JP3331290B2 - Filter material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filter material, and more particularly to a filter material used for a ventilation fan, a range hood and the like.

[0002]

2. Description of the Related Art Generally, filter materials are used in ventilation fans and range hoods to collect oily smoke and dust generated during cooking. In a kitchen or the like, the filter material may be exposed to high heat or high temperature oil fumes.To prevent combustion, conventionally, filter materials are made from flame-retardant fibers such as polyclar fiber and modacrylic fiber. Those bonded with a flame-retardant resin such as a vinyl resin have been used.

[0003] However, the above-mentioned conventional filter material is significantly shrunk when it is subjected to high heat due to a flame generated in a cooking place or the like or when it comes into contact with the flame instantaneously.
In some cases, holes were formed due to melting and the function as a filter material was lost. Further, oil may adhere to the filter material used for the ventilation fan or the range hood, but when the oil comes into contact with a flame, the attached oil may be ignited and the filter material may be burned.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in order to solve the above-mentioned drawbacks of the prior art, and is intended to provide a hole even if it comes into contact with a flame generated in a cooking place instantaneously or receives high heat. It is an object of the present invention to provide a filter material that hardly burns out and that extinguishes the fire without burning the filter material itself even if the oil ignites by contacting the flame with the oil attached.

[0005]

According to the present invention, there is provided a filter material according to the present invention, wherein a fibrous web mainly composed of cellulose fibers is bonded with a flame-retardant thermoplastic resin containing a metal hydroxide. Can be achieved.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The filter material of the present invention is made of a fibrous web mainly composed of cellulose fibers, preferably flame-retardant cellulose fibers. It is hard to make holes. In addition, since the flame-retardant thermoplastic resin containing metal hydroxide is used to bond the fibers, the filter material itself does not burn up even if oil etc. adheres, and it is carbonized by receiving high heat. Nevertheless, the bond can be maintained, a high porosity, and a strong filter material can be obtained. In addition, since the filter material is bonded with a thermoplastic resin, the filter material can be attached to a range hood, a ventilation fan, or the like by a heat seal or an ultrasonic seal.

Hereinafter, the filter material of the present invention will be described in more detail with reference to the drawings. In the filter material 1 of the present invention,
A fiber web mainly composed of cellulose fibers 2 is used. Examples of the cellulose fibers 2 used in the present invention include flame-retardant cellulose fibers such as viscose rayon, copper-ammonium rayon, cotton, and flame-retardant rayon and flame-retardant cotton. Regenerated cellulose fibers such as viscose rayon and copper ammonia rayon having excellent heat resistance, and flame-retardant cellulose fibers that are difficult to carbonize are suitable. Flame-retardant cellulose fibers are obtained, for example, by mixing and spinning a flame retardant into a stock solution for spinning cellulose, attaching a flame retardant to the surface of cellulose fibers, or crosslinking a flame-retardant component to cellulose. Can be

The fibrous web mainly comprising the cellulose fibers 2 of the present invention must contain 50% or more of the cellulose fibers. If the content of the cellulose fiber is less than 50% and fibers other than the cellulose fiber, for example, 50% or more of thermoplastic fibers (polyester fiber, acrylic fiber, polyamide fiber, etc.) are contained, heat shrinkage of these fibers and Holes may be formed in the filter material when it comes into contact with a flame or receives high heat due to thermal melting. The amount of cellulose fibers in the fibrous web is preferably 70% or more, particularly preferably 100%, from the viewpoint of suppressing the occurrence of holes due to the heat shrinkage and the thermal fusion of the fibers. In addition, when using a flame-retardant cellulose fiber as the cellulose fiber,
A similar heat resistance effect can be obtained with a small amount of fibers as compared with the case where non-flame-retardant cellulose fibers are used. When fibers other than cellulose fibers are mixed, it is desirable to use polyester fibers having heat resistance as compared with other thermoplastic fibers. It is good because the ventilation resistance can be reduced.

The basis weight of the fiber web is 10 to 200 g / m
² , more preferably in the range of 10 to 150 g / m ² , and if the basis weight is larger than this range, the pressure loss becomes too large and the exhaust power required for the ventilation fan or the range hood may not be obtained. On the other hand, if the basis weight is small, it may not be possible to collect oil smoke and dust sufficiently.

[0010] A flame-retardant thermoplastic resin 3 containing a metal hydroxide is used for bonding the fibers in the fiber web. For example,
When the fibers are bonded by entanglement of fibers such as needle punch or water entanglement, pressure loss for range hood or ventilation fan (in the present invention, the value measured using a manometer under the condition of wind speed of 2 m / sec. When using a filter material having a pressure of 30 Pa or less, it is not possible to obtain a filter material having sufficient strength because the degree of entanglement must be reduced. However, in the present invention, the fibers are bonded by using the above resin. Thus, a filter material having low pressure loss and high strength can be obtained. However, if necessary, a method using resin and a method using entanglement of fibers may be used in combination. The pressure loss of the filter material of the present invention is more preferably 25 Pa or less,
It is better to be as low as possible as long as it satisfies the strength and trapping ability.

