JP4170206B2 - Method for producing plasma or serum separation material, and method for producing plasma or serum filter - Google Patents

Description

  The present invention relates to a method for producing a plasma or serum separation material, and a method for producing a plasma or serum filter.

  Conventionally, biochemical tests have been widely performed for diagnosis of various diseases. In this biochemical test, plasma or serum is separated from blood in order to eliminate the influence of blood cells such as red blood cells. As this separation method, there is a method in which blood is coagulated and then centrifuged. However, this separation method has a problem that it takes time. Therefore, a method for separating plasma or serum using a filter has been proposed.

  For example, Japanese Patent Laid-Open No. 10-211277 (Patent Document 1) states that “an ultrafine fiber assembly is made of ultrafine fibers having an average fiber diameter of 0.5 to 3.5 μm and an average hydrodynamic radius of 0.5 to 3.0 μm. Plasma comprising the nonwoven fabric alone or a laminate of a plurality of nonwoven fabrics, wherein the blood cell separation layer has a length of 5 mm or more, and the blood flow direction is a horizontal direction with respect to the surface of the nonwoven fabric, “Serum separation filter” is disclosed, and as a method for producing the filter, a method is disclosed in which a nonwoven fabric is cut into a predetermined shape, laminated, and filled into a container. However, in this production method, not only the cutting and filling operations of the nonwoven fabric are complicated, but the usage rate of the nonwoven fabric is low, wasteful of resources and cost increase.

Japanese Patent Laid-Open No. 10-211277 (Claim 1, Examples, etc.)

  The present invention has been made to solve the above-described problems, and is excellent in manufacturing workability, uses resources without waste, and can reduce the cost increase. An object is to provide a method for producing a serum filter.

  The invention according to claim 1 of the present invention is as follows: “(1) an accumulation step in which fibers are accumulated in the through holes of the preforming support having a plurality of through holes; (2) in the through holes of the preforming support. A fixing step in which the fibers are fixed in a state in which the fibers are accumulated, and a fixed fiber assembly-holding preforming support body including a fixed fiber assembly body is formed in the through hole of the preforming support body. 3) Repeating the stacking step and the fixing step to form a plurality of fixed fiber aggregate-containing preforming supports having a fixed fiber aggregate in the through holes of the preforming support, (4) A plurality of fixed fiber aggregate-containing pre-molding supports are laminated so that the centers of the through holes of the fixed fiber aggregate-containing pre-molding support coincide with each other, and the fixed fiber aggregate-containing pre-molding support laminate (5) The fixed fiber accumulation By applying an external force to the fixed fiber assembly of the retained preform molding support laminate, the number of fixed fiber assemblies corresponding to the number of the fixed fiber aggregate retained preform support is laminated. A moving step of moving into a molding container having an inner wall surface of a desired shape, (6) molding the laminated fixed fiber assembly in the molding container along the shape of the inner wall surface of the molding container, A method for producing plasma or serum separating material, comprising a molding step for producing serum separating material. In this way, the support for pre-molding with a fixed fiber assembly that is large and easy to handle does not require the steps of cutting, laminating, and filling the sheet into small individual separator units constituting the plasma or serum separator. After the bodies are laminated, the fixed fiber aggregates are moved into the molding container in a state of being laminated, and are molded, so that the manufacturing workability is excellent. In addition, since it is not necessary to cut the sheet into separation material units constituting the plasma or serum separation material, resources can be used without waste and cost increase can be suppressed.

  According to a second aspect of the present invention, the plasma according to the first aspect is characterized in that, in the accumulation step, the fibers in which the gas is dispersed as a dispersion medium are accumulated in the through holes of the preforming support. Or a method for producing a serum separation material. As described above, the fibers dispersed as a dispersion medium are accumulated in the through-holes of the preforming support so that the fibers can be accumulated with a small density unevenness. Easy to produce plasma or serum separator.

  According to a third aspect of the present invention, “in the accumulation step, fibers dispersed by ejecting fibers from the dispersion nozzle into the gas by the action of the compressed gas are accumulated in the through holes of the preforming support. 3. A method for producing a plasma or serum separation material according to claim 1 or 2, characterized in that. In this way, the fibers ejected into the gas from the dispersion nozzle by the action of the compressed gas are well separated and dispersed into individual fibers, and the fiber aggregate in the through-hole has a small apparent density and is a post process. Thus, a plasma or serum separation material having a uniform structure with no unevenness can be obtained. Therefore, it is easy to produce a plasma or serum separation material that can efficiently separate blood cell components and plasma or serum components.

  The invention according to claim 4 of the present invention is characterized in that “in the accumulation step, fibers mainly composed of ultrafine drawn fibers having a fiber diameter of 4 μm or less are accumulated in the through holes of the preforming support, It is "the manufacturing method of the separation material for plasma or serum in any one of Claims 1-3." Since such ultrafine drawn fibers have the same fiber diameter, a separation material with small variation in fiber diameter, that is, a separation material for plasma or serum showing a good separation action, is produced by mainly using the ultrafine drawn fibers. Cheap.

  The invention according to claim 5 of the present invention states that “in the collecting step, the fibers are also collected in the non-through hole portion of the preforming support, and in the fixing step, the fibers in the non-through hole portion are also fixed. The method for producing a separation material for plasma or serum according to any one of claims 1 to 4, which is characterized. In this way, by fixing the fibers in the non-through hole portion of the preforming support, the fixed fiber assembly shrinks in the fixing step, and the area of the fixed fiber assembly becomes smaller than the through hole. In addition, since the fibers can be prevented from falling off from the preforming support by fixing the fibers in the non-through-hole portion, the molding container can be used in a state in which a desired number of the fixed fiber aggregates are securely laminated. Can be moved in.

  The invention according to claim 6 of the present invention is “for plasma or serum according to any one of claims 1 to 5, wherein in the fixing step, the fibers are fused to fix the fibers together. “Method for producing separation material”. Thus, by fusing the fibers, it is easy to produce a plasma or serum separation material that is excellent in form retention and handling.

  The invention according to claim 7 of the present invention is such that, in the repeating step, a plurality of fixed fiber aggregate-containing preform forming supports having fixed fiber aggregates having different average fiber diameters are formed, and in the laminating step, fixed fiber accumulation is performed. It is laminated | stacked so that the average fiber diameter of a body may become large in order, or it may become small in order, and the support body laminate for fixed fiber holding possession preforming may be formed, It is characterized by the above-mentioned. Or a method for producing a plasma or serum separation material according to any one of the above. By supplying blood from the side of the plasma or serum separating material having a large average fiber diameter, blood cell components having a large particle diameter can be captured in order, so that a plasma or serum separating material that can be separated efficiently is manufactured. Cheap.

  The invention according to claim 8 of the present invention is such that, in the stacking process in the repeating process, a plurality of preforming supports having different through-hole sizes are used as the preforming support, and in the laminating process, a fixed fiber is used. It is characterized by forming a support laminate for fixed fiber aggregate-containing preforming by laminating so that the size of the through-holes of the aggregate-holding preforming support becomes larger or smaller in order. The method for producing a plasma or serum separation material according to any one of claims 1 to 7. According to this production method, it is possible to produce a columnar plasma or serum separation material whose cross-sectional area increases or decreases in order from one surface to the other surface. The columnar plasma or serum separation material is transferred to a separation container having a constant cross-sectional area in the loading region in which the plasma or serum separation material is loaded. By loading so as to come into contact with the sealing part that is fixed in contact with the plasma or serum separation material, the compressibility of the columnar plasma or serum separation material becomes higher as it approaches the sealing part. Since a density density can be formed on the separation material for blood, it is easy to produce a plasma or serum filter that can be captured in order from blood cell components having a larger particle size and can be separated efficiently.

  The invention according to claim 9 of the present invention is characterized in that “in the molding step, the laminated fixed fiber assembly in the molding container is thermoformed in a compressed state. The method for producing a plasma or serum separation material according to any one of the above. By thermoforming in such a compressed state, the uniformity of the apparent density of the laminated fixed fiber aggregate is increased, and a plasma or serum separator having a uniform structure with no unevenness can be easily produced.

  The invention according to claim 10 of the present invention is “following the method for producing a plasma or serum separation material according to any one of claims 1 to 9, the plasma or serum separation material is loaded into a separation container. A method for producing a filter for plasma or serum, comprising a loading step of: According to this manufacturing method, the molded plasma or serum separation material is simply loaded into the separation container, so that the manufacturing method is excellent in manufacturing workability, can use resources without waste, and can suppress cost increase. is there.

