Method for producing an activated carbon cartridge with a ceramic core, and activated carbon cartridge

Abstract

To provide a technique for manufacturing a more compact activated carbon cartridge, and the more compact activated carbon cartridge.SOLUTION: In the method for manufacturing the active carbon cartridge having the ceramic core material, the ceramic core material 10A curvedly extending by baking is manufactured, the ceramic core material 10G is immersed in slurry S containing granular active carbon 10A, the granular active carbon 10G and fibrous binder 10H are adsorbed on the outer peripheral surface of the ceramic core material 10A, and a molded adsorption body 10A having the granular active carbon 10G and the fibrous binder 10H adsorbed on the outer peripheral surface of the ceramic core material is dried. 10B.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing an activated carbon cartridge with a ceramic core, and to an activated carbon cartridge. [Background technology]

[0002] Patent Document 1 discloses a curved water purification cartridge, which is formed by adsorbing fibrous activated carbon onto the outer peripheral surface of a cylindrical shaft member made of a porous or mesh material. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2004-82096 Summary of the Invention [Problem to be solved by the invention]

[0004] The device disclosed in Patent Document 1 further includes a pair of disk-shaped nonwoven fabrics with a disk-shaped sterilizing ceramic sandwiched between them, located adjacent to the downstream end of the cylindrical shaft member. In other words, the device disclosed in Patent Document 1 has a longer shaft length due to the pair of nonwoven fabrics and the sterilizing ceramic being adjacent to the downstream end. The present disclosure is intended to solve the above-mentioned problems, and aims to provide a technology for manufacturing a more compact activated carbon cartridge and a more compact activated carbon cartridge. [Means for solving the problem]

[0005] The method for manufacturing an activated carbon cartridge with a ceramic core material of the first disclosure involves producing a porous ceramic core material that is curved and elongated by firing, immersing the ceramic core material in a slurry containing activated carbon to adsorb the activated carbon onto the outer surface of the ceramic core material, and drying the activated carbon adsorbed onto the outer surface.

[0006] The activated carbon cartridge of the second disclosure includes a porous ceramic core material that extends in a curved shape, and activated carbon provided on the outer peripheral surface of the ceramic core material. [Brief explanation of the drawings]

[0007] [Figure 1] FIG. 2 is a side cross-sectional view showing the water purification cartridge. [Figure 2] FIG. 2 is a schematic diagram showing an intermediate. [Figure 3] FIG. 10 is a schematic diagram showing a state in which the intermediate body is placed on a mold. [Figure 4] FIG. 2 is a schematic diagram showing a slurry stored in a container. [Figure 5] FIG. 2 is a schematic diagram showing a state in which a ceramic core material is immersed in a slurry. [Figure 6] 1 is a schematic diagram showing a state in which granular activated carbon and a fibrous binder are adsorbed on the outer peripheral surface of a ceramic core material. [Figure 7] FIG. 10 is a schematic diagram showing a mold in which the center portion is curved downward. [Figure 8] FIG. 1 is a schematic diagram showing a mold in which curved grooves are formed on the plate surface. DETAILED DESCRIPTION OF THE INVENTION

[0008] <Embodiment 1> The activated carbon cartridge 10 of the first embodiment is installed in a flow path through which raw water Rw supplied from a water supply source (not shown), such as a water supply system, flows. When the raw water Rw flows through the activated carbon cartridge 10, the activated carbon cartridge 10 has a function of capturing dissolved substances contained in the raw water Rw, such as free residual chlorine, and discharging the raw water Rw as purified water Pw.

[0009] [Activated carbon cartridge composition] As shown in FIG. 1, the activated carbon cartridge 10 includes a ceramic core material 10A, a molded adsorbent body 10B, an outer nonwoven fabric 10D, a closing lid 10E, and an outflow lid 10F.

[0010] The ceramic core material 10A is formed in a cylindrical, curved, and elongated shape. Porous ceramic is used for the ceramic core material 10A. The ceramic core material 10A has numerous pores (not shown) formed on its outer circumferential surface that allow the raw water Rw to pass through a flow path 20 formed inside.

[0011] The formed adsorbent 10B includes granular activated carbon 10G and a fibrous binder 10H. The formed adsorbent 10B is cylindrical with an axis that extends in an arc-shaped curve. The formed adsorbent 10B is disposed so as to cover the outer peripheral surface of the ceramic core 10A. In other words, the formed adsorbent 10B is provided on the outer peripheral surface of the ceramic core 10A. The fibrous binder 10H is made of synthetic fibers such as acrylonitrile. The formed adsorbent 10B is formed coaxially with the ceramic core 10A.

