JP2012170914A - Electret filter medium - Google Patents
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- JP2012170914A JP2012170914A JP2011036953A JP2011036953A JP2012170914A JP 2012170914 A JP2012170914 A JP 2012170914A JP 2011036953 A JP2011036953 A JP 2011036953A JP 2011036953 A JP2011036953 A JP 2011036953A JP 2012170914 A JP2012170914 A JP 2012170914A
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本発明は、エアフィルターユニット、主に空調用、エアコン用に使用可能なフィルターユニットに用いられるろ材に関するものであって、特にＪＩＳ Ｂ ９９０８：２００１のうち形式２が適用されるやや微細な粉塵用フィルターユニットに使用されるろ材に関するものである。 TECHNICAL FIELD The present invention relates to an air filter unit, mainly for air conditioning, and a filter medium used for a filter unit that can be used for an air conditioner, and particularly for slightly fine dust to which type 2 of JIS B 9908: 2001 is applied. The present invention relates to a filter medium used for a filter unit.
エレクトレットろ材は、該ろ材を構成する繊維に半永久的に固定された電荷の静電気力によって空気中の微粒子を効果的に除去できるものであり、空調用、エアコン用、空気清浄機用フィルター、ＯＡ機器などの排気フィルターユニットに使用されている。こうした分野ではフィルターユニットの圧力損失を低く抑えつつ、大気中の微粒子を効率よく捕集する必要があるため、ろ材をジグザグに折りたたんでひだを構成したプリーツ状フィルターとして使用される。
エレクトレットろ材として使用される繊維状不織布としてはメルトブロー不織布や薄物スパンボンド不織布、薄型スパンレース不織布があるが、剛性が低いためひだ折り加工しにくいという問題があった。
The electret filter medium can effectively remove fine particles in the air by the electrostatic force of electric charges semi-permanently fixed to the fibers constituting the filter medium, and is used for air conditioning, air conditioning, air purifier filters, OA equipment. Used in exhaust filter units. In such a field, it is necessary to efficiently collect fine particles in the atmosphere while keeping the pressure loss of the filter unit low, so it is used as a pleated filter in which folds are formed by folding the filter medium in a zigzag manner.
As the fibrous nonwoven fabric used as the electret filter medium, there are a melt blown nonwoven fabric, a thin spunbond nonwoven fabric, and a thin spunlace nonwoven fabric, but there is a problem that it is difficult to fold and fold because of its low rigidity.
こうした問題を解決する方法として、薄いポリピロピレンメルトブロー不織布と太繊度の芯鞘繊維で構成された繊維ウェブを積層、加熱して剛性の高い部分と荷電が可能な部分で構成される積層型のろ材が考案されている（特許文献１）。
また、機械的強度向上のためにエレクトレット化した不織布に合成繊維の網状物を熱接着させた積層型ろ材が考案されている（特許文献２）。
こうした熱接着型の積層ろ材は、あらかじめエレクトレット化させた薄手の不織布と剛性のある基材と接合するため熱によって除電され、エレクトレットによる除塵効率が低下することがある。また、エレクトレット可能な薄手の不織布と機械的強度のある部材をあらかじめ熱接着した後に荷電されることがあるが、部材に含まれる油剤などの有機成分がエレクトレット可能な不織布に作用してエレクトレット化を阻害する問題が生じていた。
As a method for solving these problems, a laminated web composed of a thin polypyrrole meltblown nonwoven fabric and a fiber web composed of thick core-sheath fibers and heated to form a highly rigid part and a chargeable part. A filter medium has been devised (Patent Document 1).
In addition, a multilayer filter medium has been devised in which a synthetic fiber network is thermally bonded to an electret nonwoven fabric to improve mechanical strength (Patent Document 2).
Such a heat-bonded laminated filter medium is bonded to a thin non-woven fabric that has been electretized beforehand and a rigid base material, so that it is neutralized by heat, and the dust removal efficiency by the electret may decrease. In addition, a thin non-woven fabric that can be electret and a member with mechanical strength may be charged after being thermally bonded in advance, but organic components such as oil agents contained in the member act on the non-woven fabric that can be electret. There was a problem to block.
また、エレクトレットを疎外する油剤については加熱処理後の油剤付着量の減少率が６０％以上であるポリオレフィン系熱融着繊維を用いたエレクトレット不織布の記載がある（特許文献３）。この文献では加熱により油剤が減少することでエレクトレット特性が得られて粉塵捕集効率が高いことが記載されているが、実際にフィルター用のろ材としての特性と具体的な大気中の捕集上条件については何ら言及されていない Moreover, about the oil agent which alienates an electret, there exists description of the electret nonwoven fabric using the polyolefin-type heat-fusion fiber whose reduction rate of the oil agent adhesion amount after heat processing is 60% or more (patent document 3). This document describes that the electret characteristics are obtained by reducing the oil agent by heating, and the dust collection efficiency is high, but the characteristics as a filter medium for the filter and the actual collection in the atmosphere. No mention of conditions
本発明はエアフィルターの圧力損失、粉塵捕集効率や強度といった一般的なフィルター特性を維持しつつ、安定した捕集効率を発現できるエレクトレットろ材を提供する。 The present invention provides an electret filter medium capable of expressing stable collection efficiency while maintaining general filter characteristics such as pressure loss, dust collection efficiency and strength of an air filter.
