JP4932564B2 - Gas removal filter medium, method for producing the same, and gas removal element using the gas removal filter medium - Google Patents

Description

  The present invention includes a deodorizing filter medium used by attaching to an air conditioner in a living environment for filtering and purifying fluid contaminated with odor components, and it is included in air or atmosphere in semiconductor or liquid crystal production facilities or clean rooms. The present invention relates to a gas removal filter medium such as a chemical filter filter medium for removing gaseous pollutants, a method for producing the same, and a gas removal element using the gas removal filter medium.

  In living spaces such as residential rooms and offices of buildings, interior materials and furniture used there contain a lot of chemical substances such as adhesives. These chemicals such as adhesives are harmful to the human body. It is known that volatile substances and volatile substances having an unpleasant odor are generated. In addition, exhaust gases from automobiles, etc., are known to generate gases harmful to the human body, such as sulfur dioxide, nitrogen dioxide, and acetic acid gas, and gases with unpleasant odors. There is a need for a technique for removing substances and volatile substances having an unpleasant odor. Therefore, the present applicant has proposed a deodorizing filter medium described in Patent Documents 1 and 2. The deodorizing filter medium of Patent Document 1 is a deodorizing filter medium in which deodorized powder particles are fixed to one surface of a web composed of a connecting portion made of a hot melt resin and a resin agglomerated portion via the resin agglomerated portion. is there. Further, the deodorizing filter medium of Patent Document 2 is a laminate in which deodorized powder particles are fixed to one surface of a web composed of a connecting portion made of a hot melt resin and a resin agglomerated portion via the resin agglomerated portion. A deodorizing filter medium comprising a unit, the other surface of the web, and a deodorized powder granule constituting another laminated unit fixed through a resin aggregation part. However, since then, these deodorizing filter media have been used for a wide range of applications, and a longer-life deodorizing filter media has been demanded.

  In addition, in a semiconductor or liquid crystal production facility or a clean room or the like used in connection with semiconductor or liquid crystal peripheral technology, high cleanliness is required for the air or atmosphere in the production facility or the clean room. That is, such air and atmosphere contain organic gaseous pollutants and inorganic gaseous pollutants, and organic gaseous pollutants and inorganic gaseous pollutants from clean room components and workers. Since pollutants are generated, a technique for removing such gaseous pollutants as much as possible is required.

  Of gaseous pollutants, acidic gas such as sulfur dioxide is said to cause corrosion due to the presence of moisture in the air when it directly touches a metal part such as an aluminum wiring layer. In addition, when a basic gas such as ammonia is present, the protons generated in the chemically amplified resist are consumed, resulting in a decrease in pattern resolution, or a precipitate formed by adsorption or reaction on the glass or mirror surface. Is said to cause trouble.

  In addition, organic substances with low polarity among gaseous pollutants can be removed by surface cleaning or heating even if they are physically adsorbed on the surface of a silicon wafer or glass substrate, but are difficult to remove if they are present in large quantities. become. In particular, organic substances having a high boiling point (for example, 150 ° C. or higher) and / or organic substances having a high polarity, such as additives, among pollutants are strongly formed on the surface of a silicon wafer or a glass substrate after becoming gaseous. Adsorbs and cannot be removed easily. For example, it is believed that dioctyl phthalate, a plasticizer used for polymer materials, has a strong adhesive force on the wafer and drives out and replaces a substance having a low adhesive force already attached to the wafer.

  Such additives are substances added to improve the functionality of polymer materials and the like, for example, plasticizers, antioxidants, ultraviolet absorbers, light stabilizers, flame retardants, lubricants, antistatic agents. , Nucleating agent, foaming agent and the like. As materials for these additives, in particular, phthalate ester plasticizers, trimellitic ester plasticizers, aliphatic dibasic ester plasticizers, fatty ester plasticizers, epoxy plasticizers, phosphoric acid Ester plasticizers, polyester plasticizers, phenolic antioxidants, thio antioxidants, phosphorus antioxidants, benzotriazole UV absorbers, benzophenone UV absorbers, UVA UV absorbers, hindered amine light stabilizers Agents, phosphorus flame retardants, etc. are problematic.

  In order to prevent the adsorption of these organic substances on the wafer surface, it is necessary to manage the concentration of the organic substances in the clean room atmosphere as low as possible. Therefore, the present applicant has proposed a filter material for chemical filters described in Patent Document 3. This filter material for chemical filters is a filter material for chemical filters formed by laminating a physical adsorption layer that adsorbs pollutants generated from the ion exchange resin downstream of the ion exchange resin layer. By providing a physical adsorption layer downstream of the layer, the gas to be treated can remove pollutants generated from the ion exchange resin layer with the physical adsorption layer, and it can be acidic or basic without releasing the pollutants into the gas to be treated. The gas removal can be realized. As a specific example of the above-described ion exchange resin layer or physical adsorption layer, an ion exchange resin is formed on one surface of a web composed of a connecting portion made of hot melt resin and a resin agglomerated portion via the resin agglomerated portion. It is formed by adhering powder particles or physically adsorbed powder particles, and the other surface of the web, the ion-exchange resin particles and the physically adsorbed powder particles constituting the other laminated unit are interposed via the resin agglomerated part. An example of sticking is shown. However, in such a filter material for chemical filters, the layer of the ion exchange resin is one layer, and the life is about half that of the conventional one provided with two layers, and the cost is higher for the effect. There was a problem. Therefore, there has been a demand for a filter material for a chemical filter having a longer lifetime. Moreover, it cannot be said that the solution to the problem of removing pollutants generated from the filter medium itself for chemical filters as much as possible is sufficient.

JP-A-11-76747 Japanese Patent Laid-Open No. 11-253720 JP 2002-248308 A

  The present invention solves the above problems, and in gas removal filter media such as deodorizing filter media and chemical filter media, the volatile substances generated from these filter media themselves are small, and the gas removal life of these filter media is extended. Another object is to provide a gas removal filter medium having a high gas removal capability. In pursuit of this problem, the present inventor has paid attention to the hot-melt resin connecting the deodorized powder particles and the ion exchange resin, and as a result of earnest research, a large amount of volatile substances are also obtained from the hot-melt resin. The present invention has been achieved by ascertaining the occurrence of this phenomenon and examining the prevention method.

