JP2016055224A - Electret filter medium - Google Patents
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Abstract
Description
本発明は、気体中の微粒子の捕捉に用いられる高捕集効率、低通気抵抗、長寿命で易プリーツ性を有するエレクトレット濾材に関する。 The present invention relates to an electret filter medium having high collection efficiency, low ventilation resistance, long life, and easy pleating properties used for capturing fine particles in a gas.
従来、平板で取り扱いが容易でさらにはプリーツ加工が可能な剛性を持ち、低通気抵抗で高捕集効率なエレクトレット濾材が種々提案されている。例えば、ポリプロピレンフィルムをエレクトレット化し、ついで開繊カッターで等で微細に割繊して得たエレクトレット化フィルムスプリット繊維と補強ネットを積層した濾材が開示されている（例えば、特許文献１、２）。これらの濾材では、電荷密度の高いエレクトレットフィルムを用いているので、捕集効率は高いが、エレクトレット繊維がフィルムを割繊した形状である為、フィルム繊維同士の重なり部分が生じ、繊維の有効濾過面積および粉塵保持空間が十分でなかった。さらに、特許文献２では熱融着により毛羽立ちや脱落、層間剥離を防止しているが、熱融着時の熱によりエレクレット性能の劣化が生じ、捕集効率が低下するという問題があった。 Conventionally, various electret filter media have been proposed which are flat and easy to handle, have rigidity that allows pleating, and have low ventilation resistance and high collection efficiency. For example, a filter medium in which an electret film split fiber and a reinforcing net obtained by electretizing a polypropylene film and then finely splitting it with an opening cutter or the like is disclosed (for example, Patent Documents 1 and 2). Since these filter media use electret films with high charge density, the collection efficiency is high, but because the electret fibers are in the form of splitting the film, overlapping portions of the film fibers occur, and the fibers are effectively filtered. The area and dust holding space were not enough. Furthermore, in Patent Document 2, fuzzing, dropping, and delamination are prevented by heat fusion, but there is a problem that the electret performance is deteriorated by heat at the time of heat fusion, and the collection efficiency is lowered.
また、フィルムスプリット繊維を使用した以外の高帯電濾材として、摩擦帯電濾材とネットとの積層濾材が開示されている（例えば、特許文献３、４）。これらの濾材は、繊維同士の重なりは無いと考えられるが、濾材表面の毛羽立ちや厚み制御、層間剥離について検討されておらず、濾材としてのハンドリング性に問題があるばかりか、プリーツ加工時の加工性、厚みや毛羽立ちによる構造圧損が大きいという問題があった。 Further, as a highly charged filter medium other than using film split fibers, a laminated filter medium of a frictionally charged filter medium and a net is disclosed (for example, Patent Documents 3 and 4). These filter media are thought to have no overlap between fibers, but the fuzz and thickness control of the filter media surface, delamination have not been studied, and there are problems in handling properties as a filter media, as well as processing during pleating There is a problem that structural pressure loss due to property, thickness and fluffing is large.
本発明は、低通気抵抗で高い粒子捕集効率を発現し、ダスト負荷時の圧損上昇が緩やかで、プリーツ加工性に優れユニット加工時の通気抵抗、ダスト保持性に優れたエレクトレット濾材を提供するものである。 The present invention provides an electret filter medium that expresses high particle collection efficiency with low ventilation resistance, has a moderate increase in pressure loss when dust is loaded, has excellent pleat processability, and has excellent ventilation resistance and unit dust retention during unit processing. Is.
本発明は、以下のとおりである。
１．上流側に位置するポリエステル繊維サーマルボンド不織布からなる密度が０．０３ｇ／ｃｃ〜０．２５ｇ／ｃｃの熱融着繊維層と下流側に位置する摩擦帯電濾材からなる密度が０．０３ｇ／ｃｃ〜０．０９ｇ／ｃｃのエレクトレット層で構成されていることを特徴とするエレクトレット濾材。
２．前記熱融着繊維層の密度に勾配があり、上流側が粗、下流側が密となっている上記１に記載のエレクトレット濾材。
３．上記１または２に記載の濾材にプリーツ加工を施し、枠体に保持してなるフィルタユニット。
The present invention is as follows.
1. Density of 0.03 g / cc to 0.25 g / cc of a heat-bonded fiber layer composed of a polyester fiber thermal bond nonwoven fabric located on the upstream side and 0.03 g / cc to density of a frictionally charged filter medium located on the downstream side. An electret filter medium comprising an electret layer of 0.09 g / cc.
2. 2. The electret filter medium according to 1 above, wherein the density of the heat-bonding fiber layer has a gradient, the upstream side is coarse, and the downstream side is dense.
3. A filter unit obtained by subjecting the filter medium according to 1 or 2 above to pleating and holding the filter medium.
以下に本発明を詳細に説明する。
本発明のエレクトレット濾材は、上流側に位置するポリエステル繊維からなる熱融着繊維層と、下流側に位置する摩擦帯電濾材よりなるエレクトレット層で構成される。
The present invention is described in detail below.
