JP5102992B2 - Functional separator, gas adsorber and tobacco deodorant filter - Google Patents

Description

  The present invention relates to a functional separation material having a filler-fixed fiber in which a functional filler is fixed to the fiber surface, and a tobacco deodorizing filter capable of deodorizing odor components contained in tobacco smoke components.

  In recent years, indoor environmental pollution by harmful chemical substances has become a problem. Among the harmful chemical substances, the smoke component of tobacco contains harmful gas components and odor components, and is therefore cited as one of the causes of polluting indoor environments such as homes, buildings, and cars. Therefore, a functional separator that removes tobacco odor is desired. As the functional separation material, a fiber sheet carrying an adsorbent such as activated carbon or a photocatalyst is provided.

Patent Document 1 discloses a laminated structure in which activated carbon particles are mixed between two sheets and integrated with a hot melt agent, the sheet having an air permeability of 20 seconds or less and an average interfiber distance of 1 to 1. There has been proposed a planar deodorant which is a 100 μm non-woven fabric, wherein the activated carbon powder has a particle size of 100 to 1000 μm and the hot melt agent powder has a particle size of 100 to 1000 μm. Further, Patent Document 2 proposes a breathable pollution prevention photocatalyst deodorizing filter in which a photocatalyst is sandwiched between breathable pollution prevention filters.
JP-A-10-99421 JP 2001-516 A

  However, cigarette smoke components contain spider components (nicotine, tar, etc.) in addition to toxic gas components and odor components. In a sheet carrying an adsorbent or photocatalyst, stains of the spider component are adsorbent. In addition, there is a problem that the deodorizing function is remarkably lowered due to adhesion to the surface of the photocatalyst. Moreover, in the planar deodorant body of patent document 1, activated carbon particle | grains were embedded in resin inside with the hot-melt agent, and there existed a case where sufficient deodorizing effect was not acquired. Furthermore, in such an immobilization method, since the contact area between the hot melt agent and the activated carbon particles is small, the activated carbon particles may fall off. In addition, when the activated carbon particles are sandwiched between the two sheets, it is necessary to use the activated carbon particles having a large particle size of 100 to 1000 μm so that the activated carbon particles do not fall off. For this reason, there is a problem that the specific surface area of the activated carbon particles is small and a sufficient deodorizing effect cannot be obtained.

  Furthermore, although the deodorizing filter of Patent Document 2 attempts to prevent deterioration of the deodorizing function from the spear component by laminating a breathable pollution prevention filter layer, the photocatalyst particles are simply sandwiched between the breathable pollution prevention filter layers. There was a risk of falling through the filter layer. Therefore, attempts are made to prevent the particles from falling off by aggregating the photocatalyst particles and deodorant particles to form an aggregated composite. However, the aggregated composite does not only exhibit the desired functionality because the surface area of the individual functional particles decreases, but also adheres with an emulsion binder resin, which may further reduce the functionality of the particles. there were.

  As described above, conventional functional separators are required to have a function of adsorbing, decomposing, and removing various odor components, particle components, adhesive components, and the like, like tobacco smoke. The fact is that the separating material has not been put into practical use yet. In order to solve the above-described conventional problems, the present invention can prevent the functional filler fixed to the fiber surface from falling off and suppress the decrease in the specific surface area of the functional filler. Provided are a functional separator and a cigarette deodorizing filter that prevent deterioration of functions due to adhesion of components other than odor such as components.

The functional separation material of the present invention has a filler-fixed fiber including a fiber, a wet heat gelled resin on the surface thereof, and a functional filler fixed to the wet heat gelled resin. A functional layer fixed by a gelled product obtained by wet-heat gelation of the wet heat gelled resin by steam treatment, and a basis weight of 0.5 to 20 g / m ² containing ultrafine fibers having a fiber diameter of 10 μm or less on both surfaces of the functional layer. The surface fiber layer including the ultrafine fiber layer is laminated, and the surface fiber layer is laminated with a fiber layer having an average fiber diameter larger than the ultrafine fiber layer on both surfaces of the ultrafine fiber layer, and the functional layer and the surface the fibrous layer are integrated by partial compression, the functional filler and having adsorption, and at least one functionality selected from deodorant or Ranaru group.

