JP2003275519A - Filter base material and filter - Google Patents
Filter base material and filterInfo
- Publication number
- JP2003275519A JP2003275519A JP2002075643A JP2002075643A JP2003275519A JP 2003275519 A JP2003275519 A JP 2003275519A JP 2002075643 A JP2002075643 A JP 2002075643A JP 2002075643 A JP2002075643 A JP 2002075643A JP 2003275519 A JP2003275519 A JP 2003275519A
- Authority
- JP
- Japan
- Prior art keywords
- filter
- melting point
- point component
- basis weight
- nonwoven fabric
- 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
Links
Landscapes
- Filtering Materials (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、部分的に熱接着さ
れた不織布からなるフィルター基材およびそのフィルタ
ー基材を支持体としてなるフィルターに関するものであ
る。本発明により供される不織布は、通気性が高いた
め、特にポリテトラフルオロエチレン、またはポリフッ
化ビニリデンのような通気性の低いフィルター材料の支
持体として好適であり、また剛軟度が高いため、特にプ
リーツ形状のフィルターとする場合、プリーツ加工性や
形態保持性に優れ好適である。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filter substrate made of a partially heat-bonded nonwoven fabric and a filter having the filter substrate as a support. Since the nonwoven fabric provided by the present invention has high air permeability, it is particularly suitable as a support for low air permeability filter materials such as polytetrafluoroethylene, or polyvinylidene fluoride, and also has high bending resistance, In particular, a pleat-shaped filter is preferable because it is excellent in pleat workability and shape retention.
【０００２】[0002]
【従来の技術】従来、フィルター基材として種々の不織
布が提案されている。一般にフィルター基材として使用
される不織布は、プリーツ加工を施し、フィルターユニ
ット中での表面積を大きくし、濾過性能を高めたものが
使用される。よって、フィルター基材として使用される
不織布には、プリーツ加工性やプリーツ形態保持性を高
めるため、剛性や強度が要求される。特に長繊維不織布
は、生産コストや縦方向の剛性、強度に優れるため使用
される分野も急速に拡大している。2. Description of the Related Art Conventionally, various non-woven fabrics have been proposed as a filter substrate. Generally, the non-woven fabric used as a filter substrate is one that has been subjected to pleating to increase the surface area in the filter unit and enhance the filtration performance. Therefore, the nonwoven fabric used as the filter base material is required to have rigidity and strength in order to enhance the pleating processability and the pleated shape retention. In particular, long-fiber nonwoven fabrics are rapidly expanding in fields of use because they are excellent in production cost, longitudinal rigidity, and strength.
【０００３】さらに近年では、フィルター基材である不
織布に、微多孔を有するポリテトラフルオロエチレンや
ポリフッ化ビニリデンなどをフィルター材として貼合せ
ることにより捕集性能を向上させ、かつ表面に付着した
粉塵の離脱性を高めたものが。高性能フィルターとして
使用されている。Further, in recent years, a non-woven fabric as a filter substrate is laminated with a finely porous polytetrafluoroethylene, polyvinylidene fluoride or the like as a filter material so as to improve the collecting performance and to prevent dust from adhering to the surface. The one with improved detachability. Used as a high performance filter.
【０００４】[0004]
【発明が解決しようとする課題】上記のポリテトラフル
オロエチレンやポリフッ化ビニリデンは、一般に膜厚が
数十〜数百μｍであるため、エアーフィルターなどのフ
ィルター材として使用する場合、ある程度の硬さ、強度
を有する支持体と貼り合わせることが不可欠である。さ
らに、プリーツ型フィルター材として使用する場合、こ
れら支持体には、プリーツ加工やプリーツの形態を保持
するのに必要な程度の剛性などが必要とされる。Since the above-mentioned polytetrafluoroethylene and polyvinylidene fluoride generally have a film thickness of several tens to several hundreds of μm, when used as a filter material such as an air filter, they have a certain degree of hardness. It is indispensable to bond it to a strong support. Further, when used as a pleat-type filter material, these supports are required to have a degree of rigidity necessary for pleating and maintaining the shape of the pleat.
【０００５】また、ポリテトラフルオロエチレンやポリ
フッ化ビニリデンなどのフィルター膜は、孔径０．０１
〜１０μｍ程度の微細孔を有しているため、通気性が非
常に低いという特徴がある。このため、これらフィルタ
ー膜の支持体は、より通気性の高いものが求められる。Further, a filter membrane such as polytetrafluoroethylene or polyvinylidene fluoride has a pore size of 0.01
Since it has fine pores of about 10 μm, it has a feature that the air permeability is extremely low. Therefore, the support for these filter membranes is required to have higher air permeability.
【０００６】従来、これら支持体として種々の不織布が
提案されているが、いずれもプリーツ材として使用する
に十分な剛性と、フィルター材として使用するに十分な
通気性を兼ね備えたものでは無かった。特にポリテトラ
フルオロエチレンやポリフッ化ビニリデンなどの支持体
として使用される場合には、著しく通気性を損なうもの
であった。Conventionally, various non-woven fabrics have been proposed as these supports, but none of them has sufficient rigidity for use as a pleated material and sufficient air permeability for use as a filter material. Especially when it is used as a support for polytetrafluoroethylene, polyvinylidene fluoride, etc., the air permeability is significantly impaired.
【０００７】本発明は、かかる従来技術の背景に鑑み、
熱可塑性連続フィラメントからなる熱圧着型不織布であ
り、かつフィルター基材として十分な剛性と通気性を兼
ね備えたフィルター基材、および該フィルター基材を骨
材として使用したフィルターを提供せんとするものであ
る。In view of the background of such prior art, the present invention is
It is intended to provide a filter base material which is a thermocompression-bonded non-woven fabric composed of thermoplastic continuous filaments and has sufficient rigidity and air permeability as a filter base material, and a filter using the filter base material as an aggregate. is there.
【０００８】[0008]
【課題を解決するための手段】本発明は、かかる課題を
解決するために、次のような手段を採用するものであ
る。The present invention employs the following means in order to solve the above problems.
