CN111971105A - 过滤器用湿式无纺布、过滤器用滤材、以及过滤器 - Google Patents

过滤器用湿式无纺布、过滤器用滤材、以及过滤器 Download PDF

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Publication number
CN111971105A
CN111971105A CN201980023208.6A CN201980023208A CN111971105A CN 111971105 A CN111971105 A CN 111971105A CN 201980023208 A CN201980023208 A CN 201980023208A CN 111971105 A CN111971105 A CN 111971105A
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China
Prior art keywords
filter
nonwoven fabric
wet
average fiber
fibers
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CN201980023208.6A
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高见健人
日高裕辅
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Dongyang Textile Mc Co ltd
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Toyobo Co Ltd
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Priority claimed from JP2018068398A external-priority patent/JP7200495B2/ja
Priority claimed from JP2018068385A external-priority patent/JP7200494B2/ja
Application filed by Toyobo Co Ltd filed Critical Toyobo Co Ltd
Publication of CN111971105A publication Critical patent/CN111971105A/zh
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    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D39/00Filtering material for liquid or gaseous fluids
    • B01D39/14Other self-supporting filtering material ; Other filtering material
    • B01D39/16Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D46/00Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0027Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B01D46/0035Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions by wetting, e.g. using surfaces covered with oil
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D46/00Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0027Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B01D46/0036Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions by adsorption or absorption
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B01PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01DSEPARATION
    • B01D53/00Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
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    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022Non-woven fabric
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
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    • B32B5/22Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Materials Engineering (AREA)
  • Analytical Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Filtering Materials (AREA)

Abstract

本发明的过滤器用湿式无纺布包含维尼纶、聚酯以及聚乙烯醇,含有10~20重量%的所述聚乙烯醇,配置于通气的上游侧的面的表面粗糙度(SMD)为2.7μm以下。

Description

过滤器用湿式无纺布、过滤器用滤材、以及过滤器
技术领域
本发明涉及对于所附着的异物的除去优异的过滤器用湿式无纺布、过滤器用滤材、以及过滤器。
背景技术
近年来,在空调用、空气调节器(air conditioner)用、汽车用等的过滤器中,对于滤材的高性能化、低成本的要求提高起来,进行了很多兼顾除尘性能和脱臭性能的过滤器用滤材的研究(例如参照专利文献1~3)。作为进一步的高功能化,对于能够简易地除去所附着的异物的过滤器的要求也提高起来。但是,由于无法容易地除去异物,因此过滤器的再利用处于艰难的状况。关于过滤器的再利用,例如有使用了抽吸喷嘴的粉尘除去方法(专利文献4)。
现有技术文献
专利文献
专利文献1:日本特开平11-5058号公报
专利文献2:日本特开平3-98642号公报
专利文献3:日本特开2001-218824号公报
专利文献4:日本特开2014-136475号公报
发明内容
发明所要解决的问题
然而,若使用抽吸喷嘴除去异物,则过滤器发生变形,有不会充分地恢复性能的问题。
因而,本发明鉴于上述问题,目的在于,提供可以容易地除去所附着的异物、能够再利用的过滤器用湿式无纺布、过滤器用滤材、以及过滤器。
用于解决问题的方法
本发明人等进行了深入研究,结果发现,利用以下所示的方式,能够解决上述问题,从而达成了本发明。即,本发明如下所示。
(1)一种过滤器用湿式无纺布,其包含维尼纶、聚酯、以及聚乙烯醇,配置于通气的上游侧的面的表面粗糙度(SMD)为2.7μm以下。
(2)根据(1)中记载的过滤器用湿式无纺布,其中,配置于通气的上游侧的面的平均摩擦系数(MIU)为0.15以下。
(3)根据(1)或(2)中记载的过滤器用湿式无纺布,其含有10~20重量%的所述聚乙烯醇。
(4)根据(1)~(3)中任一项记载的过滤器用湿式无纺布,其特征在于,由纤维长度30mm以下的纤维制成。
(5)根据(1)~(4)中任一项记载的过滤器用湿式无纺布,其含有0.001~0.1重量%的聚丙烯酸酯。