In the gas adsorbing material of the present invention, the functional filler is a gas adsorbing filler, and the gas adsorbing filler is a porous filler having an average particle diameter in the range of 10 to 100 μm.
The tobacco deodorizing filter of the present invention is characterized by incorporating the gas adsorbent.

  Since the functional separator of the present invention is fixed by the gelled product obtained by wet heat gelation in which the functional filler is fixed to the surface of the fiber, the functional filler can be fixed in a state where the functional filler is exposed on the surface. As a result, it is possible to prevent the functional filler adhered to the fiber surface from falling off, and to suppress a decrease in the specific surface area of the functional filler. Adsorption / deodorization performance of contained harmful gas components and odor components can be improved.

Further, the functional separator of the present invention is more breathable than necessary by laminating a surface fiber layer containing an ultrafine fiber layer having a basis weight of 0.5 to 20 g / m ² containing an ultrafine fiber on at least one side of the functional layer. For example, components containing particulate components and sticky components such as spear components contained in cigarette smoke can be removed without reducing the functional layer adsorption / decomposition / deodorization function and function. The life of the sex separator can be extended.

  The tobacco deodorizing filter of the present invention incorporates the functional separating material to adsorb, decompose, and deodorize and remove all components such as harmful gas components, odor components, and spear components contained in tobacco smoke. Therefore, it can be used for applications such as air purifiers, smoke separators, and vehicle cabin filters.

The functional separation material of the present invention refers to a substance that separates a causative substance from a gas or a liquid by providing the function of the functional filler.
Functions that can be added include adsorption, decomposition, deodorization, aroma, antibacterial, antifungal, anti-dard, anti-virus
Examples include oxidation, reduction, hydrophilicity, water repellency, and addition.

  The wet heat gelling resin used for the functional separation material of the present invention refers to a resin that can be gelled by heating in the presence of moisture. The “resin that can be gelled” refers to a resin that swells by gelling at a temperature of 50 ° C. or higher and that can fix the constituent fibers of the functional layer by the swollen gelled product. Examples of the wet heat gelled resin include powder, chip, and fiber. In particular, the wet heat gelled resin is preferably fibrous. The fibrous wet heat gelled resin (hereinafter referred to as “wet heat gelled fiber”) is a fiber containing a wet heat gelled resin, or a composite fiber containing a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component. (Hereinafter referred to as “wet heat gelled composite fiber”). As a result, other fibers or at least other thermoplastic synthetic fiber components exhibit the function of functioning as a binder that maintains the fiber form and the wet heat gelled resin is gelled to fix the functional filler to the fiber surface. . The functional filler is fixed by a gelled product obtained by wet-heat gelation of the wet-heat gelled resin fiber component or the wet-heat gelled resin bonded to the fiber surface. Preferably, the functional filler is exposed and fixed. Also, the wet heat gelled fibers and / or the wet heat gelled fibers and other fibers are bonded to each other by the gelled product obtained by wet heat gelation of the wet heat gelled resin fiber component or the wet heat gelled resin bonded to the fiber surface. Has been.

  The wet heat gelling resin is preferably an ethylene-vinyl alcohol copolymer resin. It is because it can be gelled by wet heat and does not alter other fibers and / or other thermoplastic synthetic fiber components.

  The ethylene-vinyl alcohol copolymer resin is a resin obtained by saponifying an ethylene-vinyl acetate copolymer resin, and the saponification degree is preferably 95% or more. A more preferable degree of saponification is 98% or more. Moreover, a preferable ethylene content rate is 20 mol% or more. A preferable ethylene content is 50 mol% or less. A more preferable ethylene content is 25 mol% or more. A more preferable ethylene content is 45 mol% or less. If the degree of saponification is less than 95%, it may be difficult to produce a fiber structure due to adhesion to a roll or the like during gel processing. Similarly, when the ethylene content is less than 20 mol%, production of a fiber structure may be difficult due to adhesion to a roll or the like during gel processing. On the other hand, if the ethylene content exceeds 50 mol%, the wet heat gelation temperature becomes high, and the processing temperature has to be raised to the vicinity of the melting point, and as a result, the dimensional stability of the fiber structure may be adversely affected. .

