JP2011020102A - Filter medium mainly used for air intake side of range hood - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a filter medium repeatedly usable by cleaning, in particular, suited to be attached to the air intake side of a range hood or the like. <P>SOLUTION: The filter medium is three-dimensional fabric constituted of an outer material 10, lining cloth 11, connection yarns 12 (warp 3a made of core-sheath type monofilament) connecting the outer material 10 to the lining cloth 11, and weft 3b made of core-sheath type monofilaments disposed between the outer material 10 and lining cloth 11. The outer material 10 and lining cloth 11 are woven by the warp and weft made of rayon monofilaments. The warp 3a is woven with the weft 1b of the outer material 10 and weft 2b of the lining cloth 11. The weft 3b is disposed between the wefts 1b and 2b along the wefts 1b and 2b. The core-sheath type monofilaments comprise the core component of a polymer of a high melting point and a sheath component of a polymer of a low melting point, and are jointed at contact points of the warps 3a with wefts 3b by fusion/solidification of the polymer of a low melting point. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a filter material for capturing dust, oily smoke, and the like, and particularly to a filter material attached to an intake port side of a range hood, a ventilation fan or the like used in a kitchen, a kitchen, or the like.

  The range hood ventilation fans and inner walls used in kitchens and kitchens are prone to oil stains and are unclean if left unattended. A filter material for removing or capturing is attached. As such a filter material, a glass fiber mat or a flame-retardant nonwoven fabric has been conventionally used (Patent Document 1). However, filter materials made of glass fiber mats and flame retardant nonwoven fabrics are discarded after use and are disposable products, which are not preferable because of their large environmental load.

JP-A-9-234316

  An object of the present invention is to provide a filter material that can be used repeatedly by washing without being discarded after use. In order to obtain a filter material that can be used repeatedly, it is necessary to adopt a filter material that does not easily collapse during cleaning. Non-woven fabrics cannot solve the problems of the present invention because constituent fibers fall off during washing.

  Therefore, the present invention employs a three-dimensional woven fabric as a filter material and makes it difficult for the shape to collapse during washing or the like by using a special thread. That is, the present invention is woven with a surface made of woven warp 1a and weft 1b made of rayon monofilament, a lining made of warp 2a and weft 2b made of rayon monofilament, and wefts 1b and 2b. A three-dimensional fabric composed of a warp 3a made of a core-sheath monofilament and a weft 3b made of a core-sheath monofilament disposed between the wefts 1b and 2b, the core-sheath monofilament, An air inlet of a range hood mainly characterized in that the core component is a high-melting polymer and the sheath component is a low-melting polymer, and is joined by melting and solidifying the low-melting polymer at the contact between the warp 3a and the weft 3b. It is related with the filter material used for the side.

  The filter material according to the present invention is composed of a three-dimensional fabric. This three-dimensional woven fabric is basically composed of a surface material 10 and a lining material 11, and a connecting yarn 12 (a warp yarn 3a made of a core-sheath monofilament in the present invention) that connects the surface material 10 and the lining material 11.

  The outer material 10 is formed by weaving a warp 1a and a weft 1b made of rayon monofilament with an arbitrary woven structure. The lining 11 is also woven with an arbitrary woven structure using warp yarns 2a and weft yarns 2b made of rayon monofilament. The reason for using rayon monofilament is that when it comes into contact with a flame, it is difficult to open a hole just by carbonization, and the flame does not spread easily. In addition, the reason for not using a multifilament in which a number of fine filaments of several deniers to several tens of deniers are converged using a monofilament is that the fine filaments may be cut and dropped during cleaning. It is. Therefore, the fineness of the monofilament is generally several hundred deniers, that is, a fineness of about 100 to 1000 deniers.

  Arbitrary woven structures are adopted as the woven structure of the outer material 10 and the lining 11. For example, a plain weave structure, an oblique weave structure, a satin weave structure, and other weave structures are adopted. Specifically, a pattern weave as shown in the organization charts of FIGS. 2 and 3 is adopted for the outer material 10 and the lining material 11. The density of the warp 1a, the weft 1b, the warp 2a and the weft 2b is arbitrary, but a relatively coarse density is preferable in order to reduce the pressure loss and improve the air flow. For example, both the warp density and the weft density are preferably about 20 to 70 / inch. Alternatively, a relatively large eye may be formed between the warp yarns 1a, between the weft yarns 1b, between the warp yarns 2a, and between the weft yarns 2b so as to reduce the pressure loss. In the filter material shown in FIG. 7, each thread is in close contact with each other, and a relatively large eye is formed by providing an interval of 2 to 4 mm at a place where the close contact of these three threads is adjacent to each other. It is a thing.

