CN109982765A - 过滤器滤材、具有该过滤器滤材的过滤器元件以及过滤器滤材的制造方法 - Google Patents

过滤器滤材、具有该过滤器滤材的过滤器元件以及过滤器滤材的制造方法 Download PDF

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Publication number
CN109982765A
CN109982765A CN201780072333.7A CN201780072333A CN109982765A CN 109982765 A CN109982765 A CN 109982765A CN 201780072333 A CN201780072333 A CN 201780072333A CN 109982765 A CN109982765 A CN 109982765A
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China
Prior art keywords
filter
filtration material
filter filtration
gas permeability
permeability substrate
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CN201780072333.7A
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English (en)
Inventor
菅野友章
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Feiler Co Ltd
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Feiler Co Ltd
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Abstract

提供一种即使在进行压褶加工的过滤器滤材的吸附材料填充量大的情况下，也能够实现对压褶加工的斥力小，且透气透水阻力及过滤器性能优异，压力损失低的过滤器滤材、具有该过滤器滤材的过滤器元件以及过滤器滤材的制造方法。本发明的过滤器滤材在透气性基材之间安装有吸附层，且在至少一片所述透气性基材的内表面侧具有折痕。

Description

过滤器滤材、具有该过滤器滤材的过滤器元件以及过滤器滤 材的制造方法
技术领域
本发明涉及一种具有吸附层的过滤器滤材、具有该过滤器滤材的过滤器元件以及过滤器滤材的制造方法。
背景技术
大气中的污染物质种类繁多，其包括硫化氢、氨、醛、乙酸等极性气体以及苯、甲苯、苯乙烯等弱极性气体。
近年来，在空气调节用、空气调节器用、汽车用、半导体用的过滤器等领域，作为用于去除大气中的这些污染物质的除臭剂，普遍使用活性炭、硅胶、离子交换树脂这些多孔质材料。在住宅屋内为了除尘、去除有害气体等，会设置收纳有空气调节过滤器的空气净化器，在建筑物或楼房等的户外空气引入口，安装空气调节过滤器以引入洁净的空气。
这些设备中所使用的空气调节过滤器包括：过滤器滤材，通过对长条状的无纺布实施形成为褶形状的折叠加工(压褶加工)从而折叠成锯齿状而成；空间维持构件(夹在滤材间的波浪形状铝隔板或由粘接剂形成的条状加强筋)，夹在过滤器滤材的内折空间中；以及过滤器框(框体)，利用合成树脂密封材料将该滤材安装到内表面(例如，参照专利文献1。)。