  A preferred gelling temperature of the wet heat gelling resin is 50 ° C. or higher. A more preferable gelation temperature is 80 ° C. or higher. If a resin that can be gelled at a temperature lower than 50 ° C. is used, it may become difficult to produce a fiber structure during gel processing due to intense adhesion to a roll or the like, or may not be used in summer or in a high-temperature environment. . The “gel processing” refers to processing for gelling a wet heat gelled resin.

As a preferable combination of the fiber and the wet heat gelled resin,
(I) a composite fiber comprising a wet heat gelled resin fiber component and another thermoplastic synthetic fiber component,
(II) a mixture of the composite fiber and other fibers,
(III) a mixture of the composite fiber and wet heat gelled resin, and
(IV) At least one selected from a mixture of a wet heat gelled resin and other fibers (hereinafter referred to as “forms (I) to (IV)”). The form (I) is a wet heat gelled composite fiber in which “wet heat gelled resin” is a wet heat gelled resin fiber component and “fiber” is another thermoplastic synthetic fiber component. In the form (II), “wet heat gelled resin” is a wet heat gelled composite fiber, and “fiber” is another fiber and is mixed. In the form (III), the “fiber” is a wet heat gelled composite fiber, and a wet heat gelled resin is further mixed. The form (IV) includes a wet heat gelled resin other than the wet heat gelled composite fiber (for example, a wet heat gelled resin alone fiber, a powder form, a chip form), and “fiber” as other fibers. Are mixed.

  It is preferable that the wet heat gelled composite fiber used in the forms (I) to (III) is a composite fiber in which the wet heat gelled resin fiber component is exposed or partially divided. The composite shape indicates a concentric core-sheath type, an eccentric core-sheath type, a parallel type, a split type, a sea-island type, and the like. In particular, the concentric core-sheath type is preferable because the functional filler is easily fixed to the fiber surface. In addition, the cross-sectional shape may be any of a circle, a hollow, an irregular shape, an ellipse, a star, a flat shape, and the like, but is preferably a circle from the standpoint of easy fiber production. It is preferable that the split-type composite fiber is partially split in advance by jetting a high-pressure water stream or the like. If it does in this way, the divided | segmented wet heat gelled resin fiber component will gelatinize by wet heat processing, will form a gelled material, will adhere to the surface of another fiber, and will adhere a functional filler. That is, it functions as a binder.

  The fineness of the wet heat gelled composite fiber is preferably 0.9 to 11 dtex, and more preferably 2 to 9 dtex. When the fineness of the wet heat gelled composite fiber is less than 0.9 dtex, sufficient air permeability may not be ensured when used in the functional separation material. When the fineness exceeds 11 dtex, the functional filler becomes a gelled product. There is a case where it is buried or there is a case where the fixed amount of the functional filler is reduced.

  The ratio of the wet heat gelled resin fiber component to the wet heat gelled composite fiber is preferably in the range of 10 to 90% by mass. The content of the wet heat gelled resin fiber component is more preferably 30 to 70% by mass. When the content of the wet heat gelled resin fiber component is less than 10% by mass, the functional filler tends to be difficult to adhere. When the content of the wet heat gelled resin fiber component exceeds 90% by mass, the fiber formability of the composite fiber tends to be lowered.

  The thermoplastic synthetic fiber component in the wet heat gelled composite fiber may be any material such as polyolefin, polyester, polyamide, etc., but is preferably polyolefin. Examples of the polyolefin include polyethylene, polypropylene, polybutene, and polystyrene. When ethylene-vinyl alcohol copolymer resin is used as the wet heat gelled resin fiber component, it is easy to form a composite fiber (conjugate fiber) by melt spinning.