(6)一种过滤器,其使用了(1)~(5)中任一项记载的过滤器用湿式无纺布。
(7)一种过滤器用滤材,其具有层叠有长纤维无纺布和(1)~(5)中任一项记载的湿式无纺布的层叠体结构。
(8)根据(7)中记载的过滤器用滤材,其特征在于,所述长纤维无纺布为纺粘无纺布。
(9)根据(7)或(8)中记载的过滤器用滤材,其特征在于,在所述长纤维无纺布与所述湿式无纺布之间夹入有吸附剂。
(10)一种过滤器,其使用了(7)~(9)中任一项记载的过滤器用滤材。
发明效果
本发明的过滤器用湿式无纺布由于配置于通气的上游侧的面平坦,所以能够简易地除去异物。因此,能够使得使用了本发明的过滤器用湿式无纺布的过滤器用滤材及过滤器的清扫变得容易。
具体实施方式
以下,对本发明的实施方式进行详细说明。
本实施方式的湿式无纺布包含维尼纶、聚酯、以及聚乙烯醇,含有10~20重量%的所述聚乙烯醇,配置于通气的上游侧的面的表面粗糙度(SMD)为2.7μm以下,用于过滤器用滤材、过滤器中。
本说明书中所谓表面粗糙度,是在利用KatoTech制摩擦感测试仪(KES-SE)的评价中表示表面的凹凸数据的平均偏差的SMD的值。随着SMD的值变大,表示表面粗糙、具有凹凸性。
本实施方式的湿式无纺布的配置于通气的上游侧的面的表面粗糙度(SMD)为2.7μm以下。若大于2.7μm,则所附着的异物因表面的凹凸性而难以除去。
本说明书中所谓平均摩擦系数,是在利用KatoTech制摩擦感测试仪(KES-SE)的评价中所测定的表面的平滑程度的平均摩擦系数(MIU)的值。随着MIU的值变小,表示表面易滑。
关于本实施方式的湿式无纺布,表示配置于通气的上游侧的面的平均摩擦系数的MIU为0.15。若大于0.15,则所附着的异物因表面的摩擦而难以除去。
构成本实施方式的湿式无纺布的纤维的平均纤维直径优选为1~100μm,更优选为5~50μm。若构成纤维的平均纤维直径小于1μm,则纤维间的空隙也变窄,空气中的尘埃堆积于外罩层上,通气阻力急剧升高。若构成纤维的平均纤维直径大于100μm,则难以除去异物。
构成本实施方式的湿式无纺布的纤维的纤维长度优选为30mm以下。若纤维长度大于30mm,则纤维易于沿厚度方向取向,表面粗糙度变大。
本实施方式的湿式无纺布的厚度优选为0.1~3.0mm。若厚度小于0.1mm,则产生质地(日文原文:地合い)的问题。若厚度大于3.0mm,则过滤器整体的厚度过大,将过滤器制成褶状时结构阻力变大,其结果是,过滤器整体的通气阻力变得过高,在实用上存在问题。
本实施方式的湿式无纺布的基重量(日文原文:目付け量)优选为10~100g/m2,更优选为20~80g/m2。若基重小于10g/m2,则质地变差。若基重大于100g/m2,则厚度变大,在用于过滤器中时褶裥加工时的结构阻力变大。
构成本实施方式的湿式无纺布的纤维结构体的原材料包含维尼纶、聚酯、以及聚乙烯醇。此处,优选含有10~20重量%的聚乙烯醇。若小于10%,则湿式无纺布的坚韧度弱,此外难以获得表面平滑性。若大于20重量%,则通气阻力升高。
本实施方式的湿式无纺布优选含有0.001~0.1重量%的聚丙烯酸酯。若小于0.001%,则表面平滑性及表面滑动性不提高,若大于0.1重量%,则通气阻力升高。
本实施方式的湿式无纺布可以利用公知的湿式抄纸法以公知的抄纸机来制造。
本实施方式的滤材是具有层叠有长纤维无纺布和上述的湿式无纺布的层叠体结构的过滤器用滤材,长纤维无纺布相对于湿式无纺布配置于通气的下游。
本实施方式的长纤维无纺布是包含聚烯烃系纤维、聚酯系纤维、聚酰胺系纤维、聚氨酯系纤维等纤维的片状物,优选聚酯系纤维。若为聚酯系纤维,则刚性较高,因此滤材的强度提高,褶裥加工变得容易。长纤维无纺布的制造方法优选纺粘法。
本实施方式的长纤维无纺布的基重优选为5~100g/m2,更优选为10~80g/m2。若基重小于5g/m2,则刚性变弱,另一方面,若大于100g/m2,则随着纤维根数的增加,不仅压力损失变高,而且纤维间的粉尘保持空间减少,粉尘保持量降低。
