CN107530607B - 过滤器及圆筒型过滤器 - Google Patents
过滤器及圆筒型过滤器 Download PDFInfo
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Abstract
本发明提供一种难以发生粉体的凝聚(桥接)、直至产生差压上升为止的时间长,即过滤寿命长的过滤器及圆筒型过滤器。本发明的过滤器包括基材层、过滤层、及表皮层,基材层是将无纺布卷缠多层且经热压接而成的层,过滤层是将至少层叠热风无纺布与网而成的层叠体卷缠多层且未经热压接的层,所述表皮层是含有无纺布的层,且构成所述基材层及所述表皮层的无纺布的平均细孔径大于构成所述过滤层的热风无纺布的平均细孔径。
Description
技术领域
本发明涉及一种用于对浆料、或含有固体成分的凝胶状流动体进行过滤的过滤器及圆筒型过滤器。
背景技术
一般而言,关于含有粉体微粒子的流体,当对固体成分浓度低、流动性高的流体进行精制过滤时使用过滤器。
作为过滤器性能的指标之一,有表示可使用过滤器的时间长度或累积流量的过滤寿命(filter life)。用于改善过滤寿命的尝试已知有:例如在包含无纺纤维集合体的过滤器内至少设置前过滤层与微滤层(microfiltration layer)这两层,前过滤层构成为构成纤维的纤维直径沿过滤方向变细,且微滤层包含无纺纤维集合体,所述无纺纤维集合体含有比前过滤层的最小纤维直径更细的纤维(专利文献1)。
然而,为了以纤维直径沿过滤方向变细的方式构成前过滤层,需要预先准备平均纤维直径沿长度方向变化的无纺纤维集合体。为了制造此种无纺纤维集合体,必须设定特殊的纺丝条件,故在成本方面不利,另外,可制造的无纺纤维集合体的最小纤维直径存在极限,故在微滤性的方面而言也未必充分。
另外,为了获得形态保持性良好、过滤器过滤精度与过滤寿命的平衡优异的高精度过滤器,提出有层叠至少两层无纺布,且将上层侧的无纺布的填充率设为0.3~0.8、将下层侧的无纺布的填充率设为0.01~0.25的过滤器用无纺布(专利文献2)。本发明是通过将填充率低的无纺布层配置于过滤器的下层侧,而在无纺布层与支撑材(support material)的接触面保持微小的空间,另外还使其作为缓冲材(cushion material)发挥作用,从而使过滤器的利用效率与形态保持性提升。
然而,所述文献中被视为对象的过滤物是以50ppm的浓度使0.6μm的氧化铝(alumina)粒子分散而成的水溶液,即,是对极小粒径且低浓度的液体进行过滤。
另一方面,近年来为了实现过滤后的干燥时间的缩短或挥发的液体的凝结量的减容化等,要求固体成分的高浓度化。
若固体成分为高浓度,则流体的流动性消失,作为固体成分的粉体彼此的相互作用增强。因此,当为现有的水用筒式过滤器(cartridge filter)时,已知有如下问题:即便是小于过滤器的平均孔径的粉体,也在粉体的粒子通过过滤器时发生拥堵(rush)现象而产生粉体的凝聚(桥接),从而表观粒径增大,进而引起过滤器的堵塞。
专利文献3提出如下过滤器:在粘性流体的过滤中,在解决过滤精度因差压而变化、过滤器寿命变短的问题的同时,即便产生脉压或高差压,也可捕捉柔软的凝胶状固体成分。专利文献3的发明在过滤器的主过滤层中具有进行压接处理而将空隙率设为50%~80%的第一主过滤层、及未进行压接处理而空隙率为80%以上的第二主过滤层,并且第二主过滤无纺布构成为空隙率是第一主过滤无纺布的1.2倍以上。
[现有技术文献]
[专利文献]
专利文献1:国际公开第98/13123号手册
