JP5360567B2 - Friction charging media - Google Patents
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- JP5360567B2 JP5360567B2 JP2009150223A JP2009150223A JP5360567B2 JP 5360567 B2 JP5360567 B2 JP 5360567B2 JP 2009150223 A JP2009150223 A JP 2009150223A JP 2009150223 A JP2009150223 A JP 2009150223A JP 5360567 B2 JP5360567 B2 JP 5360567B2
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- 239000000835 fiber Substances 0.000 claims description 95
- 239000004745 nonwoven fabric Substances 0.000 claims description 37
- 230000003014 reinforcing effect Effects 0.000 claims description 22
- 238000002844 melting Methods 0.000 claims description 17
- 230000008018 melting Effects 0.000 claims description 14
- 239000000203 mixture Substances 0.000 claims description 12
- 229920000728 polyester Polymers 0.000 claims description 12
- 229920000098 polyolefin Polymers 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 6
- 238000007789 sealing Methods 0.000 claims description 5
- 229920005989 resin Polymers 0.000 claims description 3
- 239000011347 resin Substances 0.000 claims description 3
- 230000008021 deposition Effects 0.000 claims 1
- 239000010410 layer Substances 0.000 description 101
- -1 polypropylene Polymers 0.000 description 39
- 238000000034 method Methods 0.000 description 21
- 239000004743 Polypropylene Substances 0.000 description 18
- 229920001155 polypropylene Polymers 0.000 description 18
- 239000003795 chemical substances by application Substances 0.000 description 14
- 229920000139 polyethylene terephthalate Polymers 0.000 description 11
- 239000005020 polyethylene terephthalate Substances 0.000 description 11
- 239000004698 Polyethylene Substances 0.000 description 7
- 230000032798 delamination Effects 0.000 description 7
- 239000000428 dust Substances 0.000 description 7
- 239000002245 particle Substances 0.000 description 7
- 229920000573 polyethylene Polymers 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 238000011156 evaluation Methods 0.000 description 6
- 230000004927 fusion Effects 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 4
- 238000001914 filtration Methods 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 3
- 239000000470 constituent Substances 0.000 description 3
- 238000009423 ventilation Methods 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 2
- 230000002411 adverse Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000010354 integration Effects 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 238000004080 punching Methods 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000012209 synthetic fiber Substances 0.000 description 2
- 229920002994 synthetic fiber Polymers 0.000 description 2
- 238000011144 upstream manufacturing Methods 0.000 description 2
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000008034 disappearance Effects 0.000 description 1
- 239000003063 flame retardant Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920005672 polyolefin resin Polymers 0.000 description 1
- 229920002215 polytrimethylene terephthalate Polymers 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
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- Electrostatic Separation (AREA)
- Filtering Of Dispersed Particles In Gases (AREA)
- Laminated Bodies (AREA)
- Nonwoven Fabrics (AREA)
- Filtering Materials (AREA)
Description
本発明は、物理的絡合と熱接着によって構成層を一体化することにより層間剥離を防止した摩擦帯電濾材に関する。 The present invention relates to a frictionally charged filter medium that prevents delamination by integrating constituent layers by physical entanglement and thermal bonding.
従来より、平板で取扱いが容易で、さらにプリーツ加工が可能な剛性を有する摩擦帯電濾材が多数提案されている（特許文献１〜４参照）。 Conventionally, many frictionally charged filter media having a rigidity that can be easily handled by a flat plate and can be pleated have been proposed (see Patent Documents 1 to 4).
これらの特許文献の摩擦帯電濾材は、剛性を確保するために補強ネット層や不織布層が積層されるが、積層された各層の一体化及び接着性が不十分なために容易に層間剥離が生じていた。 In these triboelectric filter media, reinforcing net layers and non-woven fabric layers are laminated in order to ensure rigidity, but delamination easily occurs due to insufficient integration and adhesion of the laminated layers. It was.
これに対して各層を接着バインダーで結合することも提案されているが、濾材カット時にカット面で層間剥離したり、エアブロー試験時にユニットの層間剥離を生じる問題があった。 On the other hand, it has also been proposed to bond each layer with an adhesive binder, but there is a problem in that delamination occurs on the cut surface when the filter medium is cut and delamination of the unit occurs during the air blow test.
本発明は、かかる従来技術の問題点に鑑み創案されたものであり、その目的は、濾材カット時やエアブロー試験時でも層間剥離を生じない、補強ネット層と不織布層を積層された摩擦帯電濾材、及びそれを使用したフィルターユニットを提供することにある。 The present invention was devised in view of the problems of the prior art, and the purpose thereof is a frictionally charged filter medium in which a reinforcing net layer and a nonwoven fabric layer are laminated, and does not cause delamination even when a filter medium is cut or during an air blow test. And providing a filter unit using the same.