  Moreover, it is preferable to use the thermoplastic synthetic fiber component which has melting | fusing point higher than the temperature which gelatinizes a wet heat gelled resin fiber component as another thermoplastic synthetic fiber component. If the other thermoplastic synthetic fiber component is a thermoplastic synthetic fiber component having a melting point lower than the temperature at which the gelled product is formed, the other thermoplastic synthetic fiber component itself tends to melt and become hard. May become non-uniform with shrinkage.

  The ratio of the wet heat gelled composite fiber to the functional layer is not particularly limited as long as it is an amount capable of fixing the functional filler, but the fiber is fixed by the gelled product and / or the functional filler is effectively fixed. It is preferable that the ratio of the composite fiber required for this is 10 mass% or more. A more preferable ratio of the composite fiber is 30% by mass or more. A more preferable ratio of the composite fiber is 50% by mass or more.

  In the form (III), the wet heat gelled composite fiber may further contain a wet heat gelled resin to form a gelled product on the surface of the composite fiber. Thereby, the adhesion effect of a functional filler can be improved more.

  Other fibers used in the form (II) or the form (IV) include chemical fibers such as rayon, natural fibers such as cotton, hemp, wool, polyolefin resin, polyester resin, polyamide resin, acrylic resin, polyurethane Arbitrary things, such as a synthetic fiber which uses synthetic resins, such as resin, as a single ingredient or a plurality of ingredients, can be selected and used.

  In the form (IV), the wet heat gelled resin is preferably contained in the range of 1 to 90% by mass with respect to the functional layer. A more preferable content is 3 to 70% by mass. When the content of the wet heat gelled resin is less than 1% by mass, it is difficult to fix other fibers by the gelled product, or it is difficult to fix the functional filler. If the content of the wet heat gelled resin exceeds 90% by mass, the fiber shape may be lost to form a film, or the functional filler may be buried in the gelled product.

  The functional layer is preferably a fiber structure. The fiber structure refers to, for example, a nonwoven fabric, a woven fabric, a knitted fabric, a net-like material, a fiber bundle, and the like. A functional filler is fixed to the surface of the fiber constituting the fiber structure.

  The functional filler, for example, adsorbs and deodorizes gaseous substances such as harmful gas components and odor components contained in tobacco smoke, VOC (volatile organic compound) gas, or dichloroethylene contained in flue gas and exhaust gas. There is no particular limitation as long as it has a function. For example, activated carbon particles, zeolite, silica gel, activated clay, porous particles such as layered phosphate, photocatalyst particles coated with a porous inorganic compound such as titanium oxide, and acidic substances and formaldehyde adsorbents on these porous particles A porous particle containing a functional compound such as is preferable. Among the porous particles, activated carbon particles are particularly preferable.

  The type of the activated carbon is not particularly limited, and examples thereof include those using coconut shells or wood as raw materials, and the activation method includes a method using steam or a method using chemicals.

  The said functional filler says a particulate thing, for example. When the functional filler is in the form of particles, the average particle diameter of the functional filler is preferably in the range of 10 to 100 μm. A more preferable average particle diameter is 15 to 80 μm, and an even more preferable average particle diameter is 20 to 50 μm. When the average particle size is less than 10 μm, the functional filler may be buried in the gelled product. On the other hand, when the average particle diameter exceeds 100 μm, the specific surface area of the functional filler becomes small, and the effect of the functional filler (for example, tobacco deodorizing effect) may not be sufficiently obtained. Even if the functional filler of the present invention has a small particle size of the functional filler, it adheres in a state of being exposed on the fiber surface, so that an excellent effect is exhibited with a small amount of the functional filler. In particular, when the average particle diameter of the functional filler is 100 μm or less, the specific surface area becomes large, so that even a small amount of the functional filler exhibits an excellent effect. The average particle size is a value according to JIS standard sieve (JIS Z 8801).

