JP4421257B2 - Paint booth filter - Google Patents
Paint booth filter Download PDFInfo
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- JP4421257B2 JP4421257B2 JP2003347706A JP2003347706A JP4421257B2 JP 4421257 B2 JP4421257 B2 JP 4421257B2 JP 2003347706 A JP2003347706 A JP 2003347706A JP 2003347706 A JP2003347706 A JP 2003347706A JP 4421257 B2 JP4421257 B2 JP 4421257B2
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- 239000003973 paint Substances 0.000 title description 9
- 239000000835 fiber Substances 0.000 claims description 195
- 238000002844 melting Methods 0.000 claims description 96
- 230000008018 melting Effects 0.000 claims description 75
- 239000002131 composite material Substances 0.000 claims description 24
- 238000010422 painting Methods 0.000 claims description 18
- 239000004745 nonwoven fabric Substances 0.000 claims description 6
- 239000010410 layer Substances 0.000 description 59
- 229920000728 polyester Polymers 0.000 description 49
- 238000010438 heat treatment Methods 0.000 description 20
- 238000000034 method Methods 0.000 description 17
- 238000001914 filtration Methods 0.000 description 16
- 238000004080 punching Methods 0.000 description 14
- -1 polypropylene Polymers 0.000 description 11
- 239000011248 coating agent Substances 0.000 description 10
- 238000000576 coating method Methods 0.000 description 10
- 239000000428 dust Substances 0.000 description 7
- 239000004743 Polypropylene Substances 0.000 description 6
- 238000009960 carding Methods 0.000 description 6
- 238000004140 cleaning Methods 0.000 description 6
- 229920001155 polypropylene Polymers 0.000 description 6
- 241000239290 Araneae Species 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 239000004698 Polyethylene Substances 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 229920000573 polyethylene Polymers 0.000 description 4
- 239000002356 single layer Substances 0.000 description 4
- 201000004384 Alopecia Diseases 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 230000004927 fusion Effects 0.000 description 3
- 208000024963 hair loss Diseases 0.000 description 3
- 230000003676 hair loss Effects 0.000 description 3
- 238000003475 lamination Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 230000003746 surface roughness Effects 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229920005822 acrylic binder Polymers 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000004439 roughness measurement Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
Description
本発明は塗装ブースに供給される空気を清浄化するための塗装ブース用フィルターに関するものである。
The present invention relates to a filter for a painting booth for cleaning air supplied to the painting booth.
塗装ブースは、被塗装物をその取り付け，取り外し位置と、塗装作業位置との間で搬送装置を用いて出し入れしながら塗装作業位置の被塗装物を塗装ロボットで自動的に塗装する作業場をほぼ密閉状に囲んで、周囲の作業場の環境に悪影響をあ与えないために用いられており、例えば特開平７−２１３９６６号公報では同塗装ブースの排気量を塗装ロボットの指令により変化させるようにしたものが提案されており、また特開平３−２７５１６２号公報では被塗装物の表面に形成された塗膜に温風を吹き付けて該塗膜中から水分や溶剤を蒸発させるフラッシュオフゾーンを設けた設備において、プレナムチャンバからフィルターを通じて塗装ブース内に導入される清浄空気の一部を前記フィルターの下方で吸引して加熱装置に送る吸引ダクトと、その加熱装置で加熱した清浄空気をフラッシュオフゾーンに導入する吐出ダクトを配設したものが提案されている。
しかし、上述の塗装設備や工程では、主に装置や工程の効率化に重点が置かれていて、塗装時に供給する空気のクリーン化やクリーン化するためのフィルターについては殆ど取り上げられていない。
The painting booth almost seals the work place where the painting robot automatically paints the painting object at the painting work position with the transfer device between the installation / removal position of the painting object and the painting work position. For example, in Japanese Patent Laid-Open No. 7-213966, the exhaust amount of the painting booth is changed by the command of the painting robot. Japanese Patent Laid-Open No. 3-275162 discloses a facility provided with a flash-off zone for blowing hot air to a coating film formed on the surface of an object to be coated to evaporate moisture and solvent from the coating film. In the suction duct, a part of the clean air introduced from the plenum chamber into the painting booth through the filter is sucked below the filter and sent to the heating device , Which were provided with discharge duct for introducing the clean air heated by the heating device in the flash-off zone has been proposed.
However, in the above-described painting facilities and processes, the emphasis is mainly on improving the efficiency of the apparatuses and processes, and almost no mention has been made of filters for cleaning or cleaning the air supplied during painting.
しかし、実際には一般に塗装ブースに供給される空気は塵や埃が皆無であることが必要であり、もし、塵や埃が少しでもあれば、それが塗装表面に付着して塗装品質の低下を招く。
従って、供給空気のクリーン化は極めて重要であり、供給空気の清浄化をはかるフィルターは頗る重要な課題である。
However, in general, the air supplied to the painting booth must be free of dust and dirt. If there is even a small amount of dust or dirt, it will adhere to the paint surface and reduce the paint quality. Invite.
Therefore, cleaning of the supply air is extremely important, and a filter for cleaning the supply air is an important issue.
本発明は上述の如き実状に鑑み、特に塗装ブース用の供給空気の清浄化に好適なフィルターを見出すことにより、塗装表面の汚れの原因をなくし、塗装品質を向上せしめることを目的とするものである。
In view of the actual situation as described above, the present invention aims to eliminate the cause of dirt on the paint surface and improve the paint quality, particularly by finding a filter suitable for cleaning the supply air for the paint booth. is there.
上記目的を達成する本発明の解決手段は、熱融着性複合繊維を含む短繊維層の単層又は複数の積層からなる不織布の片面又は両面に熱融着性繊維シートを被覆し、少なくとも一部の熱融着性繊維が融着し接着されてなる塗装ブース用のフィルターである。 The solving means of the present invention for achieving the above object comprises coating a heat-fusible fiber sheet on one side or both sides of a nonwoven fabric comprising a single layer or a plurality of laminated short fiber layers containing a heat-fusible conjugate fiber , and at least one heat-fusible fibers parts are filters for fused glued ing in painting booths.