本発明はかかる問題点に鑑み、鋭意検討した結果得られたものであり、以下の通りである。
（１）エレクトレットろ材、特にＪＩＳ Ｂ ９９０８：２００１で規定されている性能評価方法のうち、初期におけるＪＩＳ１１種比色法捕集効率が５０％から９９％を発現するプリーツ型フィルターユニットに用いられるエレクトレットろ材において、ろ材が単一層で構成された不織布であり、かつ以下の（Ａ）〜（Ｃ）の要件を満たすエレクトレットろ材。
（Ａ）不織布の嵩密度が０．０３〜０．２０ｇ／ｃｍ３であり、かつ厚みが１．５ｍｍ以下であること。
（Ｂ）ガーレ法における曲げ反発性が１００〜５００mgであること。
（Ｃ）ろ材に含まれる油剤の付着量が０．１重量％以下であること。
（２）上記（１）に記載の不織布が、ポリオレフィン系熱融着繊維を６０〜１００重量％含む熱融着された不織布であるエレクトレットろ材。
The present invention has been obtained as a result of intensive studies in view of such problems, and is as follows.
(1) Electret filter media, particularly electrets used in pleated filter units that exhibit 50% to 99% JIS11 colorimetric collection efficiency in the early stage of the performance evaluation method defined in JIS B 9908: 2001 In the filter medium, the filter medium is a non-woven fabric composed of a single layer and satisfies the following requirements (A) to (C).
(A) The bulk density of the nonwoven fabric is 0.03 to 0.20 g / cm 3 and the thickness is 1.5 mm or less.
(B) The bending resilience in the Gurley method is 100 to 500 mg.
(C) The adhesion amount of the oil contained in the filter medium is 0.1% by weight or less.
(2) An electret filter medium in which the non-woven fabric described in (1) is a heat-sealed non-woven fabric containing 60 to 100% by weight of polyolefin heat-sealing fibers.
本発明により、エアフィルターの圧力損失、粉塵捕集効率や強度といった一般的なフィルター特性を維持しつつ、フィルターの製造や使用時に必要である適度な強度を得ることが出来、かつ安定した捕集効率を得ることが出来る。 According to the present invention, while maintaining general filter characteristics such as pressure loss, dust collection efficiency and strength of an air filter, it is possible to obtain an appropriate strength necessary for manufacturing and using the filter, and stable collection. Efficiency can be obtained.
以下、本発明を詳細に説明する。
本発明はエレクトレットろ材、特にＪＩＳ Ｂ ９９０８：２００１で規定されている性能評価方法のうち、初期におけるＪＩＳ１１種比色法捕集効率が５０％から９９％を発現するプリーツ型フィルターユニットに用いられるエレクトレットろ材に適用される。該ろ材は不織布であるが、複数のシートの積層および／また接合された形態ではなく、単一層をなすことが特徴であり、具体的には以下（A）〜（Ｃ）の要件を満たなくてはならない。
（Ａ）不織布の嵩密度が０．０３〜０．２０ｇ／ｃｍ３であり、かつ厚みが１．５ｍｍ以下であること。
（Ｂ）ガーレ法における曲げ反発特性が１００〜５００mgであること。
（Ｃ）ろ材に含まれる油剤の付着量が０．１重量％以下であること。
Hereinafter, the present invention will be described in detail.
The present invention relates to an electret filter medium, particularly an electret used for a pleated filter unit in which the initial JIS11 colorimetric collection efficiency is 50% to 99% of the performance evaluation method defined in JIS B 9908: 2001. Applied to filter media. The filter medium is a non-woven fabric, but is not a laminated and / or bonded form of a plurality of sheets, but is characterized by forming a single layer, and specifically does not satisfy the following requirements (A) to (C) must not.
(A) The bulk density of the nonwoven fabric is 0.03 to 0.20 g / cm 3 and the thickness is 1.5 mm or less.
(B) The bending repulsion characteristic in the Gurley method is 100 to 500 mg.
(C) The adhesion amount of the oil contained in the filter medium is 0.1% by weight or less.
また、本発明を実現するには、上記不織布が、ポリオレフィン系熱融着繊維を６０〜１００重量％含む熱融着された不織布であることが必要である。 Moreover, in order to implement | achieve this invention, it is required for the said nonwoven fabric to be the heat-fused nonwoven fabric which contains 60-100 weight% of polyolefin-type heat-fusion fibers.
本発明におけるエレクトレットろ材において必要とされる不織布の嵩密度はろ材の持つ粉塵捕集効率と通気抵抗のバランスを考慮した場合、０．０３〜０．２０ｇ／ｃｍ３、好ましくは０．０４〜０．１８ｇ／ｃｍ３が好ましい。嵩密度が０．０３ｇ／ｍ３より小さい場合、繊維の量が少ないためエレクトレット後の粉塵捕集効率が低下し、０．２０ｇ／ｃｍ３より高い場合、ろ材の空気抵抗が高くフィルターユニットにした場合の圧力損失が高くなり、かつ粉塵保持量が小さくなり、いずれも好ましくない。 The bulk density of the nonwoven fabric required in the electret filter medium in the present invention is 0.03 to 0.20 g / cm 3 , preferably 0.04 to 0, considering the balance between dust collection efficiency and ventilation resistance of the filter medium. .18 g / cm 3 is preferred. When the bulk density is less than 0.03 g / m 3 , the amount of fibers is small, so the dust collection efficiency after the electret is lowered. When the bulk density is higher than 0.20 g / cm 3 , the air resistance of the filter medium is high and the filter unit is made. In some cases, the pressure loss increases, and the dust holding amount decreases, which is not preferable.