The functional layer is preferably ^{2 to} 200 g, more preferably 10 to 100 g, per 1 m ^{2 of the} tobacco deodorizing layer in order to efficiently exhibit the function of the functional filler. It is preferably 20 to 80 g. When the amount of the filler fixed is less than 2 g, it is not possible to sufficiently adsorb and deodorize harmful gas components, odor components and the like contained in tobacco smoke. When the fixed amount of the filler exceeds 200 g, the gap between the fibers of the tobacco deodorizing layer becomes small, and the air permeability when used as a filter is lowered.

  The functional separation material of the present invention may further contain a functional compound. Examples of the functional compound include acidic substances such as phosphoric acid, sulfanilic acid, acrylic acid, and polyphenol, hydrazide compounds, and polyamine compounds such as aromatic polyamine, polyallylamine, and polyvinylamine. The functional compound referred to here is a liquid compound, for example, a compound that is easily dissolved or dispersed in a solvent such as water. Use of a liquid functional compound is convenient because the functional compound is uniformly dispersed in the fiber structure. When the functional separation material contains an acidic substance, it exhibits an excellent effect for adsorption of ammonia gas and the like, and when it contains a hydrazide compound, a polyamine compound, etc., it exhibits an excellent performance for adsorption of formaldehyde and the like.

The functional layer is a fiber structure having a filler-fixed fiber including a fiber, a wet heat gelled resin on the surface thereof, and a functional filler fixed to the wet heat gelled resin. The specific configuration of the functional layer is a functional nonwoven fabric in which the fiber and the wet heat gelled resin contain 50% by mass or more of a composite fiber containing a wet heat gelled resin component and another thermoplastic synthetic fiber component. Is preferred. The content of the wet heat gelled composite fiber is more preferably 70% by mass or more, and still more preferably 80% by mass or more. This is because the filler can be effectively fixed with such a configuration. The basis weight of the functional nonwoven fabric is preferably 30 to 200 g / m ² , and the amount of the functional filler fixed is preferably ^{2 to} 200 g per 1 m ^{2 of the} functional nonwoven fabric. With such a configuration, functions such as adsorption, decomposition, and deodorization can be efficiently performed while ensuring air permeability.

Air permeability of the functional layer is preferably 20~200cm ³ / cm ² · sec, and more preferably 30~150cm ³ / cm ² · sec. When the air permeability is less than 20 cm ³ / cm ² · sec, for example, when used in a filter such as an air purifier filter or a smoke filter, the air circulation efficiency is lowered, and the air permeability is 200 cm ³ / cm ^2. -If it exceeds sec, the voids in the functional layer are too large, and harmful gas components and odor components do not sufficiently contact the filler, and the adsorption / deodorization efficiency may decrease.

A surface fiber layer including an ultrafine fiber layer having a basis weight of 0.5 to 20 g / m ² including an ultrafine fiber having a fiber diameter of 10 μm or less is laminated on at least one surface of the functional layer. By using such a surface fiber layer, it is possible to remove spider components contained in tobacco smoke without reducing air permeability more than necessary, so that the adsorption / deodorization function of the functional layer is reduced. It can be suppressed and the life can be extended. In addition, the said fiber diameter expands the cross section of an ultrafine fiber layer, and measures the diameter of a single fiber, or enlarges the ultrafine fiber layer which permeate | transmits and is visible from a surface fiber layer, and measures the diameter of a single fiber It can ask for. Moreover, the average fiber diameter is obtained by enlarging the cross section of the ultrafine fiber layer, obtaining the fiber diameters of 50 single fibers, respectively, averaging, or enlarging the surface of the nonwoven fabric 700 times, and taking a photograph. The median value in the length direction of single fibers that can be visually recognized within the range is defined as the fiber diameter, and the fiber diameter of each single fiber is determined and averaged.