ここで、上記フィルターにおける短繊維層は、高融点繊維と熱融着性複合繊維の混繊からなり、その目付質量が２００ｇ／ｍ2〜５００ｇ／ｍ2の範囲で、高融点繊維が４０質量％から８５質量％の範囲を構成し、かつ高融点繊維の融点が熱融着性複合繊維の低融点成分の融点より５０℃以上高いものであることが肝要である。また、短繊維層に被覆される熱融着性繊維シートはその融点が１００℃〜１８０℃の範囲にあり、目付質量が１０ｇ／ｍ 2 〜１００ｇ／ｍ 2 の範囲のシートであることが重要である。 Here, the short fiber layer that put in the filter consists commingled refractory fibers and heat-fusible conjugate fiber, a range that basis weight mass of 200g / m 2 ~500g / m 2 , the high melting fibers It is important that the melting point of the high-melting fiber is in the range of 40% by mass to 85% by mass, and the melting point of the high-melting fiber is 50 ° C. or higher than the melting point of the low-melting component of the heat-fusible composite fiber . Further, heat fusion fiber sheet is coated on the short fiber layer is in the range a melting point of 100 ° C. to 180 ° C., important that the basis weight mass of sheet in the range of 10g / m 2 ~100g / m 2 It is.
請求項２は本発明に用いられる好ましい熱融着性複合繊維が高融点成分と低融点成分を含む複合繊維であり、サイドバイサイド型あるいは芯鞘型からなり、熱融着性複合繊維を構成する高融点成分の融点が低融点成分の融点より５０℃以上高く、かつ低融点成分の融点が１００℃〜１８０℃の範囲にあるものである。 Claim 2 is a composite fiber containing a high-melting component and a low-melting component as a preferable heat-fusible conjugate fiber used in the present invention, and is composed of a side-by-side type or a core-sheath type. The melting point of the melting point component is 50 ° C. or more higher than the melting point of the low melting point component, and the melting point of the low melting point component is in the range of 100 ° C. to 180 ° C.
本発明フィルターは前述の如く高融点繊維と熱融着性複合繊維を所定の割合で混繊した所定目付の短繊維層を主材とする不織布を用い熱融着性繊維シートを被覆せしめることにより、初期圧損が低く、濾過性能に優れて、塵埃を充分捕集し、供給空気による塗装表面の汚染を皆無ならしめると共に、熱融着性複合繊維の併用により、その一部融着による接着効果によって短繊維層における繊維間が固定されて繊維の脱落を防止し、かつ、熱融着性繊維シートの融着により表面をフラットで滑らかとして取り扱い易く、塗装ブース用に適した特性をもつフィルターを提供することができる。
As described above, the filter of the present invention is formed by coating a heat-fusible fiber sheet using a nonwoven fabric mainly composed of a short fiber layer having a predetermined basis weight in which high-melting fibers and heat-fusible composite fibers are mixed at a predetermined ratio. The initial pressure loss is low, the filtration performance is excellent, dust is collected sufficiently, the paint surface is not contaminated by the supply air, and the heat-bonding composite fiber is used together to achieve the adhesive effect of partial fusion. between the fibers are fixed in the short fiber layer to prevent falling off of the fibers, and treats the surface by fusion of the heat-fusible fiber sheet as a smooth flat rather easily, have properties suitable for painting booths by A filter can be provided.
以下、更に本発明の実施の形態について詳述する。
先ず、フィルターとして必要な要件は、濾過性能が充分、満足できること、即ち、低初期圧損で高効率であることと、流出面から繊維脱落がないことである。
Hereinafter, embodiments of the present invention will be described in detail.
First, the necessary requirements for the filter are that the filtration performance is sufficiently satisfactory, that is, high efficiency with low initial pressure loss, and that no fibers fall off from the outflow surface.
本発明はこの要件を達成するフィルターとして、短繊維層が単層あるいは複層が積層されてなる不織布を基材とし、その片面又は両面に熱融着性繊維シートを被覆し、少なくとも熱融着性繊維の一部を融着，接着することによって構成されている。
As a filter that achieves this requirement, the present invention uses a nonwoven fabric in which short fiber layers are laminated in a single layer or multiple layers as a base material, and is coated with a heat-fusible fiber sheet on one or both sides, and at least heat-sealed. It is configured by fusing and adhering a part of the conductive fiber.
ここで、上記短繊維層は単一の繊維層であってもよいが、好ましくは高融点繊維と熱融着性繊維、特に熱融着性複合繊維との混繊が用いられる。
高融点繊維としてはナイロン，ポリエステル，ポリプロピレン等の合成繊維が含まれ、熱融着性繊維、特に熱融着性複合繊維としては、芯鞘型，サイドバイサイド型構造で、例えばポリエステル系樹脂，ポリエチレン系樹脂，ポリプロピレン系樹脂，ポリアミド系樹脂の何れかの熱可塑性樹脂の高融点成分と低融点成分からなる複合繊維が用いられる。
Here, the short fiber layer may be a single fiber layer, but a mixed fiber of a high-melting fiber and a heat-fusible fiber, particularly a heat-fusible composite fiber is preferably used.
High-melting fibers include synthetic fibers such as nylon, polyester, and polypropylene, and heat-fusible fibers, especially heat-fusible composite fibers, which have a core-sheath type and side-by-side structure, such as polyester-based resins and polyethylene-based fibers. A composite fiber composed of a high melting point component and a low melting point component of a thermoplastic resin of any one of resin, polypropylene resin, and polyamide resin is used.