【０００９】すなわち、本発明のフィルター基材は、熱
可塑性連続フィラメントからなる不織布で、該熱可塑性
連続フィラメントが高融点成分と低融点成分とからな
り、該不織布は部分的に熱圧着されたものであって、目
付が１００〜３００ｇ／ｍ2 で、目付と通気量の関係が
次式を満たし、かつ剛軟度が５００ｍｇｆ以上であるこ
とを特徴とするフィルター基材である。That is, the filter substrate of the present invention is a non-woven fabric composed of thermoplastic continuous filaments, which is composed of a high melting point component and a low melting point component, and the non-woven fabric is partially thermocompressed. The filter base material is characterized in that the basis weight is 100 to 300 g / m 2 , the relation between the basis weight and the air flow rate satisfies the following equation, and the bending resistance is 500 mgf or more.
【００１０】０．２５Ｘ＋Ｙ＞８０
Ｘ：目付（ｇ／ｍ2 ）
Ｙ：通気量（ｃｍ3 ／ｃｍ2 ／ｓｅｃ）
また、本発明のフィルターは、好ましくは上記フィルタ
ー基材を支持体とし、少なくともその片面にフィルター
層を有することを特徴とするフィルターである。さらに
好ましくは、フィルター層はポリテトラフルオロエチレ
ン、またはポリフッ化ビニリデンであることを特徴とす
るフィルターである。さらにまた、好ましくは、フィル
ターがプリーツ形状であることを特徴とするものであ
る。0.25X + Y> 80 X: basis weight (g / m 2 ) Y: air flow rate (cm 3 / cm 2 / sec) Further, the filter of the present invention preferably has the above-mentioned filter substrate as a support, and at least A filter having a filter layer on one surface thereof. More preferably, the filter layer is a filter characterized by being made of polytetrafluoroethylene or polyvinylidene fluoride. Furthermore, preferably, the filter is pleated.
【００１１】[0011]
【発明の実施の形態】本発明は、長繊維不織布を構成す
るフィラメントとして、高融点成分と低融点成分を使用
し、高融点成分と低融点成分の種類、重量比率、フィラ
メントの繊度、さらには熱圧着面積を適正化することに
より、高い剛性と高い通気性という相反する性能を兼ね
備えたフィルター基材を提供できるという事実を究明し
たものである。BEST MODE FOR CARRYING OUT THE INVENTION The present invention uses a high-melting point component and a low-melting point component as filaments constituting a long-fiber non-woven fabric, the types of high-melting point component and low-melting point component, weight ratio, filament fineness, and further By optimizing the thermocompression bonding area, the fact that a filter base material having both high rigidity and high air permeability, which are contradictory properties, can be provided is clarified.
【００１２】すなわち、本発明のフィルター基材として
は、剛軟度が５００ｍｇｆ以上であり、かつ目付が１０
０〜３００ｇ／ｍ2 であり、さらに目付（Ｘ：ｇ／
ｍ2 ）と通気量（Ｙ：ｇ／ｍ2 ）の関係が次式（１）を
満たす不織布が使用される。That is, the filter substrate of the present invention has a bending resistance of 500 mgf or more and a basis weight of 10
0 to 300 g / m 2 , and further has a basis weight (X: g /
A non-woven fabric is used in which the relationship between m 2 ) and air permeability (Y: g / m 2 ) satisfies the following formula (1).
【００１３】０．２５Ｘ＋Ｙ＞８０ ………（１）
また、より好ましくは次式（２）を満たす不織布であ
る。0.25X + Y> 80 (1) Further, more preferably, the nonwoven fabric satisfies the following formula (2).
【００１４】０．２５Ｘ＋Ｙ＞９５ ………（２）
本発明の不織布における通気性は、ＪＩＳ Ｌ１０９６
のフラジール型試験に基づいて測定した通気量の値によ
り表した。0.25X + Y> 95 (2) The breathability of the nonwoven fabric of the present invention is JIS L1096.
It was represented by the value of the aeration amount measured based on the Frazier type test.
【００１５】目付と通気量の関係が上記式（１）を満た
さない場合、不織布は通気性が低く、フィルター基材と
して使用した場合に圧損が高くなり、フィルター性能が
低いものとなる。また、ポリテトラフルオロエチレンや
ポリフッ化ビニリデンなどのフィルター膜と貼り合わせ
た場合、通気性が著しく低下して圧損が高くなり、フィ
ルター性能が著しく低いものとなる。When the relationship between the basis weight and the air flow rate does not satisfy the above formula (1), the nonwoven fabric has low air permeability, and when it is used as a filter base material, the pressure loss becomes high and the filter performance becomes low. Further, when it is attached to a filter membrane such as polytetrafluoroethylene or polyvinylidene fluoride, the air permeability is significantly reduced, the pressure loss is increased, and the filter performance is significantly reduced.
【００１６】また、不織布の目付は上記の通り１００〜
３００ｇ／ｍ2 であることが好ましく、さらに好ましく
は１５０〜２８０ｇ／ｍ2 である。目付が１００ｇ／ｍ
2 未満の場合は、不織布の剛性が低くなるため好ましく
なく、目付が３００ｇ／ｍ2を超える場合、不織布の剛
性は十分であるが、通気性が低くなるため好ましくな
い。The basis weight of the non-woven fabric is 100 to 100 as described above.
Is preferably 300 g / m 2, more preferably from 150~280g / m 2. Basis weight is 100 g / m
When it is less than 2 , the nonwoven fabric has low rigidity, which is not preferable. When the weight per unit area is more than 300 g / m 2 , the nonwoven fabric has sufficient rigidity, but it has poor air permeability, which is not preferable.
