U.S. patent application number 10/154771 was filed with the patent office on 2002-11-28 for water purification filter.
Invention is credited to Akiyama, Motoharu, Hokkirigawa, Kazuo, Yoshimura, Noriyuki.
Application Number | 20020175118 10/154771 |
Document ID | / |
Family ID | 19001392 |
Filed Date | 2002-11-28 |
United States Patent
Application |
20020175118 |
Kind Code |
A1 |
Hokkirigawa, Kazuo ; et
al. |
November 28, 2002 |
Water purification filter
Abstract
There is provided a water purification filter capable of molding
into free shapes in which RB ceramics and/or CRB ceramics of 10 to
2,000 angstrom in pore diameter and 0.1 to 1.1 cm.sup.3/g in pore
volume is used as an absorption and filtration material.
Inventors: |
Hokkirigawa, Kazuo;
(Yonezawa-shi, JP) ; Akiyama, Motoharu;
(Nagano-ken, JP) ; Yoshimura, Noriyuki;
(Nagano-ken, JP) |
Correspondence
Address: |
FLYNN, THIEL, BOUTELL & TANIS, P.C.
2026 Rambling Road
Kalamazoo
MI
49008-1699
US
|
Family ID: |
19001392 |
Appl. No.: |
10/154771 |
Filed: |
May 24, 2002 |
Current U.S.
Class: |
210/266 ;
210/263 |
Current CPC
Class: |
B01J 20/28042 20130101;
B01J 20/28069 20130101; B01J 2220/485 20130101; B01D 2239/1216
20130101; B01D 2239/065 20130101; B01J 20/28033 20130101; B01J
20/28078 20130101; B01D 2239/0241 20130101; B01D 2239/0407
20130101; B01J 20/20 20130101; B01D 39/1623 20130101; B01D
2239/1241 20130101; B01J 20/28004 20130101; C02F 1/285 20130101;
B01J 20/28035 20130101; B01J 20/28073 20130101; B01D 39/2055
20130101; B01J 20/28071 20130101; C02F 1/288 20130101; B01D 39/2068
20130101; B01D 39/2062 20130101; B01J 20/28026 20130101; B01J 20/18
20130101; B01J 20/28014 20130101; B01D 2239/1208 20130101; C02F
1/286 20130101; B01D 2239/0618 20130101 |
Class at
Publication: |
210/266 ;
210/263 |
International
Class: |
B01D 024/00; C02F
001/58 |
Foreign Application Data
Date |
Code |
Application Number |
May 25, 2001 |
JP |
2001-157546 |
Claims
What is claimed is:
1. A water purification filter in which RB ceramics and/or CRB
ceramics of 10 to 2,000 angstrom in pore diameter and 0.1 to 1.1
cm.sup.3/g in pore volume is used as an absorption and filtration
material.
2. A water purification filter claimed in claim 1 in which RB
ceramics and/or CRB ceramics is a filter molded into a cylindrical
form.
3. A water purification filter claimed in claim 2 in which plural
thin cylindrical filters are fitted in order while altering a
diameter of each cylinder.
4. A water purification filter claimed in claim 3 in which a
zeolite fine powder or active carbon fine powder is filled between
cylinders.
5. A water purification filter claimed in claim 1 in which RB
ceramics and/or CRB ceramics is a filter molded into a solid
cylinder form.
6. A water purification filter in which a RB ceramics fine powder
and/or CRB ceramics fine powder of 1 to 500 .mu.m in an average
particle diameter, 10 to 2,000 angstrom in pore diameter and 0.1 to
1.1 cm.sup.3/g in pore volume is supported on non-woven fabric or
felt.
7. A water purification filter claimed in claim 6 in which an
active carbon fine powder is supported on non-woven fabric or felt
in addition to RB ceramics fine powder and/or CRB fine powder.
8. A water purification filter claimed in claim 7 in which a ratio
of a RB ceramics fine powder and/or CRB ceramics fine powder to a
well-known active carbon fine powder is 50 to 90:50 to 10 by
weight.
