CN114867896A - Fiber aggregate - Google Patents

Fiber aggregate Download PDF

Info

Publication number
CN114867896A
CN114867896A CN202080085304.6A CN202080085304A CN114867896A CN 114867896 A CN114867896 A CN 114867896A CN 202080085304 A CN202080085304 A CN 202080085304A CN 114867896 A CN114867896 A CN 114867896A
Authority
CN
China
Prior art keywords
less
fiber
fibers
fiber aggregate
air
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.)
Granted
Application number
CN202080085304.6A
Other languages
Chinese (zh)
Other versions
CN114867896B (en
Inventor
垰口信一
尾下竜大
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.)
Yamashin Filter Corp
Original Assignee
Yamashin Filter Corp
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 Yamashin Filter Corp filed Critical Yamashin Filter Corp
Publication of CN114867896A publication Critical patent/CN114867896A/en
Application granted granted Critical
Publication of CN114867896B publication Critical patent/CN114867896B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • 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
    • B32B5/22Layered 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
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/016Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the fineness

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Filtering Materials (AREA)

Abstract

Provided is a fiber aggregate which is particularly useful as a filter medium for an air filter. A fiber aggregate in which the average fiber diameter of fibers constituting the fiber aggregate is 600nm to 1500nm, the content of fibers having a fiber diameter of 1 μm to less than 2 μm is 10% to 50%, and the fibers constituting the fiber aggregate contain a thermoplastic resin as a main component.