本発明者は、かかる目的を達成するために鋭意検討した結果、摩擦帯電濾材を構成する各層を物理的な絡合で一体化するとともに、特定の層に熱融着成分を含有させて各層を熱接着させることにより、各層間を強固に接着一体化できることを見出した。また、不織布層の油剤を存在させないか又は減少させることによって各層間の接着性や捕集効率が向上することも見出した。本発明は、これらの知見に基づいて完成に至った。 As a result of intensive studies to achieve the above object, the present inventor integrated each layer constituting the frictionally charged filter medium by physical entanglement, and incorporated each layer with a heat-sealing component in a specific layer. It was found that the respective layers can be firmly bonded and integrated by thermal bonding. Moreover, it discovered that the adhesiveness and collection efficiency between each layer improved by not making the oil agent of a nonwoven fabric layer exist or reducing it. The present invention has been completed based on these findings.
即ち、本発明は、ポリオレフィン系繊維とポリエステル系繊維を含む繊維混合層の片面に補強ネット層を設け、さらに最外層に油剤付着量が０．１重量％未満の不織布層を設けてなり、これらの各層間が絡合および熱融着成分による熱接着により一体化される摩擦帯電濾材であって、補強ネット層及び不織布層は、鞘部に芯部より融点が低い樹脂を使用し、かつ鞘部のみが熱接着時に熱融着する芯鞘構造からなる繊維を含み、補強ネット層及び不織布層には熱接着時に熱融着する成分が３〜３０重量％含まれているが、繊維混合層には熱接着時に熱融着する成分が含まれていないことを特徴とする摩擦帯電濾材である。 That is, the present invention, the one side reinforcing net layers of fiber mixture layer containing a polyolefin fiber and a polyester fiber is provided, oil adhesion amount in the outermost layer is provided with a nonwoven layer of less than 0.1 wt% In addition, these And a reinforcing net layer and a nonwoven fabric layer using a resin whose melting point is lower than that of the core portion in the sheath portion, includes fibers only part consists of core-sheath structure to thermally fuse at the time of thermal bonding, although the reinforcing net layers and non-woven layer contains components that heat fusion during thermal bonding of 3 to 30 wt%, the fiber mixture layer Is a frictionally charged filter medium characterized in that it does not contain a component that is thermally fused during thermal bonding .
また、本発明は、上記摩擦帯電濾材にプリーツ加工を施し、これを枠体に保持してなることを特徴とするフィルターユニットである。 In addition, the present invention is a filter unit characterized in that the frictionally charged filter medium is subjected to pleating and held on a frame.
本発明の摩擦帯電濾材は、帯電列が異なるポリオレフィン系繊維とポリエステル系繊維からなる繊維を含有しているため、低圧力損失で高い粒子捕集効率を実現でき、さらに繊維混合層に補強ネット層を設け、最外層に不織布層を設けて、これらの各層を絡合により一体化し、補強ネット層及び不織布層に含有させた熱融着成分の熱接着により接着しているので、層間の接着性が良好で、濾材カット時やエアブロー試験時でも層間剥離がなく、しかも剛性が高く、プリーツ加工性に優れ、フィルターユニット加工時の圧力損失やダスト保持性に優れる。また、最外層を構成する不織布層の油剤付着量を０．１重量％未満にしているので、各層間の接着性や捕集効率に悪影響を及ぼさない。 The triboelectric filter material of the present invention contains fibers composed of polyolefin fibers and polyester fibers having different charge trains, so that high particle collection efficiency can be realized with low pressure loss, and a reinforcing net layer is added to the fiber mixture layer. the provided a nonwoven layer is provided on the outermost layer, these layers are integrated by entanglement, since the bonded by thermal bonding of heat-sealing component is contained in the reinforcing net So及beauty nonwoven fabric layer, interlayer Adhesiveness is good, there is no delamination even during filter media cutting or air blow test, high rigidity, excellent pleatability, and excellent pressure loss and dust retention during filter unit processing. Moreover, since the oil agent adhesion amount of the nonwoven fabric layer constituting the outermost layer is less than 0.1% by weight, the adhesiveness and collection efficiency between the respective layers are not adversely affected.
以下、本発明の摩擦帯電濾材を詳細に説明する。 Hereinafter, the frictionally charged filter medium of the present invention will be described in detail.
本発明の摩擦帯電濾材は、ポリオレフィン系繊維とポリエステル系繊維を含む繊維混合層の片面に補強ネット層を設け、さらに最外層に油剤付着量が０．１重量％未満の不織布層を設けた構成を採用し、特にこれらの各層間が絡合と熱融着成分による熱接着により強固に一体化されていることを特徴とする。 The frictionally charged filter medium of the present invention has a configuration in which a reinforcing net layer is provided on one side of a fiber mixed layer containing polyolefin fibers and polyester fibers, and a non-woven fabric layer having an oil agent adhesion amount of less than 0.1% by weight is provided on the outermost layer. In particular, each of these layers is firmly integrated by entanglement and thermal bonding using a heat-fusion component.