具体例としては、ポリエステル繊維（融点２５０℃〜２７０℃程度）と、低融点ポリエステル繊維（融点１００℃〜１５０℃程度）の複合繊維，エステル／ナイロン複合繊維，ポリエステル／ポリエチレン複合繊維，ポリプロピレン／ポリエチレン複合繊維などが挙げられ、特に高融点ポリエステルと、低融点ポリエステルとの複合繊維は最も実用的である。
この場合、複合繊維を構成する高融点成分の融点が低融点成分の融点より５０℃以上、高いこと、また、低融点成分の融点が１００℃〜１８０℃の範囲にあることが好ましい。
高融点成分の融点が低融点成分の融点より５０℃未満であると、短繊維間の接着時に高融点繊維側も軟化して所望のフィルターを得ることができない。
また、低融点成分の融点が１００℃未満であると、繊維間の接着を実施する処理条件が難しく、耐熱性の点から好ましくない。
低融点成分の融点が１８０℃を超えると、高融点繊維の熱特性に影響し、接着を実施することでフィルター特性が変動するので好ましくない。また、熱融着性複合繊維の繊度は１〜１０デシテックスの範囲が好ましい。繊度が１デシテックス未満であると濾過性能を有する充分な嵩高性のあるフィルターを得ることができない。
Specific examples include composite fibers of polyester fibers (melting point of about 250 ° C. to 270 ° C.) and low melting point polyester fibers (melting point of about 100 ° C. to 150 ° C.), ester / nylon composite fibers, polyester / polyethylene composite fibers, polypropylene / polyethylene. Examples include composite fibers, and in particular, composite fibers of high-melting polyester and low-melting polyester are most practical.
In this case, the melting point of the high melting point component constituting the composite fiber is preferably 50 ° C. or more higher than the melting point of the low melting point component, and the melting point of the low melting point component is preferably in the range of 100 ° C. to 180 ° C.
When the melting point of the high melting point component is less than 50 ° C. than the melting point of the low melting point component, the high melting point fiber side is also softened at the time of bonding between the short fibers, and a desired filter cannot be obtained.
Moreover, when the melting point of the low melting point component is less than 100 ° C., the treatment conditions for carrying out adhesion between fibers are difficult, which is not preferable from the viewpoint of heat resistance.
When the melting point of the low melting point component exceeds 180 ° C., the thermal characteristics of the high melting point fiber are affected, and the filter characteristics are changed by performing the adhesion, which is not preferable. The fineness of the heat-fusible conjugate fiber is preferably in the range of 1 to 10 dtex. If the fineness is less than 1 dtex, a sufficiently bulky filter having filtration performance cannot be obtained.
一方、繊度が１０デシテックスを超えると繊維本数が減少し、繊維間接着点も減少して嵩高性は得られるが、所望の濾過性能を有するフィルターを得ることができない。
そして、上記高融点繊維と、熱融着性繊維の混繊からなる短繊維層を用いてフィルターを構成するにあたっては、該繊維層の目付質量が２００ｇ／ｍ２〜５００ｇ／ｍ２の範囲であり、かつ高融点繊維の構成が４０〜８５質量％であって高融点繊維の融点が熱融着性複合繊維の低融点成分の融点より５０℃以上高いことが効果的である。
On the other hand, when the fineness exceeds 10 dtex, the number of fibers is reduced and the inter-fiber adhesion point is reduced to obtain bulkiness, but a filter having desired filtration performance cannot be obtained.
Then, the above-described high-melting fibers, in order to constitute a filter using a short fiber layer consisting of the mixed fiber of heat-fusible fibers, to the extent basis weight by weight of the fiber layer of 200g / m 2 ~500g / m 2 In addition, it is effective that the high melting point fiber has a composition of 40 to 85% by mass and the melting point of the high melting point fiber is 50 ° C. or higher than the melting point of the low melting point component of the heat-fusible composite fiber.
目付質量が２００ｇ／ｍ２未満では満足する濾過性能を得ることがてきず、満足したものができても濾過寿命が短くなるので好ましくない。
一方、５００ｇ／ｍ２を超えると低初期圧損を得るのが難しい。また高融点繊維の構成が４０質量％未満であると、即ち、熱融着性複合繊維が６０質量％を超えると嵩高性（厚いものが得にくく）が乏しく、低初期圧損のフィルターが得にくい。
逆に、８５質量％を超えると熱融着性複合繊維が少ないため、嵩高いフィルターを得てもすぐに型崩れし、へたってしまう。また、短繊維の抜けが生じ易くなり好ましくない。
そして、厚さを保持して嵩高のフィルターを得るには、厚さが１５ｍｍ〜３０ｍｍが良く、この範囲で嵩高性を確保するには、単層の場合、高融点繊維と熱融着性繊維の混繊で厚さと濾過性能を確保するために高融点繊維の繊度構成が太繊度と細繊度の組み合わせで達成し易く、繊度範囲は太繊維の繊度が１０〜３０デシテックスで、細繊維の繊度が３〜１０デシテックスの範囲がよく、太，細の繊度組み合わせによって低初期圧損で高濾過性能のフィルターを得るために条件を調整することにより得ることができる。
If the mass per unit area is less than 200 g / m 2 , satisfactory filtration performance cannot be obtained, and even if it is satisfactory, the filtration life is shortened.
On the other hand, if it exceeds 500 g / m 2 , it is difficult to obtain a low initial pressure loss. Further, when the composition of the high melting point fiber is less than 40% by mass, that is, when the heat-fusible conjugate fiber exceeds 60% by mass, the bulkiness (thickness is difficult to obtain) is poor, and it is difficult to obtain a filter with low initial pressure loss. .
On the contrary, when it exceeds 85 mass%, since there are few heat-fusible composite fibers, even if it obtains a bulky filter, it will lose shape immediately and will fall. Further, short fibers are likely to come off, which is not preferable.