Further, in the present invention, since the flame-retardant thermoplastic resin 3 containing a metal hydroxide is used, the flame retardancy is excellent.
Even if oil or the like adheres, it is difficult to burn, and the bond can be maintained even if the resin itself is carbonized by high heat. As the flame-retardant thermoplastic resin, a resin containing a halogen element in a repeating unit of a polymer structure such as a vinyl chloride resin or a vinylidene chloride resin, or a thermoplastic resin such as a polyester resin or an acrylic resin may be a flame retardant. The added resin can be used. As the flame retardant added to the resin, an antimony flame retardant, a phosphorus flame retardant, a halogen flame retardant, or the like can be used. These flame retardants may be used as a mixture with a vinyl chloride resin or a vinylidene chloride resin. Further, a vinyl chloride resin or a vinylidene chloride resin may be used as a mixture with another resin, or may be a copolymer with another component. For example, vinyl chloride-acrylic resin, vinylidene chloride-acrylic resin, and the like can be used as the flame-retardant thermoplastic resin.

Aluminum hydroxide, magnesium hydroxide and the like are suitable for the metal hydroxide. These metal hydroxides may be used in appropriate combination. The ratio of the metal hydroxide to the flame-retardant thermoplastic resin (flame-retardant thermoplastic resin / metal hydroxide) is desirably in the range of 4: 6 to 9: 1. When the oxide is contained, it is possible to obtain a filter material having sufficient flame resistance, heat resistance, and strength that does not easily burn even when oil or the like adheres.
In particular, the ratio of the metal hydroxide to the preferred flame-retardant thermoplastic resin is from 5: 5 to 8: 2.

Flame retardant thermoplastic resin containing metal hydroxide 3
For example, a mixture of a metal hydroxide and a solution such as an emulsion made of a flame-retardant thermoplastic resin is applied to a fiber web by spraying, coating, impregnating, and the like, and is attached to the fiber web by drying. . The weight ratio of the above resin: fiber web is 10:90 to 8
0:20 is desirable, and when the amount of the resin is larger than this, the pressure loss may be too large because the resin closes the gap between the fibers, and when the amount of the resin is smaller than this, the amount of the filter material may be reduced. Insufficient strength or insufficient sealing strength when attached to an aluminum frame or the like by heat sealing or ultrasonic sealing. In terms of pressure loss and strength, the weight ratio of resin: fiber web is 20: 80-7.
More preferably, it is in the range of 0:30.

Since the flame-retardant thermoplastic resin 3 containing a metal hydroxide used in the present invention is thermoplastic, as shown in FIGS. 2 to 5, a filter material 1 is used as a filter for a range hood or a filter for a ventilation fan. It can also be attached to a frame for attachment by a heat seal or an ultrasonic seal.
For example, when an aluminum frame 4 or the like is used as a frame, if a film 5 such as a vinyl chloride resin is provided on the surface of the aluminum frame 4, a filter 6 is formed by forming a seal portion 6 by heat sealing or ultrasonic sealing. The material 1 can be simply and firmly attached to the frame. The filter for the range hood or the filter for the ventilation fan to which the filter material is attached is mounted on the range filter or the ventilation fan, respectively. However, the filter material of the present invention does not necessarily need to be attached to a frame for mounting a filter of a range hood or a ventilation fan by a heat seal, and a fixing tool such as a double-sided tape, a hook-and-loop fastener, a magnet, etc., according to the type of the range hood or the ventilation fan. Or a mounting mechanism provided in advance on a range hood or a ventilation fan.

[0015] Incidentally, the apparent density of the filter material of the present invention is 0.005~0.07g / cm ^3, more preferably it is desirable in the range of 0.005~0.05g / cm ^3, an apparent density than this If the density is too small, the strength may be insufficient, or oil fumes or dust may not be collected sufficiently.If the apparent density is higher than this, the pressure loss will be too large and the exhaust power required for the ventilation fan and range hood will not be obtained. May not be possible.

[0016]

【Example】

Example 1 A basis weight of 100 g of viscose rayon fiber of 60 g /
A vinyl chloride-acrylic resin emulsion (trade name: G-351, manufactured by Zeon Corporation) in which aluminum hydroxide is mixed at a solid content of 40% is sprayed onto a m ² fiber web, dried, and has a basis weight of 140 g / m 2. ^2. A filter material having an apparent density of 0.016 g / cm ³ and a pressure loss of 22 Pa was obtained.