专利文献2:日本专利特开2000-218113号公报
专利文献3:日本专利特开2010-137121号公报
发明内容
[发明要解决的问题]
如上所述,已对过滤器进行了各种改良,但进而要求能够过滤更高浓度的过滤物且过滤寿命长的过滤器。
即,本发明的课题在于提供一种难以发生粉体的凝聚(桥接)、直至产生差压上升为止的时间长,即过滤寿命长的过滤器。
[解决问题的技术手段]
发明人等人在研究含有过滤层用无纺布的层叠体的层构成的过程中,构思除了对从前已考虑的纤维直径或空隙率等过滤层用无纺布的构成进行控制外,还对过滤器的厚度方向(过滤物的通过方向)的构成进行控制。而且发现,通过使构成过滤器的过滤层用无纺布的厚度方向的纤维密度疏密有致,即在经层叠的无纺布间赋予适度的间隙,能够实现过滤物所含的粉体的分散,并且桥接的形成得以抑制。进而发现,可利用特定的构成制成恰当的过滤层,并且通过还对其他层的细孔径加以控制而可获得桥接的发生得到抑制,且过滤寿命长、分级性也优异的过滤器,从而完成本发明。
即本发明包括以下构成。
[1]一种过滤器,其包括基材层、过滤层、及表皮层,
所述基材层是将无纺布卷缠多层且经热压接而成的层,
所述过滤层是将至少层叠热风(through-air)无纺布与网而成的层叠体卷缠多层且未经热压接的层,
所述表皮层是含有无纺布的层,且
构成所述基材层及所述表皮层的无纺布的平均细孔径大于构成所述过滤层的热风无纺布的平均细孔径。
[2]根据所述[1]所记载的过滤器,其中在构成所述过滤层的层叠体中,除了所述热风无纺布与网以外,还层叠有熔喷无纺布(melt blown nonwoven fabric)。
[3]根据所述[1]或[2]所记载的过滤器,其中构成所述基材层的无纺布是在重叠10片时具有200cc/cm2/sec~300cc/cm2/sec的范围的透气度的熔喷无纺布或热风无纺布。
[4]根据所述[1]至[3]中任一项所记载的过滤器,其中构成所述过滤层的热风无纺布是具有0.1μm~200μm的范围的平均纤维直径的热风无纺布。
[5]根据所述[1]至[4]中任一项所记载的过滤器,其中所述网的网格尺寸是1mm~5mm的范围,且所述网具有50μm~300μm的范围的平均纤维直径。
[6]根据所述[1]至[5]中任一项所记载的过滤器,其中构成所述过滤层的热风无纺布的纤维彼此在所述热风无纺布中的纤维的交点处熔接和/或接着。
[7]一种圆筒型过滤器,其包括根据所述[1]至[6]中任一项所记载的过滤器。
[发明的效果]
根据本发明可提供一种即便对于高浓度且具有粘性的流体而言,也难以发生粉体的凝聚(桥接)、直至产生差压上升为止的时间长,即过滤寿命长的过滤器。
附图说明
图1是表示将本发明的实施例、及比较例的过滤器的过滤寿命加以比较而得的试验结果的图表。
图2是表示将本发明的实施例、及比较例的过滤器的初期捕集性能加以比较而得的试验结果的图表。
图3(a)及图3(b)是表示本发明的实施例(图3(b))、及比较例2(图3(a))的过滤器的剖面的照片。
[符号的说明]
1、2、5:过滤层
3:成形品芯
4:表皮层
6:基材层
具体实施方式
本发明的过滤器包括基材层、过滤层、及表皮层,所述基材层是将无纺布卷缠多层且经热压接而成的层,所述过滤层是将至少层叠热风无纺布与网而成的层叠体卷缠多层且未经热压接的层,所述表皮层是含有无纺布的层,且构成所述基材层及所述表皮层的无纺布的平均细孔径大于构成所述过滤层的热风无纺布的平均细孔径。