作为在这样的空气调节过滤器中使用的具有吸附性能的过滤器滤材，目前已提出有：在两片基材片之间夹入活性炭从而形成活性炭片的方法(例如，参照专利文献2以及3)；或将吸附被吸附物的粒状吸附材料固定并保持在网状物或无纺布这样的中间基材上，再在其两面叠放除尘用的无纺布并接合成一体的构件(例如，参照专利文献4)；或利用粘结剂使除臭剂和除尘材料形成期望的形状的过滤器(例如，参照专利文献5)。作为吸附材料的固定方法，公知有使用乳剂类粘接剂的方法或使用热熔型粘合剂的方法。
然而，在具有经过压褶加工的过滤器滤材的过滤器单元或滤芯式过滤器(Cartridge filter)等过滤器元件中，为了高性能地除臭，需要增加吸附材料填充量(单位面积的吸附材料的重量)。但是，若增加吸附材料填充量，会使压力损失上升，且过滤器滤材的厚度的增加会使过滤器滤材的压褶加工变得困难。其结果是会存在如下的问题：折叠的过滤器滤材的斥力变大从而使装入框体的折数减少，或折叠的折的顶点变圆从而使过滤器单元以及滤芯式过滤器的结构压损变高。
在片状滤材的压褶加工中，还提出有交替压痕的方法(例如，参照专利文献6)。然而，若吸附材料填充量高，则会存在滤材的刚性变高，在压褶加工时产生裂纹的问题。
另外，过滤器滤材还可以用于水处理用的滤芯式过滤器。滤芯式过滤器被用于各种各样的领域，其中，被用于制药工业领域、电子工业领域等领域中所使用的纯净水的水过滤、食品工业领域中的酒精饮料的制造工序中的过滤以及汽车工业中的涂装剂的过滤等。
但是，对于残留氯的去除、有机物的去除等溶于水中的离子性杂质的去除与微粒子的去除、细菌的去除等粒子状杂质的去除，分开使用的情况较多。
使用吸附材料的滤芯式过滤器被用于使用以自来水为原水的净水器，或被用于食品工业、半导体工业等中的纯水或高纯水的制造工序等中的水中残留氯的去除、有机物的去除等，褶式过滤体能够使滤芯内的过滤面积增大。
即使在滤芯式过滤器中，为了兼具高性能地除臭及去除粒子状杂质的功能，也需要增加吸附材料填充量。但是，若使吸附材料填充量增加，则会因滤材的厚度增加而使滤材的压褶加工变得困难，并使折叠的滤材的斥力变大。因此会存在装入规定框内的折数减少，折叠的折的顶点变圆，从而使结构压损变高的问题。
现有技术文献
专利文献
专利文献1：日本特开2002-361016号公报
专利文献2：日本特开昭61-119269号公报
专利文献3：日本特开2004-50151号公报
专利文献4：日本特开2002-17832号公报
专利文献5：日本特开平8-117524号公报
专利文献6：日本特开2003-265910号公报
发明内容
发明要解决的问题
本发明是考虑了上述情况而提出的，其目的在于，提供一种即使在进行压褶加工的过滤器滤材的吸附材料填充量大的情况下，也能够实现对压褶加工的斥力小，且透气透水阻力及过滤器性能优异，压力损失低的过滤器滤材、具有该过滤器滤材的过滤器元件以及过滤器滤材的制造方法。
用于解决问题的手段
本发明的过滤器滤材为了解决上述问题，如权利要求1所述那样，提供一种过滤器滤材，在透气性基材之间安装有吸附层，其中，在至少一片所述透气性基材的内表面侧具有折痕。
另外，根据权利要求2所述的过滤器滤材，在权利要求1所述的过滤器滤材中，所述吸附层是通过热粘接剂将吸附材料粘接固化而成。