Example 2 A weight of 60 g / 100% viscose rayon fiber
A vinylidene chloride-acrylic resin emulsion (trade name: Diophan 232D, manufactured by Mitsubishi Chemical BASF Co., Ltd.) in which aluminum hydroxide is mixed at a solid content of 40% is sprayed onto a m ² fiber web, dried, and dried to obtain a basis weight of 140.
g / m ² , an apparent density of 0.016 g / cm ³ and a pressure loss of 22 Pa were obtained.

Example 3 A phosphorus-based flame retardant was added to an undiluted viscose solution, kneaded, and spun.
of the fibrous web in m ^2, vinyl chloride were mixed 40% aluminum hydroxide in solid content - acrylic resin emulsion (manufactured by Nippon Zeon Co., Ltd. trade name: G-351) was sprayed and dried to basis weight 140 g / m ² Thus, a filter material having an apparent density of 0.016 g / cm ³ and a pressure loss of 22 Pa was obtained.

Example 4 A phosphorus-based flame retardant was added to a stock solution of viscose, kneaded and spun, and the basis weight was 60 g / 100% of a flame-retardant rayon fiber.
A vinylidene chloride-acrylic resin emulsion (trade name: Diophan 232D, manufactured by Mitsubishi Chemical BASF Co., Ltd.) in which aluminum hydroxide is mixed at a solid content of 40% is sprayed onto a m ² fiber web, dried, and dried to obtain a basis weight of 140.
g / m ² , an apparent density of 0.016 g / cm ³ and a pressure loss of 22 Pa were obtained.

Example 5 A phosphorus-based flame retardant was added to an undiluted viscose solution, kneaded and spun, and the basis weight was 60 g / m ² consisting of 75% of flame-retardant rayon fibers and 25% of polyester fibers (number of crimps 4 / cm). 40% aluminum hydroxide in the fiber web
The mixed vinyl chloride-acrylic resin emulsion (trade name: G-351 manufactured by Nippon Zeon Co., Ltd.) was sprayed and dried to give a basis weight of 140 g / m ² and an apparent density of 0.0.
A filter material having 16 g / cm ³ and a pressure loss of 17 Pa was obtained.

Example 6 A phosphorus-based flame retardant was added to an undiluted viscose solution, kneaded and spun, and the basis weight was 50 g / m ^2, comprising 50% of flame-retardant rayon fibers and 50% of polyester fibers (number of crimps 4 / cm). 40% aluminum hydroxide in the fiber web
The mixed vinyl chloride-acrylic resin emulsion (trade name: G-351 manufactured by Nippon Zeon Co., Ltd.) was sprayed and dried to give a basis weight of 140 g / m ² and an apparent density of 0.0.
A filter material having 16 g / cm ³ and a pressure loss of 15 Pa was obtained.

Example 7 A mixture of 75% flame retardant rayon fiber, 15% polyester fiber (4 crimps / cm), and 10% polychloral fiber which were kneaded and spun by adding a phosphorus-based flame retardant to a stock solution of viscose. Vinyl chloride-acrylic resin emulsion (a product of Nippon Zeon Co., Ltd.) in which aluminum hydroxide is mixed with a fiber web having a basis weight of 60 g / m ^{2 at} a solid content of 40%.
G-351), and dried to give a basis weight of 140 g /
m ² , apparent density 0.016 g / cm ³ , pressure loss 17
A filter material of Pa was obtained.

Example 8 A phosphorus-based flame retardant was added to a stock solution of viscose, kneaded and spun, and the basis weight was 60 g / 100% made of flame-retardant rayon fibers.
A vinyl chloride-acrylic resin emulsion (product name: G-351, manufactured by Nippon Zeon Co., Ltd.) in which magnesium hydroxide is mixed at a solid content ratio of 40% is sprayed onto a m ² fiber web, dried, and has a basis weight of 140 g / m 2. ^2. A filter material having an apparent density of 0.016 g / cm ³ and a pressure loss of 22 Pa was obtained.

Example 9 A phosphorus-based flame retardant was added to a stock solution of viscose, kneaded and spun, and the basis weight was 60 g / 100% of flame-retardant rayon fibers.
the fiber web m ^2, 40% aluminum hydroxide in solid content, of a phosphoric ester flame retardant in solid content 18
% Acrylic resin emulsion (trade name: Boncoat JT-80, manufactured by Dainippon Ink and Chemicals, Inc.), dried and dried to give a basis weight of 140 g / m ² , an apparent density of 0.016 g / cm ³ and a pressure loss of 22 Pa. A filter material was obtained.