如上所述,本发明的过滤器的过滤层是将至少层叠热风无纺布与网而成的层叠体卷缠且未经热压接的层。热风无纺布具有蓬松、纤维取向还分布在无纺布的厚度方向(进行过滤的流体的流动方向)上的特征。因此,流体的压力损失得以降低,即便为高浓度且具有粘性的流体也可无滞留地进行过滤。另外,通过层叠热风无纺布与网,实质上在担负过滤功能的热风无纺布间形成适度的间隙。因此,流体或流体中的粉体在过滤层内的流动性提升,从而抑制桥接的形成,故而可获得过滤寿命长的过滤器。另外,通过在无纺布间具有间隙,无纺布的叠层所致的细孔的直径变小或闭塞得以避免,故捕集效率及过滤效率也优异。进而,通过不进行热压接,无纺布间的间隙得以保持,同时无纺布可在过滤层内略微地活动,流体或流体中的粉体的流动性进一步提升,并且利用网来保持过滤层的形态,故稳定地发挥过滤性能。
<过滤层用无纺布>
如上所述,过滤层是使用至少层叠热风无纺布与网而成的层叠体而形成。在本发明中,所谓热风无纺布是指通过热风接着工艺而获得的无纺布。所谓热风接着工艺是指用以通过以下方式而获得提高接着效果、在厚度方向上均匀的无纺布的方法,别名还称为热风(air through)方式,即,在烘箱中具备输送带或者滚筒(rotary drum),并且在使料片(web)通过后进而向一方向吸引。
一般而言,热风接着工艺具有如下等优点:1)可生产具有蓬松性的无纺布,2)可进行比较简单且均匀的温度控制,3)可进行收缩的控制。
利用所述优点,使卷缩的短纤维通过梳理机(carding machine)而制成料片,对所获得的料片进行热风处理,使短纤维彼此的交络点热熔接,从而获得热风无纺布。通过使用交络点经热熔接的无纺布,可将无纺布中的平均细孔径保持为一定,且可稳定地发挥本来所具有的过滤性能,故可维持作为过滤器的稳定的性能。
为了维持稳定的性能,作为构成热风无纺布的短纤维,优选为短纤维彼此在短纤维的交点处熔接和/或接着。因此,可优选地利用热熔接性复合纤维作为短纤维。热熔接性复合纤维的种类并无特别限定,可使用公知的复合纤维。作为热熔接性复合纤维,可使用包含具有熔点差的两种以上的成分的复合纤维,具体可例示包含高熔点成分与低熔点成分的复合纤维。作为复合纤维的高熔点成分,可例示聚丙烯(Polypropylene,PP)、聚对苯二甲酸乙二酯(Polyethylene terephthalate,PET)、聚对苯二甲酸丁二酯、聚对苯二甲酸丙二醇酯(Polytrimethylene terephthalate)、尼龙6、尼龙6,6、聚-L-乳酸等热塑性树脂;作为复合纤维的低熔点成分,可例示低密度聚乙烯、直链状低密度聚乙烯、高密度聚乙烯等聚乙烯(Polyethylene,PE),聚对苯二甲酸乙二酯共聚物、聚-DL-乳酸、丙烯共聚物、聚丙烯等热塑性树脂。热熔接性复合纤维的高熔点成分与低熔点成分的熔点差并无特别限定,但为了使热熔接的加工温度范围广,优选为15℃以上,更优选为30℃以上。另外,复合的形态并无特别限定,可采用同心鞘芯型、偏心鞘芯型、并列型、海岛型、放射状型等复合形态。尤其是为了具有蓬松性,适宜为偏心鞘芯型复合纤维。
另外,热熔接性复合纤维的剖面形状也无特别限定,例如可为圆、椭圆、三角、四边、U型、回力棒(boomerang)型、八叶型等异型,中空等任意的剖面形状。作为复合纤维,例如可列举PE/PP复合纤维、PE/PET复合纤维等。另外,根据过滤物的特性或目的,也可混纺氟系纤维或玻璃纤维等特殊纤维。
本发明所使用的热熔接性复合纤维可在不妨碍本发明的效果的范围内含有功能剂,作为功能剂可例示抗菌剂、除臭剂、抗静电剂、平滑剂、亲水剂、拨水剂、抗氧化剂、耐候剂等。另外,也可利用纤维整理剂(fiber finishing agent)对热熔接性复合纤维的表面进行处理,由此可赋予亲水性或拨水性、抗静电性、表面平滑性、耐磨耗性等功能。