另外，根据权利要求3所述的过滤器滤材，在权利要求1或2所述的过滤器滤材中，所述吸附层的两面与所述透气性基材粘接成一体。
另外，根据权利要求4所述的过滤器滤材，在权利要求1～3中任一项所述的过滤器滤材中，所述吸附层设置有多层。
另外，根据权利要求5所述的过滤器滤材，在权利要求1～4中任一项所述的过滤器滤材中，所述透气性基材中的至少一片透气性基材具有集尘功能。
另外，本发明的过滤器元件如权利要求6所述那样，具有权利要求1～5中任一项所述的过滤器滤材。
另外，根据权利要求7所述的过滤器元件，在权利要求6所述的过滤器元件中，在折叠的所述过滤器滤材的内折空间内夹有空间维持构件。
另外，根据权利要求8所述的过滤器元件，在权利要求6所述的过滤器元件中，对折叠后的所述过滤器滤材实施波形加工。
本发明的过滤器滤材的制造方法如权利要求9所述那样，包括：在第一透气性基材的表面散布并堆积吸附材料和热粘接剂来形成吸附层的工序；从所述吸附层的上方沿所述第一透气性基材的宽度方向进行压痕的工序；用第二透气性基材以夹持所述吸附材料的方式覆盖所述第一透气性基材的工序；以及对层叠的所述第一透气性基材及第二透气性基材进行热压从而使所述热粘接剂硬化的工序。
发明效果
在本发明的过滤器滤材、过滤器元件以及过滤器滤材的制造方法中，即使在进行压褶加工的过滤器滤材的吸附材料填充量大的情况下，也能够实现对压褶加工的斥力小，且透气透水阻力以及过滤器性能优异，压力损失低的效果。
附图说明
图1是示出本实施方式的过滤器滤材的制造工序的说明图。
具体实施方式
对本发明的过滤器滤材、具有该过滤器滤材的过滤器元件以及过滤器滤材的制造方法的实施方式进行说明。
过滤器滤材是通过在透气性基材之间安装吸附层而形成。另外，过滤器滤材在至少一片透气性基材的内表面侧具有折痕。
吸附层是吸附材料通过热粘接剂粘接固化后而形成的层，吸附层的一面或两面与透气性基材粘接成一体。吸附层也可以设置有多个，这种情况下的过滤器滤材具有所需数量的用于夹持吸附层的透气性基材。例如，可以通过对两片在一对透气性基材间安装吸附层而形成的过滤器滤材进行层叠来设置多个吸附层。另外，也可以通过将吸附层和透气性基材交替地夹在一对透气性基材间来设置多个吸附层。
也可以使至少一片透气性基材具有集尘功能。
过滤器元件具有上述过滤器滤材，例如是通过将折叠成锯齿状从而折叠加工成褶形状的(进行压褶加工后的)过滤器滤材收纳到框体内而构成的过滤器单元，或者是通过使上述过滤器滤材以圆形方式卷绕在芯筒上而构成的滤芯式过滤器。
在过滤器元件的过滤器滤材中，可以在折叠后的内折空间中夹入空间维持构件。设置空间维持构件是为了确保过滤器滤材的有效过滤面积。作为空间维持构件，例如是形成为波浪形的铝或树脂制成的隔板或梳齿状的稳定件(Stabilizer)，或者是以与褶(折痕方向)垂直的方式附着在过滤器滤材背侧表面的树脂条状加强筋等。
或者，过滤器元件的过滤器滤材不使用空间维持构件，可以对经过压痕后的滤材进行波形加工使其形成波浪状。在这种情况下，由于未使用空间维持构件，可以以低价格制造过滤器，并且由于滤材被加工成波浪状，装入框体中的滤材增加，从而能够得到高寿命、低压损的过滤器。波形加工一般是使滤材通过一对齿轮之间从而使其形成波浪状，该波浪状的高度能够由所使用的齿轮的模块来控制，包括正齿轮或斜齿轮等。
作为透气性基材，例如可列举纸、织布、无纺布等，从经济性的观点考虑优选无纺布。