9. A water purification filter described in either one of claims 6
to 8 in which non-woven fabric or felt has properties of average 1
to 30 .mu.m and the maximum 80 .mu.m or less in pore diameter and
pure water filtration discharge of 3 l/m.sup.2.multidot.min. or
more at differential pressure of 1 cm-H.sub.2O.
Description
FIELD OF THE INVENTION
[0001] This invention relates to a water purification filter used
for filtering water, especially for filtering tap water, industrial
water, river water, waste
BACKGROUND OF THE INVENTION
[0002] Conventional water purification filters comprise polyolefin
or polyester fabric or felt, or dry or wet non-woven fabric or
felt, span-bond non-woven fabric or felt, equivalents. and active
carbon materials or zeolite supported between such fabric or
non-woven fabric or felt.
[0003] For example, Japanese Patent Nos.A-H07-26,460, A-H0 8-24,535
and A-H07-207,566 describe a filter material which is relatively
cheap and makes it possible to reduce the critical particle
diameter of filtration by laminating and gluing melt-blow non-woven
fabric or felt and span-bond non-woven fabric or felt.
[0004] In any case of conventional water purification filters, it
is necessary to form non-woven fabric or felt into a specific shape
and support zeolite or active carbon thereon.
[0005] The inventors have found that a water purification filter
itself can be formed by simply applying RB ceramics and/or CRB
ceramics as a moldable carbon material, thereby the present
invention being developed.
SUMMARY OF THE INVENTION
[0006] Accordingly, it is an object of the present invention to
provide a water purification filter which is directly molded from
RB ceramics and/or CRB ceramics.
[0007] Further object of the present invention is to provide a
water purification filter in which a fine powder of RB ceramics
and/or CRB ceramics is supported on non-woven fabric or felt.
[0008] According to the present invention, RB ceramics and/or CRB
ceramics of 10 to 2,000 angstrom in pore diameter and 0.1 to 1.1
cm.sup.3/g in pore volume is used as a filter material of water
purification filter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1a is an illustration of a relatively large pore of CRB
ceramics;
[0010] FIG. 1b is an illustration of pores of CRB ceramics caused
by rice bran;
[0011] FIG. 1c is an illustration of pores of CRB ceramics caused
by polymer chain;
[0012] FIG. 2 is a perspective view of a disk-form water
purification filter of the present invention;
[0013] FIG. 3 is a perspective view of a cylindrical water
purification filter of the present invention; and
[0014] FIG. 4 is a sectional view of a cylindrical water
purification filter of the present invention in which non-woven
fabric or felt is used.
PREFERRED EMBODIMENTS OF THE INVENTION
[0015] A RB ceramics and/or CRB ceramics material applied to a
water purification filter of the present invention is prepared from
a defatted product of rice bran as a main raw material and a
thermosetting resin.
[0016] As is known that Dr. Kazuo Hokkirigawa, the first inventor
of the present invention, proposed an idea to obtain a porous
carbon material by the use of rice bran which is by-produced 0.9
million ton/year in Japan or 3.3 million ton/year in the world
(see, Kinou Zairyou, Vol. 17, No. 5, pp. 24 to 28, May 1997).
[0017] The above mentioned literature describes a carbon material
or so-called RB ceramics by mixing and kneading a defatted product
of rice bran and a thermosetting resin, press-molding the mixture
to form a molded material, followed by drying and then baking the
dried material in an atmosphere of inert gas.
[0018] Defatted rice bran used in the present invention is not
limited to a specific species of rice and may either be a product
of Japan or foreign countries.
[0019] A thermosetting resin used herein may also be any resin
which can be thermally set and typically includes phenol-,
diarylphthalate-, unsaturated polyester-, epoxy-, polyimide- and
triazine resins, although a phenol resin is preferably used.
[0020] A thermoplastic resin such as polyamide may also be used
together without departing from a scope of the present
invention.
[0021] A mixing ratio of the defatted rice bran to the
thermosetting resin is in the range of 50 to 90:50 to 10 and
preferably 70 to 80:30 to 20 in by weight.