In order to obtain a bulky filter while maintaining the thickness, the thickness is preferably 15 mm to 30 mm. To ensure bulkiness in this range, in the case of a single layer, a high melting point fiber and a heat-fusible fiber In order to ensure the thickness and filtration performance of the mixed fiber, the fineness composition of the high melting point fiber is easy to achieve by the combination of the fineness and fineness, the fineness range is 10-30 dtex for the thick fiber, the fineness of the fine fiber Is in the range of 3 to 10 dtex, and can be obtained by adjusting the conditions in order to obtain a filter with low initial pressure loss and high filtration performance by combining fine and fine fineness.
太繊維は嵩を出すための骨格の役目をするもので、繊度が１０デシテックス未満では細く、骨格としての役目が果たせない。また、３０デシテックスを超えると構成本数が少なく、濾過性能が低下するので好ましくない。
なお、太，細繊維の混繊比率は厚さと濾過性能により適宜決められる。積層の場合は太高融点繊維と熱融着性繊維の混繊層と細高融点繊維と熱融着性繊維の混繊で、この太，細高融点繊維層を積層することで得られる。
そして、積層にあたっては、太繊度側を粗層とし、細繊度側を密層とする。
厚さと濾過性能を確保するためには太，細繊維層の比率を決めればよく、その繊度範囲は単層の場合と同じ考えでよい。
なお、太，細繊維の積層比率は厚さと濾過性能により適宜決められる。
The thick fiber serves as a skeleton for increasing the bulk. If the fineness is less than 10 decitex, the thick fiber is thin and cannot serve as the skeleton. On the other hand, if it exceeds 30 dtex, the number of components is small, and the filtration performance is deteriorated.
The mixing ratio of thick and fine fibers is appropriately determined depending on the thickness and filtration performance. In the case of lamination, it is obtained by laminating these thick and thin high melting point fiber layers with a mixed fiber layer of thick high melting point fibers and heat fusible fibers and thin high melting point fibers and heat fusible fibers.
And in lamination | stacking, let the fineness side be a rough layer, and let the fineness side be a dense layer.
In order to ensure the thickness and filtration performance, the ratio of the thick and thin fiber layers may be determined, and the fineness range may be the same as in the case of a single layer.
The lamination ratio of thick and fine fibers is appropriately determined depending on the thickness and filtration performance.
次に短繊維層に被覆される熱融着性繊維シートは、嵩高な短繊維層の表面に熱融着性繊維シートを接着し、表面をフラットで滑らかにし、繊維層にある短繊維の抜けを防止するものであり、その融点は１００℃〜１８０℃の範囲がよく、融点が１００℃未満であると短繊維層との接着を実施する処理条件が難しく、また耐熱性の点からも好ましくない。
融点が１８０℃を超えると短繊維層の表面の特性が変わり、接着を実施することでフィルター特性の変動が大きくなる。
この熱融着性繊維シートの目付質量は、１０ｇ／ｍ２〜１００ｇ／ｍ２の範囲が好適であり、１０ｇ／ｍ２未満では濾過性能を損なうことはないが、短繊維層の表面を十分に滑らかにできず、毛抜け防止も充分に防止することができないので好ましくない。
１００ｇ／ｍ２を超えると短繊維層の表面を十分に滑らかにでき、毛抜け防止も充分であるが、流出側の表面の抵抗が増加するために低初期圧損を得ることが難しくなる。
なお、短繊維層表面を滑らかにし、繊維の脱落を防止するため、ポリエチレン割繊維を短繊維層表面に接着し、あるいは樹脂バインダーを塗布する方法があるが、前者は表面滑らかで毛抜け防止が可能であるとしても、低初期圧損のフィルターが得難く、また後者は充分に表面を滑らかにすることが難しく、しかも取り扱い性にも問題があり、さらに工程が増加するためコストの増加となるので、好ましくない。
これに対し、本発明の熱融着性繊維シートは、それらの問題を解消し、表面の滑らかさと毛抜け防止ならびに低初期圧損を得てフィルター適性を達成する。
Next, the heat-fusible fiber sheet to be coated on the short fiber layer is obtained by adhering the heat-fusible fiber sheet to the surface of the bulky short fiber layer, making the surface flat and smooth, and removing the short fibers in the fiber layer. The melting point is preferably in the range of 100 ° C. to 180 ° C., and if the melting point is less than 100 ° C., the treatment conditions for carrying out adhesion with the short fiber layer are difficult, and it is also preferable from the viewpoint of heat resistance. Absent.
When the melting point exceeds 180 ° C., the characteristics of the surface of the short fiber layer change, and the fluctuation of the filter characteristics increases by performing the adhesion.
Basis weight mass of the heat-fusible fiber sheet is preferably in the range of 10g / m 2 ~100g / m 2 , but not impair the filtration performance is less than 10 g / m 2, sufficient surface of the short fiber layer It is not preferable because it cannot be smoothly smoothed and the hair loss cannot be prevented sufficiently.
If it exceeds 100 g / m 2 , the surface of the short fiber layer can be sufficiently smoothed, and the hair removal can be prevented sufficiently. However, since the resistance of the surface on the outflow side increases, it is difficult to obtain a low initial pressure loss.
In order to smooth the surface of the short fiber layer and prevent the fibers from falling off, there are methods of adhering polyethylene split fibers to the surface of the short fiber layer or applying a resin binder, but the former has a smooth surface and prevents hair loss. Even if it is possible, it is difficult to obtain a filter with low initial pressure loss, and the latter is difficult to smooth the surface sufficiently, and there is also a problem in handling, and further, the process increases, resulting in an increase in cost. It is not preferable.
On the other hand, the heat-fusible fiber sheet of the present invention solves these problems, achieves smoothness of the surface, prevention of hair loss and low initial pressure loss, and achieves filter suitability.