The electret filter medium of the present invention includes a heat-fused fiber layer made of polyester fibers located on the upstream side and an electret layer made of a frictionally charged filter medium located on the downstream side.
熱融着繊維層は、ポリエステル繊維からなるサーマルボンド不織布であり、濾材に剛性を付与し、形状保持性を向上させる。ポリエステル繊維としては、ポリエチレンテレフタレート、ポリブチレンテレフタレート等のポリエステル系樹脂を使用した単成分繊維または芯鞘状に複合した複合繊維を用いることができる。ポリエステル繊維を使用するのはエレクトレット層を構成する繊維にも使用されているため、親和性が良いという利点があるからである。 The heat-sealing fiber layer is a thermal bond nonwoven fabric made of polyester fibers, imparts rigidity to the filter medium, and improves shape retention. As the polyester fiber, a single component fiber using a polyester resin such as polyethylene terephthalate or polybutylene terephthalate or a composite fiber combined in a core-sheath shape can be used. The polyester fiber is used because it is also used for fibers constituting the electret layer, and therefore has an advantage of good affinity.
熱融着繊維層の密度は、０．０２ｇ／ｃｃ〜０．２５ｇ／ｃｃであり、好ましくは０．０３ｇ／ｃｃ〜０．２ｇ／ｃｃである。密度がこの範囲であると、熱融着繊維層は、濾材に剛性を付与し、粉塵保持空間を十分に確保することが出来るからである。密度が０．０２ｇ／ｃｃより小さいと、剛性が不足するために、シートとして取り扱うのが困難である。密度が０．２５ｇ／ｃｃを超えると、濾材の通気抵抗が高くなり、粉塵保持空間が十分でなくなるため、ダスト負荷時の通気抵抗上昇が早くなる。 The density of the heat-fusible fiber layer is 0.02 g / cc to 0.25 g / cc, and preferably 0.03 g / cc to 0.2 g / cc. This is because, when the density is in this range, the heat-bonding fiber layer can impart rigidity to the filter medium and sufficiently secure the dust holding space. If the density is less than 0.02 g / cc, the rigidity is insufficient, and it is difficult to handle as a sheet. When the density exceeds 0.25 g / cc, the ventilation resistance of the filter medium is increased, and the dust holding space is not sufficient, so that the increase of the ventilation resistance during dust load is accelerated.
熱融着繊維層の密度は、上流側が粗、下流側が密の勾配を有することが好ましい。密度勾配を有することにより、大きな捕集物は上流側にて捕捉され、小さな捕集物は下流側にて捕集されることになり、ダスト負荷時の圧損上昇を抑制する作用がある。また、熱融着繊維層の下流側であるエレクトレット層との境界側の密度が高いことにより、エレクトレット層と一体化した際に、接着がより強固なものとなる。 It is preferable that the density of the heat-fusible fiber layer has a rough gradient on the upstream side and a dense gradient on the downstream side. By having a density gradient, a large collected material is captured on the upstream side, and a small collected material is collected on the downstream side, which has an action of suppressing an increase in pressure loss during dust loading. Moreover, when the density of the boundary side with the electret layer which is the downstream of a heat-fusion fiber layer is high, when integrated with an electret layer, adhesion | attachment becomes stronger.
密度勾配を有する熱融着繊維層は、例えばエアースルー方式のサーマルボンド法により得ることが出来る。カード機等で形成されたフリースをネット上に乗せて搬送し、フリースに熱風を通過させて融着させる方法であり、熱風の上流側を粗な構造に、下流側（ネット側）を密な構造にすることで、密度勾配を有するサーマルボンド不織布が得られる。 The heat-fused fiber layer having a density gradient can be obtained by, for example, an air-through thermal bond method. A fleece formed by a card machine or the like is transported on a net, and hot air is passed through the fleece to fuse it. The upstream side of the hot air has a rough structure and the downstream side (net side) is dense. By making the structure, a thermal bond nonwoven fabric having a density gradient can be obtained.
エレクトレット層は、ポリエステル系繊維を少なくとも２０質量％とポリオレフィン系繊維を少なくとも３０質量％含み、摩擦によりエレクトレット化された摩擦帯電濾材からなり、該摩擦帯電濾材中にリン原子および／またはイオウ原子が３００ｐｐｍ以上含有されていることが好ましい。これらリン原子および／またはイオウ原子は、ホスフィン酸化合物および／またはスルホン酸化合物としてポリエステル分子鎖と共重合して存在していることが好ましい。このような摩擦帯電濾材は、例えば特開２００５−２９６８２５号公報に開示されているような公知の方法にて作成することができ、難燃性と濾過性能に優れている。 The electret layer is composed of a frictionally charged filter medium containing at least 20% by mass of polyester fibers and at least 30% by mass of polyolefin fibers, and electretized by friction, and phosphorus atoms and / or sulfur atoms are 300 ppm in the frictionally charged filter medium. It is preferable that it is contained above. These phosphorus atoms and / or sulfur atoms are preferably present as a phosphinic acid compound and / or sulfonic acid compound copolymerized with the polyester molecular chain. Such a frictionally charged filter medium can be prepared by a known method as disclosed in, for example, JP-A-2005-296825, and is excellent in flame retardancy and filtration performance.