[0022] According to the above mentioned method, difference in ratio
of shrinkage between the press-molded material and the finally
molded material which is baked in an atmosphere of inert gas
reached almost 25%. Such a difference made it substantially
difficult to form a precisely molded material, but has been finally
improved as a result of development of CRB ceramics.
[0023] CRB ceramics used in the present invention is an improved
material of RB ceramics obtained from defatted rice bran and a
thermosetting resin and is prepared by mixing and kneading both of
these materials and primarily baking the mixture in an inert gas at
700 to 1,000.degree. C., followed by grinding to form a carbonated
powder of about 60 mesh or less, which is then mixed and kneaded
with the thermosetting resin to yield a mixture (hereinafter
referred to as a CRB precursor), press-molded at a pressure of 20
to 30 Mpa and further heat-treated the thus molded material in an
atmosphere of inert gas at 500 to 1,100.degree. C. to form a molded
product.
[0024] CRB ceramics is a porous material having innumerable pores.
These pores formed in CRB ceramics can be classified into three
kinds of types depending on a formation process thereof.
[0025] A pore shown in FIG. 1(a) is relatively large one having a
pore diameter of 5 .mu.m or more, which is formed as a space
between CRB fine particles when they overlap each other. A peak
pore value of this type is about 15 .mu.m.
[0026] What is shown in FIG. 1(b) is a pore having a pore diameter
of less than 5 .mu.m which is formed by fiber structure caused by
rice bran. A peak pore value of this type is about 1.8 .mu.m.
[0027] A pore shown in FIG. 1(c) is a small one having a pore
diameter of 0.2 .mu.m or less which is formed as a space between
molecular chains of high molecular polymer such as a phenol resin
when the polymer is carbonated at high temperatures. A peak pore
value of this type is about 0.05 .mu.m.
[0028] The thus formed three kinds of pores of CRB ceramics
function as a filter for fine particles of various size
corresponding to each pore diameter, respectively.
[0029] The most typical distinction of RB ceramics and CRB ceramics
is that a difference in ratio of shrinkage between molded RB
ceramics and a final product thereof is almost 25%, while that of
CRB ceramics is so low as 3% or less, which makes the latter
material much useful.
[0030] General properties of RB ceramics and CRB ceramics are as in
the following:
[0031] extremely high hardness;
[0032] extremely small heat expansion coefficient;
[0033] porous structure;
[0034] electrical conductivity;
[0035] low specific gravity, light weighted;
[0036] improved abrasion resistance;
[0037] easiness of molding and mold making;
[0038] capable of being powdered; and
[0039] less negative effect to global environment and more resource
conservation due to rice bran to be used as a starting
material.
[0040] When a water purification filter is prepared directly from
RB ceramics and/or CRB ceramics as a molded material, it is
desirable to use CRB ceramics because of its precise moldability.
However, even in the above mentioned case, RB ceramics should not
be excluded from embodiments of the present invention, because it
is possible to mold RB ceramics by means of a little bit larger
mold, which is then reduced to a desired size through secondary
processing.
[0041] Porosity of RB ceramics and/or CRB ceramics can be
controlled by changing baking conditions, which is one of
characteristic features of these materials.
[0042] It is generally confirmed that such porosity is increased
with an increase in heat-treating temperature.
[0043] When a water purification filter is prepared as a molded
material directly from RB ceramics and/or CRB ceramics according to
the present invention, the molded material desirably has a pore
diameter of 10 to 2,000 angstrom and a pore volume of 0.1 to 1.1
cm.sup.3/g.
[0044] When powdery RB ceramics is used in the present invention,
it is not necessary to consider a difference in shrinkage between
RB ceramics and CRB ceramics so that basically either of these
materials may be used on an equal footing. Particle size of RB
ceramics or CRB ceramics powder varies depending on the purpose to
be used, although an average particle diameter of 1 to 500 .mu.m is
generally used.
[0045] Porosity is an important factor of RB ceramics and/or CRB
ceramics used in the present invention, which is influenced by the
primary baking temperature of RB ceramics and by both of the
primary baking temperature and the secondary heat-treating
temperature of CRB ceramics.
