JPH11104415A - Functional material for air filter and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To facilitate to obtain functional optional material for an air filter exhibiting an excellent deodorization effect by comprising a crimped yarn allowed to support mineral material fillers. SOLUTION: Crimped yarn obtained from split yarn of polymer with extensibility, e.g. polypropylene, is used for filter material and allowed to support mineral material fillers as functional material. The crimped yarn of polypropylene is manufactured as follows. Extruded film with a specified thickness is produced by conventional extrusion molding from polypropylene resin. The extruded film of polypropylene is cut off to width of about 1-2 cm and then extended by a monoaxial stretching method (about 6-8 times to produce flat yarn. The flat yarn is fibrillated to produce split yarn. The split yarn is crimped to produce crimped yarn. Activated clay, zinc oxide, calcium carbonate, titanium oxide, active carbon, and the like are cited as the mineral material fillers.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a functional material for an air filter and a method for producing the same, and more particularly to a method for removing odors in the air in a room or harmful substances such as harmful gases generated from new building materials. The present invention relates to a functional material for an air filter and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, a home air conditioner or an air conditioner for air conditioning has been known as a device for continuously purifying indoor air. An air filter material made of glass fiber is known as a filter material of an air conditioner for air conditioning.

[0003] Of the odors in the air, odors that are generally repelled are called malodorous gases. And, indoor air contains various odorous gases, harmful gases such as formaldehyde generated from new building materials of new houses, and harmful substances such as germs attached to dust floating in the air. .

The odorous gases include basic gases such as ammonia and trimethylamine (hereinafter referred to as basic odorous gases), acid gases such as hydrogen sulfide and methyl mercaptan (hereinafter referred to as acidic odorous gases), and sulfuric acid. It can be roughly classified into three types of neutral gases such as methyl, methyl disulfide, and acetaldehyde (hereinafter, referred to as neutral malodorous gases).
In addition, there is an odorous gas of a non-polar substance such as styrene. Usually, several types of malodorous gases are often mixed. It is said that there are about 400,000 types of components having an odor, and in order to be sensed by the sense of smell, it is required that they have 5 to 17 carbon atoms having a molecular weight of about 300 or less and have volatile, hydrophilic, or lipophilic properties. Table 1 shows the statutory malodorous substances that are the main cause of odor pollution and are often used for measuring the deodorizing effect.
Shown in

[0005]

[Table 1]

Means for removing malodorous gas from the air include, for example, chemical reaction deodorization in which a deodorant is sprayed to neutralize the deodorant and malodorous gas by a chemical reaction, or, for example, charcoal adsorbs malodorous gas. Adsorption and deodorization are known.

The following is also known as a device provided with a means for removing the odorous gas from the air. JP-A-8-173762 proposes a titanium oxide supporting sheet in which a film-forming inorganic material-containing layer is provided on a support, and a titanium oxide-containing layer is laminated thereon. Also, JP-A-8-28
No. 1030 proposes an air cleaning filter sheet in which a sheet-shaped electret filter and a reinforcing material sheet are laminated, and an adsorption sheet is laminated on the electret filter side. JP-A-8-266866 proposes a deodorizing filter in which a deodorizing catalyst and a zeolite powder having a SiO ₂ / Al ₂ O ₃ ratio of 15 or more are supported on a catalyst carrier for a gas phase reaction. JP-A-2-309969 proposes a breathable deodorizing film obtained by melt-molding a polyolefin resin composition containing a polyolefin resin, a filler, a radical generator, and a deodorant, and then stretching the resulting composition. Japanese Patent Application Laid-Open No. 6-296672 discloses a ventilation method in which activated clay and a basic substance or / and a neutral substance are kneaded with a polyolefin resin, then melted and formed into a film, and the film is stretched. Sex deodorizing films have been proposed.

[0008]

SUMMARY OF THE INVENTION In the case of a glass fiber air filter material of an air conditioner for air conditioning which is widely used as a means for purifying indoor air for a long time, a glass fiber filter is manufactured. Not only requires expensive equipment, but also has a problem that the glass fiber itself is easily broken, so that it is difficult to handle and the secondary workability is poor. Also, since home air conditioners are designed to remove large-sized dust particles from indoor air,
There is a problem that the odorous gas present in the air cannot be removed.

In the case of the chemical reaction deodorization method in which the deodorant and the malodorous gas are neutralized by a chemical reaction by spraying the above-mentioned deodorant, a method for deodorizing a considerably high concentration of malodorous gas in a short time. In consideration of safety to the human body, it is easy to use as a deodorizing means, but it has to be deodorized each time, it is not persistent, and the substance that has undergone chemical reaction remains in the room. There is.