  According to an eleventh aspect of the present invention, “in the loading step, a loading port for loading plasma or serum separation material as a separation container, and the loading port is opposed to the plasma or serum separation material. And has a constant cross-sectional area from the loading port side end of the loading area where the plasma or serum separation material is loaded to the sealing area side end of the loading area. The present invention is characterized in that a certain material is used, and a separation material for plasma or serum is used whose cross-sectional area of the surface in contact with the sealing portion is larger than the cross-sectional area in the sealing portion of the separation container. 10. The method for producing a plasma or serum filter according to 10. According to this manufacturing method, the separation container and the plasma or serum separation material are in close contact, and no gap is formed between the separation container and the plasma or serum separation material, so that blood cell components are captured. Therefore, it is possible to manufacture a filter for plasma or serum that does not cause the problem of passing through the separation material for plasma or serum.

  According to a twelfth aspect of the present invention, “in the loading step, a loading port for loading plasma or serum separation material as a separation container, and the loading port is opposed to the plasma or serum separation material. And has a continuous cross-sectional area from the loading port side end of the loading area where the plasma or serum separation material is loaded toward the sealing section side end of the loading area. Or, use a material that becomes discontinuously smaller, and use a plasma or serum separation material that has a cross-sectional area that is larger than the cross-sectional area of the sealing portion of the separation container. The method for producing a plasma or serum filter according to claim 10, which is characterized. According to this manufacturing method, the separation container and the plasma or serum separation material are in close contact, and no gap is formed between the separation container and the plasma or serum separation material, so that blood cell components are captured. Therefore, it is possible to manufacture a filter for plasma or serum that does not cause the problem of passing through the separation material for plasma or serum. In addition, since the plasma or serum separation material is compressed by the separation container, the density can be increased as it approaches the sealing portion of the separation container. A filter for plasma or serum that can be separated efficiently can be produced.

  The method for producing a separation material for plasma or serum of the present invention is a method for producing a separation material for plasma or serum that is excellent in production workability, can use resources without waste, and can suppress an increase in cost.

  The method for producing a filter for plasma or serum of the present invention is a method for producing a filter for plasma or serum that is excellent in production workability, can use resources without waste, and can suppress an increase in cost.

  A method for producing the separation material for plasma or serum of the present invention (hereinafter sometimes simply referred to as “separation material”) will be described with reference to FIGS.

  First, as shown in a schematic perspective view of the accumulation step in FIG. 1, (1) an accumulation step for collecting the fibers f in the through holes 1a of the preforming support body 1 having a large number of through holes 1a is performed. . In the accumulating step in FIG. 1, after placing a perforated plate (preliminary support 1) having a large number of through-holes 1a drilled in a columnar shape on a collector 2 (for example, a net), fibers f are arranged. While being supplied from above the preforming support 1, it is sucked by a suction device 3 installed below the collector 2. When the fiber f is supplied and sucked by the suction device 3 in this way, the fiber f is accumulated in the through-hole 1a of the preforming support 1 that is a gas passage, and a fiber aggregate is formed. Since the through-hole 1a of the preforming support 1 in FIG. 1 is cylindrical, a cylindrical fiber assembly can be formed, and a cylindrical separator can be produced. Depending on the desired outer shape of the separator Thus, a preforming support having a through hole different from that shown in FIG. 1 can be used. The number of through holes in the preforming support is not particularly limited. In FIG. 1, the fibers f are accumulated in the through holes 1a of the preforming support 1 by installing and sucking the suction device 3, but the fibers are sprayed onto the preforming support together with gas. Thus, the fibers may be accumulated in the through holes 1a of the preforming support, or the fiber spraying and the fiber suction may be used in combination.

  The preforming support that can be used in the present invention has excellent adhesion to the collector so that the fibers do not enter between the collector and the preforming support during fiber accumulation. There is no particular limitation as long as it has good dimensional stability so that the position of the through hole does not shift. Examples of the former material having excellent adhesion include rubber-based or soft vinyl chloride-based sheets, and examples of the latter material having high dimensional stability include films, woven fabrics, knitted fabrics, nonwoven fabrics, and nets. Therefore, it is preferable to use a preforming support made of a composite material obtained by bonding these materials.

  The size of the through-hole is not particularly limited, but the through-hole has a cross-sectional area that is 1 to 30% higher than the cross-sectional area of the loading port side end of the separation container or the sealing portion. Is preferred. Due to the through hole having such a cross-sectional area, the separation container and the separation material can be brought into close contact with each other, and a separation material capable of reliably capturing blood cell components can be produced. In the fixing step described later, when the fiber aggregate contracts, it is preferably a through hole having a larger cross-sectional area than the above range.

  Further, the depth of the through-hole is not particularly limited, but if it is too shallow, the number of laminated layers of the fixed fiber aggregate-containing preforming support described later increases, and the manufacturing tends to become complicated, and if it is too deep Since it tends to be difficult to form a fiber aggregate in which fibers are uniformly dispersed, the depth is preferably about 0.5 to 3 mm.

  In addition, as the fiber f, it is preferable that fibers mainly composed of ultrafine drawn fibers having a fiber diameter of 4 μm or less are accumulated in the through holes 1 a of the preforming support 1. This is because the ultrafine drawn fibers have the same fiber diameter, and therefore, by using the ultrafine drawn fibers as a main component, it is easy to produce a separating material having a small variation in fiber diameter, that is, a separating material having a good separating action. This ultra-fine stretched fiber efficiently separates blood into blood cell components and plasma or serum components, has a short time to filter only plasma or serum components, and contains as little blood cell components or blood cell destructive substances (hemolysis) as possible in the filtrate. Thus, the fiber diameter is preferably 3 μm or less, and more preferably 2 μm or less. On the other hand, if the finely drawn fiber is too thin, the pore size of the separation material becomes too small, blood cells are likely to be clogged, the filtration time becomes too long, and plasma or serum components may not be filtered. The fiber diameter of the fiber is preferably 0.01 μm or more. “Fiber diameter” in the present invention is a fiber diameter measured from an electron micrograph, and when the cross-sectional shape of the fiber is circular, it refers to the diameter, and when the cross-sectional shape of the fiber is non-circular Means the diameter of a circle with the same cross-sectional area and area.

  The fiber length of the ultrafine stretched fiber is not particularly limited, but is preferably 3 mm or less, and more preferably 2 mm or less so that the dispersibility of the ultrafine stretched fiber is excellent. The lower limit of the fiber length of the ultrafine stretched fiber is not particularly limited, but about 0.1 mm is appropriate. Moreover, it is preferable that it is the cut | pulled ultra fine stretched fiber so that fiber length may be uniform. The “fiber length” in the present invention refers to the length obtained by JIS L 1015 (chemical fiber staple test method) B method (corrected staple diagram method).

  The ultra-fine stretched fiber may be composed of any component as long as it does not inhibit the filtration of plasma or serum components. For example, a polyamide resin, a polyvinyl alcohol resin, a polyvinylidene chloride resin, Vinyl chloride resin, polyester resin, polyacrylonitrile resin, polyolefin resin (eg, polyethylene resin, polypropylene resin, etc.), polystyrene resin (eg, crystalline polystyrene, amorphous polystyrene, etc.), wholly aromatic It can be comprised from organic components, such as a polyamide-type resin and a polyurethane-type resin. Moreover, as long as the filtration of plasma or a serum component is not inhibited, it is not limited to these components, You may be comprised from the inorganic component. Further, the ultrafine drawn fiber may be subjected to a surface treatment (for example, a surface treatment so that the fiber surface does not have a positive charge) so as not to adsorb proteins.

  In addition, it is preferable that the ultrafine stretched fiber can be fused so that the ultrafine stretched fiber is fused so that the separation material is excellent in form stability and handleability. It is sufficient that at least a part of the components constituting the surface of the ultrafine stretched fiber is composed of a thermoplastic resin. For example, the component constituting the surface of the ultrafine drawn fiber is a polyolefin resin (for example, polyethylene resin, polypropylene resin, etc.), polyvinylidene chloride resin, polyester resin, polyamide resin, crystalline polystyrene resin, etc. It may be composed of a crystalline thermoplastic resin or an amorphous thermoplastic resin such as polyvinyl chloride resin, amorphous polystyrene resin, polyacrylonitrile resin, or polyvinyl alcohol resin.

  When this meltable ultrafine stretched fiber is composed of two or more types of components, even if one type of thermoplastic resin constituting the fiber surface is fused, the fiber form is maintained by at least one type of component. This is preferable. The cross-sectional shape of the ultrafine stretched fiber composed of two or more kinds of components can be, for example, a core-sheath type, an eccentric type, a sea-island type, a side-by-side type, a multiple bimetal type, and an orange type. A sheath type, an eccentric type, or a sea-island type is preferable.

