CN113039003A - 深度过滤器 - Google Patents

深度过滤器 Download PDF

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Publication number
CN113039003A
CN113039003A CN201980074453.XA CN201980074453A CN113039003A CN 113039003 A CN113039003 A CN 113039003A CN 201980074453 A CN201980074453 A CN 201980074453A CN 113039003 A CN113039003 A CN 113039003A
Authority
CN
China
Prior art keywords
nonwoven fabric
layer
fiber
filter
fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
CN201980074453.XA
Other languages
English (en)
Inventor
峯尾良太
西原尚人
山口修
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
JNC Corp
JNC Filter Co Ltd
Original Assignee
JNC Corp
JNC Filter Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by JNC Corp, JNC Filter Co Ltd filed Critical JNC Corp
Publication of CN113039003A publication Critical patent/CN113039003A/zh
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
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    • B01D39/08—Filter cloth, i.e. woven, knitted or interlaced material
    • B01D39/083—Filter cloth, i.e. woven, knitted or interlaced material of organic material
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Abstract

课题在于提供一种即便对于高浓度/高粘度的包含粉体微粒子的流体，过滤精度及耐压性能也优异的深度过滤器。一种深度过滤器，依序具有基材层、过滤层、以及表皮层，所述深度过滤器中，所述基材层及所述表皮层是将无纺布卷绕并热熔接而成的层，所述过滤层是将至少层叠有无纺布与网的层叠体卷绕成双层以上，且所述过滤层中所含的无纺布包含混纤无纺布，所述混纤无纺布是包含平均纤维径彼此不同的两种以上的纤维而成。

Description

深度过滤器
技术领域
本发明涉及一种用于对包含微粒子的流体进行过滤的深度过滤器(depthfilter)。
背景技术
作为包含微粒子的流体，有浆料或包含粉体的凝胶状流动体等。为了从此种流体中精制过滤固体成分而使用过滤器。
另一方面，在锂二次电池材料的浆料等中，以过滤后的干燥时间的缩短或挥发的液体的凝缩量的减容化等为目的，正推进固体成分的高浓度化。但是，越为高浓度，流体的粘度越上升，粉体彼此的相互作用越强，因此难以利用过滤器进行过滤。例如，已知，若将水用的筒式过滤器(cartridge filter)用于浆料的过滤，则即便浆料中的粉体比过滤器的平均孔径小，在通过过滤器时也会产生粉体粒子的凝聚(桥接(bridge))，表观粒径增大，从而引起堵塞。将所述现象称为拥堵(rush)现象。
专利文献1提出有如下过滤器：在粘性流体的过滤中，解决过滤精度因差压而变化、过滤器寿命变短等问题，并且即便产生脉压或高差压，也可捕捉柔软的凝胶状固形物。关于专利文献1的发明，在过滤器的主过滤层中，具有进行热熔接处理而将空隙率设为50％～80％的第一主过滤层、以及未进行热熔接处理的空隙率为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。