【００１７】さらに、本発明における不織布の剛軟度
は、ＪＩＳ Ｌ１０９６のガーレ法試験に基づいて測定
される剛軟度で表したとき、５００ｍｇｆ以上であるも
のが好ましく、８００ｍｇｆ以上であるものがさらに好
ましい。剛軟度が５００ｍｇｆより低い場合、不織布の
剛性不足のため、プリーツ加工性が著しく低下し、シー
トが蛇行したり、不均一なピッチが発生しやすいため好
ましくない。さらに、プリーツフィルターとしてフィル
ターに組み込んだ場合、剛性が弱いため、プリーツ山部
が風圧により湾曲、変形し、濾過面積が少なくなるため
好ましくない。ただし、本発明者らの各種知見によれ
ば、フィルターの一構成部材としての性能なども踏まえ
れば、剛軟度値の上限は４５００ｍｇｆ程度までであ
る。Further, the bending resistance of the nonwoven fabric of the present invention is preferably 500 mgf or more, more preferably 800 mgf or more, when expressed by the bending resistance measured by the Gurley method test of JIS L1096. preferable. When the bending resistance is lower than 500 mgf, the rigidity of the nonwoven fabric is insufficient, so that the pleating processability is remarkably reduced, the sheet is apt to meander, and uneven pitch is likely to occur, which is not preferable. Furthermore, when incorporated into a filter as a pleated filter, the rigidity is weak and the pleat peaks are curved and deformed by wind pressure, and the filtration area is reduced, which is not preferable. However, according to various findings of the present inventors, the upper limit of the bending resistance value is up to about 4500 mgf in view of the performance as a constituent member of the filter.
【００１８】本発明において使用される不織布は、熱可
塑性長繊維からなる不織布が好ましい。さらに該熱可塑
性長繊維が高融点成分と低融点成分からなることが好ま
しい。該高融点成分としては、不織布の強度、さらには
耐熱性の点からポリエチレンテレフタレートが好まし
く、該低融点成分としては、不織布を熱圧着させ適度な
剛性を得るために、共重合ポリエステルまたはポリブチ
レンテレフタレートが好ましい。該共重合ポリエステル
の共重合成分としては特に限定されるものではないが、
イソフタル酸、アジピン酸などが特に好ましい。該低融
点成分として最も好ましいものは、イソフタル酸を共重
合成分とした共重合ポリエステルである。The nonwoven fabric used in the present invention is preferably a nonwoven fabric made of thermoplastic long fibers. Further, it is preferable that the thermoplastic continuous fiber comprises a high melting point component and a low melting point component. As the high melting point component, polyethylene terephthalate is preferable from the viewpoint of strength of the nonwoven fabric, and also from the viewpoint of heat resistance, and as the low melting point component, in order to obtain appropriate rigidity by thermocompression bonding of the nonwoven fabric, copolyester or polybutylene terephthalate Is preferred. The copolymerization component of the copolymerized polyester is not particularly limited,
Isophthalic acid and adipic acid are particularly preferable. The most preferable one as the low melting point component is a copolyester having isophthalic acid as a copolymerization component.
【００１９】また、該低融点成分と該高融点成分の融点
差は１５℃以上であることが、熱圧着の点から好まし
い。該融点差が１５℃未満の場合、低融点成分だけでな
く、高融点成分も熱圧着により変形、ダメージを受け、
不織布の剛性、強度が低下するため好ましくない。低融
点成分と高融点成分の融点差は、より好ましくは２０℃
以上である。From the viewpoint of thermocompression bonding, it is preferable that the difference in melting point between the low melting point component and the high melting point component is 15 ° C. or more. If the melting point difference is less than 15 ° C., not only the low melting point component but also the high melting point component is deformed and damaged by thermocompression bonding,
It is not preferable because the rigidity and strength of the non-woven fabric are reduced. The melting point difference between the low melting point component and the high melting point component is more preferably 20 ° C.
That is all.
【００２０】さらに、該低融点成分の重量割合は不織布
全体の５〜４０％であることが好ましく、より好ましく
は１０〜３０％である。該低融点成分の重量割合が５％
未満の場合、熱接着力が低下し、不織布の層間が剥離、
さらには不織布の剛性が不足し、プリーツ加工時にシー
トが蛇行したり、折り曲げピッチが不均一となるため好
ましくない。また該低融点成分の重量割合が４０％を超
える場合、熱圧着力が著しく向上し、不織布の通気性が
低下するため好ましくない。Further, the weight ratio of the low melting point component is preferably 5 to 40%, more preferably 10 to 30% of the whole nonwoven fabric. The weight percentage of the low melting point component is 5%
If less than, the thermal adhesive strength is reduced, the interlayer of the non-woven fabric peels,
Furthermore, the rigidity of the non-woven fabric is insufficient, the sheet meanders during pleating, and the bending pitch becomes uneven, which is not preferable. Further, when the weight ratio of the low melting point component exceeds 40%, the thermocompression bonding force is remarkably improved and the air permeability of the nonwoven fabric is lowered, which is not preferable.
【００２１】本発明の不織布を構成する熱可塑性長繊維
は、高融点成分からなるフィラメントと、低融点成分か
らなるフィラメントの混繊であっても良いが、適度な熱
圧着により、剛性と通気性を調整しやすい点から、高融
点成分の周りを低融点成分が被覆してなる芯鞘型のフィ
ラメントが好ましい。The thermoplastic continuous fibers constituting the nonwoven fabric of the present invention may be a mixture of filaments composed of a high melting point component and filaments composed of a low melting point component, but by appropriate thermocompression bonding, rigidity and air permeability are obtained. A core-sheath type filament in which a high melting point component is coated with a low melting point component is preferable from the viewpoint of easy adjustment.