厚みについてはプリーツ後のフィルターユニットの圧力損失に大きく影響するため、１．５ｍｍ以下、好ましくは１．４ｍｍ以下に調整されることが好ましい。厚みが１．５ｍｍより大きい場合、プリーツ後のフィルターユニットにおける通気時の構造抵抗が増加するため圧力損失が大きくなり、好ましくない。 Since the thickness greatly affects the pressure loss of the filter unit after pleating, it is preferably adjusted to 1.5 mm or less, preferably 1.4 mm or less. When the thickness is larger than 1.5 mm, the structural resistance at the time of ventilation in the filter unit after pleating increases, so that the pressure loss increases, which is not preferable.
さらに、本発明におけるエレクトレットろ材のガーレ法における曲げ反発特性が１００〜５００ｍｇ、好ましくは１２０〜４８０ｍｇであることが適度なプリーツ加工性を維持する上で必要である。曲げ反発特性が１００ｍｇより低い場合、ろ材の曲げ強度が低下するのでプリーツ加工時にきれいな山状のプリーツが形成されず、いびつな形状を形成する。反対に５００ｍｇより大きい場合、強度が高いためプリーツ加工時に折り曲げることが出来ず、頂点がいびつな形状に形成されるため、いずれも好ましくない。 Furthermore, it is necessary to maintain an appropriate pleat workability that the bending repulsion characteristics in the Gurley method of the electret filter medium in the present invention are 100 to 500 mg, preferably 120 to 480 mg. When the bending resilience characteristic is lower than 100 mg, the bending strength of the filter medium is lowered, so that a beautiful mountain-shaped pleat is not formed at the time of pleating, and an irregular shape is formed. On the other hand, if it is larger than 500 mg, the strength is high and it cannot be bent during pleating, and the apex is formed in an irregular shape.
本発明においてはろ材に含まれる油剤の付着量が０．１重量％以下であることがプリーツ型フィルターユニット用におけるエレクトレットろ材において必要な捕集性能を得る上で重要である。短繊維不織布に使用される原綿にはカード時に発生する静電気を抑制してウエブ形成性を安定化するために有機成分が主である油剤が含有されている。こうした油剤はウエブの形成を安定化する反面、シート化後に荷電処理を行いエレクトレット化した場合においても抑制する効果を有する。したがって本発明における油剤の付着量はシートの重量に対して０．１重量％以下であることが必要な荷電効果を得る上で重要である。油剤の付着量が０．１重量％より多い場合、仮に荷電されても電荷が安定せず、必要な粉塵捕集効率を得ることが出来なくなり、好ましくない。なお、こうしたエレクトレットろ材を得るためにはエレクトレットが可能な素材、特にポリオレフィン系の成分でポリオレフィン系熱融着繊維を６０〜１００重量％含む熱融着された不織布であることが必要である。ポリオレフィン系の熱融着繊維の含有率が６０重量％より低い場合、必要な荷電効果が得られず、かつシートとして必要な強度が得られないため好ましくない。 In the present invention, the adhesion amount of the oil contained in the filter medium is 0.1% by weight or less, which is important for obtaining the necessary collection performance in the electret filter medium for the pleated filter unit. The raw cotton used for the short fiber nonwoven fabric contains an oil mainly composed of organic components in order to suppress static electricity generated during carding and to stabilize the web-forming property. Such an oil agent stabilizes the formation of the web, but also has an effect of suppressing the electret after being charged and then sheeted. Therefore, the amount of the oil agent attached in the present invention is important in obtaining a charging effect that is required to be 0.1% by weight or less with respect to the weight of the sheet. When the amount of the oil agent adhered is more than 0.1% by weight, the charge is not stable even if it is charged, and the required dust collection efficiency cannot be obtained, which is not preferable. In order to obtain such an electret filter medium, it is necessary to be a non-woven fabric that can be electretized, particularly a heat-bonded non-woven fabric containing 60 to 100% by weight of a polyolefin-based heat-bonding fiber with a polyolefin-based component. When the content of the polyolefin-based heat-fusible fiber is lower than 60% by weight, a necessary charging effect cannot be obtained, and a necessary strength as a sheet cannot be obtained.
続いて、本発明を実現するための具体的な製造方法について説明する。本発明は、特にポリプロピレンを芯に、ポリエチレンを鞘に構成される芯鞘繊維を用い、ウェブ状にしてからシート化することが融着特性と工程の合理性の観点から好適に用いられる。該芯鞘繊維はシートの強度と圧力損失を考慮した場合、２．２〜２２ｄｔｅｘの繊維を用いることが好ましく、それより繊度の大きいものである場合、難燃剤が含有した場合の融着強度が低下するためシートの強度が弱くなる。また２．２ｄｔｅｘ未満である場合、繊維直径が細くなるためにシートにした場合の圧力損失が高くなり、好ましくない。主成分のポリプロピレン繊維と接着成分としてのポリエチレンとの比率は配合の方法により様々であるが充分な接着性を得るためにはポリプロピレン（ＰＰ）繊維とポリエチレン（ＰＥ）が重量比で１：４〜４：１に調整されることが望ましい。こうしたポリオレフィン系の芯鞘繊維と他の繊維を混綿して公知の方法でカード機にかけウエブ状にした後、熱接着を行って不織布を製造する。ポリオレフィン系の芯鞘繊維と混綿する他の繊維はシートに要求される機能に応じて選択される。例えば、抗菌、高カビ性や難燃性を付与したい場合はこうした機能を持つ公知の添加剤が添加された繊維をエレクトレット性が損なわない程度に混ぜてもよい。 Then, the specific manufacturing method for implement | achieving this invention is demonstrated. In the present invention, it is particularly preferable to use a core-sheath fiber composed of polypropylene as a core and polyethylene as a sheath, and then form a web and then form a sheet from the viewpoint of fusion characteristics and process rationality. When considering the strength and pressure loss of the sheet, the core-sheath fiber is preferably a fiber of 2.2 to 22 dtex, and if the fiber has a fineness greater than that, the fusion strength when the flame retardant is contained is The strength of the sheet is weakened due to the decrease. Moreover, when it is less than 2.2 dtex, since the fiber diameter becomes thin, the pressure loss at the time of making it into a sheet becomes high, and it is not preferable. The ratio of the main component polypropylene fiber to polyethylene as an adhesive component varies depending on the blending method, but in order to obtain sufficient adhesion, polypropylene (PP) fiber and polyethylene (PE) are in a weight ratio of 1: 4 to It is desirable to adjust to 4: 1. Such a polyolefin-based core-sheath fiber and other fibers are blended and applied to a card machine by a known method to form a web, and then thermally bonded to produce a nonwoven fabric. Other fibers blended with the polyolefin-based core-sheath fibers are selected according to the function required for the sheet. For example, in order to impart antibacterial properties, high moldability and flame retardancy, fibers to which known additives having such functions are added may be mixed to such an extent that electret properties are not impaired.