另外，为了获得形态保持性良好、过滤精度与过滤寿命的平衡优异的高精度过滤过滤器，提出有如下过滤器用无纺布，所述过滤器用无纺布中，至少层叠有两层无纺布，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(专利文献2)。本发明是以高精度地对次微米粒子等微小粒子进行过滤为目的，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，也使其作为缓冲材(cushion material)发挥作用，从而使过滤器的利用效率与形态保持性提高。
进而，提出有如下过滤器：其以提供难以产生粉体粒子的凝聚体(桥接)、至产生过滤差压为止的时间长、即过滤寿命长的过滤器为课题，且在具有基材层、过滤层及表皮层的过滤器中，将过滤层设为将至少层叠有热风(through-air)无纺布与网的层叠体卷绕成多层且未经压接的层，另外，构成基材层及表皮层的无纺布的平均细孔径大于构成过滤层的热风无纺布的平均细孔径(专利文献3)。
现有技术文献
专利文献
专利文献1：日本专利特开2010-137121号公报
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2015-97979号公报
发明内容
发明所要解决的问题
如上所述，对过滤器进行了各种改良，但尚未获得对于高浓度/高粘度化的浆料具有充分的过滤精度、能够进行长时间的过滤的过滤器。尤其是，在锂二次电池用浆料中，现状是随着高固体成分浓度化，浆料的高粘度化进展，另一方面，此种浆料中包含粗大粒子。因此，要求一种在去除高粘度的浆料中的粗大粒子的同时，且使微粒子通过的过滤器。有用的微粒子的粒径虽也取决于电池器件的规格，但大多情况是约数μm～50μm。
鉴于所述状况，本发明的课题在于提供一种即便对于高浓度/高粘度的包含粉体微粒子的流体，过滤精度及能够进行长时间的过滤所需的耐压性能也优异的过滤器。
解决问题的技术手段
发明人等人在致力于所述课题的过程中，发现，在高粘度的浆料通过过滤器时，会对过滤器施加大的负荷，因此，过滤器需要可耐受所述负荷的耐压性能，进而，在高浓度浆料的过滤中，经常发生拥堵现象，容易产生堵塞，发明人等人将这些情况作为主要的着眼点而致力于过滤器的改良。而且，发现，作为过滤器的过滤层，采用将无纺布与网卷绕成双层以上的结构，进而，作为过滤层中使用的无纺布，通过在至少一部分中含有包含纤度(纤维径)不同的多种纤维而成的混纤无纺布，而过滤精度大幅提高，且耐压性能提高，难以产生堵塞，因此可获得过滤精度与耐压性能优异的过滤器，从而完成了本发明。
即，本发明具有以下结构。
[1]一种深度过滤器，依序具有基材层、过滤层、以及表皮层，所述深度过滤器中，
所述基材层及所述表皮层是将无纺布卷绕并热熔接而成的层，
所述过滤层是将至少层叠有无纺布与网的层叠体卷绕成双层以上，且所述过滤层中所含的无纺布包含混纤无纺布，所述混纤无纺布是包含平均纤维径彼此不同的两种以上的纤维而成。
[2]根据[1]所述的深度过滤器，其中构成所述基材层或所述表皮层的无纺布、与构成所述过滤层的无纺布是彼此不同的无纺布，
构成所述基材层或所述表皮层的无纺布的平均纤维径大于构成所述过滤层的无纺布的平均纤维径。
[3]根据[1]或[2]所述的深度过滤器，其中所述过滤层中所含的、包含平均纤维径彼此不同的两种以上的纤维而成的混纤无纺布是平均纤维径为0.5μm以上的第一纤维、与平均纤维径为1μm以上且比第一纤维粗的第二纤维以1：99～90：10的比例混纤而成的无纺布。
[4]根据[1]至[3]中任一项所述的深度过滤器，其中所述过滤层中所含的、包含平均纤维径彼此不同的两种以上的纤维而成的混纤无纺布均包含聚烯烃系鞘芯型复合纤维。
[5]根据[1]至[4]中任一项所述的深度过滤器，其中所述过滤层包含：
混纤无纺布，其是包含所述平均纤维径彼此不同的两种以上的纤维而成；以及
无纺布，包含平均纤维径为0.5μm～200μm的一种纤维。
[6]根据[1]至[4]中任一项所述的深度过滤器，其中所述过滤层包含两种以上的混纤无纺布，
所述混纤无纺布是包含所述平均纤维径彼此不同的两种以上的纤维而成。
[7]根据[1]至[6]中任一项所述的深度过滤器，其中所述过滤层中所含的无纺布为熔喷无纺布和/或热风无纺布。
[8]根据[1]至[7]中任一项所述的深度过滤器，其中所述网为每网眼是1mm～5mm的范围的网眼大小，且具有50μm～300μm的范围的平均纤维径。
[9]根据[1]至[8]中任一项所述的深度过滤器，其中构成所述基材层的无纺布是聚烯烃系纤维的熔喷无纺布或热风无纺布。
