JP3526320B2 - Air conditioning filter - Google Patents

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to an air conditioning filter.

[0002]

2. Description of the Related Art Conventionally, as a filter used in an air conditioner, an air conditioner, an air cleaner, an electric vacuum cleaner, etc., a filter in which a non-woven fabric and a net are bonded together has been known. For example, Japanese Utility Model Publication No. 5-9056 discloses a filter made of a non-woven fabric containing heat-fusible fibers and a synthetic resin net, which is integrated by softening and melting only the heat-fusible fibers in the non-woven fabric. There is. However, when this filter is reused and dust-collected or washed with a vacuum cleaner, the non-woven fabric and the net are easily separated from each other, which makes it difficult to reuse. In addition, when thermocompression bonding is performed to improve the adhesive strength between the non-woven fabric and the net, the heat-fusible fibers are fused in the compressed state, and the thickness of the non-woven fabric is crushed. There was a problem that it became a short filter.

[0003]

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned drawbacks, and an object of the present invention is to separate the fiber web from the net even if dust or water is washed with a vacuum cleaner. No, it can be recycled and has a large amount of dust absorption,
It is to provide an air conditioning filter having a long life.

[0004]

In the air-conditioning filter of the present invention (hereinafter sometimes referred to as "filter"), the fiber web and the net are entangled and integrated, and the constituent fibers of the fiber web (hereinafter " Sometimes referred to as "web constituent fibers")
However, the adhesive is applied and bonded in a state having a three-dimensional crimp. In particular, when the fiber web and the net are entangled and integrated by the needle punching method, the dust absorption amount does not decrease and the filter has a long life.

Further, heat-shrinkable fibers are contained as web-constituting fibers, and when the heat-shrinkable fibers are heat-shrinked, the fiber web and net are separated even if dust is collected or washed with a cleaner. It is a filter that is hard to do and can be reused more.

When the filter is pleated, the amount of dust suction can be increased and the filter has a longer life.

[0007]

In the filter of the present invention, not only the fiber web and the net are intertwined and integrated, but also the fibers constituting the web are in contact with each other.
Since the adhesive is applied and adhered, the entanglement of the fiber web with the net is unlikely to be lost. Therefore, even if the filter is washed with dust or washed with a vacuum cleaner, the fibrous web and the net are not separated from each other, so that the filter can be reused.
Further, since the web-constituting fibers are adhered in a state having a three-dimensional crimp, that is, in a bulky state, dust can be absorbed even inside the fiber web, and the filter has a large amount of dust absorption.

Examples of the fibers constituting the web include polyclar fiber, polyvinylidene chloride fiber, polyvinyl chloride fiber, polyester fiber, polyamide fiber, acrylic fiber, polyvinyl alcohol fiber, polypropylene fiber,
Synthetic fibers such as polyethylene fibers and polyurethane fibers, regenerated fibers such as rayon and viscose, semi-synthetic fibers such as acetate, and inorganic fibers such as carbon fibers and glass fibers can be used. Polyclar fiber, polyvinylidene chloride fiber, and polyvinyl chloride fiber, which have excellent properties, can be preferably used.

Further, when the heat-shrinkable fibers are contained as the web-constituting fibers and the heat-shrinkable fibers are heat-shrinked, the entanglement between the fiber web and the net becomes stronger and the fiber web and the net are more separated. Since it is difficult to do so, it is preferable that the heat shrinkable fiber is contained in an amount of 40% by weight or more. More preferably, the content is 50% by weight or more.

The heat-shrinkable fiber in the present invention means
Vertical 4 made by the card method from the same fiber 100%
This is a fiber having an area shrinkage of 20% or more when a fiber web having a size of 0 cm, a width of 25 cm and a basis weight of 40 g / m ² is heat-treated at the melting point of the fiber for 30 seconds. When the fiber is a composite fiber, heat treatment is performed at the melting point temperature of the resin component having the lowest melting point among the resins exposed on the fiber surface. For example, in the case of the core-sheath type composite fiber, the treatment is carried out at the melting point temperature of the sheath resin, and in the case of the side-by-side type composite fiber, the treatment is carried out at the melting point temperature of the resin having the lower melting point. Further, the area shrinkage rate means a value obtained by the following formula.

