside of the cap with the ion exchange resin. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2020-89817 Summary of the Invention [Problem to be solved by the invention]

[0005] Known ion exchange resins include ion exchangers having different heat resistance temperatures, such as anion exchange resins and cation exchange resins. When fixing the lid member to the cap filled with the ion exchange resin, the cap and the lid member may be heat-sealed or heat-sealed. In this case, the heat generated during the heat-sealing or heat-sealing process may cause the ion exchange resin to deteriorate, resulting in a decrease in the ion exchange efficiency of the ion exchange resin. This problem is particularly pronounced for ion exchangers that have a low heat resistance temperature. Therefore, there is room for improvement in the manufacture of ion exchanger cartridges. [Means for solving the problem]

[0006] A method for manufacturing an ion exchange cartridge for solving the above problem includes a cylindrical cap having an opening, an ion exchange resin containing a first ion exchanger and a second ion exchanger having a higher heat resistance temperature than the first ion exchanger and filled inside the cap, and a lid member covering the opening. The method includes a pouring step of pouring the ion exchange resin into the cap, which is open upward, and a fixing step of fixing the cap with the ion exchange resin poured into it and the lid member by thermal welding or thermal crimping. In the pouring step, the first ion exchanger is poured into the cap to form a first layer made of the first ion exchanger, and then the second ion exchanger is poured on top of the first layer to form a second layer made of the second ion exchanger as the uppermost layer.

[0007] According to the above configuration, in the loading step, the second layer made of the second ion exchanger is formed as the uppermost layer on the first layer made of the first ion exchanger. Therefore, even if heat generated in the immobilization step is transferred to the second layer, deterioration of the second ion exchanger can be suppressed as long as the temperature of the second layer does not rise to its heat-resistant temperature. Furthermore, since the second layer is formed on the first layer, the heat is less likely to reach the first layer. Therefore, deterioration of the first ion exchanger, which has a lower heat-resistant temperature than the second ion exchanger, can be suppressed. Therefore, deterioration of the ion exchange resin can be suppressed. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a cross-sectional view showing an ion exchanger according to one embodiment. [Figure 2] FIG. 2 is an exploded perspective view showing the cartridge of the ion exchanger of FIG. [Figure 3] FIG. 3(a) is a cross-sectional view of the cartridge showing the first layer forming step, and FIG. 3(b) is a cross-sectional view of the cartridge showing the first leveling step. [Figure 4] FIG. 4(a) is a cross-sectional view of the cartridge showing the second layer forming step, and FIG. 4(b) is a cross-sectional view of the cartridge showing the second leveling step. [Figure 5] FIG. 5 is a cross-sectional view of the cartridge showing the fixing step. [Figure 6] FIG. 6(a) is a cross-sectional view of the cartridge showing the first layer forming step and the second layer forming step of the modified example, and FIG. 6(b) is a cross-sectional view of the cartridge showing the second leveling step of the modified example. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, one embodiment of a method for manufacturing an ion exchange cartridge will be described with reference to FIGS. (Overall configuration of ion exchanger 10) 1, the ion exchanger 10 is connected to a cooling circuit (not shown) through which coolant flows for cooling a vehicle fuel cell. The ion exchanger 10 removes ions contained in the coolant.

[0010] The ion exchanger 10 includes a case 20 and a cartridge 30. The cartridge 30 is configured to be detachable from the case 20. (Configuration of Case 20) The case 20 has a storage section 21, an inlet pipe 22, and an outlet pipe .

[0011] The accommodation portion 21 has a cylindrical shape that opens upward. An internal thread (not shown) is formed on the inner peripheral surface of the upper end portion of the accommodation portion 21. The inlet pipe 22 and the outlet pipe 23 are connected to the lower part of the storage section 21. The inlet pipe 22 and the outlet pipe 23 are oriented in opposite directions. The cooling water flowing through the cooling circuit flows into the cartridge 30 housed in the storage section 21 through the inlet pipe 22. The outlet pipe 23 allows the cooling water in the cartridge 30 to flow out into the cooling circuit.