Description

Fiber aggregate
Technical Field
The present invention relates to a fiber aggregate.
Background
Nonwoven fabrics have been used for various purposes such as filter media for air filters, filter media for oil filters, oil absorbent materials, sound absorbing materials, impact absorbing materials, heat insulating materials, and heat insulating materials.
For example, patent document 1 describes a nonwoven fabric and a bag filter medium having not only excellent trapping performance but also excellent pleating properties, and the nonwoven fabric is characterized by comprising: an ultrafine fiber A having a fiber diameter D of 100 to 1000nm and a fiber B having a fiber diameter larger than that of the ultrafine fiber A, wherein the nonwoven fabric has a lattice stiffness of 2000mgf or more.
In addition, patent document 2 describes a filter medium for an air filter, which is characterized in that the filter medium for an air filter mainly comprises glass fibers, the glass fibers include chopped glass fibers and ultrafine glass fibers, and the cumulative frequency in a fiber diameter distribution of the filter medium for an air filter is 2 to 15% in a range of more than 1.5 μm and 2.9 μm or less, in order to provide a filter medium for an air filter with less energy consumption, high efficiency, and low pressure loss.
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. 2019-99946
Patent document 2: japanese patent laid-open publication No. 2019-177331
Disclosure of Invention
Problems to be solved by the invention
The invention aims to provide a fiber assembly which is particularly useful as a filter medium for an air filter.
Means for solving the problems
The present inventors have conducted intensive studies and, as a result, have found that: the above problem can be solved by setting the average fiber diameter and the distribution of the fiber diameters to specific ranges.
That is, the present invention relates to the following <1> - <11 >.
<1> a fiber aggregate in which the average fiber diameter of the fibers constituting the fiber aggregate is 600nm or more and 1500nm or less,
the content of fibers having a fiber diameter of 1 μm or more and less than 2 μm is 10% or more and 50% or less,
the fibers constituting the fiber aggregate contain a thermoplastic resin as a main component.
<2> the fiber assembly according to <1>, which comprises 35% or more of fibers having a fiber diameter of 400nm or more and less than 1000 nm.
<3> the fiber assembly according to <1> or <2>, wherein a content of the fibers having a fiber diameter of 2 μm or more is 20% or less.
<4> the fiber assembly according to any one of <1> to <3>, wherein a content of the fibers having a fiber diameter of 400nm or more and less than 600nm is 5% or more and 40% or less.
<5> the fiber assembly according to any one of <1> to <4>, wherein a content of the fiber having a fiber diameter of 600nm or more and less than 800nm is 5% or more and 40% or less.
<6> the fiber assembly according to any one of <1> to <5>, wherein a content of the fibers having a fiber diameter of 800nm or more and less than 1000nm is 5% or more and 40% or less.
<7> the fiber assembly according to any one of <1> to <6>, wherein a content of the fibers having a fiber diameter of less than 400nm is 20% or less.
<8> the fiber assembly according to any one of <1> to <7>, wherein the fiber assembly is a dry fiber assembly.
<9> the fiber assembly according to any one of <1> to <8>, wherein the thermoplastic resin is at least 1 selected from the group consisting of polyolefin resins and polyester resins.
<10> the fiber aggregate according to any one of <1> to <9>, wherein the thermoplastic resin is at least 1 selected from the group consisting of polypropylene and polybutylene terephthalate.
<11> the fiber aggregate according to any one of <1> to <10>, wherein a CV value of a mass per unit area of the fiber aggregate is 20% or less.
ADVANTAGEOUS EFFECTS OF INVENTION
According to the present invention, a fiber aggregate particularly useful as a filter medium for an air filter can be provided.
Drawings
Fig. 1 is a schematic diagram showing an outline of a meltblowing apparatus 1.
Detailed Description
[ fiber aggregate ]
The fiber aggregate of the present invention is as follows: the average fiber diameter of fibers constituting the fiber aggregate is 600nm to 1500nm, the content of fibers having a fiber diameter of 1 μm to less than 2 μm is 10% to 50%, and the fibers constituting the fiber aggregate contain a thermoplastic resin as a main component.
According to the present invention, a fiber assembly which has a low pressure loss and a high collection efficiency and is useful as a filter medium for an air filter can be obtained. The detailed reason why the above-described effects can be obtained is not clear, but is considered as follows in some cases.
When the content of the fibers having a fiber diameter of 1 μm or more and less than 2 μm is in the above range, it is considered that a proper presence of the fibers having a large fiber diameter provides appropriate voids to the fiber aggregate, thereby reducing the pressure loss. On the other hand, it is considered that a fiber aggregate having a high collection rate is obtained by setting the average fiber diameter to 1500nm or less, and that the pressure loss is reduced by setting the average fiber diameter to 600nm or more.
The invention discovers that: the average fiber diameter and the fiber diameter distribution of the fiber diameters constituting the fiber aggregate are set to specific ranges, whereby the fiber aggregate particularly useful as a filter medium for an air filter is formed.
The present invention will be described in more detail below.
< fiber diameter >
[ average fiber diameter ]
The average fiber diameter of the fibers constituting the fiber aggregate of the present invention is 600nm or more and 1500nm or less. When the average fiber diameter of the fibers constituting the fiber assembly is within the above range, the pressure loss is low and the collection rate is high.
From the viewpoint of forming a lower pressure loss and a high trapping rate, the average fiber diameter is preferably 700nm or more, more preferably 800nm or more, further preferably 900nm or more, and preferably 1450nm or less, more preferably 1400nm or less, further preferably 1300nm or less.
The average fiber diameter of the fibers constituting the fiber aggregate was measured according to the method described in examples.
[ content of fiber having a fiber diameter of 1 μm or more and less than 2 μm ]
The content of the fibers having a fiber diameter of 1 μm or more and less than 2 μm in the fibers constituting the fiber aggregate of the present invention is 10% or more and 50% or less. When the content of the fibers having a fiber diameter of 1 μm or more and less than 2 μm is in the above range, the pressure loss is low and the collection rate is high.
The content of the fibers having a fiber diameter of 1 μm or more and less than 2 μm is preferably 15% or more, more preferably 18% or more, further preferably 20% or more, and preferably 47% or less, more preferably 45% or less, further preferably 42% or less.
The content of the fibers having a fiber diameter of 1 μm or more and less than 2 μm was measured by the method described in examples.
[ content of fiber having a fiber diameter of 400nm or more and less than 1000nm ]
From the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate, the content of the fibers having a fiber diameter of 400nm or more and less than 1000nm in the fibers constituting the fiber aggregate of the present invention is preferably 35% or more, more preferably 36% or more, further preferably 38% or more, and preferably 90% or less, more preferably 85% or less, further preferably 75% or less.
