JP4267436B2 - Method for producing plasma or serum filter - Google Patents

Description

  The present invention relates to 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 provides a method for producing a plasma or serum filter that is excellent in manufacturing workability, can use resources without waste, and can suppress an increase in cost. With the goal.

  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. In the fiber fixing step, the fibers are fixed to each other while the fibers are accumulated, and a fixed fiber assembly holding preforming support body is provided that has a fixed fiber assembly body in the through hole of the preforming support body. (3) A repeating step of repeating the accumulation step and the fiber 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 body. ) 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 preforming support is stacked. Lamination process to form a laminate, (5) Create external force A loading step of loading into the separation container in a state where the fixed fiber aggregate of the fixed fiber aggregate-containing preform forming support laminate is laminated, (6) fixing in the separation container A method for producing a filter for plasma or serum, comprising: an assembly fixing step for fixing a fiber aggregate to form a filter for plasma or serum. Thus, a fixed fiber aggregate-containing preform that is easy to handle without requiring the steps of cutting, laminating, and filling sheets into small individual separation material units constituting the separation material for plasma or serum filters. After laminating the supporting body, the laminated fixed fiber aggregate is used as a separating material by being loaded and fixed in the separation container in a state where the fixed fiber aggregate is laminated, and thus excellent in workability. . In addition, since it is not necessary to cut the sheet into the separating material units constituting the separating 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 filter. 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 manufacture plasma or serum filters.

  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 filter for plasma or serum according to claim 1 or 2, characterized in that. Thus, 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 the aggregate A fixed fiber assembly (that is, a separating material) having a uniform structure with no unevenness can be obtained by the fixing process, and thus a plasma or serum filter capable of efficiently separating blood cell components and plasma or serum components is manufactured. It's easy to do.

  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 filter for plasma or serum in any one of Claims 1-3." Since such ultra-fine stretched fibers have the same fiber diameter, by using the ultra-fine stretched fibers as a main component, it is easy to produce a plasma or serum filter that exhibits a small separation in the fiber diameter and exhibits a good separation action.

  The invention according to claim 5 of the present invention states that “in the accumulation step, the fibers are also accumulated in the non-through hole portion of the preforming support, and the fibers in the non-through hole portion are also fixed in the fiber fixing step. The method for producing a filter for plasma or serum according to any one of claims 1 to 4, characterized in that. In this way, by fixing the fibers in the non-through hole portion of the preforming support, the fixed fiber assembly shrinks in the fiber fixing step, and the volume of the fixed fiber assembly becomes smaller than the through hole. However, by fixing the fibers in the non-through hole portion, it is possible to prevent the fixed fiber aggregate from falling off from the preforming support, so that it is possible to reliably separate the desired number of fixed fiber aggregates in a stacked state. It can be loaded into a container.

  The invention according to claim 6 of the present invention is the “plasma or serum according to any one of claims 1 to 5, wherein in the fiber fixing step, the fibers are fused to fix the fibers together. Manufacturing method of a filter for use. " Thus, by fixing the fibers, it is easy to produce a fixed fiber assembly having excellent shape retention and handling properties.

  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, the fixed fiber aggregate is formed. Are laminated so that the average fiber diameter becomes larger or smaller in order, thereby forming a fixed fiber aggregate-containing preform forming support laminate, and fixing with a smaller average fiber diameter in the loading step. The method for producing a filter for plasma or serum according to any one of claims 1 to 6, wherein the fiber aggregate is loaded so as to be downstream in the blood flow direction of the separation container. It is. When blood is supplied to the plasma or serum filter thus manufactured, blood cell components having a large particle diameter can be captured in order, so that a plasma or serum filter that can be separated efficiently can be manufactured.

  According to an eighth aspect of the present invention, “in the loading step, as a separation container, a loading port for loading a laminated fixed fiber assembly, and a contact with the laminated fixed fiber assembly facing the loading port. And the cross-sectional area is constant from the loading port side end of the loading region where the laminated fixed fiber assembly is loaded toward the sealing unit side end of the loading region. The fixed fiber assembly that uses a certain thing and is larger than the cross-sectional area in the sealing portion of the separation container is used as the fixed fiber assembly that comes into contact with the sealing portion of the laminated fixed fiber assembly. It is "the manufacturing method of the filter for plasma or serum in any one of Claims 1-7." According to this manufacturing method, at least the inner wall surface in the vicinity of the sealing portion of the separation container and the fixed fiber assembly that comes into contact with the sealing portion can be brought into close contact with each other. A filter for plasma or serum that does not cause a problem of passing through a fixed fiber assembly (separation material) can be manufactured.

