JP2006021189A - Gas adsorbent - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a gas adsorption material capable of preventing a gas adsorptive filler stuck to the surface of a fiber from coming off and capable of suppressing the reduction of a specific surface area in the gas adsorptive filler. <P>SOLUTION: The subject gas adsorbent contains the fiber, a binder resin on its surface and the gas adsorptive filler, the binder resin is a moist heat gelatinized resin, and the gas adsorptive filler is stuck by a gelatinized substance that the moist heat gelatinized resin is moist heat gelified. For example, the gas adsorptive filler (3) is effectively stuck to a sheath component (1) of combined fibers (5) which component comprises a core component (2) of polypropylene as a thermoplastic synthesized resin component and the sheath component (1) of ethylene-vinylalcohol copolymer as a moist heat gelatinized fiber component. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a gas adsorbent having filler-fixed fibers in which a gas-adsorbing filler is fixed to the fiber surface.

  In recent years, since the occurrence of allergic symptoms such as sick house syndrome due to inhalation of volatile organic compounds (hereinafter abbreviated as VOC) has increased, a gas adsorbent that adsorbs harmful gases such as VOC gas has been desired. As the gas adsorbing material, for example, Patent Literature 1 proposes a gas adsorbing sheet having an adsorbing effect on all VOC gases.

In the gas adsorbing sheet proposed in Patent Document 1, activated carbon particles are sandwiched and fixed between two sheet materials, and adsorbent particles are fixed to at least one of the sheet materials. . As a method for fixing the adsorbent particles, 1) a method in which adsorbent particles are mixed in a binder resin solution and coated on one sheet material, and the other sheet material is stacked thereon, or 2) one sheet material in advance. For example, a method of coating a hot melt agent or the like on the surface, spraying adsorbent particles thereon, and further stacking the other sheet material thereon is exemplified.
JP 2000-246827 A

  However, in the immobilization method of 1), the adsorbent particles are buried in the binder resin solution, and there is a possibility that a sufficient gas adsorption effect cannot be obtained. Further, in the immobilization method of 2), the contact area between the hot melt agent and the adsorbent particles is small, so that the adsorbent particles may fall off. In addition, the gas adsorbing sheet proposed in Patent Document 1 uses a porous sheet material for at least one of the two sheet materials in order to improve air permeability. When the activated carbon particles are sandwiched between them, it is necessary to make the particle diameter of the activated carbon particles larger than the maximum pore diameter of the porous sheet material so that the activated carbon particles do not fall off. For this reason, activated carbon particles having a particle diameter of 100 μm to 1000 μm are used, and the activated carbon particles sometimes have a small specific surface area, so that a sufficient gas adsorption effect may not be obtained.

  In order to solve the above-mentioned conventional problems, the present invention provides a gas adsorbent capable of preventing the gas adsorbent filler fixed on the fiber surface from falling off and suppressing the decrease in the specific surface area of the gas adsorbent filler. To do.

  The gas adsorbent of the present invention is a gas adsorbent having filler-fixed fibers containing fibers, a binder resin on the surface thereof, and a gas-adsorptive filler fixed to the binder resin. It is a gelling resin, and the gas adsorbing filler is fixed by a gelled product obtained by gelling the wet heat gelled resin.

  According to the gas adsorbing material of the present invention, the gas adsorbing filler is fixed by the wet heat-gelled gelled material fixed to the surface of the fiber, so that the gas adsorbing filler is fixed in a state of being exposed on the surface. be able to. As a result, it is possible to prevent the gas-adsorptive filler adhered to the fiber surface from falling off, and to suppress a decrease in the specific surface area of the gas-adsorptive filler. Can be improved.

  In the gas adsorbent of the present invention, the wet heat gelled resin refers to a resin that can be gelled by heating in the presence of moisture. The “resin capable of gelling” is swollen by gelling at a temperature of 50 ° C. or higher, and the swollen gelled product can fix the constituent fibers of the gas adsorbent (fiber structure) of the present invention. Refers to resin. Examples of the wet heat gelled resin include powder, chip, and fiber. In particular, the wet heat gelled resin is preferably fibrous. The fibrous wet heat gelled resin (hereinafter referred to as “wet heat gelled fiber”) is a fiber containing a wet heat gelled resin, or a composite containing a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component. Fiber (hereinafter referred to as “wet heat gelled composite fiber”) is used. Thereby, another fiber or at least another thermoplastic synthetic fiber component maintains the form of the fiber and exhibits a function as a binder for fixing the gas-adsorbing filler by gelling the wet heat gelled resin. The gas-adsorbing filler is fixed by a gelled product obtained by wet-heat gelation of a wet heat gelled resin fiber component or a wet heat gelled resin bonded to the surface of the fiber. Preferably, the gas adsorbing filler is exposed and fixed. Also, the wet heat gelled fibers and / or the wet heat gelled fibers and other fibers are bonded to each other by the gelled product obtained by wet heat gelation of the wet heat gelled resin fiber component or the wet heat gelled resin bonded to the fiber surface. Has been.

  The fiber structure includes the fiber and the binder resin. The term “fiber structure” as used herein refers to a fiber structure formed of fibers such as fiber bundles, yarns, fiber masses, nonwoven fabrics, woven and knitted fabrics, and nets. In particular, non-woven fabrics have high processability and can be applied to various uses.

  The wet heat gelling resin is preferably an ethylene-vinyl alcohol copolymer resin. It is because it can be gelled by wet heat and does not alter other fibers and / or other thermoplastic synthetic fiber components.

  The ethylene-vinyl alcohol copolymer resin is a resin obtained by saponifying an ethylene-vinyl acetate copolymer resin, and the saponification degree is preferably 95% or more. A more preferable degree of saponification is 98% or more. Moreover, a preferable ethylene content rate is 20 mol% or more. A preferable ethylene content is 50 mol% or less. A more preferable ethylene content is 25 mol% or more. A more preferable ethylene content is 45 mol% or less. If the degree of saponification is less than 95%, it may be difficult to produce a fiber structure due to adhesion to a roll or the like during gel processing. Similarly, when the ethylene content is less than 20 mol%, production of a fiber structure may be difficult due to adhesion to a roll or the like during gel processing. On the other hand, if the ethylene content exceeds 50 mol%, the wet heat gelation temperature becomes high, and the processing temperature has to be raised to the vicinity of the melting point, and as a result, the dimensional stability of the fiber structure may be adversely affected. .

  A preferred gelling temperature of the wet heat gelling resin is 50 ° C. or higher. A more preferable gelation temperature is 80 ° C. or higher. If a resin that can be gelled at a temperature lower than 50 ° C. is used, it may become difficult to produce a fiber structure during gel processing due to intense adhesion to a roll or the like, or may not be used in summer or in a high-temperature environment. . The “gel processing” refers to processing for gelling a wet heat gelled resin.

As a preferable combination of the fiber and the binder resin,
(I) a composite fiber comprising a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component,
(II) a mixture of the composite fiber and other fibers,
(III) a mixture of the composite fiber and wet heat gelled resin, and
(IV) At least one selected from a mixture of a wet heat gelled resin and other fibers (hereinafter referred to as “forms (I) to (IV)”). The form (I) is a wet heat gelled composite fiber in which the “binder resin” is a wet heat gelled resin fiber component and the “fiber” is another thermoplastic synthetic fiber component. In the form (II), the “binder resin” is a wet heat gelled composite fiber, and the “fiber” is another fiber and is mixed. In the form (III), the “fiber” is a wet heat gelled composite fiber, and the “binder resin” is a wet heat gelled resin, which are mixed. In the form (IV), the “binder resin” is a wet heat gelled resin that takes a form other than the wet heat gelled composite fiber (for example, a fiber of a wet heat gelled resin alone, a powder form, a chip form), and the “fiber” is It is a mixture of other fibers.