构成过滤层用无纺布的纤维优选为0.1μm~200μm的范围的纤维直径,更优选为1μm~180μm的范围的纤维直径,最优选为15μm~160μm的范围的纤维直径。通过设为0.1μm~200μm的范围的纤维直径,所获得的过滤层用无纺布的蓬松性与缓冲性优异。若使用细纤维直径的纤维,则有捕集效率提升但过滤寿命(life)变短的倾向。因此,通过设为15μm~160μm的范围的纤维直径,过滤寿命与捕集效率的平衡变得特别良好。
过滤层用无纺布的平均细孔径必须调整为基材层用无纺布及网的平均细孔径,但可根据过滤液的性状或过滤的目的而适当选择,通常与以捕集为目的的粒径相应地来进行设计。例如,当以捕集为目的的粒径为50μm时,平均细孔径优选为40μm~60μm的范围,更优选为45μm~50μm。另外,一般而言,桥接形成极限视粉体粒径而定,但将以细孔径(De)与粒径(Dp)的关系成为De>5Dp的方式进行设计视为基准,而可基于所述指标来设定平均细孔径。根据所述式、或要使用过滤器进行去除的大粒径、可通过的小粒径等物性、及要求的捕集效率等来选择细孔径。
过滤层用无纺布的单位面积重量某种程度上由纤维的材质、纤维直径或与平均细孔径的关系来规定,例如可使用5g/m2~40g/m2者,更优选为10g/m2~30g/m2者。若单位面积重量为5g/m2~40g/m2,则用于调整过滤层的厚度与平均细孔径的选择范围广,因此优选。
<网>
插入至过滤层的网用于不会对过滤器的捕集效率造成影响地,在热风无纺布间形成间隙,并且对过滤层的形态加以保持进而维持·提升耐压。因此,网优选为使用纤维直径为50μm~300μm的范围的单丝(monofilament),更优选为使用纤维直径为60μm~280μm的范围的单丝。进而,网的网格尺寸优选为设为1mm~5mm的范围,更优选为设为1mm~4mm的范围。通过使用所述范围的网,不会对捕集效率造成影响,且过滤器的强度得以确保,故可获得过滤寿命更长的过滤器。
单丝优选为包含热塑性树脂,可利用单一构成纤维、复合纤维、混纤纤维。单丝可使用的热塑性树脂若为能够进行熔融纺丝的热塑性树脂,则并无特别限定,例如可使用如热熔接性复合纤维中例示那样的热塑性树脂,可使用单一的热塑性树脂,也可使用两种以上的热塑性树脂的混合物。当单丝为复合纤维时,例如可使用如热熔接性复合纤维中例示那样的热塑性树脂的组合。例如可列举PE、PP、PET、尼龙6、尼龙6,6、尼龙6,12等,特别优选为PP或尼龙。
<过滤层的构成>
过滤器的过滤层是将至少层叠所述过滤层用热风无纺布与网而成的层叠体卷缠多层而形成。热风无纺布与网的层叠顺序并无特别限制,优选为将热风无纺布与网各一片地、即以热风无纺布与网一层一层地交替的方式卷绕。如此形成的过滤层成为在热风无纺布间夹入网眼粗大的网的结构,热风无纺布层彼此不会密接地被层叠。
另外,过滤层层叠体未经热压接,从而热风无纺布的蓬松度得以保持。其中,所谓“未经热压接”是指并非为过滤层的整体通过热压接而一体地被硬化的形态,也可出于提高过滤器的形态保持性等目的而对过滤层的一部分进行热压接。另外,过滤层与基材层之间、或过滤层与表皮层之间也可熔接或接着。
另外,视需要也可除了热风无纺布与网以外,层叠进一步的无纺布或网等。例如,除了热风无纺布与网以外,插入网眼比热风无纺布粗大的熔喷无纺布,且对三层结构的层叠体进行卷缠,从而可提升过滤层的保形性或捕集效率。当使用熔喷无纺布时,可优选地使用与基材层或表皮层使用的熔喷无纺布相同的熔喷无纺布。