繊維混合層に使用されるポリオレフィン系繊維としては、ポリプロピレン繊維、ポリエチレン繊維が挙げられ、特にポリプロピレン繊維が好ましい。また、繊維混合層に使用されるポリエステル系繊維としては、ポリエチレンテレフタレート繊維、ポリトリメチレンテレフタレート繊維、芳香族ポリエステル繊維が挙げられ、特にポリエチレンテレフタレート繊維が好ましい。ポリオレフィン系繊維とポリエステル系繊維の繊維径は１０〜４０μｍであることが好ましい。かかる範囲であれば、低圧力損失であり、かつ微細塵を十分に除去できるためである。ポリオレフィン系繊維とポリエステル系繊維の混合割合（質量比）は２０：８０〜８０：２０であることが好ましい。かかる範囲であれば、繊維を有効に荷電することができるためである。ポリオレフィン系繊維もポリエステル系繊維も上記の繊維径及び混合割合を満足する限り、複数種の繊維径のものを使用することができる。 Examples of polyolefin fibers used in the fiber mixture layer include polypropylene fibers and polyethylene fibers, and polypropylene fibers are particularly preferable. Moreover, as a polyester fiber used for a fiber mixing layer, a polyethylene terephthalate fiber, a polytrimethylene terephthalate fiber, and an aromatic polyester fiber are mentioned, Especially a polyethylene terephthalate fiber is preferable. The fiber diameter of the polyolefin fiber and the polyester fiber is preferably 10 to 40 μm. This is because within such a range, the pressure loss is low and fine dust can be sufficiently removed. The mixing ratio (mass ratio) of the polyolefin fiber and the polyester fiber is preferably 20:80 to 80:20. This is because the fiber can be effectively charged within this range. As long as the polyolefin fiber and the polyester fiber satisfy the above-mentioned fiber diameter and mixing ratio, those having a plurality of fiber diameters can be used.
繊維混合層を構成する繊維は、いずれも丸断面の短繊維から構成されていることが好ましい。繊維同士の接触を最小限に抑え、有効濾過面積及び粉塵負荷時の粉塵保持空間を十分に確保するためである。ここで丸断面とは、真円に限定されず楕円形を含む概念であり、断面形状中に直線部を含まないことが望ましい。繊維混合層を構成する繊維は、難燃性を向上するためにリン系難燃剤を含有することが望ましい。 It is preferable that all the fibers constituting the fiber mixed layer are composed of short fibers having a round cross section. This is to minimize the contact between the fibers and to ensure a sufficient filtration area and a dust holding space when the dust is loaded. Here, the round cross section is a concept including an ellipse without being limited to a perfect circle, and it is desirable that a straight line portion is not included in the cross-sectional shape. The fibers constituting the fiber mixture layer preferably contain a phosphorus-based flame retardant in order to improve flame retardancy.
上記の構成繊維を混繊、カーディングし、ウェブ化して繊維混合層が得られる。得られた繊維混合層は、摩擦帯電を容易にするために繊維表面の油剤付着量を０．１重量％未満になるように油剤を除去することが好ましい。油剤の除去方法としては、例えば繊維混合層を溶剤や界面活性剤等の槽に浸漬した後にすすぎ処理する方法や高圧水を繊維混合層に噴射する方法などが挙げられる。高圧水を噴射する場合は構成繊維間の交絡も同時に行うことができるので好ましい。 The above-mentioned constituent fibers are mixed, carded, and formed into a web to obtain a fiber mixed layer. In the obtained fiber mixed layer, it is preferable to remove the oil so that the amount of oil attached to the fiber surface is less than 0.1% by weight in order to facilitate triboelectric charging. Examples of the method for removing the oil include a method of rinsing after the fiber mixed layer is immersed in a tank of a solvent or a surfactant, and a method of spraying high-pressure water onto the fiber mixed layer. Injecting high-pressure water is preferable because entanglement between constituent fibers can be performed simultaneously.
繊維混合層の目付は好ましくは５〜１０００ｇ／ｍ２であり、より好ましくは１０〜５００ｇ／ｍ２である。かかる範囲であれば、濾材の圧力損失や微細塵捕集効率を満足することができるためである。また、繊維混合層の厚みは好ましくは０．１〜３．０ｍｍ、より好ましくは０．５〜２．０ｍｍである。厚さが上記範囲未満であると、プリーツ加工時の圧力損失が高く、上記範囲を越えると、剛性が不足するためにシートとして取扱うのが困難である。 The basis weight of the fiber mixed layer is preferably 5 to 1000 g / m 2 , more preferably 10 to 500 g / m 2 . This is because within such a range, the pressure loss of the filter medium and the fine dust collection efficiency can be satisfied. The thickness of the fiber mixture layer is preferably 0.1 to 3.0 mm, more preferably 0.5 to 2.0 mm. If the thickness is less than the above range, the pressure loss during pleating is high, and if it exceeds the above range, the rigidity is insufficient and it is difficult to handle as a sheet.