The content of the fibers having a fiber diameter of 400nm or more and less than 1000nm was measured by the method described in examples.
[ content of fiber having a fiber diameter of 2 μm or more ]
From the viewpoint of obtaining a fiber aggregate having a high collection rate, the content of the fibers having a fiber diameter of 2 μm or more in the fibers constituting the fiber aggregate of the present invention is preferably 20% or less, more preferably 18% or less, and further preferably 16% or less.
The content of the fibers having a fiber diameter of 2 μm or more was measured by the method described in examples.
[ content of fiber having a fiber diameter of 400nm or more and less than 600nm ]
From the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate, the content of fibers having a fiber diameter of 400nm or more and less than 600nm in the fibers constituting the fiber aggregate of the present invention is preferably 5% or more, and preferably 40% or less, more preferably 30% or less, and still more preferably 25% or less.
The content of the fibers having a fiber diameter of 400nm or more and less than 600nm was measured by the method described in examples.
[ content of fiber having a fiber diameter of 600nm or more and less than 800nm ]
From the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate, the content of fibers having a fiber diameter of 600nm or more and less than 800nm in the fibers constituting the fiber aggregate of the present invention is preferably 5% or more, more preferably 8% or more, further preferably 10% or more, and preferably 40% or less, more preferably 35% or less, further preferably 30% or less.
The content of the fiber width having a fiber diameter of 600nm or more and less than 800nm was measured by the method described in examples.
[ content of fiber having a fiber diameter of 800nm or more and less than 1000nm ]
From the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate, the content of fibers having a fiber diameter of 800nm or more and less than 1000nm in the fibers constituting the fiber aggregate of the present invention is preferably 5% or more, more preferably 6% or more, further preferably 8% or more, and preferably 40% or less, more preferably 35% or less, further preferably 30% or less.
The content of the fiber width having a fiber diameter of 800nm or more and less than 1000nm was measured by the method described in examples.
[ content of fiber having a fiber diameter of less than 400nm ]
From the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate, the content of fibers having a fiber diameter of less than 400nm in the fibers constituting the fiber aggregate of the present invention is preferably 20% or less, more preferably 18% or less, and still more preferably 15% or less. The lower limit is not particularly limited, and may be 0%.
The content of the fiber width having a fiber diameter of less than 400nm was measured by the method described in examples.
[ geometric Standard deviation ]
From the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate, the geometric standard deviation of the fiber diameter of the entire fibers constituting the fiber aggregate of the present invention is preferably 3.0 μm or less, more preferably 2.6 μm or less, further preferably 2.2 μm or less, and further preferably 0.5 μm or more, more preferably 0.8 μm or more, further preferably 1.0 μm or more. It is preferable that the fiber aggregate has excellent in-plane uniformity in which the geometric standard deviation of the fiber diameter of the entire fiber is within the above range.
From the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate, the geometric standard deviation of the fiber diameter of the fibers having a fiber diameter of less than 1 μm (less than 1000nm) among the fibers constituting the fiber aggregate of the present invention is preferably 5.0 μm or less, more preferably 3.0 μm or less, further preferably 2.2 μm or less, and from the viewpoint of ease of production, preferably 0.3 μm or more, more preferably 0.5 μm or more, further preferably 1.0 μm or more.
From the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate, the geometric standard deviation of the fiber diameter of the fibers having a fiber diameter of 1 μm or more among the fibers constituting the fiber aggregate of the present invention is preferably 3.0 μm or less, more preferably 2.0 μm or less, and further preferably 1.5 μm or less, and from the viewpoint of ease of production, preferably 0.1 μm or more, more preferably 0.3 μm or more, and further preferably 0.5 μm or more.
The fibers constituting the fiber aggregate of the present invention preferably have the above-described distribution of fiber diameters, but from the viewpoint of ease of production and uniformity in plane, a collection of fibers having a broad distribution and optionally having 2 or more peaks is preferred, rather than using a mixture of fibers having a large diameter and fibers having a small diameter.
< thermoplastic resin >
The fibers constituting the fiber aggregate of the present invention contain a thermoplastic resin as a main component. The fiber aggregate of the present invention is preferably produced by a melt blowing method as described later, and a thermoplastic resin is suitable as a fiber material.
As the thermoplastic resin, polyolefin resins such as Polyethylene (PE), polypropylene (PP), and the like; polyester resins such as polybutylene terephthalate (PBT) and polyethylene terephthalate (PET); polyamide resin (PA), and the like. Among them, the thermoplastic resin is preferably at least 1 selected from polyolefin resins and polyester resins, more preferably at least 1 selected from polypropylene and polybutylene terephthalate, and further preferably polypropylene.
The thermoplastic resin may be used alone in 1 kind, or may be used in combination in 2 or more kinds.
The fibers constituting the fiber aggregate of the present invention contain the thermoplastic resin in an amount of 50 mass% or more, preferably 70 mass% or more, more preferably 90 mass% or more, and further preferably 95 mass% or more, and may be 100 mass% or less, and the amount of the thermoplastic resin may be 100 mass%.
In the present invention, the fiber aggregate may contain other components in addition to the thermoplastic resin. Examples of the other components include surfactants, colorants, antioxidants such as phosphorus-based and phenol-based antioxidants, weather-resistant stabilizers such as benzotriazole-based stabilizers, light-resistant stabilizers such as hindered amine-based stabilizers, antiblocking agents, dispersants such as calcium stearate, lubricants, nucleating agents, pigments, softeners, hydrophilizers, water repellents, auxiliary agents, water repellents, fillers, antibacterial agents, agricultural chemicals, insect repellents, chemicals, natural oils, synthetic oils, and the like.
< method for producing fiber aggregate >
The fiber aggregate of the present invention is not particularly limited as long as the average fiber diameter and the fiber diameter distribution can be obtained, and it may be produced in a dry manner or a wet manner. Among these, the thermoplastic resin is preferably produced by a melt blowing method, and more preferably by a melt blowing method in which a thermoplastic resin is melted and discharged from a nozzle of an extruder and is blown out under a high-speed and high-temperature air flow.
More specifically, it is preferable that the fiber aggregate is produced by discharging the molten thermoplastic resin from above to below in a high-temperature atmosphere, blowing high-temperature and high-pressure air in a substantially horizontal direction from an air nozzle to the discharged thermoplastic resin, forming the molten thermoplastic resin into a fibrous resin, and collecting the fibrous resin. In the above method, the molten thermoplastic resin is stretched by air blown from an air nozzle to form a fibrous resin.