エレクトレット層の密度は、０．０３ｇ／ｃｃ〜０．０９ｇ／ｃｃである。密度が０．０３ｇ／ｃｃよりも低い場合は、ろ材の厚みが大きくなり、ユニット形状に加工した際に構造抵抗が大きくなる。密度が０．０９ｇ／ｃｃよりも高い場合は、熱融着繊維層と積層した際に、エレクトレット層の繊維がより多く熱融着繊維層の繊維と密着することとなる。その結果、熱融着繊維層の繊維と密着した状態のエレクトレット層の繊維は、実質的に集塵に寄与しないため、フィルター性能の低下を招く。 The density of the electret layer is 0.03 g / cc to 0.09 g / cc. When the density is lower than 0.03 g / cc, the thickness of the filter medium increases, and the structural resistance increases when processed into a unit shape. When the density is higher than 0.09 g / cc, when laminated with the heat-bonding fiber layer, more fibers in the electret layer are in close contact with the fibers in the heat-bonding fiber layer. As a result, since the fibers of the electret layer in close contact with the fibers of the heat-fusible fiber layer do not substantially contribute to dust collection, the filter performance is deteriorated.
上流側の熱融着繊維層と下流側のエレクトレット層の積層方法は、単に積層するのみでもよく、その場合でも互いの繊維が交絡することによりある程度の接着力を得られる。また、ニードルパンチ加工等により、各層を交絡させて積層しても良い。必要に応じて、熱可塑性樹脂等の接着成分を使用して接着しても良い。例えば、オレフィン系やゴム系の熱可塑性樹脂を加熱し、熱融着繊維層に塗布した後、エレクトレット層と張り合わせる方法で接着しても良い。この方法は、接着時の圧力や熱による負荷が低く、熱融着繊維層の密度低下やエレクトレット層の性能低下を低く抑えることができる。 The method of laminating the upstream heat-bonding fiber layer and the downstream electret layer may be simply laminating, and even in that case, a certain degree of adhesion can be obtained by entanglement of the fibers. Further, the layers may be entangled and stacked by needle punching or the like. If necessary, an adhesive component such as a thermoplastic resin may be used for bonding. For example, an olefin-based or rubber-based thermoplastic resin may be heated and applied to the heat-fusible fiber layer and then bonded to the electret layer. In this method, the load due to pressure and heat at the time of bonding is low, and the decrease in the density of the heat-bonded fiber layer and the decrease in the performance of the electret layer can be suppressed to a low level.
本発明のエレクトレット濾材は、補強用として熱融着繊維層を含んでいるので容易にプリーツ加工してフィルタユニットとして使用することができる。プリーツ加工を施すことにより、同じ通風開口部でも濾過面積を大幅に増大することができ、フィルタの捕集効率の向上と低圧損化、およびダスト負荷時の圧損上昇の抑制が可能である。 Since the electret filter medium of the present invention includes a heat-bonded fiber layer for reinforcement, it can be easily pleated and used as a filter unit. By applying the pleating process, the filtration area can be significantly increased even in the same ventilation opening, and it is possible to improve the collection efficiency of the filter, to reduce the pressure loss, and to suppress the pressure loss increase during dust loading.
以下、実施例により本発明を詳細に説明する。 Hereinafter, the present invention will be described in detail by way of examples.
（濾材厚み、密度）
濾材の厚みは荷重７ｇ/ｃｍ２のシックネスゲージにて測定した。測定した濾材の厚みの値および濾材１ｍ２サンプルの重量の測定値より、ろ材の密度を算出した。
(Thickness and density of filter media)
The thickness of the filter medium was measured with a thickness gauge with a load of 7 g / cm 2 . From the measured value of the thickness of the filter medium and the measured value of the weight of the 1 m 2 sample of the filter medium, the density of the filter medium was calculated.
（通気抵抗）
濾材を内径５０ｍｍφ（断面積０．００２ｍ２）のダクト内に設置し、空気濾過速度が１０ｃｍ／秒になるよう大気を通気させ、濾材上流、下流の静圧差を差圧計にて読み取り、通気抵抗とした。
(Ventilation resistance)
The filter medium is installed in a duct with an inner diameter of 50 mmφ (cross-sectional area of 0.002 m 2 ), and the atmosphere is vented so that the air filtration speed is 10 cm / sec. The difference in static pressure between the upstream and downstream of the filter medium is read with a differential pressure gauge It was.
（粒子捕集効率）
濾材を内径５０ｍｍφ（断面積０．００２ｍ２）のダクト内に設置し、空気濾過速度が１０ｃｍ／秒になるよう大気を通気させ、濾材上流、下流の大気塵に含まれる０．３〜０．５μｍ粒子の個数濃度をパーティクルカウンター（例：ＲＩＯＮ ＫＣ−０１Ａ）にて計測し、次式にて粒子捕集効率を算出した。
粒子捕集効率（％）＝［１−（下流側濃度／上流側濃度）］×１００
(Particle collection efficiency)
The filter medium is installed in a duct having an inner diameter of 50 mmφ (cross-sectional area of 0.002 m 2 ), and the atmosphere is vented so that the air filtration speed becomes 10 cm / sec. The number concentration of 5 μm particles was measured with a particle counter (eg, RION KC-01A), and the particle collection efficiency was calculated by the following formula.