本発明の摩擦帯電濾材は、上記の繊維混合層の片面に補強ネット層を設け、さらに最外層に不織布層を設けた構成を採用する。かかる摩擦帯電濾材の層構成の例としては、図１（ａ），（ｂ）が挙げられる。図１（ａ）は、繊維混合層の上面に補強ネット層を設け、さらに補強ネット層の上面に不織布層を設けた構成を示し、図１（ｂ）は、図１（ａ）の構成に加えて、さらに繊維混合層の下面に不織布層を設けた構成を示し、これらの各層が絡合及び熱接着により一体化されている。 The frictionally charged filter medium of the present invention employs a configuration in which a reinforcing net layer is provided on one side of the above-mentioned fiber mixed layer and a nonwoven fabric layer is further provided on the outermost layer. Examples of the layer configuration of the frictionally charged filter medium include FIGS. 1 (a) and 1 (b). FIG. 1A shows a configuration in which a reinforcing net layer is provided on the upper surface of the fiber mixture layer, and a nonwoven fabric layer is further provided on the upper surface of the reinforcing net layer, and FIG. 1B is a configuration in FIG. In addition, the structure which provided the nonwoven fabric layer further in the lower surface of the fiber mixing layer is shown, and each of these layers is integrated by entanglement and thermal bonding.
補強ネット層は、濾材に剛性を付与し、形状保持性を向上させるためのものであり、合成繊維、無機繊維、金属繊維のいずれかのものから構成されてもよいが、プリーツ加工性の点で合成繊維から構成されることが好ましい。補強ネット層の繊度及び目開きは補強効果及び通気抵抗の点でそれぞれ１０〜１５００ｄｔｅｘ，１〜１００ｍｍ２であることが好ましい。また、補強ネット層の厚みは同様の理由から好ましくは０．１〜３．０ｍｍであり、より好ましくは０．３〜１．５ｍｍである。 The reinforcing net layer is for imparting rigidity to the filter medium and improving the shape retention, and may be composed of any one of synthetic fiber, inorganic fiber, and metal fiber. And is preferably composed of synthetic fibers. The fineness and openings of the reinforcing net layer are preferably 10 to 1500 dtex and 1 to 100 mm 2 in terms of reinforcing effect and ventilation resistance, respectively. The thickness of the reinforcing net layer is preferably 0.1 to 3.0 mm, more preferably 0.3 to 1.5 mm, for the same reason.
不織布層は、濾材に剛性を付与するため、及び、繊維混合層と絡合させ、その間の補強ネット層を固定するためのものである。その素材は特に限定されないが、ポリプロピレン、ポリエチレン等のポリオレフィン系樹脂、ポリエチレンテレフタレート、ポリブチレンテレフタレート等のポリエステル系樹脂などからなることができ、これらを用い、スパンボンド法やメルトブロー法等で得られる長繊維不織布、エアースルー法、サーマルボンド法、ウォーターパンチ法やニードルパンチ法等で得られる短繊維不織布が例示できる。不織布は、濾過性能を阻害しない程度に低圧損であることが好ましく、その繊維径は１０〜５０μｍが好ましく、２０〜３５μｍがより好ましく、目付は５〜５０ｇ／ｍ２が好ましく、１０〜３０ｇ／ｍ２がより好ましい。繊維径が小さく目付が大きいと通気抵抗が高くなり、逆に繊維径が大きく目付が小さいと繊維混合層との絡合が弱くなり好ましくない。 The non-woven fabric layer is for imparting rigidity to the filter medium, and for interlacing with the fiber mixed layer and fixing the reinforcing net layer therebetween. The material is not particularly limited, but can be made of polyolefin resins such as polypropylene and polyethylene, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, etc., and can be obtained by a spunbond method or a melt blow method. Nonwoven fabrics obtained by fiber nonwoven fabric, air-through method, thermal bond method, water punch method, needle punch method and the like can be exemplified. The nonwoven fabric preferably has a low pressure loss to such an extent that the filtration performance is not impaired. The fiber diameter is preferably 10 to 50 μm, more preferably 20 to 35 μm, and the basis weight is preferably 5 to 50 g / m 2 and 10 to 30 g / m. m 2 is more preferable. If the fiber diameter is small and the basis weight is large, the ventilation resistance is high. Conversely, if the fiber diameter is large and the basis weight is small, the entanglement with the fiber mixed layer is weak, which is not preferable.
不織布層は、油剤付着量を０．１重量％未満にすることが必要である。不織布層中の油剤はできるだけ少ないことが好ましく、油剤を不織布層に存在させないことがより好ましい。不織布が長繊維からなる場合は、油剤が存在しないためそのまま使用できるが、短繊維からなる場合は、油剤付着量を０．１重量％未満にするように除去することが必要である。不織布層に油剤が０．１重量％以上存在すると、ニードルパンチ法で各層間の物理的絡合と繊維混合層の摩擦帯電を同時に実施した場合に、油剤が繊維混合層に浸透して摩擦帯電が十分に行えないために濾材の捕集効率に影響が出るとともに、各層間の熱融着成分による熱接着にも悪影響を及ぼすため好ましくない。不織布層からの油剤の除去方法は繊維混合層と同様の方法で行うことができる。 The nonwoven fabric layer needs to have an oil agent adhesion amount of less than 0.1% by weight. The oil agent in the nonwoven fabric layer is preferably as small as possible, and more preferably the oil agent is not present in the nonwoven fabric layer. When the nonwoven fabric is made of long fibers, it can be used as it is because there is no oil agent. However, when it is made of short fibers, it is necessary to remove the oil agent so that the amount of oil agent attached is less than 0.1% by weight. When the oil agent is present in the nonwoven fabric layer in an amount of 0.1% by weight or more, when the physical entanglement between each layer and the frictional charging of the fiber mixed layer are simultaneously performed by the needle punch method, the oil penetrates the fiber mixed layer and is triboelectrically charged. Is not preferable because the trapping efficiency of the filter medium is affected, and the thermal adhesion by the heat fusion component between the layers is also adversely affected. The method of removing the oil agent from the nonwoven fabric layer can be performed in the same manner as the fiber mixed layer.