The heat-shrinkable fiber may be a fiber composed of a single component such as polyvinyl chloride fiber, or a composite composed of a plurality of resin components such as a core-sheath type, an eccentric type and a side-by-side type in cross section. The fiber may be used, but the latter is more suitable because it is more easily contracted and entangled with the net.

As a combination of resin components constituting this composite fiber, for example, polypropylene / polyethylene,
Polyester / Low melting point polyester, Polypropylene /
There are low melting point polypropylene, nylon 66 / nylon 6, nylon 6 / low melting point nylon, polyester / nylon 6, nylon 6 / polyethylene, polyester / polypropylene and the like.

When the low melting point resin component of the composite fiber has thermal adhesiveness, the web component fiber can be thermally adhered by this resin component. As described above, when the low melting point resin component of the composite fiber has thermal adhesiveness, the fiber form can be maintained by the high melting point resin component, so that a filter having excellent strength, excellent washability, and easy to recycle can be obtained. However, the fiber having thermal adhesiveness does not have to be a composite fiber, and may be a single component, for example, polyethylene fiber, polypropylene fiber, polyamide fiber, polyester fiber, polyvinyl chloride fiber, polyurethane fiber, or the like. .

Further, a fiber mixed with an aromatic agent, an antibacterial agent, an antifungal agent or the like and imparting functions such as aromaticity, antibacterial property and antifungal property may be used.

The fineness of such web-constituting fibers is 3 to.
It is preferably 30 denier. When it is less than 3 denier, the fibers constituting the web are easily broken and peeled off from the net when washed, so that it is difficult to recycle it. This is because it tends to decrease. More preferably 1
It is 0 to 20 denier.

After laminating the fiber web made of the fibers as described above and the net, the entanglement-integrating treatment is performed, and the fibers constituting the web are adhered with an adhesive to obtain the filter of the present invention.

The fiber web of the present invention can be obtained by, for example, a card method, an air lay method, a spun bond method, a melt blow method, a wet method or the like. The fibrous web may be lightly entangled with a needle or water flow to improve the handleability.

As the net of the present invention, a woven filament or a thermoformed filament can be used. A woven filament net is preferable because it is easy to make the mesh fine and pleated. Can be used for The net woven from the filaments will be described below.

When a composite filament is included as the filaments constituting this net, it is possible to fuse only one resin component of the composite filament and not to fuse the other resin component. The net shape can be maintained, and it is possible to obtain a net that is not deformed even if washed and the inter-filament distance does not change.

As the composite filament, a core-sheath type, an eccentric type, and a side-by-side type having a cross-sectional shape can be used, and examples of the combination of constituent resin components include 6 nylon / polyethylene, polyester / nylon 6, polypropylene / polyethylene. , Polypropylene / ethylene-vinyl acetate copolymer, polyester / polypropylene, polyester / polyethylene, 6 nylon / 66 nylon, high melting point polyester / low melting point polyester, high density polyethylene / low density polyethylene and the like can be used.

As filaments other than the composite filament, for example, regenerated fiber such as rayon, semi-synthetic fiber such as acetate, polyamide fiber, polyvinyl alcohol fiber, polyvinylidene chloride fiber, polyvinyl chloride fiber, polyester fiber. Fibers, synthetic fibers such as polyacrylonitrile fibers, polyethylene fibers, polypropylene fibers, polyurethane fibers, polyclar fibers, and inorganic fibers such as carbon fibers can be used.

In order to impart rigidity to the net, these filaments preferably have a fineness of 200 denier or more, and when the fineness is 1000 denier or less, they are excellent in workability in pleating. A more preferable fineness is 250 to 650 denier.

It is preferable that such filaments are woven in a warp and weft amount of 4 to 20 filaments per inch. If the number of driven fibers is more than 20 / inch, the distance between filaments is short, so the net rigidity is excellent, but the cleaning performance is poor and the pressure loss is high. If the number of driven fibers is less than 4 / inch, the inter-filament distance becomes long, so that needle breakage is likely to occur.
This is because the entire net loses its rigidity and is easily deformed when washed. A more preferable number to be driven is 5 to 17 / inch.