根据对数透视法则由流体所通过的过滤层的厚度来控制捕集效率是公知的,且过滤层的厚度(层叠体的卷绕数)可根据所要求的捕集效率而适当选择。过滤层的厚度(层叠体的卷绕数)越大,捕集效率越提升,越可捕集粒径小的粉体。
<基材层用无纺布>
本发明使用的基材层用无纺布若在重叠10片时具有200cc/cm2/sec~300cc/cm2/sec的范围的透气度,则可为熔喷无纺布或热风无纺布的任一者。透气度为所述范围的无纺布在低压损的方面而言优选。
当使用熔喷无纺布时,构成熔喷无纺布的极细纤维的种类、或其制造方法并无特别限定,可使用公知的极细纤维或制造方法。例如,可通过如下方式来制造熔喷无纺布:将热塑性树脂熔融挤出,并从熔喷纺丝喷嘴纺出,进而利用高温高速的气体以极细纤维束的形式进行吹纺丝(blow spinning),并利用捕集装置以料片的形式捕集极细纤维,对所获得的料片进行热处理,从而使极细纤维彼此热熔接。熔喷纺丝中使用的高温高速的气体通常使用空气、氮气等惰性气体。一般而言,在气体温度为200℃~500℃、压力为0.1kgf/cm2~6.5kgf/cm2的范围内使用。
当将熔喷无纺布用于基材层用无纺布时,熔喷无纺布的平均纤维直径优选为1μm~100μm,更优选为6μm~60μm,最优选为8μm~30μm。若熔喷无纺布的平均纤维直径为1μm以上,则生产性良好,且构成熔喷无纺布的极细纤维的力学强度高,从而难以产生极细纤维的单丝断开或极细纤维层的破裂。另外,若构成熔喷无纺布的极细纤维的平均纤维直径为100μm以下,则得自纤维直径的狭小度(细度)的极细纤维的本来特性得以充分发挥。
另外,熔喷无纺布可利用包含单一构成纤维的熔喷无纺布、包含复合纤维的熔喷无纺布、包含混纤纤维的熔喷无纺布等。另外,所述熔喷无纺布可使用的树脂若为能够进行熔融纺丝的热塑性树脂,则并无特别限定,例如可使用如热熔接性复合纤维中例示那样的热塑性树脂,可使用单一的热塑性树脂,也可使用两种以上的热塑性树脂的混合物。进而,热塑性树脂也可在不妨碍本发明的效果的范围内含有各种功能剂,具体可例示抗菌剂、除臭剂、亲水化剂、拨水化剂、表面活性剂等。另外,为了赋予功能,也可在不妨碍熔喷无纺布的效果的范围内对熔喷无纺布实施二次加工,可例示亲水化或拨水化的涂布处理、在构成熔喷无纺布的极细纤维的表面导入特定的官能基的化学处理、灭菌处理等。
作为基材层用无纺布使用的树脂,例如可列举PE、PP、PET、尼龙6、尼龙6,6、尼龙6,12等。另外,当基材层用无纺布使用热风无纺布时,可利用过滤层用无纺布中例示的一般的热风无纺布。
基材层用无纺布的平均细孔径能够根据过滤液的性状或过滤的目的而适当选择,但使用平均细孔径大于过滤层用的热风无纺布的平均细孔径的基材层用无纺布。通常优选为设为90μm~130μm的范围,特别优选为设为100μm~120μm的范围。基材层用无纺布的单位面积重量某种程度上由纤维的材质、纤维直径或与平均细孔径的关系来规定,例如可使用5g/m2~50g/m2的单位面积重量,更优选为使用30g/m2~45g/m2的单位面积重量。若为所述范围的单位面积重量,则就过滤器的外径调整及基材层的强度设计的调节的观点而言适宜。
基材层是主要用于确保过滤器的强度的层,且优选为层叠有熔喷无纺布并通过热压接而经一体化的层。基材层的厚度或卷绕数是根据所使用的熔喷无纺布而恰当地设定,但若可确保过滤器的强度且可获得一定的过滤性能,则并无特别限制。
<表皮层>