Moreover, it is preferable that the fiber diameters between the ultrafine drawn fibers are substantially the same so that the finely drawn fibers can easily obtain good filtration performance of plasma or serum. Specifically, the value (σ / d) obtained by dividing the standard deviation value (σ) of the fiber diameter distribution of the ultrafine drawn fiber by the average fiber diameter (d) of the ultrafine drawn fiber is 0.2 or less (preferably 0.00. 1 or less). In addition, since the standard deviation value (σ) is 0 when the fiber diameters of the ultrafine drawn fibers are all the same, the lower limit value of the value (σ / d) is 0. The “average fiber diameter (d) of the ultrafine drawn fibers” is taken by taking an electron micrograph of the separating material, measuring the fiber diameters of 100 or more ultrafine drawn fibers in this electron micrograph, and measuring the measured fiber diameters. Arithmetic mean value. In addition, the “standard deviation value (σ)” of the ultrafine drawn fiber is a value calculated from the measured diameter (X) of each of the n (100 or more) ultrafine drawn fibers by the following formula.
Standard deviation ^{= {(nΣX 2 - (ΣX} ) 2) / n (n-1)} 1/2

  It is preferable that the diameters of the ultrafine drawn fibers are substantially the same in the fiber axis direction so that the fiber diameter does not vary and the separation material can exhibit good filtration performance of plasma or serum. .

  As described above, the ultrafine drawn fibers having substantially the same fiber diameter between the ultrafine drawn fibers and the ultrafine drawn fibers whose diameters are substantially the same in the fiber axis direction include, for example, the sea component of the sea-island fiber obtained by the composite spinning method. It can be obtained by removing.

  The ultrafine drawn fibers are in a drawn state so as to have a uniform fiber diameter and appropriate fiber strength characteristics. This “stretched state” means that the film is stretched by a stretching process different from the spinning process (for example, a stretching process by a stretching yarn threading machine). The fiber formed by blowing hot air is not considered to be drawn because the spinning process and the drawing process are the same and the degree of drawing is low. In addition, when generating ultra-fine drawn fibers from sea-island type fibers, it is not necessary to go through a drawing process after generation, and if the sea-island type fibers have undergone a drawing process before generation, the ultra-fine drawn fibers are in a drawn state It is in.

  In addition, as a fiber, you may contain 2 or more types of the ultra fine stretched fiber from which a fiber diameter, fiber length, and / or a component differ.

  Although it is preferable to use such ultra-fine drawn fibers as a main component (that is, 50 mass% or more), the larger the amount of ultra-fine drawn fibers, the better the separation performance. Therefore, the fibers account for 70 mass% or more. More preferably, it occupies 80 mass% or more, more preferably 90 mass% or more, and most preferably 100 mass% is composed of ultrafine drawn fibers.

  Examples of fibers other than the ultrafine drawn fibers include finely drawn fibers having a fiber diameter exceeding 4 μm. By including such finely drawn fibers, the form stability of the separating material can be enhanced. The upper limit of the fiber diameter of the finely drawn fiber is not particularly limited, but is preferably 15 μm or less so as not to impair the separation performance. The fiber length of the finely drawn fiber is preferably 10 mm or less, more preferably 8 mm or less, and even more preferably 5 mm or less so that the dispersibility is excellent. The lower limit of the fiber length of the finely drawn fiber is not particularly limited, but about 0.1 mm is appropriate. Moreover, it is preferable that it is the finely drawn fiber cut | disconnected so that fiber length may be uniform.

  The finely drawn fiber may be composed of any component as long as it does not inhibit the filtration of plasma or serum components, and can be composed of the same component as the above-mentioned ultrafine stretched fiber. It is preferable that this finely drawn fiber can be fused so that the shape stability of the separating material is excellent. As for the finely drawn fiber that can be fused, the thermoplastic resin similar to the ultrafine drawn fiber may occupy at least a part of the surface of the finely drawn fiber. Further, the finely stretchable fiber that can be fused is also preferably composed of two or more kinds of components, as in the case of the ultrafine stretched fiber. In this case, the arrangement state in the cross section is a core-sheath type, an eccentric type, Alternatively, it is preferably a sea-island type. Two or more kinds of finely drawn fibers having different fiber diameters, fiber lengths, and / or components may be included.

In the method for producing a separating material of the present invention, it is preferable to use the above-mentioned ultra-fine drawn fibers and / or fine drawn fibers. However, these fibers do not have an adhering substance that impedes the filtration performance of plasma or serum components. It is preferably not included. More specifically, it is preferable that the percentage of the mass of the adhering material with respect to the mass of the fiber defined by the following formula is 0.5 mass% or less, more preferably 0.3 mass% or less. It is more preferably 1% by mass or less, further preferably 0.08% by mass or less, further preferably 0.06% by mass or less, further preferably 0.04% by mass or less, and 0.02% by mass. More preferably, it is as follows.
A = (ms / mf) × 100
Here, A means the adhesion rate (%) of the deposit, ms means the mass (g) of the deposit, and mf means the mass (g) of the fiber. This deposit includes an extract obtained by immersing the fiber in hot water (for example, water at 80 to 100 ° C.) for 15 minutes, and an extract obtained by immersing the fiber in a hot methanol solution for 15 minutes. Both are included.

  In addition, it is preferable to use fibers in which a gas is dispersed as a dispersion medium (especially air is preferable) because fibers can be easily collected in a state where density unevenness is small and a separation material exhibiting a good separation action can be easily manufactured. In particular, the fibers dispersed by ejecting fibers from the dispersion nozzle into the gas by the action of the compressed gas are preferable because they are separated into individual fibers and can be uniformly dispersed. For example, it is possible to use a fiber in which a fiber is ejected from a dispersion nozzle into a gas by the action of a compressed gas described in JP-A-2002-155458.

  More specifically, a fiber group is first prepared. This fiber group is a group of fibers, and the number thereof is not particularly limited. Moreover, the state is not particularly limited, and examples thereof include a bundle state in which fibers are regularly aligned in a certain direction, and an agglomerated state in which the fibers are randomly aligned. Among these, the bundle state is preferable because of excellent dispersibility due to the action of the compressed gas. In addition, when the fiber is in an entangled state, the fiber is preferably not in an entangled state because it is difficult to separate the fibers into individual fibers and uniformly disperse even by the action of the compressed gas. For example, it is preferable not to use an aggregate of ultrafine stretched fibers obtained by beating a splittable fiber that can be mechanically divided by a beater or the like, or pulp that is beaten by a beater or the like because the fibers are in an entangled state. It should be noted that ultra-fine drawn fibers are generated by the action of compressed gas, and the ultra-fine drawn fibers are in an entangled state (for example, fully aromatic polyamide fiber, cellulose fiber obtained by solvent extraction method, etc.) A group of can be used. For example, the ultra-fine drawn fiber group is produced by removing the sea component of the sea-island type fiber produced by the composite spinning method or the mixed spinning method, thereby generating the ultra-fine drawn fiber composed of the island component or by the super draw method. be able to. According to the former method, a bundle of ultrafine stretched fibers can be formed, and no adherent such as a surfactant or a paste is attached, and the filterability of plasma or serum components is inhibited. It is preferable because there is no.

  Next, the fiber group is supplied to the dispersion nozzle, and is blown into the gas from the dispersion nozzle by the action of the compressed gas so as to be separated and dispersed into individual fibers.

  If the flow of the compressed gas supplied to the dispersion nozzle is spiral, fibers tend to be entangled with each other to generate pills or evenly disperse. The flow is preferably substantially laminar. As a dispersion nozzle capable of supplying compressed gas that is substantially laminar in this way, for example, a Venturi tube can be mentioned.

  In addition, it is preferable to provide a collision member in front of the dispersion nozzle ejection part in order to collide with the fiber group and promote separation into individual fibers or promote dispersion of the generated fibers. This collision member may have any shape, but in order to achieve the above-mentioned effect, a flat collision member, a bell-shaped collision member, a conical collision member, a bell-shaped projection and a flat collision member Can be used, or a conical protrusion and a flat collision part can be integrated, and the bell-shaped protrusion and the flat collision part are integrated. A collided member in which a conical protrusion or a conical protrusion and a flat collision are integrated is preferable.