Particle collection efficiency (%) = [1− (downstream concentration / upstream concentration)] × 100
（ダスト保持量）
濾材をダクト内に設置し、空気濾過速度が５０ｃｍ／秒になるよう大気を通気させ、濾材上流側から、ＪＩＳ１５種粉塵を７０ｍｇ／ｍ３の濃度にて負荷し、通気抵抗が初期から１５０Ｐａ上昇するまで粉塵を負荷した。この時の濾材単位面積あたりのダスト捕集量をダスト保持量とした。
(Dust retention)
The filter medium is installed in the duct, the atmosphere is vented so that the air filtration speed is 50 cm / sec, JIS15 seed dust is loaded at a concentration of 70 mg / m3 from the upstream side of the filter medium, and the ventilation resistance increases by 150 Pa from the beginning. Dust loaded up to. The amount of dust collected per unit area of the filter medium at this time was defined as the amount of dust retained.
（プリーツ加工性）
エレクトレット濾材をプリーツ加工し、加工性を確認して○、△、×の３段階で評価した。剛性が高いほど、プリーツ加工性は良くなる傾向にある。
○：プリーツ加工性が良好であり、加工後も折りぐせが付いて折りたたみ構造を維持している。
△：プリーツ加工は実施できるが、折りぐせが付きにくい、または、折りぐせが付いてもプリーツの山形状が広がり、形状の保持性が不十分である。（○と×の中間の評価）
×：折りぐせが付かない、または折りぐせが付いても、ろ材の剛性が低く、プリーツ形状を保持しない。
(Pleated workability)
The electret filter medium was pleated, and the processability was confirmed and evaluated in three stages of ○, Δ, and ×. The higher the stiffness, the better the pleatability.
○: Pleated workability is good, and the folded structure is maintained even after processing to maintain the folding structure.
Δ: Pleating can be performed, but it is difficult to fold, or even if folds are attached, the mountain shape of the pleats spreads and the shape retention is insufficient. (Evaluation between ○ and ×)
X: Even if it does not fold, even if it folds, the rigidity of a filter medium is low and a pleat shape is not hold | maintained.
［実施例１］
リンを含有する難燃性の円形断面ポリエステル繊維（繊度：１．７ｄｔｅｘ、繊維長：４４ｍｍ）と円形断面ポリプロピレン繊維（繊度：２．２ｄｔｅｘ、繊維長：５１ｍｍ）を１：１の重量比で混綿、カーディングして得られた目付２５ｇ／ｍ２の混繊ウェブを、スパンボンド不織布（素材：ポリプロピレン、繊度：５ｄｔｅｘ、目付：１５ｇ／ｍ２）上に乗せて搬送し、ニードルパンチ加工により帯電加工を施してエレクトレット層を得た。
カード機によりポリエステル短繊維Ａ（繊度：４．４ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１５０℃）ポリエステル））、ポリエステル短繊維Ｂ（繊度：２２ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１９０℃）ポリエステル））、ポリエステル短繊維Ｃ（繊度：１７ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：レギュラーポリエステル１００％）をポリエステル短繊維Ａ：Ｂ：Ｃを重量比３：１４：３で混綿しフリースを形成し、熱ロールにて繊維同士を融着させることにより、目付６５ｇ／ｍ２のサーマルボンド不織布を作成し、密度０．０４ｇ／ｃｃの熱融着繊維層を得た。
得られたエレクトレット層と熱融着繊維層を積層して、エレクトレット濾材を作成した。積層は、ゴム系の熱可塑性樹脂を加熱し、熱融着繊維層の密面に吹き付け塗布した後、エレクトレット層のスパンボンド不織布側ではない面と張り合わせる方法で実施した。
[Example 1]
Flame retardant circular cross-section polyester fiber (fineness: 1.7 dtex, fiber length: 44 mm) and circular cross-section polypropylene fiber (fineness: 2.2 dtex, fiber length: 51 mm) containing phosphorus in a weight ratio of 1: 1 The mixed fiber web having a basis weight of 25 g / m 2 obtained by carding is carried on a spunbonded nonwoven fabric (material: polypropylene, fineness: 5 dtex, basis weight: 15 g / m 2 ), and charged by needle punching. Processing was performed to obtain an electret layer.
Polyester short fiber A (fineness: 4.4 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (150 ° C.) polyester)), polyester short fiber by card machine B (fineness: 22 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (190 ° C.) polyester)), polyester short fiber C (fineness: 17 dtex, fiber length) : 51-76 mm, fiber structure: 100% regular polyester) by mixing polyester short fibers A: B: C at a weight ratio of 3: 14: 3 to form fleece, and fusing the fibers together with a hot roll A thermal bond nonwoven fabric with a basis weight of 65 g / m 2 was prepared, and a heat-bonded fiber layer having a density of 0.04 g / cc was obtained.