Means for solving the above problem is that in the invention according to claim 1, the gas removal particles having a gas removal particle layer in which gas removal particles made of an ion exchange resin are connected by a hot melt resin made of a polyamide resin . A filter medium, wherein the gas removal particle layer is formed by fixing the gas removal particles to one surface of a web composed of a connecting portion made of the hot melt resin and a resin aggregation portion via the resin aggregation portion. When heated to 80 ° C. by the dynamic head space method, the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) generated from the hot melt resin is 1.0 μg / g · hr or less. , and the and the amount (n- hexadecane equivalent amount) of the organic substances having a high boiling point (0.99 ° C. or higher) generated from the gas removal filter medium 1.0μg ^/ m 2 · min or less Filter media for gas removal, characterized in that. According to the first aspect of the present invention, in gas removal filter media such as deodorizing filter media and chemical filter media, particularly, there are few volatile substances generated from these filter media themselves, and the gas removal life of these filter media is increased and gas is removed. It is possible to provide a gas removal filter medium having a high removal capability.
Moreover, in the invention which concerns on Claim 1, the said hot-melt resin is a polyamide-type resin, and it becomes possible to connect gas removal particle | grains using water vapor | steam. Therefore, it can be suitably used for gas removal particles made of an ion exchange resin whose activity decreases at a temperature exceeding 100 ° C. Also, when heat treatment with water vapor is employed using a hot-melt nonwoven fabric, the polyamide-based resin has a characteristic that it is easily shrunk and cut at the time of wet heat, so that melt cutting can be performed efficiently.
Moreover, in the invention which concerns on Claim 1, the said gas removal particle | grains are ion exchange resins, and it becomes possible to provide the filter medium for gas removal with a high gas removal capability especially as a filter medium for chemical filters. In addition, since the ion exchange resin hardly absorbs organic gas, the effect of the present invention is remarkable.
In the invention according to claim 1, the gas removal particle layer is disposed on one surface of a web composed of a connecting portion made of the hot melt resin and a resin agglomerated portion via the resin agglomerated portion. The particles are fixed, and a particularly preferable form can be obtained as a gas removal filter medium.

In the invention according to claim 2 , the gas removal particle layer is constituted by a plurality of laminated units, and the laminated unit is formed on one surface of a web constituted by a connecting portion made of the hot melt resin and a resin aggregating portion. The gas removal particles are fixed through the resin agglomerated part, and the other surface of the web and the other gas removal particles constituting another laminated unit are fixed through the resin agglomerated part. The gas removing filter medium according to claim 1, wherein According to the second aspect of the present invention, it is possible to obtain a preferable form having a particularly long life as a filter medium for gas removal.

According to a third aspect of the present invention, there is provided a gas removal element comprising: the gas removal filter medium according to claim 1 or 2 pleated; and a frame member fixed to a peripheral edge of the gas removal filter medium. In addition, since the filter medium for gas removal is pleated, there is an advantage that the life is extremely long and the pressure loss is low as compared with the plate-like case.

In the invention according to claim 4 , in producing a gas removal filter medium having a gas removal particle layer formed by connecting gas removal particles made of an ion exchange resin with a hot melt resin made of a polyamide resin, The gas-removed particle layer is formed by fixing the gas-removed particles to one surface of the web composed of the connecting portion and the resin-aggregated portion via the resin-aggregated portion. By using the hot melt resin, the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) generated from the hot melt resin when heated is 1.0 μg / g · hr or less . , the amount of organic substances having a high boiling point (0.99 ° C. or higher) generated from the gas removal filter material (n- hexadecane equivalent amount) of 1.0 [mu] g / ^{m 2} is a manufacturing method of the gas removal filter material, characterized in that the min or less. According to the invention of claim 4 , the gas removal filter medium of claim 1 or 2 can be produced.

  According to the present invention, it is included in deodorizing filter materials used by attaching to air conditioners in living environments for filtering and purifying fluid contaminated with odor components, and in air and atmosphere in semiconductor and liquid crystal production facilities and clean rooms, etc. In the filter media for gas removal such as filter media for chemical filters that remove the gaseous pollutants generated, there are few volatile substances generated from these filter media themselves, and the gas removal life of these filter media is increased and the gas removal capability is high. It is possible to provide a filter medium for gas removal.

  BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, preferred embodiments of a gas removal filter medium according to the present invention, a manufacturing method thereof, and a gas removal element using the gas removal filter medium will be described in detail. The method for producing the gas removal filter medium will be described in the description of the gas removal filter medium.

  The gas removal filter medium of the present invention is a gas removal filter medium having a gas removal particle layer in which gas removal particles are connected by a hot melt resin. The thickness is preferably a sheet-like material having a thickness of 0.2 to 4 mm so as to facilitate pleating. Moreover, it is preferable to have a breathable cover material on one side or both sides of the gas removal particle layer. Further, it is possible to provide a composite filter having a dust removing filter medium for removing dust on one side or both sides of the gas removing particle layer.

  As a form of the gas removal filter medium, for example, as shown in FIG. 1, a gas composed of gas removal particles (3) and hot-melt resins (10) and (10 ′) connecting the gas removal particles (3). There is a gas removal filter medium (13) in which a breathable cover material (5) is laminated and integrated on both surfaces of the removal particle layer (8). In this example, the hot-melt resin (3) is connected to one or both sides of the gas-removable particle layer (8) formed into a sheet by connecting the hot-melt resin (10 ') made of thermally adhesive fibers. 10), the breathable cover material (5) is bonded.