[10]根据[1]至[9]中任一项所述的深度过滤器，其中构成所述基材层的无纺布、与构成所述表皮层的无纺布是相同的无纺布。
发明的效果
根据本发明，可提供一种过滤器，其中，即便对于高浓度、高粘度的浆料，过滤精度、耐压性能也优异，另外，在去除粗大粒子的同时使微粒子通过的分级性能优异，进而难以产生堵塞。
附图说明
图1是表示本发明的实施例的深度过滤器的剖面。
具体实施方式
本发明的深度过滤器依序具有基材层、过滤层、以及表皮层，所述深度过滤器中，所述基材层及所述表皮层是将无纺布卷绕并热熔接而成的层，所述过滤层是将至少层叠有无纺布与网的层叠体卷绕成双层以上，且所述过滤层中所含的无纺布是混纤无纺布，所述混纤无纺布是包含平均纤维径彼此不同的两种以上的纤维而成。
如上所述，本发明的深度过滤器的过滤层具有如下特征：卷绕有至少层叠有无纺布与网的层叠体，另外，构成过滤层的无纺布包含混纤无纺布，所述混纤无纺布是包含平均纤维径彼此不同的两种以上的纤维而成。虽不受特定理论的约束，但本发明的深度过滤器通过在过滤层中层叠无纺布与网，而在实质上发挥过滤功能的无纺布的叠层间形成适度的间隙。因此，认为，在过滤层内，流体或流体中的粉体的流动性提高，桥接的形成得到抑制。另外，通过使网位于无纺布的叠层间，可避免由无纺布的重层引起的细孔的小径化或闭塞。进而，认为，通过无纺布与网的层叠体的粘接弱，或者对至少一部分不进行热熔接，而无纺布可在过滤层内稍微移动，流体或流体中的粉体的流动性进一步提高，并且通过网来保持过滤层的形态而稳定地发挥过滤性能。此外，认为，通过采用包含平均纤维径彼此不同的两种以上的纤维而成的混纤无纺布作为过滤层中所含的无纺布的至少一部分，可获得分级性能(捕捉粗大的粒子，使粒径为一定以下的粒子通过)优异，并且耐压性能高的深度过滤器。
＜过滤层用无纺布＞
如上所述，过滤层是使用至少层叠有无纺布与网的层叠体而构成。作为过滤层中所使用的无纺布，只要可获得所期望的性能，则并无特别限制，例如可使用热风无纺布、熔喷无纺布、纺粘无纺布、水刺(spunlace)无纺布等，其中，就蓬松、在无纺布的厚度方向(过滤的流体的流动方向)上也分布纤维取向的方面而言，优选为使用热风无纺布。所谓热风无纺布，是指通过热风粘接工艺而获得的无纺布。所谓热风粘接工艺，是指用于通过如下方式、即在烘箱中包括输送带或者滚筒(rotary drum)并且在使料片(web)通过后进而向一方吸引的方式，来获得提高粘接效果、在厚度方向上均匀的无纺布的方法，也被称为空气通过(air through)方式。热风无纺布也被称为空气通过无纺布。
热风无纺布通常是使具有卷曲的短纤维通过梳理机(carding machine)而制成料片，并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而获得。作为构成热风无纺布的短纤维，为了维持稳定的性能，优选为短纤维彼此在短纤维的交点处熔接和/或粘接。根据所述情况，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，可使用现有的复合纤维。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，具体而言，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、超高分子量聚乙烯等聚乙烯(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，为了使热熔接的加工温度范围广，熔点差优选为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，适宜的是偏心鞘芯型复合纤维。
在本发明中，过滤层中的无纺布包含混纤无纺布，所述混纤无纺布是包含平均纤维径彼此不同的两种以上的纤维而成。混纤无纺布中所含的纤维的种类只要可获得发明的效果，则只要为两种以上即可，可为三种、四种、四种以上，优选为两种。
作为构成过滤层用无纺布的纤维，可使用平均纤维径为0.1μm～200μm的范围的纤维，能够根据过滤液的性状或过滤的目的来适宜选择。在本发明中，作为两种纤维，例如优选为将平均纤维径为0.5μm以上的第一纤维、与平均纤维径为1μm以上且比第一纤维粗的第二纤维混纤，更优选为将作为细纤维(第一纤维)的平均纤维径为5μm～50μm的纤维、与作为粗纤维(第二纤维)的平均纤维径为20μm～200μm的纤维混纤。相对于第一纤维的平均纤维径，第二纤维的平均纤维径优选为1.5倍以上，更优选为1.7倍以上。进行混纤的纤维可使用彼此为相同组成而仅纤维径不同的纤维，也可将组成及纤维径不同的两种以上的纤维混纤来使用。另外，在过滤层中，混纤无纺布可为一种，也优选为使用两种以上的混纤无纺布。再者，在称为混纤无纺布的平均纤维径的情况下，是指由所含的多种纤维的平均纤维径与各自的含有比例来算出的、混纤无纺布整体的平均纤维径。