以下、更に本発明を実施例により説明する。
Hereinafter, the present invention will be further described with reference to examples.
繊度１４．４デシテックス、繊維長６４ｍｍのポリエステル短繊維４０質量％と、繊度６．６デシテックスで、繊維長６４ｍｍのポリエステル短繊維２０質量％と、繊度４．４デシテックスで繊維長５１ｍｍのポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）４０質量％を均一混合して（目付質量約３６０ｇ／ｍ２）、次いでカーディング加工を施し針深さ０（ウエブの厚さだけの針入をいう）で、打ち込み本数３１本／ｃｍ２のニードルパンチ加工を施し、連続して熱処理機（ホットエアースルー方式）で温度１７０℃、滞留時間９０秒間の熱処理をした。
得られた短繊維層の表面（ニードルパンチ加工時、針の進入した面）に熱融着性繊維、通常、くもの巣状の如き薄層の低融点ポリエステル繊維シート（目付質量２０ｇ／ｍ２、融点１４３℃）を加熱ローラー（温度１６０℃で速度５．０ｍ／ｍｉｎ）で熱融着して表面を被覆し、本発明の塗装ブース用フィルターを得た。
40% by mass polyester short fiber with a fineness of 14.4 dtex and fiber length of 64 mm, 20% by mass of polyester short fiber with a fiber length of 64 mm and fineness of 6.6 dtex, polyester with a fineness of 4.4 dtex and a fiber length of 51 mm / low Melting point polyester composite fiber (melting point of low melting point polyester: 110 ° C.) 40% by mass (weight per unit area: about 360 g / m 2 ), then carding, needle depth 0 (needle with web thickness only) In this case, needle punching was performed at a driving number of 31 / cm 2 , and heat treatment was continuously performed with a heat treatment machine (hot air through method) at a temperature of 170 ° C. and a residence time of 90 seconds.
On the surface of the obtained short fiber layer (the surface into which the needle has entered during needle punching), a low-melting-point polyester fiber sheet having a thin layer such as a spider web (usually mass 20 g / m 2) , Mp 143 ° C.) was heat-sealed with a heating roller (temperature 160 ° C., speed 5.0 m / min) to cover the surface, and the coating booth filter of the present invention was obtained.
繊度１４．４デシテックス、繊維長６４ｍｍのポリエステル短繊維４０質量％と、繊度６．６デシテックスで繊維長６４ｍｍのポリエステル短繊維４０質量％と繊度４．４デシテックスで繊維長５１ｍｍのポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）２０質量％を均一混合して（目付質量約３６０ｇ／ｍ２）、次いで、カーディング加工を施し、針深さ１．０ｍｍ（ウエブの厚さより１．０ｍｍの針入を言う）で、打ち込み本数２０本／ｃｍ２のニードルパンチ加工を施し、連続して熱処理機（ホットエアースルー方式）で、温度１７０℃、滞留時間９０秒間の熱処理をした。
得られた短繊維層の表面（ニードルパンチ加工時、針の進入した面）に熱融着性繊維、通常、くもの巣状の如き薄層の低融点ポリエステル繊維シート（目付質量２０ｇ／ｍ２、融点１４３℃）を加熱ローラー（温度１６０℃で速度５．０ｍ／ｍｉｎ）で熱融着して表面を被覆し、本発明の塗装ブース用フィルターを得た。
40% by mass polyester short fibers with a fineness of 14.4 dtex and a fiber length of 64 mm, 40% by mass of polyester short fibers with a fineness of 6.6 dtex and a fiber length of 64 mm, and a polyester / low melting point polyester with a fineness of 4.4 dtex and a fiber length of 51 mm 20% by mass of composite fiber (melting point of low-melting polyester: 110 ° C.) is uniformly mixed (weight per unit area: about 360 g / m 2 ), then carded, and needle depth of 1.0 mm (1% from the web thickness) 0.0 mm needle penetration), 20 punches / cm 2 needle punching was performed, and heat treatment was continuously performed with a heat treatment machine (hot air through method) at a temperature of 170 ° C. and a residence time of 90 seconds.
On the surface of the obtained short fiber layer (the surface into which the needle has entered during needle punching), a low-melting-point polyester fiber sheet having a thin layer such as a spider web (usually mass 20 g / m 2) , Mp 143 ° C.) was heat-sealed with a heating roller (temperature 160 ° C., speed 5.0 m / min) to cover the surface, and the coating booth filter of the present invention was obtained.
繊度１４．４デシテックス、繊維長６４ｍｍのポリエステル短繊維４０質量％と、繊度６．６デシテックスで繊維長６４ｍｍのポリエステル短繊維２０質量％と、繊度４．４デシテックスで、繊維長５１ｍｍのポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）４０質量％を均一混合して（目付質量約３６０ｇ／ｍ２）、次いで、カーディング加工を施し、針深さ０で、打ち込み本数３１本／ｃｍ２のニードルパンチ加工を施し、連続して熱処理機（ホットエアースルー方式）で温度１７０℃、滞留時間９０秒間の熱処理をした。得られた短繊維層の表面（ニードルパンチ加工時、針の進入した面）に熱融着性繊維、通常、くもの巣状の如き薄層の低融点ポリエステル繊維シート（目付質量８０ｇ／ｍ２、融点１４３℃）を加熱ローラー（温度１６０℃で速度５．０ｍ／ｍｉｎ）で熱融着して表面を被覆し、本発明の塗装ブース用フィルターを得た。
40% by mass of polyester short fibers with a fineness of 14.4 dtex and a fiber length of 64 mm, 20% by mass of polyester short fibers with a fineness of 6.6 dtex and a fiber length of 64 mm, polyester with a fineness of 4.4 dtex and a fiber length of 51 mm / low 40% by mass of a melting point polyester composite fiber (melting point of low melting point polyester: 110 ° C.) is uniformly mixed (weight per unit area: about 360 g / m 2 ), and then carded, with a needle depth of 0 and a driving number of 31 / Cm 2 of needle punching was performed, and heat treatment was continuously performed with a heat treatment machine (hot air through method) at a temperature of 170 ° C. and a residence time of 90 seconds. The surface of the obtained short fiber layer (the surface into which the needle has entered during needle punching) is a low-melting polyester fiber sheet having a thin layer such as a spider web (usually mass 80 g / m 2). , Mp 143 ° C.) was heat-sealed with a heating roller (temperature 160 ° C., speed 5.0 m / min) to cover the surface, and the coating booth filter of the present invention was obtained.
