JP2004017041A - Filter medium for high performance air filter and high performance air filter using filter medium - Google Patents
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【０００１】
【発明が属する技術分野】
本発明は精密工業、電子工業、医薬品工業、食品工業等の分野及び、医療、ビル空調等の分野 及び一般空気浄化装置設備に使用される高性能エアフィルタのろ材について安価で、実用強度が大きく 又、使用済みに際して焼却処分ができる高性能エアフィルタ用ろ材及びそれを使用したエアフィルタに関する。
【０００２】
【従来の技術】
従来の高性能エアフィルタ用ろ材は湿式抄紙製造法 又は、乾式ウェブ製造法により製造される。湿式抄紙製造法による高性能エアフィルタ用ろ材の多くはガラス繊維であり、安価で高性能なろ材が得られるが、脆性で変形力や衝撃力（外力）に弱い。
又、使用済みに際して不燃性なので焼却処分ができず、環境汚染の問題を生ずる。（埋め立て処分しかできないので捨て場所に困る。）
【０００３】
一方、乾式ウェブ製造法による高性能エアフィルタ用ろ材は有機繊維（ポリプロピレン樹脂・ポリエステル樹脂 など）であり、変形や衝撃力（外力）に強く、使用済みに際して焼却処分ができるが、価格が高く、静電気帯電（エレクトレット化）による粉塵捕集機構のため粉塵捕集性能が不安定で、今日に至ってもあまり普及していない。 等の課題がある。
【０００４】
特公昭６３−５６８０６、特開平１０−１８００２０で湿式抄紙製造法による焼却減容処理可能な難燃性高性能ろ材が提案されている。 しかし、これらの方法はろ材を難燃化するためにハロゲン化合物、ホウ素化合物、リン化合物などを塗布したり化合してろ材に相当量含有させることで難燃性を実現している。 これらのハロゲン化合物、ホウ素化合物、リン化合物などは燃焼により有毒ガスを発生するという問題があるため焼却処分は必ずしも適切ではない。
【０００５】
有機繊維と微細な繊維を配合して成るエアフィルタ用ろ材に関して特公昭６２−１１０７１８、特公昭６３−４４９１４、特公昭６３−４４９１５、特公昭６３−４４９１６、特公昭６３−５６８０６、特公平６−１３０８２、特開平１０−１８００２０がある。
【０００６】
特公昭６２−１１０７８１及び特公平６−１３０８２で直径４μｍ以下の微細ガラス繊維と０．０５〜０．５デニールの細デニール化合繊 及びポリビニールアルコール系繊維を配合して成るエアフィルタ用ろ材を挙げている。 クリーンルームで使用する用途の高性能フィルタ用ろ材は少なくとも繊維径１μｍ以下の繊維が不可欠であること 及び有機繊維が０．１〜０．２デニールに限定しなければならないことが本発明と異なる。 更にガラス繊維含有率が６０〜９７重量％と高く、ろ材の脆性改善は望めない。
【０００７】
特公昭６３−４４９１４，特公昭６３−４４９１５、特公昭６３−４４９１６で平均繊維径０．３〜４μｍの極細ガラス繊維とチョップアンドストランドビニロン繊維やチョップアンドストランドアクリル繊維やチョップアンドストランドレーヨン繊維を配合して成るエアフィルタろ材を挙げている。
チョップアンドストランドビニロン繊維、チョップアンドストランドアクリル繊維、チョップアンドストランドレーヨン繊維については繊維径についての制約がない。 ちなみに、繊維径が太くなれば捕集率の低下を招き、細くなれば圧力損失の上昇を招くなど、捕集率と圧力損失のバランスは有用なエアフィルタろ材に不可欠な性能である。 即ち、本例示の諸特許で必ずしも有用なエアフィルタろ材を得ることができるとは限らない。
【０００８】
特公昭６３−５６８０６でガラス繊維２０重量％、再生セルロース繊維５０重量％、天然セルロース繊維３０重量％を配合して成るろ紙を挙げている。ガラス繊維は極細ガラス繊維があげられているが、繊維径についての制約はない。 本発明で、マイクロガラス繊維は極細ガラス繊維とも呼称され、特に繊維径は０．１〜１μｍの物が選ばれる。即ち、高性能エアフィルタ用ろ材は極細ガラス繊維の中、限定された繊維径の繊維が不可欠である。
【０００９】
特公昭６３−５６８０６で再生セルロース繊維として１．０デニール以下の極細銅アンモニア法再生セルロース繊維があげられている。 本発明で、有機繊維は繊維径２．７〜６．５μｍ（０．１〜０．２デニール）範囲内のみ高性能エアフィルタ用ろ材が得られた。 特公昭６３−５６８０６で極細ガラス繊維の配合率２０重量％が最小限度量とされる。 本発明で、ポリ−Ｐ−フェニレンテレフタルアミド繊維またはポリ−Ｐ−フェニレンテレフタルアミド−３・４−ジフェニルエーテルテレフタルアミド繊維等のマイクロフィブリル化物である微細な有機繊維とを併用することにより、ガラス繊維含有率が１１〜２５重量％である高性能エアフィルタ用ろ材を得る。
【００１０】
特開平１０−１８００２０で平均繊維径０．６５μｍ以下のガラス繊維１０〜５０重量％ 自己消火性有機繊維５０〜９０重量％に繊維状バインダーを配合してなる高性能エアフィルタ用ろ材が挙げられている。本発明の有機繊維はハロゲンやリン化合物を含まない繊維であり、特に自己消火性である必要はない。
【００１１】
特開平１０−１８００２０で自己消火性有機繊維の繊維径１〜７０μｍが挙げられている。本発明で有機繊維は繊維径２．７〜６．５μｍの範囲で、これ以上太い繊維は捕集率の著しい低下を招く。
【００１２】
特開平１０−１８００２０で、極細ガラス繊維（マイクロガラス繊維と同義）は平均繊維径０．６５μｍ以下を挙げている。この極細ガラス繊維はその製造方法の特徴で、比較的広くランダムな繊維径分布を持った綿状の繊維製品で、単一の繊維径の値をもってろ材の原材料である極細ガラス繊維を的確に表記することは難しく、ここで挙げられている平均繊維径０．６５μｍ以下とは本発明の詳細説
明
【００１７】の表１にあるＢＥＴ法による表面積の値より算出された値と推察され、特公開平１０−１８００２０の極細ガラス繊維は表１のコード番号で＃１０６，＃１０４，＃１００，＃９０等が推測される。 ちなみに、本発明でマイクロガラス繊維がコード番号＃９０及び＃１００及び＃１０４である。
【００１３】
【発明が解決しようとする課題】
本発明はかかる問題に対し、従来のガラス繊維ろ材と同等の性能を有する有機繊維を主成分とした高性能エアフィルタ用ろ材で、静電気帯電処理（エレクトレット化）を行わず、湿式抄紙製造法により製造することで、安定した捕集性能を有し、安価で変形や衝撃力（外力）に強く、使用済みに際して焼却処分ができる高性能エアフィルタ用ろ材を実現すべく、鋭意研究の結果、本発明に至った。 なお、ろ材の難燃性の必要性についてはエアフィルタは一般に火気のない用途に使用される場合がほとんどであり、今日エアフィルタの構成部材として合板、紙、合成樹脂、合成繊維等が多く使用され、これらの材料は難燃性でない場合が多い。これは、今日使用後の廃棄物処理に際しての環境汚染を最小限にすることが社会的に優先課題となっている結果である。
【００１４】
【課題を解決するための手段】
本発明で繊維径２．７〜６ ５μｍ繊維長０．５〜５ｍｍの有機繊維はろ材の骨格を形成する繊維で、従来のガラス繊維ろ材の場合では、繊維径１〜４μｍのマイクロガラス繊維（コード番号＃１０８及び＃１１０及び＃１１２）に相当する繊維でろ材の７０〜８０重量％を占めることから、ろ材の有機繊維化を意図する場合、この繊維径成分の有機繊維化が重要となる。
【００１５】
本来ならば本発明での有機繊維も繊維径１〜４μｍの物を使用するのが好ましいと推測される。しかしながら、現状では工業的に生産され、本用途に適用できる有機繊維は０．１ｄ（デニール）ポリエステル繊維（ＰＥＴ）繊維（繊維径２．７〜４．５μｍ）が限度である。本有機繊維の繊維径は２．７〜６．５μｍ（０．１ｄ〜０．３ｄ）の物が使用できるが、好ましくは２．７〜５μｍ（０．１ｄ〜０．２ｄ）である。 繊維径が６．５μｍを越える物は圧力損失を上昇させ粒子捕集率を低下させるため、高性能エアフィルタ用ろ材には適さない。結果を後記実施例１ 及び表２に示す。
【００１６】
本発明で繊維径０．１〜１．０μｍが主成分で、繊維長２０〜５０００μｍの微細繊維はろ材の粒子捕集率を向上させる目的で使用する。従来のガラス繊維ろ材の場合では繊維径０．１〜１．０μｍが主成分であるマイクロガラス繊維（コード番号＃９０及び＃１００及び＃１０６）を使用する。本発明で微細繊維は無機繊維として、マイクロガラス繊維の他に有機繊維としてポリ−Ｐ−フェニレンテレフタルアミド繊維またはポリ−Ｐ−フェニレンテレフタルアミド−３・４−ジフェニルエーテルテレフタルアミド繊維等のマイクロフィブリル化物が使用できる。これらのマイクロフィブリル化物は微細な有機繊維であり、繊維径０．２〜１．０μｍが主成分であることからマイクロガラス繊維（コード番号＃９０及び＃１００及び＃１０４）の代替として、本発明で微細繊維の全部または一部として使用することができ、従来のろ材よりも無機繊維含有量を大幅に減じ、折り曲げ強さ（脆性）、対衝撃強さ（耐変形破壊）を改善し、エアーフィルタ製造工程及びエアーフィルタ取り扱いに際して破損が生じにくいろ材を得ることができる。