混纤无纺布中的混纤的重量比只要可发挥所期望的过滤性能，则并无特别限制，例如可将细纤维(第一纤维)与粗纤维(第二纤维)的重量比设为1：99～90：10的比例，优选为设为10：90～80：20的比例。更具体而言，例如，更优选为将平均纤维径为5μm～50μm的第一纤维与平均纤维径为20μm～200μm且比第一纤维粗的第二纤维以10：90～90：10的比例混纤，进而优选为将平均纤维径为10μm～50μm的第一纤维与平均纤维径为30μm～100μm且比第一纤维粗的第二纤维以10：90～80：20的比例混纤。
在第一纤维与第二纤维的混纤中，通过将平均纤维径的比率与混纤的重量比设为所述范围，可获得耐压性能优异的深度过滤器。虽不受特定理论的约束，但认为在混纤无纺布中，粗纤维发挥去除粗大粒子及维持耐压性能的作用，细纤维发挥微粒子的分级的作用，因此，通过在具有所期望的过滤精度的过滤层用无纺布的一部分中混纤粗纤维，可获得耐压性能提高的效果。进而，认为，由于粗纤维牢固地结合，因此防止纤维间所形成的开孔部的变形或扩张，结果，可在滤材的外侧着实地捕捉粗大粒子，因此能够进行有效率的深层过滤。
另外，作为过滤层用无纺布，除了使用所述混纤无纺布以外，也优选为使用包含平均纤维径为0.5μm～200μm的一种纤维的无纺布(称为单纤无纺布)。单纤无纺布的平均纤维径更优选为10μm～200μm。作为与混纤无纺布并用的单纤无纺布，可使用热风无纺布、熔喷无纺布、纺粘无纺布、水刺无纺布等，与混纤无纺布同样地，优选为使用热风无纺布。另外，无纺布的材质也可例示与混纤无纺布相同的材质，具体而言，例如可使用如下热风无纺布，所述热风无纺布包含将作为高熔点成分的聚丙烯设为芯成分、将作为低熔点成分的聚乙烯设为鞘成分的偏心鞘芯型复合纤维。
于在过滤层中并用混纤无纺布与单纤无纺布的情况下，包含单纤无纺布的部分可位于过滤层的上游侧，包含单纤无纺布的部分也可位于过滤层的下游侧。另外，单纤无纺布的平均纤维径可大于混纤无纺布的平均纤维径，也可小于混纤无纺布的平均纤维径。在单纤无纺布的平均纤维径大于混纤无纺布的平均纤维径的情况下，通过将单纤无纺布配置于过滤层的外侧(滤液的上游侧)，可进一步粗化过滤精度。另外，相反地，在单纤无纺布的平均纤维径比混纤无纺布的平均纤维径小的情况下，通过将单纤无纺布配置于过滤层的内侧(滤液的下游侧)，可进一步细化过滤精度。
在并用混纤无纺布与单纤无纺布的情况下，混纤无纺布与单纤无纺布的比例可设为90：10～10：90。越增加混纤无纺布的比例，分级性能越提高。通过在混纤无纺布的外侧插入包含粗纤度的纤维的单纤无纺布，可去除粗大粒子，因此过滤寿命延长。另一方面，通过在混纤无纺布的内侧插入包含细纤度的纤维的单纤无纺布，微粒子的粒子捕捉率提高。即，只要对应于浆料来决定过滤器滤材中的混纤无纺布与单纤无纺布的插入位置即可。若混纤无纺布与单纤无纺布的比例为15：85～85：15，则分级性能与耐压性能的平衡优异，因此优选。为了获得使用混纤无纺布的本发明的效果，优选为在过滤层用无纺布中，使用15％以上的混纤无纺布。
过滤层用无纺布的单位面积重量在某种程度上是由与纤维的材质、纤维径的关系来规定，例如可使用5g/m2～100g/m2的单位面积重量，优选为20g/m2～60g/m2，更优选为25g/m2～55g/m2。若单位面积重量为25g/m2～55g/m2，则用于调整过滤层的厚度与过滤性能的选择范围扩大，因此优选。
过滤层用无纺布中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包含功能剂，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、制电制、表面平滑性、耐磨耗性等功能。
＜网＞
插入至过滤层的网是用于不会对深度过滤器的捕集效率造成影响地，在无纺布间制成间隙，并且对过滤层的形态加以保持，进而维持/提高耐压性能。因此，网优选为使用纤维径为50μm～300μm的范围的单丝(monofilament)，更优选为使用纤维径为60μm～280μm的范围的单丝。进而，网的网眼大小优选为设为每网眼是1mm～5mm的范围，更优选为设为每网眼是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，且过滤器的强度得到确保，因此可获得过滤寿命更长的过滤器。