  In order to obtain the gas removal particle layer (8) having such a structure, for example, the gas removal particles (3) are held in the voids of the mat-like material having air permeability and made of a hot melt resin component, Thereafter, the gas removal particles (3) can be obtained by adhering to the mat-like material by heat treatment. Further, for example, the gas removal particles (3) are held in the voids of the mat-like material having air permeability and made of a hot melt resin component, and then the mat-like material is melted by heat treatment to remove the gas removal particles. It can be obtained by linking (3). Examples of such a mat-like material having air permeability include porous materials such as nonwoven fabrics, woven fabrics, membranes, filter papers, sponges, etc. Among them, nonwoven fabrics are preferable because they have high air permeability. In the present invention, the mat-like material is a hot melt resin for connecting the gas removing particles.

  As another method for obtaining the gas removal particle layer (8) having the above-described structure, for example, a breathable cover material obtained by mixing a mixture of fibers made of hot melt resin having a short fiber length and gas removal particles (3) is used. (5) is deposited on the sheet to form a sheet-like material, and then the sheet-like material is heated to cause the fibers to exhibit adhesiveness or melt to form a hot melt resin. It can be obtained by connecting the gas removal particles (3) with a melt resin. In addition, when this method is used, the fiber length is preferably 1 to 15 mm, and more preferably 2 to 10 mm.

  As another form of the gas removal filter medium, for example, as illustrated in FIG. 2 or FIG. 4, a gas removal particle (3) and a hot melt resin (hereinafter referred to as a connecting portion) for connecting the gas removal particle (3). (1), (1 ′), (10), and (10 ′) and agglomerated hot melt resin (hereinafter referred to as resin agglomerated part) (2) and (2 ′) There is a gas removal filter medium (13) in which air-permeable cover materials (5) and (5 ′) are laminated and integrated on both surfaces of (8). In this example, the gas removal particles (3) are connected to each other by a hot melt resin (1), (1 ′), (10), or (10 ′) to form a sheet-like gas removal particle layer (8). Breathable cover materials (5) and (5 ') are laminated and integrated. More specifically, the gas-removed particles (3) are formed on one surface of the web composed of the connecting part (1) made of hot melt resin and the resin agglomerated part (2) via the resin agglomerated part (2). Is fixed.

  As another form of the filter medium for gas removal, as illustrated in FIG. 3 or FIG. 5, for example, the gas removal particles (3) and (3 ′) and the gas removal particles (3) and (3 ′) are combined. Hot melt resins (1), (1 ′), (1 ″), (10), (10 ′) and (10 ″) to be joined and hot melt resins (2), (2 ′) and (2 ″) to be aggregated The gas-removing filter medium (13) in which the breathable cover materials (5) and 5 ′ are laminated and integrated on both surfaces of the gas-removal particle layer 8 is formed in this example. ) And (3 ′) are laminated units (4) of gas-removable particle layers connected by hot melt resins (1), (1 ′), (1 ″), (10) and (10 ′) to form a sheet. ) And (4 ′) are laminated, and the breathable cover materials (5) and (5 ′) The melt resins (1), (1 ′), (10), and (10 ′) and the agglomerated hot melt resins (2), (2 ′), and (2 ″) are laminated and integrated. Includes a plurality of laminated units (4), and the laminated unit (4) has a resin on one surface of a web composed of a connecting portion (1) made of hot melt resin and a resin agglomerated portion (2). The gas removal particles (3) are fixed through the agglomeration part (2), and the other surface of the web and the gas removal particles (3 ′) constituting the other laminated unit (4 ′) are resin agglomerated. It is fixed via the part (2 ″).

  Moreover, as a method of obtaining the gas removal filter medium having such a structure, for example, when the lamination unit (4) is two or more layers as shown in FIG. 3 or FIG. 5, the surface of the hot melt nonwoven fabric (10) After the gas removal particles (3) are disposed on the resin agglomerated part (2) is formed at the part where the hot melt nonwoven fabric and the gas removed particles are in contact with each other by heat treatment, and the resin agglomerated part (2) and the connecting part ( A first step of forming a web consisting of 1), and a second step of forming the laminated unit (4) by leaving only the gas-removed particles fixed to the web among the gas-removed particles, After laminating the hot melt nonwoven fabric (10 ″) in contact with the gas removal particles (3) of the lamination unit (4), and subsequently arranging the gas removal particles (3 ′) on the surface of the hot melt nonwoven fabric (10 ″) , Sequentially performing the first step and the second step There is a law. In addition, instead of the hot-melt nonwoven fabrics (10) and (10 ′) serving as both surfaces of the gas removal particle layer 8, a sheet in which the hot-melt nonwoven fabric is attached to the cover materials (5) and (5 ′) is used. In addition, a gas removal filter medium (13) in which the air-permeable cover materials (5) and (5 ′) are laminated and integrated can be obtained.

  As another form of the gas removal filter medium, for example, a gas-permeable particle is formed by bonding gas removal particles to each other with a hot melt resin to form a sheet, and a breathable cover material is laminated and integrated. There is a filter medium for gas removal. In order to obtain a gas removal particle layer having such a structure, for example, there is a method in which gas removal particles and hot melt resin powder are mixed and then sandwiched between cover materials and used as a gas removal filter medium by heat treatment.

  2 to 5 described above, since the surface of the gas removal particles is effectively used particularly with low pressure loss, it is harmful to a gas harmful to the human body or a gas having an odor, and a clean room. Excellent gas removal efficiency can be exhibited with respect to gas. Further, the gas removal filter medium having such a structure has an advantage that it is easy to pleat because it has excellent flexibility while the gas removal particles are present at a high density.

The gas removal particles applied to the present invention are used for removing unpleasant odorous substances in living environment, or remove gaseous pollutants contained in air or atmosphere in semiconductor or liquid crystal production facilities or clean rooms. For this purpose, it is possible to apply solid particles that can adsorb gaseous substances or change gaseous substances to substances that are easily adsorbed. Examples of such solid particles include activated carbon, zeolite, various chemical adsorbents, ion exchange resins, photocatalysts, and the like, and one or more of them can be appropriately selected. In the present invention, it is possible to select an activated carbon with excellent ability to adsorb various gaseous substances, specific surface area if you select the activated carbon preferably has 200 meters 2 / ^g or more porous, 500 meters ² / g or more is more preferable, and 800 m ² / g or more is more preferable.