繊度１４．４デシテックス、繊維長６４ｍｍのポリエステル短繊維５０質量％と、繊度１７．０デシテックスで、繊維長６４ｍｍのポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）５０質量％を均一混合して目付質量約２１０ｇ／ｍ２をカーディング加工を施し、太繊維層を得た。更に、繊度６．６デシテックス、繊維長６４ｍｍのポリエステル短繊維５０質量％と、繊度４．４デシテックスで繊維長５１ｍｍのポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）５０質量％を均一混合して目付質量約２１０ｇ／ｍ２をカーディング加工を施し細繊維層を得た。引き続き、太繊維層の上に細繊維層を重ね、その上から針深さ０で、打ち込み本数３１本ｃｍ２のニードルパンチ加工を施し、連続して熱処理機（ホットエアースルー方式）で温度１７０℃、滞留時間９０秒間の熱処理をした。
得られた短繊維層の表面（ニードルパンチ加工時、針の進入した面）に熱融着性繊維、通常、くもの巣状の如き薄層の低融点ポリエステル繊維シート（目付質量２０ｇ／ｍ２）、融点１２０℃）を加熱ローラー（温度１６０℃で速度５．０ｍ／ｍｉｎ）で熱融着して表面を被覆し、本発明の塗装ブース用フィルターを得た。
比較例１
50% by mass of polyester short fibers having a fineness of 14.4 dtex and a fiber length of 64 mm, and 50% by mass of polyester / low-melting polyester composite fibers having a fineness of 17.0 dtex and a fiber length of 64 mm (melting point of low-melting polyester: 110 ° C.) The thick fiber layer was obtained by carrying out a carding process with a basis weight of about 210 g / m 2 by uniform mixing. Furthermore, 50% by mass of polyester short fiber having a fineness of 6.6 dtex and a fiber length of 64 mm, and 50% by mass of polyester / low-melting polyester composite fiber having a fineness of 4.4 dtex and a fiber length of 51 mm (melting point of low-melting polyester: 110 ° C.). Were uniformly mixed, and a weight of about 210 g / m 2 was carded to obtain a fine fiber layer. Subsequently, a fine fiber layer is overlaid on the thick fiber layer, and needle punching with a needle depth of 31 cm 2 is performed from above the thick fiber layer, and a temperature of 170 is continuously performed by a heat treatment machine (hot air through method). Heat treatment was performed at a temperature of 90 ° C. and a residence time of 90 seconds.
On the surface of the obtained short fiber layer (the surface into which the needle has entered during needle punching), a low-melting-point polyester fiber sheet having a thin layer such as a spider web (usually mass 20 g / m 2) ), Melting point 120 ° C.) was heat-sealed with a heating roller (temperature 160 ° C., speed 5.0 m / min) to coat the surface, and the coating booth filter of the present invention was obtained.
Comparative Example 1
繊度１４．４デシテックス、繊維長６４ｍｍのポリエステル短繊維４０質量％と繊度６．６デシテックスで、繊維長６４ｍｍのポリエステル短繊維２０質量％と、繊度４．４デシテックスで、繊維長５１ｍｍのポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）４０質量％を均一混合して（目付質量約３６０ｇ／ｍ２）、次いでカーディング加工を施し、針深さ０で、打ち込み本数３１本／ｃｍ２のニードルパンチ加工を施し、連続して熱処理機（ホットエアースルー方式）で温度１７０℃、滞留時間９０秒間の熱処理をし、塗装ブース用フィルターを得た。
比較例２
40% by mass polyester short fiber with a fineness of 14.4 dtex, fiber length of 64 mm and a fineness of 6.6 dtex, 20% by mass of polyester short fiber with a fiber length of 64 mm, polyester with a fineness of 4.4 dtex and a fiber length of 51 mm / low Melting point polyester composite fiber (melting point of low melting point polyester: 110 ° C.) is uniformly mixed (weight per unit area: about 360 g / m 2 ), then carded, with needle depth of 0 and 31 / A needle punching process of cm 2 was performed, and heat treatment was continuously carried out with a heat treatment machine (hot air through method) at a temperature of 170 ° C. and a residence time of 90 seconds to obtain a coating booth filter.
Comparative Example 2
繊度１４．４デシテックス、繊維長６４ｍｍのポリエステル短繊維４０質量％と、繊度６．６デシテックスで、繊維長６４ｍｍのポリエステル短繊維２０質量％と、繊度４．４デシテックスで繊維長５１ｍｍのポリエステル／低融点ポリエステル複合繊維（低融点ポリエステルの融点：１１０℃）４０質量％を均一混合して（目付質量約３６０ｇ／ｍ２）、次いでカーディング加工を施し、針深さ０で、打ち込み本数３１本／ｃｍ２のニードルパンチ加工を施し、連続して熱処理機（ホットエアースルー方式）で温度１７０℃、滞留時間９０秒間の熱処理をした。
得られた短繊維層の表面（ニードルパンチ加工時、針の進入した面）に熱融着性繊維、通常、くもの巣状の如き薄層の低融点ポリエステル繊維シート（目付質量約１６０ｇ／ｍ２、融点１４３℃）を加熱ローラー（温度１６０℃で速度５．０ｍ／ｍｉｎ）で熱融着して表面を被覆し、塗装ブース用フィルターを得た。
比較例３
40% by mass polyester short fiber with a fineness of 14.4 dtex and fiber length of 64 mm, 20% by mass of polyester short fiber with a fiber length of 64 mm and fineness of 6.6 dtex, polyester with a fineness of 4.4 dtex and a fiber length of 51 mm / low Melting point polyester composite fiber (melting point of low melting point polyester: 110 ° C.) is uniformly mixed (weight per unit area: about 360 g / m 2 ), then carded, with needle depth of 0 and 31 / A needle punching process of cm 2 was performed, and a heat treatment was continuously performed with a heat treatment machine (hot air through method) at a temperature of 170 ° C. and a residence time of 90 seconds.