【００２２】また、該熱可塑性長繊維の繊度は４〜１３
デシテックスであることが好ましく、５〜１１デシテッ
クスがより好ましく、７〜１０デシテックスがさらに好
ましい。繊度が４デシテックス未満の場合、熱接着した
不織布の通気性が低くなってしまう場合があるので好ま
しくなく、また繊度が１３デシテックスを超える場合、
繊維を紡糸するときに十分に冷却することが困難になる
場合があり、生産性の点から好ましくない。また、上記
の繊度範囲４〜１３デシテックスを満たすフィラメント
の重量割合が、全フィラメントの５０％以上であること
が好ましく、より好ましくは７５％以上、最も好ましい
のは９０％以上である。該フィラメントの重量割合が５
０％未満の場合は、得られる不織布の通気性が低くなる
方向であり、特にポリテトラフルオロエチレンやポリフ
ッ化ビニリデンなどのフィルター膜と貼り合わせた場合
に、通気性が著しく低下してフィルターの圧損が高くな
ってしまう場合があり、フィルター性能として高いもの
を得ることが難しくなり好ましくないものである。The fineness of the thermoplastic long fibers is 4 to 13
It is preferably decitex, more preferably 5 to 11 decitex, further preferably 7 to 10 decitex. When the fineness is less than 4 decitex, the air permeability of the heat-bonded nonwoven fabric may be low, which is not preferable, and when the fineness exceeds 13 decitex,
It may be difficult to sufficiently cool the fiber when spinning the fiber, which is not preferable from the viewpoint of productivity. Further, the weight ratio of the filaments satisfying the above-mentioned fineness range of 4 to 13 decitex is preferably 50% or more, more preferably 75% or more, and most preferably 90% or more of the total filaments. The weight ratio of the filament is 5
When it is less than 0%, the air permeability of the obtained nonwoven fabric tends to be low, and particularly when it is attached to a filter membrane such as polytetrafluoroethylene or polyvinylidene fluoride, the air permeability is significantly reduced and the pressure loss of the filter is reduced. May increase, which makes it difficult to obtain high filter performance, which is not preferable.
【００２３】また、本発明における熱可塑性長繊維の高
融点成分、低融点成分のいずれにおいても、酸化チタン
やカーボンブラック等の添加剤を含んでもよいことはい
うまでもない。Needless to say, the high melting point component and the low melting point component of the thermoplastic long fiber according to the present invention may contain additives such as titanium oxide and carbon black.
【００２４】不織布の熱圧着面積は５〜４０％が好まし
く、より好ましくは１０〜３０％である。該熱圧着面積
が５％未満の場合、接着力が低下し、不織布の層間が剥
離し、さらに不織布に十分な剛性、強度が得られず、プ
リーツ加工性も低下する。また、該熱圧着面積が４０％
を超える場合、熱圧着力が著しく向上し、不織布の通気
性が低下するため好ましくない。The thermocompression bonding area of the nonwoven fabric is preferably 5 to 40%, more preferably 10 to 30%. When the thermocompression bonding area is less than 5%, the adhesive force is reduced, the layers of the non-woven fabric are peeled off, the non-woven fabric does not have sufficient rigidity and strength, and the pleating processability is also reduced. The thermocompression bonding area is 40%
When it exceeds, the thermocompression bonding strength is remarkably improved and the air permeability of the nonwoven fabric is lowered, which is not preferable.
【００２５】本発明にかかるフィルター基材を得るに
は、必ずしも限定されるものではないが、特に、熱可塑
性連続フィラメントを細孔より溶融紡出し、これをエア
ーサッカー装置等により引き取り、５０００ｍ／ｍｉｎ
程度で牽引した後、高圧印加や衝突帯電により熱可塑性
フィラメントを開繊させ、引き続き移動面上に噴射、捕
集して不織布ウェブを形成し、これを連続して熱圧着し
て不織布を製造することが重要である。特に、剛軟度が
５００ｍｇｆ以上、かつ目付が１００〜３００ｇ／
ｍ2 、さらに目付（Ｘ：ｇ／ｍ2 ）と通気量（Ｙ：ｇ／
ｍ2 ）の関係が上述の（１）式を満たす不織布を製造す
るためには、該熱可塑性連続フィラメントは、高融点成
分と低融点成分とからなることが重要であり、さらに該
不織布の熱圧着が部分的に施されることが重要である。
また、該高融点成分としてポリエチレンテレフタレート
を使用し、該低融点成分として共重合ポリエステルまた
はポリブチレンテレフタレートを使用し、かつ該低融点
成分の重量割合が、熱可塑性連続フィラメント中５〜４
０％とすることが肝要である。さらに該熱可塑性連続フ
ィラメントとして、高融点成分の周りを低融点成分が被
覆してなる芯鞘型フィラメントを用いることが肝要であ
る。In order to obtain the filter substrate according to the present invention, it is not particularly limited, but in particular, a thermoplastic continuous filament is melt-spun from pores and taken out by an air sucker or the like, and 5000 m / min.
After pulling at a certain degree, the thermoplastic filament is opened by high voltage application or collision charging, and then it is sprayed and collected on the moving surface to form a nonwoven web, which is continuously thermocompressed to produce a nonwoven. This is very important. Particularly, the bending resistance is 500 mgf or more, and the basis weight is 100 to 300 g /
m 2 , further, areal weight (X: g / m 2 ) and air flow rate (Y: g /
In order to produce a non-woven fabric having a relationship of m 2 ) satisfying the above-mentioned formula (1), it is important that the thermoplastic continuous filament comprises a high melting point component and a low melting point component. It is important that the crimp is partially applied.
Further, polyethylene terephthalate is used as the high melting point component, copolymerized polyester or polybutylene terephthalate is used as the low melting point component, and the weight ratio of the low melting point component is 5 to 4 in the thermoplastic continuous filament.
It is important to set it to 0%. Further, it is important to use, as the thermoplastic continuous filament, a core-sheath type filament in which a high melting point component is coated with a low melting point component.
【００２６】特に、従来における当該不織布分野のフィ
ルター基材の製造にあっては、一般に、ポリエステルや
ポリプロピレンを溶融紡糸して、熱圧着や機械的絡合、
あるいはこれらの組合せにより一体化するものが通常で
あったが、繊維の原料や、原料の複合比率、さらには繊
維の繊度（太さ）、また熱圧着の面積などが不適当であ
ったため、フィルター基材として使用する場合に、十分
な剛軟度と通気性を併せ持つものは得られず、例えば剛
軟度が５００ｍｇｆ以上のものでは、上述（１）式の値
は６０〜７０程度のものが一般的であった。In particular, in the conventional manufacture of the filter substrate in the non-woven fabric field, generally, polyester or polypropylene is melt-spun, and thermocompression bonding or mechanical entanglement,
Ordinarily, they were integrated by combining these, but because the raw materials of fibers, the composite ratio of raw materials, the fineness (thickness) of fibers, the area of thermocompression bonding, etc. were unsuitable, When it is used as a base material, a material having both sufficient bending resistance and air permeability cannot be obtained. For example, when the bending resistance is 500 mgf or more, the value of the above formula (1) is about 60 to 70. It was common.