构成本实施方式的长纤维无纺布的纤维的纤维直径优选为3~100μm,更优选为5~80μm,进一步优选为10~60μm。若为该范围,则可以防止压力损失的增加,并且可以获得足够的刚性。
本实施方式的长纤维无纺布的纤维取向没有特别限定,例如若为无纺布状,则可以是无规状、交叉状、平行状的任意种。
本实施方式的滤材的厚度优选为0.1~3.0mm。若厚度小于0.1mm,则质地变差。若厚度大于3.0mm,则滤材整体的厚度过大,在制成褶状的过滤器时结构阻力变大,其结果是,过滤器整体的通气阻力变得过高,在实用上存在问题。
本实施方式的滤材可以在长纤维无纺布与湿式无纺布之间夹持粒状吸附材料和粘接材料(粘结剂)。
被夹持的粘结剂优选包含热塑性树脂,作为该热塑性树脂,可以举出聚烯烃系树脂、聚酰胺系树脂、聚酯系树脂、乙烯-丙烯酸类共聚物树脂等。粘结剂的成分没有特别限定,然而优选聚酯系树脂。这是因为,作为长纤维无纺布的材质优选聚酯系纤维已如前所述,成为与它们相同成分的聚酯系树脂时,基材层(长纤维无纺布或湿式无纺布)与粘结剂的界面被牢固地粘接,可以获得高的剥离强度。
本实施方式的滤材的粘结剂中使用的热塑性树脂优选为粉末状(粒状),其大小以平均粒径计为100~300μm。若粒状的热塑性树脂(粒状粘结剂)小于100μm,则会在粒状吸附材料与热塑性树脂之间作用由范德华力、静电力所致的附着力,热塑性树脂无法与基材层积极地接触,无法获得足够的剥离强度。另一方面,若大于300μm,则滤材的厚度变大,制成过滤器时的结构阻力增加,在实用上不优选。
本实施方式的滤材中使用的粒状粘结剂优选相对于粒状吸附材料使用10~80重量%,更优选使用20~60重量%。这是因为,若为该范围内,则能够得到与基材层的粘接力、压力损失、脱臭性能优异的滤材。
作为本实施方式的滤材的粒状吸附材料,可以使用活性炭、硅胶、沸石、海泡石等无机物,此外还可以使用以苯乙烯-二乙烯基苯交联体为代表的有机系的多孔体。特别是,由于具有极大的比表面积,因此优选活性炭。
在使用活性炭作为粒状吸附材料的情况下,例如适合为椰壳系、木质系、煤系、沥青系等活性炭。利用表面观察看见的向内部的导入孔、即所谓微孔的数目多则更好。若微孔的数目多,则即使在制造包含活性炭和粒状粘结剂的混合粉粒体时,粘结剂覆盖活性炭表面,也可以在热压加工时利用气体从细孔内部的脱附而打开能够吸附的孔。另外,对于活性炭表面而言,在一定程度上粗糙时,熔融了的粘结剂树脂的流动性也变差,从而能够抑制吸附性能降低。
本实施方式的滤材中,对于粒状吸附材料,出于提高极性物质、醛类的吸附性能的目的,可以实施化学药品处理后使用。作为化学药品处理中使用的化学药品,在吸附对象为醛系气体、NOx等氮化合物、SOx等硫化合物、乙酸等酸性的极性物质的情况下,例如可以举出乙醇胺、聚乙烯亚胺、苯胺、对甲氧基苯胺、磺胺酸、四氢-1,4-噁嗪、酰肼化合物等胺系药剂。作为胺系药剂优选四氢-1,4-噁嗪。由于能够比较容易地获取、另外易溶于水,因此添附加工容易。另外,在此以外,还可以合适地使用氢氧化钠、氢氧化钾、碳酸胍、磷酸胍、氨基胍硫酸盐、5,5-二甲基乙内酰脲、苯胍胺、2,2-亚氨基二乙醇、2,2,2-硝基三乙醇、乙醇胺盐酸盐、2-氨基乙醇、2,2-亚氨基二乙醇盐酸盐、对氨基苯甲酸、磺胺酸钠、L-精氨酸、甲胺盐酸盐、氨基脲盐酸盐、肼、对苯二酚、硫酸羟基胺、高锰酸盐、碳酸钾、碳酸氢钾等。在吸附对象为氨、甲基胺、三甲胺、吡啶等碱性的极性物质的情况下,例如可以合适地使用磷酸、柠檬酸、苹果酸、抗坏血酸、酒石酸等。利用这些化学药品进行了处理的吸附材料可以单独使用,或者也可以与未进行化学药品处理的吸附材料混合使用。
需要说明的是,例如通过向吸附材料担载、添附化学药品来进行化学药品处理。另外,除了对吸附材料直接进行化学药品的处理以外,也可以采用向滤材表面附近利用通常的涂布法等进行添附加工的方法、向滤材整体浸渗添附。此时,也可以实施制作混入有海藻酸钠、聚环氧乙烷等增稠剂的化学药品水溶液、并担载、添附该化学药品水溶液的方法。该方法对于担载、添附在水中的溶解度低的化学药品、进一步抑制化学药品的脱落也有效。