【００１７】
即ち、本発明で微細繊維は無機繊維としては繊維径０．１〜１．０μｍが大部分を占めるマイクロガラス繊維で、スピニング方、火炎挿入法、ロータリー法などで製造される綿状のガラス繊維の中、コード番号＃９０及び＃１００及び＃１０４と称する物である。 前記製造方法によるガラス繊維は含有する主要な繊維径範囲毎にコード番号により類別され市販されている。各コード番号のマイクロガラス繊維は電子顕微鏡により視野内の繊維径別繊維数の割合を観察した結果、表１のような繊維径の繊維より構成されている。
【表１】
マイクロガラス繊維は製品毎に広い繊維径範囲の繊維を含有し、平均繊維径による区分は厳密な物ではなく、概ねその付近の値になることを意味する。 この事に鑑み、本発明ではマイクロガラス繊維は表１に示す如く大部分を占める繊維の繊維径とコード番号で表現した。
【００１９】
本発明で、微細繊維は有機繊維としてポリ−Ｐ−フェニレンテレフタルアミド繊維またはポリ−Ｐ−フェニレンテレフタルアミド−３・４−ジフェニルエーテルテレフタルアミド繊維等のマイクロフィブリル化物で繊維径０．１〜４μｍの範囲で、０．２〜１．０μｍが大部分を占め、繊維長０．０２〜２ｍｍである。
ここでいうマイクロフィブリル化物とはアラミド系繊維など高結晶性、高配向性繊維を適宜の長さに切断した物を水中に分散させホモジナイザー，叩解機等を用いてフィブリル化する方法（特願昭５６−１００８０１，特開昭５９−９２０１１）や、 合成高分子を溶媒の沸点以上で高圧側から低圧側へ爆発的に噴出させ繊維状にフィブリル化する方法（フラッシュ紡糸法）や水中に分散させた適宜の長さに切断した合成高分子繊維、又はパルプ状繊維を高圧、高速でオリフィスを通過させ器壁に衝突させ急激に減速させることで、合成高分子繊維、又はパルプ状繊維に剪断力を与えて繊維状にフィブリル化する方法 などで得ることができる。
【００２０】
本発明で、微細繊維は繊維径０．１〜１μｍの繊維が大部分を構成して成る繊維で、無機繊維としては繊維径０．１５〜０．４μｍの繊維が特に多いコード番号＃９０のマイクロガラス繊維、及び繊維径０．２５〜０．４μｍの繊維が特に多いコード番号＃１００のマイクロガラス繊維、及び繊維径０．４〜０．８μｍの繊維が特に多いコード番号＃１０４のマイクロガラス繊維等であるが、好ましくは繊維径０．４μｍ以下の繊維が特に多いコード番号＃９０と＃１００のマイクロガラス繊維であり、また、有機繊維としてはポリ−Ｐ−フェニレンテレフタルアミド繊維またはポリ−Ｐ−フェニレンテレフタルアミド−３・４−ジフェニルエーテルテレフタルアミド繊維等のマイクロフィブリル化物で繊維径０．１〜４μｍで大部分の繊維が繊維径０．２〜１μｍで、特に多くが繊維径０．２〜０．５μｍである。 微細繊維が繊維径０．５μｍ以上の繊維が特に多い場合はろ材の粒子捕集率の低下を招く。 後記 実施例２ 表３に示す。
【００２１】
本発明で、微細繊維のマイクロガラス繊維、コード番号＃９０とコード番号＃１００とコード番号＃１０４は複数または単独で用いることができる。
【００２２】
この微細繊維としての無機繊維（マイクロガラス繊維コード番号＃９０と＃１００及び＃１０４）と有機繊維（ポリ−Ｐ−フェニレンテレフタルアミド繊維またはポリ−Ｐ−フェニレンテレフタルアミド−３・４−ジフェニルエーテルテレフタルアミド繊維等のマイクロフィブリル化物）との混合割合は無機繊維７２〜１００重量％、好ましくは７４〜１００重量％ 有機繊維０〜２８重量％、好ましくは０〜２６重量％である。 有機繊維が２６重量％より多くなると粒子捕集率の低下を招く。
後記 実施例３ 表４に示す。
【００２３】
本発明の、粉末状又は繊維状のポリビニールアルコール（ＰＶＡ）系バインダーは湿式抄紙後の乾燥工程で熱溶融し、その後の冷却で固化することで、ろ材構成繊維同士を強固に接着することにより、ろ材シートの強度を発現する。 このポリビニールアルコール（ＰＶＡ）系バインダーは水中溶融温度が６０〜１１０℃でポリビニールアルコール、カチオン変性ポリビニールアルコール、カルボキン変性ポリビニールアルコールが主に使用されるが、これらの他に公知のあらゆる抄紙用バインダー樹脂、例えばポリアクリル系樹脂、ポリアクリルアミド系樹脂、澱粉系の粉末状又はエマルジョン抄紙用バインダーを用いることができる。
【００２４】
本発明の高性能エアフィルタ用ろ材のはっ水性付与は、有機繊維、微細繊維 及び、粉末状又は繊維状バインダーを混合した水性スラリーを作成し、該スラリーを抄紙機で抄紙し、軽くプレスして得たろ材シートを、サイズロール等を用いてはっ水剤を含浸し、乾燥させることにより得ることができる。 はっ水剤は通常のエアフィルタ用ろ材に用いられるはっ水剤で良く、例えば、フッ素樹脂系はっ水剤、シリコン系はっ水剤、ワックス系エマルジョン、アクリル樹脂系エマルジョン等が用いられる。
【００２５】
本発明で、繊維径２．７〜６．５μｍ、繊維長０．５〜５ｍｍの有機繊維７０〜８５重量％と、繊維径０．１〜１μｍが大部分を占め、繊維長０．０２〜５ｍｍの微細繊維１５〜３０重量％と、前記有機繊維と微細繊維の合計重量１００部に対し、１〜４部のポリビニールアルコール系バインダーを配合して、湿式抄紙してなる無機繊維１１〜２５重量％を含有する高性能エアフィルタ用ろ材は、一般の紙類と同様に焼却処分ができる。ちなみに、一般の紙類の無機成分含有率はグラビア紙で２０〜３０重量％、硬質紙で１５〜２０重量％であり、本発明の高性能エアフィルタ用ろ材はこれらの紙類と同等の無機成分含有率で有り、難燃剤などの有害な物質を含まない。
【００２６】
有機繊維含有率を高くすれば無機成分を低減できるが、有機繊維含有率が８９重量％を越えると粒子捕集率が低下する。 後記 実施例４ 表５に示す。 有機繊維含有率が７０重量％より低くなると折り曲げによる強度低下が著しく脆性なろ材となり、高性能エアフィルタ用ろ材として好ましくない。 後記 実施例５
表６に示す。
【００２７】
【実施例】
実施例１
０．１デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維（ジョンマンビル社製 コード番号＃１００）２５重量％とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料１−１とした。
次に、０．３デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維（ジョンマンビル社製 コード番号＃１００）２５重量％とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料１−２とした。
次に、０．５デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維（ジョンマンビル社製 コード番号＃１００）２５重量％とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料１−３とした。
ろ材シート 試料１−１、 試料１−２ 及び試料１−３について、ＪＩＳ Ｂ９９２７クリーンルーム用エアフィルタ性能試験方法の付属書１（規定）クリーンルーム用エアフィルタろ材性能試験方法により粒子捕集率、圧力損失を測定した。 測定した粒子捕集率と圧力損失の値からα値を算出した。 結果を後記表２に示す。
【００２８】
実施例２
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製 繊維径０．２〜１．２μｍ）２５重量％とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料２−１とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維コード番号＃９０（ジョンマンビル社製 繊維径０．１〜１．５μｍ）２５重量％とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料２−２とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維コード番号＃１０４（ジョンマンビル社製 繊維径０．２〜２μｍ）２５重量％とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料２−３とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維コード番号＃１０６（ジョンマンビル社製 繊維径０．２〜３μｍ）２５重量％とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料２−４とした。