本発明の摩擦帯電濾材は、上記の繊維混合層、補強ネット層及び不織布層を積層したものを絡合によって物理的に一体化するとともに、補強ネット層及び不織布層に含まれる熱融着成分の溶融によって各層間の熱接着を図ることを特徴とする。 Friction charged filter material of the present invention, the fiber mixture layer, as well as physically integrated by intertwining a material obtained by laminating a reinforcing net layers and non-woven layer, heat contained in the reinforcing net So及beauty nonwoven fabric layer It is characterized by achieving thermal bonding between the respective layers by melting the adhering components.
絡合による各層の一体化は、ニードルパンチ法やウォーターパンチ法などの方法を単独で又は組み合わせて絡合することにより行われる。この絡合処理は、各層間の繊維同士の物理的な絡みを強め、結果として各層間の接着強度及び剥離強度を著しく向上させる。ニードルパンチ法は摩擦帯電と絡合を同時に行うことができる。なお、ウォーターパンチ法を行う時は帯電の消失を避けるために摩擦帯電する工程の前に実施することが好ましい。 The integration of each layer by entanglement is performed by entanglement methods such as a needle punch method and a water punch method alone or in combination. This entanglement treatment strengthens the physical entanglement between the fibers between the respective layers, and as a result, remarkably improves the adhesive strength and peel strength between the respective layers. The needle punch method can simultaneously perform tribocharging and entanglement. In addition, when performing the water punch method, it is preferable to carry out before the step of frictional charging in order to avoid the disappearance of charging.
熱融着成分による熱接着は、積層された構成層を例えば空気循環型オーブンや遠赤外線ヒーターなどによって３０秒〜１０分間、熱接着成分の融点以上に加熱して熱融着成分を溶融させ、隣接する繊維間及び層間を融着することによって行われる。熱融着成分は、熱により溶融して接着に寄与する限り、いかなる公知のものでもよいが、例えば低融点ポリプロピレンが使用できる。熱融着成分は、単一成分でも複数成分からなる繊維でもよく、複数成分からなる場合、芯鞘構造やサイドバイサイド構造を採用することができる。芯鞘構造は、鞘部に芯部より融点が低い樹脂を使用することが好ましく、例えば鞘部に低融点ポリプロピレン、芯部に高融点ポリプロピレンを使用する組み合わせや、鞘部にポリエチレン、芯部にポリエチレンテレフタレートを使用する組み合わせが挙げられる。 The heat bonding by the heat-bonding component is performed by heating the laminated component layer to a temperature equal to or higher than the melting point of the heat-bonding component for 30 seconds to 10 minutes using, for example, an air circulation oven or a far infrared heater, This is done by fusing adjacent fibers and layers. Any heat-sealing component may be used as long as it is melted by heat and contributes to adhesion, and for example, low-melting polypropylene can be used. The heat fusion component may be a single component or a fiber composed of a plurality of components. When the component is composed of a plurality of components, a core-sheath structure or a side-by-side structure can be adopted. For the core-sheath structure, it is preferable to use a resin having a melting point lower than that of the core for the sheath. For example, a combination using a low-melting polypropylene for the sheath and a high-melting polypropylene for the core, polyethylene for the sheath, Examples include combinations using polyethylene terephthalate.
熱融着成分は、補強ネット層と不織布層の両方に含有され、繊維混合層には含有されないことが必要である。繊維混合層に熱融着成分を入れると摩擦帯電が阻害される可能性があるからである。不織布層中の熱融着成分の含有量は好ましくは１〜４０重量％、より好ましくは３〜３０重量％である。含有量が少なすぎると十分な接着効果が発揮されず、逆に多すぎると微細塵の捕集効率が低下するからである。また、補強ネット層中の熱融着成分の含有量は好ましくは１〜４０重量％、より好ましくは３〜３０重量％である。捕集効率の低下を抑えながら十分な接着効果を発揮するためである。 Heat sealing component is contained in both the reinforcing net layer and the nonwoven fabric layer, the fiber mixture layer it is necessary not contained. This is because friction charging may be hindered when a heat fusion component is added to the fiber mixture layer . The content of heat Chakuseibun the nonwoven fabric layer is preferably 1 to 40% by weight, more preferably 3 to 30 wt%. This is because if the content is too small, a sufficient adhesive effect cannot be exhibited, and if it is too large, the collection efficiency of fine dust is reduced. The content of heat Chakuseibun the reinforcement net layer is preferably 1 to 40% by weight, more preferably 3 to 30 wt%. This is because a sufficient adhesion effect is exhibited while suppressing a decrease in the collection efficiency.