Here, the longer the distance to capture, the lower the density of the fiber aggregate tends to be obtained. Further, the fiber diameter of the fibrous resin tends to be smaller as the temperature of the air blown to the discharged thermoplastic resin is higher, and the fiber diameter of the fibrous resin tends to be smaller as the amount of the air blown is higher. In addition, if the discharge amount per unit time of the thermoplastic resin after melting is reduced, the fiber diameter tends to be small.
In addition, when the fiber aggregate is produced while winding the collected fibrous resin, the weight per unit area (mass per unit area) can be increased by reducing the winding speed.
In the present invention, a method for producing a particularly suitable fiber aggregate will be described in detail with reference to fig. 1. Fig. 1 is a schematic diagram showing an outline of a meltblowing apparatus 1.
The meltblowing apparatus 1 mainly has: resin supply unit 10, air flow generation unit 20, trap unit 30, and superheated steam supply unit 40.
The resin supply section 10 mainly includes: hopper 11, extruder 12, die 13, and resin nozzle 14. The raw material chips of the thermoplastic resin are put into the hopper 11, and the raw material chips are heated by a heater, not shown, provided in the extruder 12 to melt the thermoplastic resin, thereby obtaining a molten thermoplastic resin. The extruder 12 extrudes the molten thermoplastic resin to the die 13 by a gear pump, not shown.
The resin nozzle 14 is provided in the die head 13 and discharges the molten thermoplastic resin. The molten thermoplastic resin is discharged from the resin nozzle 14 from the upper side to the lower side.
The airflow generation unit 20 mainly includes: a compressor 21 for generating compressed air, a pipe 22 through which the compressed air passes, a regulator 23, a heater 24 for heating the pipe 22, and an air nozzle 25. The compressor 21, the pipe 22, and the heater 24 correspond to a high-temperature high-pressure air generating unit that generates high-temperature high-pressure air. The air nozzle 25 is provided adjacent to the resin nozzle 14, and discharges high-temperature and high-pressure air generated by the high-temperature and high-pressure air generating unit.
The temperature of the air discharged from the air nozzle 25 may be appropriately selected depending on the kind of the thermoplastic resin, and is preferably 400 ℃ or higher, more preferably 450 ℃ or higher, further preferably 470 ℃ or higher, and preferably 800 ℃ or lower, more preferably 700 ℃ or lower, further preferably 650 ℃ or lower, further preferably 620 ℃ or lower, from the viewpoint of obtaining a desired average fiber diameter and fiber diameter distribution.
The resin nozzles 14 and the air nozzles 25 are arranged in a row in the depth of the drawing sheet, the arrangement direction of the air nozzles 25 is substantially parallel to the arrangement direction of the resin nozzles 14, and the arrangement region of the air nozzles 25 includes the arrangement region of the resin nozzles 14.
The air nozzle 25 discharges high-temperature and high-pressure air in a substantially horizontal direction. From the viewpoint of obtaining a desired average fiber diameter and fiber diameter distribution, the flow rate of air discharged from the air nozzle 25 is preferably 5L/min or more, more preferably 10L/min or more, further preferably 15L/min or more, and is preferably 60L/min or less, more preferably 45L/min or less, further preferably 35L/min or less. By blowing the air discharged from the air nozzle 25, the molten thermoplastic resin discharged from the resin nozzle 14 is stretched to form a fibrous resin.
The trap unit 30 mainly includes: a substantially cylindrical vacuum drum 31 for collecting the fibrous resin, a blower 32, a suction unit 33 connected to the blower 32, nonwoven fabric rolls 34 and 35 around which nonwoven fabrics 51 and 52 are wound, and a winding drum 36. Here, the nonwoven fabric 51 is a base material, and the nonwoven fabric 52 is a covering material (protective material).
The molten polymer discharged from the resin nozzle 14 is formed into fine fibers (for example, nanofibers) by the air discharged from the air nozzle 25 and blown to the vacuum drum 31. The nonwoven fabric 51 spun from the nonwoven fabric roll 34 is wound around the vacuum drum 31, and air is sucked from the suction unit 33 to adsorb the fibrous resin on the surface of the nonwoven fabric 51.
The end of the nonwoven fabric 51 is provided on the winding drum 36. As the winding drum 36 rotates at a constant speed, the nonwoven fabric 51 having the fibrous resin adsorbed on the surface thereof moves toward the winding drum 36 at a constant speed.
The nonwoven fabric 52 spun from the nonwoven fabric roll 35 is also provided at the end on the winding drum 36. Therefore, the nonwoven fabric 52 covers the fiber layer on the surface of the nonwoven fabric 51 as the take-up drum 36 rotates at a constant speed. The nonwoven fabric 52 covers the fiber layer on the surface of the nonwoven fabric 51 and is integrated by calendering or the like, so that the fiber aggregate is sandwiched between the nonwoven fabrics 51 and 52, and wound around the take-up drum 36.
In the present invention, the base material and the covering material are not essential features, and the fiber aggregate is a portion in which the resin discharged from the resin nozzle 14 is formed into a fibrous resin and laminated. Therefore, the fiber aggregate of the present invention may be used in a form of being sandwiched between the base material and the covering material, or only the fiber aggregate may be used.
The superheated steam supply unit 40 supplies superheated steam to a space surrounded by the resin nozzle 14, the air nozzle 25, and the vacuum drum 31. The space surrounded by the resin nozzle 14, the air nozzle 25, and the vacuum drum 31 is a region where the molten thermoplastic resin is fiberized by the air blown from the air nozzle 25. The superheated steam supply unit 40 mainly includes: a heater 41 for generating superheated steam, a pipe 42, and a superheated steam nozzle 43.
The heater 41 further heats saturated steam generated by a boiler or the like, not shown, to generate superheated steam having a high temperature. The superheated steam is dry steam having a temperature higher than the boiling point, and is used in a temperature range of 200 ℃ to 700 ℃, for example.
The superheated steam generated by the heater 41 is supplied to the superheated steam nozzle 43 through the pipe 42 and discharged from the superheated steam nozzle 43. The superheated steam nozzles 43 are arranged in a row deep in the paper plane, the arrangement direction of the superheated steam nozzles 43 is substantially parallel to the arrangement direction of the resin nozzles 14 and the air nozzles 25, and the arrangement region of the superheated steam nozzles 43 includes the arrangement regions of the resin nozzles 14 and the air nozzles 25.
By supplying a large amount of superheated steam from the superheated steam nozzle 43, the space surrounded by the resin nozzle 14, the air nozzle 25, and the vacuum drum 31 can be placed in a high-temperature and high-humidity atmosphere.
The center axis of the resin nozzle 14 is substantially perpendicular. Therefore, the molten thermoplastic resin discharged from the resin nozzle 14 falls vertically downward due to its own weight.
The center axis of the air nozzle 25 is substantially horizontal. Therefore, high-temperature and high-pressure air is blown out from the air nozzle 25 in the horizontal direction.