【００２７】特に、０．２５Ｘ＋Ｙ＞９５ である
（２）式を満たす不織布を製造するには、本発明者らの
各種知見によれば、更に、該熱可塑性連続フィラメント
として、全フィラメントの５０重量％以上が繊度４〜１
３デシテックスのものを用い、さらには該不織布の熱圧
着面積を５〜４０％程度とすることが肝要である。In particular, in order to produce a non-woven fabric satisfying the formula (2) with 0.25X + Y> 95, according to various findings of the present inventors, further, as the thermoplastic continuous filament, 50 weight% of all filaments is used. % Or more has a fineness of 4 to 1
It is important to use the one having 3 decitex and further to set the thermocompression bonding area of the non-woven fabric to about 5 to 40%.
【００２８】いずれにしても、複合繊維の複合比率、繊
維の繊度（太さ）、圧着面積の存在比率、個々の圧着部
の大きさや、不織布の圧着程度などを組合せることによ
り、所望とする特性の不織布を得ることができる。In any case, it is desired by combining the composite ratio of the composite fibers, the fineness (thickness) of the fibers, the existence ratio of the crimping area, the size of each crimping portion, the crimping degree of the nonwoven fabric, etc. A characteristic nonwoven fabric can be obtained.
【００２９】また、本発明の不織布の特性を損なわない
範囲で、不織布に薬剤を付与することにより、抗菌性や
防カビ性を付与してもよい。In addition, antibacterial properties and antifungal properties may be imparted to the non-woven fabric of the present invention by adding a chemical to the non-woven fabric within a range that does not impair the properties of the non-woven fabric.
【００３０】さらに、高性能のフィルター基材として本
発明にかかるフィルター基材用不織布を使用する場合、
該フィルター基材はフィルター層の支持体として用いる
のがより好ましい使用方法である。特に、本発明にかか
るフィルター基材を山谷折り（プリーツ加工）して支持
体として成形賦型し、該支持体におけるその少なくとも
片面にフィルター層（濾過層としての機能を第一の機能
として有する層）を配置してフィルターを構成して使用
することがより高性能を発揮し得て好ましいものであ
る。該山谷折り（プリーツ加工）して支持体としての成
形賦型を良好に行わしめる上で、剛軟度は一定値以上は
あることが重要なものなのである。Furthermore, when the nonwoven fabric for a filter substrate according to the present invention is used as a high performance filter substrate,
The filter base material is more preferably used as a support of the filter layer. In particular, the filter base material according to the present invention is mountain-folded (pleated) to be shaped as a support, and a filter layer (a layer having a function as a filtration layer as a first function) on at least one surface of the support. It is preferable to arrange (1) to form a filter and to use it because it can exhibit higher performance. It is important that the bending resistance is not less than a certain value in order to satisfactorily perform the shaping of the support as a result of the mountain valley folding (pleating).
【００３１】該フィルター層としては、捕集性能が向上
し、捕集した粉塵の離脱性に優れるものであれば特に限
定されるものではないが、ポリテトラフルオロエチレン
やポリフッ化ビニリデンが好ましい。該ポリテトラフル
オロエチレンやポリフッ化ビニリデンを該フィルター基
材に貼り合わせる方法としては特に限定されるものでは
ないが、生産性や簡便さの点から、接着剤によりフィル
ター膜を不織布表面に接着させる方法や、フィルター
膜、あるいは不織布の表面を溶融させ、お互いを接着さ
せる方法が好ましい。The filter layer is not particularly limited as long as it has an improved collection performance and an excellent removability of the collected dust, but polytetrafluoroethylene or polyvinylidene fluoride is preferable. The method for attaching the polytetrafluoroethylene or polyvinylidene fluoride to the filter substrate is not particularly limited, but from the viewpoint of productivity and convenience, a method of adhering the filter membrane to the nonwoven fabric surface with an adhesive agent. Alternatively, a method of melting the surface of the filter membrane or the nonwoven fabric and adhering them to each other is preferable.
【００３２】[0032]
【実施例】以下、本発明をさらに実施例により詳細に説
明する。実施例における各特性値は以下の方法で測定し
たものである。
（１）目付（ｇ／ｍ2 ）：ＪＩＳ Ｌ１０９６に基づき
不織布の１ｍ2 当たりの質量を測定した。
（２）通気性（ｃｍ3 ／ｃｍ2 ／ｓｅｃ）：ＪＩＳ Ｌ
１０９６のフラジール型試験に基づき、不織布試験片を
通過する空気量を測定した。
（３）剛軟度（ｍｇｆ）：ＪＩＳ Ｌ１０９６のガーレ
法に基づき、不織布の縦方向２．５インチ×横方向１イ
ンチの試験片の剛軟度を測定した。
（４）シート剥離：幅２０ｃｍ×長さ８０ｃｍの試料を
長さ方向全体にわたって、半径１０ｃｍの円弧状に折り
曲げ、剥離の状況を以下の基準で評価した。EXAMPLES The present invention will now be described in more detail with reference to Examples. Each characteristic value in the examples is measured by the following method. (1) Unit weight (g / m 2 ): The mass per 1 m 2 of the non-woven fabric was measured based on JIS L1096. (2) Breathability (cm 3 / cm 2 / sec): JIS L
The amount of air passing through the nonwoven test piece was measured based on the Frazier type test of 1096. (3) Stiffness (mgf): Based on the Gurley method of JIS L1096, the stiffness of a test piece of a non-woven fabric measuring 2.5 inches in the longitudinal direction and 1 inch in the lateral direction was measured. (4) Sheet peeling: A sample having a width of 20 cm and a length of 80 cm was bent in an arc shape having a radius of 10 cm over the entire length direction, and the peeling condition was evaluated according to the following criteria.