单丝并无特别限定，优选为包含热塑性树脂，例如可利用单一结构纤维、复合纤维、混纤纤维。单丝中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，可使用热熔接性复合纤维中所例示的那样的热塑性树脂。例如，可列举聚乙烯、聚丙烯、聚酯、尼龙6、尼龙6,6、尼龙6,12等，其中，特别优选为聚丙烯、尼龙6或尼龙6,6。单丝可使用这些的一种热塑性树脂，也可使用两种以上的热塑性树脂的混合物。另外，在单丝为复合纤维的情况下，通过使用热熔接性复合纤维中所例示的那样的热塑性树脂的组合，可利用热处理使单丝彼此的交点热熔接，因此不会产生错位(misalignment)，因此优选。
＜过滤层的结构＞
本发明的深度过滤器的过滤层是将至少层叠有所述混纤无纺布与网的层叠体卷绕成双层以上而形成。无纺布与网的层叠顺序并无特别限制，优选为将无纺布与网分别各为一片地、即以无纺布与网各为一层地进行交替的方式缠卷。如此形成的过滤层成为在无纺布与无纺布之间夹入网眼粗的网的结构，无纺布彼此不会密接地被层叠。作为无纺布，在并用混纤无纺布与单纤无纺布的情况下，可首先将混纤无纺布(或单纤无纺布)与网层叠并卷绕至规定长度，继而，将单纤无纺布(或混纤无纺布)与网层叠并卷绕至规定长度。
过滤层中使用的层叠体可全部热熔接，也可具有未经热熔接的部分。若具有未经热熔接的部分，则无纺布的蓬松度得到保持。再者，所谓“未经热熔接”，是过滤层的至少一部分并非通过热熔接而一体地硬化的形态的含义，出于提高过滤器的形态保持性等目的，过滤层的一部分也可经热熔接。另外，过滤层与基材层之间、或过滤层与表皮层之间也可经热压接、热熔接或粘接。
另外，视需要，除了层叠所述无纺布与网以外，也可层叠进一步的无纺布或网等。例如，除了插入混纤无纺布、单纤无纺布及网以外，还可插入网眼粗的熔喷无纺布，来卷绕三层结构的层叠体，提高过滤层的保形性或捕集效率。于在过滤层层叠熔喷无纺布的情况下，优选为使用与基材层或表皮层中使用的熔喷无纺布相同的熔喷无纺布。
根据对数透过则而现有的是通过流体所通过的过滤层的厚度来控制捕集效率，且过滤层的厚度(层叠体的缠卷数)可根据所要求的捕集效率来适宜选择。过滤层的厚度(层叠体的缠卷数)越大，捕集效率越提高，越可捕集粒径小的粉体。
＜基材层用无纺布＞
本发明中使用的基材层用无纺布若能够热熔接、且可在热熔接后确保作为深度过滤器的基材层所需的保形性，则并无特别限制，可使用熔喷无纺布、热风无纺布、纺粘无纺布、水刺无纺布等。
在使用熔喷无纺布作为基材层用无纺布的情况下，构成熔喷无纺布的纤维的种类或其制造方法并无特别限定，可使用现有的纤维或制造方法。例如，熔喷无纺布可通过如下方式来制造：将热塑性树脂熔融挤出，并从熔喷纺丝喷嘴进行纺出，进而利用高温高速的气体以极细纤维流的形式进行吹纺(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是使用空气、氮气等惰性气体。通常是在气体温度为200℃～500℃、压力为0.1kgf/cm2～6.5kgf/cm2的范围内使用。
在将熔喷无纺布用于基材层用无纺布的情况下，其纤维径能够根据过滤液的性状或过滤的目的来适宜选择，优选为大于构成过滤层的无纺布的平均纤维径。具体而言，例如，平均纤维径优选为1μm～149μm，更优选为6μm～149μm，最优选为8μm～149μm。若构成熔喷无纺布的纤维的平均纤维径为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纤维的平均纤维径为149μm以下，则缘于纤维径小(细)的程度的极细纤维的本来的特性得以充分发挥。
另外，基材层用无纺布的单位面积重量在某种程度上是由与纤维的材质或纤维径的关系来规定，例如，可使用5g/m2～100g/m2的单位面积重量，更优选为使用30g/m2～60g/m2的单位面积重量。若为所述范围的单位面积重量，则自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。