  The invention according to claim 9 of the present invention is such that, in the loading step, a loading port for loading a laminated fixed fiber assembly as a separation container, and abutting the laminated fixed fiber assembly facing the loading port. And the cross-sectional area is continuous from the loading port side end of the loading region where the laminated fixed fiber assembly is loaded toward the sealing portion side end of the loading region. Alternatively, a non-continuously smaller one is used, and the fixed fiber assembly that comes into contact with the sealed portion of the laminated fixed fiber assembly is to be 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 any one of claims 1 to 7, which is characterized. According to this manufacturing method, at least the inner wall surface in the vicinity of the sealing portion of the separation container and the fixed fiber assembly that comes into contact with the sealing portion can be brought into close contact with each other. A filter for plasma or serum that does not cause a problem of passing through a fixed fiber assembly (separation material) can be manufactured.

  The invention according to claim 10 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 stacking process, the fixed fiber stacking is performed. The body-holding preform support is laminated so that the size of the through-holes increases in order or decreases in order, thereby forming a fixed fiber aggregate-containing preform support stack. 10. A method for producing a filter for plasma or serum according to claim 8 or claim 9. According to this manufacturing method, since it is possible to form a laminated fixed fiber assembly in which the cross-sectional area increases or decreases in order from one surface to the other surface, the laminated fixed fiber assembly as described in claim 8, When loaded into a separation container having a constant cross-sectional area from the loading port side end to the sealing unit side end of the loading region, the laminated fixed fiber assembly is compressed, and density density can be formed. When the laminated surface of the fixed fiber assembly is loaded so that the surface having a larger cross-sectional area is in contact with the sealing portion, the compressibility of the laminated fixed fiber assembly increases as the sealing portion is approached. Since the density can be increased as approaching, a plasma or serum filter that can be sequentially captured from blood cell components having a larger particle size and can be separated efficiently can be manufactured.

  Further, the laminated fixed fiber assembly as described in claim 9 is separated into a separation container having a reduced transverse area from the loading port side end of the loading region toward the sealing portion side end. When loaded so that the larger surface is in contact with the sealing part, the laminated fixed fiber aggregates are compressed to form density density, while the surface with the smaller cross-sectional area is in contact with the sealing part. When loading, loading work in the loading process is easy.

  The invention according to claim 11 of the present invention is as follows: “In the assembly fixing step, the laminated fixed fiber assembly is fixed in a compressed state by a perforated plate. The manufacturing method of the filter for plasma or serum as described in 1). By fixing in such a compressed state, the uniformity of the apparent density of the laminated fixed fiber assembly (separation material) is increased, and a plasma or serum filter having excellent separation performance can be easily produced.

  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 a plasma or serum filter of the present invention (hereinafter sometimes simply referred to as “filter”) 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 is formed. Depending on the shape of the inner wall surface of the separation container, a through-hole different from FIG. A preforming support 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. By using the through-hole having such a cross-sectional area, the separation container and the laminated fixed fiber assembly (hereinafter sometimes referred to as “laminated fixed fiber assembly”) can be brought into close contact with each other. In addition, a filter capable of capturing blood cell components can be manufactured. In the fiber fixing step described later, when the fiber aggregate shrinks, it is preferable that the through hole has 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.

  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. Since the ultrafine drawn fibers have the same fiber diameter, it is easy to produce a laminated fixed fiber assembly (separating material) having a small variation in fiber diameter, that is, a filter having a good separation action, by using the ultrafine drawn fibers as a main component. Because. 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, more preferably 2 μm or less. On the other hand, if the ultrafine drawn fibers are too thin, the pore size of the laminated fixed fiber aggregate (separation material) becomes too small, blood cells are likely to be clogged, the filtration time becomes too long, and plasma or serum components cannot be filtered. In some cases, the fiber diameter of the ultrafine drawn 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 Refers to 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 ultrafine stretched fiber may be composed of any component as long as it does not inhibit the filtration of plasma or serum components. For example, polyamide-based resin, polyvinyl alcohol-based resin, polyvinylidene chloride-based 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 ultra fine stretched fibers can be fused so that the ultra fine stretch fibers are fused, so that the fixed fiber assembly 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 fixed fiber assembly, measuring the fiber diameter of 100 or more ultrafine drawn fibers in the electron micrograph, and measuring the measured fiber. Arithmetic mean value of diameter. 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 individual ultrafine drawn fibers are substantially the same in the fiber axis direction so that the fiber diameter does not vary and the filter 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 shape stability of the fixed fiber assembly 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. The finely drawn fibers are preferably capable of being fused so that the shape stability of the fixed fiber assembly 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 filter of the present invention, it is preferable to use the above-mentioned ultra-fine drawn fibers and / or fine drawn fibers, but these fibers contain an adhering substance that impairs the filtration performance of plasma or serum components. Preferably not. 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 a fiber in which a gas is dispersed as a dispersion medium (especially air is preferable) because it is easy to accumulate in a state where density unevenness is small and it is easy to manufacture a filter having a good separation action. 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 fiber fixing step described later, so that the fixed fiber assembly from the preforming support body 1 is fixed. Dropping can be prevented, and the desired number of fixed fiber assemblies can be reliably loaded into the separation container in a stacked state. That is, in the fiber fixing step (especially when fusing), even if the fixed fiber aggregate shrinks and the volume of the fixed fiber aggregate becomes smaller than the through hole 1a, the fibers in the non-through hole portion 1b Since the fixed fiber aggregates can be prevented from falling off from the preforming support 1 by fixing each other, the desired number of fixed fiber aggregates can be reliably loaded into the separation container in a stacked state. is there. 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 fiber 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 fiber fixing step of forming a fixed fiber aggregate-containing preforming support body having a fixed fiber aggregate body in the through hole of the preforming support body is performed. In the fiber 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 in the through hole of the preforming support 1 is formed. The 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 fixed fiber aggregate does not contain an adherent that impairs the filtration performance of plasma or serum components, and it is preferable that the fixed fiber aggregate be 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 accumulation step and the fiber fixing step, a fixed fiber aggregate-holding preforming support having a fixed fiber aggregate in the through hole of the preforming support is obtained. A repeating step of forming a plurality is performed. As the preforming support used in this repeating process, the preforming support 1 used in the accumulating process is used so that it can be loaded in a state where the fixed fiber aggregates are laminated in the loading process 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. 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 depth of the filter, the thickness of the preforming support, etc., and is not particularly limited and can be set as appropriate.