本発明の摩擦帯電濾材の摩擦帯電は、油剤を除去された繊維混合層だけに直接行うか、又は各層を積層してから行うことができる。摩擦帯電の方法としては、例えば二つのギアロール間に繊維混合層を噛み合わせて通過させながら摩擦を行う方法やニードルパンチ処理によって積層された層の交絡と摩擦を同時に行う方法などが挙げられる。 The triboelectric charging medium of the present invention can be triboelectrically charged only on the fiber mixture layer from which the oil agent has been removed, or after each layer is laminated. Examples of the triboelectric charging method include a method of performing friction while meshing and passing a fiber mixed layer between two gear rolls, and a method of simultaneously entangling and rubbing layers stacked by needle punching.
本発明の摩擦帯電濾材は、図２のように、プリーツ加工を施し、これを枠体に保持することによりフィルターユニットとして使用することができる。プリーツ加工を施すことにより、同じ通風開口部でも濾過面積を大幅に増大することができ、フィルターの捕集効率の向上と低圧力損失化、及びダスト負荷時の圧損上昇の抑制が可能である。 The frictionally charged filter medium of the present invention can be used as a filter unit by performing pleating as shown in FIG. 2 and holding it on a frame. By applying the pleating process, the filtration area can be greatly increased even in the same ventilation opening, and it is possible to improve the collection efficiency of the filter, reduce the pressure loss, and suppress the increase in pressure loss when dust is loaded.
以下、実施例により本発明の摩擦帯電濾材の優れた効果を示すが、本発明はこれらに限定されない。なお、実施例中で測定した特性値は以下の方法で評価された。 Hereinafter, although the example shows the excellent effect of the frictionally charged filter medium of the present invention, the present invention is not limited thereto. The characteristic values measured in the examples were evaluated by the following methods.
（エアブロー耐性）
濾材（１０×１０ｃｍ）により３ｃｍ離れた距離から、０．４ＭＰａの圧縮空気を連続で３分間、濾材に均一にエアブローした時の剥離強度を弱・中・強の３段階で評価した。
(Air blow resistance)
The peel strength when 0.4 MPa compressed air was blown uniformly over the filter medium continuously for 3 minutes from a distance of 3 cm by a filter medium (10 × 10 cm) was evaluated in three stages: weak, medium and strong.
（０．３μｍ粒子捕集効率）
濾材をダクト内に設置し、空気濾過速度が３０ｃｍ／秒になるよう大気を通気させ、濾材上流、下流の０．３〜０．５μｍ粒子の個数濃度をパーティクルカウンターにて計測し、次式にて捕集効率を算出した。
０．３μｍ粒子捕集効率（％）＝[１−（下流側濃度／上流側濃度）]×１００
(0.3 μm particle collection efficiency)
Install the filter medium in the duct, vent the atmosphere so that the air filtration speed becomes 30 cm / sec, measure the number concentration of 0.3-0.5 μm particles upstream and downstream of the filter medium with a particle counter, The collection efficiency was calculated.
0.3 μm particle collection efficiency (%) = [1− (downstream concentration / upstream concentration)] × 100
〔実施例１〕
円形断面ポリプロピレン繊維（繊維径１８μｍ、繊維長５１ｍｍ）と、円形断面ポリエステル繊維（繊維径１３μｍ、繊維長４４ｍｍ）を１：１の重量比で混綿、カーディングし、ウェブ化して目付１５ｇ／ｍ２、厚み０．６ｍｍの混繊ウェブを作製した。これに目付１５ｇ／ｍ２、繊維径３０μｍ、融点１６４℃のポリプロピレンスパンボンド長繊維不織布Ａを積層した後３ＭＰａの高圧水を連続的に噴霧して交絡させると同時に油剤を除去、乾燥し、積層体を作成した。
[Example 1]
Circular cross-section polypropylene fiber (fiber diameter: 18 μm, fiber length: 51 mm) and circular cross-section polyester fiber (fiber diameter: 13 μm, fiber length: 44 mm) are mixed and carded at a weight ratio of 1: 1, and formed into a web to have a basis weight of 15 g / m 2. A mixed fiber web having a thickness of 0.6 mm was produced. A polypropylene spunbond long fiber nonwoven fabric A having a basis weight of 15 g / m 2 , a fiber diameter of 30 μm, and a melting point of 164 ° C. was laminated, and then 3 MPa of high-pressure water was continuously sprayed and entangled. Created the body.