Any gas may be used as the compressed gas, but air is suitable for manufacturing. The compressed gas is separated from the fiber group into individual fibers, and the gas passage speed at the dispersion nozzle outlet is 100 m / sec. So that the fibers can be sufficiently dispersed. The above is preferable. For the same reason, the pressure of the compressed gas is preferably ² kg / cm ² or more. The “gas passage speed” means a value obtained by dividing the flow rate (m ³ / sec) of the gas ejected from the dispersion nozzle at 1 atm by the transverse area (m ² ) at the dispersion nozzle ejection port.

  Further, the gas as a dispersion medium for dispersing the fibers ejected from the dispersion nozzle is not particularly limited, but air is suitable for production.

  In the accumulation step of the present invention, it is preferable that the fibers f are also accumulated in the non-through hole portion (1b in FIG. 1) of the preforming support 1. In this way, the fibers f are accumulated also in the non-through-hole portion 1b, and the fibers in the non-through-hole portion 1b are also fixed in the fixing step described later, so that the fixed fiber assembly is removed from the preforming support body 1. In the state where a desired number of fixed fiber aggregates are laminated with certainty, it can be moved into the molding container. That is, in the fixing step (especially in the case of fusion), the fibers in the non-through-hole portion 1b are connected even when the fixed-fiber assembly shrinks and the volume of the fixed-fiber assembly is smaller than the through-hole 1a. Since the fixed fiber assembly can be prevented from falling off from the preforming support 1, the fixed fiber assembly can be reliably moved into the molding container in a state where a desired number of fixed fiber assemblies are laminated. . As a method for accumulating fibers in the non-through hole portion 1b of the preforming support 1 in this way, for example, the surface of the non-through hole portion 1b of the preforming support 1 is made to have a rough surface structure, or uneven processing is performed. Or a method of making the fiber easy to get caught, such as a material made of a material having a high coefficient of friction, or a method of facilitating the accumulation in the non-through-hole portion by reducing the suction force when sucking the gas, or these And the like.

  Next, as shown in a schematic perspective view in which a part of the fixing step is cut out in FIG. 2, (2) the fibers are fixed while the fibers are accumulated in the through holes of the preforming support. Then, a fixing step of forming the fixed fiber assembly-containing preforming support body including the fixed fiber assembly in the through hole of the preforming support body is performed. In the fixing step in FIG. 2, the fibers f are supplied to the oven 4 while being accumulated in the through holes 1 a of the preforming support 1, and the accumulated fibers f are heated by the heat of the oven 4. Therefore, the fiber f is fused, and the fixed fiber aggregate-containing preforming support 10 having the fixed fiber aggregate ff in which the fibers are fixed is provided in the through hole of the preforming support 1 is formed. . Since the fibers are fused and fixed while the fibers f are accumulated in the through holes 1a of the preforming support 1, a fixed fiber aggregate ff corresponding to the shape of the through holes 1a is formed. The In the case of FIG. 2, a columnar fixed fiber assembly ff is formed. In the case of FIG. 2, the fiber f is fused and fixed by the heat of the oven 4. For example, the fiber f may be fused and fixed by a hot air dryer, an infrared heater, a hot press machine, a reliant press machine, or the like. good. Moreover, it is not limited to fusion fixing, It can also fix by adhesion | attachment by a liquid binder, adhesion | attachment by a powdery binder, etc. However, it is preferable that the separating material does not contain an adhering substance that impairs the filtration performance of plasma or serum components, and it is preferable that the separation material is fused and fixed so as to be excellent in form retention and handling.

  As described above, when the fibers f are also accumulated in the non-through hole portion 1b of the preforming support 1, the fibers are also fixed and the fixed fiber assembly ff is used as the preforming support. It is preferable not to drop off from 1. In particular, when the fibers f are fixed by fusing the fibers f, the fixed fiber assembly ff contracts depending on the fiber characteristics and the fusing temperature, and the volume tends to be smaller than the through-hole 1a of the preforming support 1. However, the above-mentioned problem can be effectively solved by fusing the fibers f in the non-through-hole portions 1b of the preforming support 1 as well. In addition, although fixation of the fiber f in the through-hole 1a of the preforming support body 1 and fixation in the non-through-hole part 1b are generally performed simultaneously, you may carry out by providing a time difference. Moreover, the fixing method of the fiber f in the through-hole 1a of the preforming support body 1 and the fixing method in the non-through-hole portion 1b are not necessarily the same.

  Next, although not shown in the drawing, (3) by repeating the stacking step and the fixing step, a plurality of fixed fiber aggregate-containing preforming supports each having a fixed fiber aggregate in the through holes of the preforming support body. A repeating step of forming is performed. The preforming support used in this repeating step is a preforming support used in the accumulation step so that the fixed fiber assembly can be moved in a continuously laminated state in the movement step described later. It is preferable to use a preforming support having a through hole that can be laminated so as to coincide with the center of any through hole of the body 1. In particular, it is preferable to use a preforming support provided with exactly the same size of through holes in the same arrangement. The number of repetitions varies depending on the thickness of the separating material produced by laminating and molding the fixed fiber assembly, the thickness of the preforming support, etc., and is not particularly limited, and is set as appropriate. can do.

  In the repetition process, a plurality of fixed fiber aggregate-containing preform forming supports having fixed fiber aggregates having different average fiber diameters are formed, and the average fiber diameter of the fixed fiber aggregates increases in order in the laminating process described later. Or a laminate so as to become smaller in order, forming a fixed fiber aggregate-containing preform forming support laminate, it is possible to produce a separating material in which the average fiber diameter changes in order, the average of this separating material By supplying blood from the side having the larger fiber diameter, blood cell components having larger particle diameters can be captured in order, and this separating material is preferable because it can be separated efficiently. In addition, it is preferable that the difference of the average fiber diameter of the adjacent fixed fiber aggregate in the support laminated body for preforming fixed fiber aggregate-containing preforming is 0.1 to 2 μm. In this way, the fixed fiber aggregate-containing preform forming support including fixed fiber aggregates having different average fiber diameters has different fiber diameters, different fiber blends, or a combination thereof as fibers supplied in the accumulation process. Can be formed.

  In addition, in the stacking process in the repetition process, a plurality of preforming supports having different through-hole sizes are used as the preforming support, and in the lamination process, the preforming support having a fixed fiber stack is penetrated. Laminating so that the size of the holes is increased in order or decreasing in order to form a fixed fiber aggregate-containing preform forming support laminate, the cross-sectional area increases in order from one surface to the other. Alternatively, it is possible to manufacture a columnar separating material that becomes smaller. By loading this columnar separation material into a separation container having a constant cross-sectional area in the loading region so that the larger surface of the columnar separation material is in contact with the sealing portion, the columnar separation material is loaded. Since the compressibility of the sample increases as it approaches the sealing part and density density can be formed in the separation material, it is easy to produce a plasma or serum filter that can be captured in order from blood cell components with larger particle sizes and can be separated efficiently. Is preferred. The preforming support 1 used in the accumulation step is also used so that the preforming support used in this case can be moved in a state where the fixed fiber assembly is continuously laminated in the movement step described later. A preforming support having a through hole that can be laminated so as to coincide with the center of any of the through holes is preferable.

  Next, as shown in a schematic perspective view of the lamination step in FIG. 3, (4) possessing a plurality of fixed fiber aggregates so that the centers of the through holes of the fixed fiber aggregate-holding preform 10 are aligned. A lamination step is performed in which the preforming support 10 is laminated to form the fixed fiber aggregate-containing preforming support laminate 5. In the laminating step in FIG. 3, a fixed fiber assembly-containing preforming support 10 having through holes of exactly the same size in exactly the same arrangement is stacked as the fixed fiber assembly-containing preforming support 10. Therefore, the through holes are in a columnar state having a continuous height, and the fixed fiber assembly ff is laminated in the continuous through holes.

  As described above, in the repetition process, when a plurality of fixed fiber aggregate-containing preform forming supports having fixed fiber aggregates having different average fiber diameters are formed, the average fiber diameters of the fixed fiber aggregates are in order. It is preferable that the fixed fiber aggregate-containing preform forming support laminate 5 is formed by being laminated so as to increase or decrease in order. In addition, as described above, when a plurality of preforming supports having different through-hole sizes are used as the preforming support in the stacking process in the repetitive process, the support for supporting preforming with a fixed fiber aggregate is used. It is preferable to form the support laminate 5 for pre-molding having fixed fiber aggregates by laminating so that the size of the through-holes of the body becomes larger or smaller in order.