基材层用的熔喷无纺布可利用包含单一结构纤维的熔喷无纺布、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，所述熔喷无纺布中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，例如可使用热熔接性复合纤维中所例示的那样的热塑性树脂，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包含各种功能剂，具体而言，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，可例示亲水化或疏水化的涂布处理、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中使用的树脂，例如可列举：聚乙烯(低密度聚乙烯、直链状低密度聚乙烯、高密度聚乙烯、超高分子量聚乙烯)、聚丙烯(以丙烯为主成分的丙烯共聚物、结晶性聚丙烯)等聚烯烃系树脂、聚对苯二甲酸乙二酯、聚对苯二甲酸丁二酯等聚酯系树脂、尼龙6、尼龙6,6、尼龙6,12等聚酰胺系树脂。另外，于在基材层用无纺布中使用热风无纺布的情况下，可利用在过滤层用无纺布中所例示的一般的热风无纺布。
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熔接而经一体化的层。基材层的厚度或缠卷数是根据所使用的熔喷无纺布来适当设定，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，并且是以如下情况为主目的的层：除了阻挡尤其是大粒径的凝聚物或夹杂物以使这些不会侵入至过滤层内以外，还保护过滤层且保持过滤器形态。
表皮层为包含无纺布的层，优选为是由无纺布构成的层。表皮层中使用的无纺布并无特别限制，优选为平均纤维径大于过滤层用无纺布的平均纤维径。无纺布的材质也无特别限制，可使用平均纤维径、材质均与基材层用无纺布中所例示的情况相同的无纺布。作为表皮层用无纺布，可使用与基材层用无纺布相同的无纺布。具体而言，例如，作为表皮层用无纺布及基材层用无纺布，可使用聚烯烃系纤维的熔喷无纺布。
表皮层的缠卷数或厚度并无特别限制，若缠卷数或厚度变大，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，就可减少桥接的形成的方面而言，优选为将熔喷无纺布缠卷1圈～5圈、优选1圈～2圈并进行热熔接来形成。
＜深度过滤器的制造方法＞
本发明的深度过滤器可通过如下方式来制造：一边依序层叠基材层用无纺布、过滤层用无纺布及网、表皮层用无纺布，一边进行卷绕。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熔接，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，不进行加热地进行卷起而形成过滤层。最后，将作为表皮层用无纺布的熔喷无纺布卷绕1圈～2圈并进行热熔接，由此形成深度过滤器。
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)中熔融基材层用无纺布且将基材层用无纺布热熔接的温度即可。另外，制造线的速度并无特别限制，在过滤层的形成时，施加至无纺布的张力(tension)优选为10N以下，且优选为不施加张力地进行卷起。
深度过滤器的直径或厚度可根据目标性能或过滤液的性状来适宜设定，并无特别限制，例如，在为锂二次电池材料的制造工序中的浆料过滤中所使用的深度过滤器的情况下，可制成内径为23mm～45mm左右、外径为60mm～80mm左右的深度过滤器。此种深度过滤器例如可通过将基材层用无纺布卷取0.2m～20m左右、将过滤层用无纺布及网的层叠体卷取0.2m～8m左右、进而将表皮层卷取0.2m～7m左右来制造。
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(endcap)而适宜地用作圆筒型过滤器。
另外，所述制造方法仅为概略，除了所述工序以外，视需要可实施热处理、冷却、药剂处理、成型、清洗等现有的工序。
实施例
以下，利用实施例更详细地说明本发明，但本发明并不受这些实施例的限制。
实施例中所示出的物性值的测定方法或定义为如下所述。
1)平均纤维径的测定方法
根据用电子显微镜拍摄的过滤器滤材的剖面，测量100根每1根纤维的长度方向与直角方向上的长度(直径)，将算术平均值设为平均纤维径。所述计算是使用塞恩公司(Scion Corporation)的图像处理软件“塞恩影像(Scion Image)”(商品名)来进行。
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。
[实施例1]＜使用混纤无纺布(55μm/32μm＝80/20)作为过滤层用无纺布的例子＞
(材料)