The obtained electret layer and the heat sealing | fusion fiber layer were laminated | stacked, and the electret filter medium was created. Lamination was performed by a method in which a rubber-based thermoplastic resin was heated and sprayed onto the dense surface of the heat-bonding fiber layer, and then bonded to the surface of the electret layer that is not on the spunbond nonwoven fabric side.
［実施例２］
リンを含有する難燃性の円形断面ポリエステル繊維（繊度：１．７ｄｔｅｘ、繊維長：４４ｍｍ）と円形断面ポリプロピレン繊維（繊度：２．２ｄｔｅｘ、繊維長：５１ｍｍ）を１：１の重量比で混綿、カーディングして得られた目付２５ｇ／ｍ２の混繊ウェブを、スパンボンド不織布（素材：ポリプロピレン、繊度：５ｄｔｅｘ、目付：１５ｇ／ｍ２）上に乗せて搬送し、ニードルパンチ加工により帯電加工を施してエレクトレット層を得た。
カード機によりポリエステル短繊維Ａ（繊度：４．４ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１５０℃）ポリエステル））、ポリエステル短繊維Ｂ（繊度：２２ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１９０℃）ポリエステル））、ポリエステル短繊維Ｃ（繊度：１７ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：レギュラーポリエステル１００％）をポリエステル短繊維Ａ：Ｂ：Ｃを重量比３：１４：３で混綿しフリースを形成し、熱ロールにて繊維同士を融着させることにより、目付６５ｇ／ｍ２のサーマルボンド不織布を作成し、密度０．２ｇ／ｃｃの熱融着繊維層を得た。
得られたエレクトレット層と熱融着繊維層を積層して、エレクトレット濾材を作成した。積層は、ゴム系の熱可塑性樹脂を加熱し、熱融着繊維層の密面に吹き付け塗布した後、エレクトレット層のスパンボンド不織布側ではない面と張り合わせる方法で実施した。
[Example 2]
Flame retardant circular cross-section polyester fiber (fineness: 1.7 dtex, fiber length: 44 mm) and circular cross-section polypropylene fiber (fineness: 2.2 dtex, fiber length: 51 mm) containing phosphorus in a weight ratio of 1: 1 The mixed fiber web having a basis weight of 25 g / m 2 obtained by carding is carried on a spunbonded nonwoven fabric (material: polypropylene, fineness: 5 dtex, basis weight: 15 g / m 2 ), and charged by needle punching. Processing was performed to obtain an electret layer.
Polyester short fiber A (fineness: 4.4 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (150 ° C.) polyester)), polyester short fiber by card machine B (fineness: 22 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (190 ° C.) polyester)), polyester short fiber C (fineness: 17 dtex, fiber length) : 51-76 mm, fiber structure: 100% regular polyester) by mixing polyester short fibers A: B: C at a weight ratio of 3: 14: 3 to form fleece, and fusing the fibers together with a hot roll A thermal bond nonwoven fabric with a basis weight of 65 g / m 2 was prepared, and a heat-bonded fiber layer having a density of 0.2 g / cc was obtained.
The obtained electret layer and the heat sealing | fusion fiber layer were laminated | stacked, and the electret filter medium was created. Lamination was performed by a method in which a rubber-based thermoplastic resin was heated and sprayed onto the dense surface of the heat-bonding fiber layer, and then bonded to the surface of the electret layer that is not on the spunbond nonwoven fabric side.
［実施例３］
リンを含有する難燃性の円形断面ポリエステル繊維（繊度：１．７ｄｔｅｘ、繊維長：４４ｍｍ）と円形断面ポリプロピレン繊維（繊度：２．２ｄｔｅｘ、繊維長５１ｍｍ）を１：１の重量比で混綿、カーディングして得られた目付２５ｇ／ｍ２の混繊ウェブを、スパンボンド不織布（素材：ポリプロピレン、繊度：５ｄｔｅｘ、目付：１５ｇ／ｍ２）上に乗せて搬送し、ニードルパンチ加工により帯電加工をを施してエレクトレット層を得た。
カード機によりポリエステル短繊維Ａ（繊度：４．４ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１５０℃）ポリエステル））、ポリエステル短繊維Ｂ（繊度：２２ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１９０℃）ポリエステル））、ポリエステル短繊維Ｃ（繊度：１７ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：レギュラーポリエステル１００％）をポリエステル短繊維Ａ：Ｂ：Ｃを重量比３：１４：３で混綿しフリースを形成し、エアースルー方式にて繊維同士を融着させることにより、目付６５ｇ／ｍ２のサーマルボンド不織布を作成し、密度０．０４ｇ／ｃｃの熱融着繊維層を得た。
得られたエレクトレット層と熱融着繊維層を積層して、エレクトレット濾材を作成した。積層は、ゴム系の熱可塑性樹脂を加熱し、熱融着繊維層の密面に吹き付け塗布した後、エレクトレット層のスパンボンド不織布側ではない面と張り合わせる方法で実施した。
[Example 3]
Cotton blended with flame retardant circular cross-section polyester fiber (fineness: 1.7 dtex, fiber length: 44 mm) and circular cross-section polypropylene fiber (fineness: 2.2 dtex, fiber length 51 mm) containing phosphorus in a weight ratio of 1: 1. A mixed fiber web having a basis weight of 25 g / m 2 obtained by carding is transported on a spunbonded nonwoven fabric (material: polypropylene, fineness: 5 dtex, basis weight: 15 g / m 2 ), and charged by needle punching. To obtain an electret layer.