【００３３】
○：剥離は全く認められないもの
△：１ｃｍ未満の剥離があるもの
×：１ｃｍ以上の剥離があるもの
（５）プリーツ加工性：幅５０ｃｍ×長さ１ｍの試料
を、ロータリー式プリーツ加工機で、ピッチが３ｃｍと
なるようプリーツ加工し、以下の基準で評価した。◯: Peeling is not observed at all Δ: Peeling less than 1 cm ×: Peeling more than 1 cm (5) Pleating workability: A sample of width 50 cm × length 1 m was put into a rotary pleat. Pleating was performed with a processing machine so that the pitch was 3 cm, and evaluation was performed according to the following criteria.
【００３４】
○：プリーツが鋭角で均一であり、シートに蛇行の見ら
れないもの
△：プリーツがやや不均一であり、シートに僅かな蛇行
が見られるもの
×：プリーツが不均一で、シートに蛇行が見られるもの
実施例１
高融点成分を固有粘度が０．６６、融点が２６０℃であ
るポリエチレンテレフタレートとし、低融点成分を固有
粘度が０．６８、融点が２３０℃であるイソフタル酸共
重合ポリエステルとして、該低融点成分の重量を全体の
２０％とし、該高融点成分の周りを該低融点成分が被覆
してなる芯鞘型のフィラメントを単糸繊度９デシテック
ス（ｄｔｅｘ）となるように吐出量を設定して溶融紡出
し、連続して空気圧にて約５０００ｍ／ｍｉｎの高速牽
引を実施した。◯: The pleats are sharp and uniform, and there is no meandering on the sheet. Δ: The pleats are slightly uneven, and a slight meandering is seen on the sheet. ×: The pleats are uneven and the sheet is not uniform. Example 1 A high melting point component is polyethylene terephthalate having an intrinsic viscosity of 0.66 and a melting point of 260 ° C., and a low melting point component is isophthalic acid copolymer having an intrinsic viscosity of 0.68 and a melting point of 230 ° C. As the polyester, the weight of the low melting point component is 20% of the whole, and a core-sheath type filament in which the high melting point component is coated with the low melting point component has a single yarn fineness of 9 decitex (dtex). A discharge rate was set, melt spinning was performed, and a high speed traction of about 5000 m / min was continuously carried out by air pressure.
【００３５】引き続き、フィラメントを空気圧にて噴
射、開繊し、移動するネット上に堆積させ不織布ウェブ
とし、これを一対の加熱エンボスロールにより線圧６０
ｋｇ／ｃｍ、ロール表面温度２００℃、接着面積２３％
の条件で圧着し、目付が１５０、２００、２５０ｇ／ｍ
2 の不織布をそれぞれ得た。
実施例２
芯鞘型フィラメントの単糸繊度を６デシテックスとなる
よう吐出量を設定し、加熱エンボスロールの接着条件
を、線圧５０ｋｇ／ｃｍ、ロール表面温度１９０℃、接
着面積２０％とし、その他の条件は全て実施例１と同じ
条件で、目付１５０、２００、２５０ｇ／ｍ2 の不織布
をそれぞれ得た。
実施例３
高融点成分を固有粘度が０．６６、融点が２６０℃であ
るポリエチレンテレフタレートとして単糸繊度が９デシ
テックスとなるよう吐出量を設定し、低融点成分を固有
粘度が０．６８、融点が２３０℃であるイソフタル酸共
重合ポリエステルとして単糸繊度９デシテックスとなる
よう吐出量を設定、それぞれ溶融紡出して紡糸混繊し、
連続して空気圧にて約５０００ｍ／ｍｉｎの高速牽引を
実施した。なお低融点成分の重量は全体の２３％とし
た。引き続きフィラメントを空気圧にて噴射、開繊し、
移動するネット上に堆積させ不織布ウェブとし、これを
一対の加熱エンボスロールにより線圧７０ｋｇ／ｃｍ、
ロール表面温度２０５℃、接着面積２３％の条件で圧着
し、目付が１５０ｇ／ｍ2 、２００ｇ／ｍ2 、２５０ｇ
／ｍ2 の不織布をそれぞれ得た。Subsequently, the filament is sprayed by air pressure, opened, and deposited on a moving net to form a non-woven web, which is linearly pressured by a pair of heating embossing rolls.
kg / cm, roll surface temperature 200 ° C, adhesive area 23%
Pressure is applied under the conditions of and the basis weight is 150, 200, 250 g / m
Two non-woven fabrics were obtained respectively. Example 2 The discharge rate was set so that the single yarn fineness of the core-sheath filament was 6 decitex, and the bonding conditions of the heating embossing roll were a linear pressure of 50 kg / cm, a roll surface temperature of 190 ° C., and a bonding area of 20%. The conditions were all the same as in Example 1, and nonwoven fabrics having a basis weight of 150, 200, and 250 g / m 2 were obtained. Example 3 Polyethylene terephthalate having a high-melting point component having an intrinsic viscosity of 0.66 and a melting point of 260 ° C., the discharge amount was set so that the single yarn fineness was 9 decitex, and the low-melting point component had an intrinsic viscosity of 0.68 and a melting point. The discharge amount was set so that the single yarn fineness was 9 decitex as the isophthalic acid copolyester having a temperature of 230 ° C.
High-speed traction of about 5000 m / min was continuously carried out by air pressure. The weight of the low melting point component was 23% of the whole. Continue to inject and open the filament with air pressure,
A non-woven web is deposited on a moving net, and a linear pressure of 70 kg / cm is applied by a pair of heating embossing rolls.
The roll surface temperature is 205 ° C. and the bonding area is 23%. The weight is 150 g / m 2 , 200 g / m 2 , 250 g.
/ M 2 of non-woven fabric was obtained.