The surface of the obtained short fiber layer (the surface into which the needle entered during needle punching) is a low-melting-point polyester fiber sheet having a thin layer such as a spider web (usually about 160 g / m). 2 and a melting point of 143 ° C.) was heat-sealed with a heating roller (at a temperature of 160 ° C. and a speed of 5.0 m / min) to coat the surface to obtain a filter for a coating booth.
Comparative Example 3
繊度２０．０デシテックス、繊維長６４ｍｍのポリプロピレン短繊維５０質量％と、繊度３．３デシテックスで繊維長５１ｍｍの変性ポリプロピレン短繊維５０質量％を均一混合して（目付質量約２６０ｇ／ｍ２）、次いでカーディング加工を施し、上層用繊維層を得た。
次に繊度３．３デシテックスで繊維長５１ｍｍの変性ポリプロピレン短繊維を均一混合して（目付質量約１００ｇ／ｍ２）、次いでカーディング加工を施し、下層用繊維層を得た。
得られた上層繊維層と下層繊維層を積層して下層繊維層側から針深さ２．０ｍｍで、打ち込み本数２０本／ｃｍ２のニードルパンチ加工を施し、連続して熱処理機（ホットエアースルー方式）で温度１４０℃、滞留時間９０秒間の熱処理をした。
得られた積層短繊維層の表面（ニードルパンチ加工時、針の進入した面）に加熱ローラー面（温度１８０℃で速度３．０ｍ／ｍｉｎ、反対側ローラーは１００℃）が当たるようにして下層繊維層側の表面を鏡面加工して塗装ブース用フィルターを得た。
比較例４
50% by mass of polypropylene short fibers having a fineness of 20.0 decitex and a fiber length of 64 mm and 50% by mass of modified polypropylene short fibers having a fineness of 3.3 dtex and a fiber length of 51 mm were uniformly mixed (weight per unit mass: about 260 g / m 2 ). Next, carding was performed to obtain an upper fiber layer.
Next, a modified polypropylene short fiber having a fiber length of 51 mm was uniformly mixed with a fineness of 3.3 dtex (weight per unit area: about 100 g / m 2 ), and then carded to obtain a lower layer fiber layer.
The obtained upper layer fiber layer and lower layer fiber layer are laminated, needle punching is performed at a needle depth of 2.0 mm from the lower layer fiber layer side, and the number of driven needles is 20 / cm 2. Method) was heat-treated at a temperature of 140 ° C. and a residence time of 90 seconds.
The surface of the resulting laminated short fiber layer (the surface into which the needle has entered during needle punching) is contacted with the heating roller surface (temperature: 180 ° C., speed: 3.0 m / min, opposite roller: 100 ° C.). The fiber layer side surface was mirror-finished to obtain a paint booth filter.
Comparative Example 4
繊度１７．０デシテックス、繊維長６４ｍｍのポリエステル短繊維５０質量％と、繊度６．６デシテックスで繊維長６４ｍｍのポリエステル短繊維５０質量％を均一混合して（目付質量約１５０ｇ／ｍ２）、次いでカーディング加工を施し、上層用繊維層を得た。
次に繊度６．６デシテックスで繊維長６４ｍｍのポリエステル短繊維を均一混合して（目付質量約１００ｇ／ｍ２）、次いでカーディング加工を施し、中層用繊維層を得た。
更に、繊度３．３デシテックス、繊維長５１ｍｍのポリエステル短繊維５０質量％と繊度２．２デシテックスで、繊維長５１ｍｍのポリエステル短繊維５０質量％を均一混合して（目付質量約６０ｇ／ｍ２）、次いでカーディング加工を施し、下層用繊維層を得た。
得られた上層，中層，下層の各繊維層を積層して上層側から針深さ２．０ｍｍで、打ち込み本数２０本／ｃｍ２のニードルパンチ加工を施し、積層不織布を得た。
この積層不織布の全体にアクリル性バインダーをサーキュレーター法により付与し（付与量約４０ｇ／ｍ２）、次いでニードルパンチ加工面側に１５ｇ／ｍ２付与し、乾燥は１４０℃で行って塗装ブース用フィルターを得た。
50% by mass of polyester short fibers having a fineness of 17.0 decitex and a fiber length of 64 mm and 50% by mass of polyester short fibers having a fineness of 6.6 decitex and a fiber length of 64 mm were mixed uniformly (weight per unit mass: about 150 g / m 2 ). Carding was performed to obtain an upper fiber layer.
Next, polyester short fibers having a fineness of 6.6 dtex and a fiber length of 64 mm were uniformly mixed (weight per unit area: about 100 g / m 2 ), and then subjected to carding to obtain a middle layer fiber layer.
Further, 50% by mass of polyester short fibers having a fineness of 3.3 decitex and a fiber length of 51 mm and 50% by mass of polyester short fibers having a fiber length of 51 mm and a fineness of 2.2 decitex were uniformly mixed (weight per unit mass: about 60 g / m 2 ). Then, carding was performed to obtain a lower fiber layer.