  It is preferable that the wet heat gelled composite fiber used in the forms (I) to (III) is a composite fiber in which the wet heat gelled resin fiber component is exposed or partially divided. The composite shape indicates a concentric core-sheath type, an eccentric core-sheath type, a parallel type, a split type, a sea-island type, and the like. In particular, the concentric core-sheath type is preferable because the gas-adsorbing filler is easily fixed to the fiber surface. In addition, the cross-sectional shape may be any of a circle, a hollow, an irregular shape, an ellipse, a star, a flat shape, and the like, but is preferably a circle from the standpoint of easy fiber production. It is preferable that the split-type composite fiber is partially split in advance by jetting a high-pressure water stream or the like. If it does in this way, the divided | segmented wet heat gelled resin fiber component will gelatinize by wet heat processing, will form a gelled material, will adhere to the surface of another fiber, and will adhere a gas adsorbent filler. That is, it functions as a binder.

  The ratio of the wet heat gelled resin fiber component in the wet heat gelled composite fiber is preferably in the range of 10 mass% to 90 mass%. A more preferable wet heat gelled resin fiber component content is 30 mass% or more. A more preferable wet heat gelled resin fiber component content is 70 mass% or less. When the content of the wet heat gelled resin fiber component is less than 10 mass%, the gas adsorbing filler tends to be difficult to adhere. When the content of the wet heat gelled resin fiber component exceeds 90 mass%, the fiber formability of the composite fiber tends to decrease.

  The thermoplastic synthetic fiber component in the wet heat gelled composite fiber may be any material such as polyolefin, polyester, polyamide, etc., but is preferably polyolefin. Examples of the polyolefin include polyethylene, polypropylene, polybutene, and polystyrene. When ethylene-vinyl alcohol copolymer resin is used as the wet heat gelled resin fiber component, it is easy to form a composite fiber (conjugate fiber) by melt spinning.

  Moreover, it is preferable to use the thermoplastic synthetic fiber component which has melting | fusing point higher than the temperature which gelatinizes a wet heat gelled resin fiber component as another thermoplastic synthetic fiber component. If the other thermoplastic synthetic fiber component is a thermoplastic synthetic fiber component having a melting point lower than the temperature at which the gelled product is formed, the other thermoplastic synthetic fiber component itself tends to melt and become hard. May become non-uniform with shrinkage.

  The ratio of the wet heat gelled composite fiber to the fiber structure is not particularly limited as long as it is an amount capable of fixing the gas-adsorbing filler, but the fiber is fixed by the gelled substance and / or the gas-adsorbing filler is effective. It is preferable that the ratio of the composite fiber required for adhering to is 10 mass% or more. A more preferable ratio of the composite fiber is 30 mass% or more. Furthermore, the ratio of a preferable composite fiber is 50 mass% or more. In this case, the “ratio of the composite fiber” means, for example, in the fiber structure, when the web containing the composite fiber is present on both surfaces and other fibers are present inside, the content in the web containing the composite fiber is included. Refers to the quantity.

  In the form (III), the wet heat gelled composite fiber may further contain a wet heat gelled resin to form a gelled product on the surface of the composite fiber. Thereby, the adhering effect of the gas adsorbing filler can be further improved.

  Other fibers used in the form (II) or the form (IV) include chemical fibers such as rayon, natural fibers such as cotton, hemp, wool, polyolefin resin, polyester resin, polyamide resin, acrylic resin, polyurethane Arbitrary things, such as a synthetic fiber which uses synthetic resins, such as resin, as a single ingredient or a plurality of ingredients, can be selected and used.

  In the form (IV), the wet heat gelled resin is preferably contained within a range of 1 mass% to 90 mass% with respect to the fiber structure. A more preferable content is 3 mass% or more. A more preferable content is 70 mass% or less. When the content of the wet heat gelled resin is less than 1 mass%, it tends to be difficult to fix other fibers by the gelled product, or it is difficult to fix the gas adsorbing filler. If the content of the wet heat gelled resin exceeds 90 mass%, the fiber shape may be lost to form a film, or the gas adsorbing filler may be buried in the gelled product.

  The gas adsorbing filler is not particularly limited as long as it has a function of adsorbing gaseous substances in the air, but is not limited to activated carbon particles, zeolite, silica gel, activated clay, layered phosphate and other porous particles, and these porous materials. Porous particles or the like in which a gas adsorbing compound such as an acidic substance or a formaldehyde adsorbent is included in the porous particles are preferable. Among the porous particles, activated carbon particles are particularly preferable.

  Although the kind of activated carbon is not specifically limited, For example, the thing using coconut husk, woody, etc. is mentioned as a raw material, The activation method includes the method by water vapor | steam, the method by a chemical | medical agent, etc.

  The gas adsorbent of the present invention may further contain a gas adsorbing compound. Examples of the gas adsorbing compound include acidic substances such as phosphoric acid, sulfanilic acid, acrylic acid, and polyphenol, hydrazide compounds, and polyamine compounds such as aromatic polyamine, polyallylamine, and polyvinylamine. The gas adsorbing compound referred to here is a liquid compound, for example, a compound that is easily dissolved or dispersed in a solvent such as water. Use of a liquid gas adsorbing compound is advantageous because the gas adsorbing compound is uniformly dispersed in the fiber structure. When the gas adsorbent contains an acidic substance, it exhibits an excellent effect for adsorbing ammonia gas and the like, and when it contains a hydrazide compound, a polyamine compound, etc., it exhibits excellent performance for adsorbing formaldehyde and the like.

  The gas adsorbing filler is, for example, in the form of particles or short fibers. When the gas adsorbing filler is in the form of particles, the gas adsorbing filler preferably has an average particle size in the range of 0.01 to 1000 μm. A more preferable average particle diameter is 0.1 μm or more, and an even more preferable average particle diameter is 1 μm or more. A more preferable average particle diameter is 100 μm or less, and an even more preferable average particle diameter is 80 μm or less. When the average particle size is less than 0.01 μm, the gas adsorbing filler may be buried in the gelled product. On the other hand, when the average particle diameter exceeds 1000 μm, the specific surface area of the gas adsorbing filler becomes small, and the effect of the gas adsorbing filler (for example, the gas adsorption effect) may not be sufficiently obtained. The gas-adsorbing filler-fixed fiber structure (gas-adsorbing material) of the present invention is excellent in a small amount of gas-adsorbing filler because it is fixed on the fiber surface even when the particle size of the gas-adsorbing filler is small. Demonstrate the effect. In particular, when the average particle size of the gas-adsorbing filler is 100 μm or less, the specific surface area becomes large, so that even a small amount of gas-adsorbing filler exhibits an excellent effect.

  When the gas-adsorbing filler is in the form of short fibers, the larger length of the fiber length or fiber cross-sectional length (hereinafter referred to as “short fiber length”) is preferably in the range of 0.1 to 1000 μm. A range of ˜500 μm is more preferable. If the short fiber length is less than 0.1 μm, the gas-adsorbing filler may be buried in the gelled product. If it exceeds 1000 μm, the fiber length is long, so that it is not uniformly dispersed in the dispersion, and the specific surface area of the gas-adsorbing filler becomes small, and the effect of the gas-adsorbing filler may not be sufficiently obtained.