  The fiber diameter of the ultrafine fiber used in the ultrafine fiber layer is 10 μm or less, preferably 6 μm or less, more preferably 4 μm or less. If the fiber diameter of the ultrafine fiber exceeds 10 μm, the air permeability is ensured, but the spear component mainly contained in the tobacco smoke cannot be sufficiently removed. Moreover, it is preferable that the average fiber diameter of an ultrafine fiber layer is 8 micrometers or less, More preferably, it is 0.5-6 micrometers, More preferably, it is 1-5 micrometers. When the average fiber diameter of the ultrafine fiber layer exceeds 8 μm, the air permeability is ensured, but on the other hand, the spear component mainly contained in tobacco smoke cannot be sufficiently removed. If the fiber diameter of the ultrafine fiber or the average fiber diameter of the ultrafine fiber layer is too small, the size of the voids in the ultrafine fiber layer tends to be small, and the voids are blocked by the spear component, etc., and the functionality is likely to deteriorate. .

Basis weight of the microfiber layer is preferably 0.5 to 20 g / m ^2, more preferably 1 to 15 g / m ^2, even more preferably 1 to 10 g / m ^2. If the basis weight of the ultrafine fiber layer is less than 0.5 g / m ² , it is not possible to sufficiently remove the spider component mainly contained in tobacco smoke. If the basis weight of the ultrafine fiber layer exceeds 20 g / m ² , the air permeability may be lowered.

  The surface fiber layer includes the ultrafine fiber layer. By laminating the ultrafine fiber layer, it is possible to sufficiently remove, for example, spider components contained in tobacco smoke while ensuring air permeability (removal effect). Even if the filler of the tobacco deodorizing layer falls off The filler can be prevented from flowing out of the tobacco deodorant (barrier effect). In the surface fiber layer, it is preferable that a fiber layer (hereinafter referred to as a thick fiber layer) having an average fiber diameter larger than that of the ultrafine fiber layer is laminated on at least one surface of the ultrafine fiber layer. More preferably, the thick fiber layer is laminated on both surfaces of the ultrafine fiber layer. When the thick fiber layer is laminated on both sides of the ultrafine fiber layer, the filler fixed to the functional layer and the ultrafine fiber layer are not in direct contact with each other. There is no. Further, the thick fiber layer serves as a pre-removal layer for the spider component.

  The fiber diameter of the fibers constituting the thick fiber layer is preferably larger than 10 μm and not larger than 40 μm. If the fiber diameter of the fibers constituting the thick fiber layer is 10 μm or less, the air permeability may be lowered, and if it exceeds 40 μm, it may be difficult to maintain the strength of the nonwoven fabric when the basis weight is low.

The basis weight of the surface fiber layer (when laminated on both surfaces of the functional layer, the total of both surfaces) is 10 to 60 g / m ² , preferably 12 to 40 g / m ² . If the basis weight of the surface fiber layer is less than 10 g / m ² , the air permeability is ensured, but it is not possible to sufficiently remove the spear component mainly contained in tobacco smoke. If the basis weight exceeds 60 g / m ² , the air permeability may be lowered.

As a specific configuration of the surface fiber layer, the ultrafine fiber layer is preferably a meltblown fiber layer, and the thick fiber layer is preferably a spunbond fiber layer. When it is a melt blown fiber layer, it is possible to achieve both a removal effect and a barrier effect while having a low basis weight of 0.5 to 20 g / m ² . Moreover, when it is a spunbond fiber layer, air permeability is ensured, and it can laminate | stack, absorbing the unevenness | corrugation of the layer surface by the filler in a functional layer.

  The surface fiber layer may be simply overlapped between the ultrafine fiber layer and the thick fiber layer, but it is preferable that the surface fiber layer is integrated by thermal bonding or the like in consideration of handleability. As an integration method, for example, integration by partial pressure bonding can be mentioned.

The surface fiber layer preferably has an air permeability of 50 to 250 cm ³ / cm ² · sec, and more preferably 70 to 220 cm ³ / cm ² · sec. When the air permeability is less than 50 cm ³ / cm ² · sec, for example, when used for a filter such as an air purifier filter or a smoke filter, the air circulation efficiency is lowered, and the air permeability is 250 cm ³ / cm ^2. -If it exceeds sec, for example, a spear component contained in tobacco smoke cannot be sufficiently removed.

  In the functional separator of the present invention, the surface fiber layer is laminated on at least one surface of the functional layer. The layers may be simply overlapped but are preferably integrated by thermal bonding or the like in consideration of handleability. The integration method is preferably integration by partial pressure bonding.