不織布を製造する方法は公知の方法でよく、例えばカードウエブをニードルパンチにかける方法、カードウエブを水流によって交絡させシートを構成する方法がある。しかしながら必要な強度を得るためにはシート構成後、熱融着繊維の鞘成分の融点以上の温度で十分に熱が行き渡る時間、具体的には１０〜６０秒間ヒートスルーオーブンで加熱して鞘部を融解させて繊維間接着をする必要がある。この場合、必要とされる厚みにするためにはウエブを交絡した不織布を所定のギャップに調整したネットに挟み込んで加熱する事で可能となる。また、ウエブを交絡した不織布をオーブンで加熱させた後所定のギャップに調整したプレスローラー中を通過させることによってでも可能である。プリーツろ材として必要な曲げ反発特性を得るには熱融着繊維成分が加熱溶融した状態で所定の厚みに調整して冷却させることが必要で、このような状態で厚みを調整する方法であれば特に限定されるものではない。 The method for producing the nonwoven fabric may be a known method, for example, a method in which the card web is subjected to needle punching, or a method in which the card web is entangled with a water stream to form a sheet. However, in order to obtain the required strength, after the sheet is constructed, the sheath part is heated by a heat-through oven for a period of time during which heat is sufficiently distributed at a temperature equal to or higher than the melting point of the sheath component of the heat-sealing fiber, specifically 10-60 seconds. It is necessary to melt and melt the fibers. In this case, in order to obtain a required thickness, it is possible to sandwich and heat a nonwoven fabric entangled with a web that is adjusted to a predetermined gap. Alternatively, the nonwoven fabric entangled with the web is heated in an oven and then passed through a press roller adjusted to a predetermined gap. In order to obtain the required bending resilience characteristics as a pleated filter medium, it is necessary to adjust the thickness to a predetermined thickness in a state where the heat-fusible fiber component is heated and melted, and to cool it. It is not particularly limited.
続いて必要なエレクトレット性を得る上で必要な油剤の除去方法について説明する。油剤は不織布形成後５０〜８０℃程度の温浴に数分間含浸して脱水することによって得られる。また連続的には未加熱の不織布を温浴に通した後所定の温度で乾燥し、そのまま融点以上の温度に加熱して得ることも可能である。また、加熱によって油剤成分が減少する繊維（特許文献３）を用いてもよい。油剤が除去されたシートは荷電処理によって荷電され、エレクトレットフィルターろ材になる。荷電方法特に限定されるものではないがコロナ放電による方法や水などの液体を通過させて得られる方法、シートを摩擦によって静電気を発生させる方法など公知の方法でよい。 Then, the removal method of the oil agent required when obtaining required electret property is demonstrated. The oil agent is obtained by impregnating in a warm bath of about 50 to 80 ° C. for several minutes and then dehydrating after forming the nonwoven fabric. It is also possible to continuously obtain an unheated non-woven fabric by passing it through a warm bath, drying it at a predetermined temperature, and heating it to a temperature equal to or higher than the melting point. Moreover, you may use the fiber (patent document 3) from which an oil agent component reduces by heating. The sheet from which the oil agent has been removed is charged by the charging process and becomes an electret filter medium. The charging method is not particularly limited, and may be a known method such as a method using corona discharge, a method obtained by passing a liquid such as water, or a method of generating static electricity by rubbing the sheet.
次に実施例、比較例を用いて本発明を具体的に説明するが、本発明は実施例のみに限定されるものではない。なお、測定方法は下記の方法で実施した。 Next, the present invention will be specifically described using examples and comparative examples, but the present invention is not limited to the examples. In addition, the measuring method was implemented with the following method.
（１）目付（ｇ／ｍ２）：２００ｍｍ角の寸法で切り出し、秤量して寸法で除した。
（２）厚み（ｍｍ）：荷重０．７ｋＰａの厚みを読み取った。
（３）嵩密度（ｇ／ｃｍ３）：目付を厚みで除した値を採用した。
（４）曲げ反発性：ＪＩＳ Ｌ １０９６（１９９０）６．２０．１ Ａ法に準拠。
（５）油剤付着量：試料２ｇを採取し、エタノール／メタノール：重量混合比２／１の抽出液５０ｃｃに含浸させて油剤を抽出した。抽出前後の重量を測定して単位重量あたりの抽出量（重量％）を算出した。
（６）フィルターユニットの特性
ろ材６０５ｍｍ巾×２０ｍ長を製造し、山高さ５８ｍｍにてひだ折りして山ピッチ６ｍｍになる様に公知の方法でビード樹脂を２５ｍｍ間隔で流し込んで成型し、プリーツを形成した。６１０ｍｍ角のアルミ枠材にプリーツを装填して圧力損失とＪＩＳ１１種の初期捕集効率を測定した。測定装置はＪＩＳ Ｂ ９９０８（２００１）の形式２に基づく装置を用いた。風量は５６ｍ３／ｍｉｎで実施し、粉塵負荷は２９４Paで終了した。
(1) Weight per unit area (g / m 2 ): Cut out with a size of 200 mm square, weighed and divided by the size.