The air nozzle 25 preferably intersects the central axis of the resin nozzle 14. That is, the tip of the air nozzle 25 is preferably located forward of the center axis of the resin nozzle 14. The air blown out from the air nozzle 25 generates a wake, and the molten thermoplastic resin discharged from the resin nozzle 14 is blown off in the horizontal direction by the wake, and thereafter, is blown off forward by the air discharged from the air nozzle 25, and is stretched to form a fibrous resin, which is blown onto the vacuum drum 31 disposed in front of the air nozzle 25.
The center axis of the superheated steam nozzle 43 is inclined in the horizontal direction, and preferably, the superheated steam is discharged to the air nozzle 25 from below and behind the air nozzle 25. The superheated steam discharged from the superheated nozzle 43 flows in the horizontal direction with a wake flow, and is supplied into the atmosphere surrounded by the resin nozzle 14, the air nozzle 25, and the vacuum drum 31. By placing the superheated steam on the wake, the superheated steam can be easily diffused into the space surrounded by the resin nozzle 14, the air nozzle 25, and the vacuum drum 31.
Since the superheated steam is supplied to the space surrounded by the resin nozzle 14, the air nozzle 25, and the vacuum drum 31, the molten thermoplastic resin discharged from the resin nozzle 14 is drawn in a high-temperature atmosphere to be formed into a fiber shape.
< Properties of fiber aggregate >
[ weight per unit area of fiber aggregate ]
In the present invention, when the fiber aggregate is used for an air filter, the weight per unit area (mass per unit area) of the fiber aggregate is preferably 10g/m from the viewpoint of obtaining a fiber aggregate having a low pressure loss and a high collection rate 2 More preferably 15g/m or more 2 Above, more preferably 20g/m 2 More than or preferably 25g/m 2 Above, and preferably 50g/m 2 Below, more preferably 40g/m 2 Hereinafter, more preferably 35g/m 2 The following.
The fiber aggregate of the present invention is also characterized by excellent in-plane uniformity, and the CV value per unit area weight is preferably 20% or less, more preferably 16% or less, further preferably 12% or less, and from the viewpoint of ease of production, preferably 0.5% or more, more preferably 1% or more, further preferably 2% or more.
The basis weight and CV value of the fiber assembly were measured by the methods described in examples.
[ thickness of fiber aggregate ]
The thickness of the fiber aggregate of the present invention can be appropriately selected depending on the application, and when the fiber aggregate is used for an air filter application, the thickness of the fiber aggregate is preferably 30 μm or more, more preferably 45 μm or more, further preferably 60 μm or more, further preferably 85 μm or more, further preferably 100 μm or more, from the viewpoint of improvement in the collection efficiency, and is preferably 500 μm or less, more preferably 400 μm or less, further preferably 300 μm or less, further preferably 240 μm or less, further preferably 180 μm or less, from the viewpoint of reduction in pressure loss.
When the fiber aggregate is used for an air filter, the thickness of the fiber aggregate is measured by a thickness gauge manufactured by Mitutoyo co.
In the case of forming a thicker fiber aggregate, the thickness of the fiber aggregate may be appropriately changed depending on the application, and the thickness may be measured by a side-standing ruler to be a natural thickness.
[ Capture ratio of particles having a diameter of 0.3 μm of fiber aggregate ]
When the fiber aggregate of the present invention is used for a filter medium for an air filter, the collection rate (collection efficiency) of particles having a diameter of 0.3 μm at a transmission wind speed of 5.3 cm/sec is preferably 55% or more, more preferably 57% or more, and still more preferably 60% or more.
The trapping ratio is measured by the effect of trapping particles by eliminating static electricity by removing electric charges from the filter medium for an air filter. The fiber aggregate has excellent trapping performance by forming a fiber aggregate having a specific average fiber diameter and distribution of fiber diameters.
The collection rate was measured according to the method described in examples.
[ pressure loss of fiber aggregate ]
When the fiber aggregate of the present invention is used for a filter medium for an air filter, the pressure loss is preferably low, and the pressure loss when the permeation air velocity is 5.3 cm/sec is preferably 40Pa or less, more preferably 35Pa or less, and still more preferably 32Pa or less.
The pressure loss was measured according to the method described in examples.
[ PF value ]
The PF value is a value representing the balance between the trapping rate and the pressure loss, is generally used as an index representing the performance of the filter medium for an air filter, and is represented by the following formula (1).
PF value (1/kPa)
=-log 10 { (100-Capture (%)/100 }/(pressure loss (Pa)/1000) (1)
The higher the PF value, the higher the performance as a filter medium for an air filter.
When the fiber aggregate of the present invention is used for a filter medium for an air filter, the PF value (1/kPa) obtained from the collection rate of particles having a diameter of 0.3 μm at a permeation air velocity of 5.3 m/sec and the pressure loss at a permeation air velocity of 5.3 m/sec is preferably 10 or more, more preferably 15 or more, and further preferably 18 or more.
< use >)
The fiber aggregate of the present invention is useful as a filter medium for an air filter as described above, but is not limited thereto, and can be used as a filter medium for an oil filter, an oil absorbing material, a heat insulating material, a heat accumulating material, a heat insulating material, a sound absorbing material, and the like.
The fiber aggregate of the present invention may have a lower layer (base material) and an upper layer (cover material) thereof, and may be used for various applications such as the filter medium for an air filter by being laminated with other layers.
Examples
The features of the present invention will be described in more detail below with reference to examples and comparative examples. The materials, amounts, ratios, processing contents, processing steps and the like shown in the following examples may be appropriately changed without departing from the gist of the present invention. Therefore, the scope of the present invention should not be construed as being limited to the specific examples shown below. In the examples and comparative examples, "part(s)" and "%" represent "part(s) by mass" and "% by mass", respectively, unless otherwise specified.
[ measurement/evaluation ]
< determination of fiber diameter >
[ measuring device ]
A splash device: MODEL MSP-1S Magnetron Sputer, manufactured by Vacuum Device Inc
SEM: VHX-D510 manufactured by KEYENCE CORPORATION
VHX-950F manufactured by KEYENCE CORPORATION
[ measurement method ]
Gold vapor deposition was performed on the measurement sample by the sputtering device, and the diameter of 100 or more fibers was measured at a magnification (2500 to 3000 times) at which 100 fibers fall in the field of view. From the obtained data, the distribution of the fiber diameters was calculated.
In the case of a fiber aggregate having a width of about 1m, the central portion (about 40 to 60cm from the end portion) of the fiber aggregate divided into 5 parts in the width direction was used as a sample.
Average fiber diameter calculation method
(1) The measured values were classified into the following ranks, and the relative degrees were obtained.