  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 in order to form a fixed fiber aggregate-holding preform support laminate, and in the loading process, the fixed fiber aggregate having a smaller average fiber diameter is separated from the blood in the separation container. When loaded so as to be on the downstream side in the flow direction, the laminated fixed fiber aggregate (separating material) is loaded so that the average fiber diameter decreases in order from the upstream side to the downstream side in the blood flow direction. Thus, it is possible to produce a filter that can be captured in order from blood cell components having a larger particle size and can be separated efficiently. It is preferable that the difference in the average fiber diameters of adjacent fixed fiber aggregates in this fixed fiber aggregate-holding preform laminate 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. The “flow direction of blood in the separation container” means a direction from the blood supply port to the filtrate discharge port. Therefore, the “downstream side in the blood flow direction of the separation container” refers to the filtrate outlet side of the separation container.

  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.

  Next, as shown in a schematic perspective view of the loading process in FIG. 4, (5) a state where the fixed fiber aggregate ff of the fixed fiber aggregate-containing preform forming support laminate is laminated by applying an external force. Then, the loading step of loading into the separation container 7 is performed. In the loading step in FIG. 4, as an external force, the projection plate 6 is pressed by a projection plate 6 provided with a number of cylindrical projections having a center that coincides with the center of any through-hole of the preforming support. A fixed fiber assembly ff is loaded in a laminated state into a separation container 7 having a cylindrical inner wall surface located on the opposite side, and the loaded laminated fixed fiber assembly acts as a 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 protruding plates 6 are used for simultaneous loading. However, it is also possible to apply an external force to the individual laminated fixed fiber assemblies and load them 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.

  In FIG. 4, the separation container 7 having a cylindrical inner wall surface is used. However, the separation container 7 does not have to be cylindrical, and the inner wall surface of the separation container 7 may have an inverted truncated cone shape. Further, the separation containers 7 do not have to be independent of each other, and workability is excellent when the separation containers are temporarily connected to each other.

  In this loading step, as shown in a schematic perspective perspective view in FIG. 5 as a schematic perspective view in the loading step, as the separation container 7, a loading port 7a for loading the laminated fixed fiber assembly S, and the loading port 7a, A sealing portion 7b that abuts and fixes the laminated fixed fiber assembly S is provided, and the loading region 7f is sealed from the loading port side end portion 7fa of the loading region 7f in which the laminated fixed fiber assembly S is loaded. A sealing part 7b of the separation container 7 is used as a fixed fiber assembly Sb that is in contact with the sealing part 7b of the laminated fixed fiber assembly S and has a constant cross-sectional area toward the stop part side end part 7fb. When using a truncated cone-shaped laminated fixed fiber assembly S having a larger cross-sectional area than in FIG. 1, a part or all of the laminated fixed fiber assembly S was loaded in a compressed state by the separation container 7. Can produce filters That. Since the laminated fixed fiber assembly S (separation material) loaded in the separation container 7 in this filter has a higher compressibility and a higher density as it is closer to the sealing portion 7b, blood is introduced from the loading port 7a. Is a filter that can capture in order from blood cell components having a larger particle size and can be separated efficiently. In addition, at least the inner wall surface in the vicinity of the sealing portion 7b of the separation container 7 and the fixed fiber assembly Sb that comes into contact with the sealing portion 7b are in close contact with each other. A filter that does not cause the problem of passing through the aggregate S (separating material) can be manufactured. Further, by compressing the laminated fixed fiber assembly S, even if there is density unevenness in each fixed fiber assembly, the density unevenness is alleviated and can be loaded in a state where the hole diameters are uniform. This is a method for producing a filter capable of efficiently separating blood cell components and plasma or serum components.