本实施方式的滤材可以包含抗菌剂、抗霉剂、抗病毒剂、阻燃剂等具有附加的功能的成分等而构成。这些成分可以混入构成基材层的纤维类、无纺布中,也可以利用后加工来添附、以及担载而赋予。例如,通过包含阻燃剂地构成滤材,能够制造符合FMVSS.302中所规定的滞燃性的基准或UL阻燃标准的滤材。
使用了本实施方式的滤材的本实施方式的过滤器也是本发明的范畴。对于本实施方式的过滤器也可以实施例如褶裥加工、向框等上的安装加工。另外,本实施方式的过滤器也可以在本实施方式的滤材中组合其他材料而形成。
实施例
以下给出实施例,对本发明进一步具体说明,然而本发明并不限定于实施例中记载的内容。首先,对实施例及比较例中所用的湿式无纺布及过滤器用滤材的物性的测定方法进行说明。
[表面凹凸性]
利用KatoTech制的摩擦感测试仪(KES-SE)进行评价。在对固定于工作台的试样(无纺布)以1mm/s的速度施加10gf的载荷的同时,扫描触头,将所检测出的表面凹凸数据的平均偏差作为表面粗糙度(SMD)的值。
[平均摩擦系数]
利用KatoTech制的摩擦感测试仪(KES-SE)进行评价。对固定于工作台的试样以1mm/s的速度施加25gf的载荷的同时,扫描触头,算出所检测出的平均摩擦系数(MIU)。
[异物除去性]
以15cm见方的尺寸切出试样,以5m3/min使之负荷JIS15种粉尘,在通气阻力相对于基线升高了50Pa的时刻停止负荷。利用重量来评价由试样捕集的粉尘量。此后,将15cm见方的试样垂直于桌上地设于夹具,从高10cm的地方落下10次。最后测定试样的重量,确认从试样掉落的重量。若从试样掉落的重量为附着量的7成,则判定为异物除去性能良好(○)。
[压力损失]
将滤材设置于导管内,以使空气过滤速度为50cm/秒的方式流通大气,利用差压计读取试样的上游及下游的静压差,测定压力损失(Pa)。
[剥离强度]
测定长纤维无纺布与湿式无纺布之间的平均剥离强度。试验片的尺寸设为宽50mm、长200mm,以拉伸强度100mm/分钟实施。
[刚性]
依照JIS L-1096A法(Gurley法),测定MD方向的硬挺度。
〔实施例1〕
将维尼纶纤维(17dtex、平均纤维长度12mm、平均纤维直径40μm)、维尼纶纤维(7dtex、平均纤维长度10mm、平均纤维直径25μm)、维尼纶纤维(2.2dtex、平均纤维长度6mm、平均纤维直径15μm)聚酯纤维(0.6dtex、平均纤维长度5mm、平均纤维直径8μm)、聚酯纤维(2.2dtex、平均纤维长度5mm、平均纤维直径15μm)、PVA纤维(1.1dtex、平均纤维长度3mm、平均纤维直径10μm)以26:31.25:5.25:11.25:11.25:15的重量比混织,用碎浆机分散于水中,制备出湿式抄纸用原液。
对该湿式抄纸用原液利用短网式抄纸法进行抄纸而制成湿润网(wet web),其后用压辊轻轻地压挤并在140℃用干燥转筒干燥,得到基重40g/m2、厚度0.3mm的实施例1的湿式无纺布。
然后,在所得的实施例1的湿式无纺布的成为下游的一侧,以使基重为90g/m2的方式撒布平均粒径200μm的椰壳活性炭及平均粒径200μm的聚酯系热塑性树脂的重量比为1:0.5的混合粉末。继而,从其上方叠加基重20g/m2的聚酯系长纤维无纺布,利用140℃的加热处理进行片化,制作出实施例1的过滤器用滤材。
〔实施例2〕
将维尼纶纤维(7dtex、平均纤维长度10mm、平均纤维直径25μm)、维尼纶纤维(2.2dtex、平均纤维长度6mm、平均纤维直径15μm)、聚酯纤维(0.6dtex、平均纤维长度5mm、平均纤维直径8μm)、聚酯纤维(2.2dtex、平均纤维长度5mm、平均纤维直径15μm)、PVA纤维(1.1dtex、平均纤维长度3mm、平均纤维直径10μm)以51:7.6:16.2:16.2:9的重量比混织,继而以相对于所投入的纤维重量为0.05%的方式称量聚丙烯酸酯,用碎浆机分散于水中,制备出湿式抄纸用原液。
对该湿式抄纸用原液利用短网式抄纸法进行抄纸而制成湿润网,其后用压辊轻轻地压挤并在140℃用干燥转筒干燥,得到基重30g/m2、厚度0.2mm的实施例2的湿式无纺布。