Less than 200nm, 200nm or more and less than 400nm, 400nm or more and less than 600nm, 600nm or more and less than 800nm, 800nm or more and less than 1000nm, 1 μm or more and less than 2 μm, 2 μm or more and less than 3 μm, 3 μm or more and less than 5 μm, 5 μm or more and less than 10 μm, 10 μm or more
(2) The rank values of the respective ranks are as follows.
Below 200 nm; grade value of 200nm
200nm or more and less than 400 nm; grade value 300nm
400nm or more and less than 600 nm; grade value 550nm
More than 600nm and less than 800 nm; grade value 750nm
800nm or more and 1000 nm; grade value 850nm
1 μm or more and less than 2 μm; grade value 1500nm
2 μm or more and less than 3 μm; rank value 2500nm
3 μm or more and less than 5 μm; grade value 4000nm
5 μm or more and less than 10 μm; grade value of 7500nm
More than 10 μm; grade value 10000nm
(3) The average fiber diameter was taken as the logarithmic average of the measured fiber diameters.
< thickness >
The thickness of the fiber assembly and the nonwoven fabric used as the base material and the covering material was measured using a thickness meter (547-301) made by Mitutoyo co.
For the following items, a fiber aggregate having a width of about 1m was divided into 5 segments in the width direction, and the average value was determined for each measurement.
< weight per unit area >
Weight per unit area throughA sample cut into a 10cm square was measured with a precision balance, and the mass (g) was divided by the area (0.01 m) 2 ) And the resulting value. For the weight per unit area, the CV value was calculated together with the average value.
CV value (%) - (standard deviation of weight distribution per unit area/average weight per unit area) × 100
The CV value was calculated as the basis weight of the fiber aggregate by measuring the basis weight of the filter medium for an air filter in which the base material, the fiber aggregate, and the covering material were sequentially laminated in this order, and subtracting the basis weight of the base material and the covering material.
< pressure loss >
A measurement sample of a filter medium for an air filter, which was obtained by stacking a base material, a fiber aggregate, and a covering material in this order, was attached to a filter medium having a diameter of 113mm (effective filter medium area 100 cm) 2 ) The filter holder (2) was adjusted by a flow meter so that the air velocity of the filter medium passing therethrough became 5.3 cm/sec. Then, the pressure loss generated upstream and downstream of the sample filter at this time was measured by a pressure gauge. The filter medium for an air filter as a measurement sample was subjected to charge elimination processing in advance, and then the pressure loss was measured. Charge removal of filter medium for air filter is in accordance with JIS B9908: 2011 "performance test method of air filter unit for ventilation and electric dust collector for ventilation", 5.2.3.3d) of 2) IPA saturated vapor exposure method.
The base material and the covering material are formed of a nonwoven fabric having a large mesh, and have almost no influence on the pressure loss.
< trapping efficiency >
After a filter medium for an air filter as a measurement sample was attached to the same filter holder as that used for the measurement of the pressure loss, atmospheric dust was introduced to the upstream side of the filter medium, and the number of particles upstream and downstream of particles having a diameter of 0.3 μm when air was passed at a flow rate of 5.3 cm/sec was measured by a particle measuring instrument (Beckman Coulter, inc., MET ONE HHPC 3 +). The collection efficiency was calculated by the following equation. The filter medium for an air filter as a measurement sample was subjected to charge elimination treatment in advance, and then the collection efficiency was measured. Charge removal of filter medium for air filter is in accordance with JIS B9908: 2011 "method for testing performance of air filter unit for ventilation and electric dust collector for ventilation" 5.2.3.3d) of 2) IPA saturated vapor exposure method.
Collection efficiency (%) (1- (CO/CI)) × 100
CO-particle count of downstream 0.3 μm particles
CI is the number of particles of 0.3 μm particles on the upstream side
The base material and the covering material are formed of a nonwoven fabric having a large mesh, and have almost no influence on the collection efficiency.
< PF value >
The PF value was determined from the pressure loss and the collection efficiency (collection efficiency of particles having a particle diameter of 0.3 μm) determined as described above according to the following equation. The PF value is a conventionally used value as an index indicating the balance between the trapping performance and the pressure loss of the filter medium for an air filter, and the PF value increases as the performance is better.
PF value (1/kPa)
{ -log ((100-capture efficiency (%)/100) }/(pressure loss (Pa)/1000)
[ production of fiber aggregate ]
Using the meltblowing apparatus shown in fig. 1, fiber aggregates were produced by changing the discharge amount per hole (discharge amount per 1 hole), the discharge air volume per 1 hole (L/min) of the air nozzle 25, the discharge temperature (c) from the air nozzle 25, and the thickness of the fiber aggregate as shown in table 1, and the obtained fiber aggregates were measured and evaluated according to the above-described method.
In addition, a spunbonded nonwoven fabric (made of polyester and having a basis weight of 12 g/m) was used in the production 2 R004 manufactured by Mitsui chemical Co., Ltd, and having a thickness of 0.13mm, as a base material, a polyethylene terephthalate long fiber nonwoven fabric (having a basis weight of 25 g/m) was used 2 E1025 (manufactured by Asahi Kasei Co., Ltd.) and a thickness of 0.15mm) was used as a covering material.
The results are shown in table 1 below.
[ Table 1]
TABLE 1
Figure BDA0003684306750000161
As shown in table 1, the fiber aggregate of the examples had a collection efficiency of 60% or more, a pressure loss (pressure loss) of 32Pa or less, and a PF value of 15.0 or more.
On the other hand, as in comparative example 1, when the content of the fibers having a diameter of 1 μm or more and less than 2 μm is less than 10%, the number of fine fibers is large, and the pressure loss is large. In comparative example 2 in which the content of fibers having a size of 1 μm or more and less than 2 μm was 50% or more, a sufficient collection rate (collection efficiency) could not be obtained.
Further, in comparative example 3 in which the average fiber diameter was less than 600nm, the pressure loss was large because many fibers were thin. In addition, the content of fibers having a diameter of 1 μm or more and less than 2 μm was less than 10%, and in comparative example 4 having a small average fiber diameter, the pressure loss was high, and a sufficient PF value could not be obtained.
Industrial applicability
The fiber aggregate of the present invention is suitably used as a filter medium for an air filter, and is expected to be used in various nonwoven fabric applications such as a filter medium for an oil filter, an oil absorbing material, a sound absorbing material, a heat insulating material, and a heat insulating material.
Description of the reference numerals
1: melt-blown device
10: resin supply part
11: hopper
12: extruding machine
13: die head
14: resin nozzle
20: air flow generating part
21: compressor with a compressor housing having a plurality of compressor blades
22: piping
23: regulator
24: heating device
25: air nozzle
30: collecting part
31: vacuum drum
32: blower fan
33: suction part
34. 35: non-woven fabric roll
36: winding drum
40: superheated steam supply unit
41: heating device
42: piping
43: superheated steam nozzle
51: nonwoven (substrate)
52: nonwoven fabric (covering material (protective material)).