  In FIG. 5, as the laminated fixed fiber aggregate S, ones having different areas of the fixed fiber aggregate Sb in contact with the sealing portion 7 b and the fixed fiber aggregate Sa on the opposite surface opposite to the fixed fiber aggregate Sb are used. It may be the same. Moreover, it is preferable that any fixed fiber assembly has a cross-sectional area wider than the cross-sectional area of the separation container 7 at the place where it finally comes into contact.

  As shown in FIG. 5, the truncated cone-shaped laminated fixed fiber assembly S including the fixed fiber assembly Sb having a cross-sectional area larger than the cross-sectional area in the sealing portion 7b of the separation container 7 is the above-described structure. 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. It can manufacture by laminating | stacking so that a magnitude | size may become large in order or it may become small in order, and forming the support laminated body for fixed fiber holding pre-molding support. Note that the preforming support used in this case is the same as the preforming support used in the stacking process before the repeating process so that the fixed fiber stack can be loaded in a stacked state in the loading process. 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.

  Further, in this loading step, as shown in FIG. 6 which is another schematic perspective perspective view in the loading step, as a separation container 7 ′, a loading port 7a ′ for loading the laminated fixed fiber assembly S ′, and this Loading of loading area 7f 'which is provided with sealing part 7b' which faces loading slot 7a ', contacts and fixes laminated fixed fiber aggregate S', and is loaded with laminated fixed fiber aggregate S ' The one having a continuously decreasing cross-sectional area from the mouth side end portion 7fa ′ toward the sealing portion side end portion 7fb ′ of the loading region 7f ′ is used, and the sealing portion 7b ′ of the laminated fixed fiber assembly S ′ is used. When a cylindrical laminated fixed fiber aggregate S ′ having a larger cross-sectional area than the sealing portion 7b ′ of the separation container 7 ′ is used as the fixed fiber aggregate Sb ′ that comes into contact with the laminate fixed fiber Part or all of the aggregate S ′ is separated by the separation container 7 ′. It can be manufactured loaded in a compressed state filter. Since the laminated fixed fiber aggregate S ′ (separation material) loaded in the separation container 7 ′ in this filter is closer to the sealing portion 7b ′, the compression rate is higher and the density is higher. When blood is supplied from 7a ', it is a filter that can capture in order from blood cell components having larger particle diameters and can be separated efficiently. Further, since at least the inner wall surface in the vicinity of the sealing portion 7b ′ of the separation container 7 ′ and the fixed fiber assembly Sb ′ in contact with the sealing portion 7b ′ can be brought into close contact with each other, blood cell components are not captured. Thus, it is possible to manufacture a filter that does not cause a problem of passing through the loaded laminated fixed fiber aggregate S ′ (separating material). Further, by compressing the laminated fixed fiber aggregate S ′, even if there is density unevenness in each fixed fiber aggregate, the density unevenness is alleviated and can be loaded in a state where the hole diameters are uniform. Therefore, this is a method for producing a filter capable of efficiently separating blood cell components and plasma or serum components.

  In addition, it is preferable that any fixed fiber assembly has a cross-sectional area wider than the cross-sectional area of the separation container 7 ′ at the place where it finally comes into contact. Further, in FIG. 6, the separation container 7 ′ whose cross-sectional area is continuously reduced is used. However, a separation container that becomes discontinuously small, such as a stepwise decrease, can be used.

  In FIG. 6, as the laminated fixed fiber aggregate S ′, the fixed fiber aggregate Sb ′ in contact with the sealing portion 7 b ′ and the fixed fiber aggregate Sa ′ on the opposite surface facing the same are the same. Although a thing is used, it may be a frustum-shaped laminated fixed fiber assembly like the laminated fixed fiber assembly S of FIG. When such a truncated cone-shaped laminated fixed fiber assembly is combined with a separation container whose cross-sectional area decreases from the loading port side end to the sealing unit side end of the loading region as shown in FIG. When loaded so that the larger surface of the trapezoidal laminated fixed fiber assembly is in contact with the sealing portion, the frustoconical laminated fixed fiber assembly is compressed to form density density, and the cross sectional area can be formed. When the smaller surface is loaded so as to contact the sealing portion, the loading operation in the loading process is easy.