  In addition, an acidic gas removing agent can be attached to the solid particles for the acidic gas, and an alkaline gas removing agent can be attached to the solid particles for the alkaline gas. Is possible. As the acid gas removing agent, for example, alkali metal carbonates such as potassium carbonate, potassium hydrogen carbonate, sodium carbonate and sodium hydrogen carbonate, and amine compounds such as ethanolamine, hexamethylenediamine and piperazine are preferable. Potassium carbonate and / or potassium hydrogen carbonate, which is excellent in acid gas removal ability, is more preferable. Moreover, as the above-mentioned alkaline gas removing agent, for example, phosphoric acid, sulfuric acid, nitric acid, malic acid, citric acid, ascorbic acid and the like are preferable, and among these, phosphoric acid having excellent alkaline gas removal ability is more preferable.

  Next, the effect when, for example, activated carbon is selected as the gas removal particle applied to the present invention will be described. Conventionally, activated carbon is known to adsorb organic gaseous substances, and when the activated carbon is selected as the gas removal particles, even if volatile substances are generated from the hot melt resin itself, It is predicted that this generated volatile substance will be adsorbed. However, by adsorbing volatile substances, the gas adsorption life of the gas removal particles is surely shortened. On the other hand, the filter medium for gas removal of the present invention with less volatile substances generated from the hot melt resin itself has an advantage that the gas removal life of the filter medium is kept long. Further, in the prior art, when at least a part of the hot melt resin is disposed downstream of the gas removal particles, if a volatile substance is generated from the hot melt resin in this portion, the gas removal particles cause this. It was impossible to adsorb volatile substances. On the other hand, the gas removal filter medium of the present invention that generates less volatile substances from the hot melt resin itself has the advantage that less volatile substances are generated from the filter medium itself.

  Next, the effect when, for example, an ion exchange resin is selected as the gas removal particles applied to the present invention will be described. Conventionally, it has been known that an ion exchange resin cannot adsorb organic gaseous substances. When an ion exchange resin is selected as the gas removal particles, volatile substances are generated from the hot melt resin itself. Even if it is generated, the generated volatile substance cannot be adsorbed. On the other hand, in the filter medium for gas removal of the present invention that generates less volatile substances from the hot melt resin itself, the volatile substances generated from the filter medium itself can be obtained by selecting an ion exchange resin as the gas removal particles. The effect that there is little can be acquired notably.

  In the present invention, the gas removal particles preferably have an average particle size of 0.147 mm (100 mesh) to 1.65 mm (10 mesh) in order to achieve both high efficiency and low pressure loss. The average particle size is more preferably 0.212 mm (70 mesh) to 1.0 mm (16 mesh). If gas removal particles having a fine average particle diameter of less than 0.147 mm (100 mesh) are used, the gas removal efficiency can be increased, but the problem of increased pressure loss may occur. Further, when gas removal particles having a coarse average particle diameter exceeding 1.65 mm (10 mesh) are used, gas removal efficiency may be insufficient.

  In the present invention, in the gas removal particle layer, the gas removal particles are connected by a hot melt resin. As the hot melt resin, when heated to 80 ° C. by the dynamic headspace method, the amount of high boiling point (150 ° C. or higher) organic substance generated from the hot melt resin (n-hexadecane conversion amount) is 22 μg / g · It is not particularly limited as long as it is hr or less, and for example, a thermoplastic polyamide-based resin, a thermoplastic polyester resin, a thermoplastic polyurethane resin, a polyolefin resin, or a polyolefin-modified resin can be used alone or in combination. . Examples of the polyolefin-modified resin include ethylene-vinyl acetate copolymer, saponified ethylene-vinyl acetate copolymer, ethylene-ethyl acrylate copolymer, ethylene-acrylic acid copolymer, ethylene-methacrylic acid copolymer. Examples thereof include a polymer, an ethylene-maleic acid copolymer, and an ionomer resin (a heat-sensitive resin obtained by adding a metal to an ethylene-methacrylic acid copolymer). Among these hot-melt resins, a resin of a type that melts with wet heat is preferable. For example, a thermoplastic polyamide-based resin can connect gas removal particles using water vapor. Therefore, it can be suitably used for gas removal particles made of an ion exchange resin whose activity decreases at a temperature exceeding 100 ° C. In addition, even when heat treatment using water vapor is adopted using a hot-melt nonwoven fabric, if the thermoplastic polyamide-based resin is used, the resin has a characteristic of being easily shrunk and cut at the time of wet heat, so that melt cutting can be performed efficiently. Can do.

  The melting point of the hot melt resin is preferably 60 to 140 ° C, and the melting point of the hot melt resin is more preferably 90 to 125 ° C. When the melting point is less than 60 ° C., there is a problem that the gas removal filter medium is deformed when the ambient temperature exceeds the melting point during storage, transportation or use. If the melting point exceeds 140 ° C., the gas removal particles themselves may be altered during processing. The hot melt resin preferably has a melt index at 160 ° C. of 20 (g / 10 minutes) or more and 500 (g / 10 minutes) or less. A resin having a melt index lower than this preferred range has low fluidity during heat treatment, and resin agglomerated portions are not easily formed during heat treatment, and the gas removal particles may not be firmly fixed. Furthermore, if the resin is higher than the above range, the fluidity during the heat treatment is high, and it may be difficult to process.

  In the present invention, when heated to 80 ° C. by the dynamic headspace method, the amount of high boiling point (150 ° C. or higher) organic substance generated from the hot melt resin (n-hexadecane conversion amount) is 22 μg / g · hr or less. Need to be. Further, the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane equivalent amount) generated from the hot melt resin is preferably 11 μg / g · hr or less, preferably 5 μg / g · hr or less. Is more preferably 1.0 μg / g · hr or less. When the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) exceeds 22 μg / g · hr, volatile substances generated from these filter media increase, and the required gas removal filter media. Cannot be obtained, the gas removal life of the gas removal filter medium cannot be extended, or a gas removal filter medium having a high gas removal ability cannot be obtained. Moreover, as a minimum, 1 pg / g * hr of a detection limit can be mentioned, for example.