ろ材シート 試料２−１、試料２−２、試料２−３ 及び試料２−４について、実施例１と同様に粒子捕集率、圧力損失を測定し、α値を算出した。 結果を表３に示す。
【００２９】
実施例３
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製：繊維径０．２〜１．２μｍ）２２重量％とポリ−Ｐ−フェニレンテレフタルアミド繊維のマイクロフィブリル化物（ダイセル化学工業（株）：ティアラＫＹ−４００Ｓ）３重量％（固形分のみ）とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料３−１とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製 繊維径０．２〜１．２μｍ）１８．５重量％とポリ−Ｐ−フェニレンテレフタルアミド繊維のマイクロフィブリル化物（ダイセル化学工業（株）：ティアラＫＹ−４００Ｓ）６．５重量％（固形分のみ）とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料３−２とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）７５重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製繊維径０．２〜１．２μｍ）１８重量％とポリ−Ｐ−フェニレンテレフタルアミド繊維のマイクロフィブリル化物（ダイセル化学工業（株）：ティアラＫＹ−４００Ｓ）７重量％（固形分のみ）とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料３−３とした。
ろ材シート 試料３−１、試料３−２ 及び試料３−３について、実施例１、実施例２と同様に粒子捕集率、圧力損失を測定し、α値を算出した。 結果を 後記 表４に示す。
【００３０】
実施例４
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）６５重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製 繊維径０．２〜１．２μｍ）２５．９重量％とポリ−Ｐ−フェニレンテレフタルアミド繊維のマイクロフィブリル化物（ダイセル化学工業（株）：ティアラＫＹ−４００Ｓ）９．１重量％（固形分のみ）とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料４−１とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）７０重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製 繊維径０．２〜１．２μｍ）２２．２重量％とポリ−Ｐ−フェニレンテレフタルアミド繊維のマイクロフィブリル化物（ダイセル化学工業（株）：ティアラＫＹ−４００Ｓ）７．８重量％（固形分のみ）とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料４−２とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）８０重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製 繊維径０．２〜１．２μｍ）１４．８重量％とポリ−Ｐ−フェニレンテレフタルアミド繊維のマイクロフィブリル化物（ダイセル化学工業（株）：ティアラＫＹ−４００Ｓ）５．２重量％（固形分のみ）とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。
このろ材シートを試料４−３とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）８５重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製 繊維径０．２〜１．２μｍ）１１．１重量％とポリ−Ｐ−フェニレンテレフタルアミド繊維のマイクロフィブリル化物（ダイセル化学工業（株）：ティアラＫＹ−４００Ｓ）３．９重量％（固形分のみ）とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料４−４とした。
繊維長３ｍｍの０．１デニールポリエステル繊維（帝人（株）テピルス）８８重量％とマイクロガラス繊維コード番号＃１００（ジョンマンビル社製 繊維径０．２〜１．２μｍ）８．９重量％とポリ−Ｐ−フェニレンテレフタルアミド繊維のマイクロフィブリル化物（ダイセル化学工業（株）：ティアラＫＹ−４００Ｓ）３．１重量％（固形分のみ）とを配合して成る混合繊維に、この混合繊維１００重量部に対して重量２部の繊維状ＰＶＡバインダー（クラレ（株）クラウンＶＰ：ＶＰＢ１０１）を配合し、ミキサーにて水性スラリーを作成し、ＪＩＳ Ｐ８２０９の標準角形手漉き抄紙機にて抄紙し、軽くプレスした後、ロータリードライヤーで乾燥し、坪量８０ｇ／ｍ２のろ材シートを得た。 このろ材シートを試料４−５とした。
ろ材シート 試料４−１、試料４−２、試料４−３、試料４−４ 及び試料４−５について、実施例１、実施例２、実施例３と同様に粒子捕集率、圧力損失を測定し、α値を算出した。 後記 表５に示す。
【００３１】
実施例５
実施例４で得たろ材シートの試料４−２、試料４−３、試料４−４について、折り曲げ後強度低下［％］ 及び、帯電中和処理による粒子通過率の増加率を下記の方法で求めた。
結果を後記表６に示す。
折り曲げ後強度低下率試験方法
ＪＩＳ Ｐ８１１３（紙及び板紙の引っ張り強さ試験方法）に従い試験片を６枚採取する。この中、３枚についてはＪＩＳ Ｐ８１１３の方法に従って「引っ張り強さ」試験を行い、その平均値を「初期引っ張り強さ」とする。
他の３枚については、下記の方法で「繰り返し折り曲げ後の試験片」を調製する。
即ち、試験片を平面上に置き、長手方向の中央において長手方向に対し直角な中心線に沿って厚さ２ｍｍ、縦幅約５０ｍｍ、横幅約５０ｍｍの平板をその一辺が中心線上になるように置く。
次に、試験片を平板を挟むようにして中心線に沿って１８０度折り曲げ、平板の上面に２秒間密着させた後、試験片を元の折り曲げない状態に戻す。
この「折り曲げ」と「元に戻す」操作を５回行い、この試験片を「繰り返し折り曲げ後の試験片」とする。
この「繰り返し折り曲げ後の試験片」３枚をＪＩＳ Ｐ８１１３に記載の方法で「引っ張り強さ」試験を行い、その平均値を「折り曲げ後の引っ張り強さ」とする。
式５により引っ張り強度低下率を算出する
ろ材シートの粒子捕集率をＪＩＳ Ｂ９９２７付属書１（規定）クリーンルーム用エアフィルタろ材性能試験方法に記載の方法で測定する。この測定値を「処理前の粒子捕集率」とする。
次にこのろ材シートに帯電中和剤を十分に含浸した後、常温で乾燥する。
次にこのシートをＪＩＳ Ｂ９９２７付属書１（規定）クリーンルーム用エアフィルタろ材性能試験方法に記載の方法で測定する。この測定値を「処理後の粒子捕集率」とする。
次に、測定値から式６により、帯電中和による粒子通過率の増加率［％］を算出する。
【比較例】
比較例１
市販の高性能エアフィルタ用ガラス繊維ろ材（北越製紙（株）製 Ｈ３０５ＡＲ）について実施例１と同様の性能試験を行い、後記、表２の比較試料１に示す。ざらに、実施例５と同様に折り曲げ後の引っ張り強度低下率を測定した結果 及び、帯電中和処理後の粒子捕集率を測定した結果を後記表６に示す。
【００３３】
比較例２
市販の高性能エアフィルタ用ろ材で、ガラス繊維３０重量％と有機成分（有機繊維と有機バインダー）７０重量％から成る難燃性ろ材（北越製紙（株）製 Ｈ３８８）について、実施例５と同様に折り曲げ後の引っ張り強度低下率を測定した結果及び、帯電中和処理後の粒子捕集率を測定した結果を後記、表６に示す。
【００３４】
比較例３
市販の乾式法による高性能エアフィルタ用有機繊維ろ材（東燃タピルス（株）Ｐ８０ＵＷ−ＥＰ４）について、実施例５と同様に折り曲げ後の引っ張り強度低下率を測定した結果 及び、帯電中和処理後の粒子捕集率を測定した結果を後記、表６に示す。
【００３５】
【表２】
本有機ろ材が従来のマイクロガラス繊維を代替することで、ろ材の折曲強さ、耐衝撃強さを改善し、エアーフィルター製造工程及び、エアフィルタ取り扱いに於ける破損が生じないろ材を得た。
【００３６】
【表３】
【００３７】
【表４】
【００３８】
【表５】
【表６】
【発明の効果】
本発明による高性能エアフィルタ用ろ材は、従来にない高い有機繊維含有率で高性能を実現すると共に、有害物質を含まず、柔軟で破れにくく、加工性に優れている。
本発明のろ材を使用したエアフィルタは使用後に一般可燃物と同様に焼却処分ができる高性能エアフィルタを提供する。[0001]