【００３６】実施例１〜３に記載した不織布の通気性、
剛軟度、シート剥離、さらにプリーツ加工性の評価結果
を表１に示した。表１から明らかなように、実施例１〜
３の不織布はいずれも０．２５Ｘ＋Ｙの値が８０以上で
あり、さらに剛軟度が５００ｍｇｆ以上で、シート剥離
もなく、プリーツ加工性も良好で、フィルター基材とし
て満足できる特性を有するものであった。
比較例１
芯鞘型フィラメントの単糸繊度が２．８デシテックスと
なるよう吐出量を設定し、加熱エンボスロールの接着条
件を、線圧６０ｋｇ／ｃｍ、ロール表面温度２００℃、
接着面積２３％とし、その他の条件は全て実施例１と同
じ条件で、目付１５０、２００、２５０ｇ／ｍ2 の不織
布をそれぞれ得た。この不織布の各種特性の評価結果を
表１に示した。The breathability of the nonwoven fabrics described in Examples 1-3,
Table 1 shows the evaluation results of bending resistance, sheet peeling, and pleating workability. As is clear from Table 1, Examples 1 to 1
All of the non-woven fabrics of No. 3 had a value of 0.25X + Y of 80 or more, a bending resistance of 500 mgf or more, no sheet peeling, good pleating workability, and satisfactory properties as a filter substrate. It was Comparative Example 1 The discharge amount was set so that the single yarn fineness of the core-sheath filament was 2.8 decitex, and the heating embossing roll was bonded under the following conditions: linear pressure 60 kg / cm, roll surface temperature 200 ° C.
Adhesive area was set to 23% and the other conditions were all the same as in Example 1 to obtain nonwoven fabrics having a basis weight of 150, 200 and 250 g / m 2 , respectively. Table 1 shows the evaluation results of various characteristics of this nonwoven fabric.
【００３７】表１から明らかなように、この不織布は、
シート剥離はなく、プリーツ加工性も優れていたが、通
気性が非常に低く、０．２５Ｘ＋Ｙの値がいずれも８０
以下であり、特にポリテトラフルオロエチレンやポリフ
ッ化ビニリデンなどのフィルター膜の支持体とした場
合、通気性が著しく低くなるため好ましくないものであ
った。
比較例２
高融点成分の単糸繊度が３．５デシテックス、低融点成
分の単糸繊度が３．５デシテックス、低融点成分の重量
が全体の４％となるよう吐出量を設定し、その他の条件
は全て実施例３と同じ条件で、目付１５０、２００、２
５０ｇ／ｍ2 の不織布をそれぞれ得た。この不織布の各
種特性の評価結果を表１に示した。表１から明らかなよ
うに、この不織布は、通気性が低く、０．２５Ｘ＋Ｙの
値が８０以下であった。また接着も不十分であり、シー
ト剥離があり、プリーツ加工性にも劣るものであった。As is clear from Table 1, this nonwoven fabric is
There was no peeling of the sheet, and the pleating processability was excellent, but the air permeability was very low, and the values of 0.25X + Y were all 80.
The following is unfavorable especially when used as a support for a filter membrane such as polytetrafluoroethylene or polyvinylidene fluoride, because the air permeability is significantly lowered. Comparative Example 2 The discharge amount was set so that the single-filament fineness of the high-melting point component was 3.5 decitex, the single-filament fineness of the low-melting point component was 3.5 decitex, and the weight of the low-melting point component was 4% of the whole. The conditions are all the same as in Example 3, with a basis weight of 150, 200, 2
Nonwoven fabrics of 50 g / m 2 were obtained. Table 1 shows the evaluation results of various characteristics of this nonwoven fabric. As is clear from Table 1, this nonwoven fabric had a low air permeability, and the value of 0.25X + Y was 80 or less. Further, the adhesion was insufficient, the sheet was peeled off, and the pleating processability was poor.
【００３８】[0038]
【表１】 [Table 1]
【００３９】[0039]
【発明の効果】本発明のフィルター基材は、目付（Ｘ）
と通気量（Ｙ）が０．２５Ｘ＋Ｙ＞８０となり、かつ剛
軟度を５００ｍｇｆ以上とすることにより、シートの剥
離もなく、プリーツ加工性も良好であり、さらに通気性
が高いことからフィルターユニットとした場合、圧損が
低く良好な性能を示すものであり、特にポリテトラフル
オロエチレンやポリフッ化ビニリデンなどのフィルター
膜の支持体とした場合、その効果は顕著である。The filter substrate of the present invention has a basis weight (X)
And a ventilation amount (Y) of 0.25X + Y> 80, and a bending resistance of 500 mgf or more, there is no peeling of the sheet, good pleating workability, and high air permeability. In this case, the pressure loss is low and the performance is good, and the effect is remarkable when used as a support for a filter membrane such as polytetrafluoroethylene or polyvinylidene fluoride.
Claims (8)
からなり、該熱可塑性連続フィラメントが高融点成分と
低融点成分とからなり、該不織布は部分的に熱圧着され
たものであって、目付が１００〜３００ｇ／ｍ2 で、ま
た目付と通気量の関係が次式（１）を満たし、かつ剛軟
度が５００ｍｇｆ以上であることを特徴とするフィルタ
ー基材。 ０．２５Ｘ＋Ｙ＞８０ ………（１）式 Ｘ：目付（ｇ／ｍ2 ） Ｙ：通気量（ｃｍ3 ／ｃｍ2 ／ｓｅｃ）1. A non-woven fabric comprising thermoplastic continuous filaments, said thermoplastic continuous filaments comprising a high melting point component and a low melting point component, said non-woven fabric being partially thermocompressed and having a basis weight of 100. A filter base material having a hardness of up to 300 g / m 2 , a relationship between the basis weight and the air flow rate satisfying the following expression (1), and a bending resistance of 500 mgf or more. 0.25X + Y> 80 (1) Formula X: basis weight (g / m 2 ) Y: air flow rate (cm 3 / cm 2 / sec)
点成分がポリエチレンテレフタレートであり、該低融点
成分が共重合ポリエステルまたはポリブチレンテレフタ
レートであり、かつ該低融点成分の重量割合が、該熱可
塑性連続フィラメント中５〜４０％のものを用いてなる
ことを特徴とする請求項１記載のフィルター基材。2. A thermoplastic continuous filament, wherein the high melting point component is polyethylene terephthalate, the low melting point component is copolymerized polyester or polybutylene terephthalate, and the low melting point component has a weight ratio of the thermoplastic continuous filament. The filter base material according to claim 1, which comprises 5 to 40% of filaments.