  Then, as shown in a schematic perspective perspective view of the assembly fixing process in FIG. 7, (6) an assembly fixing process for fixing the laminated fixed fiber assembly S in the separation container 7 and using it as a filter is performed. To do. In the assembly fixing process in FIG. 7, a separation container 7 having a protrusion 7 c on the inner wall surface corresponding to the loading port side end 7 fa of the loading region 7 f of the separation container 7 is used and loaded. By inserting the perforated plate 8 from the opening 7a deeper than the projection 7c, the perforated plate 8 is fixed by the projection 7c, and the laminated fixed fiber assembly S is fixed in a compressed state. Therefore, since the loaded laminated fixed fiber assembly S (separation material) does not move, a filter that can exhibit a stable separation action can be manufactured. In addition, since the height of the laminated fixed fiber assembly S is higher than the length of the loading region 7f and the laminated fixed fiber assembly S can be fixed in a compressed state by the perforated plate 8, the laminated fixed fiber assembly S The uniformity of the apparent density of the body S (separating material) can be increased, and a filter having excellent separation performance can be manufactured. The compression rate (= (height when the laminated fixed fiber assembly S is not pressurized) / (height when the laminated fixed fiber assembly S is compressed and fixed)) is not particularly limited. It can be suitably designed in the range of 1 to 10 times. The shape of the perforated plate 8 is generally a shape corresponding to the cross-sectional shape of the inner wall of the separation container 7, but is not limited to this shape as long as the laminated fixed fiber assembly can be compressed and fixed. The material of the porous plate 8 is not particularly limited, but may be a polyolefin resin, a polycarbonate resin, a polyester resin, a polystyrene resin, or the like.

  When the perforated plate 8 is used in this way, the perforated plate 8 is placed on the fixed fiber aggregate on which the external force of the fixed fiber aggregate-containing preform forming support laminate is applied before the aforementioned loading step. Then, the loading process and the assembly fixing process can be performed simultaneously by applying an external force to perform the loading process. In this case, a perforated plate-forming sheet having a cut to become the perforated plate 8 is placed at a position corresponding to the through hole of the uppermost preforming support in the fixed-fiber-contained preform-forming support laminate. After laminating on the body-holding preform support laminate, by applying an external force to the perforated plate forming sheet, the perforated plate forming sheet can be punched to form the perforated plate 8 and loaded.

  When the laminated fixed fiber assembly S (separating material) is compressed and fixed, if the laminated fixed fiber assembly S can be fixed by the elasticity of the perforated plate 8 or the like, the protrusion 7c is not necessarily provided on the separation container 7. Not necessary. Further, in FIG. 7, the laminated fixed fiber assembly S is fixed using the porous plate 8, but is not limited to the porous plate 8, and is supplied to a heating device such as an oven to fuse the fibers. It can also be fixed.

  As described above, the method for producing a filter of the present invention is a method of laminating a fixed fiber aggregate-containing preform support that is large and easy to handle, and then loading the fixed fiber aggregate into a separation container in a laminated state. By doing so, since the laminated fixed fiber assembly is used as the separating material, the manufacturing workability is excellent. 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.

  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 ( A gas passage speed at the vent outlet of the venturi tube: 147 m / s, an ejection amount from the jet port: about 0.5 m ³ / min., And a collision member (conical protrusion) provided in front of the vent outlet of the venturi tube 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) fiber 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 preforming support exactly the same as the preforming support, the stacking step and the fiber 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. Next, a circular perforated plate made of polyolefin resin (diameter: 11.2 mm) was placed on each fused ultrafine stretched fiber assembly.

(5) loading step and (6) assembly fixing step;
By pressing the circular perforated plate with a projection plate provided with a large number of cylindrical projections (diameter: 10 mm, height: 200 mm) having a center that coincides with the center of any through hole of the preforming support, 100 is obtained. In a state in which a single sheet of fused ultrafine stretched fiber assembly and a circular perforated plate are laminated, the frustum-shaped separation container is loaded so that the sealing portion and the laminated fused ultrafine stretched fiber assembly are in contact with each other, A filter was manufactured by hooking the circular perforated plate to the internal protrusions of the frustoconical separation container to fix the laminated fusion ultrafine stretched fiber assembly in a compressed state (compression ratio: 3.4 times). In addition, as a frustoconical separation container, the cross-sectional area is continuously small 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 (sealed from the loading port) in which a polycarbonate membrane (pore diameter: 0.4 μm) is welded to the surface of the sealing portion opposite to the contact surface with the laminated fused ultrafine stretched fiber assembly Length to the portion: 50 mm, and a loading region was formed by having a protrusion at a position on the loading port side by 22 mm from the sealing portion). Further, in this filter, the entire laminated fused ultrafine drawn fiber assembly was loaded in a compressed state by the separation container.