TECHNICAL FIELD OF THE INVENTION
INDUSTRIAL APPLICABILITY The present invention relates to the fields of precision industry, electronics industry, pharmaceutical industry, food industry, etc., medical field, building air conditioning, etc., and high performance air filter media used in general air purification equipment. The present invention also relates to a high-performance air filter medium that can be incinerated when used, and an air filter using the same.
[0002]
[Prior art]
A conventional high-performance air filter medium is manufactured by a wet papermaking method or a dry web method. Most of the filter media for high-performance air filters manufactured by the wet papermaking method are glass fibers, and inexpensive and high-performance filter media can be obtained. However, they are brittle and weak in deformation force and impact force (external force).
Further, since it is nonflammable when used, it cannot be incinerated, which causes a problem of environmental pollution. (Since it can only be landfilled, it is troublesome to throw it away.)
[0003]
On the other hand, the filter media for high-performance air filters manufactured by the dry web manufacturing method is organic fiber (polypropylene resin, polyester resin, etc.), resistant to deformation and impact force (external force), and can be incinerated when used, but is expensive. Dust collection performance is unstable due to a dust collection mechanism by electrostatic charging (electretization), and it has not been widely used even today. There are issues such as.
[0004]
JP-B-63-56806 and JP-A-10-180020 propose a flame-retardant high-performance filter medium capable of being incinerated and reduced in volume by a wet papermaking method. However, these methods achieve flame retardancy by applying a halogen compound, a boron compound, a phosphorus compound, or the like in order to make the filter medium flame-retardant or by adding a considerable amount to the filter medium.焼 These halogen compounds, boron compounds, phosphorus compounds, etc. have the problem of generating toxic gases by combustion, so incineration is not always appropriate.
[0005]
Japanese Patent Publication No. 62-110718, Japanese Patent Publication No. 63-44914, Japanese Patent Publication No. 63-44915, Japanese Patent Publication No. 63-44916, Japanese Patent Publication No. 63-56806, and Japanese Patent Publication No. 13082 and JP-A-10-180020.
[0006]
Japanese Patent Publication No. 62-110781 and Japanese Patent Publication No. 6-13082, filter media for air filters comprising fine glass fibers having a diameter of 4 μm or less, fine denier synthetic fiber of 0.05 to 0.5 denier and polyvinyl alcohol-based fiber. ing. The present invention differs from the present invention in that {a filter medium having a fiber diameter of at least 1 μm is indispensable for a filter medium for use in a clean room, and an organic fiber must be limited to 0.1 to 0.2 denier. Furthermore, the glass fiber content is as high as 60 to 97% by weight, and the brittleness of the filter medium cannot be improved.
[0007]
JP-B-63-44914, JP-B-63-44915, and JP-B-63-44916 blend ultrafine glass fiber with an average fiber diameter of 0.3-4 μm, chop-and-strand vinylon fiber, chop-and-strand acrylic fiber, and chop-and-strand rayon fiber. An air filter medium made of:
There is no restriction on the fiber diameter of chop and strand vinylon fiber, chop and strand acrylic fiber, and chop and strand rayon fiber. Incidentally, the balance between the collection rate and the pressure loss is an indispensable performance for a useful air filter medium, for example, as the fiber diameter increases, the trapping rate decreases, and as the fiber diameter decreases, the pressure loss increases. That is, it is not always possible to obtain useful air filter media in the patents of this example.