[0046] RB ceramics or CRB ceramics of optimum porosity can be
yielded by primary baking or secondary heat treatment thereof at a
temperature of 800 to 1,000.degree. C.
[0047] When RB ceramics and/or CRB ceramics is used as a fine
powder, non-woven fabric or felt is a suitable material to support
the powder. A well-known carbon fine powder may be used together
with the ceramics powder.
[0048] A ratio of the fine powder of RB ceramics and/or CRB
ceramics to the carbon powder is desirably 50 to 90:50 to 10 by
weight.
[0049] The fine powder of RB ceramics or CRB ceramics is hard,
while its surface is quite rough, which characteristically
increases maintaining properties thereof as a powdery material on a
support and allows the powder to be hardly flown away by a fluid
flow.
[0050] Further, there may be used inorganic materials such as glass
wool and asbestos, synthetic polymers such as polyester and
polyamide and natural materials such as cellulose, hemp and cotton
as a fibrous material in the present invention.
[0051] It is required for non-woven fabric or felt used in the
present invention to have properties of average 1 to 30 .mu.m and
the maximum 80 .mu.m or less in pore diameter and pure water
filtration discharge of 3 l/m.sup.2.multidot.min. or more at
differential pressure of 1 cm-H.sub.2O. Non-woven fabric or felt
having such properties is well-known and commercially
available.
[0052] Embodiments of the present invention will be summarised as
in the following.
[0053] 1. A water purification filter in which RB ceramics and/or
CRB ceramics of 10 to 2,000 angstrom in pore diameter and 0.1 to
1.1 cm.sup.3/g in pore volume is used as an absorption and
filtration material.
[0054] 2. A water purification filter described in the above item 1
in which RB ceramics and/or CRB ceramics is a filter molded into a
cylindrical form. A water purification filter described in the
above item 2 in which plural thin cylindrical filters are fitted in
order while altering a diameter of each cylinder.
[0055] 3. A water purification filter described in the above item 3
in which a zeolite fine powder or active carbon fine powder is
filled between cylinders.
[0056] 4. A water purification filter described in the above item 1
in which RB ceramics and/or CRB ceramics is a filter molded into a
solid cylinder form.
[0057] 5. A water purification filter in which a RB ceramics fine
powder and/or CRB ceramics fine powder of 1 to 500 .mu.m in an
average particle diameter, 10 to 2,000 angstrom in pore diameter
and 0.1 to 1.1 cm.sup.3/g in pore volume is supported on non-woven
fabric.
[0058] 6. A water purification filter described in the above item 6
in which an active carbon fine powder is supported on non-woven
fabric in addition to RB ceramics fine powder and/or CRB fine
powder.
[0059] 8. A water purification filter described in the above item 6
in which a ratio of a RB ceramics fine powder and/or CRB ceramics
fine powder to a well-known active carbon fine powder is 50 to
90:50 to 10 by weight.
[0060] 9. A water purification filter described in either one of
the aboveitems 6 to 8 in which non-woven fabric has properties of
average 1 to 30 .mu.m and the maximum 80 .mu.m or less in pore
diameter and pure water filtration discharge of 3
l/m.sup.2.multidot.min.or more at differential pressure of 1
cm-H.sub.2O.
[0061] It has been found that a water purification filter of the
present invention can be molded into free shapes while keeping
predetermined properties due to the use of RB ceramics and CRB
ceramics. It has been also found a fine powder of RB ceramics and
CRB ceramics exhibits suitable properties as a water purification
filter.
[0062] This invention will be further described in the following
examples.
EXAMPLE 1
[0063] Preparation of CRB Ceramics Precursor
[0064] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0065] The mixture was primarily baked by means of a rotary kiln in
a nitrogen atmosphere at 900.degree. C. for 60 minutes. The
carbonated material thus baked was screened through a 300-mesh
screen to form a carbonated powder of 50 to 80 .mu.m in particle
diameter.
[0066] The carbonated powder thus obtained in an amount of 75 kg
and a solid phenol resin (resol) in an amount of 25 kg were mixed
and kneaded by heating at 100 to 150.degree. C. to form a plastic
and homogeneous mixture as a plastic CRB ceramics precursor.