Also, in the case of the titanium oxide supporting sheet proposed in Japanese Patent Application Laid-Open No. 8-173762, although the concentration of harmful substances in the air such as offensive odors can be reduced, it is in the form of a sheet.
There is a problem that the contact efficiency between the supporting sheet and the harmful substance is poor, and the sheet is not suitable for a functional material for an air filter. In the case of the filter sheet for air cleaning proposed in JP-A-8-281030, dust and odorous gas in the air can be removed, but the filter itself adsorbs the sheet-shaped electret filter and the reinforcing material sheet. There is a problem that the electret filter has a laminated structure of a conductive sheet and requires an electric charge treatment, and the production of the filter sheet is complicated. Further, in the case of the deodorizing filter proposed in JP-A-8-266866, it is possible to remove the malodorous gas in the air, but the catalyst carrier for the gas phase reaction has a honeycomb structure made of inorganic fiber paper having a high porosity. There is a problem that the production of the catalyst carrier for the gas phase reaction is complicated. Further, in the case of a breathable deodorizing film proposed in Japanese Patent Application Laid-Open No. 2-309969, although the film itself has breathability, the pressure loss is high because the film is not suitable for an air filter functional material. There's a problem. Further, in the case of the breathable deodorizing film proposed in JP-A-6-296672, although the film itself has breathability, the pressure loss is high because the film is not suitable for a functional material for an air filter. There's a problem. An object of the present invention is to solve the problems of the prior art and to provide a functional material for an air filter exhibiting a deodorizing effect and a method for producing the same.

[0011]

The present inventors have conducted intensive studies to achieve the above-mentioned object, and as a solution, as a solution, a polymer having extensibility such as polypropylene (e.g., polypropylene) without using glass fiber for the filter material. By using a crimp yarn obtained from the split yarn of PP) and carrying an inorganic filler as a functional substance,
It has been found that an odorous gas in the air can be brought into contact with this functional substance to remove it properly.

The functional material for an air filter and the method of manufacturing the same according to the present invention have been made based on such findings. That is, the functional material for an air filter of the present invention is characterized by comprising a crimp yarn carrying a filler of an inorganic agent. Further, in the functional material for an air filter according to claim 2, the crimp yarn is any one of high-density polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl alcohol, polyacrylonitrile, polyvinylidene chloride, polyamide, and polyester. There is a feature. The functional material for an air filter according to claim 3, wherein the filler of the inorganic agent is a solid acid such as activated clay, a neutral substance such as zinc oxide, calcium carbonate,
It is characterized by being at least one of a solid alkali such as aluminum hydroxide, a photocatalyst such as titanium oxide, and activated carbon. In the functional material for an air filter according to claim 4, the filler of the inorganic agent has a particle size of 10 μm.
m or less. Further, the method for producing a functional material for an air filter of the present invention, after kneading a filler of an inorganic agent into a polymer having stretchability, forming an extruded film by performing an extrusion treatment, and performing a stretching treatment on the extruded film. After forming a stretched film and subjecting the stretched film to splitting to form a split yarn, the split yarn is heated to form a crimped yarn of the polymer. Further, in the method for producing a functional material for an air filter according to claim 6, after a filler of an inorganic agent is supported on an extruded polymer film having stretchability, the stretched film is subjected to a stretching treatment to form a stretched film. It is characterized in that, after being formed, the stretched film is subjected to a splitting treatment to form a split yarn, and then the split yarn is subjected to a heat treatment to form a crimp yarn. The method for producing a functional material for an air filter according to claim 7, wherein the polymer having stretchability is a high-density polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl alcohol, polyacrylonitrile, polyvinylidene chloride, or polyamide. , Or polyester. The method for producing a functional material for an air filter according to claim 8, wherein the filler of the inorganic agent is a solid acid such as activated clay, a neutral substance such as zinc oxide, a solid such as calcium carbonate or aluminum hydroxide. It is characterized by being at least one of an alkali, a photocatalyst such as titanium oxide, and activated carbon. The method for producing a functional material for an air filter according to claim 9 is characterized in that the particle diameter of the filler of the inorganic agent is 10 μm or less.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION As the polymer used in the present invention, any polymer may be used as long as it is a polymer having stretchability. Such polymers include thermoplastic resins such as high-density polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl alcohol, polyacrylonitrile, polyvinylidene chloride, polyamides, polyesters and copolymers belonging to these series, cellulose, and the like. Derivatives, and polymers having a crystalline thin film-forming property are also included.

A crimped yarn is prepared from a polymer having the above-mentioned drawability, for example, polypropylene, which is the most industrially used polymer among the polymers, as follows. An extruded film of a predetermined thickness is prepared from a polypropylene resin by a usual extrusion molding method. After cutting a polypropylene extruded film to a width of 1 to 2 cm, the film is stretched (6 to 8 times) by a uniaxial stretching method to produce a flat yarn. Split yarn is applied to the flat yarn (for example, a cut is made with a rotating roll or a garment roll) to produce a split yarn. The split yarn is crimped by, for example, a gear pump method, a steam crimp method, or a dry heat crimp method of a general processing method to produce a crimp yarn.