[0012] (Configuration of cartridge 30) The cartridge 30 includes a cap 31, a flow path member 40, a lid member 45, and an ion exchange resin R. The cap 31 is cylindrical and opens downward. The cap 31 is housed in the housing portion 21. The flow path member 40 forms a flow path inside the cap 31 through which cooling water flows. The lid member 45 covers the opening of the cap 31. The ion exchange resin R is filled inside the cap 31. The cap 31, the flow path member 40, and the lid member 45 are formed of a thermoplastic resin material such as polyamide (PA), for example.

[0013] The cap 31 has a top wall 32 and a peripheral wall 33. The top wall 32 is circular in plan view. The peripheral wall 33 protrudes downward from the outer periphery of the top wall 32. A male thread 34 that meshes with the female thread of the accommodating portion 21 is formed on the outer peripheral surface of the peripheral wall 33. By screwing the cap 31 onto the accommodating portion 21, the cartridge 30 is detachably attached to the case 20.

[0014] A plurality of bosses 35 are formed at intervals in the circumferential direction on the inner circumferential surface of the peripheral wall 33. The bosses 35 extend in the vertical direction and protrude outward from the opening of the cap 31. Each boss 35 is cylindrical. The tip of each boss 35 protrudes downward beyond the lower end of the peripheral wall 33.

[0015] An exhaust hole 36 penetrating the peripheral wall 33 is formed in a portion of the peripheral wall 33 below the male thread 34. The exhaust hole 36 has a circular cross section. The exhaust hole 36 faces the inner peripheral surface of the storage section 21. The exhaust hole 36 has the function of discharging air inside the cartridge 30 to the outside when the cartridge 30 is inserted into the case 20 in which the coolant is stored during replacement of the cartridge 30. Discharging air from the exhaust hole 36 prevents the coolant from overflowing from the case 20 during replacement of the cartridge 30.

[0016] A joint surface 33a that surrounds the exhaust hole 36 is formed on the outer circumferential surface of the peripheral wall 33. The joint surface 33a is recessed relative to the other portions of the peripheral wall 33. A first mesh member 50 that covers the exhaust hole 36 is joined to the joining surface 33a. The first mesh member 50 is joined to the joining surface 33a by, for example, vibration welding or ultrasonic welding. The first mesh member 50 has a circular shape. The first mesh member 50 is formed from a thin metal plate such as stainless steel. The mesh size of the first mesh member 50 is set to allow the passage of cooling water while preventing the passage of the ion exchange resin R.

[0017] A seal groove 37 is formed around the entire outer circumferential surface of the peripheral wall 33 above the male thread 34. An annular first seal member 55 is attached to the seal groove 37. The first seal member 55 provides a seal between the outer circumferential surface of the cap 31 and the inner circumferential surface of the housing portion 21. The first seal member 55 is made of an elastic material.

[0018] As shown in FIGS. 1 and 2, the flow path member 40 has a pipe portion 41, an annular portion 42, and a plurality of first ribs 43. The pipe part 41 has a cylindrical shape and extends vertically in the center of the interior of the cap 31. An upper end of the pipe part 41 has a gap between it and the top wall 32. The lower end of the pipe part 41 passes through the lid member 45.

[0019] The annular portion 42 is annular and surrounds the upper end of the pipe portion 41. The annular portion 42 is fitted inside the upper end of the cap 31. The first ribs 43 connect the outer peripheral surface of the pipe portion 41 and the inner peripheral surface of the annular portion 42 at multiple locations spaced apart in the circumferential direction of the pipe portion 41 .

[0020] An annular second seal member 56 is attached to the outer circumferential surface of the annular portion 42. The second seal member 56 provides a seal between the outer circumferential surface of the annular portion 42 and the inner circumferential surface of the cap 31. The second seal member 56 is made of an elastic material.

[0021] The second mesh member 51 is integrated with the flow path member 40 by insert molding. The second mesh member 51 is disk-shaped. The second mesh member 51 is integrated with the flow path member 40 so as to be flush with the annular portion 42 and the lower surfaces of the plurality of first ribs 43. The second mesh member 51 is formed from a thin metal plate such as stainless steel. The mesh size of the second mesh member 51 is set to allow the passage of cooling water while preventing the passage of the ion exchange resin R.