  Next, the dynamic headspace method will be described with reference to FIG. FIG. 6 is an explanatory diagram of a generated gas collection device (MSTD-258M manufactured by GL Sciences Inc.) used in this method. In the present invention, the amount of volatile components generated is measured at a high temperature of 80 ° C. using this dynamic headspace method. First, the gas removal filter medium is cut into a circle having a diameter of 7 cm to obtain a sample (9). This sample (9) is placed on the central gas outlet (15) in the chamber (14). Next, while the clean helium gas (11) is continuously passed through the chamber (14) at a flow rate of 120 ml / min, the inside of the chamber (14) is heated to 80 ° C. When the helium gas (11) comes into contact with the sample (9), the substance generated from the sample (9) is mixed in the helium gas, so that after the gas concentration becomes equilibrium, the solid adsorption is performed at a collection rate of 100 ml / min. Collected in agent (12) (component; 2,6-diphenylene oxide). Subsequently, the substance collected in the solid adsorbent (12) was analyzed with a gas chromatograph mass spectrometer (QP-5050, manufactured by Shimadzu Corporation), and the amount of organic substance having a high boiling point (150 ° C. or higher) The amount of generated gas is quantified in terms of hexadecane.

  In the above-described dynamic headspace method, the sample to be measured is a filter medium. However, when the sample to be measured is a hot melt resin, a simpler method can be employed. . In this method, first, 0.02 g of hot-melt resin is inserted into a glass tube having an inner diameter of 5 mm, and the entire glass tube is heated to 80 ° C. Next, helium gas is passed through the glass tube to heat and desorb a substance generated from the hot melt resin, and further cold trap. Subsequently, it analyzes with a gas chromatograph mass spectrometer (QP-5050 by Shimadzu Corporation Corp.), and about the quantity of the organic substance of a high boiling point (150 degreeC or more), the amount of generated gas is quantified by n-hexadecane conversion.

  In the gas removal filter medium of the present invention, the proportion of the gas removal particles and the hot melt resin is preferably 60 to 98% by mass of the gas removal particles and 40 to 2% by mass of the hot melt resin. More preferably, the gas removal particles are 70 to 95% by mass and the hot melt is 30 to 5% by mass, the gas removal particles are 80 to 95% by mass, and the hot melt resin is 20 to 5% by mass. More preferably. When the gas removal particles are less than 60% by mass, the gas removal efficiency may decrease. Moreover, when the hot-melt resin is less than 2% by mass, the gas removal particles may not be sufficiently connected and the gas removal particles may fall off.

  The cover material is not particularly limited as long as it is a breathable material. For example, a fiber substrate such as a woven fabric, a knitted fabric, a net, or a nonwoven fabric can be applied. A material is preferred. Among these, a non-woven fabric is particularly preferable because it can efficiently use the total area of the fiber surface widely and has many small voids formed by the fibers.

  The nonwoven fabric (hereinafter referred to as the nonwoven fabric substrate) as the fiber substrate is not particularly limited, and the structure of the nonwoven fabric substrate is typically a fiber length of 15 to 100 mm and a crimp number of 5 to 30 / inch. Generally called a dry method, in which a fiber called a staple fiber is formed on a fiber web using a card machine or an air array device, and then the constituent fibers are bonded together using an adhesive fiber or an adhesive. There is a nonwoven fabric obtained by a manufacturing method.

  Moreover, the nonwoven fabric formed not only by a dry method but by the manufacturing method of arbitrary nonwoven fabrics, for example, a wet method, a spun bond method, a melt blow method, an electrostatic spinning method, a flash spinning method etc. is applicable. In the case of the spunbond method, for example, a fiber made of a thermoplastic resin is spun from a nozzle to form a fiber fleece made of a long fiber, and then the fiber fleece is pressed between a heating roll having irregularities and a smooth roll. However, there is a method of forming a nonwoven fabric base material in which fibers made of a thermoplastic resin are partially fused.

  The fibers constituting the nonwoven fabric substrate are not particularly limited, and synthetic fibers made of thermoplastic resin, semi-synthetic fibers such as rayon, natural fibers such as cotton and pulp fibers, or inorganic fibers such as metals can be applied. Although possible, fibers with less generation of volatile substances are preferred, and fibers made of thermoplastic resins are preferred in view of durability and processability. The fibers made of thermoplastic resin include synthetic fibers that are generally used in the production of nonwoven fabrics. For example, polyester fibers such as polyethylene terephthalate and polybutylene terephthalate, polyamide fibers such as nylon 6 and nylon 66, polypropylene, and polyethylene. And the like, polyolefin fibers such as polyacrylonitrile, acrylic fibers such as polyacrylonitrile, and polyvinyl alcohol fibers.

It is preferable that the fiber base be as breathable as possible as long as the gas removal particles can be prevented from falling off. Specifically, the surface density of the fiber base material is preferably from 5 to 50 g / ^{m 2,} and more preferably 10 to 40 g / ^{m 2.}

The thickness of the gas removal filter medium of the present invention is preferably 0.2 to 4 mm, more preferably 0.3 to 3 mm, and more preferably 0.4 to 2 mm in consideration of pleating. More preferably it is. If it is less than 0.2 mm, the gas removal efficiency may be insufficient. In addition, when the length exceeds 4 mm, when pleating is performed, the portion that does not contribute to the filtration of the gas or the portion that contributes very little (hereinafter referred to as dead space) increases, and on the contrary, the gas removal efficiency becomes insufficient. There is. Moreover, as a relationship between the average particle diameter of the gas removal particles and the thickness of the filter medium for gas removal, the average particle diameter of the gas removal particles is 0.1 to 1.0 times the thickness of the filter medium for gas removal. It is preferable. The average particle diameter of the gas removal particles is more preferably 0.2 to 0.8 times the thickness of the gas removal filter medium. The thickness means a thickness at a weight per unit area of 0.5 g / m ² .