(2) Thickness (mm): The thickness at a load of 0.7 kPa was read.
(3) Bulk density (g / cm 3 ): A value obtained by dividing the basis weight by the thickness was adopted.
(4) Bending resilience: Conforms to JIS L 1096 (1990) 6.20.1 A method.
(5) Oil agent adhesion amount: 2 g of a sample was collected and impregnated in 50 cc of an extract of ethanol / methanol: weight mixing ratio 2/1 to extract the oil agent. The weight before and after extraction was measured to calculate the amount of extraction (% by weight) per unit weight.
(6) Characteristics of the filter unit A filter medium of 605 mm width × 20 m length is manufactured, and bead resin is poured at a 25 mm interval and molded so as to be folded at a peak height of 58 mm to a peak pitch of 6 mm. Formed. A 610 mm square aluminum frame was loaded with pleats, and pressure loss and JIS11 initial collection efficiency were measured. As the measuring apparatus, an apparatus based on type 2 of JIS B 9908 (2001) was used. The air flow was 56 m 3 / min, and the dust load was finished at 294 Pa.
以下実施例中および比較例で用いたシートの荷電方法を以下に示した。
（１）荷電装置
アース側：アルミ板に厚さ２ｍｍのシリコンシートを敷設した。
電極側：針間隔１０ｍｍの針電極
電極−アース間距離：針先端からシリコンシートまで１０ｍｍ
（２）荷電方法
印加電圧：２０ｋＶ
荷電時間：３０秒
The sheet charging method used in the examples and comparative examples is shown below.
(1) Charging device Ground side: A silicon sheet having a thickness of 2 mm was laid on an aluminum plate.
Electrode side: Needle electrode with 10 mm needle spacing Electrode-earth distance: 10 mm from needle tip to silicon sheet
(2) Charging method Applied voltage: 20 kV
Charging time: 30 seconds
＜実施例１＞
ポリプロピレン（芯成分）／ポリエチレン（鞘成分）（ポリプロピレン：ポリエチレン重量比は１：１）で構成される２．２ｄｔｅｘ、長さ３８ｍｍの短繊維、および６．６ｄｔｅｘ、長さ６４ｍｍの短繊維（いずれも宇部日東化成株式会社製耐熱脱油繊維ＨＲ−ＬＥ）を８：２の割合で混繊してカード機にかけてウエブとし、ウエブをクロスレイヤーで連続的に積層し、ステンレスメッシュをウエブの上下から挟む形で搬送してエアスルーオーブンに通し、温度１５０℃、１分間加熱融着させ、目付８５ｇ／ｍ２、厚み１．０ｍｍのサーマルボンド不織布を得た。該不織布を荷電装置に通して荷電し、エレクトレットろ材を得た。このろ材をひだ折りしてフィルターユニットを製作しユニット特性を評価した。ろ材の目付、厚み、嵩密度、油剤付着量、フィルターユニットの圧力損失、粉塵保持量、初期におけるＪＩＳ１１種捕集効率を表１に示す。
<Example 1>
2.2 dtex composed of polypropylene (core component) / polyethylene (sheath component) (polypropylene: polyethylene weight ratio is 1: 1), short fiber with a length of 38 mm, and short fiber with a length of 6.6 dtex and a length of 64 mm (any Is also heat-resistant deoiled fiber HR-LE manufactured by Ube Nitto Kasei Co., Ltd. at a ratio of 8: 2 and put on a card machine to form a web. The heat-bonded nonwoven fabric having a basis weight of 85 g / m 2 and a thickness of 1.0 mm was obtained by transporting in a sandwiched manner and passing through an air-through oven and heating and fusing at 150 ° C. for 1 minute. The nonwoven fabric was charged through a charging device to obtain an electret filter medium. This filter medium was folded and a filter unit was manufactured to evaluate the unit characteristics. Table 1 shows the basis weight, thickness, bulk density, oil agent adhesion amount, filter unit pressure loss, dust retention amount, and initial JIS 11 species collection efficiency of the filter medium.