无纺布可以使用聚酰胺类纤维、聚酯类纤维、聚氨酯类纤维、聚乙烯醇类纤维、聚偏二氯乙烯类纤维、聚氯乙烯类纤维、聚丙烯腈类纤维、聚烯烃类纤维、酚类纤维等合成纤维、玻璃纤维、金属纤维、氧化铝纤维、活性炭纤维等无机纤维、木浆、棉绒浆等天然纤维以及再生纤维等。
所述无纺布的制造方法没有特别的限制，可以根据目的、用途来选用干法、湿法、熔喷法、纺粘法、针刺法以及热结合法等。
作为形成吸附层的吸附材料，可以使用粉末或粒状吸附材料。作为这样的粉末或粒状吸附材料，优选离子交换树脂、粒状活性炭、硅胶、活性氧化铝以及催化剂颗粒。作为催化分解有机物等的催化剂颗粒，例如可列举铁、锰、铜、铝、镁、锌、镍、钴、白金、钌、铑等金属单质、这些单质的金属氧化物或金属氯化物、氧化钛以及酞菁等。这些粉末或粒状吸附材料可以单独使用，也可以两种以上同时使用。
另外，粉末或粒状吸附材料也可以是例如浸渍活性炭等使化学除臭剂附着在上述粉末或粒状吸附材料的表面而形成的吸附材料。作为浸渍活性炭上附着的针对醛类气体或NOx、SOx、乙酸等酸性气体的化学吸附材料，可列举碳酸钾、碳酸氢钾、碳酸钠、碳酸氢钠等碱金属碳酸盐，氢氧化钠、氢氧化钾等碱金属氢氧化物，乙醇胺、己二胺、甲胺、哌嗪、苯胺、p-茴香胺、对氨基苯磺酸、氨基苯甲酸等氨基化合物及其盐类，聚乙烯亚胺、二乙醇胺等亚胺或亚胺化合物及其盐类，胍类化合物及其盐类，L-精氨酸，甲胺盐酸盐类，盐酸氨基脲类，肼，硫酸羟胺，以及高锰酸盐等。另外，作为针对氨、胺类、吡啶等碱性气体的化学吸附材料，例如可列举盐酸、硫酸、硝酸、苹果酸、柠檬酸、抗坏血酸等有机酸以及无机酸等。此外，也可以使这些化学吸附材料含浸到透气性基材中，或使用预先含浸有这些化学吸附材料的透气性基材。
所述粉末或粒状吸附材料的平均粒径优选在4～200目程度的范围内。这是因为粉末或粒状吸附材料的平均粒径过大会使过滤器变厚从而使压褶加工变困难，平均粒径过小会使压力损失变高。
作为热粘接剂，可以使用热熔树脂。热熔树脂的使用量优选为所使用的粉末或粒状吸附材料的重量的10～50％，更优选为20～40％。当少于10％时，粘接会不充分从而粉末或粒状吸附材料不能固定在无纺布等透气性基材上，容易从透气性基材上脱落，进而使过滤器滤材的褶形状变形。另一方面，当多于50％时，热熔树脂会覆盖粉末或粒状吸附材料表面的大部分从而损害除臭性能等，并且，存在吸附层变得过硬从而使压褶加工时的加工性变差，或熔融时热熔树脂被透气性基材吸收从而损害透气性基材的透气性，或外观呈斑点状这些方面的担忧。
优选热熔树脂的平均粒径为10～400目。这是因为当热熔树脂的平均粒径大于10目时不能获得充分的粘接力，小于400目时会增加透气阻力。
由于需要赋予透气性基材或吸附材料抗菌性、抗霉性、抗病毒性、阻燃性以及其他功能，所以可以预先在透气性基材自身或热熔树脂中混入或混合抗菌剤、抗病毒剂、阻燃剂、功能性药剂等药剂。另外，可以用不会损害其原本的性能的方法以及量来使这些药剂粘附或固定在粉末或粒状吸附材料上，也可以通过涂敷等使这些药剂附着在透气性基材上。
也可以赋予透气性基材上述以外的功能性，例如驻极体性质。驻极体性质在空气过滤器滤材中用于捕捉细菌或花粉等微米大小的粉尘，可以使用驻极体熔喷无纺布。对于用于赋予驻极体性质的驻极体加工的方法没有特别限定，例如将电晕放电法、摩擦带电法这样的公知的方法应用于熔喷无纺布片即可。作为熔喷无纺布，为了获得更好的捕捉性能，优选使用聚丙烯、聚乙烯、聚苯乙烯、聚对苯二甲酸丁二醇酯、聚四氟乙烯等具有高电阻率的材料，也可以是上述各无纺布的复合品、层叠品。
图1是示出本实施方式的过滤器滤材的制造工序的说明图。