  The gas removal element of the present invention is obtained by pleating the gas removal filter medium. Specifically, as illustrated in FIG. 7, the gas removal element of the present invention is a filter element in which the gas removal filter medium (21) is pleated and the pleat shape is held by the frame member (22 a). (20). FIG. 7 also illustrates an example in which the frame member (22b) is mounted in the direction of arrow A on the end surface of the pleated filter (21) that intersects the pleated ridgeline direction. The pleating process of the gas removal filter medium is not limited as long as it is folded into a zigzag shape. There are ways to do it.

  Further, the frame material is not particularly limited as long as the pleated shape can be maintained. For example, a sheet-like material such as a woven or knitted fabric, a nonwoven fabric, a synthetic resin sheet, a foamed sheet, paper, a metal material, or a composite thereof is used. Can be applied. Of these, non-woven fabrics are particularly preferable because they are excellent in strength, excellent in cushioning properties when the filter element is attached to the rigid frame, and excellent in sealing performance with the rigid frame. Specifically, these sheet-like materials can be attached to an end surface intersecting with the pleated ridge line direction by heat-sealing or adhering via an adhesive or an adhesive sheet. The shape-retaining member is not limited to a sheet-like member, and can be formed by foaming by attaching a foamable resin or the like. Further, the shape retaining member can be mounted not only on the end face intersecting with the pleated line direction but also on an end face parallel to the pleated line direction.

  Before or after the pleating process, as illustrated in FIG. 7, the gas removal filter medium (21) is arranged in parallel with a space in the direction intersecting the pleated ridge line direction with a linear hot It is also preferable to provide a separator (24) to which a melt resin is attached to prevent the pleated mountain slopes from coming into contact and forming a dead space. As shown in these figures, it is preferable that the linear hot melt resin adheres intermittently to the peak of the pleat and not to the valley of the pleat. It is also a preferable aspect that it is provided only on the upstream side.

  Further, the overall size of the gas removal element is such that the dimension of one side of the air inflow surface is 80 in the case of a gas removal element used by being mounted on an air conditioner in a living environment such as an automobile or a domestic air cleaner. -500 mm is preferable, 100-400 mm is more preferable, and 150-300 mm is still more preferable. Moreover, 5-100 mm is preferable, 8-50 mm is more preferable, and 10-30 mm is still more preferable. In addition, in the case of gas removal elements used as gas removal filters such as package filters, fan coil units, and central air conditioning filter units in air purifiers installed in buildings, factories, offices, etc. The dimension of one side is preferably 200 to 1500 mm, more preferably 300 to 1000 mm, and still more preferably 400 to 700 mm. Moreover, 10-500 mm is preferable, 20-400 mm is more preferable, and 30-300 mm is still more preferable.

  When the gas removal element is applied to an air conditioner, the gas removal element can be attached to a rigid frame. The rigid frame is not particularly limited as long as it is a rigid material, and wood, metal, plastic, or the like is applied, and wood is preferable when incinerated and discarded after several washing and regeneration.

  As described above, according to the present invention, in a deodorizing filter medium used by attaching to an air conditioner in a living environment for filtering and cleaning a fluid contaminated with an odor component, a semiconductor or liquid crystal production facility, a clean room, etc. In filter media for gas removal such as filter media for chemical filters that remove gaseous pollutants contained in air and atmosphere, there are few volatile substances generated from these filter media themselves, and the gas removal life of these filter media is extended. At the same time, it has become possible to provide a gas removal filter medium having a high gas removal capability. In addition, it is possible to provide a gas removal element in which a gas removal filter medium is pleated.

  Examples of the present invention will be described below, but these are only suitable examples for facilitating the understanding of the present invention, and the present invention is not limited to the contents of these examples.

(Dust removal filter media pressure drop test method)
As the initial pressure loss (Pa), a value measured at a wind speed of 0.1 m / sec is used.

(Raw material adjustment 1)
A thermoplastic polyamide resin A (melting point: 95 to 100 ° C., melt index at 160 ° C .: 49 g / 10 min) manufactured by Company A was prepared. The amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) generated from this thermoplastic polyamide-based resin A was 0.4 μg / g · hr when measured by the dynamic headspace method.
Next, this thermoplastic polyamide-based resin A was melt-spun to form a spider web-like hot melt nonwoven fabric A having a surface density of 20 g / m ² .
Moreover, after forming this hot melt nonwoven fabric A, a spunbond made of polyester fibers having a fiber diameter of 10 to 30 μm, an area density of 20 g / m ² , a thickness of 0.12 mm, and a pressure loss of 1.0 Pa (wind speed of 10 cm / s). Laminated on the nonwoven fabric. The hot melt nonwoven fabric A was cooled and adhered to the spunbond nonwoven fabric to obtain a cover material A having a surface density of 50 g / m ² to which the hot melt nonwoven fabric A was adhered.

(Raw material adjustment 2)
A thermoplastic polyamide resin B manufactured by B Company (melting point: 115 ° C., melt index at 160 ° C .: 90 g / 10 min) was prepared. When the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane equivalent amount) generated from this thermoplastic polyamide resin B was measured by the dynamic headspace method, it was 30 μg / g · hr.
Next, this thermoplastic polyamide-based resin B was melt-spun to form a spider web-like hot melt nonwoven fabric B having an area density of 20 g / m ² .
In addition, after forming this hot melt nonwoven fabric B, a spunbond made of polyester fiber having a fiber diameter of 10 to 30 μm, a surface density of 20 g / m ² , a thickness of 0.12 mm, and a pressure loss of 1.0 Pa (wind speed of 10 cm / s) is immediately obtained. Laminated on the nonwoven fabric. The hot melt nonwoven fabric B was cooled and adhered to the spunbond nonwoven fabric to obtain a cover material B having a surface density of 50 g / m ² to which the hot melt nonwoven fabric B was adhered.