Claims (11)

1. A fiber aggregate in which the average fiber diameter of the fibers constituting the fiber aggregate is 600nm or more and 1500nm or less,
the content of fibers having a fiber diameter of 1 μm or more and less than 2 μm is 10% or more and 50% or less,
the fibers constituting the fiber aggregate contain a thermoplastic resin as a main component.
2. The fiber assembly according to claim 1, wherein the fiber diameter of the fiber assembly is 400nm or more and less than 1000nm at 35% or more.
3. The fiber assembly according to claim 1 or 2, wherein the content of the fibers having a fiber diameter of 2 μm or more is 20% or less.
4. The fiber assembly according to any one of claims 1 to 3, wherein a content of fibers having a fiber diameter of 400nm or more and less than 600nm is 5% or more and 40% or less.
5. The fiber assembly according to any one of claims 1 to 4, wherein a content of fibers having a fiber diameter of 600nm or more and less than 800nm is 5% or more and 40% or less.
6. The fiber assembly according to any one of claims 1 to 5, wherein a content of fibers having a fiber diameter of 800nm or more and less than 1000nm is 5% or more and 40% or less.
7. The fiber assembly according to any one of claims 1 to 6, wherein the content of fibers having a fiber diameter of less than 400nm is 20% or less.
8. The fiber assembly according to any one of claims 1 to 7, wherein the fiber assembly is a dry fiber assembly.
9. The fiber assembly according to any one of claims 1 to 8, wherein the thermoplastic resin is at least 1 selected from a polyolefin resin and a polyester resin.
10. The fiber assembly according to any one of claims 1 to 9, wherein the thermoplastic resin is at least 1 selected from polypropylene and polybutylene terephthalate.
11. The fiber assembly according to any one of claims 1 to 10, wherein the CV value of the mass per unit area of the fiber assembly is 20% or less.
CN202080085304.6A 2019-12-18 2020-12-15 Fiber aggregate Active CN114867896B (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2019228650A JP6831132B1 (en) 2019-12-18 2019-12-18 Fiber laminate
JP2019-228650 2019-12-18
PCT/JP2020/046707 WO2021125157A1 (en) 2019-12-18 2020-12-15 Fiber aggregate