  In the production of this filter, after laminating the fused ultrafine stretched fiber aggregate-holding preform support, it is loaded into a separation container and fixed, so that the laminated fixed fiber aggregate is used as a separation material. Excellent manufacturing workability. 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 ultrafine stretched fibers A and B in the non-through hole portion was less than the amount of ultrafine stretched fibers A and B accumulated in the through holes of the preforming support, The amount of extra fine drawn fibers not involved was small, and the filter could be produced efficiently using extra fine drawn fibers.

(Example 2)
A filter was produced in 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 Example 1 (1) accumulation step was 80:20. In this filter, the entire laminated fused ultrafine stretched fiber assembly was loaded in a compressed state by a separation container and a circular perforated plate. Moreover, also in the manufacture of this filter, it was excellent in manufacturing workability, and the filter could be manufactured efficiently using ultra fine drawn fibers.

(Example 3)
A filter was produced 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 Example 1 (1) accumulation step was set to 50:50. In this filter, the entire laminated fused ultrafine stretched fiber assembly was loaded in a compressed state by a separation container and a circular perforated plate. Moreover, also in the manufacture of this filter, it was excellent in manufacturing workability, and the filter could be manufactured efficiently using ultra fine drawn fibers.

(Example 4)
The mass ratio of ultrafine stretched fiber A and ultrafine stretched fiber B in Example 1 (1) accumulation step was set to 80:20, and a polyolefin resin circular perforated plate (diameter: 10.9 mm) was used. And as a separation container, 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 laminated fusion ultrafine stretching of the sealing portion Cylindrical separation container (length from loading port to sealing part: 50 mm, from sealing part) with polycarbonate membrane (pore diameter: 0.4 μm) welded to the surface opposite to the contact surface with the fiber assembly A filter was manufactured in exactly the same manner as in Example 1 except that a loading region was formed by having a protrusion at a position on the loading port side by 22 mm. In this filter, the entire laminated fused ultrafine stretched fiber assembly was loaded in a compressed state by a separation container and a circular perforated plate. Moreover, also in the manufacture of this filter, it was excellent in manufacturing workability, and the filter could be manufactured efficiently using ultra fine drawn fibers.

(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) Fiber 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 fiber fixing step (a) were repeated 30 times to form 30 fusion-supported ultrafine stretched fiber assembly-containing preforming supports (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 ′) fiber 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 fiber fixing step (b) were repeated 30 times to form 30 fusion-supported ultrafine stretched fiber assembly-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 ″) Fiber 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 fiber fixing step (c) were repeated 40 times to form 40 sheets of preformed supports (c) having a fused 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, A) 30 sheets, 30 sheets of fused ultrafine stretched fiber assembly-containing preforming support (b) 30 sheets, 40 layers of fused ultrafine stretched fiber aggregate-containing preforming support (c), and laminating in that order A support laminate for preforming with a stretched fiber assembly was formed. Next, a circular perforated plate made of polyolefin resin (diameter: 11.2 mm) was placed on each of the fused ultrafine stretched fiber assemblies of the preformed support (c) having the fused ultrafine stretched fiber assemblies. .

(5) loading step and (6) assembly fixing step;
By pressing the circular perforated plate with a projection plate provided with a large number of cylindrical projections (diameter: 10 mm, height: 200 mm) having a center that coincides with the center of any through hole of the preforming support, 100 is obtained. In a state in which a single sheet of fused ultrafine stretched fiber assembly and a circular perforated plate are laminated, the container is loaded so that the sealing portion and the laminated fused ultrafine stretched fiber assembly (A) are in contact with each other. At the same time, the laminated fused ultrafine stretched fiber assembly was fixed in a compressed state (compression ratio: 3.4 times) by hooking the circular perforated plate to the internal protrusion of the frustoconical separation container to produce a filter. . In addition, as a frustoconical separation container, the cross-sectional area is continuously small 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 (sealed from the loading port) in which a polycarbonate membrane (pore diameter: 0.4 μm) is welded to the surface of the sealing portion opposite to the contact surface with the laminated fused ultrafine stretched fiber assembly Length to the portion: 50 mm, and a loading region was formed by having a protrusion at a position on the loading port side by 22 mm from the sealing portion). Further, in this filter, the entire laminated fused ultrafine drawn fiber assembly was loaded in a compressed state by the separation container. Moreover, also in the manufacture of this filter, it was excellent in manufacturing workability, and the filter could be manufactured efficiently using ultra fine drawn fibers.

(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) Fiber 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 stacking step (d) and the fiber fixing step (d) were repeated 50 times to form 50 sheets of preformed support (d) having an ultra-thin stretched fiber assembly.