＜実施例２＞
ポリプロピレン（芯成分）／ポリエチレン（鞘成分）（ポリプロピレン：ポリエチレン重量比は１：１）で構成される２．２ｄｔｅｘ、長さ３８ｍｍの短繊維（宇部日東化成株式会社製耐熱脱油繊維ＨＲ−ＬＥ）、および６．６ｄｔｅｘ、長さ６４ｍｍのポリエステル短繊維（東レ株式会社製Ｔ２０１）を８：２の割合で混繊してカード機にかけてウエブとし、ウエブをクロスレイヤーで連続的に積層し、ステンレスメッシュをウエブの上下から挟む形で搬送してエアスルーオーブンに通し、温度１５０℃、１分間加熱融着させ、目付９５ｇ／ｍ２、厚み１．０ｍｍのサーマルボンド不織布を得た。該不織布を荷電装置に通して荷電し、エレクトレットろ材を得た。このろ材をひだ折りしてフィルターユニットを製作してユニット特性を評価した。ろ材の目付、厚み、嵩密度、油剤付着量、フィルターユニットの圧力損失、粉塵保持量、初期におけるＪＩＳ１１種捕集効率を表１に示す。
<Example 2>
2.2 dtex, 38 mm long short fiber made of polypropylene (core component) / polyethylene (sheath component) (polypropylene: polyethylene weight ratio 1: 1) (heat-resistant deoiled fiber HR-LE manufactured by Ube Nitto Kasei Co., Ltd.) ), And 6.6 dtex, 64 mm long polyester short fibers (T201 manufactured by Toray Industries, Inc.) at a ratio of 8: 2, mixed into a card machine to form a web, and the web was continuously laminated with a cross layer. The mesh was conveyed between the top and bottom of the web, passed through an air-through oven, and heat-sealed at 150 ° C. for 1 minute to obtain a thermal bond nonwoven fabric having a basis weight of 95 g / m 2 and a thickness of 1.0 mm. The nonwoven fabric was charged through a charging device to obtain an electret filter medium. This filter medium was folded and a filter unit was manufactured to evaluate the unit characteristics. Table 1 shows the basis weight, thickness, bulk density, oil agent adhesion amount, filter unit pressure loss, dust retention amount, and initial JIS 11 species collection efficiency of the filter medium.
＜実施例３＞
実施例２と同じ繊維組成で目付１００ｇ／ｍ２、厚み０．７ｍｍのサーマルボンド不織布を得た。該不織布を荷電装置に通して荷電し、エレクトレットろ材を得た。このろ材をひだ折りしてフィルターユニットを製作してユニット特性を評価した。ろ材の目付、厚み、嵩密度、油剤付着量、フィルターユニットの圧力損失、粉塵保持量、初期におけるＪＩＳ１１種捕集効率を表１に示す。
<Example 3>
A thermal bond nonwoven fabric having the same fiber composition as in Example 2 and a basis weight of 100 g / m 2 and a thickness of 0.7 mm was obtained. The nonwoven fabric was charged through a charging device to obtain an electret filter medium. This filter medium was folded and a filter unit was manufactured to evaluate the unit characteristics. Table 1 shows the basis weight, thickness, bulk density, oil agent adhesion amount, filter unit pressure loss, dust retention amount, and initial JIS 11 species collection efficiency of the filter medium.
＜実施例４＞
実施例２と同じ繊維組成で目付７０ｇ／ｍ２、厚み１．３ｍｍのサーマルボンド不織布を得た。該不織布を荷電装置に通して荷電し、エレクトレットろ材を得た。このろ材をひだ折りしてフィルターユニットを製作してユニット特性を評価した。ろ材の目付、厚み、嵩密度、油剤付着量、フィルターユニットの圧力損失、粉塵保持量、初期におけるＪＩＳ１１種捕集効率を表１に示す。
<Example 4>
A thermal bond nonwoven fabric having the same fiber composition as in Example 2 and a basis weight of 70 g / m 2 and a thickness of 1.3 mm was obtained. The nonwoven fabric was charged through a charging device to obtain an electret filter medium. This filter medium was folded and a filter unit was manufactured to evaluate the unit characteristics. Table 1 shows the basis weight, thickness, bulk density, oil agent adhesion amount, filter unit pressure loss, dust retention amount, and initial JIS 11 species collection efficiency of the filter medium.
＜実施例５＞
ポリプロピレン（芯成分）／ポリエチレン（鞘成分）（ポリプロピレン：ポリエチレン重量比は１：１）で構成される２．２ｄｔｅｘ、長さ３８ｍｍの短繊維（宇部日東化成株式会社製ＨＲ−ＣＫ）、および６．６ｄｔｅｘ、長さ６４ｍｍのポリエステル短繊維（東レ株式会社製Ｔ２０１）を８：２の割合で混繊してカード機にかけてウエブとし、ウエブをクロスレイヤーで連続的に積層し、ステンレスメッシュをウエブの上下から挟む形で搬送してエアスルーオーブンに通し、温度１５０℃、１分間加熱融着させ、目付９０ｇ／ｍ２、厚み１．０ｍｍのサーマルボンド不織布を得た。該不織布を７０℃に設定された温浴中に５分間含浸させよく揉んで水分が不織布中に行き渡るように洗浄し、その後脱水して油剤を除去した。油剤の除去を２回繰り返した後、乾燥させて荷電装置に通して荷電し、エレクトレットろ材を得た。このろ材をひだ折りしてフィルターユニットを製作してユニット特性を評価した。ろ材の目付、厚み、嵩密度、油剤付着量、フィルターユニットの圧力損失、粉塵保持量、初期におけるＪＩＳ１１種捕集効率を表１に示す。
<Example 5>
2.2 dtex composed of polypropylene (core component) / polyethylene (sheath component) (polypropylene: polyethylene weight ratio is 1: 1), 38 mm long short fibers (HR-CK manufactured by Ube Nitto Kasei Co., Ltd.), and 6 .6 dtex, 64 mm long polyester short fiber (T201 manufactured by Toray Industries, Inc.) at a ratio of 8: 2, mixed into a card machine to form a web, the web was continuously laminated with a cross layer, and a stainless mesh was used as the web. It was conveyed in a form sandwiched from above and below, passed through an air-through oven, and heated and fused at 150 ° C. for 1 minute to obtain a thermal bond nonwoven fabric having a basis weight of 90 g / m 2 and a thickness of 1.0 mm. The non-woven fabric was impregnated in a warm bath set at 70 ° C. for 5 minutes and thoroughly rinsed and washed so that moisture spread throughout the non-woven fabric, and then dehydrated to remove the oil agent. After removing the oil agent twice, it was dried and charged through a charging device to obtain an electret filter medium. This filter medium was folded and a filter unit was manufactured to evaluate the unit characteristics. Table 1 shows the basis weight, thickness, bulk density, oil agent adhesion amount, filter unit pressure loss, dust retention amount, and initial JIS 11 species collection efficiency of the filter medium.