  The gas adsorbing material using the gas adsorbing filler of the present invention may be a gas adsorbing module in which a fiber bundle formed by bundling a plurality of the gas adsorbing filler fixing fibers is used as a gas adsorbing portion. Also, a gas adsorbing filter can be used in which the aggregate of the gas adsorbing filler-fixed fibers is wound into a cylindrical shape or formed into a pleated shape.

In order for the fiber structure to efficiently exhibit the function of the gas adsorbent filler, the amount of the gas adsorbent filler fixed is preferably 2 g or more per 1 m ^{2 of the} fiber structure, and more preferably 10 g or more. It is preferably 20 g or more. Further, the upper limit of the gas adsorbing filler is preferably about 5 times the mass of the fiber structure.

  Next, the manufacturing method of the said gas adsorbent filler fixed fiber and the said fiber structure (gas adsorbent) is demonstrated. The wet heat treatment in the following description is performed in a wet heat atmosphere. The “humid heat atmosphere” here refers to an atmosphere containing moisture and heated. The wet heat treatment refers to a fiber provided with a binder resin, a fiber containing a wet heat gelling fiber component, or a fiber structure before treatment containing these fibers (hereinafter, also referred to as “treated fiber structure”), for example, It refers to a process of heating after applying a gas-adsorbing filler dispersion solution containing a gas-adsorbing filler (hereinafter referred to as filler dispersion solution) or a process of heating while applying the gas-adsorbing filler dispersion solution. Examples of the heating method include a method of exposing to a heated atmosphere, a method of penetrating through heated air, and a method of contacting a heated body. Further, as another method, after gas-adsorbing filler is sprayed on the fiber structure to be treated, moisture is applied and heat treatment is performed. There is also a method of heat treatment after spraying the filler. The method of spraying is not particularly limited, and examples thereof include a method using a sieve, a method using jetting, and a method performed electrically.

  The method for producing the fiber structure to be treated is not particularly limited, but at least one method selected from methods such as a needle punch method, a hydroentanglement method, an airlaid method, a spunbond method, a melt blow method, and a wet method. Is preferably used.

  The treated fiber structure may be subjected to a hydrophilic treatment. When hydrophilic treatment is performed, when the fiber structure to be treated contains hydrophobic fibers, moisture can be imparted to the fiber structure to be treated substantially uniformly. As a result, it is preferable because the composite fiber is gelled almost uniformly by wet heat and the gas adsorbing filler is easily fixed. As hydrophilic treatment, surfactant treatment, corona discharge method, glow discharge method, plasma treatment method, electron beam irradiation method, ultraviolet ray irradiation method, γ ray irradiation method, photon method, flame method, fluorine treatment method, graft treatment method, Examples thereof include a sulfonation treatment method.

The preferred range of the basis weight of the treated textile material is 10 to 1000 g / m ^2, more preferably in the range of basis weight is 30 to 200 g / m ^2, more preferably in the range of basis weight, 40 and 80 g / m ² . When the basis weight is lower than 10 g / m ^2, the amount of the gas-adsorbing filler that adheres after the wet heat treatment decreases, and the function may not be sufficiently exhibited. If the basis weight is higher than 1000 g / m ² , the gas adsorbing filler may not easily enter the fiber structure to be treated when the gas adsorbing filler is applied.

  Another fiber structure may be laminated on one side or both sides of the treated fiber structure. When laminating other fiber structures, for example, it may be laminated before applying the gas-adsorbing filler, or after applying the gas-adsorbing filler, it may be laminated before wet heat treatment, or wet heat treatment Alternatively, the gas adsorbing filler may be fixed and then laminated. When laminated on one side of the fiber structure to be treated, the functions of other fiber structures can be imparted, and for example, moldability and adhesiveness can be improved. For example, in order to increase the strength of the gas adsorbent of the present invention, the treated fiber structure may be disposed on both surfaces of the spunbond serving as a reinforcing material, and the gas adsorbent of the present invention is desired to have hydrophilicity. In this case, the treated fiber structure may be disposed on both surfaces of the hydrophilic fiber layer. In addition, when other fiber structures are laminated on both surfaces of the treated fiber structure, for example, even when the gas-adsorbing filler is not sufficiently fixed, the gas-adsorbing filler can be prevented from falling off, An effect of hiding the color of the gas adsorbing filler can be given. Moreover, the efficiency of the cleaning operation in the manufacturing process may be improved by suppressing the dropout of the gas adsorbing filler. Furthermore, the function of another fiber structure can be provided, for example, moldability and adhesiveness can be improved. For example, in applications in which the gas adsorbent filler is dropped or the gas adsorbent filler color is concerned, it is preferable to heat roll a nonwoven fabric containing thermal adhesive fibers on both sides of the treated fiber structure.

  For the fiber structure after applying the gas adsorbing filler, for the same reason as described above, another fiber structure can be laminated and integrated on one side or both sides. In a more preferred form, the fiber structure containing the heat-adhesive fibers is integrated on both surfaces of the fiber structure after the gas adsorbent filler has been applied by heat treatment.

Examples of other fiber structures described above include spunbond, hydroentangled nonwoven fabric, thermal bond nonwoven fabric, and needle punched nonwoven fabric. The range of the basis weight of the other fiber structure is not particularly limited as long as it has an effect of preventing dropout, an effect of concealing the color of the gas-adsorbing filler, and the like. a to 300 g / m ^2, more preferably in the range of mass per unit area is 20 to 100 g / m ^2.

  In the case of heating after applying the filler dispersion solution, the ratio of moisture to be applied to the fiber or the fiber structure to be treated in the wet heat treatment (hereinafter referred to as “moisture ratio”) is preferably 20 mass% to 1500 mass%. . A more preferable moisture content is 30 mass% or more. A more preferable moisture content is 1000 mass% or less. An even more preferable moisture content is 40 mass% or more. An even more preferable moisture content is 900 mass% or less. If the moisture content is less than 20 mass%, wet heat gelation may not occur sufficiently. On the other hand, when the moisture content exceeds 1500 mass%, the wet heat treatment is not uniformly performed between the surface and the inside of the fiber structure to be treated, and the degree of wet heat gelation tends to be non-uniform. In addition, as a provision method of a water | moisture content, it can carry out by well-known methods, such as the spray method and the immersion method in a water tank. In particular, the method of impregnating the fiber structure to be treated with the gas-adsorbing filler dispersion solution is preferable because a large amount of the gas-adsorbing filler is easily taken into the fiber structure to be treated. The fiber or treated fiber structure to which moisture has been applied can be adjusted to a predetermined moisture content by a method such as squeezing with a squeeze roll or the like.

  In the case of heating after applying the filler dispersion solution, the ratio of the filler dispersion solution applied to the fiber or the fiber structure to be treated in the wet heat treatment (hereinafter referred to as “pickup rate”) is 20 mass% to 1500 mass%. Is preferred. A more preferable pickup rate is 30 mass% or more. A more preferable pickup rate is 1000 mass% or less. An even more preferable pickup rate is 40 mass% or more. An even more preferable pickup rate is 900 mass% or less. If the pickup rate is less than 20 mass%, the wet heat gelation may not occur sufficiently. On the other hand, when the pickup rate exceeds 1500 mass%, the wet heat treatment is not uniformly performed between the surface and the inside of the fiber structure to be treated, and the degree of wet heat gelation tends to be non-uniform. In addition, as a provision method of a water | moisture content, it can carry out by well-known methods, such as spray and immersion to a water tank.