透气性基材2卷绕成卷状，并通过搬运装置1按流水线方向送出。由锟式散布机3的料斗3a供给的吸附材料4和热粘接剂5从散布锟3b散布并堆积到透气性基材2的表面上，从而形成吸附层。通过压痕机6的刀片6a从吸附层的上方沿宽度方向对透气性基材2进行压痕。之后，透气性基材2被另外的透气性基材7覆盖以夹持吸附层。层叠的透气性基材2、7被搬运到热压机8进行热压从而使热粘接剂5硬化。之后，层叠的透气性基材2、7作为过滤器滤材9被卷绕成卷状。
锟式散布机3包括储存粉体的料斗3a以及能够旋转地支撑于该料斗3a下部的散布锟3b。粉末以及粒状吸附材料向透气性基材2散布的散布方法不限定于上述方法，也可以是以往公知的任何散布方法。
压痕机6如冲裁切断成规定形状的汤姆逊(thomson)式机型那样，包括液压缸等驱动机构、上下升降台、安装于升降台上的刀片6a、与刀片6a形状相同的刀具承受台或平板台形状的刀具承受台。刀片6a相对于行进中的片从吸附层的上方垂直地上下运动，并通过刀片6a的刀尖在散布堆积的固化前的吸附层以及透气性基材2上形成槽(条痕)。以这种方式形成的槽随着吸附层的固化，形成为过滤器滤材的压褶加工用的折痕。槽的间隔可以根据过滤器滤材折叠的折叠宽度任意调整。槽的宽度以及深度可以在考虑折叠时的斥力或结构压损的基础上，配合散布并堆积的吸附材料4的量来进行调整。
另外，刀片6a的形状不仅仅为直线形状，也可以是锯齿形状、波浪形形状等。当为锯齿形状或波浪形形状等时，装入过滤器框内的滤材面积增加，并且，即使没有隔板或由粘接剂形成的条状加强筋，也能够维持折叠的滤材之间的空间，因而能节约成本。
此外，也可以替代利用压痕机6进行的分段(striping)式压痕，而采用转动式压痕，即，使每隔规定间隔设有槽的锟以及以同等间隔设有突起的锟在上下进行转动，并在将透气性基材2夹持在其间的状态下进行压痕。
热压机8具有一对平面加热带，以规定的温度和压力连续加热规定时间。由此，吸附材料4通过热粘接剂5固定在透气性基材2、7上。热压机8也可以使用公知的辊间压制方法来替代上述的热压方法。
在上述制造工序之后，作为对过滤器滤材进行压褶加工的方法，例如可以采用使用往复式褶成型机等公知的压褶加工成型机的方法，所述往复式褶成型机通过使上下各配置一片的刀具交替运动来对过滤器滤材进行压褶加工。
上述说明的过滤器滤材以及具有该过滤器滤材的过滤器元件，通过下述方法进行制造，即，设置槽来作为用于按规定的折叠宽度进行压褶加工的条痕，之后，使过滤器滤材的吸附层固化，从而制造形成上述说明的过滤器滤材以及具有该过滤器滤材的过滤器元件。由此，即使在为了高性能地除臭或去除粒子状杂质而增加吸附材料填充量(单位面积的吸附材料重量)从而增加了过滤器滤材的厚度的情况下，也能减小对过滤器滤材进行压褶加工后的斥力，从而使压褶加工变得容易。
另外，当将过滤器滤材用于作为过滤器元件的一个例子的过滤器单元中时，能够使装入框体的折数变多。其结果是，能够使过滤器单元的吸附量变多，且能够获得除臭等的过滤器性能。另外，能够使折叠的折的顶点变得尖锐(锐角)，从而能够降低过滤器单元的结构压损。
实施例
接下来对本发明的过滤器滤材以及过滤器元件的具体的实施例进行说明。
在下面的实施例中，过滤器滤材的单位面积重量、厚度、透气性等物性通过JISL1096“一般织物试验方法”所记载的方法进行了测量。
实施例1