表皮层是位于过滤器的最外侧(过滤液的上游侧)的层,并且是除尤其阻挡大粒径的凝聚物或夹杂物以使它们不会侵入至过滤层内外,以保护过滤层且保持过滤器形态为主要目的的层。
表皮层是包含无纺布的层,优选为包含无纺布的层。表皮层使用的无纺布并无特别限制,但优选为平均细孔径比过滤层用无纺布的平均细孔径大(粗大)的无纺布。
无纺布的材质也无特别限制,例如优选为使用与基材层使用的无纺布同样的熔喷无纺布。
表皮层的卷绕数或厚度并无特别限制,但若卷绕数或厚度变大,则产生过滤液在到达过滤层以前在表皮层内形成桥接的不良情况,因此优选为设为尽可能薄的表皮层。例如优选为将熔喷无纺布卷缠1圈~5圈、优选为1圈~2圈并进行热压接来形成表皮层。
<过滤器的制造方法>
本发明的过滤器可通过一边依序层叠基材层用无纺布、过滤层用无纺布及网一边进行卷缠来制造。具体而言,例如首先,一边对作为基材层用无纺布的熔喷无纺布进行热压接一边将其卷起至圆柱状的铁棒,从而形成作为芯(core)的基材层。继而,依序插入作为过滤层用无纺布的热风无纺布及网,并且不进行加热地进行卷起,从而形成过滤层。最后,将熔喷无纺布卷缠1圈~2圈并进行热压接而形成表皮层。
在所述方法中,形成基材层的温度只要是在卷取部分(圆柱状的铁棒)熔融基材层用无纺布且将基材层用无纺布压接的温度即可。另外,生产线的速度并无特别限制,但在过滤层的形成时,施加至无纺布的张力(tension)优选为10N以下,优选为不施加张力地进行卷起。
可将如所述那样制造的过滤器切断为适当的大小并且在两端贴附端帽(end cap)而适宜地用作圆筒型过滤器。
另外,所述制造方法仅为概略,除了所述步骤以外,可视需要实施热处理、冷却、药剂处理、成型、清洗等公知的步骤。
实施例
以下,利用实施例对本发明更详细地进行说明,但本发明并不受这些实施例的限制。
实施例中示出的物性值的测定方法或定义如下所述。
1)平均细孔径的测定方法
平均细孔径是基于鼓泡点(bubble point)法(美国试验材料协会(AmericanSociety for Testing Material,ASTM)F316-86)并利用PMI公司制造的波尔母孔率仪(Perm Porometer)CFP-1200-A来进行测定。
2)单位面积重量的测定方法
测定切断为250mm×250mm的无纺布的重量,求出每单位面积的重量(g/m2),将其设为单位面积重量。
3)透气度的测定方法
使用日本工业标准(Japanese Industrial Standards,JIS)L 1096中记载的弗雷泽型(Frazier type)试验机来进行测定。
[实施例]
(材料)
作为基材层用无纺布,使用单位面积重量为42g/m2、重叠10片时的透气度为280cc/cm2/sec的聚丙烯熔喷无纺布。
作为过滤层用无纺布,使用包含聚丙烯/聚乙烯的偏心鞘芯型复合纤维(平均纤维直径31μm)的单位面积重量为30g/m2且平均细孔径为46μm(重叠4片)的热风无纺布。
作为网,使用包含聚丙烯单丝(平均纤维直径为250μm)的网格尺寸为2.0mm的网。
(过滤器的制造方法)
将中芯(铁棒)预先加热至215℃,并且使基材层中使用的熔喷无纺布接着于所述中芯而进行卷取。此时,将卷取加热器(最靠近卷取部的加热器)的输出功率设定为约7.8kW左右来进行加热。
基材层使用的熔喷无纺布的总长为8.6m,并且对其中作为基材层的约5.6m的熔喷无纺布一边利用加热器以输出功率7.8kW进行加热并使其热熔接,一边进行卷取,从而制成基材层。