  The concentration of the gas-adsorptive filler in the filler dispersion solution may be set as appropriate depending on the basis weight and fixing amount of the fiber structure to be used, or the temperature and viscosity of the filler dispersion solution, but the preferred range is 0. .1 to 75 mass%, and a more preferable range is 1 to 50 mass%. If the concentration of the gas adsorbing filler is lower than 0.1 mass%, the effect of the gas adsorbing filler may not be sufficiently obtained. If the concentration of the gas adsorbing filler is higher than 75 mass%, the workability is deteriorated, and therefore the gas adsorbing filler may not be uniformly attached.

  The particle diameter of the gas-adsorbing filler is not particularly limited, but the gas-adsorbing filler-fixed fiber structure of the present invention is fixed in an exposed state on the fiber surface even if the particle diameter of the gas-adsorbing filler is small. Excellent effect with a small amount of gas-adsorptive filler.

  It is preferable that the filler dispersion solution further contains a gas adsorbing compound. It does not specifically limit about the density | concentration of a gas adsorbing compound, What is necessary is just to set suitably according to the fabric weight of the to-be-processed fiber structure, and the fixed amount, but a preferable range is 0.1-10 mass%. If the concentration of the gas adsorbing compound is lower than 0.1 mass%, the effect of the gas adsorbing filler may not be sufficiently obtained. If the concentration of the gas adsorbing compound is higher than 10 mass%, the workability may be deteriorated. Further, when the concentration of the gas adsorbing compound is higher than 10 mass%, an effect commensurate with the increase in concentration may not be obtained.

  The wet heat treatment temperature in the wet heat treatment is preferably not less than the gelling temperature of the wet heat gelled resin or wet heat gelled resin fiber component (hereinafter also referred to as “binder resin”) and the melting point is −20 ° C. or lower. . A more preferable wet heat treatment temperature is 50 ° C. or higher. Even more preferable wet heat treatment temperature is 80 ° C. or higher. On the other hand, a more preferable wet heat treatment temperature is a melting point of the binder resin of −30 ° C. or lower. An even more preferable wet heat treatment temperature is a melting point of the binder resin of −40 ° C. or lower. If the wet heat treatment temperature is lower than the gelation temperature of the binder resin, the gas adsorbing filler may not be effectively fixed. When the wet heat treatment temperature exceeds the melting point of the binder resin, −20 ° C., the temperature becomes close to the melting point of the binder resin, so that shrinkage may be caused when the gas adsorbing filler-fixed fiber structure is formed.

  The fiber structure subjected to the wet heat treatment may be subjected to 1) drying treatment as it is, 2) washing once with water, then drying treatment, and 3) once drying, then washing with water. After that, a drying process may be performed. When washing with water, the above method 3) is convenient because the amount of the gas-adsorbing filler is increased.

  The drying treatment temperature is not particularly limited as long as the gas adsorbing filler-fixed fiber structure is dried. In this drying process, the gas adsorbing filler-fixed fiber structure may be dried while being widened in the width direction (direction perpendicular to the machine base). By widening in the width direction, the basis weight can be adjusted and the dimensional stability in the length direction and the width direction can be achieved.

Examples of wet heat treatment methods include the following methods, and the respective production methods will be described.
(1) A method of performing a steam treatment after applying a filler dispersion solution to a treated fiber structure (hereinafter referred to as a steam treatment method).
(2) A method in which a filler dispersion solution is applied to a fiber structure to be treated and then brought into contact with a heating body (hereinafter referred to as a heating body contact method).
(3) A method of bringing the fiber structure to be treated into contact with the heated filler dispersion solution (hereinafter referred to as heating liquid contact method)
The steam treatment method is suitable for giving bulkiness and / or flexibility to the obtained gas-adsorbing filler-fixed fiber structure, and is a treated fiber structure comprising a web containing the fiber and the wet heat gelled resin. In addition, after applying the filler dispersion solution, after adjusting to a predetermined moisture content, by performing a steam treatment, a gelled product obtained by gelling the wet heat gelled resin is formed to fix the gas adsorbing filler. Examples of the steam treatment method include a method of spraying steam from above and / or below the treated fiber structure adjusted to a predetermined moisture content, and contacting the treated fiber structure with the steam in a chamber filled with steam. And a method of exposing the fiber structure to be treated to steam using an autoclave or the like. According to such a method, pressure is not applied to the treated fiber structure more than necessary during gel processing. As a result, the gas-adsorbing filler can be fixed in a state of being exposed on the fiber surface of the treated fiber structure while maintaining the fiber form of the treated fiber structure. Furthermore, since the fiber structure to be treated is covered with a gelled material (hereinafter referred to as a film-like gelled product) that spreads in a film shape at the entangled portion between the fibers, the effective area for fixing the gas-adsorbing filler is increased, and the gas adsorption The performance can be further improved. In the pad steamer method, the steam discharged from the steam outlet is not directly in contact with the fiber structure to be treated, but is steam-treated in a uniform steam atmosphere, so that the heat-and-humidity gelled resin is wet-heated and gelled. Since a gelled product can be formed, it is particularly preferable. It is also convenient for continuous operation. Furthermore, according to the pad steamer method, since the temperature can be easily controlled, the strength and air permeability of the fiber structure can be controlled according to the purpose while maintaining the function of the gas adsorbing filler. It is particularly preferable because a gelled product that spreads in the form of a film can be formed. For example, if the gas adsorbent filler on the gelled resin that maintains the fiber shape is insufficiently fixed, increasing the temperature of the pad steamer improves the fluidity of the gelled resin and strengthens the gas adsorbent filler. It can be fixed to. Moreover, since the pad steamer method plays the role of the preliminary process of a drying process simultaneously with gel processing, the efficiency of a drying process can also be aimed at.

  The temperature of the filler dispersion solution may be a temperature at which the wet heat gelling resin does not gel or a temperature at which gelation starts, and the type, particle size, and shortness of the gas adsorbing filler and gas adsorbing compound. What is necessary is just to set suitably by fiber length, the density | concentration, viscosity, etc. of a filler dispersion solution. For example, when the moisture content of the fiber structure to be treated is high, the fiber structure to be treated may be heated in a temperature range in which the fiber structure to be treated does not gel so that the wet heat gelled resin is easily gelled during the wet heat treatment. In addition, if the wet heat gelled resin is equal to or higher than the temperature at which gelation starts, the method is combined with a heating liquid contact method described later, which is effective in fixing the gas adsorbing filler more firmly.

  The steam treatment temperature is not particularly limited as long as the temperature in the vicinity of the fiber structure to be treated is not less than the gelation temperature of the wet heat gelled resin or the wet heat gelled resin fiber component and the melting point is -20 ° C or lower. A preferable temperature range is 80 to 120 ° C, and a more preferable temperature range is 90 to 110 ° C.

  Since the gas adsorbing filler is fixed in a state of being exposed on the surface of the wet heat gelled resin or the wet heat gelled resin fiber by the steam treatment, an excellent effect is exhibited with a small amount of the gas adsorbing filler. When the filler dispersion solution further contains a gas adsorbing compound, the gas adsorbing compound is fixed not only on the surface of the gas adsorbing filler but also on the surface of the wet heat gelled resin or the wet heat gelled resin fiber. As a result, a more excellent effect is exhibited as compared with the case where only the gas adsorbing compound is used as the gas adsorbing component. Therefore, for example, in the conventional gas adsorbent, a remarkable effect is exhibited even for gases such as formaldehyde and acetaldehyde that are difficult to remove.