Example 1
As shown in FIG. 4, gas-removed particles made of an anion exchange resin having an average particle diameter of 600 μm on the surface of the hot melt nonwoven fabric (10) of the cover material A having a surface density of 50 g / m ² prepared in the raw material preparation 1 Spray (3). Subsequently, a steam treatment of about 5 Kg / cm ² is performed for about 7 seconds from the cover material (5) side (hot melt nonwoven fabric (10) side), and the hot melt nonwoven fabric (10) is plasticized and melted. The gas removal particles (3) were fixed to the web composed of the connecting part (1) and the resin agglomerated part (2), via the resin agglomerated part (2). Subsequently, the gas removal particles other than the fixed gas removal particles are removed, whereby the gas removal particles (3) having an areal density of 280 g / m ² are fixed and the laminated unit (4) bonded to the cover material (5). )
Next, cover material A (5 ′) having a surface density of 50 g / m ² to which hot melt nonwoven fabric A prepared in raw material preparation 1 is adhered is placed so that the hot melt nonwoven fabric (10 ′) side is in contact with the laminated unit (4). And laminated on the lamination unit (4). Next, the hot melt nonwoven fabric (10 ') is plasticized and melted through a laminate through a pair of heating rolls, and is composed of a connecting portion (1') made of hot melt resin and a resin agglomerating portion (2 '). The gas removal particles (3) were fixed to the web through the resin agglomeration part (2 ′) to obtain a gas removal filter medium (13) having a surface density of 380 g / m ² and a thickness of 0.8 mm. When the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane equivalent amount) generated from the gas removal filter medium (13) was measured by the dynamic headspace method, it was 0.4 μg / m ² · min. . In addition, the amount of the generated high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) per unit mass of the hot-melt resin was 0.6 μg / g · hr.

  Next, using the obtained gas removing filter medium, as shown in FIG. 7, the gas removing element (21) has a gas removing element having a total size of 225 mm on the frame material side × 235 mm on the side perpendicular to the frame material. In addition, after forming the pleats so that the pleat height H is about 29 mm, the pleat height is about 6 mm, and the number of ridges is 37, hot melt is applied to one side of the frame material (24) made of nonwoven fabric. A frame member (24) to which a resin sheet was bonded was prepared, and the frame member (24) was fixed in the direction of arrow A shown in FIG. 7 to obtain a filter element. The evaluation results of Example 1 are shown in Table 1.

(Comparative Example 1)
In Example 1, it replaced with the hot-melt nonwoven fabric A and cover material A which were prepared by the raw material adjustment 1, and it was the same as that of Example 1 except having used the hot-melt nonwoven fabric B and the cover material B prepared by the raw material adjustment 2. A gas removal filter medium (13) having a surface density of 380 g / m ² and a thickness of 0.8 mm was obtained. When the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) generated from the gas removal filter medium (13) was measured by the dynamic headspace method, it was 21 μg / m ² · min. The amount of high boiling point (150 ° C. or higher) organic substance generated from the resin (in terms of n-hexadecane) was 31 μg / g · hr. The evaluation results of Comparative Example 1 are shown in Table 2.

(Example 2)
As shown in FIG. 5, gas-removed particles made of an anion exchange resin having an average particle diameter of 600 μm on the surface of the hot melt nonwoven fabric (10) of the cover material A having a surface density of 50 g / m ² prepared in the raw material preparation 1 Spray (3). Subsequently, a steam treatment of about 5 Kg / cm ² is performed for about 7 seconds from the cover material (5) side (hot melt nonwoven fabric (10) side), and the hot melt nonwoven fabric (10) is plasticized and melted. The gas removal particles (3) were fixed to the web composed of the connecting part (1) and the resin agglomerated part (2), via the resin agglomerated part (2). Subsequently, by removing gas removal particles other than the fixed gas removal particles, the gas removal particles (3) having a surface density of 280 g / m ² are fixed, and the first layer bonded to the cover material (5) is adhered. A laminate unit (4) was obtained. Further, the hot melt nonwoven fabric A (10 ″) having an areal density of 20 g / m ² is laminated on the laminated unit (4) in this state, and the gas removal particles (3 ′) are dispersed, the steam treatment, and the gas removal particles not fixed. Then, a second layer stack unit (4 ′) having gas removal particles (3 ′) with an area density of 320 g / m ² was formed.
Next, the cover material A (5 ′) having a surface density of 50 g / m ² to which the hot melt nonwoven fabric A prepared in the raw material preparation 1 is adhered is placed so that the hot melt nonwoven fabric (10 ′) side is in contact with the laminated unit (4 ′). And laminated on the lamination unit (4 ′). Next, the hot melt nonwoven fabric (10 ') is plasticized and melted through a laminate through a pair of heating rolls, and is composed of a connecting portion (1') made of hot melt resin and a resin agglomerating portion (2 '). The gas removal particles (3 ′) were fixed to the web through the resin agglomeration part (2 ′) to obtain a gas removal filter medium (13) having a surface density of 720 g / m ² and a thickness of 1.3 mm. When the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane equivalent amount) generated from the gas removal filter medium (13) was measured by the dynamic headspace method, it was 0.6 μg / m ² · min. . In addition, the amount of the generated high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) per unit mass of the hot-melt resin was 0.6 μg / g · hr.

  Next, using the obtained gas removing filter medium, as shown in FIG. 7, the gas removing element (21) has a gas removing element having a total size of 225 mm on the frame material side × 235 mm on the side perpendicular to the frame material. In addition, after forming the pleats so that the pleat height H is about 29 mm, the pleat height is about 6 mm, and the number of ridges is 37, hot melt is applied to one side of the frame material (24) made of nonwoven fabric. A frame member (24) to which a resin sheet was bonded was prepared, and the frame member (24) was fixed in the direction of arrow A shown in FIG. 7 to obtain a filter element. The evaluation results of Example 2 are shown in Table 1.

(Reference Example 1)
In Example 2, instead of the hot melt nonwoven fabric A prepared in the raw material preparation 1, a surface density of 720 g / m ² was obtained in the same manner as in Example 2 except that the hot melt nonwoven fabric B prepared in the raw material preparation 2 was used. A gas removal filter medium (13) having a thickness of 1.3 mm was obtained. When the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane equivalent amount) generated from the gas removal filter medium (13) was measured by the dynamic headspace method, it was 10 μg / m ² · min. Further, the amount of the generated high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) per unit mass of the hot melt resin was 10 μg / g · hr. The evaluation results of Reference Example 1 are shown in Table 1.