基材层用无纺布：使用单位面积重量50g/m2、平均纤维径107μm且包含混纤比率为1：1的以丙烯为主成分的丙烯共聚物(熔点135℃)与结晶性聚丙烯(熔点165℃)的混纤熔喷无纺布。
过滤层用无纺布A：使用包含结晶性聚丙烯(熔点165℃；芯)/高密度聚乙烯(熔点135℃；鞘)的偏心鞘芯型复合纤维的、单位面积重量为40g/m2的热风无纺布。所述热风无纺布是将纤维径55μm的偏心鞘芯型复合纤维与纤维径32μm的偏心鞘芯型复合纤维以80：20的比例(重量比)混合的混纤无纺布。
网：使用包含聚丙烯单丝(平均纤维径250μm)的网眼大小为每网眼是2.0mm的网。
(制造方法)
将中芯(铁棒)预先加热至150℃，并且一边在150℃下持续进行加热，一边以5.6m的量将基材层用无纺布卷取至所述中芯。继而，开始插入过滤层用无纺布A与网。将过滤层用无纺布A及网的插入长度设为2m并与基材层用熔喷无纺布一同进行卷取。此时，对于最初的1m，以加热器功率7.8kW、150℃进行加热而使其热熔接，对于剩余的1m，将加热器功率设为0kW，并不进行加热且不使其热熔接地进行卷取，从而形成过滤层。继而，以加热器功率为7.8kW进行加热，并且一边使基材层用熔喷无纺布热熔接，一边卷取1m来作为表皮层，从而制造圆筒型过滤器。
[实施例2]＜使用混纤无纺布(55μm/32μm＝80/20)及单纤无纺布(73μm)作为过滤层用无纺布的例子＞
(材料)
过滤层用无纺布A：使用包含结晶性聚丙烯(熔点165℃；芯)/高密度聚乙烯(熔点135℃；鞘)的偏心鞘芯型复合纤维的、单位面积重量为40g/m2的热风无纺布。所述热风无纺布是将平均纤维径55μm的复合纤维与平均纤维径32μm的复合纤维以80：20的比例(重量比)混合的混纤无纺布。
过滤层用无纺布B：平均纤维径73μm的包含结晶性聚丙烯(熔点165℃；芯)/高密度聚乙烯(熔点135℃；鞘)的偏心鞘芯型复合纤维的单纤热风织布。
(制造方法)
将所述过滤层用无纺布A 1.7m及所述过滤层用无纺布B 0.3m接长并制成一反。以过滤层用无纺布B配置于圆筒形过滤器的外侧的方式进行卷取，除此以外，利用与实施例1相同的方法制造圆筒形过滤器。
[实施例3]＜使用混纤无纺布(55μm/32μm＝80/20)及单纤无纺布(32μm)作为过滤层用无纺布的例子＞
(材料)
过滤层用无纺布A：使用包含结晶性聚丙烯(熔点165℃；芯)/高密度聚乙烯(熔点135℃；鞘)的偏心鞘芯型复合纤维的、单位面积重量为40g/m2的热风无纺布。所述热风无纺布是将纤维径55μm的复合纤维与纤维径32μm的复合纤维以80：20的比例(重量比)混合的混纤无纺布。
过滤层用无纺布C：平均纤维径32μm的包含结晶性聚丙烯(熔点165℃；芯)/高密度聚乙烯(熔点135℃；鞘)的偏心鞘芯型复合纤维的单纤热风无纺布。
(制造方法)
将所述过滤层用无纺布A 1.7m及所述过滤层用无纺布C 0.3m接长并制成一反。以过滤层用无纺布C配置于圆筒形过滤器的内侧的方式进行卷取，除此以外，利用与实施例1相同的方法制造圆筒形过滤器。
[比较例1]＜使用一种单纤无纺布作为过滤层用无纺布的例子＞
(材料)
过滤层用无纺布E：纤维径32μm的包含结晶性聚丙烯(熔点165℃；芯)/高密度聚乙烯(熔点165℃；鞘)的偏心鞘芯型复合纤维的单纤热风无纺布。
(制造方法)
除了将所述过滤层用无纺布E 2m用作过滤层用无纺布以外，利用与实施例1相同的方法制造圆筒形过滤器。
＜捕集效率＞
关于实施例1～实施例3及比较例1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。
试验粉体是使用日本工业标准(Japanese Industrial Standards，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(RION)制造)来测定。
捕集效率是利用以下定义式来求出。
捕集效率(％)＝(1-通过过滤器后的粒径xμm的粒子数/通过过滤器前的粒径xμm的粒子数)×100
将捕集效率的测定结果示于表1中。
[表1]
Figure BDA0003061950750000151
如表1所示那样，实施例1～实施例3的过滤器捕集99.9％以上的100μm以上的粒子，且30μm的粒子的捕集效率小于50％(即，使半数以上通过)。另一方面，比较例1的过滤器捕集100％的100μm以上的粒子，但30μm的粒子的捕集效率为57.2％(即，捕集半数以上)。在50μm的粒子的捕集效率中，实施例1～实施例3也为84.9％～88.3％，相对于此，比较例1为91.2％而显示出高的值。其结果表示，实施例1～实施例3的过滤器确实地捕集应去除的粗大粒子，另外，与比较例1的过滤器相比，能够确实地使应通过的小粒子通过，即，难以产生堵塞，分级性能优异。