(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 ′) Fiber 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 fiber 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 preforming supports (d) and 50 Then, fifty super-stretched fiber aggregate-containing preform forming support (d) was laminated in the order of 50 sheets to form a spun ultra-fine stretched fiber aggregate-containing preform forming support laminate. Subsequently, a polyolefin resin circular perforated plate (diameter: 11.4 mm) was placed on each of the fused ultrafine stretched fiber assemblies of the preformed support (d) having the fused ultrafine stretched fiber assemblies. .

(5) loading step and (6) assembly fixing step;
By pressing the circular perforated plate with a projection plate provided with a large number of cylindrical projections (diameter: 10 mm, height: 200 mm) having a center that coincides with the center of any through hole of the preforming support, 100 is obtained. In a state where a single sheet of fused ultrafine stretched fiber assembly and a circular perforated plate are laminated, the cylindrical separation container is loaded so that the sealing portion and the laminated fused ultrafine stretched fiber assembly (e) are in contact with each other. At the same time, the laminated perforated ultrafine stretched fiber assembly was fixed in a compressed state (compression ratio: 3.4 times) by hooking the circular perforated plate to the internal protrusions of the cylindrical separation container to produce a filter. In addition, as the cylindrical separation container, the cross-sectional area of the loading port side end portion (diameter: 11.5 mm) of the loading region and the sealing portion side end portion (diameter: 11.5 mm) of the loading region is the same and sealed. Cylindrical separation container (length from the loading port to the sealing portion) in which a polycarbonate membrane (pore diameter: 0.4 μm) is welded to the surface opposite to the contact surface with the laminated fused ultrafine stretched fiber assembly : Forming a loading region by having a protrusion at a position on the loading port side by 22 mm from the sealing portion by 50 mm). Further, in this filter, the entire laminated fused ultrafine drawn fiber assembly was loaded in a compressed state by the separation container. Moreover, also in the manufacture of this filter, it was excellent in manufacturing workability, and the filter could be manufactured efficiently using ultra fine drawn fibers.

(Example 7)
(1) Accumulation process (f);
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) Fiber fixing step (f);
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 (f) having a fused ultrafine stretched fiber assembly having a fused ultrafine stretched fiber assembly in the through-hole of the preforming support. ) 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 (f);
The accumulation step (f) and the fiber fixing step (f) were repeated 35 times to form 35 fused ultrafine stretched fiber assembly-containing preforming supports (f).

(1 ') Accumulation process (g);
In Example 1 (1), the mass ratio of the ultrafine stretched fiber A and the ultrafine stretched fiber B in the accumulation step was set to 80:20, and a cylindrical through hole having a diameter of 12.5 mm was staggered as a preforming support. Preliminary support in the same manner as in Example 1 except that a preforming support (composite sheet obtained by bonding a silicone rubber sheet and a fluoroglass sheet) having a thickness of 1.1 mm was used. Ultrafine drawn fibers A and B were accumulated in the through-holes of the body. Note that the ultrafine drawn fibers A and B were also accumulated in the non-through hole portion.

(2 ′) Fiber fixing step (g);
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 fusion-supported ultrafine-drawn fiber assembly-containing preforming support (t ) 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 (g);
The accumulation step (g) and the fiber fixing step (g) were repeated 35 times to form 35 fused ultrafine stretched fiber aggregate-containing preformed supports (g).

(1 ″) Accumulation process (H);
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 ″) Fiber fixing process (H);
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 fusion-supported ultrafine-drawn fiber assembly-containing preforming support (ch ) 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 (H);
The accumulation step (chi) and the fiber fixing step (chi) were repeated 30 times to form 30 fusion-supported ultrafine stretched fiber aggregate-containing preforming supports (chi).

(4) Lamination process;
The fusion-supported ultra-stretched fiber assembly-containing preforming support (f), (g), and (h) so that the centers of the through-holes coincide with each other, H) Laminating 30 sheets, 35 sheets of pre-molding support (f) holding ultra-fine stretched fiber assembly (35), 35 support bodies for pre-molding holding ultra-fine stretched fiber assembly (f) A support laminate for preforming with a stretched fiber assembly was formed. Subsequently, a polyolefin resin circular perforated plate (diameter: 11.2 mm) was placed on each of the fused ultrafine stretched fiber assemblies of the fused ultrafine stretched fiber aggregate-containing preformed support (f). .