  Next, as shown in a schematic perspective view of the moving step in FIG. 4, (5) by applying an external force to the fixed fiber aggregate ff of the fixed fiber aggregate-containing preforming support laminate 5, A moving step of moving into a molding container 7 having an inner wall surface of a desired shape is performed in a state where the number of fixed fiber aggregates ff corresponding to the number of laminations of the fixed fiber aggregate-containing preforming support is laminated. . In the moving step in FIG. 4, as an external force, the projection plate 6 is pressurized by a projection plate 6 having a number of columnar projections having a center that coincides with the center of any through-hole of the preforming support. The fixed fiber assembly ff is moved in a laminated state into a molding container 7 having a cylindrical inner wall surface located on the opposite side. The molding container 7 has an inner wall surface corresponding to the outer shape of the separating material. In FIG. 4, the protruding plate 6 is used as an external force. However, the protruding plate 6 is not limited to the protruding plate, and may be a gas such as air or a liquid such as water. In FIG. 4, the projection plate 6 is used for simultaneous movement, but it is also possible to apply an external force to each fixed fiber assembly and move it with a time difference. Further, if the projection plate 6 can press the fixed fiber assembly ff, the projection plate 6 does not need to have a center that coincides with the center of any through-hole of the preforming support, and needs to be cylindrical. Nor. Furthermore, in FIG. 4, although the molding container 7 having a cylindrical inner wall surface is used, it does not have to be cylindrical. In some cases, when the inner wall surface of the molding container 7 is conical, a conical separating material can be produced, and this separating material is transferred to a separating container having a constant cross-sectional area in the loading region. By loading so that the surface having a larger cross-sectional area is in contact with the sealing portion, the compressibility of the separating material increases as it approaches the sealing portion, and the density of the separating material can be increased. The feature is that it is easy to produce a filter for plasma or serum that can be captured in order from large blood cell components and can be separated efficiently. The molding containers 7 do not have to be independent of each other, and the molding containers may be connected to each other.

  Then, as shown in a schematic perspective view in which a part of the molding process is cut out in FIG. 5, (6) the laminated fixed fiber assembly ff in the molding container 7 is formed into the shape of the inner wall surface of the molding container 7. And forming a plasma or serum separation material. In the molding step in FIG. 5, the forming container 7 holding the laminated fixed fiber aggregate ff is supplied to the oven 40, and the laminated fixed fiber aggregate ff is heated by the heat of the oven 40 to produce a separating material. is doing. Therefore, the fibers are fused together to form a separating material that is molded into a shape along the inner wall surface of the molding container 7. In the case of FIG. 5, it becomes a columnar separating material. In addition, when thermoformed in a compressed state, the uniformity of the apparent density of the laminated fixed fiber assembly is increased, it is easy to produce a uniform separation material with no unevenness, and a uniform separation material is produced. It is suitable because it is easy. As a method of thermoforming in this compressed state, for example, a method of supplying to the oven in a compressed state using a jig can be mentioned, and the protruding plate 6 used as an external force as the jig (see FIG. 4) Can be used, and a jig other than the external force can be used. In addition, a spacer can be interposed between the molding container 7 and the jig so that the laminated fixed fiber assembly ff can be compressed to a desired thickness. As this spacer, it is possible to use a part or all of the preforming support constituting the fixed fiber aggregate-containing preforming support laminate 5, or a separately prepared spacer can be used. In general, if some or all of the projection plate 6 used as an external force or the preforming support constituting the preformed support laminate 5 having a fixed fiber assembly is used, a separate jig or spacer is prepared. This is preferable because there is no need to do this.

  As described above, the manufacturing method of the separation material of the present invention is a large fiber and easy to handle fixed fiber aggregate-containing preform forming support, and then moved into a molding container in a state where the fixed fiber aggregate is laminated, Since it is a molding method, it is excellent in manufacturing workability. Further, since all or most of the fibers are accumulated in the through holes of the preforming support and the fibers can be used without waste, this is a manufacturing method that can suppress an increase in cost.

  The method for producing a filter for plasma or serum of the present invention (hereinafter sometimes simply referred to as “filter”) is a method of loading a separation material into a separation container following the method for producing a separation material as described above. Process. As shown in a schematic perspective view in the loading process in FIG. 6, as the separation container 8, a loading port 8 a for loading the separating material, and the loading port 8 a are opposed to and contacted with the separating material and fixed. A sealing section 8b is provided, and the cross-sectional area is constant from the loading port side end portion 8fa of the loading region 8f in which the separation material is loaded toward the sealing portion side end portion 8fb of the loading region 8f. , And the separation material S having a larger cross-sectional area than the cross-sectional area of the sealing portion 8b of the separation container 8 is used as the separation material S. It is possible to manufacture a filter loaded with a part or the whole of the filter being compressed by the separation container 8. Since the separation material S in this filter is closer to the sealing portion 8b and has a higher compressibility and is in a higher density state, when blood is supplied from the loading port 8a, the blood cell components having larger particle diameters can be captured in order and efficiently. It is a filter that can be separated. Further, since the separation container 8 and the separation material S are in close contact with each other and no gap is formed between the separation container 8 and the separation material S, the blood cell component is not captured and passes through the separation material S. A filter that does not cause problems can be manufactured. Furthermore, by compressing the separation material S, even if there is density unevenness in the separation material S, the density unevenness of the separation material S is alleviated, and the pore diameter of the separation material S can be made uniform. Or it is the manufacturing method of the filter which can isolate | separate a serum component efficiently.

  In FIG. 6, the separating material S is different in the area of the Sa surface and the Sb surface that is opposite to the Sa surface, but the areas of the Sa surface and the Sb surface are the same. Also good. Moreover, it is preferable that the cross-sectional area in any place of the separating material S is wider than the cross-sectional area of the separating container 8 in the place where the separating material S finally comes into contact. In FIG. 6, since the protrusion 8c is provided on the inner wall surface corresponding to the loading port side end portion 8fa of the loading region 8f of the separation container 8, the movement of the separating material S can be prevented. In addition, when the height of the separating material S is higher than the length of the loading region 8f, since the separating material S can be fixed in a compressed state in the height direction by providing the protrusion 8c, the hole diameter is uniform. Can contribute to However, as described above, the protrusion 8c is not necessarily required as long as the separation material S and the separation container 8 can be in close contact with each other.

  Further, as shown in FIG. 7 which is a schematic perspective view of another loading step, as a separation container 8 ′, a loading port 8a ′ for loading a separating material S ′ and the loading port 8a ′ are opposed to each other and separated. A sealing portion 8b ′ that contacts and fixes the material S ′ and seals the loading region 8f ′ from the loading port side end 8fa ′ of the loading region 8f ′ in which the separating material S ′ is loaded. Crossing of the surface (Sb ′ in FIG. 7) that comes into contact with the sealing portion 8b ′ is used as the separating material S ′. When the one having an area larger than the cross-sectional area of the sealing portion 8b ′ of the separation container 8 ′ is used, a filter loaded in a state where a part or all of the separation material S ′ is compressed by the separation container 8 ′ is used. Can be manufactured. As the separating material S ′ in this filter is closer to the sealing portion 8b ′, the compression rate is higher and the density is higher. Therefore, when blood is supplied from the loading port 8a ′, the blood cell components having larger particle sizes can be captured in order. It is a filter that can be separated efficiently. Further, according to this manufacturing method, the separation container 8 ′ and the separation material S ′ are in close contact with each other, and no gap is formed between the separation container 8 ′ and the separation material S ′. In this way, it is possible to manufacture a filter that does not cause the problem of passing through the separating material S ′. Further, by compressing the separating material S ′, even if the separating material S ′ has density unevenness, the density unevenness of the separating material S ′ can be reduced, and the pore diameter of the separating material S ′ can be made uniform. This is a method for producing a filter capable of efficiently separating blood cell components and plasma or serum components.

  In FIG. 7, the same material is used as the separating material S ′ for the Sa ′ surface and the Sb ′ surface, which is the opposite surface opposite to the Sa ′ surface, but the areas of the Sa ′ surface and the Sb ′ surface. May be different. Further, it is preferable that the separation material S ′ has a wider cross-sectional area at any location than the cross-sectional area of the separation container 8 ′ where the separation material S ′ finally comes into contact. In FIG. 7, the separation container 8 ′ having a continuously reduced cross-sectional area is used. However, a separation container that decreases discontinuously, such as a stepwise decrease, may be used. In FIG. 7, since the projection 8c ′ is provided on the inner wall surface corresponding to the loading port side end 8fa ′ of the loading region 8f ′ of the separation container 8 ′, the separation material S ′ can be prevented from moving. ing. Further, when the height of the separating material S ′ is higher than the length of the loading region 8f ′, by providing the protrusion 8c ′, the separating material S ′ can be fixed in a compressed state in the height direction. This can contribute to the uniform pore diameter. However, as described above, the protrusion 8c 'is not necessarily required as long as the separation material S' and the separation container 8 'can be in close contact with each other.