  The gas adsorbent filler-fixed fiber structure after the drying treatment may be pressed through a pair of press rolls at the outlet after the drying treatment. By performing press working at the outlet after the drying treatment, the gas-adsorbing filler is firmly fixed while maintaining flexibility.

  Next, the heating body contact method will be described. In the heating body contact method, when the gas adsorbing filler is more firmly fixed, a predetermined moisture content is obtained after a filler dispersion solution is applied to the fiber structure to be treated including the fiber and the web containing the wet heat gelled resin. By adjusting this to a heated body, a gelled product obtained by gelling the wet heat gelled resin is formed and the gas adsorbing filler is fixed. Examples of the method for bringing the fiber structure to be treated into contact with the heating body include a method for bringing it into contact with a hot roll, a method for bringing it into contact with a hot press plate, and the like. According to such a method, the wet heat gelled resin fiber component can be instantly wet heat gelled, and at the same time the gelled product can be expanded, so that the gas adsorbent filler can be fixed over a wide area. Moreover, according to this method, when it heats and gelates, the gas adsorbent filler is pushed into the gelled product, and the gas adsorbent filler can be more firmly fixed to the fiber surface.

  When the said heating body is planar things like a hot press board, it is preferable that the surface pressure at the time of making a to-be-processed fiber structure contact is 0.01-3 Mpa. A more preferable lower limit of the surface pressure is 0.02 MPa. A more preferable upper limit of the surface pressure is 2.5 MPa. When the surface thickness is less than 0.01 Mpa, the gas adsorbent filler may not be sufficiently fixed, and when the surface thickness exceeds 3 Mpa, the texture may become stiff.

  Moreover, when the said heating body contact method is the method of compression-molding processing with a hot roll, it is preferable that the linear pressure of a hot roll is 10-400 N / cm. A more preferable lower limit of the linear pressure of the hot roll is 50 N / cm. A more preferable upper limit of the linear pressure of the hot roll is 200 N / cm. When the linear pressure is less than 10 N / cm, the gas-adsorbing filler may not be sufficiently fixed, and when the linear pressure exceeds 400 N / cm, the texture may become stiff.

  The set temperature of the heating body (for example, the set temperature of the wet heat treatment machine) is not particularly limited as long as it is not less than the gelation temperature of the wet heat gelled resin or the wet heat gelled resin fiber component and the melting point is -20 ° C or lower. A preferable temperature range is 50 to 160 ° C, and a more preferable temperature range is 80 to 150 ° C. Note that when the set temperature is set to 100 ° C. or higher in order to gel the fiber structure to be treated containing moisture, the moisture in the fiber structure to be treated first evaporates. At that time, since the gelation of the wet heat gelled resin proceeds, the actual temperature of the gel processing tends to be lower than the set temperature. Therefore, even when the melting point of the other fiber is lower than the set temperature, it may not melt or shrink substantially, and the gel processing temperature is a temperature at which the other fiber does not substantially shrink. It is preferable to process.

  By treating with a heating element, the gas-adsorbing filler is firmly fixed in a state exposed to the surface of the wet heat gelled resin or wet heat gelled resin fiber, so when using a small amount of the gas adsorbent filler Even when using a large amount of gas-adsorbing filler, it can be firmly fixed, and most of the gas-adsorbing filler can be firmly fixed, so the amount of gas-adsorbing filler can be reduced and the effect is excellent. . Further, when the filler dispersion solution further contains a gas adsorbing compound, the gas adsorbing compound is fixed not only on the surface of the gas adsorbing filler but also on the surface of the wet heat gelled resin or the wet heat gelled resin fiber. As a result, a more excellent effect is exhibited as compared with the case where only the gas adsorbing compound is used as the gas adsorbing component. Therefore, for example, in the conventional gas adsorbent, a remarkable effect is exhibited even for gases such as formaldehyde and acetaldehyde that are difficult to remove.

  Next, the heating liquid contact method will be described. In the heating liquid contact method, the fiber structure to be treated is brought into contact with a heated filler dispersion solution to form a gelled product in which the wet heat gelled resin is gelled, and the gas adsorbing filler is fixed. Examples of the method of bringing the fiber structure to be treated into contact with the heating liquid include a method of immersing in a heated filler dispersion solution, and a method of spraying the heated filler dispersion solution onto the fiber structure to be processed. According to this method, since the surface pressure is not applied more than necessary to the fiber structure to be treated at the time of gelation, the fluidity of the gelled wet heat gelled fiber is reduced, and the fiber form of the fiber structure to be treated The gas-adsorbing filler is obtained by adhering the gelled product without spreading in the form of a film at the entangled portion between the fibers while maintaining the properties, and fixing the gas-adsorbing filler exposed to the fiber surface. The fixed fiber structure can be given bulkiness and / or flexibility. Further, when the wet heat gelled resin is gelled, gelation of the wet heat gelled fiber proceeds simultaneously with the application of moisture, so the concentration of the gas adsorbing filler in the filler dispersion solution and the temperature of the filler dispersion solution The amount of gas adsorbent filler adhering may be adjusted. Specifically, the gas adsorbing filler can be fixed to the fiber surface by impregnating the fiber or the fiber structure to be treated into hot water (85 ° C. or higher) containing the gas adsorbing filler. In particular, the method of immersing in a heated filler dispersion solution is preferable because the wet heat gelled fiber can be uniformly gelled.

  The gel processing temperature of the heating liquid contact method is not particularly limited as long as it is not less than the gelation temperature of the wet heat gelled resin or the wet heat gelled resin fiber component, and the melting point is −20 ° C. or less. It is 85-120 degreeC, and a more preferable temperature range is 90-100 degreeC. When the temperature is lower than 85 ° C., the filler may not be sufficiently fixed. When the temperature is higher than 120 ° C., the texture becomes stiff and may become a film.

  What is necessary is just to set the filler density | concentration of the filler dispersion solution in the said heating liquid contact method suitably with the fabric weight and fixed amount of the to-be-processed fiber structure to be used, the temperature and viscosity of a filler dispersion solution, A preferable range is 0.1-75 mass. %, And a more preferable range is 1 to 50 mass%.

  In the heated liquid contact method, by immersing the fiber structure to be treated in a heated filler dispersion solution, the gelation of the wet heat gelled resin or the wet heat gelled resin fiber and the fixation of the gas adsorbing filler are simultaneously performed in the liquid. Done in As a result, the gas-adsorbing filler can be fixed more uniformly and exposed on the fiber surface than when the gel is formed after the gas-adsorbing filler is applied. Demonstrate the effect. In addition, when the filler dispersion solution further contains a gas adsorbing compound, the gas adsorbing compound is fixed not only on the surface of the gas adsorbing filler but also on the surface of the wet heat gelled resin or wet heat gelled resin fiber. Compared with the case where only a gas adsorbing compound is used as a gas adsorbing component, a further excellent effect is exhibited. Therefore, for example, in the conventional gas adsorbent, a remarkable effect is exhibited even for gases such as formaldehyde and acetaldehyde that are difficult to remove.

  As described above, the wet heat treatment method for the fiber structure to be treated includes a steam treatment method, a heating body contact method, a heating liquid contact method, etc., but the same treatment may be repeated or other treatment methods. It may be done in combination.

  Next, an embodiment of the present invention will be described with reference to the drawings.