[0022] An annular third seal member 57 is attached to the outer peripheral surface of the lower end of the pipe portion 41. The third seal member 57 seals between the outer peripheral surface of the pipe portion 41 and the inner peripheral surface of the inner annular portion 46, which will be described later. The third seal member 57 is made of an elastic material.

[0023] The cover member 45 has an inner annular portion 46, an outer annular portion 47, and a plurality of second ribs 48. The inner annular portion 46 has an annular shape that surrounds the lower end of the pipe portion 41. The inner annular portion 46 protrudes in the same direction as the boss 35 from the surface of the cover member 45 where a through-hole 49 (described later) opens, i.e., from the underside of the cover member 45.

[0024] The outer annular portion 47 is annular and surrounds the inner annular portion 46. The outer annular portion 47 is fitted inside the lower end portion of the cap 31. The outer annular portion 47 has a plurality of through holes 49 that penetrate the outer annular portion 47 in the up-down direction and are spaced apart in the circumferential direction.

[0025] 1, the boss 35 of the cap 31 is inserted into the through-hole 49. The tip of the boss 35 is formed into a dome shape by heat caulking. This fixes the lid member 45 to the cap 31.

[0026] The second ribs 48 connect the outer peripheral surface of the inner annular portion 46 and the inner peripheral surface of the outer annular portion 47 at multiple locations spaced apart in the circumferential direction of the inner annular portion 46 . An annular fourth seal member 58 is attached to the outer peripheral surface of the outer annular portion 47. The fourth seal member 58 provides a seal between the outer peripheral surface of the outer annular portion 47 and the inner peripheral surface of the cap 31. The fourth seal member 58 is made of an elastic material.

[0027] The third mesh member 52 is integrated with the cover member 45 by insert molding. The third mesh member 52 is disk-shaped. The third mesh member 52 is integrated with the cover member 45 so as to be flush with the lower surface of the cover member 45. The third mesh member 52 is formed from a thin metal plate such as stainless steel. The mesh size of the third mesh member 52 is set to allow the passage of cooling water while preventing the passage of the ion exchange resin R.

[0028] The ion exchange resin R is filled in the space inside the cap 31 around the pipe portion 41 and between the annular portion 42 and the lid member 45. The ion exchange resin R includes a first ion exchanger R1 and a second ion exchanger R2 having a higher heat resistance temperature than the first ion exchanger R1 (see FIG. 5). The first ion exchanger R1 is, for example, a granular anion exchange resin. The second ion exchanger R2 is, for example, a granular cation exchange resin. The heat resistance temperature of the first ion exchanger R1 is, for example, about 60°C. The heat resistance temperature of the second ion exchanger R2 is, for example, about 120°C.

[0029] Most of the cooling water that flows into the inside of the case 20 from the inlet pipe 22 passes through the third mesh member 52 integrated with the lid member 45, and reaches the region inside the cap 31 that is filled with the ion exchange resin R. As the cooling water passes through the ion exchange resin R, ions are removed from the cooling water by ion exchange with the ion exchange resin R. After passing through the ion exchange resin R, the cooling water passes through the second mesh member 51 integrated with the flow path member 40, and then flows into the inside of the pipe portion 41 through the opening at the upper end of the pipe portion 41. Thereafter, the cooling water flows into the inside of the outlet pipe 23 from the lower end of the pipe portion 41, and then flows out of the outlet pipe 23 into the cooling circuit.

[0030] (Manufacturing method of cartridge 30) The manufacturing method of the cartridge 30 includes a pouring step, a first layer leveling step, a second layer leveling step, and a fixing step. The pouring step is a step of forming a first layer L1 and a second layer L2, which will be described later, by pouring ion exchange resin R into the interior of the cap 31 that is open upward. The first layer leveling step is a step of leveling the upper surface of the first layer L1. The second layer leveling step is a step of leveling the upper surface of the second layer L2. The fixing step is a step of fixing the cap 31, into which the ion exchange resin R has been poured, and the lid member 45 by thermal caulking.