  As described above, the filter manufacturing method of the present invention is merely a method of loading the formed separation material into the separation container, so that it is excellent in manufacturing workability, can use resources without waste, and can suppress an increase in cost. It is.

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

(Preparation of extra fine stretched fiber A)
Sea island type fiber obtained by the composite spinning method (25 mins fineness: 1.7 dtex, length: 1 mm) in which 25 island components consisting of high density polyethylene and polypropylene are present in the sea component consisting of polylactic acid ) Was prepared. This sea-island type fiber is immersed in a 10 mass% sodium hydroxide aqueous solution, and polylactic acid, which is a sea component, is extracted and removed by hydrolysis, then air-dried, and ultra-fine drawn fiber A in which high-density polyethylene and polypropylene are mixed ( Fiber diameter: 2 μm, cut fiber length: 1 mm, σ / d = 0.06, not fibrillated, having substantially the same diameter in the fiber axis direction, cross-sectional shape: sea-island type, deposit rate: 0 A bundle group of ultrafine stretched fibers A in which a bundle of less than .02 mass%) was bundled was prepared.

(Preparation of ultrafine stretched fiber B)
Sea island type fiber obtained by the composite spinning method (25 fineness: 1.7 tex, length: 0.5 mm) Prepared). This sea-island type fiber is immersed in a 10 mass% sodium hydroxide aqueous solution, and polylactic acid, which is a sea component, is extracted and removed by hydrolysis, then air-dried, and ultra-fine drawn fiber B in which high-density polyethylene and polypropylene are mixed ( Fiber diameter: 1 μm, cut fiber length: 0.5 mm, σ / d = 0.06, not fibrillated, having substantially the same diameter in the fiber axis direction, cross-sectional shape: sea-island type, deposit rate : Less than 0.02 mass%) was prepared as a bundle of ultrafine drawn fibers B.

(Example 1)
(1) Accumulation process;
By introducing compressed air (pressure: 6 kg / cm ² , substantially laminar flow) from a compressed gas inlet into a Venturi tube (dispersing nozzle) having a circular cross section at the jet outlet (diameter: 8.5 mm) , A bundle group of ultra-fine drawn fibers A and a bundle group of ultra-fine drawn fibers B are supplied to the venturi pipe at a mass ratio of 90:10, and the ultra-fine drawn fibers A and B are ejected from the venturi pipe into the air ( gas passing speed in the spout of the venturi: 147m / s, the ejection amount from the ejection outlet:. to about 0.5 m 3 / ^min), and the collision member provided on spout front of the venturi tube (conical protrusion And the flat colliding part are collided with each other, the distance between the colliding part of the colliding member and the dispersion nozzle ejection part side surface of the colliding part is 15 mm), and the ultrafine drawn fibers A and B are dispersed in the air. .

Next, a 1.1 mm thick spare having a cylindrical through-hole with a diameter of 12 mm, which is further placed on a wet nonwoven fabric (weight per unit: 20 g / m ² ) placed on a moving collector (net). The dispersed ultrafine drawn fibers A and B were accumulated in the through holes of a molding support (a composite sheet obtained by bonding a silicone rubber sheet and a fluoroglass sheet). The preforming support was placed so that the silicone rubber sheet surface was in contact with the wet nonwoven fabric, and air was sucked (0.7 m ³ / min.) By a suction box placed under the collector. Further, the ultrafine drawn fibers A and B were also accumulated in the non-through hole portion.

(2) fixing step;
By supplying ultra-fine drawn fibers A and B in the through holes of the preforming support body to a reliant press machine (press pressure: 2 kg / cm ² ) set at a temperature of 130 ° C., A high-density polyethylene component of drawn fibers A and B is fused to form a preformed support having a fused ultrafine drawn fiber assembly having a fused ultrafine drawn fiber assembly in the through hole of the preforming support. did. At the same time, the ultrathin drawn fibers A and B in the non-through hole portions were also fused.

(3) Repeating process;
Using the same preforming support as the preforming support, the stacking step and the fixing step were repeated 100 times to form 100 fusion-supported ultra-stretched fiber aggregate-containing preforming supports.

(4) Lamination process;
By laminating the 100 fused ultrafine stretched fiber assembly-containing preforming supports so that the centers of the through-holes of the fused ultrafine stretched fiber aggregate-containing preforming support coincide, A support laminate for preforming with a stretched fiber assembly was formed.

(5) moving process;
A cylindrical protrusion having a center coinciding with the center of any through-hole of the preforming support for each fused ultrafinely stretched fiber assembly of the fusion-supported ultra-stretched fiber aggregate-containing preform preform support laminate By pressing with a protruding plate having a large number (diameter: 10 mm, height: 120 mm), a cylindrical molding having an inner diameter of 12 mm and a depth of 120 mm in a state where 100 fused ultrafine stretched fiber assemblies are laminated. Moved to a container.

(6) molding step;
The fused ultra-fine stretched fiber assembly moved to the cylindrical molding container was compressed by the cylindrical projection plate used in the moving process until the height of the fused ultra-fine stretched fiber assembly was 22 mm. Supply to an oven set at a temperature of 130 ° C. in the state, melt after cooling the high-density polyethylene component of the ultrafine stretched fibers A and B, mold along the shape of the inner wall surface of the cylindrical molding container, and separate A material (see FIG. 7, diameter: 11.5 mm, height: 22 mm, apparent density: 0.15 g / cm ³ ) was produced.

  In the production of this separating material, the fused ultrafine stretched fiber aggregate-containing preform forming support was laminated and then moved to the molding container, so that the manufacturing workability was excellent. In addition, since the ultra-fine stretched fibers A and B are accumulated and fused also in the non-through-hole portion, the work can be performed without dropping the fused ultra-fine stretched fiber assembly from the preformed support having the fused ultra-fine stretched fiber assembly. The workability was excellent. In addition, since the amount of extra fine drawn fibers A and B in the non-through hole portion was less than the amount of extra fine drawn fibers A and B accumulated in the through holes of the preforming support, the extra fine drawn fibers that do not participate in the separation component constituting fibers The separation material was able to be manufactured efficiently by using ultra fine drawn fibers in a small amount.

(7) loading step;
The cross-sectional area continuously decreases from the loading port side end portion (diameter: 11.3 mm) of the loading region to the sealing portion side end portion (diameter: 10.7 mm) of the loading region. A frustum-shaped separation container having a polycarbonate membrane (pore diameter: 0.4 μm) welded to the surface opposite to the contact surface (length from loading port to sealing portion: 50 mm, loading port side end of loading region From the loading area to the end of the sealing portion side: 22 mm), and the separation material is loaded so that the sealing portion of the separation container and the separation material come into contact with each other to produce a filter. did. In this filter, the entire separating material was loaded in a state compressed by the separating container.

(Example 2)
In the same manner as in Example 1 except that the mass ratio of the ultrafine stretched fiber A and the ultrafine stretched fiber B in the (1) accumulation step of Example 1 was set to 80:20, a cylindrical separator (see FIG. 7). , diameter: 11.5 mm, height: 22 mm, apparent density: 0.14g / cm ³⁾ was prepared. Also in the production of this separating material, it was excellent in manufacturing workability, and the separating material could be efficiently produced using ultrafine drawn fibers.

  Next, (7) loading process was performed in exactly the same manner as in Example 1 to produce a filter. In this filter, the entire separating material was loaded in a state compressed by the separating container.

(Example 3)
In the same manner as in Example 1 except that the mass ratio between the ultrafine drawn fiber A and the ultrafine drawn fiber B in the (1) accumulation step of Example 1 was set to 50:50, a cylindrical separator (see FIG. 7). , Diameter: 11.5 mm, height: 22 mm, apparent density: 0.14 g / cm ³ ). Also in the production of this separating material, it was excellent in manufacturing workability, and the separating material could be efficiently produced using ultrafine drawn fibers.

  Next, (7) loading process was performed in exactly the same manner as in Example 1 to produce a filter. In this filter, the entire separating material was loaded in a state compressed by the separating container.

Example 4
In the same manner as in Example 1 except that the mass ratio of the ultrafine stretched fiber A and the ultrafine stretched fiber B in the (1) accumulation step of Example 1 was set to 80:20, a cylindrical separator (see FIG. 7). , Diameter: 11.5 mm, height: 22 mm, apparent density: 0.15 g / cm ³ ). Also in the production of this separating material, it was excellent in manufacturing workability, and the separating material could be efficiently produced using ultrafine drawn fibers.