Polyester short fiber A (fineness: 4.4 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (150 ° C.) polyester)), polyester short fiber by card machine B (fineness: 22 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (190 ° C.) polyester)), polyester short fiber C (fineness: 17 dtex, fiber length) : 51-76mm, fiber structure: regular polyester 100%) short polyester fiber A: B: C is blended at a weight ratio of 3: 14: 3 to form a fleece, and the fibers are fused together by an air-through method. Thus, a thermal bond nonwoven fabric having a basis weight of 65 g / m 2 was prepared, and a heat-bonded fiber layer having a density of 0.04 g / cc was obtained.
The obtained electret layer and the heat sealing | fusion fiber layer were laminated | stacked, and the electret filter medium was created. Lamination was performed by a method in which a rubber-based thermoplastic resin was heated and sprayed onto the dense surface of the heat-bonding fiber layer, and then bonded to the surface of the electret layer that is not on the spunbond nonwoven fabric side.
［比較例１］
リンを含有する難燃性の円形断面ポリエステル繊維（繊度：１．７ｄｔｅｘ、繊維長：４４ｍｍ）と円形断面ポリプロピレン繊維（繊度：２．２ｄｔｅｘ、繊維長５１ｍｍ）を１：１の重量比で混綿、カーディングして得られた目付２５ｇ／ｍ２の混繊ウェブを、スパンボンド不織布（素材：ポリプロピレン、繊度：５ｄｔｅｘ、目付：１５ｇ／ｍ２）上に乗せて搬送し、ニードルパンチ加工により帯電加工を施してエレクトレット層を得た。
カード機によりポリエステル短繊維Ａ（繊度：４．４ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１５０℃）ポリエステル））、ポリエステル短繊維Ｂ（繊度：２２ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１９０℃）ポリエステル））、ポリエステル短繊維Ｃ（繊度：１７ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：レギュラーポリエステル１００％）をポリエステル短繊維Ａ：Ｂ：Ｃを重量比３：１４：３で混綿しフリースを形成し、熱ロールにて繊維同士を融着させることにより、目付６５ｇ／ｍ２のサーマルボンド不織布を作成し、密度０．０１ｇ／ｃｃの熱融着繊維層を得た。
得られたエレクトレット層と熱融着繊維層を積層して、エレクトレット濾材を作成した。積層は、ゴム系の熱可塑性樹脂を加熱し、熱融着繊維層の密面に吹き付け塗布した後、エレクトレット層のスパンボンド不織布側ではない面と張り合わせる方法で実施した。
[Comparative Example 1]
Cotton blended with flame retardant circular cross-section polyester fiber (fineness: 1.7 dtex, fiber length: 44 mm) and circular cross-section polypropylene fiber (fineness: 2.2 dtex, fiber length 51 mm) containing phosphorus in a weight ratio of 1: 1. A mixed fiber web having a basis weight of 25 g / m 2 obtained by carding is transported on a spunbonded nonwoven fabric (material: polypropylene, fineness: 5 dtex, basis weight: 15 g / m 2 ), and charged by needle punching. To obtain an electret layer.
Polyester short fiber A (fineness: 4.4 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (150 ° C.) polyester)), polyester short fiber by card machine B (fineness: 22 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (190 ° C.) polyester)), polyester short fiber C (fineness: 17 dtex, fiber length) : 51-76 mm, fiber structure: 100% regular polyester) by mixing polyester short fibers A: B: C at a weight ratio of 3: 14: 3 to form fleece, and fusing the fibers together with a hot roll A thermal bond nonwoven fabric having a basis weight of 65 g / m 2 was prepared, and a heat-bonded fiber layer having a density of 0.01 g / cc was obtained.
The obtained electret layer and the heat sealing | fusion fiber layer were laminated | stacked, and the electret filter medium was created. Lamination was performed by a method in which a rubber-based thermoplastic resin was heated and sprayed onto the dense surface of the heat-bonding fiber layer, and then bonded to the surface of the electret layer that is not on the spunbond nonwoven fabric side.