将平均粒径40目、熔点105℃的低密度聚乙烯的热塑性粉末树脂(株式会社东京油墨(東京インキ(株))制，PR1050M)作为热粘接剂相对于作为吸附材料的平均粒径32～60目的椰壳活性炭(株式会社可乐丽(クラレケミカル(株))制，椰壳活性炭3260)以25％的重量比混合。将该混合粒状物散布到作为透气性基材的单位面积重量30g/m2的聚酯纺粘无纺布上，之后，在与散布堆积的混合粒状物的长度方向垂直地以92mm的间隔进行了压痕加工。然后，以夹持混合粒状物的方式从上方叠加单位面积重量为30g/m2的聚酯纺粘无纺布。在155℃条件下加热处理75秒，使设有折痕的吸附层固定化，并使吸附层与两片聚酯纺粘无纺布粘接，从而得到了除臭用的过滤器滤材。
固定的活性炭量为600g/m2，过滤器滤材的透气性为50cc/cm2/s，厚度为1.7mm。
利用褶成型机对得到的过滤器滤材进行压褶加工，在内折空间内安装由PET制成的波浪形状隔板并插入铝框内。由此，得到了折高度为92mm、折数为65折的610mm(W)×610mm(H)×100mm(D)的过滤器单元。
过滤器单元的折叠的斥力小，折叠的过滤器滤材的折的顶点为锐角，滤材面积为7.2m2。在0.5m/s的面速度条件下，测量的过滤器单元的压力损失为16.6Pa。
从该过滤器单元切下10cm×10cm的四方形块，利用甲苯用检测管(株式会社气体技术(ガステック(株)(GASTEC)制)在甲苯浓度为20ppm、面速度为0.5m/s的条件下测量了去除寿命，达到90％突破时的寿命为6.6小时。
实施例2
层叠两片实施例1所制造的过滤器滤材，以与实施例1同样的方式，得到了610mm(W)×610mm(H)×100mm(D)的过滤器单元。折高度为92mm，折数为47折。过滤器单元的折叠的斥力小，折叠的过滤器滤材的折的顶点为锐角，滤材面积为10.5m2。在0.5m/s的面速度条件下，测量的过滤器单元的压力损失为45.7Pa。
利用与实施例1同样的方式对该过滤器单元的去除寿命进行了测量，达到90％突破时的寿命为13.5小时。
实施例3
作为一侧的透气性基材即与被压痕后的聚酯纺粘无纺布重合的那一侧的聚酯纺粘无纺布，由具有集尘功能的聚丙烯制熔喷无纺布(株式会社三井化学(三井化学(株))制，MPECO4S)与实施例1中所使用的单位面积重量为30g/m2的聚酯纺粘无纺布贴合而形成，并且除压痕加工的间隔设置成285mm以外，以与实施例1同样的方式，得到了活性炭片的除臭用过滤器滤材。
固定的活性炭量为300g/m2，过滤器滤材的透气性为45cc/cm2/s，厚度为1.3mm。
利用褶成型机对得到的过滤器滤材进行压褶加工，在内折空间内安装由PET制成的波浪形状隔板并插入铝框中。由此，得到了折高度为285mm、折数为41折的610mm(W)×610mm(H)×290mm(D)的过滤器单元。
过滤器单元的折叠的斥力小，折叠的过滤器滤材的折的顶点为锐角，滤材面积为14.1m2。在2.5m/s的面速度的条件下，测量的过滤器单元的压力损失为93.1Pa。
实施例4
使用离子交换树脂(株式会社三菱化学(三菱化学(株))制，SK1BH)作为吸附材料，并使用熔点为125℃的热熔聚酯(株式会社东京油墨(東京インキ(株))制，G120)作为热粘接剂，除压痕加工的间隔为45mm以外，以与实施例1同样的方式，得到了阳离子片的除臭用过滤器滤材。
固定的阳离子交换树脂量为500g/m2，过滤器滤材的透气性为80cc/cm2/s，厚度为1.5mm。