[0031] 3(a), in the loading step, first, an operator or a device such as a robot places the cap 31 on the first support stand 60 with the opening facing upward. The flow path member 40 is inserted into the cap 31 in advance.

[0032] The first support base 60 has a recess 61 in which an end of the cap 31 is accommodated. The recess 61 opens to the upper surface of the first support base 60. The inner surface of the recess 61 is shaped to fit the top wall 32 and peripheral wall 33 of the cap 31. Although not shown, an engagement portion that engages with the cap 31 is provided on the inner surface of the recess 61. Therefore, the cap 31 is positioned relative to the first support base 60 by being accommodated in the recess 61.

[0033] The introducing step includes a first layer forming step and a second layer forming step. The first layer forming step is a step of forming a first layer L1 made of the first ion exchanger R1 by introducing a first ion exchanger R1 into the inside of the cap 31. The second layer forming step is a step of forming a second layer L2 made of the second ion exchanger R2 as the uppermost layer by introducing a second ion exchanger R2 onto the first layer L1.

[0034] In the introduction step, a resin introduction device (not shown) introduces ion exchange resin R into the inside of cap 31. The ion exchange resin R is introduced into a cylindrical storage space inside cap 31 that is defined by the peripheral wall 33 of cap 31, flow path member 40, and second mesh member 51. When introducing ion exchange resin R, the opening of pipe portion 41 of flow path member 40 may be blocked from above by a jig (not shown).

[0035] In the first layer forming step, all of the first ion exchangers R1 constituting the ion exchange resin R filled in the cap 31 are poured into the inside of the cap 31 to form the first layer L1. The amount of the first ion exchangers R1 poured occupies, for example, more than half the volume of the storage space. As described above, since the ion exchange resin R is granular, the upper surface of the ion exchange resin R poured into the inside of the cap 31 is unlikely to become flat.

[0036] As shown in Figure 3(b), a first layer leveling step is performed between the first layer forming step and the second layer forming step. In the first layer leveling step, one or more pressing jigs 70 press the upper surface of the first layer L1 toward the top wall 32 of the cap 31. The pressing surface of the pressing jig 70 is flat. Therefore, the upper surface of the first layer L1 is flattened by being pressed by the pressing jig 70.

[0037] As shown in Fig. 4(a), the first layer leveling step is followed by the second layer forming step. In the second layer forming step, all of the second ion exchangers R2 constituting the ion exchange resin R filled in the cap 31 are poured onto the first layer L1 that has been subjected to the first layer leveling step, thereby forming the second layer L2. In the pouring step of this embodiment, only the first layer L1, which is the bottom layer, and the second layer L2, which is the top layer, are formed. The amount of the second ion exchangers R2 poured is adjusted so that the upper surface of the second layer L2 immediately after pouring the second ion exchangers R2 does not exceed the edge of the opening of the cap 31.

[0038] As shown in FIG. 4(b), the second layer forming step is followed by a second layer leveling step. In the second layer leveling step, one or more pressing jigs 71 press the upper surface of the second layer L2 toward the top wall 32 of the cap 31. The pressing surface of the pressing jig 71 is flat. Therefore, the upper surface of the second layer L2 is flattened by being pressed by the pressing jig 71. Note that, since there is a risk that the first ion exchanger R1 may be adhering to the pressing surface of the pressing jig 70 used in the first layer leveling step, it is preferable to use a pressing jig 71 different from the pressing jig 70 used in the first layer leveling step in the second layer leveling step.

[0039] In the second layer leveling process, the upper surface of the second layer L2 is leveled so that the upper surface of the second layer L2 is positioned lower than the lower surface of the lid member 45 when the cap 31 and the lid member 45 are fixed together. That is, the pressing jig 71 presses the upper surface of the second layer L2 to a position lower than the lower surface of the lid member 45. In the second layer leveling process, the upper surface of the second layer L2 is leveled until a gap is created throughout the entire area between the lower surface of the lid member 45 and the upper surface of the second layer L2. In Figures 4(a) and 4(b), the lid member 45 covering the opening of the cap 31 is shown by a two-dot chain line.