［比較例２］
リンを含有する難燃性の円形断面ポリエステル繊維（繊度：１．７ｄｔｅｘ、繊維長：４４ｍｍ）と円形断面ポリプロピレン繊維（繊度：２．２ｄｔｅｘ、繊維長：５１ｍｍ）を１：１の重量比で混綿、カーディングして得られた目付２５ｇ／ｍ２の混繊ウェブを、スパンボンド不織布（素材：ポリプロピレン、繊度：５ｄｔｅｘ、目付：１５ｇ／ｍ２）上に乗せて搬送し、ニードルパンチ加工により帯電加工を施してエレクトレット層を得た。
カード機によりポリエステル短繊維Ａ（繊度：４．４ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１５０℃）ポリエステル））、ポリエステル短繊維Ｂ（繊度：２２ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１９０℃）ポリエステル））、ポリエステル短繊維Ｃ（繊度：１７ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：レギュラーポリエステル１００％）をポリエステル短繊維Ａ：Ｂ：Ｃを重量比３：１４：３で混綿しフリースを形成し、熱ロールにて繊維同士を融着させることにより、目付６５ｇ／ｍ２のサーマルボンド不織布を作成し、密度０．５ｇ／ｃｃの熱融着繊維層を得た。
得られたエレクトレット層と熱融着繊維層を積層して、エレクトレット濾材を作成した。積層は、ゴム系の熱可塑性樹脂を加熱し、熱融着繊維層の密面に吹き付け塗布した後、エレクトレット層のスパンボンド不織布側ではない面と張り合わせる方法で実施した。
[Comparative Example 2]
Flame retardant circular cross-section polyester fiber (fineness: 1.7 dtex, fiber length: 44 mm) and circular cross-section polypropylene fiber (fineness: 2.2 dtex, fiber length: 51 mm) containing phosphorus in a weight ratio of 1: 1 The mixed fiber web having a basis weight of 25 g / m 2 obtained by carding is carried on a spunbonded nonwoven fabric (material: polypropylene, fineness: 5 dtex, basis weight: 15 g / m 2 ), and charged by needle punching. Processing was performed to obtain an electret layer.
Polyester short fiber A (fineness: 4.4 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (150 ° C.) polyester)), polyester short fiber by card machine B (fineness: 22 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (190 ° C.) polyester)), polyester short fiber C (fineness: 17 dtex, fiber length) : 51-76 mm, fiber structure: 100% regular polyester) by mixing polyester short fibers A: B: C at a weight ratio of 3: 14: 3 to form fleece, and fusing the fibers together with a hot roll A thermal bond nonwoven fabric having a basis weight of 65 g / m 2 was prepared, and a heat-bonded fiber layer having a density of 0.5 g / cc was obtained.
The obtained electret layer and the heat sealing | fusion fiber layer were laminated | stacked, and the electret filter medium was created. Lamination was performed by a method in which a rubber-based thermoplastic resin was heated and sprayed onto the dense surface of the heat-bonding fiber layer, and then bonded to the surface of the electret layer that is not on the spunbond nonwoven fabric side.
［比較例３］
リンを含有する難燃性の円形断面ポリエステル繊維（繊度：１．７ｄｔｅｘ、繊維長：４４ｍｍ）と円形断面ポリプロピレン繊維（繊度：２．２ｄｔｅｘ、繊維長：５１ｍｍ）を１：１の重量比で混綿、カーディングして得られた目付２５ｇ／ｍ２の混繊ウェブを、スパンボンド不織布（素材：ポリプロピレン、繊度：５ｄｔｅｘ、目付：１５ｇ／ｍ２）上に乗せて搬送し、ニードルパンチ加工により帯電加工を施してエレクトレット層を作成した。
このエレクトレット層にホットメルト樹脂を吹き付け、ポリプロピレン製ネット（繊度：１４４４ｄｔｅｘ、目開き：３ｍｍ×５ｍｍ、目付：５５ｇ／ｍ2）を積層してエレクトレット濾材を作成した。
[Comparative Example 3]
Flame retardant circular cross-section polyester fiber (fineness: 1.7 dtex, fiber length: 44 mm) and circular cross-section polypropylene fiber (fineness: 2.2 dtex, fiber length: 51 mm) containing phosphorus in a weight ratio of 1: 1 The mixed fiber web having a basis weight of 25 g / m 2 obtained by carding is carried on a spunbonded nonwoven fabric (material: polypropylene, fineness: 5 dtex, basis weight: 15 g / m 2 ), and charged by needle punching. The electret layer was created by processing.
A hot melt resin was sprayed on the electret layer, and a polypropylene net (fineness: 1444 dtex, aperture: 3 mm × 5 mm, basis weight: 55 g / m 2 ) was laminated to prepare an electret filter medium.