Examples of the filler of the inorganic agent to be carried on the crimp yarn include solid acids such as activated clay, neutral substances such as zinc oxide, solid alkalis such as calcium carbonate and aluminum hydroxide, photocatalysts such as titanium oxide and activated carbon. Is mentioned. 1) Activated clay (solid acid) Activated clay, which is a solid acid, is an Al-Si-based gel substance and is a montmorillonite or a soluble substance in the structure of montmorillonite, for example, by an activation treatment when treating halloysite with, for example, sulfuric acid. Is eluted to form a surface having fine pores, and its specific surface area is 150 to 300 m ² /
g, the average diameter of the pores is about 50 °. The activated clay is controlled by changing the activation conditions to control the acidity and specific surface area as a solid acid, as shown in FIG. 1 (A) (quoted from Japan Activated Clay Co., Ltd .: Catalog "Activated Clay"). Can be done. This is because, by the activation treatment, a part of the cations are exchanged with hydrogen ions to have the displaceable hydrogen, and the amount thereof reaches 10 to 30 me./100 g.
Under the activation conditions of (A), the activity is 30 m.e./100 g, and the specific surface area is 25.
It shows a characteristic value of 0 m ² / g. By changing the activation conditions in this way, the acidity and the specific surface area value are changed, indicating a chemical activity not found in other adsorbents. In addition, the adsorption of activated clay on the surface is selective as an adsorption property, and in the state where several types of substances coexist, it is shown in FIG. 1 (B) (quoted from Japan Activated Clay Co., Ltd .: Catalog "Activated Clay"). As shown, it exhibits a selective adsorption ability for polar substances, unsaturated substances and aromatic substances. The following summarizes the physical properties of activated clay as a deodorant. It is a solid acid having displaceable hydrogen on the surface and having a high acidity of 10 to 30 me./100 g. A solid acid is a substance having an acid activity in a non-polar solvent.
Shows the strongest deodorizing function against basic gases such as ammonia. It has a surface characteristic of an average pore diameter of 50 ° and a specific surface area of 150 to 300 m ² / g. , Can be controlled by changing the activation conditions and have a chemical activity not found in other adsorbents. In particular, for polar substances, unsaturated substances, and aromatic substances,
Has strong selective adsorption ability. Since most of the malodorous gas is a polar substance except for styrene, activated clay is selectively adsorbed in descending order of polarity. Further, the activity as a solid acid strongly acts on a basic malodorous gas such as ammonia, and its deodorizing effect is extremely large. In addition, by changing the activation conditions, the specific surface area and the acidity can be changed, and the optimum adsorption characteristics can be obtained for a plurality of types of odorous gases. Further, since styrene is an aromatic hydrocarbon, activated clay has strong adsorption characteristics. In the present invention, from these, the acidity is 10 to 30 me./100 g, and the specific surface area is 15
It is preferable to use 0 to 300 m ² / g of activated clay. This activated clay can be determined by examining the activation conditions to determine the maximum adsorption characteristics of activated clay against the physical properties (polarity, molecular weight, molecular structure, etc.) of various neutral malodorous gases. It is. 2) About zinc oxide (neutral substance) Zinc oxide (ZnO), which is a neutral substance, is known to be effective as a filler for microporous films, but also has extremely high reactivity with sulfur compounds. Is a substance having In addition, as a result of various experiments, it was found that the coexistence of activated clay and zinc oxide makes it possible to deodorize odorous gas containing sulfur compounds such as sulfur sulfide (H ₂ S) and methyl sulfide ((CH ₃ ) ₂ S). I understood. 3) Calcium carbonate and aluminum hydroxide (solid alkali) The most effective means to treat another acidic malodorous gas, which is an important odor that is subject to deodorization treatment, is to use these basic malodors with solid alkali, which is a basic substance. The gas can be neutralized and removed. However, although this is a known means, it is not carried on a crimp yarn. Calcium carbonate (CaCO ₃ ) is the most suitable substance for both the deodorizing function and the formation of air permeability. In order to further increase the deodorizing function, aluminum hydroxide (Al (OH) ₃ ) which is a strong basic substance having a pH of 12 is used. ) May be mixed in a small amount. 4) Titanium oxide Titanium oxide (TiO ₂ ) is a substance that is also called a photocatalyst. It is activated by light (ultraviolet) energy and has a strong oxidizing power. Many organic substances, ammonia, and NOx in contact with the surface It has the property of oxidatively decomposing etc.
Then, the photocatalytic function is maintained by the cycle of adsorption → photolysis → regeneration. 5) Activated carbon Activated carbon is a physical adsorbent for odorous gas like silica gel and zeolite. It preferentially adsorbs non-polar hydrocarbons and adsorbs saturated fatty acids and inorganic gases widely, but has low adsorbing power for low molecular weight and polar substances such as ammonia and hydrogen sulfide. In addition, a chemical treatment (also referred to as a secondary processing) of activated carbon can provide a deodorizing effect even on a substance having a low adsorption power. 6) Other fillers Any inorganic agent having a deodorizing effect and capable of being carried on the crimp yarn is not particularly limited, and examples thereof include Otani stone, which is frequently used as a freshness retaining agent.