然后,除了取代实施例1的湿式无纺布而使用实施例2的湿式无纺布以外,与实施例1同样地制作出实施例2的过滤器用滤材。
〔实施例3〕
将维尼纶纤维(7dtex、平均纤维长度10mm、平均纤维直径25μm)、维尼纶纤维(2.2dtex、平均纤维长度6mm、平均纤维直径15μm)聚酯纤维(0.6dtex、平均纤维长度5mm、平均纤维直径8μm)、聚酯纤维(2.2dtex、平均纤维长度5mm、平均纤维直径15μm)、PVA纤维(1.1dtex、平均纤维长度3mm、平均纤维直径10μm)以45:7.6:16.2:16.2:15的重量比混织,继而以相对于所投入的纤维重量为0.05%的方式称量聚丙烯酸酯,用碎浆机分散于水中,制备出湿式抄纸用原液。
对该湿式抄纸用原液利用短网式抄纸法进行抄纸而制成湿润网,其后用压辊轻轻地压挤并在140℃用干燥转筒干燥,得到基重30g/m2、厚度0.2mm的实施例3的湿式无纺布。
然后,除了取代实施例1的湿式无纺布而使用实施例3的湿式无纺布以外,与实施例1同样地制作出实施例3的过滤器用滤材。
〔实施例4〕
将维尼纶纤维(7dtex、平均纤维长度10mm、平均纤维直径25μm)、维尼纶纤维(2.2dtex、平均纤维长度6mm、平均纤维直径15μm)聚酯纤维(0.6dtex、平均纤维长度5mm、平均纤维直径8μm)、聚酯纤维(2.2dtex、平均纤维长度5mm、平均纤维直径15μm)、PVA纤维(1.1dtex、平均纤维长度3mm、平均纤维直径10μm)以39:7.6:16.2:16.2:21的重量比混织,用碎浆机分散于水中,制备出湿式抄纸用原液。
对该抄纸用原液利用短网式抄纸法进行抄纸而制成湿润网,其后用压辊轻轻地压挤并在140℃用干燥转筒干燥,得到基重30g/m2、厚度0.2mm的实施例4的湿式无纺布。
然后,除了取代实施例1的湿式无纺布而使用实施例4的湿式无纺布以外,与实施例1同样地制作出实施例4的过滤器用滤材。
〔实施例5〕
将维尼纶纤维(7dtex、平均纤维长度10mm、平均纤维直径25μm)、维尼纶纤维(2.2dtex、平均纤维长度6mm、平均纤维直径15μm)聚酯纤维(0.6dtex、平均纤维长度5mm、平均纤维直径8μm)、聚酯纤维(2.2dtex、平均纤维长度5mm、平均纤维直径15μm)、PVA纤维(1.1dtex、平均纤维长度3mm、平均纤维直径10μm)以45:7.6:16.2:16.2:15的重量比混织,继而以相对于所投入的纤维重量为0.15%的方式称量聚丙烯酸酯,用碎浆机分散于水中,制备出湿式抄纸用原液。
对该湿式抄纸用原液利用短网式抄纸法进行抄纸而制成湿润网,其后用压辊轻轻地压挤并在140℃用干燥转筒干燥,得到基重30g/m2、厚度0.2mm的实施例5的湿式无纺布。
然后,除了取代实施例1的湿式无纺布而使用实施例5的湿式无纺布以外,与实施例1同样地制作出实施例5的过滤器用滤材。
〔比较例1〕
将低熔点聚酯纤维(22dtex、平均纤维长度64mm、平均纤维直径45μm)、低熔点聚酯纤维(4.4dtex、平均纤维长度51mm、平均纤维直径20μm)、普通聚酯纤维(regularpolyester fibers)(17dtex、平均纤维长度51mm、平均纤维直径40μm)以重量比5:3:2混织,利用热粘合法,得到厚度0.2mm、基重65g/m2的比较例1的热粘合无纺布。
然后,除了取代实施例1的湿式无纺布而使用比较例1的热粘合无纺布以外,与实施例1同样地制作出比较例1的过滤器用滤材。
〔比较例2〕
将维尼纶纤维(7dtex、平均纤维长度10mm、平均纤维直径25μm)、维尼纶纤维(2.2dtex、平均纤维长度6mm、平均纤维直径15μm)聚酯纤维(0.6dtex、平均纤维长度5mm、平均纤维直径8μm)、聚酯纤维(2.2dtex、平均纤维长度5mm、平均纤维直径15μm)、PVA纤维(1.1dtex、平均纤维长度3mm、平均纤维直径10μm)以51:7.6:16.2:16.2:9的重量比混织,用碎浆机分散于水中,制备出湿式抄纸用原液。