[0008]
Japanese Patent Publication No. 63-56806 discloses a filter paper comprising 20% by weight of glass fiber, 50% by weight of regenerated cellulose fiber and 30% by weight of natural cellulose fiber. The glass fiber is an ultra-fine glass fiber, but there is no restriction on the fiber diameter.マ イ ク ロ In the present invention, the micro glass fiber is also called an ultra-fine glass fiber, and a fiber having a fiber diameter of 0.1 to 1 μm is particularly selected. That is, the filter medium for the high performance air filter is indispensable among the ultrafine glass fibers having a limited fiber diameter.
[0009]
JP-B-63-56806 discloses a regenerated cellulose fiber having an ultrafine copper ammonia method of 1.0 denier or less as a regenerated cellulose fiber.で In the present invention, a filter medium for a high-performance air filter was obtained only for organic fibers within a fiber diameter range of 2.7 to 6.5 μm (0.1 to 0.2 denier).で In Japanese Patent Publication No. 63-56806, the blending ratio of ultra-fine glass fiber is 20% by weight as the minimum amount. In the present invention, the glass fiber-containing material is used in combination with fine organic fibers which are microfibrillated products such as poly-P-phenylene terephthalamide fiber or poly-P-phenylene terephthalamide-3 / 4-diphenylether terephthalamide fiber. A high-performance air filter medium having a ratio of 11 to 25% by weight is obtained.
[0010]
Japanese Patent Application Laid-Open No. H10-180020 discloses a high-performance air filter medium comprising 10 to 50% by weight of glass fibers having an average fiber diameter of 0.65 μm or less 50 to 90% by weight of self-extinguishing organic fibers and a fibrous binder. I have. The organic fiber of the present invention is a fiber containing no halogen or phosphorus compound, and need not be self-extinguishing.
[0011]
Japanese Patent Application Laid-Open No. Hei 10-180020 discloses a self-extinguishing organic fiber having a fiber diameter of 1 to 70 μm. In the present invention, the organic fiber has a fiber diameter in the range of 2.7 to 6.5 μm.
[0012]
Japanese Patent Application Laid-Open No. H10-180020 discloses that ultrafine glass fibers (synonymous with micro glass fibers) have an average fiber diameter of 0.65 μm or less. This ultra-fine glass fiber is a characteristic of its manufacturing method.It is a cotton-like fiber product with a relatively wide and random fiber diameter distribution, and the value of a single fiber diameter accurately describes the ultra-fine glass fiber that is the raw material of the filter medium. The average fiber diameter of 0.65 μm or less mentioned here is a detailed explanation of the present invention.
Light
It is presumed that this is a value calculated from the surface area value by the BET method in Table 1 and the ultrafine glass fibers of Japanese Patent Application Laid-Open No. 10-180020 are identified by the code numbers in Table 1 as # 106, # 104, # 100, # 90 mag is assumed. Incidentally, the micro glass fibers in the present invention are code numbers # 90, # 100 and # 104.
[0013]
[Problems to be solved by the invention]
In order to solve this problem, the present invention provides a high-performance air filter medium mainly composed of organic fibers having performance equivalent to that of a conventional glass fiber medium. As a result of intensive research, the production of a high-performance air filter media that has stable collection performance, is inexpensive, resistant to deformation and impact force (external force), and can be incinerated when used, has been conducted. Invented the invention. Regarding the necessity of the flame retardancy of the filter media, air filters are generally used for applications without fire, and plywood, paper, synthetic resin, synthetic fibers, etc. are often used as components of air filters today. These materials are often not flame-retardant. This is a result of the social priority of minimizing environmental pollution during waste disposal after use today.
[0014]
[Means for Solving the Problems]
In the present invention, the organic fiber having a fiber diameter of 2.7 to 6 5 μm and a fiber length of 0.5 to 5 mm is a fiber forming a skeleton of a filter medium. In the case of a conventional glass fiber filter medium, a micro glass fiber having a fiber diameter of 1 to 4 μm ( Since the fibers corresponding to the code numbers # 108, # 110, and # 112) occupy 70 to 80% by weight of the filter medium, it is important to convert the fiber diameter component into organic fibers when the filter medium is intended to be converted into organic fibers. .
[0015]
Originally, it is presumed that it is preferable to use an organic fiber having a fiber diameter of 1 to 4 μm in the present invention. However, at present, organic fibers produced industrially and applicable to this application are limited to 0.1 d (denier) polyester fiber (PET) fiber (fiber diameter 2.7 to 4.5 μm). The organic fiber having a fiber diameter of 2.7 to 6.5 μm (0.1 to 0.3 d) can be used, and preferably 2.7 to 5 μm (0.1 to 0.2 d).物 A fiber having a fiber diameter of more than 6.5 µm is not suitable for a high-performance air filter medium because it increases the pressure loss and lowers the particle collection rate. The results are shown in Example 1 below and Table 2.
[0016]
In the present invention, fine fibers having a fiber diameter of 0.1 to 1.0 μm as a main component and a fiber length of 20 to 5000 μm are used for the purpose of improving the particle collection rate of the filter medium. In the case of a conventional glass fiber filter medium, micro glass fibers (code numbers # 90, # 100, and # 106) having a fiber diameter of 0.1 to 1.0 μm as a main component are used. In the present invention, the fine fibers are inorganic fibers, and microfibrillated products such as poly-P-phenylene terephthalamide fiber or poly-P-phenylene terephthalamide-3,4-diphenyl ether terephthalamide fiber as organic fiber in addition to micro glass fiber. Can be used. Since these microfibrillated products are fine organic fibers and have a fiber diameter of 0.2 to 1.0 μm as a main component, the present invention can be used as a substitute for micro glass fibers (code numbers # 90 and # 100 and # 104). It can be used as all or a part of fine fibers, greatly reduces inorganic fiber content compared to conventional filter media, improves bending strength (brittleness), impact strength (deformation resistance), and air It is possible to obtain a filter medium that is unlikely to be damaged during the filter manufacturing process and the air filter handling.
[0017]
That is, in the present invention, the fine fiber is a micro glass fiber occupying most of the inorganic fiber having a fiber diameter of 0.1 to 1.0 μm, and a cotton-like glass fiber produced by a spinning method, a flame insertion method, a rotary method, or the like. Are code numbers # 90, # 100, and # 104.ガ ラ ス Glass fibers produced by the above method are classified by code number for each major fiber diameter range and are commercially available. As a result of observing the ratio of the number of fibers by fiber diameter in the field of view using an electron microscope, the micro glass fibers of each code number are composed of fibers having fiber diameters as shown in Table 1.
[Table 1]
The micro glass fiber contains a fiber of a wide fiber diameter range for each product, and the classification based on the average fiber diameter is not strict, but means that the value is approximately in the vicinity.鑑 In view of this, in the present invention, the micro glass fibers are represented by the fiber diameter and the code number of the majority of the fibers as shown in Table 1.