The fiber web and the net as described above are laminated and entangled. Examples of this entanglement treatment include a fluid entanglement method such as a needle punch method and water flow. Among these, if the entanglement process by the needle punch method,
Since it can be entangled and integrated with the net without crushing the thickness of the fiber web, the amount of dust absorption does not decrease due to the entanglement and integration, and the life can be extended. In this way, since the fiber web and the net are integrated by the entanglement treatment, the web-constituting fibers after the integration are in a three-dimensional crimped state.

The entanglement process by the needle punching method is as follows.
The needle density is preferably ²⁰ to 300 needles / cm ² . This is because if the needle density is less than 20 needles / cm ² , the entanglement with the net is weak and the needles are easily peeled off during washing, and if it exceeds 300 needles / cm ² , the needle damages the net severely. A more preferable needle density is 50 to 150 needles / cm ² . Further, the depth of the needle entanglement process is 5 to 20.
mm is preferred. If the depth is less than 5 mm, the entanglement with the net of the fibrous web is weak and peeling easily occurs during washing, and if it exceeds 20 mm, needle breakage easily occurs. More preferable depth is 10-18mm
Is.

After this entanglement treatment, the fibers constituting the web are adhered to obtain the filter of the present invention. More preferably, the web-constituting fibers are also bonded to the net so that the fiber web and the net are more difficult to separate. In addition, it is necessary to bond the web constituent fibers without pressure. This is to maintain the three-dimensional crimp, which is possessed when the web constituent fibers are entangled and integrated, and to prevent the amount of dust absorption from decreasing.

This adhesion is performed by applying an emulsion type, suspension type, solvent type or powder type adhesive . And it allowed free of fibers having a heat-adhesive as described above in web constituent fibers, 併adhesion by the fiber
You can use it. Further, when the filaments forming the net have adhesiveness, the filaments may be bonded together.

Examples of emulsion type, suspension type, solvent type or powder type adhesives include vinyl chloride type, acrylic acid ester type, ethylene-vinyl acetate copolymer type, polyvinyl acetate type, synthetic rubber type, polyurethane. System, polyester, polyamide type can be used,
The solid content is preferably 10 to 70 g / m ² . 10
If it is less than g / m ² , the fibrous web and the net are easily separated during cleaning even if an adhesive is used, and if it exceeds 70 g / m ² , pressure loss increases. Is. More preferably, it is 20 to 60 g / m ² .

When the above-mentioned heat-shrinkable fibers are contained as the web-constituting fibers, the heat-shrinkage is performed before the bonding of the web-constituting fibers to strengthen the entanglement between the fiber web and the net. Is preferred. Further, in the case of containing heat shrinkable and adhesive fibers, they may be bonded simultaneously with heat shrink.

The filter 3 obtained as described above is
As shown in FIG. 1, the fiber web 1 and the net 2 are entangled and integrated with each other as shown in FIG. 1, and the fiber constituting the web is bonded in a state having a three-dimensional crimp. Therefore, even if it is washed, the fiber web 1 and the net 2 are not separated from each other, and the filter can be reused and has a large amount of dust.

The filter of the present invention can be further extended in life by pleating. The pleating process is not particularly limited, but the distance between adjacent ridges is preferably 10 to 40 mm. 10 mm
If the length is shorter than 40 mm, it becomes difficult to wash, and if the length is longer than 40 mm, the dust absorption amount is not improved so much even though the pleat processing is performed. More preferably 15-
It is 30 mm.

Examples of the filter of the present invention will be described below, but the present invention is not limited to the following examples.

[0033]

Example 1 A core-sheath type composite filament having a fineness of 400 denier in which a core component resin is polypropylene and a sheath component resin is polyethylene is used as a warp yarn and a weft yarn in a plain weave of 6 × 6 yarns / inch. I made a net
It was heat-treated at a temperature of 130 ° C. and heat-sealed with polyethylene which is a sheath component resin.

On the other hand, the core component resin is polypropylene and the sheath component resin is polyethylene, and the fineness is 18 denier, the heat-shrinkable and heat-adhesive fiber having a fiber length of 102 mm is 60% by weight, and the fineness is 15 denier. , Fiber length 76
40% by weight of polyclar fiber having a weight of 40 mm was mixed and carded, and then a fiber web having a basis weight of 40 g / m ² and a thickness of 15 mm was obtained in which the orientation directions of the fibers were crossed by a cross layer.