Publications (2)

Publication Number Publication Date
CN114867896A true CN114867896A (en) 2022-08-05
CN114867896B CN114867896B (en) 2024-03-01

Family

ID=74562452

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202080085304.6A Active CN114867896B (en) 2019-12-18 2020-12-15 Fiber aggregate

Country Status (3)

Country Link
JP (1) JP6831132B1 (en)
CN (1) CN114867896B (en)
WO (1) WO2021125157A1 (en)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022210895A1 (en) 2021-03-31 2022-10-06 日本製鉄株式会社 Rotating electric machine, set of iron core of stator and iron core of rotor, method for manufacturing rotating electric machine, method for manufacturing non-oriented electrical steel sheet for stator and non-oriented electrical steel sheet for rotor, method for manufacturing stator and rotor, and set of non-oriented electrical steel sheets
JP2023064242A (en) * 2021-10-26 2023-05-11 ヤマシンフィルタ株式会社 filter

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS58186412A (en) * 1982-04-26 1983-10-31 Asahi Chem Ind Co Ltd Filter medium
CN1092484A (en) * 1992-10-19 1994-09-21 三井石油化学工业株式会社 The bondedfibre fabric and the manufacture method thereof of electret [electricity is situated between] body state
CN1201846A (en) * 1997-04-08 1998-12-16 三井化学株式会社 Flexible spunbond unwoven fabric
JP2004270096A (en) * 2003-03-11 2004-09-30 Toray Ind Inc Filament nonwoven fabric and method for producing the same
CN103380242A (en) * 2011-01-28 2013-10-30 特布乐丝株式会社 Melt-blown nonwoven fabric comprising ultra-fine fibers, production method therefor, and device for producing same
CN107208338A (en) * 2015-03-16 2017-09-26 东丽精细化工株式会社 Non-woven fabrics and its manufacture method
CN107614772A (en) * 2015-07-24 2018-01-19 株式会社可乐丽 Superimposed fiber body
CN107614773A (en) * 2015-12-21 2018-01-19 松下知识产权经营株式会社 Fiber assembly
CN109219677A (en) * 2016-06-06 2019-01-15 北欧化工公司 Melt-blow fiber web with good waterproof performance

Family Cites Families (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2015190081A (en) * 2014-03-28 2015-11-02 旭化成せんい株式会社 Melt-blown nonwoven fabric

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS58186412A (en) * 1982-04-26 1983-10-31 Asahi Chem Ind Co Ltd Filter medium
CN1092484A (en) * 1992-10-19 1994-09-21 三井石油化学工业株式会社 The bondedfibre fabric and the manufacture method thereof of electret [electricity is situated between] body state
CN1201846A (en) * 1997-04-08 1998-12-16 三井化学株式会社 Flexible spunbond unwoven fabric
JP2004270096A (en) * 2003-03-11 2004-09-30 Toray Ind Inc Filament nonwoven fabric and method for producing the same
CN103380242A (en) * 2011-01-28 2013-10-30 特布乐丝株式会社 Melt-blown nonwoven fabric comprising ultra-fine fibers, production method therefor, and device for producing same
CN107208338A (en) * 2015-03-16 2017-09-26 东丽精细化工株式会社 Non-woven fabrics and its manufacture method
CN107614772A (en) * 2015-07-24 2018-01-19 株式会社可乐丽 Superimposed fiber body
CN107614773A (en) * 2015-12-21 2018-01-19 松下知识产权经营株式会社 Fiber assembly
CN109219677A (en) * 2016-06-06 2019-01-15 北欧化工公司 Melt-blow fiber web with good waterproof performance

Also Published As

Publication number Publication date
WO2021125157A1 (en) 2021-06-24
JP2021094807A (en) 2021-06-24
CN114867896B (en) 2024-03-01
JP6831132B1 (en) 2021-02-17

Similar Documents

Publication Publication Date Title
CN104854269B (en) Elastic force and concentrate the meltblown fiber web and its manufacturing method that power is improved
CN107208336B (en) Melt spun filter media for respiratory devices and face masks
CN114867896B (en) Fiber aggregate
KR102494455B1 (en) laminated nonwoven fabric
JP6264438B2 (en) Air filter medium, filter pack, and air filter unit
CN108505216A (en) The manufacturing method of polyester filament spun-bonded non-woven fabrics
JP7021852B2 (en) Multi-die melt blow system and method for forming mixed fiber structure
CN109563662B (en) System and method for making polylactic acid nonwoven fabrics
US10981095B2 (en) Nonwoven fabric and air filter including same
WO1988010330A1 (en) Reticulate polypropylene fibers, process for their production, and reticulate fiber nonwoven fabric
JP2019081998A (en) Meltblown nonwoven fabric
US20170151748A1 (en) Laminated nonwoven fabric
US20050077646A1 (en) Process for producing electret and production apparatus
CN101563576A (en) Infrared solvent stripping process
JP2020147878A (en) Core-sheath-type composite fiber, manufacturing method thereof, and fiber aggregate including the same
JP2002161467A (en) Method for producing electret processed article
CN109898148A (en) Electrostatic fibre preparation method and its products obtained therefrom
JP7352302B2 (en) Melt-blown nonwoven fabric for liquid filters, laminates of the melt-blown nonwoven fabrics, and liquid filters comprising the laminates
JP7458152B2 (en) Melt blowing equipment and nanofiber manufacturing method
CN112442743A (en) Melt-blown device
JP7515165B2 (en) Thermal insulation material
JP6129655B2 (en) Air filter medium manufacturing method
CN117180853B (en) Oil mist adsorption composite material and preparation method and application thereof
JP7468255B2 (en) Nonwoven fabric for sound absorption, sound absorbing material, and method for manufacturing nonwoven fabric for sound absorbing
JP7497016B2 (en) Composite nonwoven fabric, its manufacturing method, and composite nonwoven fabric manufacturing device

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination
GR01 Patent grant
GR01 Patent grant