COMPARATIVE EXAMPLE 1 A vinyl chloride-acrylic resin emulsion comprising a fibrous web composed of 100% polymetaphenylene isophthalamide fiber and having a basis weight of 60 g / m ² and a phosphate ester flame retardant mixed at a solid content of 40% was prepared. Nippon Zeon Co., Ltd.
Product name: G-351) is sprayed and dried, and the basis weight is 1
A filter material having 40 g / m ² , an apparent density of 0.016 g / cm ³ and a pressure loss of 25 Pa was obtained.

Comparative Example 2 A basis weight of 60 g / 100% viscose rayon fiber
the fiber web m ^2, vinyl chloride were mixed 40% of a phosphoric ester flame retardant in solid content - acrylic resin emulsion (Nippon Zeon Co., Ltd. trade name: G-351)
Was sprayed and dried to obtain a filter material having a basis weight of 140 g / m ² , an apparent density of 0.016 g / cm ³ and a pressure loss of 22 Pa.

Comparative Example 3 A phosphorus-based flame retardant was added to a stock solution of viscose, kneaded and spun, and the basis weight was 100 g / 100% of flame-retardant rayon fibers.
the fiber web m ^2, vinyl chloride were mixed 40% of a phosphoric ester flame retardant in solid content - acrylic resin emulsion (Nippon Zeon Co., Ltd. trade name: G-351)
Was sprayed and dried to obtain a filter material having a basis weight of 140 g / m ² , an apparent density of 0.016 g / cm ³ and a pressure loss of 22 Pa.

(Flame Contact Test) Using a micro burner,
A flame of about 4.5 cm in length was emitted, and the condition of the filter material when each filter material was brought into contact with the tip of the flame for 3 seconds was compared. Table 1 shows the results.

(Oil Adhesion Flame Test) After spraying 200 g / m ² of salad oil evenly on the filter material by spraying and adhering it, a flame of about 4.5 cm in length was emitted using a micro burner. The state of the filter material when each filter material was brought into contact with the tip of for 3 seconds was compared. Table 2 shows the results.

(Heat Shrinkage Test) After measuring the area of the filter material at room temperature, the filter material was placed in an electric furnace,
After heating at 0 ° C. for 1 minute, the length of the warp and the length of the weft were measured, and the shrinkage ratio was determined from the length of the warp and the weft before and after the heating. Table 3 shows the results.

[0031]

[Table 1]

[0032]

[Table 2]

[0033]

[Table 3]

[0034]

The filter material of the present invention is hardly shrunk or melted even if it is exposed to high heat due to a flame or the like and is instantly touched with the flame if it is instantaneous, and there is almost no fear of perforation. In addition, the oil adheres during use, and even if a flame comes into contact with the oil and ignites, the filter material itself does not burn and extinguishes the fire.
Further, the filter material of the present invention has a high porosity and excellent strength. In addition, the filter material can be attached to a range hood, a ventilation fan, or the like by a heat seal or an ultrasonic seal.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of a filter material of the present invention.

FIG. 2 is a view seen from below when using a filter for a range hood to which the filter material of the present invention is attached.

FIG. 3 is a schematic cross-sectional view of the range hood filter of FIG. 2 in a used state.

FIG. 4 is a front view of a ventilation fan filter to which the filter material of the present invention is attached when used.

FIG. 5 is a cross-sectional model diagram in a state of use of the ventilation fan filter of FIG. 4;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Filter material 2 ... Cellulose fiber 3 ... Flame-retardant thermoplastic resin containing metal hydroxide

Continuation of front page (56) References JP-A-5-212225 (JP, A) JP-A-59-186620 (JP, A) JP-A-57-87813 (JP, A) JP-A-9-38429 (JP) JP-A-62-106815 (JP, A) JP-A-52-147370 (JP, A) JP-A-4-293518 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB Name) B01D 39/00-39/20

Claims (8)

(57) [Claims] 1. A filter material comprising a fibrous web mainly composed of cellulose fibers bonded with a flame-retardant thermoplastic resin to which a metal hydroxide is added. 2. The filter material according to claim 1, wherein the metal hydroxide is aluminum hydroxide. 3. The filter material according to claim 1, wherein the metal hydroxide is magnesium hydroxide. 4. The filter material according to claim 1, wherein the cellulose fiber is a flame-retardant cellulose fiber. 5. A fibrous web comprising 70 to 70 cellulose fibers.
The filter material according to claim 1, which is contained at a ratio of 100%. 6. The filter material according to claim 1, wherein the flame-retardant thermoplastic resin is a vinyl chloride resin. 7. The filter material according to claim 1, wherein the flame-retardant thermoplastic resin is a vinylidene chloride resin. 8. The method according to claim 1, wherein the pressure loss is 30 Pa or less.
The filter material according to 1.