利用褶成型机对得到的过滤器滤材进行压褶加工，在内折空间内安装由PET制成的波浪形状隔板并插入铝框。由此，得到折高度为45mm、折数为75折的610mm(W)×610mm(H)×50mm(D)的过滤器单元。
过滤器单元的折叠的斥力小，折叠的滤材的折的顶点为锐角，滤材面积为4.1m2。在0.5m/s的面速度的条件下，测量的过滤器单元的压力损失为18.1Pa。
利用与实施例1同样的方式对该过滤器单元的去除寿命进行了测量，达到90％突破时的寿命为5.4小时。
实施例5
除压痕加工的间隔为33mm以外，以与实施例1同样的方式，得到了除臭用过滤器滤材。利用褶成型机对得到的过滤器滤材进行压褶加工，从而得到了折高度为33mm、折数为29折的完成了压褶加工的过滤器滤材。将该完成了压褶加工的过滤器滤材以圆形卷绕在外径为32mm的聚丙烯制多孔质芯筒上，由此得到了外径为65mm、长度为250mm的滤芯式过滤器。
滤芯式过滤器的折叠的斥力小，折叠的滤材的顶点为锐角，滤材面积为0.48m2。
比较例1
除了不在散布堆积的混合粒状物上进行压痕以外，以与实施例1同样的方式，得到了除臭用过滤器滤材。
固定的活性炭量与实施例1同样地为600g/m2，滤材的透气性为50cc/cm2/s，厚度为1.7mm。
利用与实施例1同样的方式对得到的过滤器滤材进行压褶加工，得到了610mm(W)×610mm(H)×10mm(D)的过滤器单元。
该过滤器单元的折高度为92mm，然而折叠的过滤器滤材的折的顶点形状为圆形，折高度不等，过滤器滤材的折叠斥力大，能够插入铝框的折数为60折。滤材面积为6.6m2。在0.5m/s的面速度的条件下，测量的过滤器单元的压力损失为24.8Pa。
利用与实施例1同样的方式对该过滤器单元的去除寿命进行了测量，达到90％突破时的寿命为5.1小时。
比较例2
层叠两片在比较例1中制造的过滤器滤材，以与比较例1同样的方式，得到了610mm(W)×610mm(H)×100mm(D)的过滤器单元。
该过滤器单元的折高度为92mm，然而与比较例1同样地，折叠的滤材的折的顶点形状为圆形，折高度不等，过滤器滤材的折叠斥力大，能够插入铝框的折数为43折。滤材面积为9.5m2。在0.5m/s的面速度的条件下，测量的过滤器单元的压力损失为69.3Pa。
利用与实施例1同样的方式对该过滤器单元的去除寿命进行了测量，达到90％突破时的寿命为11.2小时。
比较例3
除了不对散布堆积的混合粒状物进行压痕以外，以与实施例3同样的方式，得到了除臭用过滤器滤材。
固定的活性炭量为300g/m2，过滤器滤材的透气性为45cc/cm2/s，厚度为1.3mm。
利用褶成型机对得到的过滤器滤材进行压褶加工，在内折空间内安装由PET制成的波浪形状隔板并插入铝框，从而得到折高度为285mm、折数为35折的610mm(W)×610mm(H)×290mm(D)的过滤器单元。
该过滤器单元的折高度为285mm，然而与比较例1同样地，折叠的滤材的折的顶点形状为圆形，折高度不等，过滤器滤材的折叠斥力大，能够插入铝框的折数为35折。滤材面积为12.1m2。在2.5m/s的面速度的条件下，测量的过滤器单元的压力损失为130Pa。
比较例4
除了不对散布堆积的混合粒状物进行压痕以外，以与实施例4同样的方式，得到了阳离子片的除臭用过滤器滤材。
固定的阳离子交换树脂量为500g/m2，过滤器滤材的透气性为80cc/cm2/s，厚度为1.5mm。
以与实施例4同样的方式对得到的过滤器滤材进行压褶加工，得到了610mm(W)×610mm(H)×50mm(D)的过滤器单元。