[0067] Molding of a Water Purification Filter
[0068] Then, there was made a mold for molding a disk 1 of 20.0 cm
in diameter and 1.5 cm in thickness as shown in FIG. 2, to which
the plastic CRB ceramics precursor was pored and press-molded at a
pressure of 22 Mpa. The mold temperature was 150.degree. C.
[0069] The thus molded body was taken out of the mold die and
subjected to a heat treatment by heating-up to 500.degree. C. in a
nitrogen atmosphere at a heat rising rate of 1.degree. C. per
minute and keeping at 500.degree. C. for 60 minutes and then at
950.degree. C. for about 120 minutes.
[0070] The molded body was then cooled at a cool down rate of 2 to
3.degree. C. per minute down to 500.degree. C., followed by natural
heat dissipation under 500.degree. C. to yield a molded product of
CRB ceramics 1 as shown in FIG. 2.
[0071] Properties of the Water Purification Filter
[0072] The molded product of CRB ceramics 1 showed an average pore
diameter of 350 angstrom and a pore volume of 0.65 cm.sup.3/g.
EXAMPLE 2
[0073] Preparation of CRB Ceramics Precursor
[0074] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0075] The mixture was primarily baked by means of a rotary kiln in
a nitrogen atmosphere at 900.degree. C. for 60 minutes. The
carbonated material thus baked was screened through a 200-mesh
screen to form a carbonated powder of 50 to 120 .mu.m in particle
diameter.
[0076] The carbonated powder thus obtained in an amount of 75 kg
and a solid phenol resin (resol) in an amount of 25 kg were mixed
and kneaded by heating at 100 to 150.degree. C. to form a plastic
and homogeneous mixture as a plastic CRB ceramics precursor.
[0077] Molding of a Water Purification Filter
[0078] Then, there was made a mold for molding a disk 1 of 20.0 cm
in diameter and 1.5 cm in thickness as shown in FIG. 2, to which
the plastic CRB ceramics precursor was pored and press-molded at a
pressure of 25 Mpa. The mold temperature was 150.degree. C.
[0079] The thus molded body was taken out of the mold die and
subjected to a heat treatment by heating-up to 500.degree. C. in a
nitrogen atmosphere at a heat rising rate of 1.degree. C. per
minute and keeping at 500.degree. C. for 60 minutes and then at
1,000.degree. C. for about 150 minutes.
[0080] The molded body was then cooled at a cool down rate of 2 to
3.degree. C. per minute down to 500.degree. C., followed by natural
heat dissipation under 500.degree. C. to yield a molded product of
CRB ceramics 2 as shown in FIG. 2.
[0081] Properties of the Water Purification Filter
[0082] The molded product of CRB ceramics 1 showed an average pore
diameter of 450 angstrom and a pore volume of 0.52 cm.sup.3/g.
EXAMPLE 3
[0083] Preparation of RB Ceramics Precursor
[0084] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0085] Molding of a Water Purification Filter
[0086] Then, there was made a mold for molding a disk 1 of 20.0 cm
in diameter and 1.5 cm in thickness as shown in FIG. 2 similarly as
Example 1, to which the plastic CRB ceramics precursor was pored
and press-molded at a pressure of 22 Mpa. The mold temperature was
170.degree. C.
[0087] The thus molded body was taken out of the mold die and
subjected to a heat treatment by heating-up to 500.degree. C. in a
nitrogen atmosphere at a heat rising rate of 1.degree. C. per
minute and keeping at 800.degree. C. for 120 minutes. The molded
body was then cooled at a cool down rate of 2 to 3.degree. C. per
minute down to 500.degree. C., followed by natural heat dissipation
under 500.degree. C.
[0088] Properties of the Water Purification Filter
[0089] The molded product of CRB ceramics 1 showed an average pore
diameter of 500 angstrom and a pore volume of 0.51 cm.sup.3/g,
although it shrank slightly.