  1A to 1C are cross-sectional views of gas adsorbent filler-fixed fibers constituting a gas adsorbent according to an embodiment of the present invention. FIG. 1A is an example of a composite fiber 5 in which polypropylene is used as the core component 2 and ethylene-vinyl alcohol copolymer resin is used as the sheath component 1, and the gas adsorbing filler 3 is fixed in the sheath component 1. In this case, the sheath component 1 functions as a binder resin. FIG. 1B is a composite fiber 6 having polypropylene as the core component 2 and ethylene-vinyl alcohol copolymer resin as the sheath component 1, and the ethylene-vinyl alcohol copolymer resin is adhered to the outside of the composite fiber 6 as the binder 4. This is an example in which the gas adsorbing filler 3 is mixed in the binder 4. FIG. 1C is an example in which a composite fiber 9 in which polypropylene 8 and ethylene-vinyl alcohol copolymer resin 7 are arranged in multiple parts is used, and gas adsorbing filler 3 is fixed in the periphery of ethylene-vinyl alcohol copolymer resin 7. . In this case, the ethylene-vinyl alcohol copolymer resin 7 functions as a binder resin.

  FIG. 2 is a cross-sectional view of a three-layer gas adsorbent (fiber structure) according to an embodiment of the present invention, in which a fiber layer 11 in which polyester fiber and PP / PE core-sheath composite fiber are mixed on the outside, 11 is arranged, and the gas adsorbing filler fixed fiber layer 12 is arranged on the inner side.

  FIG. 3 is an example process diagram of a method for manufacturing a gas adsorbent (heating body contact method) according to an embodiment of the present invention. The fiber 31 (or the fiber structure 31 to be treated) is replaced with a gas-adsorbing filler dispersion solution 33 containing a gas-adsorbing filler in the tank 32 (or a gas-adsorbing filler containing a gas-adsorbing filler and an ethylene-vinyl alcohol copolymer resin). When the dispersion solution 33) is impregnated, squeezed with a squeeze roll 34, wet-heat treated between the steamer 35 and the suction 36 and wound up as it is, or when the fiber structure to be treated is wet-heat treated, 37, compression molding is performed by the patterning canvas rolls 38 and 38, and a predetermined pattern is imparted to the surface of the gas-adsorbing filler-fixed fiber structure. Instead of the steamer 35 and the suction 36, for example, pressure treatment at a temperature of 150 ° C. for 5 minutes may be performed using upper and lower hot plates. As another embodiment, there is a method of compression molding only with a pair of heating rolls without the steamer 35, and a method of compression molding only with the patterning canvas rolls 38, 38 applied to the pair of heating rolls 37, 37 without the steamer 35. .

  FIG. 4 is an example process diagram of a method for manufacturing a gas adsorbent (steam treatment method) according to an embodiment of the present invention. The fiber 31 (or the fiber structure 31 to be treated) is impregnated in a filler dispersion solution 33 containing a gas adsorbing filler in the tank 32 (or a filler dispersion solution 33 containing a gas adsorbing filler and a gas adsorbing compound), A squeezing roll 34 squeezes steam from below and steam-treats with a pad steamer 35 in which the chamber is uniformly filled with steam, and is dried, washed and dewatered (not shown) if necessary. It is dried at 41 and wound up by a winder 39. In addition, when performing the steam process with the pad steamer 35, the blown-out steam does not directly hit the fibers 31 (or the fiber structure 31 to be processed).

  FIG. 5 is an example process diagram of a method for producing a gas adsorbent (heating liquid contact method) according to an embodiment of the present invention. The fiber 31 (or the fiber structure 31 to be treated) is impregnated in the heated gas adsorbent filler dispersion solution 33 containing the gas adsorbent filler in the tank 32, dried by the dryer 41, and wound by the winder 39. take. The gas adsorbent filler dispersion solution 33 may be heated by a heating means such as a heater (not shown).

  FIGS. 6 to 8 show a gas adsorbent (nonwoven fabric) according to an embodiment of the present invention obtained by the heating body contact method and a state where the gas adsorbent filler is fixed to the constituent fibers. Among these, FIG. 6 is a scanning electron micrograph (magnification 100) showing a nonwoven fabric, FIG. 7 is a cross-sectional photograph (magnification 100), and FIG. 8 is a fiber surface enlarged photograph (magnification 1000) of the nonwoven fabric surface.

  9 to 11 show a gas adsorbent (nonwoven fabric) according to an embodiment of the present invention obtained by the steam treatment method and a state where the gas adsorbent filler is fixed to the constituent fibers. Among these, FIG. 9 is a scanning electron microscope plan photograph (magnification 200) showing the nonwoven fabric, FIG. 10 is a cross-sectional photograph (magnification 200), and FIG. 11 is a fiber surface enlarged photograph (magnification 2000) of the nonwoven fabric surface.

  12 and 13 show a gas adsorbent (nonwoven fabric) according to an embodiment of the present invention obtained by the heating liquid contact method and a state in which a gas adsorbent filler is fixed to the constituent fibers. Among these, FIG. 12 is a scanning electron microscope plan photograph (magnification 200) showing a nonwoven fabric, and FIG. 13 is the same cross-sectional photograph (magnification 200).

[Examples 1 to 4]
The following were prepared as gas adsorbents.

(Production of nonwoven fabric)
The sheath component is an ethylene-vinyl alcohol copolymer resin (EVOH, ethylene content 38 mol%, melting point 176 ° C.), the core component is polypropylene (PP, melting point 161 ° C.), and EVOH: PP is a ratio of 50:50. A core-sheath type composite fiber (fineness: 2.8 dtex, fiber length: 51 mm) having a (volume ratio) was prepared.

  The core-sheath type composite fiber was opened with a semi-random card machine to produce a card web having a basis weight shown in Table 1. Next, the card web is placed on a 90-mesh plain weave support, and the nozzle is arranged on the card web from a nozzle in which orifices (diameter: 0.12 mm, pitch: 0.6 mm) are arranged in a row in the width direction of the card web. The water flow was injected at a water pressure of 3 MPa, and then further injected at a water pressure of 4 MPa. Subsequently, the card web was turned over and a water flow was jetted from the nozzle at a water pressure of 4 MPa to produce a water-entangled nonwoven fabric raw material used in Examples 1 to 4.

(Preparation of gas-adsorbing filler)
As the gas adsorbing filler, activated carbon particles: “Kuraray Coal PL-D” (manufactured by Kuraray Chemical Co., Ltd., coconut shell charcoal, average particle diameter of 40 to 50 μm) was used.

(Preparation of nonwoven fabric containing gas-adsorbing filler-fixed fibers)
The non-woven fabric was immersed in an aqueous dispersion (20 ° C.) containing 10 mass% of the activated carbon particles, and the pick-up rate was adjusted so that the numerical value shown in Table 1 was obtained with the mangle roll squeezing pressure. Next, the nonwoven fabric original impregnated with the aqueous dispersion was made into two plain-woven plastic nets (40 cm long × 40 cm wide) having a wire diameter of 0.3 mm and the number of meshes: 30 vertical / inch × 25 horizontal / inch. ) And placed on a hot plate heated to 150 ° C., and the upper plastic net was covered with an aluminum sheet (1 g / cm ² ) and subjected to a wet heat treatment for 15 minutes. The obtained nonwoven fabric was washed with water and dried with a hot air dryer (100 ° C.) to obtain nonwoven fabrics (gas adsorbents) of Examples 1 to 4 which are Examples of the present invention.