＜耐压性能＞
对于实施例1～实施例3及比较例1的圆筒型过滤器，通过在整个面上卷付并覆盖保鲜膜(wrap film)，使过滤器表面密闭，而制成耐压试验用样品。
将所述过滤器安装于壳体，利用泵输送水，使流路内充满水。继而，提高泵的流量，由此使系统内的压力自0.1MPa起以0.02MPa为单位提高，并保持1分钟，目视确认过滤器的变形，由此，测定过滤器变形的极限压力。
将耐压性能试验的结果示于表2中。
[表2]
耐压(MPa)
实施例1 6.0
实施例2 5.0
实施例3 5.6
比较例1 3.6
(考察)
得知，实施例1～实施例3的过滤器在过滤时耐压性能高。另一方面，得知，比较例1的过滤器在耐压测试中滤材被压碎。认为其原因在于：在实施例1～实施例3的过滤器中，过滤层中包含粗的复合纤维，相对于此，比较例1的过滤器在过滤层中不含粗的纤维。通过耐压性能高，能够长时间对粘度更高的浆料进行过滤。
另外，确认到：实施例1～实施例3的过滤器由于去除相当于100μm的微粒子，并可使50μm以下的所期望的粒子的大部分通过，因此，与比较例1的过滤器相比，难以产生堵塞，分级性能高。
根据这些结果，得知，本申请发明的实施例1～实施例3的深度过滤器的过滤精度与耐压性能优异。
图1是表示本发明的实施例的深度过滤器的剖面。在图1的深度过滤器中，基材层1是卷绕熔喷无纺布而成的层。过滤层2是将混纤热风无纺布、熔喷无纺布、网重叠卷绕而成的层。表皮层3是卷绕熔喷无纺布而成的层。
产业上的可利用性
本发明的深度过滤器在对具有各种粒径的浆料进行过滤时，由于在过滤层中配置有包含粗纤维及细纤维的混纤无纺布，因此耐压性能高。进而，本发明的深度过滤器可适宜地用作如下过滤过滤器，所述过滤过滤器用于从低浓度～高浓度(10ppm～70％)的包含微粒子(粉体)的悬浮液、浆料、凝胶状流体中去除凝聚物或夹杂物，获得粒径为一定以下的微粒子。本发明的深度过滤器可适宜地用作锂二次电池的制造过程中的浆料过滤用过滤器、如下工业用过滤器，所述工业用过滤器用于对研磨剂浆料、涂料用浆料、颜料分散液、含有填料的各种流体、例如包含密封材、粘接剂、膜用组合物及涂布剂的液体或流体进行过滤。
符号的说明
1：基材层
2：过滤层
3：表皮层

Claims (10)

1.一种深度过滤器，依序具有基材层、过滤层、以及表皮层，所述深度过滤器中，
所述基材层及所述表皮层是将无纺布卷绕并热熔接而成的层，
所述过滤层是将至少层叠有无纺布与网的层叠体卷绕成双层以上，且所述过滤层中所含的无纺布包含混纤无纺布，所述混纤无纺布是包含平均纤维径彼此不同的两种以上的纤维而成。
2.根据权利要求1所述的深度过滤器，其中构成所述基材层或所述表皮层的无纺布、与构成所述过滤层的无纺布是彼此不同的无纺布，
构成所述基材层或所述表皮层的无纺布的平均纤维径大于构成所述过滤层的无纺布的平均纤维径。
3.根据权利要求1或2所述的深度过滤器，其中所述过滤层中所含的、包含平均纤维径彼此不同的两种以上的纤维而成的混纤无纺布是平均纤维径为0.5μm以上的第一纤维、与平均纤维径为1μm以上且比第一纤维粗的第二纤维以1：99～90：10的比例混纤而成的无纺布。
4.根据权利要求1至3中任一项所述的深度过滤器，其中所述过滤层中所含的、包含平均纤维径彼此不同的两种以上的纤维而成的混纤无纺布均包含聚烯烃系鞘芯型复合纤维。
5.根据权利要求1至4中任一项所述的深度过滤器，其中所述过滤层包含：
混纤无纺布，其是包含所述平均纤维径彼此不同的两种以上的纤维而成；以及
无纺布，包含平均纤维径为0.5μm～200μm的一种纤维。
6.根据权利要求1至5中任一项所述的深度过滤器，其中所述过滤层包含两种以上的混纤无纺布，所述混纤无纺布是包含所述平均纤维径彼此不同的两种以上的纤维而成。
7.根据权利要求1至6中任一项所述的深度过滤器，其中所述过滤层中所含的无纺布为熔喷无纺布和/或热风无纺布。
8.根据权利要求1至7中任一项所述的深度过滤器，其中所述网为每网眼是1mm～5mm的范围的网眼大小，且具有50μm～300μm的范围的平均纤维径。
9.根据权利要求1至8中任一项所述的深度过滤器，其中构成所述基材层的无纺布是聚烯烃系纤维的熔喷无纺布或热风无纺布。
10.根据权利要求1至9中任一项所述的深度过滤器，其中构成所述基材层的无纺布、与构成所述表皮层的无纺布是相同的无纺布。
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