As a method of supporting the filler (functional substance) of the inorganic agent on the crimp yarn, there are a master batch method, a coating method, and a powdering method. 1) Masterbatch method The masterbatch method is, for example, kneading by mixing and melting a polypropylene resin and a filler of an inorganic agent while heating between rolls at a temperature of 180 to 200 ° C, and uniformly dispersing the filler in the resin. Make things and batch (master batch)
This batch is extruded to form an extruded film, and a filler of an inorganic agent is supported. 2) Coating method Coating method is, for example, a method in which a filler of an inorganic agent is uniformly dispersed and supported on a surface of an extruded film obtained by extrusion molding a polypropylene material by roll coating or other coating methods, for example, stretching to an extruded polypropylene film. Or a method in which a filler of an inorganic agent is uniformly dispersed and supported on the surface of the processed stretched film by roll coating or other coating methods. In each case, a usual coating method can be applied. 3) Powdering method The powdering method is to move a long polymer film, for example, a polypropylene extruded film, charge the extruded film during the movement, and drop a filler (fine powder) of an inorganic agent from above. This is a method in which a filler is adhered and carried on the film of the charged portion while the film is charged. And, as the filler to be supported, titanium oxide which is a photocatalyst is optimal.

The size of the filler of the inorganic agent to be supported is, for example, kneading conditions in a masterbatch method to a polypropylene resin, a coating method to an extruded film, a coating method to a stretched film, a powdering method, or an air filter. When used as a functional material, the particle size of the filler is preferably 10 μm or less in consideration of the fact that the filler does not separate from the crimp yarn. Further, the filler of the inorganic agent may be used alone or in combination. As an example of the combination, by combining activated clay and calcium carbonate as a basic substance, furthermore, calcium hydroxide, a basic malodorous gas such as ammonia and an acidic malodorous gas such as hydrogen sulfide are simultaneously deodorized. I can do it.

[0018]

EXAMPLES Specific examples of the functional material for an air filter of the present invention will be described together with comparative examples. Example 1 Activated clay having an acidity of 30 m.e./g, a specific surface area of 250 m ² / g, and a particle size of 10 μm as an inorganic filler was added to 9000 g of a polypropylene resin (Sumitomo Chemical Industries, Ltd., trade name: Sumitomo Noblen H501). After kneading 1000 g of an activated clay fine powder (trade name, manufactured by Co., Ltd.), an extruded film having a thickness of 100 μm was prepared using an extruder at a temperature of 220 ° C. The formed extruded film was cut into a width of 2 cm, and then uniaxially stretched 6.3 times with a stretching machine to prepare a stretched film having a thickness of 43 μm. A high-speed rotary blade roll was brought into contact with the tape-shaped stretched film to make a large number of cuts and split the yarn to produce a split yarn. The temperature of this split yarn is 12
A crimp yarn was prepared by performing crimping in pressurized steam at 0 to 160 ° C.

Example 2 Zinc oxide having a particle size of 0.6 to 0.7 μm (manufactured by Shodo Chemical Co., Ltd., trade name: two kinds of zinc oxides) 1000 as an inorganic agent filler
A crimp yarn was prepared in the same manner as in Example 1 except that g was used.

Example 3 A 8000 g polypropylene resin, 1000 g of zinc oxide having a particle size of 0.6 to 0.7 μm (manufactured by Seido Chemical Co., Ltd., two types of zinc oxide) as an inorganic filler, and calcium carbonate having a particle size of 1.25 μm (Shiraishi Calcium Co., Ltd., trade name: Whiten SSB [red]) Except for using a mixture of 1000 g,
A crimp yarn was prepared in the same manner as in Example 1.

Example 4 An extruded film having a thickness of 100 μm was prepared using a polypropylene resin (Sumitomo Chemical Industries, Ltd., trade name: Sumitomo Noblen H501) as a raw material using an extruder at a temperature of 220 ° C. Acidity of 30m.e./
g, a specific surface area of 250 m ² / g and a particle size of 10 μm were activated clay (manufactured by Nippon Activated clay Co., Ltd., trade name: activated clay fine powder), and 5 g / m ^{2 was} supported on both surfaces of the extruded film by a coating method. Extruded film with activated clay supported on the surface
After being cut into cm, the film was uniaxially stretched by a stretching machine to prepare a stretched film having activated clay supported on both sides of a film having a thickness of 43 μm. A high-speed rotary blade roll was brought into contact with the tape-shaped stretched film to make a large number of cuts and split the yarn to produce a split yarn. The split yarn was crimped in pressurized steam at a temperature of 120 to 160 ° C. to produce a crimp yarn.

Example 5 Zinc oxide having a particle size of 0.6 to 0.7 μm (manufactured by Seido Chemical Co., Ltd., trade name: two types of zinc oxide) was used as an inorganic filler, and 5 g / m ^{2 was} supported on both surfaces of the extruded film. A crimp yarn was prepared in the same manner as in Example 4 except for the above.

Example 6 The same procedure as in the above Example was carried out except that the polypropylene resin was used in an amount of 8500 g, and calcium carbonate having a particle size of 1.25 μm (trade name: Whiten SSB [Red] manufactured by Shiraishi Calcium Co., Ltd.) was used as a filler for the inorganic agent. A crimp yarn was prepared in the same manner as in Example 1.

Example 7 Activated carbon having a particle size of 0.5 to 0.7 μm (trade name Ame-A activated carbon manufactured by Taihei Chemical Industry Co., Ltd.) as a filler for the inorganic agent 10
A crimped yarn was prepared in the same manner as in Example 1 except that 00 g was used.