该过滤器单元的折高度为45mm，然而与比较例1同样地，折叠的过滤器滤材的折的顶点形状为圆形，折高度不等，过滤器滤材的折叠斥力大，能够插入铝框的折数为70折。滤材面积为3.8m2。在0.5m/s的面速度的条件下，测量的过滤器单元的压力损失为27.2Pa。
利用与实施例1同样的方式对该过滤器单元的去除寿命进行了测量，达到90％突破时的寿命为3.8小时。
比较例5
除了不对散布堆积的混合粒状物进行压痕以外，以与实施例5同样的方式，得到了除臭用过滤器滤材。利用褶成型机对得到的过滤器滤材进行压褶加工，由此得到了折高度为33mm、折数为29折的完成压褶加工的过滤器滤材。欲将该滤材以圆形卷绕在外径为32mm的聚丙烯制成的多孔质芯筒上，从而得到外径为65mm、长度为250mm的滤芯式过滤器。但是，由于折高度不等，过滤器滤材的折叠斥力大，没能够芯筒化。
表1示出了对这些实施例1～5及比较例1～5中的过滤器单元以及滤芯式过滤器的各种评价结果。
[表1]
从表1可知，在本发明的过滤器滤材以及过滤器元件中，即使在进行压褶加工的过滤器滤材的吸附材料填充量大的情况下，也能够实现对压褶加工的斥力小，且透气透水阻力以及过滤器性能优异，压力损失低的效果。
实施例6
使实施例4所得到的滤材通过一对正齿轮，实施厚度为3mm的波形加工，并利用褶成型机对得到的过滤器滤材实施了压褶加工。压褶加工按每个条痕被打褶，折叠的折的顶点为锐角。
比较例6
另一方面，在以同样的方式对比较例4所得到的滤材进行了波形加工后，进行了压褶加工，然而波形加工后的波浪部被压扁，折的顶点变平，未能完成压褶加工。
由此，经确认，本实施例的过滤器元件不使用空间维持构件，能够在压痕后的滤材上以波浪状实施波形加工来形成过滤器元件。
附图标记说明
1 搬运装置
2、7 透气性基材
3 锟式散布机
3a 料斗
3b 散布锟
4 吸附材料
5 热粘接剂
6 压痕机
6a 刀片
8 热压机
9 过滤器滤材

Claims (9)

1.一种过滤器滤材，在透气性基材之间安装有吸附层，其特征在于，在至少一片所述透气性基材的内表面侧具有折痕。
2.根据权利要求1所述的过滤器滤材，其特征在于，所述吸附层是通过热粘接剂将吸附材料粘接固化而成。
3.根据权利要求1或2所述的过滤器滤材，其特征在于，所述吸附层的两面与所述透气性基材粘接成一体。
4.根据权利要求1～3中任一项所述的过滤器滤材，其特征在于，所述吸附层设置有多层。
5.根据权利要求1～4中任一项所述的过滤器滤材，其特征在于，所述透气性基材中的至少一片透气性基材具有集尘功能。
6.一种过滤器元件，其特征在于，具有权利要求1～5中任一项所述的过滤器滤材。
7.根据权利要求6所述的过滤器元件，其特征在于，在折叠的所述过滤器滤材的内折空间内夹有空间维持构件。
8.根据权利要求6所述的过滤器元件，其特征在于，对折叠后的所述过滤器滤材实施波形加工。
9.一种过滤器滤材的制造方法，其特征在于，具有：
在第一透气性基材的表面散布并堆积吸附材料和热粘接剂来形成吸附层的工序；
从所述吸附层的上方沿所述第一透气性基材的宽度方向进行压痕的工序；
用第二透气性基材以夹持所述吸附材料的方式覆盖所述第一透气性基材的工序；以及
对层叠的所述第一透气性基材及第二透气性基材进行热压从而使所述热粘接剂硬化的工序。
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