［比較例４］
リンを含有する難燃性の円形断面ポリエステル繊維（繊度：１．７ｄｔｅｘ、繊維長：４４ｍｍ）と円形断面ポリプロピレン繊維（繊度：２．２ｄｔｅｘ、繊維長：５１ｍｍ）を１：１の重量比で混綿、カーディングして得られた目付２５ｇ／ｍ２の混繊ウェブを、スパンボンド不織布（素材：ポリプロピレン、繊度：５ｄｔｅｘ、目付：１５ｇ／ｍ２）上に乗せて搬送し、ニードルパンチ加工により帯電加工を施してエレクトレット層を得た。
カード機によりポリエステル短繊維Ａ（繊度：４．４ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１５０℃）ポリエステル））、ポリエステル短繊維Ｂ（繊度：２２ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：芯鞘構造（芯部：レギュラーポリエステル、鞘部：低融点（１９０℃）ポリエステル））、ポリエステル短繊維Ｃ（繊度：１７ｄｔｅｘ、繊維長：５１〜７６ｍｍ、繊維構造：レギュラーポリエステル１００％）をポリエステル短繊維Ａ：Ｂ：Ｃを重量比３：１４：３で混綿しフリースを形成し、熱ロールにて繊維同士を融着させることにより、目付６５ｇ／ｍ２のサーマルボンド不織布を作成し、密度０．０４ｇ／ｃｃの熱融着繊維層を得た。
得られたエレクトレット層と熱融着繊維層を積層して、エレクトレット濾材を作成した。積層は、ゴム系の熱可塑性樹脂を加熱し、熱融着繊維層の密面に吹き付け塗布した後、エレクトレット層のスパンボンド不織布側ではない面と張り合わせる方法で実施した。
[Comparative Example 4]
Flame retardant circular cross-section polyester fiber (fineness: 1.7 dtex, fiber length: 44 mm) and circular cross-section polypropylene fiber (fineness: 2.2 dtex, fiber length: 51 mm) containing phosphorus in a weight ratio of 1: 1 The mixed fiber web having a basis weight of 25 g / m 2 obtained by carding is carried on a spunbonded nonwoven fabric (material: polypropylene, fineness: 5 dtex, basis weight: 15 g / m 2 ), and charged by needle punching. Processing was performed to obtain an electret layer.
Polyester short fiber A (fineness: 4.4 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (150 ° C.) polyester)), polyester short fiber by card machine B (fineness: 22 dtex, fiber length: 51 to 76 mm, fiber structure: core-sheath structure (core part: regular polyester, sheath part: low melting point (190 ° C.) polyester)), polyester short fiber C (fineness: 17 dtex, fiber length) : 51-76 mm, fiber structure: 100% regular polyester) by mixing polyester short fibers A: B: C at a weight ratio of 3: 14: 3 to form fleece, and fusing the fibers together with a hot roll A thermal bond nonwoven fabric with a basis weight of 65 g / m 2 was prepared, and a heat-bonded fiber layer having a density of 0.04 g / cc was obtained.
The obtained electret layer and the heat sealing | fusion fiber layer were laminated | stacked, and the electret filter medium was created. Lamination was performed by a method in which a rubber-based thermoplastic resin was heated and sprayed onto the dense surface of the heat-bonding fiber layer, and then bonded to the surface of the electret layer that is not on the spunbond nonwoven fabric side.
実施例および比較例の濾材の評価結果を表１に示す。実施例の濾材では低通気抵抗、高捕集効率、高ダスト保持量であった。一方、比較例１では、熱融着繊維層の密度が小さいため、捕集効率が低かった。また、剛性が低いためプリーツ形状のフィルタに加工することが困難であった。比較例２では、熱融着繊維層の密度が大きく、通気抵抗が高くなり、ダスト保持量も低下していた。比較例３では、熱融着繊維層がないために、ダスト保持量と剛性が低下していた。比較例４では、エレクトレット層の密度が大きく、捕集効率の割りに通気抵抗が高く、ダスト保持量も低い。 Table 1 shows the evaluation results of the filter media of Examples and Comparative Examples. The filter medium of the example had low ventilation resistance, high collection efficiency, and high dust retention. On the other hand, in the comparative example 1, since the density of the heat-fusible fiber layer was small, the collection efficiency was low. Further, since the rigidity is low, it has been difficult to process into a pleated filter. In Comparative Example 2, the density of the heat-sealing fiber layer was large, the ventilation resistance was high, and the dust holding amount was also reduced. In Comparative Example 3, the amount of dust retained and the rigidity were reduced because there was no heat-bonded fiber layer. In Comparative Example 4, the density of the electret layer is large, the ventilation resistance is high for the collection efficiency, and the dust holding amount is also low.
本発明のエレクトレット濾材は、低通気抵抗、高捕集効率、高ダスト保持量であり、プリーツ形状のフィルタユニットでも高性能を発揮できる。また、加工時の樹脂脱落や揮発性有機化合物の発生もなく安心して使用でき、環境汚染の少ないエレクトレット濾材として産業上有用である。 The electret filter medium of the present invention has low ventilation resistance, high collection efficiency, and a high dust holding amount, and can exhibit high performance even with a pleated filter unit. Moreover, it can be used safely without any resin dropping or volatile organic compounds during processing, and it is industrially useful as an electret filter medium with little environmental pollution.
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| JP2014182193A JP2016055224A (en) | 2014-09-08 | 2014-09-08 | Electret filter medium |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2021109118A (en) * | 2020-01-07 | 2021-08-02 | 株式会社エイ・エム・シイ | Filter of cartridge type filter element for dust collection and method for manufacturing the same |
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Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2021109118A (en) * | 2020-01-07 | 2021-08-02 | 株式会社エイ・エム・シイ | Filter of cartridge type filter element for dust collection and method for manufacturing the same |
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