卷取5.6m的熔喷无纺布后,继而,开始插入构成过滤层的热风无纺布与网。将插入长度设为2m并与熔喷无纺布一同进行卷取。此时,对于最初的1m,通过利用加热器以输出功率7.8kW进行加热而使其热熔接,对于剩余的1m,将加热器输出功率设为0kW并不进行加热且不使其热熔接地进行卷取,从而构成过滤层。继而,将加热器的输出功率设为7.8kW来进行加热,并且一边使熔喷无纺布热熔接一边卷取1m来作为表皮层,从而制造圆筒型过滤器。
将实施例的过滤器的剖面照片示于图3(b)。在图3(b)中,示出有熔喷无纺布的表皮层4、热风无纺布/网的过滤层5、经热熔接的熔喷无纺布的基材层6。
[比较例1]
一边对过滤层用热风无纺布进行热压接一边进行卷缠,除此以外,与实施例同样地制造圆筒型过滤器。
[比较例2](相当于现有品)
将作为基材的熔喷无纺布及网卷取至通过射出成形等成形的成形品芯(外径36mm、厚度3mm、长度254mm的聚丙烯制多孔圆筒),在制造中途,插入单位面积重量小于基材的熔喷无纺布的熔喷无纺布。其后,仅卷取基材的熔喷无纺布。不进行热压接。
将比较例2的过滤器的剖面照片示于图3(a)。在图3(a)中,示出有熔喷无纺布的过滤层1、对熔喷无纺布/网插入熔喷无纺布而成的过滤层2、成形品芯3。
[性能试验]
1.过滤寿命
关于实施例及比较例1、比较例2的圆筒型过滤器,依照下述的粉体及方法,测定相对于累积粉体添加量的过滤器前后的差压变化。
试验粉体使用JIS Z 8901试验用粉体中记载的七种粉体。
使以速度0.3g/min在循环水量为30L/min的水中添加所述试验粉体而成的试验流体流经过滤器,追踪相对于累积粉体添加量的过滤器前后的压力差变化(参考文献:《针对用户的过滤器指导手册》日本液体清澄化技术工业会)。
将结果示于图1。
如图1所示,实施例的过滤器的直至引起差压上升为止的累积粉体添加量显著多于比较例1、比较例2。因以一定流量添加粉体,故所述情况表示直至引起差压上升为止的时间长,即实施例的过滤器的过滤寿命长于比较例1、比较例2的过滤器。认为,实施例的过滤器使用蓬松的热风无纺布且不进行热压接而在无纺布间保持适度的间隙,由此桥接的形成得到抑制,从而过滤寿命优异。
2.捕集效率
关于实施例及比较例2的圆筒型过滤器,依照下述的试验粉体及方法,测定作为初期捕集性能的捕集效率。
试验粉体使用JIS Z 8901试验用粉体中记载的七种粉体。
使以速度0.3g/min在水中添加JIS七种粉体而成的试验流体以30L/min的流量通过过滤器,测定过滤器前后的粒子数(参考文献《针对用户的过滤器指导手册》日本液体清澄化技术工业会)。
粒子数是使用粒子传感器(particle sensor)(KS-63理音(RION)制造)并且使用粒子计数器(particle counter)(KL-11理音制造)来进行测定。
捕集效率根据以下定义式来求出。
将结果示于图2。
如图2所示,实施例的过滤器捕集90%以上的50μm以上的粒子且使大致半数的30μm的粒子通过。另一方面,比较例2的过滤器虽捕集90%以上的50μm以上的粒子,但还捕集70%的30μm的粒子。结果,与比较例2的过滤器相比,实施例的过滤器能够捕集应去除的大粒子,另一方面还能够使应通过的小粒子确实地通过,即示出优异的分级性。
[产业上的可利用性]
本发明的过滤器抑制粉体的凝聚(桥接)的发生,故过滤寿命长,分级性还优异。本发明的过滤器可适宜地用作用于自含有低浓度~高浓度(10ppm~70%)的微粒子(粉体)的悬浮液、浆料、凝胶状流体去除凝聚物或夹杂物而获得粒径为一定以下的微粒子的过滤器。
Claims (7)
1.一种过滤器,其包括基材层、过滤层、及表皮层,