对该湿式抄纸用原液利用短网式抄纸法进行抄纸而制成湿润网,其后用压辊轻轻地压挤并在140℃用干燥转筒干燥,得到基重30g/m2、厚度0.2mm的比较例2的湿式无纺布。
然后,除了取代实施例1的湿式无纺布而使用比较例2的湿式无纺布以外,与实施例1同样地制作出比较例2的过滤器用滤材。
〔比较例3〕
将维尼纶纤维(7dtex、平均纤维长度10mm、平均纤维直径25μm)、维尼纶纤维(2.2dtex、平均纤维长度6mm、平均纤维直径15μm)聚酯纤维(0.6dtex、平均纤维长度5mm、平均纤维直径8μm)、聚酯纤维(2.2dtex、平均纤维长度5mm、平均纤维直径15μm)、PVA纤维(1.1dtex、平均纤维长度3mm、平均纤维直径10μm)以45:7.6:16.2:16.2:15的重量比混织,继而以相对于所投入的纤维重量为0.0009%的方式称量聚丙烯酸酯,用碎浆机分散于水中,制备出湿式抄纸用原液。
对该湿式抄纸用原液利用短网式抄纸法进行抄纸而制成湿润网,其后用压辊轻轻地压挤并在140℃用干燥转筒干燥,得到基重30g/m2、厚度0.2mm的比较例3的湿式无纺布。
然后,除了取代实施例1的湿式无纺布而使用比较例3的湿式无纺布以外,与实施例1同样地制作出比较例3的过滤器用滤材。
表1中给出实施例及比较例的湿式无纺布、热粘合无纺布的评价。
[表1]
Figure BDA0002706516840000121
根据表1可知,通过使用配置于通气的上游的面的表面粗糙度(SMD)为2.7μm以下的湿式无纺布,异物的除去性能优异。即,能够使得使用了本发明的过滤器用湿式无纺布的过滤器的清扫变得容易。
下面,对于实施例及比较例中制作出的滤材的评价表示于表2中。需要说明的是,对于实施例1~5的滤材及比较例2、3的滤材,分别以湿式无纺布侧为通气的上游、以长纤维无纺布侧为通气的下游进行测定。另外,对于比较例1的滤材,以热粘合无纺布侧为通气的上游、以长纤维无纺布侧为通气的下游进行测定。
[表2]
Figure BDA0002706516840000141
根据表2可知,通过使用配置于通气的最上游的面的表面粗糙度(SMD)为2.7μm以下的湿式无纺布,滤材的异物的除去优异。
需要说明的是,上述公开的实施方式及各实施例均为例示,而非限制性的说明。另外,将实施方式及各实施例中公开的构成适当地组合而得的实施方式、实施例也包含于本发明中。即,本发明的技术范围根据请求保护的范围而有效,包括与请求保护的范围的记载等同的含义及范围内的所有变更、修正、置换等。
产业上的可利用性
本发明的过滤器用无纺布、过滤器用滤材、以及过滤器对于进行清扫时的异物除去而言出色,例如可以有效地用于汽车、空气净化器或空调、复印机、打印机、多功能OA设备或卫生间除臭机等中所用的所有过滤器。

Claims (10)

1.一种过滤器用湿式无纺布,其特征在于,
包含维尼纶、聚酯以及聚乙烯醇,
配置于通气的上游侧的面的表面粗糙度SMD为2.7μm以下。
2.根据权利要求1所述的过滤器用湿式无纺布,其特征在于,
配置于通气的上游侧的面的平均摩擦系数MIU为0.15以下。
3.根据权利要求1或2所述的过滤器用湿式无纺布,其特征在于,
含有10重量%~20重量%的所述聚乙烯醇。
4.根据权利要求1~3中任一项所述的过滤器用湿式无纺布,其特征在于,
含有0.001重量%~0.1重量%的所述聚丙烯酸酯。
5.根据权利要求1~5中任一项所述的过滤器用湿式无纺布,其特征在于,
由纤维长度30mm以下的纤维制成。
6.一种过滤器,其使用了权利要求1~5中任一项所述的过滤器用湿式无纺布。
7.一种过滤器用滤材,其具有层叠体结构,
所述层叠体结构中层叠有长纤维无纺布和权利要求1~5中任一项所述的过滤器用湿式无纺布。
8.根据权利要求7所述的过滤器用滤材,其特征在于,
所述长纤维无纺布为纺粘无纺布。
9.根据权利要求8或9所述的过滤器用滤材,其特征在于,
在所述长纤维无纺布与所述湿式无纺布之间夹入有吸附剂。
10.一种过滤器,其使用了权利要求7~9中任一项所述的过滤器用滤材。
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