[0012] The outer nonwoven fabric 10D is disposed so as to cover the outer peripheral surface of the formed adsorbent body 10B. For example, a nonwoven fabric specified in JIS L0222 can be used as the outer nonwoven fabric 10D. There are no particular restrictions on the type of fiber that is the raw material for the outer nonwoven fabric 10D.

[0013] The closing lid 10E is disposed so as to cover one end of the formed adsorbent body 10B. Specifically, the closing lid 10E covers the outer peripheral surface of one end side of the outer nonwoven fabric 10D, and also covers the formed adsorbent body 10B and one end of the ceramic core material 10A. The closing lid 10E closes one end of the flow path 20 of the ceramic core material 10A.

[0014] The outflow lid 10F is disposed so as to cover the other end of the formed adsorbent body 10B. The outflow lid 10F covers the outer peripheral surface of the other end side of the outer nonwoven fabric 10D, and also covers the formed adsorbent body 10B and the other end of the ceramic core material 10A. The outflow lid 10F is formed with an outlet 60 that is connected to the flow path 20 of the ceramic core material 10A and through which the purified water Pw that has flowed through the flow path 20 is discharged.

[0015] Raw water Rw flows into the activated carbon cartridge 10 formed in this manner through the outer peripheral surface of the exposed outer nonwoven fabric 10D. Dissolved substances are removed from the raw water Rw as it passes through the molded adsorbent 10B and ceramic core material 10A and reaches the flow path 20, turning it into purified water Pw. The purified water Pw flows out via the flow path 20 and the outlet 60.

[0016] [An example of a manufacturing method for activated carbon cartridges] The following describes an example of a method for manufacturing the activated carbon cartridge 10. The method for manufacturing the activated carbon cartridge 10 includes a molding step, a firing step, a slurry production step, a suction molding step, a drying step, a surface polishing step, a nonwoven fabric winding step, and a sealing step.

[0017] In the molding process, first, the clay-like ceramic core material 10A is molded using a known extrusion molding method to produce an intermediate body 20A (see FIG. 2). Then, the intermediate body 20A is placed on a mold M (see FIG. 3). The upper surface Us of the mold M is curved in a semicircular shape so that the central portion protrudes upward. The intermediate body 20A is placed on the upper surface Us of the mold M, oriented along the circumferential direction Cd of the upper surface Us. At this time, the intermediate body 20A is slightly curved by its own weight so as to fit along the upper surface Us of the mold M (see the solid line in FIG. 3).

[0018] In the firing step, the intermediate body 20A is fired while placed on the mold M. By firing, the intermediate body 20A is further curved so as to conform to the upper surface Us of the mold M (see the two-dot chain line in FIG. 3). That is, the ceramic core material 10A is curved so as to conform to the mold M by firing. After the firing step is performed, the fired ceramic core material 10A is removed from the mold M and cut to the desired length. In this way, the ceramic core material 10A is produced, which is curved and elongated by firing. That is, the ceramic core material 10A is extrusion-molded, placed on the mold M, and curved.

[0019] In the slurry production step, granular activated carbon 10G, which is the raw material for the formed adsorbent 10B, fibrous binder 10H, and water W are mixed together to obtain a slurry S containing activated carbon 10G (see FIG. 4).

[0020] In the suction molding process, a molded adsorbent 10B is molded. In the suction molding process, as shown in FIG. 5, one end of the flow path 20 of the ceramic core material 10A is connected to a suction pump (not shown) via a hose H with a flange F. At this time, the other end of the flow path 20 of the ceramic core material 10A is sealed with a cap C. The ceramic core material 10A connected to the suction pump is immersed in a slurry S in a container, and the suction pump is operated. Then, water W contained in the slurry S permeates the ceramic core material 10A. Meanwhile, granular activated carbon 10G and fibrous binder 10H contained in the slurry S remain and accumulate on the outer peripheral surface of the ceramic core material 10A. In other words, in the suction molding process, the ceramic core material 10A is immersed in the slurry S containing the granular activated carbon 10G, and the granular activated carbon 10G is adsorbed onto the outer peripheral surface of the ceramic core material 10A. As a result, a formed adsorbent body 10B is formed so as to cover the outer peripheral surface of the ceramic core material 10A (see FIG. 6). The water W contained in the slurry S sucked by the suction pump is discharged. The suction pump continues to operate, and when the formed adsorbent body 10B has been formed to a desired thickness, the suction pump is stopped and the ceramic core material 10A is pulled up from the slurry S.

[0021] In the drying step, the formed adsorbent 10B (the granular activated carbon 10G and fibrous binder 10H adsorbed on the outer peripheral surface of the ceramic core 10A) formed in the suction forming step is dried. For example, in the first embodiment, the formed adsorbent 10B is placed in a drying oven (not shown) set at 130°C and dried. By drying the formed adsorbent 10B in the drying step, the formed adsorbent 10B is hardened and the ceramic core 10A and the formed adsorbent 10B can be integrated. For example, the cap C and the flange F are removed from the ceramic core 10A after the drying step is performed.