  In the present invention, a core-sheath monofilament is used for the connecting yarn 12 that connects the outer material 10 and the lining material 11. The core-sheath monofilament is woven together with the weft 1b of the outer fabric 10 and the weft 2b of the lining 11 as the warp 3a. As the woven structure woven by the warp 3a, the weft 1b of the outer fabric 10 and the weft 2b of the lining 11, an arbitrary woven structure is adopted. For example, a woven structure as shown in the organization charts of FIGS. 4 and 5 is employed. The structure diagram of FIG. 4 shows the woven structure of the warp 3a and the weft 1b of the outer fabric 10, and the structure diagram of FIG. 5 shows the woven structure of the warp 3a and the weft 2b of the lining 11. 4 and FIG. 5, the number of warps 3a is two for every six warps 1a of the outer fabric 10 or warps 2a of the lining 11, more than the number of warps 1a and 2a. Less. This is because the warp 3a is for maintaining the three-dimensional form of the woven fabric, as long as it can be maintained.

  4 and 5, the weave structures of the warp 3a and the weft 1b of the outer fabric 10 and the weft 3a and the weft 2b of the lining 11 are the same, but the weave structure is woven by reciprocating the warp 3a left and right. It can be realized by doing. That is, as shown in FIG. 6, the warp yarn 3a woven with the weft yarn 1b of the outer material 10 moves to the right course and is woven with the weft yarn 2b of the lining material 11, while the weft yarn of the lining material 11 is woven. The warp yarn 3a woven with 2b is then moved to the left course, and woven with the weft yarn 1b of the outer fabric 10 to realize such a woven structure.

  The core-sheath monofilament is also used as the weft 3b. The weft 3b is arranged between the weft 1b and the weft 2b in a state along the weft 1b and the weft 2b. In FIG. 1, the warp yarns 3 a are arranged between the weft yarns 1 b and the weft yarns 2 b in a state along the weft yarns 1 b and the weft yarns 2 b where the warp yarns 3 a move from the outer material 10 to the lining material 11.

  In the weaving of the warp 3a and the weft 3b as described above, the warp 3a and the weft 3b are each composed of a core-sheath monofilament in which the core component is a high-melting polymer and the sheath component is a low-melting polymer. . Therefore, after weaving, when the low melting point polymer is heated to a temperature at which the low melting point polymer melts and then cooled, the low melting point polymer is melted and solidified at the contact between the warp 3a and the weft 3b and joined at the contact. Therefore, the shape is stable while maintaining the three-dimensional structure, and the shape is not easily lost even during cleaning.

  The core-sheath monofilaments constituting the warp 3a and the weft 3b are generally of the same composition. That is, it is composed of a core component made of the same high melting point polymer and a sheath component made of the same low melting point polymer. However, particularly the high melting point polymer may have a different composition. The low melting point polymer may also have a different composition as long as the compatibility is not insufficient and the polymer is joined when melted and solidified. As the combination of high melting point polymer / low melting point polymer, combinations of polyester / polyethylene, polyester / polypropylene, high melting point polyester / low melting point polyester and the like are used. In the present invention, a polyester / polyethylene combination having a large melting point difference is preferred.

  The fineness of the core-sheath monofilament is also preferably several hundred denier, that is, about 100 to 1000 denier. The core-sheath monofilament that is the warp 3a is preferably particularly thick. This is because the fineness is stiffer, it is easy to maintain the three-dimensional structure even after washing, and the shape is not easily lost. As for the core-sheath monofilament, the reason for not using a multifilament in which many core-sheath filaments with a fineness are bundled is that there is a risk that the core-sheath filament with a fineness will be cut off during washing. It is.