前記積層体のスパンボンド不織布Ａとは反対側に、ポリプロピレン／ポリプロピレン製芯鞘ネット（１３００ｄｔｅｘ、目開き３×５ｍｍ、目付６０ｇ／ｍ２、融点１６４℃（芯）／１２５℃（鞘）、鞘成分２０重量％）と、ポリエチレンテレフタレート／ポリエチレン芯鞘繊維スパンボンド不織布Ｂ（目付１５ｇ／ｍ２、融点２６０℃（芯）／１３０℃（鞘）、鞘成分２０重量％）とをポリエチレンテレフタレート／ポリエチレン芯鞘繊維スパンボンド不織布Ｂが最外層に来るように積層し、針密度３１本／ｃｍ２にてニードルパンチ処理を行い、摩擦帯電と交絡を同時に行って、全目付１０２ｇ／ｍ２の摩擦帯電濾材を得た。この摩擦帯電濾材を空気循環型オーブンにて、１４０℃で５分間加熱した。この摩擦帯電濾材の構成の詳細と評価結果を表１に示す。 On the opposite side of the laminate from the spunbond nonwoven fabric A, a polypropylene / polypropylene core-sheath net (1300 dtex, aperture 3 × 5 mm, basis weight 60 g / m 2 , melting point 164 ° C. (core) / 125 ° C. (sheath), sheath Component 20% by weight) and polyethylene terephthalate / polyethylene core-sheath fiber spunbond nonwoven fabric B (weight per unit area 15 g / m 2 , melting point 260 ° C. (core) / 130 ° C. (sheath), sheath component 20% by weight) Laminated so that the core-sheath fiber spunbond nonwoven fabric B is the outermost layer, needle punching is performed at a needle density of 31 / cm 2 , and triboelectric charging and entanglement are performed simultaneously, resulting in triboelectric charging with a total basis weight of 102 g / m 2 A filter medium was obtained. The frictionally charged filter medium was heated in an air circulation oven at 140 ° C. for 5 minutes. The details of the configuration of the frictionally charged filter medium and the evaluation results are shown in Table 1.
〔参考例２〕
ポリプロピレン／ポリプロピレン製芯鞘ネットの代わりにポリプロピレン製ネット（１３００ｄｔｅｘ、目開き３×５ｍｍ、目付６０ｇ／ｍ２、融点１６４℃）を使用した以外は、実施例１と同様に摩擦帯電濾材を得た。この摩擦帯電濾材を空気循環型オーブンにて、１４０℃で５分間加熱した。この摩擦帯電濾材の構成の詳細と評価結果を表１に示す。
[ Reference Example 2]
A frictionally charged filter medium was obtained in the same manner as in Example 1 except that a polypropylene net (1300 dtex, aperture 3 × 5 mm, basis weight 60 g / m 2 , melting point 164 ° C.) was used instead of the polypropylene / polypropylene core-sheath net. . The frictionally charged filter medium was heated in an air circulation oven at 140 ° C. for 5 minutes. The details of the configuration of the frictionally charged filter medium and the evaluation results are shown in Table 1.
〔参考例３〕
ポリエチレンテレフタレート／ポリエチレン芯鞘繊維スパンボンド不織布Ｂの代わりにポリプロピレン製スパンボンド不織布（目付１５ｇ／ｍ２、融点１６４℃）を使用した以外は、実施例１と同様に摩擦帯電濾材を得た。この摩擦帯電濾材を空気循環型オーブンにて、１４０℃で５分間加熱した。この摩擦帯電濾材の構成の詳細と評価結果を表１に示す。
[ Reference Example 3]
A frictionally charged filter medium was obtained in the same manner as in Example 1 except that a polypropylene spunbond nonwoven fabric (basis weight 15 g / m 2 , melting point 164 ° C.) was used in place of the polyethylene terephthalate / polyethylene core-sheath fiber spunbond nonwoven fabric B. The frictionally charged filter medium was heated in an air circulation oven at 140 ° C. for 5 minutes. The details of the configuration of the frictionally charged filter medium and the evaluation results are shown in Table 1.
〔実施例４〕
ポリエチレンテレフタレート／ポリエチレン芯鞘繊維スパンボンド不織布Ｂの代わりに高圧水を噴射することによって油剤付着量を０．０１重量％まで低減したポリエチレンテレフタレート／共重合ポリエステル芯鞘繊維使用短繊維不織布（目付１５ｇ／ｍ２、融点 ℃（芯）２６０／１１０℃（鞘）、鞘成分２０重量％）を使用した以外は、実施例１と同様に摩擦帯電濾材を得た。この摩擦帯電濾材を空気循環型オーブンにて、１２０℃で５分間加熱した。この摩擦帯電濾材の構成の詳細と評価結果を表１に示す。
Example 4
Polyethylene terephthalate / copolymerized polyester core / sheath fiber short fiber nonwoven fabric (weight per unit: 15 g / weight) in which the adhesion amount of the oil agent was reduced to 0.01% by spraying high-pressure water instead of polyethylene terephthalate / polyethylene core / sheath fiber spunbond nonwoven fabric B A frictionally charged filter medium was obtained in the same manner as in Example 1 except that m 2 , melting point ° C. (core) 260/110 ° C. (sheath), and sheath component 20 wt% were used. The frictionally charged filter medium was heated at 120 ° C. for 5 minutes in an air circulation oven. The details of the configuration of the frictionally charged filter medium and the evaluation results are shown in Table 1.