[0040] 5, the second layer leveling step is followed by a fixing step. In the fixing step, first, the cap 31 with its opening closed by the lid member 45 is supported by the second support base 62. The second support base 62 has a configuration similar to that of the first support base 60, for example.

[0041] 5, when the lid member 45 closes the opening of the cap 31, each boss 35 of the cap 31 is inserted into a through-hole 49 of the lid member 45, thereby penetrating the lid member 45. That is, the tip of each boss 35 protrudes from the lid member 45.

[0042] Next, the tip of each boss 35 is placed inside a horn 80 provided corresponding to each boss 35. The horn 80 irradiates the tip of the boss 35 inside the horn 80 with infrared rays. As a result, the tip of the boss 35 is heated and softened.

[0043] Next, as shown by the solid line in Figure 5, a punch 81, which is provided inside the horn 80 so that it can be raised and lowered, is lowered to apply pressure to the softened tip of the boss 35, thereby heat-caulking it. As a result, the tip of each boss 35 is formed into a dome shape. As the tip of the boss 35 is heat-caulked, heat from the boss 35 is transferred to the lid member 45, causing the temperature of the lid member 45 to rise. The temperature of the underside of the lid member 45 rises to a temperature higher than 60°C and lower than 120°C, for example.

[0044] Next, while the punch 81 is pressing the tip of the boss 35, air is supplied, for example, into the inside of the horn 80, thereby cooling the punch 81 and the tip of the boss 35. Thereafter, the punch 81 moves up, and thereby moves away from the tip of the boss 35.

[0045] In this manner, the cap 31 and the lid member 45 are fixed together. When water is passed through the cartridge 30, the first ion exchanger R1 and the second ion exchanger R2 are mixed inside the cartridge 30. Therefore, after water is passed through the cartridge 30, the first layer L1 and the second layer L2 cannot be distinguished from each other.

[0046] <Operation of this embodiment> In the introducing step, the second layer L2 made of the second ion exchanger R2 is formed as the uppermost layer on the first layer L1 made of the first ion exchanger R1. Therefore, even if heat generated in the immobilizing step is transferred to the second layer L2, deterioration of the second ion exchanger R2 can be suppressed as long as the temperature of the second layer L2 does not rise to its heat resistance temperature. Furthermore, because the second layer L2 is formed on the first layer L1, the heat is less likely to reach the first layer L1. Therefore, deterioration of the first ion exchanger R1, which has a lower heat resistance temperature than the second ion exchanger R2, can be suppressed.

[0047] <Effects of this embodiment> (1) The manufacturing method of the cartridge 30 includes a loading step and a fixing step. The loading step is a step of forming a first layer L1 made of a first ion exchanger R1 inside the cap 31, and then forming a second layer L2 made of a second ion exchanger R2 as the uppermost layer. The fixing step is a step of fixing the cap 31, into which the ion exchange resin R has been loaded, and the lid member 45 by thermal caulking.

[0048] According to the above configuration, since the second layer L2 is formed on the first layer L1, deterioration of the ion exchange resin R can be suppressed. (2) The manufacturing method of the cartridge 30 includes a first layer leveling step of leveling the first upper surface. The loading step is a step of forming the second layer L2 as the uppermost layer on the first layer L1 that has been subjected to the first layer leveling step.

[0049] According to the above configuration, the upper surface of the first layer L1 is made even, thereby reducing the variation in the distance from the upper surface of the first layer L1 to the opening edge of the cap 31 in the planar direction of the first layer L1. This makes it possible to prevent the heat generated in the fixing step from reaching a portion of the upper surface of the first layer L1 that is partially close to the opening edge of the cap 31. Therefore, deterioration of the first ion exchanger R1 can be further prevented.