(Reference Example 2)
In Example 2, instead of the cover material A prepared in the raw material adjustment 1, the surface density 720 g / m ² , thickness was obtained in the same manner as in the example 2 except that the cover material B prepared in the raw material adjustment 2 was used. A filter medium (13) for removing gas of 1.3 mm was obtained. When the amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane equivalent amount) generated from the gas removal filter medium (13) was measured by the dynamic headspace method, it was 21 μg / m ² · min. Further, the amount of the generated high boiling point (150 ° C. or higher) organic substance (in terms of n-hexadecane) was converted to 21 μg / g · hr per unit mass of the hot melt resin. The evaluation results of Reference Example 2 are shown in Table 1.

(Comparative Example 2)
In Example 2, it replaced with the hot-melt nonwoven fabric A and cover material A which were prepared by the raw material adjustment 1, and it was the same as that of Example 2 except having used the hot-melt nonwoven fabric B and the cover material B prepared by the raw material adjustment 2. A gas removal filter medium (13) having a surface density of 720 g / m ² and a thickness of 1.3 mm was obtained. The amount of high boiling point (150 ° C. or higher) organic substance (n-hexadecane conversion amount) generated from the gas removal filter medium (13) was measured by a dynamic headspace method, and was 31 μg / m ² · min. Further, the amount of the generated high boiling point (150 ° C. or higher) organic substance (in terms of n-hexadecane) was converted to 31 μg / g · hr per unit mass of the hot melt resin. The evaluation results of Comparative Example 2 are shown in Table 2.

Table 1

Table 2

As is clear from Tables 1 and 2, the amount of high-boiling organic substances generated from the gas removal filter media of Examples 1-2, Reference Examples 1-2, and Comparative Examples 1-2 is generated from the hot melt resin. It can be seen that it is approximately equal to the amount of high boiling organic substances. Moreover, the filter medium for gas removal of Examples 1-2 and Reference Examples 1-2 has a small amount of the high boiling point organic substance generated from the hot melt resin, whereas for the gas removal of Comparative Examples 1-2. The filter medium has a large amount of high-boiling organic substances generated from the hot melt resin, and the gas removal filter medium of Examples 1-2 and Reference Examples 1-2 is superior to the gas removal filter medium of Comparative Examples 1-2. I understand that.

It is a cross-sectional schematic diagram which shows an example of the filter medium for gas removal of this invention. It is a cross-sectional schematic diagram which shows another example of the filter medium for gas removal of this invention. It is a cross-sectional schematic diagram which shows another example of the filter medium for gas removal of this invention. It is a cross-sectional schematic diagram which shows another example of the filter medium for gas removal of this invention. It is a cross-sectional schematic diagram which shows another example of the filter medium for gas removal of this invention. It is a perspective view of the generated gas collection device used for fixed_quantity | quantitative_assay of the filter material for gas removal of this invention. It is a perspective view which shows an example of the gas removal element of this invention. In addition, it is a diagram illustrating a mode in which the frame member is mounted in the direction of arrow A.

Explanation of symbols

1,1 ', 1 "connecting part (hot melt resin)
2,2 ', 2 "resin agglomerated part (hot melt resin)
3, 3 'Gas removal particles 4, 4' Stacking unit 5, 5 'Cover material 8 Gas removal particle layer 9 Sample 10, 10', 10 "Hot melt resin (hot melt nonwoven fabric)
11 Helium gas 12 Solid adsorbent 13 Gas removal filter medium 14 Chamber 15 Gas outlet 20 Filter element 21 Gas removal filter medium 22a Frame material 22b Frame material 23 Fold 24 Separator

Claims (4)

A gas removal filter medium having a gas removal particle layer in which gas removal particles made of an ion exchange resin are connected by a hot melt resin made of a polyamide resin , wherein the gas removal particle layer is a connection made of the hot melt resin. The hot-melt resin when the gas-removed particles are fixed to one surface of a web composed of a resin agglomerated part and a resin agglomerated part via the resin agglomerated part and heated to 80 ° C. by a dynamic headspace method. The amount of organic substances having a high boiling point (150 ° C. or higher) generated from NO ( 1.0 equivalent to n-hexadecane) is 1.0 μg / g · hr or lower, and the high boiling point (150 ° C. or higher) generated from the gas removal filter medium. ) Is an organic substance (n-hexadecane equivalent amount) of 1.0 μg / m ² · min or less . The gas removal particle layer is composed of a plurality of laminated units, and the laminated unit is formed on one surface of a web composed of a connecting portion made of the hot melt resin and a resin agglomerated portion via the resin agglomerated portion. The gas removal particles are fixed, and the other surface of the web and the other gas removal particles constituting another stack unit are fixed through a resin agglomeration part. Item 2. A filter medium for gas removal according to Item 1 . A gas removal element comprising: a gas removal filter medium according to claim 1 or 2 pleated, and a frame member fixed to a peripheral edge of the gas removal filter medium. In producing a gas removal filter medium having a gas removal particle layer formed by connecting gas removal particles made of an ion exchange resin with a hot melt resin made of a polyamide resin, a connecting portion made of the hot melt resin and a resin aggregation portion When the gas-removed particle layer is formed on one surface of a web constituted by the resin agglomerated portion to form the gas-removed particle layer and heated to 80 ° C. by a dynamic headspace method, a hot melt resin is used. Generated from the filter medium for gas removal by using the hot melt resin having a high boiling point (150 ° C. or higher) organic substance generated from the above (conversion amount of n-hexadecane) of 1.0 μg / g · hr or less that the amount of organic substances having a high boiling point (0.99 ° C. or higher) that the (n- hexadecane equivalent amount) than 1.0μg ^/ m 2 · min Method for producing a gas removal filter material according to symptoms.

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