Example 8 Activated clay with an acidity of 30 m.e./g, a specific surface area of 250 m ² / g and a particle size of 50 μm (produced by Japan Activated Shirato Co., Ltd., trade name: Powder) 1000g and calcium carbonate of particle size 1.25μm (trade name: Whiten SSB, manufactured by Shiraishi Calcium Co., Ltd.)
[Red]) Example 1 except that 1000 g of the mixture was used.
A crimp yarn was prepared in the same manner as in the above.

Example 9 Polypropylene resin was 8000 g, titanium oxide having a particle size of 0.007 μm (trade name: ST-01, manufactured by Ishihara Techno Co., Ltd.) was used as an inorganic filler, and calcium carbonate (Shiraishi Calcium Co., Ltd.) having a particle size of 1.25 μm was used. Crimp yarn was prepared in the same manner as in Example 1 except that a mixture of 1000 g (trade name: Whiten SSB [red]) was used.

Example 10 Activated clay having an acidity of 30 m.e./g, a specific surface area of 250 m ² / g and a particle size of 50 μm (manufactured by Nippon Activated Shirato Co., trade name: Powder) and a crimped yarn in the same manner as in Example 1 except that a mixture of 1000 g of zinc oxide having a particle size of 0.6 to 0.7 μm (manufactured by Seido Chemical Co., Ltd., trade name: two types of zinc oxide) was used. It was created.

Example 11 An extruded film of polypropylene having a thickness of 100 μm was moved, the extruded film was charged during the movement, and titanium oxide having a particle size of 0.007 μm (a product of Ishihara Techno Co., Ltd., While dropping the fine powder of name ST-01), 5
1010 g / m ^{2 were} deposited. The extruded film to which the filler was attached was cut into a width of 2 cm, and then uniaxially stretched by a stretching machine to form a stretched film having titanium oxide carried on both sides of a 43 μm-thick film. By making a large number of cuts and splitting by making a high-speed rotary blade roll contact this stretched film in the form of a tape,
Titanium oxide was activated by irradiating a black light having an ultraviolet intensity of 1.6 mW / cm ² for 60 minutes continuously to prepare a split yarn carrying titanium oxide which maintained a photocatalytic function.
The split yarn was crimped in pressurized steam at a temperature of 120 to 160 ° C. to produce a crimp yarn.

Comparative Example 1 An extruded film having a thickness of 100 μm was prepared using a polypropylene resin (Sumitomo Chemical Industries, Ltd., trade name: Sumitomo Noblen H501) as a raw material using an extruder at a temperature of 220 ° C. The formed extruded film was cut into a width of 2 cm, and then uniaxially stretched by a stretching machine to form a stretched film having a thickness of 43 μm. A high-speed rotary blade roll was brought into contact with the tape-shaped stretched film to make a large number of cuts and split the yarn to produce a split yarn. The temperature of this split yarn is 12
A crimp yarn was prepared by performing crimping in pressurized steam at 0 to 160 ° C.

Comparative Example 2 Zinc oxide having a particle size of 0.6 to 0.7 μm (manufactured by Shodo Chemical Co., Ltd., trade name) was used as an inorganic filler in 9000 g of a polypropylene resin (manufactured by Sumitomo Chemical Co., Ltd., trade name: Sumitomo Noblen H501). After kneading 1000g of zinc oxide (2 types), temperature
An extruded film having a thickness of 100 μm was prepared using an extruder at 220 ° C. After cutting the extruded film to a width of 2 cm,
The film was uniaxially stretched 6.3 times with a stretching machine to prepare a stretched film having a thickness of 43 μm. A high-speed rotary blade roll was brought into contact with the tape-shaped stretched film to make a large number of cuts and split the yarn to produce a split yarn.

Comparative Example 3 Activated clay having an acidity of 30 m.e./g, a specific surface area of 250 m ² / g and a particle size of 10 μm was used as an inorganic filler in 9000 g of a polypropylene resin (Sumitomo Chemical Industries, Ltd., trade name: Sumitomo Noblen H501). After kneading 1000 g of activated clay fine powder (trade name, manufactured by Nippon Activated Clay Co., Ltd.), an extruded film having a thickness of 100 μm was formed by an extruder at a temperature of 220 ° C. The formed extruded film was cut into a width of 2 cm, and then uniaxially stretched 6.3 times with a stretching machine to prepare a stretched film having a thickness of 43 μm. A high-speed rotary blade roll was brought into contact with the tape-shaped stretched film to make a large number of cuts and split the yarn to produce a split yarn.

Comparative Example 4 An extruded polypropylene film having a thickness of 100 μm was moved, the extruded film was charged during the movement, and titanium oxide having a particle size of 0.007 μm (a product of Ishihara Techno Co., Ltd., While dropping the fine powder of name ST-01), 5
1010 g / m ^{2 were} deposited. The extruded film to which the filler was attached was cut into a width of 2 cm, and then uniaxially stretched by a stretching machine to prepare a stretched film in which titanium oxide was supported on both surfaces of a 43 μm-thick film. By making a large number of cuts and splitting by making a high-speed rotary blade roll contact this stretched film in the form of a tape,
Titanium oxide was activated by irradiating a black light having an ultraviolet intensity of 1.6 mW / cm ² for 60 minutes continuously to prepare a split yarn carrying titanium oxide which maintained a photocatalytic function.