[Example 5]
The same nonwoven fabric raw fabric as the hydroentangled nonwoven fabric used in Example 1 was dipped in an aqueous dispersion (95 ° C.) containing 5 mass% of the activated carbon particles for 30 seconds and then pulled up. And the said nonwoven fabric original fabric was supported until the temperature of the said nonwoven fabric original fabric became 50 degreeC. Then, the said nonwoven fabric original fabric was washed with water, and it dried with the hot air dryer (100 degreeC), and obtained the nonwoven fabric (gas adsorption material) of Example 5 which is an Example of this invention.

[Comparative Example 1]
A blending solution containing 15 mass% of a self-crosslinking acrylic ester emulsion (manufactured by Nippon Carbide Industries, trade name “Nicazole FX-555A”) and 10 mass% of the activated carbon particles was prepared. Next, the same nonwoven fabric raw material as the hydroentangled nonwoven fabric used in Example 1 described above is immersed in the blended solution, squeezed with a mangle roll, and a temperature of 140 ° C. and a processing time of 15 minutes using a hot air dryer. It was made to dry and hardened, and the chemical bond nonwoven fabric (comparative example 1) with the fixed amount of activated carbon particle of 38 g / m < ² > was obtained.

[Comparative Example 2]
As Comparative Example 2, a VOC gas adsorbing sheet (made by Asahi Kasei Fibers, trade name “Semia V”, weight per unit) in which activated carbon particles are fixed with a hot melt agent between two spunbond nonwoven fabrics having a deodorant fixed on the surface. 134 g / m ^2, about 40 g / m ² fixed amount of activated carbon particles) were prepared.

  In Table 1, about the nonwoven fabrics (gas adsorbents) of Examples 1 to 5 and Comparative Examples 1 and 2, the basis weight of the nonwoven fabric, the amount of activated carbon particles fixed, the adhesion rate of the activated carbon particles, and the basis weight of the nonwoven fabric (gas adsorbent) showed that.

[Examples 6 to 9]
The following were prepared as gas adsorbents.

(Preparation of gas-adsorbing compounds)
A polyallylamine 10 mass% aqueous solution was used as the gas adsorbing compound.

(Preparation of nonwoven fabric containing gas-adsorbing filler-fixed fibers)
A non-woven fabric produced by the same method as the hydroentangled non-woven fabric used in Example 1 except that the card web having the basis weight shown in Table 2 was used, and an aqueous dispersion containing the activated carbon particles of 16 mass% ( The pick-up rate was adjusted with the squeezing pressure of the mangle roll, and the fixed amount of the activated carbon particles was adjusted to the numerical value shown in Table 2. Next, wet heat treatment was performed in a pad steamer filled with steam adjusted so that the temperature in the vicinity of the nonwoven fabric was 100 ° C. The residence time was 20 seconds. Next, it is dried through a nonwoven fabric after wet heat treatment in a hot air circulation dryer, and further washed in a water washing tank, and then dried in a tenter type dryer adjusted to a temperature of 140 ° C. A nonwoven fabric (gas adsorbent) of Example 6 was obtained.

  The nonwoven fabric raw fabric produced by the same method as the hydroentangled nonwoven fabric used in Example 1 except that the card web having the basis weight shown in Table 2 was used so that the mass becomes 16 mass% of the activated carbon particles and 1 mass%. The nonwoven fabric (gas adsorbent) of Example 7 was obtained in the same manner as in Example 6 except that it was immersed in an aqueous dispersion (20 ° C.) containing the gas-adsorbing compound adjusted to 1 and the pickup rate was adjusted. It was.

A nonwoven fabric (gas adsorbent) of Example 8 was obtained in the same manner as in Example 7 except that drying was performed while widening in a tenter dryer. The basis weight of the nonwoven fabric used was 46 g / m ² .

70 mass% polyester fiber with a fineness of 1.45 dtex and a fiber length of 38 mm (trade name “403”, manufactured by Toray Industries, Inc.), PP / PE core-sheath type composite fiber with a fineness of 2.2 dtex and a fiber length of 51 mm (Yamato A 30 g / m < ² > hydroentangled nonwoven fabric was produced using 30 mass% by a spinning company make, brand name "NBF (H)"). Subsequently, the hydroentangled nonwoven fabric was placed above and below the nonwoven fabric (gas adsorbent) of Example 8, and subjected to roll processing using a heat embossing roll having a heat treatment temperature of 135 ° C., and the nonwoven fabric of Example 9 (gas adsorption) Material).

[Comparative Example 3]
A blending solution was prepared by diluting the 10 mass% polyallylamine aqueous solution to a concentration of 1 mass%. Next, the same nonwoven fabric raw fabric as the hydroentangled nonwoven fabric used in Example 6 described above is immersed in the blended solution, and the pick-up rate is adjusted by the squeezing pressure of the mangle roll to fix the gas adsorbing compound. A nonwoven fabric of Comparative Example 3 was obtained in the same manner as the nonwoven fabric of Example 6 except that the values were adjusted to the numerical values shown in Table 2.

  In Table 2, about the nonwoven fabric (gas adsorbent) of Examples 6 to 9 and Comparative Example 3, the basis weight of the nonwoven fabric, the amount of gas adsorbing components (activated carbon particles and / or gas adsorbing compounds), the amount of gas adsorbing components The adhesion rate and the basis weight of the nonwoven fabric (gas adsorbent) are shown.

[Examples 10 to 12]
The following were further prepared as gas adsorbents.

  A non-woven fabric produced by the same method as the hydroentangled non-woven fabric used in Example 1 except that the card web having the basis weight shown in Table 3 was used, and an aqueous dispersion containing the activated carbon particles of 16 mass% ( 95 ° C) for 1 minute, passed through a hot-air circulating dryer, dried in a water-washing tank, and then dried in a tenter-type dryer adjusted to a temperature of 140 ° C. The nonwoven fabric (gas adsorption material) of Example 10 and Example 12 which is an example was obtained.

  A non-woven fabric produced by the same method as the hydroentangled non-woven fabric used in Example 1 except that the card web having the basis weight shown in Table 3 was used, and an aqueous dispersion containing the activated carbon particles of 16 mass% ( 95 minutes) and then dried in a tenter dryer adjusted to a temperature of 140 ° C. to obtain a nonwoven fabric (gas adsorbent) of Example 11 which is an example of the present invention.

  In Table 3, about the nonwoven fabric (gas adsorption material) of Examples 10-12, the fabric weight of the nonwoven fabric original fabric, the fixed amount of activated carbon particle, the fixed rate of activated carbon particle, and the fabric weight of the nonwoven fabric (gas adsorption material) were shown.

[VOC gas adsorption test method-1]
The gas adsorbent sheets of Examples 1 to 5, 10 to 12 and Comparative Examples 1 and 2 were each cut into a size of 10 cm in length and 10 cm in width, and a pollution analysis bag having a capacity of 5 liters (trade name “Tedlar Bag”) ), And each VOC gas formulated with air so as to have an initial concentration shown in Tables 4 to 7 was injected. And the injection | pouring time was made into start time, and the density | concentration of each VOC gas in a bag was measured with the gas detection tube every time. The results are shown in Tables 4-7. In Tables 4 to 7, “ND” indicates a case where the concentration of each VOC gas is less than the measurement limit (toluene: 0.5 ppm, xylene: 2 ppm) of the gas detector used.