＜比較例１＞
ポリプロピレン（芯成分）／ポリエチレン（鞘成分）（ポリプロピレン：ポリエチレン重量比は１：１）で構成される２．２ｄｔｅｘ、長さ３８ｍｍの短繊維（宇部日東化成株式会社製耐熱脱油繊維ＨＲ−ＬＥ）、および６．６ｄｔｅｘ、長さ６４ｍｍのポリエステル短繊維（東レ株式会社製Ｔ２０１）を８：２の割合で混繊してカード機にかけてウエブとし、ウエブをクロスレイヤーで連続的に積層し、ステンレスメッシュをウエブの上下から挟む形で搬送してエアスルーオーブンに通し、温度１５０℃、１分間加熱融着させ、目付６０ｇ／ｍ２、厚み２．３ｍｍのサーマルボンド不織布を得た。該不織布を荷電装置に通して荷電し、エレクトレットろ材を得た。このろ材をひだ折りしてフィルターユニットを製作してユニット特性を評価した。ろ材の目付、厚み、嵩密度、油剤付着量、フィルターユニットの圧力損失、粉塵保持量、初期におけるＪＩＳ１１種捕集効率を表１に示す。
<Comparative Example 1>
2.2 dtex, 38 mm long short fiber made of polypropylene (core component) / polyethylene (sheath component) (polypropylene: polyethylene weight ratio 1: 1) (heat-resistant deoiled fiber HR-LE manufactured by Ube Nitto Kasei Co., Ltd.) ), And 6.6 dtex, 64 mm long polyester short fibers (T201 manufactured by Toray Industries, Inc.) at a ratio of 8: 2, mixed into a card machine to form a web, and the web was continuously laminated with a cross layer. The mesh was conveyed between the top and bottom of the web, passed through an air-through oven, and heat-sealed at 150 ° C. for 1 minute to obtain a thermal bond nonwoven fabric having a basis weight of 60 g / m 2 and a thickness of 2.3 mm. The nonwoven fabric was charged through a charging device to obtain an electret filter medium. This filter medium was folded and a filter unit was manufactured to evaluate the unit characteristics. Table 1 shows the basis weight, thickness, bulk density, oil agent adhesion amount, filter unit pressure loss, dust retention amount, and initial JIS 11 species collection efficiency of the filter medium.
＜比較例２＞
ポリプロピレン（芯成分）／ポリエチレン（鞘成分）（ポリプロピレン：ポリエチレン重量比は１：１）で構成される２．２ｄｔｅｘ、長さ３８ｍｍの短繊維（耐熱脱油繊維宇部日東化成株式会社製ＨＲ−ＬＥ）、および６．６ｄｔｅｘ、長さ６４ｍｍのポリエステル短繊維（東レ株式会社製Ｔ２０１）を８：２の割合で混繊してカード機にかけてウエブとし、ウエブをクロスレイヤーで連続的に積層し、ステンレスメッシュをウエブの上下から挟む形で搬送してエアスルーオーブンに通し、温度１５０℃、１分間加熱融着させ、目付４５ｇ／ｍ２、厚み１．０ｍｍのサーマルボンド不織布を得た。該不織布を荷電装置に通して荷電し、エレクトレットろ材を得た。しかし、このろ材をひだ折りしてフィルターユニットを製作したが強度がなくひだ折りすることが出来なかった。ろ材の目付、厚み、嵩密度、油剤付着量を表１に示す。
<Comparative example 2>
2.2 dtex composed of polypropylene (core component) / polyethylene (sheath component) (polypropylene: polyethylene weight ratio is 1: 1), a short fiber of 38 mm in length (heat-resistant deoiled fiber Ube Nitto Kasei HR-LE ), And 6.6 dtex, 64 mm long polyester short fibers (T201 manufactured by Toray Industries, Inc.) at a ratio of 8: 2, mixed into a card machine to form a web, and the web was continuously laminated with a cross layer. The mesh was conveyed between the top and bottom of the web, passed through an air-through oven, and heat-sealed at a temperature of 150 ° C. for 1 minute to obtain a thermal bond nonwoven fabric having a basis weight of 45 g / m 2 and a thickness of 1.0 mm. The nonwoven fabric was charged through a charging device to obtain an electret filter medium. However, a filter unit was manufactured by folding the filter medium, but it was not strong and could not be folded. Table 1 shows the basis weight, thickness, bulk density, and oil adhesion amount of the filter medium.