EXAMPLE 4
[0090] Preparation of CRB Ceramics Precursor
[0091] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0092] The mixture was primarily baked by means of a rotary kiln in
a nitrogen atmosphere at 900.degree. C. for 60 minutes. The
carbonated material thus baked was screened through a 100-mesh
screen to form a carbonated powder of 50 to 250 .mu.m in particle
diameter.
[0093] The carbonated powder thus obtained in an amount of 78 kg
and a solid phenol resin (resol) in an amount of 22 kg were mixed
and kneaded by heating at 100 to 150.degree. C. to form a plastic
and homogeneous mixture as a plastic CRB ceramics precursor.
[0094] Molding of a Water Purification Filter
[0095] Then, there was made a mold for molding a cylinder 3 of 15
cm in outer diameter, 14.0 cm in inner diameter and 30 cm in length
as shown in FIG. 3, to which the plastic CRB ceramics precursor was
pored and press-molded at a pressure of 22 Mpa. The mold
temperature was 150.degree. C.
[0096] The thus molded body was taken out of the mold die and
subjected to a heat treatment by heating-up to 500.degree. C. in a
nitrogen atmosphere at a heat rising rate of 1.degree. C. per
minute and keeping at 500.degree. C. for 60 minutes and then at
1,000.degree. C. for about 120 minutes.
[0097] The molded body was then cooled at a cool down rate of 2 to
3.degree. C. per minute down to 500.degree. C., followed by natural
heat dissipation under 500.degree. C. to yield a molded product of
CRB ceramics 2 as shown in FIG. 3.
[0098] Properties of the Water Purification Filter
[0099] The molded product of CRB ceramics 1 showed an average pore
diameter of 550 angstrom and a pore volume of 0.50 cm.sup.3/g.
EXAMPLE 5
[0100] Preparation of CRB Ceramics Precursor
[0101] A defatted product of rice bran in an amount of 75 kg and a
liquid phenol resin (resol) in an amount of 25 kg were mixed and
kneaded by heating at 50 to 60.degree. C. to form a plastic and
homogeneous mixture.
[0102] The mixture was primarily baked by means of a rotary kiln in
a nitrogen atmosphere at 900.degree. C. for 60 minutes. The
carbonated material thus baked was ground by means of a grinder and
screened through a 100-mesh screen to form a carbonated powder of
50 to 250 .mu.m in particle diameter.
[0103] The carbonated powder thus obtained in an amount of 75 kg
and a solid phenol resin (resol) in an amount of 25 kg were mixed
and kneaded by heating at 100 to 150.degree. C. to form a plastic
and homogeneous mixture.
[0104] Preparation of a Fine Powder
[0105] The plastic mixture was then press-molded at a pressure of
20 Mpa to form a spherical body of 3 cm in diameter. The mold
temperature was 150.degree. C.
[0106] The thus molded body was taken out of the mold die and
subjected to a heat treatment by heating-up to 500.degree. C. in a
nitrogen atmosphere at a heat rising rate of 1.degree. C. per
minute and keeping at 500.degree. C. for 60 minutes and sintering
at 950.degree. C. for about 120 minutes.
[0107] The molded body was then cooled at a cool down rate of 2 to
3.degree. C. per minute down to 500.degree. C., followed by natural
heat dissipation under 500.degree. C.
[0108] The sintered spherical body of 3 cm in diameter was ground
by means of a grinder and further finely ground by means of a ball
mill to form CRB ceramics fine particles of 5 to 10 .mu.m in
average particle diameter.
[0109] Preparation of a Water Purification Filter
[0110] As shown in FIG. 4, CRB ceramics fine particles 3 of 7 .mu.m
in average particle diameter were kept between nylon 6 non-woven
fabric 4 having properties of 5 .mu.m in average particle diameter,
18 .mu.m in maximum particle diameter, 6 cm.sup.3/cm.sup.2-second
of gas permeability and 31 l/cm.sup.2-minute-cm-H.sub.2O of
filtration discharge rate and sealed top and bottom ends thereof
with an adhesive 5.
[0111] Properties of the Water Purification Filter
[0112] The CRB ceramics fine particles 3 showed an average particle
diameter of 7 .mu.m and a pore volume of 0.58 cm.sup.3/g.
* * * * *