  Furthermore, it is also preferable that the functional layer on which the surface fiber layer is laminated is partially pressed so that the functional separating material is bulky and the surface area is increased, which can promote the adsorption / decomposition / deodorization function of the functional layer. .

The method of integration by partial pressure bonding is preferably a pressure bonding method using an emboss roll. By giving an embossed pattern to the functional separator using an embossing roll, the functional filler can be fixed without losing the effect of the functional filler without burying the functional filler in the fiber. Since the unevenness made of the embossed pattern increases the surface area of the functional separator, it is possible to more effectively remove the spider component contained in the tobacco smoke. In addition, the formability when the functional separator is formed into a pleated structure or a honeycomb structure is improved.
Among the embossing rolls, it is more preferable that the embossing roll having a three-dimensional shape and / or the flat roll of the pair of embossing rolls is made of rubber. This is because the bulkiness of the functional separator is further increased.

  Next, the manufacturing method of the functional separation material of this invention is demonstrated. The wet heat treatment in the following description is performed in a wet heat atmosphere. The “humid heat atmosphere” here refers to an atmosphere containing moisture and heated. The wet heat treatment refers to a fiber provided with a wet heat gelled resin, a fiber containing a wet heat gelled fiber component, or a fiber structure before treatment containing these fibers (hereinafter, also referred to as “treated fiber structure”). For example, it refers to a process of heating after applying a functional filler dispersion solution containing functional filler (hereinafter referred to as filler dispersion solution) or a process of heating while applying the functional filler dispersion solution. Examples of the heating method include a method of exposing to a heated atmosphere, a method of penetrating through heated air, and a method of contacting a heated body. Moreover, as another method, after spraying a functional filler on a to-be-processed fiber structure, a water | moisture content is given, the method of heat-processing, or a functional filler on the to-be-processed fiber structure to which the water | moisture was previously given, There is also a method of heat treatment after spraying. The method of spraying is not particularly limited, and examples thereof include a method using a sieve, a method using jetting, and a method performed electrically.

  The method for producing the fiber structure to be treated is not particularly limited, but in the case of a nonwoven fabric, at least selected from methods such as a needle punch method, a hydroentanglement method, an airlaid method, a spunbond method, a melt blow method, and a wet method. It is preferred to use one type of method. Among these, a nonwoven fabric obtained by a hydroentanglement method is preferable in order to efficiently contain and fix a filler having an average particle size in the range of 10 to 100 μm in the functional layer.

When the fiber structure to be treated is produced by the hydroentanglement method, the hydroentanglement treatment conditions are appropriately set according to the basis weight of the fiber structure, the fixed amount of the filler of the obtained nonwoven fabric, the air permeability, and the like. For example, hydroentanglement treatment of a card web having a basis weight of 30 to 80 g / m ² is performed by placing the web on a plain weave support of 80 to 100 mesh, and the orifice having a pore diameter of 0.05 mm or more and 0.5 mm or less is 0. It may be carried out by spraying a water flow with a water pressure of 2 MPa or more and 10 MPa or less onto the front and back surfaces of the card web 1 to 5 times from a nozzle provided at intervals of 3 mm or more and 1.5 mm or less. If necessary, after the water entanglement treatment under the above conditions, a web is placed on the support for forming the hole, and a water flow having a water pressure of 2 MPa or more and 10 MPa or less is sprayed from the nozzle onto the web to open it. A hole may be formed. The term “open hole” as used herein refers to a portion having a size of 0.05 to 50 mm ² where fibers are not accumulated. And the web after the said hydroentanglement process is dried in order to remove a water | moisture content, and a to-be-processed fiber structure (to-be-processed nonwoven fabric) is produced.