  The density of the warp 3a and the weft 3b made of a core-sheath monofilament is arbitrary, but is generally lower than the warp density and the weft density of the outer fabric 10 and the lining 11. When the density of the warp 3a and the weft 3b is increased, the pressure loss tends to increase. For example, the filter material shown in FIG. 7 has a warp density of about 60 / inch, a weft density of about 25 / inch, and a warp 3a density and a weft 3b density of about 20 / inch. It is inch.

  The filter material according to the present invention can be obtained easily and rationally by weaving a three-dimensional woven fabric with the above-described yarn use and heat-treating it. And you may use as it is as a filter material, and you may use it after performing post-processing, such as a flame-retardant process and an antibacterial process. In particular, when used on the intake side of a range hood, it is preferable to perform flame-retardant processing. A well-known propane process etc. are employ | adopted as a flame-retardant process.

  The filter material according to the present invention is a three-dimensional woven fabric in which a surface fabric and a lining fabric woven with rayon monofilaments are connected by warp yarns 3a made of a core-sheath monofilament. Therefore, since there are a large number of voids inside, a large amount of dust and oil can be captured. In this three-dimensional woven fabric, wefts 3b made of a core-sheath monofilament are arranged between the front and back wefts, and the contact between the warp 3a made of the core-sheath monofilament and the weft 3b is low in weight. It is joined by melting and solidifying the sheath component made of coalesced to achieve form stability. Therefore, the filter material according to the present invention has an effect that a large amount of dust and oil can be trapped in the internal voids even if it is washed after use, is not easily deformed, and is repeatedly used. Therefore, the filter material according to the present invention can be repeatedly washed and used, and is environmentally beneficial as compared with conventional disposable filter materials.

  In addition, when the filter material according to the present invention is subjected to flame retardant processing, in combination with the use of rayon monofilaments for the outer material and the lining material, even if a combustion test is performed, only carbonization does not open a large hole. Excellent flame retardancy. Therefore, it is suitable as a filter material attached to the intake side of a range hood or a ventilation fan used in a kitchen or a kitchen.

It is a typical cross-sectional view of a filter material according to an example of the present invention. It is a woven organization chart of the surface of the filter material concerning an example of the present invention. It is a woven structure chart of the lining of the filter material concerning an example of the present invention. It is a woven structure figure of the weft which comprises the surface of the filter material concerning an example of the present invention, and the warp which consists of a core sheath type monofilament. It is a woven structure figure of the weft which comprises the backing of the filter material concerning an example of the present invention, and the warp which consists of a core sheath type monofilament. FIG. 6 is a view showing a woven state of warp made of a core-sheath monofilament in the woven structure diagrams of FIGS. 4 and 5. It is a top view of the filter material which concerns on an example of this invention.

DESCRIPTION OF SYMBOLS 1a Outer warp 1b Outer weft 2a Lining warp 2b Lining weft 3a Warp made of core-sheath monofilament 3b Weft made of core-sheath monofilament 11 Outer fabric 12 Lining 13 Linking thread (warp 3a made of core-sheath monofilament)

Claims (5)

A surface fabric in which warp yarns 1a and weft yarns 1b made of rayon monofilaments are woven, a backing material in which warp yarns 2a and weft yarns 2b made of rayon monofilaments are woven, and a core-sheath monofilament in which weft yarns 1b and 2b are woven. A three-dimensional woven fabric composed of warp yarns 3a and weft yarns 3b made of core-sheath monofilaments arranged between the weft yarns 1b and 2b,
The core-sheath monofilament is characterized in that the core component is a high-melting polymer and the sheath component is a low-melting polymer, and is joined by melting and solidifying the low-melting polymer at the contact point between the warp 3a and the weft 3b. , Filter material mainly used on the intake side of the range hood.   The filter material according to claim 1, which is subjected to flame retardant processing.   2. The filter material according to claim 1, wherein a portion having a space is provided between the warps 1a, the wefts 1b, the warps 2a, and the wefts 2b to form relatively large eyes.   The filter material according to claim 1, wherein the high melting point polymer is a polyester and the low melting point polymer is a core-sheath monofilament which is polyethylene.   The filter material according to claim 1, wherein the fineness of the rayon monofilament and the core-sheath monofilament is 100 to 10,000 denier.

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