  Next, the cross-sectional area of the loading port side end portion (diameter: 11 mm) of the loading region and the sealing portion side end portion (diameter: 11 mm) of the loading region is the same, and the contact surface of the sealing portion with the separating material is Cylindrical separation container with a polycarbonate membrane (pore diameter: 0.4 μm) welded to the opposite surface (length from the loading port to the sealing portion: 50 mm, sealing from the loading port side end of the loading region to the loading region) The length to the part side end: 22 mm) was prepared, and the filter was manufactured by loading the separation material so that the sealing portion of the separation container and the separation material were in contact with each other. In this filter, the entire separating material was loaded in a state compressed by the separating container.

(Example 5)
(1) Accumulation process (I);
Example 1 (1) Through-holes of the preforming support in exactly the same manner as in Example 1 except that the mass ratio of the ultrafine drawn fiber A and the ultrafine drawn fiber B in the accumulation step was set to 50:50. Inside, ultra-fine drawn fibers A and B were accumulated. Note that the ultrafine drawn fibers A and B were also accumulated in the non-through hole portion.

(2) Fixing step (I);
By supplying ultra-fine drawn fibers A and B in the through holes of the preforming support body to a reliant press machine (press pressure: 2 kg / cm ² ) set at a temperature of 130 ° C., A high-density polyethylene component of the drawn fibers A and B is fused, and a preformed support having a fused ultrafine stretched fiber assembly having a fused ultrafine stretched fiber assembly in the through hole of the preforming support (i) ) Was formed. At the same time, the ultrathin drawn fibers A and B in the non-through hole portions were also fused.

(3) Repeat step (a);
The accumulation step (a) and the fixing step (a) were repeated 30 times to form 30 fusion-supported ultrafine stretched fiber aggregate-containing preforms (a).

(1 ') Accumulation process (b);
Example 1 (1) Through-holes of the preforming support in exactly the same manner as in Example 1 except that the mass ratio of the ultrafine drawn fiber A and the ultrafine drawn fiber B in the accumulation step was set to 80:20. Inside, ultra-fine drawn fibers A and B were accumulated. Note that the ultrafine drawn fibers A and B were also accumulated in the non-through hole portion.

(2 ′) fixing step (b);
By supplying ultra-fine drawn fibers A and B in the through holes of the preforming support body to a reliant press machine (press pressure: 2 kg / cm ² ) set at a temperature of 130 ° C., A high-density polyethylene component of the drawn fibers A and B is fused, and a preformed support having a fused ultrafine stretched fiber assembly having a fused ultrafine stretched fiber assembly in the through hole of the preforming support (B) ) Was formed. At the same time, the ultrathin drawn fibers A and B in the non-through hole portions were also fused.

(3 ′) Repeating step (b);
The accumulation step (b) and the fixing step (b) were repeated 30 times to form 30 fusion-supported ultrafine stretched fiber aggregate-containing preforming supports (b).

(1 ″) Accumulation process (c);
Example 1 (1) Through-holes of preforming support in exactly the same manner as in Example 1 except that the mass ratio of the ultrafine drawn fiber A and the ultrafine drawn fiber B in the accumulation step was set to 90:10. Inside, ultra-fine drawn fibers A and B were accumulated. Note that the ultrafine drawn fibers A and B were also accumulated in the non-through hole portion.

(2 ″) fixing process (c);
By supplying ultra-fine drawn fibers A and B in the through holes of the preforming support body to a reliant press machine (press pressure: 2 kg / cm ² ) set at a temperature of 130 ° C., A high-density polyethylene component of the drawn fibers A and B is fused, and a preformed support having a fused ultrafine stretched fiber assembly having a fused ultrafine stretched fiber assembly in the through hole of the preforming support (ha ) Was formed. At the same time, the ultrathin drawn fibers A and B in the non-through hole portions were also fused.

(3 ″) Repeating step (c);
The stacking step (c) and the fixing step (c) were repeated 40 times to form 40 sheets of preformed supports (c) having a fusion-bonded ultrafine stretched fiber assembly.

(4) Lamination process;
The fusion-supported ultra-stretched fiber assembly-containing preforming support (a), (b) and (c) so that the centers of the through holes coincide with each other, C) Laminate 40 sheets, 30 sheets of pre-molding support (b) possessing fused ultra-fine stretched fiber assemblies (b) and 30 support bodies for preforming (a) possessing fused ultra-fine stretched fiber assemblies. A support laminate for preforming with a stretched fiber assembly was formed.

(5) moving process;
Pre-molding for each fused ultra-fine stretched fiber assembly derived from the fused ultra-fine stretched fiber assembly-containing preform forming support (a) 100 fused ultrafine stretched fibers accumulated by pressing with a projection plate having a large number of cylindrical projections (diameter: 10 mm, height: 120 mm) having a center that coincides with the center of any through hole of the support for use In a state where the bodies were laminated, the body was moved to a cylindrical molding container having an inner diameter of 12 mm and a depth of 120 mm.

(6) molding step;
The fused ultra-fine stretched fiber assembly moved to the cylindrical molding container was compressed by the cylindrical projection plate used in the moving process until the height of the fused ultra-fine stretched fiber assembly was 22 mm. Supply to an oven set at a temperature of 130 ° C. in the state, melt after cooling the high-density polyethylene component of the ultrafine stretched fibers A and B, mold along the shape of the inner wall surface of the cylindrical molding container, and separate wood (see FIG. 7, the diameter: 11.5 mm, height: 22 mm, apparent density: 0.14g / cm ³⁾ was prepared. Also in the production of this separating material, it was excellent in manufacturing workability, and the separating material could be efficiently produced using ultrafine drawn fibers.

(7) loading step;
The cross-sectional area continuously decreases from the loading port side end portion (diameter: 11.3 mm) of the loading region to the sealing portion side end portion (diameter: 10.7 mm) of the loading region. A frustum-shaped separation container having a polycarbonate membrane (pore diameter: 0.4 μm) welded to the surface opposite to the contact surface (length from loading port to sealing portion: 50 mm, loading port side end of loading region To the sealing region side end of the loading region: 22 mm), the sealing portion of the separation container, and the preforming support (a) The filter was manufactured by loading the separation material so that the surface derived from the fused ultrafine stretched fiber assembly in (1) was in contact with the surface. In this filter, the entire separation material was loaded in a state compressed by the separation container.

(Example 6)
(1) Accumulation process (d);
Example 1 (1) Through-holes of the preforming support in exactly the same manner as in Example 1 except that the mass ratio of the ultrafine drawn fiber A and the ultrafine drawn fiber B in the accumulation step was set to 80:20. Inside, ultra-fine drawn fibers A and B were accumulated. Note that the ultrafine drawn fibers A and B were also accumulated in the non-through hole portion.

(2) Fixing step (d);
By supplying ultra-fine drawn fibers A and B in the through holes of the preforming support body to a reliant press machine (press pressure: 2 kg / cm ² ) set at a temperature of 130 ° C., A high-density polyethylene component of the drawn fibers A and B is fused, and a preformed support having a fused ultrafine stretched fiber assembly having a fused ultrafine stretched fiber assembly in the through-hole of the preforming support (n) ) Was formed. At the same time, the ultrathin drawn fibers A and B in the non-through hole portions were also fused.

(3) Repeating step (d);
The accumulation step (d) and the fixing step (d) were repeated 50 times to form 50 fusion-supported ultrafine stretched fiber aggregate-containing preforming supports (d).

(1 ') Accumulation process (e);
In Example 1 (1), the mass ratio of the ultrafine drawn fiber A and the ultrafine drawn fiber B in the accumulation step was set to 80:20, and cylindrical through holes with a diameter of 13 mm were staggered as a preforming support. Except for using a preforming support having a thickness of 1.1 mm (composite sheet obtained by bonding a silicone rubber sheet and a fluoroglass sheet), the same procedure as in Example 1 was performed. Ultrafine stretched fibers A and B were accumulated in the through holes. Note that the ultrafine drawn fibers A and B were also accumulated in the non-through hole portion.

(2 ′) fixing step (e);
By supplying ultra-fine drawn fibers A and B in the through holes of the preforming support body to a reliant press machine (press pressure: 2 kg / cm ² ) set at a temperature of 130 ° C., A high-density polyethylene component of the drawn fibers A and B is fused, and a preformed support having a fused ultrafine stretched fiber assembly having a fused ultrafine stretched fiber assembly in the through hole of the preforming support (e.g. ) Was formed. At the same time, the ultrathin drawn fibers A and B in the non-through hole portions were also fused.