[0022] In the surface polishing step, the outer peripheral surface of the shaped adsorbent body 10B is polished to form the outer shape of the shaped adsorbent body 10B into a desired shape.

[0023] In the nonwoven fabric winding step, outer nonwoven fabric 10D is wound around the outer peripheral surface of formed adsorbent body 10B that has been polished to a desired outer shape in the surface polishing step (see FIG. 1).

[0024] In the sealing step, a closing lid 10E is attached to one end of the formed adsorbent body 10B around which the outer nonwoven fabric 10D is wrapped, and an outflow lid 10F is attached to the other end of the formed adsorbent body 10B around which the outer nonwoven fabric 10D is wrapped (see FIG. 1). In this way, the activated carbon cartridge 10 is completed (see FIG. 1).

[0025] According to the second embodiment configured as above, the following effects are achieved.

[0026] A method for manufacturing an activated carbon cartridge with a ceramic core material involves firing a porous ceramic core material 10A that curves and extends, immersing the ceramic core material 10A in a slurry S containing granular activated carbon 10G to adsorb the granular activated carbon 10G and fibrous binder 10H onto the outer surface of the ceramic core material 10A, and then drying a formed adsorbent 10B having the granular activated carbon 10G and fibrous binder 10H adsorbed onto the outer surface of the ceramic core material 10A. This configuration, using ceramic as the core material, eliminates the need to have a ceramic adjacent to the downstream end, allowing the axial length of the activated carbon cartridge 10 to be compact. Furthermore, if the showerhead has a curved gripping portion, an activated carbon cartridge 10 shaped to fit the curved gripping portion can be manufactured.

[0027] In a method for manufacturing an activated carbon cartridge with a ceramic core material, the ceramic core material 10A is extruded and then curved while being placed on a mold M. With this configuration, the ceramic core material 10A can be curved so as to reliably conform to the shape of the mold M, making it easy to achieve the desired degree of curvature of the ceramic core material 10A.

[0028] In the method for manufacturing an activated carbon cartridge having a ceramic core material, the extruded ceramic core material 10A is curved by firing so as to fit the mold M. This configuration eliminates the need to curve the ceramic core material 10A to fit the mold M, making manufacturing easy.

[0029] The activated carbon cartridge 10 includes a curved, porous ceramic core 10A, and granular activated carbon 10G and a fibrous binder 10H attached to the outer surface of the ceramic core 10A. This configuration uses ceramic as the core, eliminating the need to place the ceramic adjacent to the downstream end, allowing for a compact axial length. Furthermore, if the showerhead has a curved, extending grip, the curved grip can efficiently accommodate the activated carbon cartridge 10.

[0030] <Other embodiments> The present disclosure is not limited to the first embodiment described above with reference to the drawings, and the following embodiments, for example, are also included within the technical scope of the present disclosure.

[0031] (1) Unlike the first embodiment, a synthetic resin other than acrylonitrile may be used as the fibrous binder. (2) The shape of the mold is not limited to that of embodiment 1. For example, it may be a mold M2 shown in Fig. 7, in which the center is recessed downward to form a semi-cylindrical shape, or a mold M3 shown in Fig. 8, in which a groove G extending in a curved manner is provided on a flat plate surface. Also, a groove extending in the circumferential direction may be provided on the upper surface Us of the mold M of embodiment 1. (3) Unlike the first embodiment, when placing the intermediate body on the mold, the intermediate body may be curved so as to fit along the upper surface of the mold. [Explanation of symbols]

[0032] 10: activated carbon cartridge, 10A: ceramic core material, 10B: molded adsorbent, 10G: activated carbon, M, M2, M3: mold, S: slurry

Claims

1. A porous ceramic core material is produced that curves and expands when fired, immersing the ceramic core material in a slurry containing activated carbon to adsorb the activated carbon onto the outer peripheral surface of the ceramic core material; A method for manufacturing an activated carbon cartridge having a ceramic core material that dries the activated carbon adsorbed on the outer peripheral surface.

2. The ceramic core material is It is extruded and A method for producing an activated carbon cartridge having a ceramic core material according to claim 1, wherein the ceramic core material is placed on a mold and curved.

3. The extruded ceramic core material is The method for manufacturing an activated carbon cartridge having a ceramic core material according to claim 2, wherein the ceramic core material is curved to fit the mold by firing.

4. a curved and extending porous ceramic core material; Activated carbon provided on the outer peripheral surface of the ceramic core material; Activated carbon cartridge with.

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