[0019]
In the present invention, the fine fibers are microfibrillated organic fibers such as poly-P-phenylene terephthalamide fibers or poly-P-phenylene terephthalamide-3,4-diphenyl ether terephthalamide fibers, and have a fiber diameter of 0.1 to 4 μm. In this case, 0.2 to 1.0 μm occupies the majority, and the fiber length is 0.02 to 2 mm.
The term microfibrillated product as used herein refers to a method of cutting highly crystalline and highly oriented fibers such as aramid-based fibers into appropriate lengths, dispersing them in water, and fibrillating them using a homogenizer, a beater, etc. 56-100801, JP-A-59-92011) and (1) a method of explosively ejecting a synthetic polymer from a high pressure side to a low pressure side at a temperature higher than the boiling point of a solvent to fibrillate into a fibrous form (flash spinning method), or dispersing it in water. The synthetic polymer fiber or pulp-like fiber cut into an appropriate length is passed through an orifice at high pressure and high speed and collides with the vessel wall to rapidly reduce the shear force on the synthetic polymer fiber or pulp-like fiber. And fibrillation into a fibrous form.
[0020]
In the present invention, the fine fiber is a fiber composed mainly of fibers having a fiber diameter of 0.1 to 1 μm. As the inorganic fibers, fibers having a fiber diameter of 0.15 to 0.4 μm are particularly frequently used. Micro glass fiber and micro glass fiber of code number # 100, which has a particularly large fiber diameter of 0.25 to 0.4 μm, and micro glass fiber of code number # 104, which has a particularly large fiber diameter of 0.4 to 0.8 μm Fibers and the like, preferably micro-glass fibers of code numbers # 90 and # 100, which are particularly often fibers having a fiber diameter of 0.4 μm or less, and poly-P-phenylene terephthalamide fibers or poly- fibers as organic fibers. A microfibrillated product such as P-phenylene terephthalamide-3,4-diphenylether terephthalamide fiber, and most of the fibers having a fiber diameter of 0.1 to 4 μm. In diameter 0.2 to 1 [mu] m, especially many of which are fiber diameter 0.2 to 0.5 [mu] m. (4) When the number of the fine fibers is particularly large with a fiber diameter of 0.5 μm or more, the particle collection rate of the filter medium is reduced. {Postscript} Example 2 Table 3 shows the results.
[0021]
In the present invention, a plurality of micro glass fibers, code number # 90, code number # 100 and code number # 104 can be used alone or in combination.
[0022]
Inorganic fibers (micro glass fiber code numbers # 90, # 100 and # 104) and organic fibers (poly-P-phenylene terephthalamide fiber or poly-P-phenylene terephthalamide-3 / 4-diphenyl ether terephthalamide) as the fine fibers The mixing ratio with inorganic fibers (microfibrillated products such as fibers) is 72 to 100% by weight of inorganic fibers, preferably 74 to 100% by weight 0 to 28% by weight of organic fibers, and preferably 0 to 26% by weight. (4) When the organic fiber content exceeds 26% by weight, the particle collection rate decreases.
Table 4 below shows {Example 3}.
[0023]
The powdery or fibrous polyvinyl alcohol (PVA) -based binder of the present invention is hot-melted in a drying step after wet papermaking, and then solidified by cooling, whereby the filter medium constituent fibers are firmly bonded to each other. Develops the strength of the filter medium sheet. The polyvinyl alcohol (PVA) -based binder has a melting temperature in water of 60 to 110 ° C., and is mainly made of polyvinyl alcohol, cation-modified polyvinyl alcohol, and carboxine-modified polyvinyl alcohol. Binder resins, for example, polyacrylic resins, polyacrylamide resins, starch-based powdery or emulsion papermaking binders can be used.
[0024]
The water repellency imparting of the filter medium for a high performance air filter of the present invention is performed by preparing an aqueous slurry in which an organic fiber, a fine fiber, and a powdery or fibrous binder are mixed, making the slurry with a paper machine, and pressing lightly. The filter medium sheet obtained in this way can be obtained by impregnating a water repellent with a size roll or the like and drying. The water-repellent agent may be a water-repellent agent used for an ordinary filter material for an air filter. .
[0025]
In the present invention, 70 to 85% by weight of an organic fiber having a fiber diameter of 2.7 to 6.5 μm and a fiber length of 0.5 to 5 mm, and a fiber diameter of 0.1 to 1 μm occupy most, and a fiber length of 0.02 to Inorganic fibers 11 to 25 obtained by blending 15 to 30% by weight of 5 mm fine fibers and 100 parts by weight of the total weight of the organic fibers and fine fibers with 1 to 4 parts of a polyvinyl alcohol-based binder and wet papermaking. The filter medium for high-performance air filters containing weight% can be incinerated in the same manner as ordinary papers. Incidentally, the inorganic component content of general papers is 20 to 30% by weight for gravure paper and 15 to 20% by weight for hard paper, and the filter medium for high-performance air filters of the present invention has the same inorganic content as these papers. It is a component content and does not contain harmful substances such as flame retardants.
[0026]
If the organic fiber content is increased, the inorganic component can be reduced. However, if the organic fiber content exceeds 89% by weight, the particle collection rate decreases. {Postscript} Example 4 Table 5 shows the results.と When the organic fiber content is lower than 70% by weight, the strength is significantly reduced due to bending, resulting in a brittle filter medium, which is not preferable as a filter medium for a high-performance air filter. << Postscript >> Example 5
It is shown in Table 6.
[0027]
【Example】
Example 1
100 parts by weight of a mixed fiber obtained by blending 75% by weight of 0.1 denier polyester fiber (Tepirus Co., Ltd.) and 25% by weight of micro glass fiber (Johnmanville Co., Ltd., code No. # 100) Was mixed with 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101), an aqueous slurry was prepared with a mixer, paper-made with a standard square handmade paper machine of JIS P8209, and lightly pressed. Then, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained.ろ This filter medium sheet was used as Sample 1-1.
Next, a mixed fiber obtained by blending 75% by weight of 0.3 denier polyester fiber (Tepils Co., Ltd., Teijin Co., Ltd.) and 25% by weight of micro glass fiber (Johnmanville Co., Ltd., code number # 100) was mixed with the mixed fiber. 100 parts by weight of 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, and papermaking was performed with a standard square handmade paper machine of JIS P8209. After pressing lightly, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained. This filter medium sheet was used as Sample 1-2.
Next, a mixed fiber obtained by blending 75% by weight of 0.5 denier polyester fiber (Tepirus Co., Ltd.) and 25% by weight of micro glass fiber (Johnmanville Co., Ltd., code No. # 100) was mixed with the mixed fiber. 100 parts by weight of 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, and papermaking was performed with a standard square handmade paper machine of JIS P8209. After pressing lightly, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained. The filter medium sheet was used as Sample 1-3.
Filter Material Sheets {Sample 1-1, {Sample 1-2} and Sample 1-3> Annex 1 of JIS B9927 Clean Room Air Filter Performance Test Method (Regulation) Particle Collection Rate and Pressure Loss According to Clean Room Air Filter Media Performance Test Method Was measured. Α The α value was calculated from the measured particle collection rate and pressure loss value. The results are shown in Table 2 below.