  As shown in Tables 4 to 6, when the nonwoven fabrics of Examples 1 to 4 were used, the rate of decrease in the concentration of each VOC gas was faster than that of Comparative Examples 1 and 2, and the gas adsorption performance was improved. In addition, as shown in Table 4, Example 5 showed the same formaldehyde adsorption performance as Comparative Example 1 although the amount of activated carbon particles fixed was smaller than that of Comparative Example 1. Furthermore, as shown in Tables 5 and 6, in Example 5, the gas adsorption performance was improved in spite of a smaller amount of the activated carbon particles fixed than in Comparative Example 2. This is because the activated carbon particles (gas-adsorptive filler) in the nonwoven fabrics of Examples 1 to 5 are fixed by the wet-heat gelled gel fixed to the surface of the fiber, so that the gas-adsorptive filler is exposed on the surface. This is considered to be because the decrease in the specific surface area of the gas-adsorbing filler was suppressed as compared with Comparative Examples 1 and 2. In addition, the nonwoven fabric of Examples 1-5 was maintaining the fiber shape, and the nonwoven fabric did not shrink | contract at the time of gel processing. Moreover, the nonwoven fabric of Examples 1-5 did not drop out the gas adsorbent filler.

  Moreover, as shown in Table 7, when the nonwoven fabrics of Examples 10 to 12 were used, the rate of decrease in the concentration of each VOC gas was faster than that of Comparative Example 2, and the gas adsorption performance was improved.

[VOC gas adsorption test method-2]
The gas adsorbent sheets of Examples 6 to 9 and Comparative Examples 1 to 3 were cut into a size (B5 size) of 28 cm in length and 17.6 cm in width, respectively, and a pollution analysis bag (trade name “ Tedlar bag "), and each VOC gas blended with air to achieve the initial concentrations shown in Tables 8-10 were injected. And the injection | pouring time was made into start time, and the density | concentration of each VOC gas in a bag was measured with the gas detection tube every time. The results are shown in Tables 8-10. In addition, about Example 7 of Table 10, two kinds of data when the temperature (measurement temperature) in the pollution analysis bag is kept at 25 ° C. and when kept at 80 ° C. are shown. In Tables 8 and 9, “ND” means that the concentration of each VOC gas is the measurement limit of the gas detector used (formaldehyde: 0.05 ppm, toluene: 0.5 ppm, xylene: 2 ppm, ethylbenzene, styrene) And paradichlorobenzene: 1 ppm).

  As shown in Table 8, when the nonwoven fabrics of Examples 6 to 9 were used, the concentration reduction rate of acetaldehyde gas was faster than that of Comparative Example 3, and the gas adsorption performance was improved. Moreover, as shown in Table 9, the nonwoven fabric of Example 7 exhibited a superior effect due to its high concentration reduction rate with respect to acetaldehyde gas, which is difficult to remove among VOC gases. Moreover, as shown in Table 10, even when the VOC gas, which was difficult to remove conventionally, was present at a low concentration, when the nonwoven fabrics of Examples 7 to 9 were used, the VOC gas could be sufficiently removed. This is because the gas-adsorbing filler in the nonwoven fabrics of Examples 7 to 9 is fixed by the wet-heat gelled gel fixed on the surface of the fiber, so that the gas-adsorbing filler is fixed on the surface. This is considered to be due to the suppression of the decrease in the specific surface area of the gas-adsorbing filler. In addition, the nonwoven fabric of Examples 7-9 was maintaining the fiber shape, and the nonwoven fabric did not shrink | contract at the time of gel processing.

  The gas adsorbing material of the present invention can be used for vehicle interior materials, building material curing sheets, wallpaper, masks, mats, carpets, filters, and the like.

AC is sectional drawing of the gas adsorbent filler fixed fiber which comprises the gas adsorbent which concerns on one Embodiment of this invention. It is sectional drawing of the gas adsorption material (fiber structure) of the 3 layer structure which concerns on one Embodiment of this invention. It is an example process drawing of the manufacturing method (heating body contact method) of the gas adsorption material concerning one embodiment of the present invention. It is an example process drawing of the manufacturing method (steam processing method) of the gas adsorbent which concerns on one Embodiment of this invention. It is an example process drawing of the manufacturing method (heating liquid contact method) of the gas adsorption material concerning one embodiment of the present invention. It is a scanning electron micrograph which shows the state which the gas adsorbent (nonwoven fabric) which concerns on one Embodiment of this invention obtained by the heating body contact method, and the gas adsorbent filler have adhered to the component fiber. It is a scanning electron micrograph which shows the state which the gas adsorbent (nonwoven fabric) which concerns on one Embodiment of this invention obtained by the heating body contact method, and the gas adsorbent filler have adhered to the component fiber. It is a scanning electron micrograph which shows the state which the gas adsorbent (nonwoven fabric) which concerns on one Embodiment of this invention obtained by the heating body contact method, and the gas adsorbent filler have adhered to the component fiber. It is a scanning electron micrograph which shows the state which the gas adsorbent (nonwoven fabric) which concerns on one Embodiment of this invention obtained by the steam processing method, and the gas adsorbent filler have adhered to the component fiber. It is a scanning electron micrograph which shows the state which the gas adsorbent (nonwoven fabric) which concerns on one Embodiment of this invention obtained by the steam processing method, and the gas adsorbent filler have adhered to the component fiber. It is a scanning electron micrograph which shows the state which the gas adsorbent (nonwoven fabric) which concerns on one Embodiment of this invention obtained by the steam processing method, and the gas adsorbent filler have adhered to the component fiber. It is a scanning electron micrograph which shows the state which the gas adsorbent (nonwoven fabric) which concerns on one Embodiment of this invention obtained by the heating liquid contact method, and the gas adsorbent filler have adhered to the constituent fiber. It is a scanning electron micrograph which shows the state which the gas adsorbent (nonwoven fabric) which concerns on one Embodiment of this invention obtained by the heating liquid contact method, and the gas adsorbent filler have adhered to the constituent fiber.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Sheath component 2 Core component 3 Gas-adsorbing filler 4 Binder 5, 6, 9 Composite fiber 7 Ethylene-vinyl alcohol copolymer resin 8 Polypropylene 11 Fiber layer 12 Gas-adsorbing filler fixed fiber layer

Claims (10)

A gas adsorbent having a filler-fixed fiber comprising a fiber, a binder resin on the surface thereof, and a gas-adsorbing filler fixed to the binder resin,
The binder resin is a wet heat gelling resin,
The gas adsorbent is characterized in that the gas adsorbing filler is fixed by a gelled product obtained by gelling the wet heat gelled resin.   The gas adsorbent according to claim 1, wherein the wet heat gelling resin is an ethylene-vinyl alcohol copolymer resin.   The gas adsorbent according to claim 1, wherein the gas adsorbing filler includes a porous filler.   The gas adsorbent according to claim 3, wherein the porous filler is activated carbon particles.   The gas adsorbent according to claim 1 or 3, wherein an average particle size of the gas adsorbing filler is in a range of 0.01 to 100 µm. The fibers and the binder resin are
(I) a composite fiber comprising a wet heat gelled resin component and another thermoplastic synthetic fiber component,
(II) a mixture of the composite fiber and other fibers,
(III) a mixture of the composite fiber and wet heat gelled resin, and
(IV) The gas adsorbent according to claim 1, which has at least one combination selected from a mixture of a wet heat gelled resin and other fibers. The gas adsorbent further includes another fiber structure,
The gas adsorbent according to claim 1, wherein the other fiber structure is laminated on at least one surface of a fiber structure including the filler fixing fiber.   The gas adsorbent according to claim 1, wherein the gas adsorbent further includes a gas adsorbing compound.   The gas adsorbent according to claim 8, wherein the gas adsorbing compound is a polyamine compound. The gas adsorbent according to claim 9, wherein the polyamine compound is at least one selected from aromatic polyamine, polyallylamine, and polyvinylamine.

Images