[0050] (3) The manufacturing method of the cartridge 30 includes a second layer leveling step of leveling the upper surface of the second layer L2. The fixing step is performed after the second layer leveling step. According to the above configuration, it is possible to prevent the heat generated in the fixing step from reaching a portion of the upper surface of the second layer L2 that is partially close to the opening edge of the cap 31. Therefore, it is possible to further prevent the second ion exchanger R2 from deteriorating.

[0051] Furthermore, with the above configuration, the upper surface of the second layer L2 is leveled, which can prevent a portion of the second layer L2 from being located near the opening edge of the cap 31. This can prevent the cap 31 and the lid member 45 from being fixed together with the second ion exchanger R2 sandwiched between them.

[0052] (4) The second layer leveling step is a step of leveling the upper surface of the second layer L2 so that the upper surface of the second layer L2 is positioned lower than the lower surface of the lid member 45 when the cap 31 and the lid member 45 are fixed together.

[0053] According to the above configuration, the cap 31 is fixed to the lid member 45 in a state where the upper surface of the second layer L2 is positioned lower than the lower surface of the lid member 45. This makes it difficult for heat generated in the fixing process to transfer to the second layer L2 and the first layer L1 via the lid member 45. Therefore, deterioration of the ion exchange resin R can be further suppressed.

[0054] (5) The introduction step is a step of introducing all of the second ion exchangers R2 constituting the ion exchange resin R filled in the cap 31 onto the first layer L1, thereby forming the second layer L2.

[0055] According to the above configuration, the thickness of the second layer L2 can be increased compared to when a layer containing the second ion exchanger R2 is formed separately from the second layer L2. This makes it difficult for heat generated in the fixing step to reach the first layer L1. This further suppresses deterioration of the first ion exchanger R1.

[0056] <Example of change> This embodiment can be modified as follows: This embodiment and the following modifications can be combined and implemented within the scope of technical compatibility.

[0057] In the introducing step, a layer containing the second ion exchanger R2 may be formed separately from the second layer L2. For example, in the introducing step, a layer containing the second ion exchanger R2 may be formed below the first layer L1, or a layer containing a mixture of the first ion exchanger R1 and the second ion exchanger R2 may be formed.

[0058] In the second layer leveling step, the upper surface of the second layer L2 may be leveled so that the upper surface of the second layer L2 is positioned at the same position as the lower surface of the lid member 45 when the cap 31 and the lid member 45 are fixed together.

[0059] The second layer leveling step may be omitted. In this case, it is preferable to adjust the amount of the second ion exchanger R2 added so that the top of the upper surface of the second layer L2 is located below the lower surface of the lid member 45 when the cap 31 and the lid member 45 are fixed together.

[0060] As shown in Figures 6(a) and 6(b), after the first layer forming step and the second layer forming step are performed without performing the first layer leveling step, the second layer leveling step may be performed by pressing the upper surface of the second layer L2 with a pressing jig 71.

[0061] After the first layer forming step and the second layer forming step are performed, the first layer leveling step and the second layer leveling step may be performed simultaneously by pressing the upper surface of the second layer L2 with the pressing jig 71. In this case, the upper surface of the second layer L2 may be pressed with a pressing force sufficient to flatten both the upper surface of the first layer L1 and the upper surface of the second layer L2.

[0062] In the first layer leveling step and the second layer leveling step, the upper surface of the first layer L1 and the upper surface of the second layer L2 may be pressed by the same pressing jig. At least one of the first layer leveling step and the second layer leveling step may be a step of leveling the upper surface of the first layer L1 or the second layer L2 by vibrating the cap 31. When both the first layer leveling step and the second layer leveling step are performed by vibrating the cap 31, or when the second layer leveling step is performed, these steps may be performed after the fixing step.

[0063] In the fixing step, the boss 35 may be thermally caulked in a state in which the cover member 45 is pressed against the cap 31 by a pressing jig (not shown). The fixing step may be a step of fixing the cap 31 containing the ion exchange resin R to the lid member 45 by thermal welding. Examples of thermal welding include welding methods that involve heating materials, such as vibration welding, ultrasonic welding, and laser welding.