When the crimps of Examples 1 to 11 and Comparative Example 1 were observed under a microscope (magnification: 100 times), in each of Examples 1 to 11, a fine slit was formed in the stretched polypropylene film. Innumerable cracks were also formed on the surface of the polymer itself, and it was found that the filler of the inorganic agent was exposed in a fine particle state between the slits and the cracks. On the other hand, Comparative Example 1
In the case of, only the crimped yarn was formed.
Accordingly, it was confirmed that each of the examples (1 to 11) of the present invention reliably supported the filler of the inorganic agent on the crimp yarn.

In each of the above embodiments, polypropylene (PP) was used as the crimp yarn. However, the present invention is not limited to this. High density polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl alcohol, polyacrylonitrile, Any of thermoplastic resins such as polyvinylidene chloride, polyamide, polyester, and copolymers belonging to these series, cellulose and other derivatives, and any polymer having a crystalline thin film-forming property may be used.

Next, a deodorizing test was performed on each of the crimped yarns and split yarns of Examples 1 to 11 and Comparative Examples 1 to 4. A. Static deodorization test The above examples and comparative examples were subjected to a deodorization test under the following conditions with hydrogen sulfide, acetaldehyde and ammonia as target odors. In addition, a deodorizing test was also performed on a blank without an air filter material for comparison with the above-mentioned Examples and Comparative Examples. 1. Relationship test of relative deodorization effect of sample 1) Deodorization test 1-1 (target odor: hydrogen sulfide) In a glass cylinder with an internal volume of 6 liters, place paper (made by Toyo Roshi Kaisha Co., Ltd., trade name ADVATEC No.2) Size diameter 9c
m) A petri dish was placed, and 600 μl of an aqueous solution of hydrogen sulfide was dropped from above and absorbed on paper, and left for 30 minutes to fill the cylinder with hydrogen sulfide gas, which is an odorous component, followed by a deodorization test. After placing (suspending) 1 g of each of Example 2, Comparative Example 1, and Comparative Example 2 as a sample in a cylinder, the cylinder was measured using a detection tube (manufactured by Komei Rika Kogyo Co., Ltd., trade name: hydrogen sulfide SE type). The concentration of hydrogen sulfide in the inside was measured. The hydrogen sulfide concentration was measured at the time of sample setting, 15 minutes, 30 minutes, 1 hour, 2 hours, and 3 minutes after sample setting.
Went after hours. The measurement results are shown in Table 2 and FIG.
The hydrogen sulfide concentration was measured in the same manner as in the measurement of the hydrogen sulfide concentration of each sample without placing the sample in the cylinder, and the results are shown in Table 2 and FIG. 2 as blanks.

[0036]

[Table 2]

2) Deodorization test 1-2 (target odor: ammonia) In a glass cylinder having an inner volume of 6 liters, a paper cylinder (ADVATEC No.2, trade name, manufactured by Toyo Roshi Kaisha, Ltd., size 9c)
m), set a petri dish on it, and drop 600 μl of 0.28% aqueous ammonia solution (W / V) from above onto the paper to absorb it, and leave it for 30 minutes to fill the cylinder with ammonia gas as an odor component. After that, 1 g of each of Example 1, Comparative Example 1, and Comparative Example 3 was set (suspended) in a cylinder as a deodorizing test sample, and then a detector tube (manufactured by Komei Rika Kogyo Co., Ltd., model: ammonia SD type) Was used to measure the concentration of ammonia in the cylinder. The measurement of the ammonia concentration was performed at the time of sample setting, 15 minutes after sample setting, 30 minutes after
Performed after 1 hour, 2 hours and 3 hours. Table 3 shows the measurement results. Also, ammonia was measured in the same manner as in the measurement of the ammonia concentration of each sample without placing the sample in the cylinder, and the results are shown in Table 3 as blanks.

[0038]

[Table 3]

2) Deodorization test 1-3 (target odor: hydrogen sulfide) Sulfurization in the cylinder was performed in the same manner as in the deodorization test 1-1, except that Example 6 was used as an air filter material installed in the cylinder. The hydrogen concentration was measured. Table 4 shows the measurement results. The hydrogen sulfide concentration was measured in the same manner as in the measurement of the hydrogen sulfide concentration of each sample without placing the sample in the cylinder, and the results are shown in Table 4 as blanks.

[0040]

[Table 4]

4) Deodorizing Test 1-4 (Odor: Acetaldehyde) Example 11 was used as an air filter material to be installed in a cylinder, and instead of hydrogen sulfide, an acetaldehyde standard solution manufactured by Wako Pure Chemical Industries, Ltd. Acetaldehyde, 2-4 dinitrophenylhydrazine, ethyl acetate solution concentration 0.509 ± 0.010 μm / ml), and the above deodorization test 1- The acetaldehyde concentration in the cylinder was measured in the same manner as in 1. Table 5 shows the measurement results. Further, the acetaldehyde concentration was measured in the same manner as in the measurement of the acetaldehyde concentration of each sample without placing the sample in the cylinder, and the results are shown in Table 5 as blanks.