After the fiber web was laminated on the heat-sealed net, needle punching was performed at a needle density of 50 needles / cm ² and a needle depth of 16 mm to entangle and integrate the fiber web and net. Next, heat treatment was carried out at a temperature of 135 ° C. to heat-shrink the heat-shrinkable and heat-adhesive fibers of the fiber web and simultaneously heat-bond them. Furthermore, spray vinyl chloride emulsion and dry at 135 ℃, solid content 40g / m ²
It adhered and the filter of this invention was obtained.

Example 2 100% by weight of a polyester fiber having a fineness of 20 denier and a fiber length of 76 mm was used as the fiber constituting the fiber web, and the basis weight was 40 g / m ² and the thickness was 15 mm.
A filter was obtained in the same manner as in Example 1 except that the fibrous web of Example 1 was used and no heat treatment was performed after the needle punching process.

(Comparative Example 1) A filter was obtained in the same manner as in Example 2 except that the needle punching treatment was not performed.

(Comparative Example 2) A filter was obtained in the same manner as in Example 2 except that the vinyl chloride emulsion was not used.

(Comparative Example 3) A fibrous web and a net obtained in the same manner as in Example 1 were laminated, and then thermocompression-bonded at a temperature of 190 ° C and a slit of 0.5 mm to integrate the fibrous web and the net. , Got the filter.

(Peeling Strength Test) The filters of Examples 1 and 2 and Comparative Examples 1 to 3 were cut into a width of 5 cm and a length of 20 cm, and the fiber web and net were respectively tested for tensile strength and elongation ((( stock)
It is sandwiched between chucks made by Orientec Co., Ltd. and the pulling speed is 1
The peel strength was measured at 0 cm / min. The results are shown in Table 1.

[0041]

[Table 1] 1) ○: No separation of net and fiber web ×: There is separation of net and fiber web Note) In the table, --- represents unmeasured

(Washing resistance test) JIS-L-1085-1
992, by the method specified in the reference washing strength test method,
The filters of Examples 1 and 2 and Comparative Examples 1 to 3 were continuously washed, and the peeled state between the fiber web and the net after 1, 2, 5, and 8 hours was observed. The results are also shown in Table 1.

(Dust absorption test) Height 40 mm, mountain distance 25
Examples 1 and 2 in which pleats were performed by bending back 45 mm.
And the dust absorption amount of the filter of Comparative Example 3 was set to ASHRAE52.
It measured using the test device based on -76. The wind speed was 2 m / sec and the final pressure loss was 10 mmAq. The results are also shown in Table 1.

[0044]

In the air-conditioning filter of the present invention, the fiber web and the net are entangled and integrated with each other, and an adhesive is applied and bonded in a state where the constituent fibers of the fiber web have a three-dimensional crimp. Therefore, even if dust is collected or washed with a vacuum cleaner, the fibrous web and the net do not separate from each other and can be reused and has a large amount of dust. When the fiber web and the net are entangled and integrated by the needle punching method,
It is an air conditioning filter that maintains the collection efficiency, does not reduce the amount of dust suction, and has a longer life.

Further, heat-shrinkable fibers are included as the constituent fibers of the fiber web. When the heat-shrinkable fibers are heat-shrinked, the constituent fibers of the fiber web and the net are strongly entangled with each other. The net is an air-conditioning filter that does not easily peel off and is easier to recycle.

Furthermore, if the air conditioning filter is pleated, the amount of dust suction can be increased and the life is longer.

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view of an air conditioning filter of the present invention.

[Explanation of symbols]

1 fiber web 2 net 3 Air conditioning filters

─────────────────────────────────────────────────── ─── Continuation of front page (58) Fields surveyed (Int.Cl. ⁷ , DB name) B01D 39/00-39/20

Claims (4)

(57) [Claims] 1. A fiber web and a net are intertwined and integrated with each other, and constituent fibers of the fiber web are bonded by applying an adhesive in a state having a three-dimensional crimp. Air conditioning filter. 2. A fiber web and a net are entangled and integrated by a needle punching method.
Air conditioning filter described. 3. The air conditioning system according to claim 1, wherein the fiber web contains heat-shrinkable fibers as constituent fibers, and the heat-shrinkable fibers are heat-shrinkable. filter. 4. The air-conditioning filter according to claim 1, 2 or 3, which is pleated.