〔比較例１〕
ポリプロピレン／ポリプロピレン製芯鞘ネットの代わりにポリプロピレン製ネット（１３００ｄｔｅｘ、目開き３×５ｍｍ、目付６０ｇ／ｍ２、融点１６４℃）を使用し、ポリエチレンテレフタレート／ポリエチレン芯鞘繊維スパンボンド不織布Ｂの代わりにポリプロピレン製スパンボンド不織布（目付１５ｇ／ｍ２、融点１６４℃）を使用した以外は、実施例１と同様に摩擦帯電濾材を得た。この摩擦帯電濾材を空気循環型オーブンにて、１４０℃で５分間加熱した。この摩擦帯電濾材の構成の詳細と評価結果を表１に示す。
[Comparative Example 1]
Instead of polypropylene / polypropylene core-sheath net, use a polypropylene net (1300 dtex, aperture 3 × 5 mm, basis weight 60 g / m 2 , melting point 164 ° C.), instead of polyethylene terephthalate / polyethylene core-sheath fiber spunbond nonwoven fabric B A frictionally charged filter medium was obtained in the same manner as in Example 1 except that a polypropylene spunbonded nonwoven fabric (basis weight 15 g / m 2 , melting point 164 ° C.) was used. The frictionally charged filter medium was heated in an air circulation oven at 140 ° C. for 5 minutes. The details of the configuration of the frictionally charged filter medium and the evaluation results are shown in Table 1.
〔比較例２〕
ポリエチレンテレフタレート／ポリエチレン芯鞘繊維スパンボンド不織布Ｂの代わりに油剤付着量０．１３重量％のポリエチレンテレフタレート／共重合ポリエステル芯鞘繊維使用短繊維不織布（目付１５ｇ／ｍ２、融点２６０℃（芯）／１１０℃（鞘）、鞘成分２０重量％）を使用した以外は、実施例１と同様に摩擦帯電濾材を得た。この摩擦帯電濾材を空気循環型オーブンにて、１２０℃で５分間加熱した。この摩擦帯電濾材の構成の詳細と評価結果を表１に示す。
[Comparative Example 2]
In place of polyethylene terephthalate / polyethylene core-sheath fiber spunbond nonwoven fabric B, a short fiber nonwoven fabric using polyethylene terephthalate / copolymerized polyester core-sheath fiber with an oil adhesion amount of 0.13% by weight (mesh weight 15 g / m 2 , melting point 260 ° C. (core) / A frictionally charged filter medium was obtained in the same manner as in Example 1 except that 110 ° C. (sheath) and sheath component 20% by weight were used. The frictionally charged filter medium was heated at 120 ° C. for 5 minutes in an air circulation oven. The details of the configuration of the frictionally charged filter medium and the evaluation results are shown in Table 1.
表１から明らかなように、不織布層及び補強ネット層に熱融着成分を入れて各層を熱接着させ絡合したものは、エアブロー耐性及び０．３μｍ粒子捕集効率が良好であった。これに対して熱融着成分による各層の熱接着がない比較例１、油剤を十分に除去していない不織布層を使用した比較例２はそれぞれ、エアブロー耐性、０．３μｍ粒子捕集効率に問題があった。 As is evident from Table 1, those layers were entangled by thermal bonding putting thermal fusion component nonwoven layer及beauty reinforcement net layer, air blow resistance and 0.3μm particle collection efficiency was good . On the other hand, Comparative Example 1 in which there is no thermal adhesion of each layer due to the heat fusion component and Comparative Example 2 in which the nonwoven fabric layer from which the oil agent has not been sufficiently removed are problems in air blow resistance and 0.3 μm particle collection efficiency, respectively. was there.
本発明の摩擦帯電濾材は、エアブロー試験時でも層間剥離を生じないので再生利用が容易であり、産業界の濾材に対するコストの低減に寄与することができる。 Since the frictionally charged filter medium of the present invention does not cause delamination even during the air blow test, it can be easily recycled and can contribute to the cost reduction of the filter medium in the industry.
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| MY183762A (en) * | 2010-10-14 | 2021-03-11 | Fairtech Investment Ltd | Nonwoven fabric, manufacturing method thereof and filters formed by it |
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| JPH0929041A (en) * | 1995-07-18 | 1997-02-04 | Toyobo Co Ltd | Filter for cleaning air |
| JP4923353B2 (en) * | 2001-08-08 | 2012-04-25 | 東洋紡績株式会社 | Electret filter medium and method for producing the same |
| JP2006218342A (en) * | 2005-01-17 | 2006-08-24 | Toyobo Co Ltd | Frictional electrification filtering medium having anti-bacterial property and anti-allergenic property and its production method |
| JP2007160275A (en) * | 2005-12-16 | 2007-06-28 | Nitto Denko Corp | Filter unit and its manufacturing method |
| JP2008086964A (en) * | 2006-10-05 | 2008-04-17 | Toyobo Co Ltd | Friction-charged filter medium and its manufacturing method |
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