[0028]
Example 2
A blend of 75% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 25% by weight of micro glass fiber code # 100 (Johnmanville Co., Ltd., fiber diameter: 0.2 to 1.2 μm) 100 parts by weight of the mixed fiber was mixed with 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101), and an aqueous slurry was prepared using a mixer. Paper is made with a standard square handmade paper machine, pressed lightly, dried with a rotary drier, and weighs 80 g / m2.2A filter material sheet was obtained. This filter medium sheet was used as Sample 2-1.
A blend of 75% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 25% by weight of micro glass fiber code # 90 (fiber diameter of 0.1 to 1.5 μm manufactured by Johnmanville Co.) 100 parts by weight of the mixed fiber was mixed with 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101), and an aqueous slurry was prepared using a mixer. Paper is made with a standard square handmade paper machine, pressed lightly, dried with a rotary drier, and weighs 80 g / m2.2A filter material sheet was obtained. This filter medium sheet was used as Sample 2-2.
A blend of 75% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 25% by weight of micro glass fiber code number # 104 (fiber diameter of 0.2 to 2 μm manufactured by John Manville Co.) 100 parts by weight of the mixed fiber was blended with 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101), and an aqueous slurry was prepared using a mixer. After making paper with a handmade paper machine, pressing lightly, drying with a rotary dryer, basis weight 80 g / m2A filter material sheet was obtained.ろ This filter medium sheet was used as Sample 2-3.
75% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 25% by weight of micro glass fiber code No. # 106 (fiber diameter of 0.2 to 3 μm manufactured by John Manville Co.) 100 parts by weight of the mixed fiber was blended with 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101), and an aqueous slurry was prepared using a mixer. After making paper with a handmade paper machine, pressing lightly, drying with a rotary dryer, basis weight 80 g / m2A filter material sheet was obtained.ろ The filter medium sheet was used as Sample 2-4.
For the filter medium sheets {Sample 2-1, Sample 2-2, Sample 2-3} and Sample 2-4, the particle collection rate and pressure loss were measured in the same manner as in Example 1, and the α value was calculated. The results are shown in Table 3.
[0029]
Example 3
75% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.), 22% by weight of micro glass fiber code number # 100 (manufactured by John Manville Co., Ltd .: fiber diameter of 0.2 to 1.2 μm) and poly To a mixed fiber obtained by mixing 3% by weight (solid content only) of a microfibrillated product of P-phenylene terephthalamide fiber (Daicel Chemical Industries, Ltd .: Tiara KY-400S) with respect to 100 parts by weight of the mixed fiber Then, 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, paper-made with a standard square handmade paper machine of JIS P8209, and lightly pressed. Dry with a rotary dryer, basis weight 80 g / m2A filter material sheet was obtained.ろ This filter medium sheet was used as Sample 3-1.
75% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 18.5% by weight of micro glass fiber code # 100 (fiber diameter of 0.2 to 1.2 μm manufactured by John Manville Co.) 100% by weight of a mixed fiber obtained by mixing 6.5% by weight (solid content only) of a microfibrillated product of poly-P-phenylene terephthalamide fiber (Daicel Chemical Industries, Ltd .: Tiara KY-400S) 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, paper was made with a standard square handmade paper machine of JIS P8209, and lightly pressed. After that, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained.ろ This filter medium sheet was used as Sample 3-2.
75% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.), 18% by weight of micro glass fiber code No. # 100 (fiber diameter of 0.2 to 1.2 μm manufactured by John Manville Co.) and poly- A mixed fiber obtained by blending 7% by weight (solid content only) of a microfibrillated product of P-phenylene terephthalamide fiber (Daicel Chemical Industries, Ltd .: Tiara KY-400S) with respect to 100 parts by weight of the mixed fiber 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, paper-made with a standard square handmade paper machine of JIS P8209, and lightly pressed. Dry with a dryer, basis weight 80g / m2A filter material sheet was obtained.ろ This filter medium sheet was used as Sample 3-3.
For the filter medium sheets {Sample 3-1 and Sample 3-2} and Sample 3-3, the particle collection rate and the pressure loss were measured in the same manner as in Example 1 and Example 2, and the α value was calculated. {Results} are shown in Table 4 below.
[0030]
Example 4
65% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepirus Co., Ltd. Tepils) and 25.9% by weight of micro glass fiber code number # 100 (fiber diameter of 0.2 to 1.2 μm manufactured by John Manville Co.) 100% by weight of a mixed fiber obtained by mixing 9.1% by weight (solid content only) of a microfibrillated product of poly-P-phenylene terephthalamide fiber (Daicel Chemical Industries, Ltd .: Tiara KY-400S) 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, paper was made with a standard square handmade paper machine of JIS P8209, and lightly pressed. After that, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained. This filter medium sheet was used as Sample 4-1.
70% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 22.2% by weight of micro glass fiber code # 100 (fiber diameter 0.2 to 1.2 μm, manufactured by John Manville Co.) 100% by weight of a mixed fiber obtained by mixing 7.8% by weight (solid content only) of microfibrillated poly-P-phenylene terephthalamide fiber (Daicel Chemical Industries, Ltd .: Tiara KY-400S) 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, paper was made with a standard square handmade paper machine of JIS P8209, and lightly pressed. After that, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained. The filter medium sheet was used as Sample 4-2.
80% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 14.8% by weight of micro glass fiber code number # 100 (fiber diameter of 0.2 to 1.2 μm manufactured by John Manville Co.) 100% by weight of a mixed fiber obtained by mixing 5.2% by weight (solid content only) of a microfibrillated product of poly-P-phenylene terephthalamide fiber (Daicel Chemical Industries, Ltd .: Tiara KY-400S) 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, paper was made with a standard square handmade paper machine of JIS P8209, and lightly pressed. After that, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained.
This filter medium sheet was used as Sample 4-3.
85% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 11.1% by weight of micro glass fiber code number # 100 (fiber diameter of 0.2 to 1.2 μm manufactured by John Manville Co.) 100% by weight of a mixed fiber obtained by mixing 3.9% by weight (solid content only) of a microfibrillated product of poly-P-phenylene terephthalamide fiber (Daicel Chemical Industries, Ltd .: Tiara KY-400S) 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, paper was made with a standard square handmade paper machine of JIS P8209, and lightly pressed. After that, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained. This filter medium sheet was used as Sample 4-4.
88% by weight of 0.1 denier polyester fiber having a fiber length of 3 mm (Tepils Co., Ltd.) and 8.9% by weight of micro glass fiber code No. # 100 (fiber diameter of 0.2 to 1.2 μm manufactured by John Manville Co.) 100% by weight of a mixed fiber obtained by mixing 3.1% by weight (solid content only) of a microfibrillated product of poly-P-phenylene terephthalamide fiber (Daicel Chemical Industries, Ltd .: Tiara KY-400S) 2 parts by weight of a fibrous PVA binder (Kuraray Co., Ltd. Crown VP: VPB101) was blended, an aqueous slurry was prepared with a mixer, paper was made with a standard square handmade paper machine of JIS P8209, and lightly pressed. After that, it is dried with a rotary drier and has a basis weight of 80 g / m.2A filter material sheet was obtained. The filter medium sheet was used as Sample 4-5.