[0064] When an anion exchange resin having higher heat resistance than a cation exchange resin is used, the above embodiment can be rephrased by assuming that the first ion exchanger R1 is a cation exchange resin and the second ion exchanger R2 is an anion exchange resin.

[0065] <Additional Notes> The above embodiment includes the configurations described in the following supplementary notes. [Appendix 1] A method for manufacturing an ion exchange cartridge comprising: a cylindrical cap having an opening; an ion exchange resin containing a first ion exchanger and a second ion exchanger having a higher heat resistance temperature than the first ion exchanger, the ion exchange resin being filled inside the cap; and a lid member covering the opening, the method comprising: a pouring step of pouring the ion exchange resin into the cap with the cap open upward; and a fixing step of fixing the cap with the ion exchange resin poured into it and the lid member by thermal welding or thermal crimping, wherein in the pouring step, the first ion exchanger is poured into the cap to form a first layer made of the first ion exchanger, and then the second ion exchanger is poured onto the first layer to form a second layer made of the second ion exchanger as a top layer.

[0066] [Appendix 2] A method for manufacturing an ion exchange cartridge as described in [Appendix 1], which includes a first layer leveling step of leveling the upper surface of the first layer, and in the loading step, the second layer is formed as a top layer on the first layer that has been subjected to the first layer leveling step.

[0067] [Appendix 3] A method for manufacturing an ion exchange cartridge according to [Appendix 1] or [Appendix 2], further comprising a second layer leveling step of leveling the upper surface of the second layer, and the fixing step being carried out after the second layer leveling step.

[0068] [Appendix 4] The method for manufacturing an ion exchange cartridge described in [Appendix 3], wherein in the second layer leveling process, the upper surface of the second layer is leveled so that the upper surface of the second layer is positioned lower than the lower surface of the cover member when the cap and the cover member are fixed.

[0069] [Appendix 5] The method for manufacturing an ion exchange cartridge according to any one of [Appendix 1] to [Appendix 4], wherein in the loading step, the second layer is formed by loading all of the second ion exchangers constituting the ion exchange resin filled in the cap onto the first layer. [Explanation of symbols]

[0070] L1…1st layer L2…Second layer R...Ion exchange resin R1: First ion exchanger R2: Second ion exchanger 10...Ion exchanger 30...Cartridge 45...Cover member 60…1st support stand 61...recess 62…Second support stand 70...Pressing jig 71...Pressing jig 80...Horn 81...Punch

Claims

1. A method for manufacturing an ion exchange cartridge, comprising: a cylindrical cap having an opening; an ion exchange resin filled inside the cap, the ion exchange resin including a first ion exchanger and a second ion exchanger having a higher heat resistance temperature than the first ion exchanger; and a lid member covering the opening, a step of pouring the ion exchange resin into the cap in an upwardly open state; a fixing step of fixing the cap containing the ion exchange resin and the lid member by heat welding or heat caulking, In the introducing step, the first ion exchanger is introduced into the cap to form a first layer made of the first ion exchanger, and then the second ion exchanger is introduced onto the first layer to form a second layer made of the second ion exchanger as a top layer. A method for manufacturing an ion exchange cartridge.

2. a first layer leveling step of leveling an upper surface of the first layer; In the adding step, the second layer is formed as a top layer on the first layer that has been subjected to the first layer leveling step. A method for producing the cartridge for an ion exchanger according to claim 1.

3. A second layer leveling step is provided for leveling the upper surface of the second layer, The fixing step is performed after the second layer leveling step. A method for producing the cartridge for an ion exchanger according to claim 1 or 2.

4. In the second layer leveling step, the upper surface of the second layer is leveled so that the upper surface of the second layer is positioned lower than the lower surface of the lid member when the cap and the lid member are fixed together. A method for producing the cartridge for an ion exchanger according to claim 3.

5. In the introducing step, all of the second ion exchangers constituting the ion exchange resin filled in the cap are introduced onto the first layer to form the second layer. A method for producing the cartridge for an ion exchanger according to claim 1.

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