The obtained upper layer, middle layer, and lower layer fiber layers were laminated, and needle punching was performed at a needle depth of 2.0 mm from the upper layer side at a needle depth of 20 / cm 2 to obtain a laminated nonwoven fabric.
An acrylic binder is applied to the entire laminated nonwoven fabric by a circulator method (applied amount: about 40 g / m 2 ), then 15 g / m 2 is applied to the needle punched surface, and drying is performed at 140 ° C. Got.
かくして、以上の各実施例及び比較例で得られたフィルターについて夫々、表面粗さ，濾過性能の評価と、繊維の脱落度合い，取り扱い性を下記の基準に準拠して行い、表１に示す結果を得た。
表中における準拠基準は下記の通りである。
（イ）目付量；ＪＩＳ Ｌ１０９６の５．２に記載の方法に準拠して求めた。
（ロ）厚さ ；ＪＩＳ Ｌ１０９６の５．１に記載の方法に従って荷重２Ｋｐａで測定した。
（ハ）濾過性能の評価
実験条件
ＪＩＳ８種塵埃 （ＪＩＳ Ｚ８９０１−ＮＯ．１５）塵埃濃度は１ｇ／ｍｉｎ
試験用の有効面積 １０００ｃｍ２の円板濾材
試験風速 ５０ｃｍ／ｓｅｃ
最終圧損 ９８ｐａ（１０ｍｍＡｑ）
初期捕集効率 濾過面積１０００ｃｍ２に対し１１ｇ供給した時 点での捕集効率
フルライフ捕集効率 増加抵抗１０ｍｍＡｑ時における捕集効率
塵埃保持量 増加抵抗１０ｍｍＡｑ時における塵埃保持量
（ニ）表面粗さ測定
測定装置 ミツトヨ製表面粗さ測定器
型式 テーラーホブソン（株）
フォームタリサーフＳ５Ｃ
測定条件 針条件 ０．２μｍ−０．７ｍＮ
測定範囲 ４ｍｍ
平均粗さ （Ｒａｘ）μｍ
粗さ曲線から、その平均線の方向に基準長さＬだけ抜き取り、この抜き取 り部分の平均線から測定曲線までの偏差の絶対値を合計し、平均した値で ある。
最大高さ （Ｒｙｘ）μｍ
粗さ曲線から、その平均線の方向に基準長さＬだけ抜き取り、この抜き取 り部分の平均線から最も高い山頂までの高さＹｐと最も低い谷底までの深 さＹｖとの和である。
（ホ）繊維の脱落性
（ａ）試料を１０ｃｍφに切り出し、試料の空気流出面を下にして試料上面１０ｃｍの ところから１０ｃｍφ×１．３ｋｇの鉄塊を落下する。
（ｂ）試料に落下する回数を５０回として試料の空気流出面から噴出した脱落繊維の量で 評価する。
（ｃ）測定回数 ｎ＝３
（ｄ）判定
噴出面に脱落繊維なし ○
噴出面に脱落繊維２，３本 △
噴出面に脱落繊維４本以上 ×
（ヘ）取り扱い性
（ａ）試料を２５ｃｍ角に切り出しフィルター枠にセットし、フィルターを取り扱う時 に加工側の面に引っ掛かりが有るか無いかを評価した。
（ｂ）評価判定
表面の引っ掛かり無し ○
表面の引っ掛かりたまにある △
表面の引っ掛かりがよくある ×
Thus, for the filters obtained in each of the above Examples and Comparative Examples, the surface roughness, filtration performance evaluation, fiber dropout degree, and handleability were performed according to the following criteria, and the results shown in Table 1 were obtained. Got.
The compliance standards in the table are as follows.
(B) Weight per unit area: Determined according to the method described in 5.2 of JIS L1096.
(B) Thickness: Measured at a load of 2 Kpa according to the method described in 5.1 of JIS L1096.
(C) Evaluation of filtration performance
Experimental conditions
JIS class 8 dust (JIS Z8901-NO.15) The dust concentration is 1 g / min.
Disc filter medium with an effective area of 1000 cm 2 for testing
Test wind speed 50cm / sec
Final pressure loss 98pa (10mmAq)
Initial collection efficiency Collection efficiency at the time when 11 g is supplied to a filtration area of 1000 cm 2
Full-life collection efficiency Collection efficiency at increased resistance of 10 mmAq
Dust retention amount Dust retention amount when increasing resistance is 10mmAq
(D) Surface roughness measurement
Measuring device Mitutoyo surface roughness measuring instrument
Model Taylor Hobson Co., Ltd.
Form Talysurf S5C
Measurement condition Needle condition 0.2μm-0.7mN
Measurement range 4mm
Average roughness (Rax) μm
This is a value obtained by extracting the reference curve L from the roughness curve in the direction of the average line and summing the absolute values of deviations from the average line of the extracted part to the measurement curve.
Maximum height (Ryx) μm
A reference length L is extracted from the roughness curve in the direction of the average line, and is the sum of the height Yp from the average line of the extracted part to the highest peak and the depth Yv to the lowest valley.
(E) Textile shedding
(A) A sample is cut out to 10 cmφ, and an iron ingot of 10 cmφ × 1.3 kg is dropped from the sample upper surface 10 cm with the air outflow surface of the sample facing down.
(B) Assume that the number of drops dropped on the sample is 50 and the amount of dropped fibers ejected from the air outflow surface of the sample.
(C) Number of measurements n = 3
(D) Judgment
No falling fibers on the ejection surface ○
A few fibers dropped on the ejection surface △
4 or more fibers falling on the ejection surface ×
(F) Handling
(A) A sample was cut into a 25 cm square and set in a filter frame, and it was evaluated whether or not the surface on the processing side was caught when the filter was handled.
(B) Evaluation judgment
No surface catching ○
Occasionally caught on the surface △
The surface is often caught ×
Claims (2)
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