For the filter medium sheets {Sample 4-1, Sample 4-2, Sample 4-3, Sample 4-4} and Sample 4-5, the particle collection rate and the pressure loss were measured in the same manner as in Examples 1, 2 and 3. It measured and calculated (alpha) value. {Postscript} Table 5
[0031]
Example 5
For the filter media sheets 4-2, 4-3, and 4-4 obtained in Example 4, the strength reduction after bending [%] and the increase rate of the particle passage rate due to the charge neutralization treatment were determined by the following methods. I asked.
The results are shown in Table 6 below.
Test method for strength reduction rate after bending
Six test pieces are collected in accordance with JIS P8113 (test method for tensile strength of paper and paperboard). Among them, three sheets are subjected to a “tensile strength” test according to the method of JIS P8113, and the average value is defined as “initial tensile strength”.
For the other three pieces, a "test piece after repeated bending" is prepared by the following method.
That is, a test piece is placed on a plane, and a flat plate having a thickness of 2 mm, a vertical width of about 50 mm, and a horizontal width of about 50 mm is placed along the center line perpendicular to the longitudinal direction at the center in the longitudinal direction so that one side thereof is on the center line. Put.
Next, the test piece is bent 180 degrees along the center line so as to sandwich the flat plate, and is brought into close contact with the upper surface of the flat plate for 2 seconds.
The “bending” and “returning” operations are performed five times, and this test piece is referred to as a “test piece after repeated bending”.
The three “test pieces after repeated bending” are subjected to a “tensile strength” test by the method described in JIS P 8113, and the average value is defined as “tensile strength after bending”.
Calculate the tensile strength reduction rate by Equation 5
The particle collection rate of the filter medium sheet is measured according to the method described in JIS B9927 Appendix 1 (Regulation) Air Filter Media Performance Test Method for Clean Room. This measured value is referred to as “particle collection rate before treatment”.
Next, the filter medium sheet is sufficiently impregnated with a charge neutralizing agent, and then dried at normal temperature.
Next, this sheet is measured by the method described in JIS No. B9927 Appendix 1 (Regulated) Air Filter Material Performance Test Method for Clean Room. This measured value is referred to as “particle collection rate after treatment”.
Next, the increase rate [%] of the particle passage rate due to the charge neutralization is calculated from the measured value by Expression 6.
[Comparative example]
Comparative Example 1
A performance test similar to that of Example 1 was performed on a commercially available glass fiber filter medium for a high-performance air filter (H305AR manufactured by Hokuetsu Paper Co., Ltd.). The results of the measurement of the tensile strength reduction rate after bending in the same manner as in Example 5 and the results of the measurement of the particle collection rate after the charge neutralization treatment are shown in Table 6 below.
[0033]
Comparative Example 2
Same as Example 5 for a commercially available filter medium for high-performance air filters, which is a flame-retardant filter medium (# H388 manufactured by Hokuetsu Paper Co., Ltd.) comprising 30% by weight of glass fiber and 70% by weight of an organic component (organic fiber and organic binder). Table 6 shows the results of measuring the tensile strength reduction rate after bending and the results of measuring the particle collection rate after the charge neutralization treatment.
[0034]
Comparative Example 3
For a commercially available organic fiber filter medium for a high-performance air filter (Tonen Tapyrus Co., Ltd., P80UW-EP4) by a dry method, the tensile strength decrease rate after bending was measured in the same manner as in Example 5, and the results after the charge neutralization treatment The results of measuring the particle collection rate are shown in Table 6 below.
[0035]
[Table 2]
By replacing the conventional micro glass fiber with this organic filter medium, the bending strength and impact resistance of the filter medium were improved, and a filter medium that did not break during the air filter manufacturing process and air filter handling was obtained. .
[0036]
[Table 3]
[0037]
[Table 4]
[0038]
[Table 5]
[Table 6]
【The invention's effect】
The high-performance air filter medium according to the present invention realizes high performance with an unprecedentedly high organic fiber content, does not contain harmful substances, is flexible and resistant to breakage, and has excellent workability.
The air filter using the filter medium of the present invention provides a high-performance air filter that can be incinerated after being used in the same manner as general combustibles.
Claims (6)
ＪＩＳ Ｐ８１１３紙及び板紙の引っ張り強さ試験方法に記載された方法で、引っ張り強さが４００ｇ／１５ｍｍ幅以上であり、下記「折り曲げ後強度低下率試験方法」による折り曲げ後の「強度低下率［％］」が５％以下である請求項１に記載の高性能エアフィルタ用ろ材。
折り曲げ後強度低下率試験方法
ＪＩＳ Ｐ８１１３（紙及び板紙の引っ張り強さ試験方法）に従い試験片を６枚採取する。この中、３枚についてはＪＩＳ Ｐ８１１３の方法に従って「引っ張り強さ」試験を行い、その平均値を「初期引っ張り強さ」とする。
他の３枚については、下記の方法で「繰り返し折り曲げ後の試験片」を調製する。
即ち、試験片を平面上に置き、長手方向の中央において長手方向に対し直角な中心線に沿って厚さ２ｍｍ、縦幅約５０ｍｍ、横幅約５０ｍｍの平板をその一辺が中心線上になるように置く。
次に、試験片を平板を挟むようにして中心線に沿って１８０度折り曲げ、平板の上面に２秒間密着させた後、試験片を元の折り曲げない状態に戻す。
この「折り曲げ」と「元に戻す」操作を５回行い、この試験片を「繰り返し折り曲げ後の試験片」とする。
この「繰り返し折り曲げ後の試験片」３枚をＪＩＳ Ｐ８１１３に記載の方法で「引っ張り強さ」試験を行い、その平均値を「折り曲げ後の引っ張り強さ」とする。
式２により引っ張り強度低下率を算出する
According to the method described in the JIS P8113 paper and paperboard tensile strength test method, the tensile strength is 400 g / 15 mm width or more, and the “strength reduction rate [% ] Is 5% or less.
Six test pieces are sampled in accordance with JIS P8113 (Test method for tensile strength of paper and paperboard) after bending. Among them, three sheets are subjected to a “tensile strength” test according to the method of JIS P8113, and the average value is defined as “initial tensile strength”.
For the other three pieces, a "test piece after repeated bending" is prepared by the following method.
That is, a test piece is placed on a plane, and a flat plate having a thickness of 2 mm, a vertical width of about 50 mm, and a horizontal width of about 50 mm is placed along the center line perpendicular to the longitudinal direction at the center in the longitudinal direction so that one side thereof is on the center line. Put.
Next, the test piece is bent 180 degrees along the center line so as to sandwich the flat plate, and is brought into close contact with the upper surface of the flat plate for 2 seconds.
This “bending” and “returning” operations are performed five times, and this test piece is referred to as a “test piece after repeated bending”.
A "tensile strength" test is performed on three of the "test pieces after repeated bending" according to the method described in JIS P8113, and the average value is defined as "tensile strength after bending".
Calculate the tensile strength reduction rate by Equation 2.
ＰＥｄ ： 静電帯電を中和する物質が付着している時のろ材の粒子捕集率［％］Even if a substance that neutralizes electrostatic charge such as a charge neutralizing agent or an organic solvent adheres, the “particle increase rate” calculated by Equation 3 is “30% or less” (increase rate of particle passage rate [%]). The high-performance air filter medium according to claim 1, 2, 3, or 4.
P Ed : Particle collection rate [%] of filter medium when a substance neutralizing electrostatic charge is attached
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