[0042]

[Table 5]

2. Test of relationship between sample amount and deodorizing effect 1) Deodorizing test 2-1 (target odor: ammonia) In a glass cylinder with an internal volume of 6 liters, place paper (made by Toyo Roshi Co., Ltd., trade name: ADVATEC No.2) Diameter 9c
m), set a petri dish on it, and drop 600 μl of 0.28% aqueous ammonia solution (W / V) from above onto the paper to absorb it, and leave it for 30 minutes to fill the cylinder with ammonia gas as an odor component. After that, 1 g, 10 g, and 50 g of Example 1 were placed (suspended) in a cylinder as a deodorization test sample, and then the cylinder was set up using a detection tube (manufactured by Komei Rika Kogyo Co., Ltd., model: ammonia SD type). The concentration of ammonia in the inside was measured. The measurement of the ammonia concentration was performed at the time of setting the sample, 15 minutes, 1 hour, 2 hours, and 3 hours after the sample was set. The measurement results are shown in Table 6 and FIG. Also, without placing the sample in the cylinder, the ammonia concentration was measured in the same manner as the ammonia concentration measurement of each sample, and the results are shown in Table 6 as blanks.

[0044]

[Table 6]

As apparent from Table 2 and FIG. 2, it was found that the crimp yarn was more effective than the split yarn and the crimp yarn. In addition, as is clear from Table 6 and FIG. 3, the deodorizing effect was quantitatively dependent.

B. Dynamic deodorization test The deodorization test 1-1, 1-2, 1-3, 1-4, 2-
1 was a static deodorization test in which the deodorization was performed in a cylinder. However, when used as a functional material for an air filter, a dynamic deodorization test was naturally required. went. 1) Deodorization test 3-1 (target odor: hydrogen sulfide) A pair of syringes (internal volume 200 ml) as shown in FIG.
A sample container (internal volume: 200 ml) 2 and an odor container (internal volume: 200 ml) 3 for filling the target odor are disposed between the sample containers (sample volume: 200 ml).
After filling Example 3 or Comparative Example 1 as a deodorizing test sample 5 and filling 0.1 ml of a solution obtained by diluting a hydrogen sulfide aqueous solution undiluted solution to 1/6 as a target odor 6 into an odor container 3, the syringe 1 , 1 reciprocates the piston 3 times, and a detection tube (not shown) (manufactured by Komei Chemical Co., Ltd., model: hydrogen sulfide SE type)
The hydrogen sulfide concentration was measured with. Table 7 shows the measurement results.

[0047]

[Table 7]

As is clear from Table 7, it was found that Example 3 was able to adsorb hydrogen sulfide gas, that is, deodorize more quickly than Comparative Example 1. 2) Deodorization test 3-2 (target gas: ammonia) Example 1 was used as a deodorization test sample to be filled in a glass container.
Alternatively, the above-mentioned deodorization test 3 was conducted using Comparative Example 1 except that ammonia gas having a concentration of 10 ppm was used as the target odor to be filled in the odor container, and the detection tube was made by Komei Chemical Industry Co., Ltd., Model: Ammonia SD type. The ammonia concentration was measured in the same manner as in Example 1. Table 8 shows the measurement results.

[0049]

[Table 8]

As is clear from Table 8, it was found that Example 1 was able to adsorb ammonia gas, that is, deodorize more quickly than Comparative Example 1. 3) Deodorization test 3-3 (target gas: hydrogen sulfide) Example 6 was used as a deodorization test sample to be filled in a glass container.
Alternatively, the concentration of hydrogen sulfide was measured in the same manner as in Deodorization Test 3-1 except that Comparative Example 1 was used. Table 9 shows the measurement results.
Shown in

[0051]

[Table 9]

As is clear from Table 9, it was found that Example 6 was able to adsorb hydrogen sulfide gas, that is, deodorize more quickly than Comparative Example 1. 4) Deodorization test 3-4 (target gas: acetaldehyde) Example 1 as a deodorization test sample filled in a glass container
Using acetaldehyde gas having a concentration of 10 ppm as a target odor to be filled in the odor container using 1 or Comparative Example 1,
The acetaldehyde concentration was measured by the same method as in the above deodorization test 3-1 except that a detector tube for acetaldehyde No. 92 manufactured by Gastech Co., Ltd. was used as the detector tube. Table 10 shows the measurement results.

[0053]

[Table 10]

As is clear from Table 10, it was found that Example 11 could adsorb acetaldehyde gas, that is, deodorize more quickly than Comparative Example 1.

5) Deodorization test 3-5 (target gas: ammonia) Example 1 was used as a deodorization test sample to be filled in a glass container.
Alternatively, the above-described deodorization test 3 was performed using Comparative Example 3 except that ammonia gas having a concentration of 10 ppm was used as a target odor to be filled in the odor container, and a detection tube manufactured by Komei Chemical Co., Ltd., Model: Ammonia SD type was used. The ammonia concentration was measured in the same manner as in Example 1. Table 11 shows the measurement results.