＜比較例３＞
ポリプロピレン（芯成分）／ポリエチレン（鞘成分）（ポリプロピレン：ポリエチレン重量比は１：１）で構成される２．２ｄｔｅｘ、長さ３８ｍｍの短繊維（耐熱脱油繊維宇部日東化成株式会社製ＨＲ−ＬＥ）、および同短繊維６．６ｄｔｅｘを１：１の割合で混繊してカード機にかけてウエブとし、ウエブをクロスレイヤーで連続的に積層し、ステンレスメッシュをウエブの上下から挟む形で搬送してエアスルーオーブンに通し、温度１５０℃、１分間加熱融着させ、目付１５０ｇ／ｍ２、厚み０．７ｍｍのサーマルボンド不織布を得た。該不織布を荷電装置に通して荷電し、エレクトレットろ材を得た。このろ材をひだ折りしてフィルターユニットを製作してユニット特性を評価した。ろ材の目付、厚み、嵩密度、油剤付着量、フィルターユニットの圧力損失、粉塵保持量、初期におけるＪＩＳ１１種捕集効率を表１に示す。
<Comparative Example 3>
2.2 dtex composed of polypropylene (core component) / polyethylene (sheath component) (polypropylene: polyethylene weight ratio is 1: 1), a short fiber of 38 mm in length (heat-resistant deoiled fiber Ube Nitto Kasei HR-LE ), And 6.6 dtex of the same short fibers are mixed at a ratio of 1: 1 to form a web on a card machine, the web is continuously laminated with a cross layer, and the stainless steel mesh is conveyed from above and below the web. It was passed through an air-through oven and heated and fused at a temperature of 150 ° C. for 1 minute to obtain a thermal bond nonwoven fabric having a basis weight of 150 g / m 2 and a thickness of 0.7 mm. The nonwoven fabric was charged through a charging device to obtain an electret filter medium. This filter medium was folded and a filter unit was manufactured to evaluate the unit characteristics. Table 1 shows the basis weight, thickness, bulk density, oil agent adhesion amount, filter unit pressure loss, dust retention amount, and initial JIS 11 species collection efficiency of the filter medium.
＜比較例４＞
実施例４で製造した不織布を洗浄せずに荷電し、ユニット化してエレクトレットろ材を得た。このろ材をひだ折りしてフィルターユニットを製作してユニット特性を評価した。ろ材の目付、厚み、嵩密度、油剤付着量、フィルターユニットの圧力損失、粉塵保持量、初期におけるＪＩＳ１１種捕集効率を表１に示す。
<Comparative example 4>
The non-woven fabric produced in Example 4 was charged without washing and unitized to obtain an electret filter medium. This filter medium was folded and a filter unit was manufactured to evaluate the unit characteristics. Table 1 shows the basis weight, thickness, bulk density, oil agent adhesion amount, filter unit pressure loss, dust retention amount, and initial JIS 11 species collection efficiency of the filter medium.
本発明のエレクトレットろ材は単純な繊維構成により電荷保持性が安定し、従来にくらべて低い圧力損失で高い粉塵捕集効率を得ることが出来る。また、組成が単純であることにより生産性が増加し、低コストなろ材を提供することが出来る。これは一般的な空調用フィルターユニットの分野では非常に有効である。 The electret filter medium of the present invention has stable charge retention due to a simple fiber structure, and can obtain a high dust collection efficiency with a lower pressure loss than in the past. In addition, since the composition is simple, productivity is increased and a low-cost filter medium can be provided. This is very effective in the field of general air conditioning filter units.
Claims (2)
（Ａ）不織布の嵩密度が０．０３〜０．２０ｇ／ｃｍ３であり、かつ厚みが１．５ｍｍ以下であること。
（Ｂ）ガーレ法における曲げ反発性が１００〜５００mgであること。
（Ｃ）ろ材に含まれる油剤の付着量が０．１重量％以下であること。 Among electret filter media, in particular, among the performance evaluation methods defined in JIS B 9908: 2001, in electret filter media used for pleated type filter units in which the initial JIS11 colorimetric collection efficiency exhibits 50% to 99%, An electret filter medium in which the filter medium is a nonwoven fabric composed of a single layer and satisfies the following requirements (A) to (C).
(A) The bulk density of the nonwoven fabric is 0.03 to 0.20 g / cm 3 and the thickness is 1.5 mm or less.
(B) The bending resilience in the Gurley method is 100 to 500 mg.
(C) The adhesion amount of the oil contained in the filter medium is 0.1% by weight or less.
An electret filter medium in which the nonwoven fabric according to claim 1 is a heat-sealed nonwoven fabric containing 60 to 100% by weight of a polyolefin-based heat-sealing fiber.
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2014117668A (en) * | 2012-12-18 | 2014-06-30 | Toyobo Co Ltd | Electret filter medium |
| JP2014208318A (en) * | 2013-04-16 | 2014-11-06 | 東洋紡株式会社 | Antibacterial electret filter medium |
| JP2018061924A (en) * | 2016-10-11 | 2018-04-19 | 倉敷繊維加工株式会社 | Nonwoven fabric filter medium for air filter |
| JP2019130472A (en) * | 2018-01-31 | 2019-08-08 | 東洋紡株式会社 | Staple fiber non-woven fabric |
| JP2019130473A (en) * | 2018-01-31 | 2019-08-08 | 東洋紡株式会社 | Filter unit and exhaust gas treatment system |
-
2011
- 2011-02-23 JP JP2011036953A patent/JP2012170914A/en not_active Withdrawn
Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2014117668A (en) * | 2012-12-18 | 2014-06-30 | Toyobo Co Ltd | Electret filter medium |
| JP2014208318A (en) * | 2013-04-16 | 2014-11-06 | 東洋紡株式会社 | Antibacterial electret filter medium |
| JP2018061924A (en) * | 2016-10-11 | 2018-04-19 | 倉敷繊維加工株式会社 | Nonwoven fabric filter medium for air filter |
| JP2019130472A (en) * | 2018-01-31 | 2019-08-08 | 東洋紡株式会社 | Staple fiber non-woven fabric |
| JP2019130473A (en) * | 2018-01-31 | 2019-08-08 | 東洋紡株式会社 | Filter unit and exhaust gas treatment system |
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| A300 | Withdrawal of application because of no request for examination |
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