(5) loading step and (6) assembly fixing step;
By pressing the circular perforated plate with a projection plate provided with a large number of cylindrical projections (diameter: 10 mm, height: 200 mm) having a center that coincides with the center of any through hole of the preforming support, 100 is obtained. In a state in which a single sheet of fused ultrafine stretched fiber assembly and a circular perforated plate are laminated, a sealing portion and a laminated fused ultrafine stretched fiber assembly (H) Are loaded so that they come into contact with each other, and the laminated fused ultrafine stretched fiber assembly is fixed in a compressed state (compression ratio: 3.4 times) by hooking the circular perforated plate to the internal projection of the frustoconical separation container. The filter was manufactured. In this filter, the entire laminated fused ultrafine stretched fiber assembly was loaded in a compressed state by the separation container. Moreover, also in the manufacture of this filter, it was excellent in manufacturing workability, and the filter could be manufactured efficiently using ultra fine drawn fibers.

(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 7 were able to separate 0.3 to 0.5 ml of plasma or serum components and filter them. Thus, the manufacturing method of the present invention was a method capable of manufacturing a filter having excellent separation performance.

Schematic perspective view of the integration process Schematic perspective view with part of the fiber fixing process cut out Schematic perspective view of the lamination process Schematic perspective view of the loading process Schematic perspective perspective view in the loading process Another schematic perspective perspective view in the loading process Schematic perspective perspective view of the assembly fixing process

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Preliminary forming support body 1a Through-hole 1b Non-through-hole part 2 Collecting body 3 Suction device 4 Oven 5 Fixed fiber aggregate-containing pre-forming support laminated body 6 Protrusion plate 7, 7 'Separation container 7a, 7a' Loading Port 7b, 7b 'Sealing portion 7c, 7c' Protrusion 7f, 7f 'Loading region 7fa, 7fa' Loading port side end 7fb, 7fb 'Sealing portion side end 8 Perforated plate 10 For holding fixed fiber assembly holding preform Support body f Fiber ff Fixed fiber assembly S Laminated fixed fiber assembly Sa, Sa ′ Fixed fiber assembly Sb, Sb ′ Fixed fiber assembly that does not contact the sealing portion

Claims (11)

(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 fiber fixing step for forming a preforming support,
(3) A repeating step of repeating the accumulation step and the fiber 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) A loading step of loading the separation fiber into the separation container in a state where the fixed fiber aggregate of the fixed fiber aggregate-holding preform support laminate is laminated by applying an external force;
(6) An assembly fixing process for fixing the fixed fiber assembly laminated in the separation container to form a plasma or serum filter,
And a method for producing a filter for plasma or serum. 2. The method for producing a plasma or serum filter according to claim 1, wherein in the accumulation step, fibers dispersed 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. 3. A method for producing a filter for plasma or serum 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. For producing a filter for plasma or serum. The fibers are accumulated in the non-through hole portion of the preforming support in the accumulation step, and the fibers in the non-through hole portion are also fixed in the fiber fixing step. A method for producing a plasma or serum filter according to any one of the above. The method for producing a filter for plasma or serum according to any one of claims 1 to 5, wherein in the fiber fixing step, the fibers are fused to fix the fibers together. 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, the average fiber diameter of the fixed fiber aggregates sequentially increases, or Laminate in order to form a fixed fiber aggregate-containing preform support laminate, and in the loading process, the fixed fiber aggregate having a smaller average fiber diameter is the blood flow in the separation container. The method for producing a filter for plasma or serum according to any one of claims 1 to 6, wherein the filter is loaded so as to be downstream in the direction. In the loading process, the separation container includes a loading port for loading the laminated fixed fiber assembly, a sealing portion facing the loading port and contacting and fixing the laminated fixed fiber assembly, and The laminated fixed fiber assembly using a layer having a constant cross-sectional area from the loading port side end of the loading region where the laminated fixed fiber assembly is loaded toward the sealing portion side end of the loading region The plasma according to any one of claims 1 to 7, wherein a fixed fiber assembly that abuts on the sealing portion of the separation vessel is larger than the cross-sectional area of the sealing portion of the separation container. Alternatively, a method for producing a serum filter. In the loading process, the separation container includes a loading port for loading the laminated fixed fiber assembly, a sealing portion facing the loading port and contacting and fixing the laminated fixed fiber assembly, and , Using the one in which the cross-sectional area decreases continuously or discontinuously from the loading port side end of the loading region loaded with the laminated fixed fiber assembly toward the sealing portion side end of the loading region, The fixed fiber assembly that comes into contact with the sealing portion of the laminated fixed fiber assembly is one that is larger than the cross-sectional area in the sealing portion of the separation container. The manufacturing method of the filter for plasma or serum in any one. 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, the size of the through-holes in the preforming support having the fixed fiber aggregate is used. The plasma according to claim 8 or 9, wherein the support fiber laminate for holding a fixed fiber aggregate-containing preform is formed so as to increase in order or decrease in order. Alternatively, a method for producing a serum filter. The method for producing a filter for plasma or serum according to any one of claims 1 to 10, wherein, in the assembly fixing step, the laminated fixed fiber assembly is fixed in a compressed state by a perforated plate.

Images