点成分の周りを低融点成分が被覆してなる芯鞘型フィラ
メントを用いてなることを特徴とする請求項１または２
記載のフィルター基材。3. A core-sheath type filament in which a high melting point component is coated with a low melting point component is used as the thermoplastic continuous filament.
The described filter substrate.
ィラメントの５０重量％以上が、繊度４〜１３デシテッ
クスのものを用いてなることを特徴とする請求項１〜３
のいずれかに記載のフィルター基材。4. A thermoplastic continuous filament comprising 50% by weight or more of all filaments having a fineness of 4 to 13 decitex.
The filter substrate according to any one of 1.
のものを用いることを特徴とする請求項１〜４のいずれ
かに記載のフィルター基材。5. The non-woven fabric has a thermocompression bonding area of 5 to 40%.
What is used is a filter base material in any one of Claims 1-4.
ー基材を支持体とし、少なくともその支持体の片面にフ
ィルター層を配してなることを特徴とするフィルター。6. A filter comprising the filter substrate according to any one of claims 1 to 5 as a support, and a filter layer disposed on at least one surface of the support.
ロエチレン、またはポリフッ化ビニリデンからなるもの
を用いてなることを特徴とする請求項６記載のフィルタ
ー7. The filter according to claim 6, wherein the filter layer is made of polytetrafluoroethylene or polyvinylidene fluoride.
るものであることを特徴とする請求項７記載のフィルタ
ー。8. The filter according to claim 7, wherein the filter has a pleat shape.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002075643A JP3767502B2 (en) | 2002-03-19 | 2002-03-19 | Filter substrate and filter |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002075643A JP3767502B2 (en) | 2002-03-19 | 2002-03-19 | Filter substrate and filter |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2003275519A true JP2003275519A (en) | 2003-09-30 |
| JP3767502B2 JP3767502B2 (en) | 2006-04-19 |
Family
ID=29204660
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2002075643A Expired - Lifetime JP3767502B2 (en) | 2002-03-19 | 2002-03-19 | Filter substrate and filter |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3767502B2 (en) |
Cited By (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005279503A (en) * | 2004-03-30 | 2005-10-13 | Matsushita Electric Ind Co Ltd | Filter unit and vacuum cleaner using the same |
| WO2007040104A1 (en) * | 2005-10-04 | 2007-04-12 | Toray Industries, Inc. | Nonwoven fabric for filters |
| JP2007098259A (en) * | 2005-10-04 | 2007-04-19 | Toray Ind Inc | Filter base material and filter unit |
| WO2007088824A1 (en) * | 2006-02-01 | 2007-08-09 | Toray Industries, Inc. | Nonwoven fabric for filters and process for production of the same |
| JP2007231500A (en) * | 2006-02-01 | 2007-09-13 | Toray Ind Inc | Nonwoven fabric for filter and method for producing the same |
| JP2008279359A (en) * | 2007-05-10 | 2008-11-20 | Nitto Denko Corp | Filter medium and filter unit using this filter medium |
| JP2011005455A (en) * | 2009-06-29 | 2011-01-13 | Toray Ind Inc | Separation membrane support, separation membrane using the same, and membrane separation element |
| WO2011158324A1 (en) * | 2010-06-15 | 2011-12-22 | 東洋紡績株式会社 | Filter support body and filter using same |
| JP2017056386A (en) * | 2015-09-15 | 2017-03-23 | 日本バイリーン株式会社 | Filter medium, and filter unit using the same |
| CN114829691A (en) * | 2019-12-23 | 2022-07-29 | 东丽株式会社 | Spun-bonded nonwoven fabric, filter material for dust collector pleated filter, and large-air-volume pulse jet type dust collector |
-
2002
- 2002-03-19 JP JP2002075643A patent/JP3767502B2/en not_active Expired - Lifetime
Cited By (13)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2005279503A (en) * | 2004-03-30 | 2005-10-13 | Matsushita Electric Ind Co Ltd | Filter unit and vacuum cleaner using the same |
| US8308833B2 (en) | 2005-10-04 | 2012-11-13 | Toray Industries, Inc. | Nonwoven fabric for filters |
| WO2007040104A1 (en) * | 2005-10-04 | 2007-04-12 | Toray Industries, Inc. | Nonwoven fabric for filters |
| JP2007098259A (en) * | 2005-10-04 | 2007-04-19 | Toray Ind Inc | Filter base material and filter unit |
| WO2007088824A1 (en) * | 2006-02-01 | 2007-08-09 | Toray Industries, Inc. | Nonwoven fabric for filters and process for production of the same |
| US8187520B2 (en) | 2006-02-01 | 2012-05-29 | Toray Industries, Inc. | Nonwoven fabric for filters and method of producing the same |
| JP2007231500A (en) * | 2006-02-01 | 2007-09-13 | Toray Ind Inc | Nonwoven fabric for filter and method for producing the same |
| JP2008279359A (en) * | 2007-05-10 | 2008-11-20 | Nitto Denko Corp | Filter medium and filter unit using this filter medium |
| JP2011005455A (en) * | 2009-06-29 | 2011-01-13 | Toray Ind Inc | Separation membrane support, separation membrane using the same, and membrane separation element |
| WO2011158324A1 (en) * | 2010-06-15 | 2011-12-22 | 東洋紡績株式会社 | Filter support body and filter using same |
| JP2017056386A (en) * | 2015-09-15 | 2017-03-23 | 日本バイリーン株式会社 | Filter medium, and filter unit using the same |
| CN114829691A (en) * | 2019-12-23 | 2022-07-29 | 东丽株式会社 | Spun-bonded nonwoven fabric, filter material for dust collector pleated filter, and large-air-volume pulse jet type dust collector |
| CN114829691B (en) * | 2019-12-23 | 2024-02-02 | 东丽株式会社 | Filter medium for spun-bonded nonwoven fabric and dust collector pleated filter, and filter and dust collector |
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