所述基材层是将无纺布卷缠多层且经热压接而成的层,
所述过滤层是将至少层叠热风无纺布与网而成的层叠体卷缠多层且未经热压接的层,其中所述网的网格尺寸是2mm~5mm的范围,
所述表皮层是含有无纺布的层,且
构成所述基材层及所述表皮层的无纺布的平均细孔径大于构成所述过滤层的热风无纺布的平均细孔径。
2.根据权利要求1所述的过滤器,其中在构成所述过滤层的层叠体中,除了所述热风无纺布与网以外,还层叠有熔喷无纺布。
3.根据权利要求1或2所述的过滤器,其中构成所述基材层的无纺布是在重叠10片时具有200cc/cm2/sec~300cc/cm2/sec的范围的透气度的熔喷无纺布或热风无纺布。
4.根据权利要求1或2所述的过滤器,其中构成所述过滤层的热风无纺布是具有0.1μm~200μm的范围的平均纤维直径的热风无纺布。
5.根据权利要求1或2所述的过滤器,其中所述网具有50μm~300μm的范围的平均纤维直径。
6.根据权利要求1或2所述的过滤器,其中构成所述过滤层的热风无纺布的纤维彼此在所述热风无纺布中的纤维的交点处熔接和/或接着。
7.一种圆筒型过滤器,其包括根据权利要求1至6中任一项所述的过滤器。
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CN1167002A (zh) * | 1996-06-03 | 1997-12-10 | 陆洪章 | 混合纤维的流体滤清器滤芯及其制造方法 |
JP2001321620A (ja) * | 2000-05-17 | 2001-11-20 | Japan Vilene Co Ltd | 筒状フィルタ |
JP2001327815A (ja) * | 2000-05-19 | 2001-11-27 | Japan Vilene Co Ltd | 筒状フィルタ |
CN101674872A (zh) * | 2007-05-28 | 2010-03-17 | 花王株式会社 | 通风扇或抽油烟机用防污过滤器 |
CN102753245A (zh) * | 2010-02-02 | 2012-10-24 | 喜开理株式会社 | 滤芯、过滤装置以及滤芯的制造方法 |
CN104107587A (zh) * | 2013-04-19 | 2014-10-22 | 李青瑛 | 一种滤芯及其制造方法 |
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TWI685370B (zh) | 2020-02-21 |
US10765978B2 (en) | 2020-09-08 |
EP3296006A1 (en) | 2018-03-21 |
KR102458282B1 (ko) | 2022-10-24 |
TW201639621A (zh) | 2016-11-16 |
PL3296006T3 (pl) | 2020-05-18 |
CN107530607A (zh) | 2018-01-02 |
EP3296006A4 (en) | 2019-01-09 |
KR20180008468A (ko) | 2018-01-24 |
EP3296006B1 (en) | 2019-11-13 |
WO2016185517A1 (ja) | 2016-11-24 |
US20180085692A1 (en) | 2018-03-29 |
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