[0056]

[Table 11]

As is clear from Table 11, it was found that Example 1 was able to adsorb and deodorize ammonia gas more quickly than Comparative Example 3.

6) Deodorization test 3-6 (target gas: acetaldehyde) Example 1 was used as a deodorization test sample filled in a glass container.
Using acetaldehyde gas having a concentration of 10 ppm as a target odor to be filled in the odor container using 1 or Comparative Example 4,
The acetaldehyde concentration was measured by the same method as in the above deodorization test 3-1 except that a detector tube for acetaldehyde No. 92 manufactured by Gastech Co., Ltd. was used as the detector tube. Table 12 shows the measurement results.

[0059]

[Table 12]

As is clear from Table 12, it was found that Example 11 was able to adsorb acetaldehyde gas, that is, deodorize more quickly than Comparative Example 4. In addition, unlike conventional air filters made of glass fiber, they have excellent flexibility, so they have excellent workability according to the shape of the air filter, as well as the resistance to the passage of air passing through the air filter material, That is, the pressure loss is low, and thus the noise generation is low due to the low pressure loss.

[0061]

According to the functional material for an air filter of the present invention, since the filler of the inorganic agent is carried on the crimped yarn in an exposed state, the odorous gas and the like existing in the air are further compared with the split yarn. The harmful substance is easily brought into contact with the inorganic filler in an exposed state, and at the same time, the harmful substance is adsorbed by the inorganic filler and the odorous gas is easily deodorized. In other words, the crimp yarn has a structure in which cracks are increased on the surface of the polymer itself as compared with the split yarn of a polymer having stretchability, and the structure has a structure in which the exposure of the filler is further increased. This has the effect of further increasing the deodorizing speed. In addition, unlike conventional glass fiber air filters, it has excellent flexibility, so it has excellent workability according to the shape of the air filter and low pressure loss of air passing through the functional material for the air filter. . In addition, when the method for producing a functional material for an air filter according to the present invention is used, the crimp yarn is excellent in processability, has low resistance to air passage, and can easily deodorize odorous gas present in the air. Thus, there is an effect that the functional material for an air filter in which the filler is carried in an exposed state can be easily manufactured.

[Brief description of the drawings]

FIG. 1A is a characteristic diagram showing a relationship between activation conditions of montmorillonite and acidity or specific surface area. FIG. 1B is a characteristic diagram showing a relationship between acidity of activated clay and decolorizing ability.

FIG. 2 is a characteristic diagram showing a relationship between elapsed time and hydrogen sulfide concentration in Examples and Comparative Examples.

FIG. 3 is a characteristic diagram showing the relationship between the passage of time and the ammonia concentration in the sample amount.

FIG. 4 is an explanatory view showing an example of a test device for a dynamic deodorization test.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Syringe 2 Sample container 3 Odor container 4 Connecting pipe 5 Deodorization test sample 6 Target odor 10 Test device

Claims (9)

[Claims] 1. A functional material for an air filter, comprising a crimp yarn carrying a filler of an inorganic agent. 2. The crimp yarn according to claim 1, wherein the crimp yarn is a high-density polyethylene,
2. The functional material for an air filter according to claim 1, wherein the functional material is any one of polypropylene, polyvinyl chloride, polystyrene, polyvinyl alcohol, polyacrylonitrile, polyvinylidene chloride, polyamide, and polyester. 3. The filler of the inorganic agent is at least one of a solid acid such as activated clay, a neutral substance such as zinc oxide, a solid alkali such as calcium carbonate and aluminum hydroxide, a photocatalytic agent such as titanium oxide, and activated carbon. The functional material for an air filter according to claim 1 or 2, wherein: 4. The particle diameter of the filler of the inorganic agent is 10 μm.
m is equal to or less than m.
Item 6. The functional material for an air filter according to any one of Items 1 to 4. 5. An extruded polymer is formed by kneading a filler having an inorganic substance into a polymer having an extensibility, and then subjecting the extruded film to an extruded film to form an extruded film. A method for producing a functional material for an air filter, comprising: performing splitting treatment to form a split yarn, and then subjecting the split yarn to a heat treatment to form a crimp yarn of the polymer. 6. An extruded polymer film having an extensibility is loaded with an inorganic filler, and then the film is subjected to a stretching treatment to form a stretched film. The stretched film is subjected to a splitting treatment to produce a split yarn. And then subjecting the split yarn to a heat treatment to form a crimp yarn. 7. The stretchable polymer according to claim 1, wherein the polymer is one of high-density polyethylene, polypropylene, polyvinyl chloride, polystyrene, polyvinyl alcohol, polyacrylonitrile, polyvinylidene chloride, polyamide and polyester. Item 7. The method for producing a functional material for an air filter according to Item 5 or 6. 8. The filler of the inorganic agent is at least one of a solid acid such as activated clay, a neutral substance such as zinc oxide, a solid alkali such as calcium carbonate and aluminum hydroxide, a photocatalytic agent such as titanium oxide, and activated carbon. The method for producing a functional material for an air filter according to any one of claims 5 to 7, wherein: 9. The particle size of the filler of the inorganic agent is 10 μm.
m is not more than m.
The method for producing a functional material for an air filter according to any one of the above items.