(3 ′) Repeat step (e);
The stacking step (e) and the fixing step (e) were repeated 50 times to form 50 sheets of preformed support (e) having a fused ultrafine stretched fiber assembly.

(4) Lamination process;
50 fused ultrafine stretched fiber assembly-containing preforms (d) and (e) 50 preformed support (d) so that the centers of the through-holes of the fused ultrafine stretched fiber assemblies (d) are aligned. Then, the fusion-supported ultrafine stretched fiber assembly-containing preforming support (e) was laminated in the order of 50 sheets to form a fused ultrafine stretched fiber assembly-containing preforming support laminate.

(5) moving process;
Pre-molding of each fused ultra-fine stretched fiber assembly derived from the fused ultra-fine stretched fiber assembly-containing pre-forming support (d) 100 fused ultrafine stretched fibers accumulated by pressing with a projection plate having a large number of cylindrical projections (diameter: 10 mm, height: 120 mm) having a center that coincides with the center of any through hole of the support for use In a state where the bodies were stacked, the body was moved to a two-stage truncated cone shaped container. The two-stage frustoconical molded container has a circular shape with an inner diameter of 13 mm at the insertion port, and a first frustoconical inner wall with a circular shape with an inner diameter of 12.5 mm at a position (intermediate part) at a depth of 98 mm from the insertion port. And a second cone having a circular shape with an inner diameter of 11.5 mm on the bottom surface facing the insertion portion, which is located at a depth of 22 mm from the intermediate portion. It had a trapezoidal inner wall part.

(6) molding step;
The fixed fiber assembly that has been moved to the two-stage frustoconical shaped container is compressed by the cylindrical projection plate used in the moving process until the height of the fused ultrafine stretched fiber assembly is 22 mm, and this compressed state As it is, it is supplied to an oven set at a temperature of 130 ° C., and the high-density polyethylene component of the ultrafine stretched fibers A and B is melted and then cooled to the shape of the second frustoconical inner wall of the two-stage frustoconical shaped container. along by molding, the separation material (see FIG. 6, the upper base diameter: 11.5 mm, the lower base diameter: 12.5 mm, height: 22 mm, apparent density: 0.14g / cm ³⁾ was prepared. Also in the production of this separating material, it was excellent in manufacturing workability, and the separating material could be efficiently produced using ultrafine drawn fibers.

(7) loading step;
The cross-sectional area of the loading port side end (diameter: 11.5 mm) of the loading region and the sealing region side end (diameter: 11.5 mm) of the loading region is the same, and the contact surface of the sealing portion with the separation material A cylindrical separation container having a polycarbonate membrane (pore diameter: 0.4 μm) welded to the opposite surface (length from the loading port to the sealing portion: 50 mm, from the loading port side end of the loading region to the loading region side The length to the sealing part side end: 22 mm) was prepared, and the filter was manufactured by loading the separation material so that the sealing part of the separation container and the lower bottom surface of the separation material were in contact with each other. . In this filter, the entire separating material was loaded in a state compressed by the separating container.

(Evaluation of separability)
First, 2 ml of blood obtained by adding heparin as a non-coagulant to the collected blood was prepared as test blood.

  Next, the test blood was injected from the loading port of each separation container kept in a vacuum state, and it was observed whether plasma or serum components were separated and filtered after 3 minutes.

  As a result, all the filters of Examples 1 to 6 were able to separate 0.3 to 0.5 ml of plasma or serum components and filter them. Thus, the production method of the present invention was a method capable of producing a separation material for plasma or serum having excellent separation performance.

Schematic perspective view of the integration process Schematic perspective view with a part of the fixing process cut out Schematic perspective view of the lamination process Schematic perspective view of moving process Schematic perspective view with a part of the molding process cut out Schematic perspective view of the loading process Schematic perspective view of another loading process

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Preliminary support body 1a Through-hole 1b Non-through-hole part 2 Collecting body 3 Suction device 4, 40 Oven 5 Fixed fiber accumulation | storage body holding | maintenance support laminated body 6 Protrusion board 7 Molding container 8, 8 'For isolation | separation Container 8a, 8a 'Loading port 8b, 8b' Sealing part 8c, 8c 'Projection 8f, 8f' Loading region 8fa, 8fa 'Loading port side end 8fb, 8fb' Sealing side end 10 Holding fixed fiber assembly Pre-molding support f Fiber ff Fixed fiber assembly S, S 'Separation material

Claims (12)

(1) An accumulation process for accumulating fibers in through holes of a preforming support having a large number of through holes,
(2) Holding a fixed fiber assembly having fixed fibers in a through hole of a preforming support, with the fibers fixed in a state where the fibers are accumulated in the through hole of the preforming support. A fixing step for forming a preforming support,
(3) Repeating the stacking step and the fixing step to form a plurality of fixed fiber aggregate-containing preforming supports each having a fixed fiber aggregate in the through-holes of the preforming support,
(4) A plurality of fixed fiber assembly-containing preforming supports are laminated so that the centers of the through holes of the fixed fiber assembly-containing preforming support coincide with each other, and the fixed fiber assembly-containing preform is used. A laminating step for forming a support laminate,
(5) By applying an external force to the fixed fiber assembly of the fixed fiber aggregate-containing preforming support laminate, the number of fixations corresponding to the number of layers of the fixed fiber aggregate-containing preforming support is applied. A moving step of moving the fiber aggregate into a molding container having an inner wall surface of a desired shape,
(6) A molding process in which the laminated fixed fiber assembly in the molding container is molded along the shape of the inner wall surface of the molding container to obtain a plasma or serum separating material,
A method for producing a plasma or serum separation material. The method for producing a separation material for plasma or serum according to claim 1, wherein in the accumulation step, fibers dispersed in a gas as a dispersion medium are accumulated in the through holes of the preforming support. The accumulation step includes collecting fibers dispersed by ejecting fibers from a dispersion nozzle into a gas by the action of a compressed gas in the through holes of the preforming support body. 2. A method for producing a plasma or serum separation material according to 2. 4. The fiber according to claim 1, wherein in the accumulation step, fibers mainly composed of ultrafine drawn fibers having a fiber diameter of 4 μm or less are accumulated in the through holes of the preforming support. A method for producing a plasma or serum separation material. The fiber is accumulated in the non-through hole portion of the preforming support in the collecting step, and the fibers in the non-through hole portion are also fixed in the fixing step. A method for producing a plasma or serum separation material according to any one of the above. The method for producing a separator for plasma or serum according to any one of claims 1 to 5, wherein in the fixing step, the fibers are fused to fix the fibers together. In the repetition process, while forming a plurality of fixed fiber aggregate-holding preforms having fixed fiber aggregates having different average fiber diameters, and in the laminating process, the average fiber diameter of the fixed fiber aggregates is sequentially increased. 7. The plasma or serum separation material according to claim 1, wherein the material is laminated so as to become smaller in order to form a fixed fiber aggregate-containing preform support laminate. Manufacturing method. In the stacking process in the repetition process, a plurality of preforming supports having different through-hole sizes are used as the preforming support, and in the laminating process, the through-holes of the fixed fiber-bearing preforming support are used. Any one of claims 1 to 7, wherein the support laminate for holding a fixed fiber aggregate-containing preform is formed by laminating so that the size becomes larger or smaller in order. A method for producing a plasma or serum separation material according to claim 1. 9. The plasma or serum separating material according to claim 1, wherein in the molding step, the laminated fixed fiber assembly in the molding container is thermoformed in a compressed state. Production method. The method for producing a separation material for plasma or serum according to any one of claims 1 to 9, further comprising a loading step of loading the separation material for plasma or serum into a separation container. A method for producing a filter for plasma or serum. In the loading step, the separation container is provided with a loading port for loading plasma or serum separation material, a sealing portion facing the loading port and contacting and fixing the plasma or serum separation material, and A plasma or serum separation material having a constant cross-sectional area from the loading port side end of the loading region where the plasma or serum separation material is loaded to the sealing portion side end of the loading region is used. The method for producing a filter for plasma or serum according to claim 10, wherein the one having a cross-sectional area of the surface in contact with the sealing part is larger than a cross-sectional area of the sealing part of the separation container. In the loading step, the separation container is provided with a loading port for loading plasma or serum separation material, a sealing portion facing the loading port and contacting and fixing the plasma or serum separation material, and Using a material whose transverse area decreases continuously or discontinuously from the loading port side end of the loading region where the plasma or serum separation material is loaded toward the sealing portion side end of the loading region, 11. The plasma or serum according to claim 10, wherein the plasma or serum separator has a cross-sectional area larger than the cross-sectional area of the sealing portion of the separation container. Manufacturing method for a filter.

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