  The treated fiber structure may be subjected to a hydrophilic treatment. When hydrophilic treatment is performed, when the fiber structure to be treated contains hydrophobic fibers, moisture can be imparted to the fiber structure to be treated substantially uniformly. As a result, the composite fiber is gelled almost uniformly by wet heat, and the functional filler is easily fixed, which is preferable. As hydrophilic treatment, surfactant treatment, corona discharge method, glow discharge method, plasma treatment method, electron beam irradiation method, ultraviolet ray irradiation method, γ ray irradiation method, photon method, flame method, fluorine treatment method, graft treatment method, Examples thereof include a sulfonation treatment method.

A preferred basis weight range of the treated fiber structure is 30 to 200 g / m ² , and a more preferred basis weight range is 35 to 100 g / m ² . When the basis weight is lower than 30 g / m ^2, the amount of the functional filler that adheres after the wet heat treatment decreases, and the function may not be sufficiently exhibited. If the basis weight is higher than 200 g / m ² , the functional filler may not easily enter the fiber structure to be treated when the functional filler is applied.

  In the case of heating after applying the filler dispersion solution, it is preferable that the ratio of moisture to be applied to the fiber or the fiber structure to be treated in the wet heat treatment (hereinafter referred to as “moisture ratio”) is 20 to 1500 mass%. . A more preferable moisture content is 30 to 1000% by mass. An even more preferable moisture content is 40 to 900 mass%. If the moisture content is less than 20% by mass, wet heat gelation may not occur sufficiently. On the other hand, when the moisture content exceeds 1500% by mass, the wet heat treatment is not uniformly performed between the surface and the inside of the fiber structure to be treated, and the degree of wet heat gelation tends to be uneven. In addition, as a provision method of a water | moisture content, it can carry out by well-known methods, such as the spray method and the immersion method in a water tank. In particular, the method of impregnating the fiber structure to be treated with the functional filler dispersion solution is preferable because a large amount of the functional filler is easily taken into the fiber structure to be treated. The fiber or treated fiber structure to which moisture has been applied can be adjusted to a predetermined moisture content by a method such as squeezing with a squeeze roll or the like.

  In the case of heating after applying the filler dispersion solution, the ratio of the filler dispersion solution to be applied to the fiber or the fiber structure to be treated in the wet heat treatment (hereinafter referred to as “pickup rate”) is 20 to 1500 mass%. Is preferred. A more preferable pickup rate is 30 to 1000% by mass. An even more preferable pickup rate is 40 to 900% by mass. If the pick-up rate is less than 20% by mass, the wet heat gelation may not occur sufficiently. On the other hand, when the pickup rate exceeds 1500% by mass, the wet heat treatment is not uniformly performed between the surface and the inside of the fiber structure to be treated, and the degree of wet heat gelation tends to be non-uniform. In addition, as a provision method of a water | moisture content, it can carry out by well-known methods, such as spray and immersion to a water tank.

  The concentration of the functional filler in the filler dispersion solution may be set as appropriate depending on the basis weight and the amount of fixing of the fiber structure to be used, or the temperature and viscosity of the filler dispersion solution. It is 1-75 mass%, and a more preferable range is 1-50 mass%. When the concentration of the functional filler is lower than 0.1% by mass, the effect of the functional filler may not be sufficiently obtained. If the concentration of the functional filler is higher than 75% by mass, the workability is deteriorated, so that the functional filler may not be uniformly attached.

  It is preferable that the filler dispersion solution further contains a gas adsorbing compound. The concentration of the gas-adsorbing compound is not particularly limited, and may be set as appropriate depending on the basis weight and the fixed amount of the fiber structure to be treated, but a preferable range is 0.1 to 10% by mass. If the concentration of the gas adsorbing compound is lower than 0.1% by mass, the effect of the gas adsorbing filler may not be sufficiently obtained. If the concentration of the gas adsorbing compound is higher than 10% by mass, the workability may be deteriorated. Further, when the concentration of the gas adsorbing compound is higher than 10% by mass, an effect commensurate with the increase in concentration may not be obtained.

  The wet heat treatment temperature in the wet heat treatment is preferably not less than the gelling temperature of the wet heat gelled resin and not more than the melting point-20 ° C. A more preferable wet heat treatment temperature is 50 ° C. or higher. Even more preferable wet heat treatment temperature is 80 ° C. or higher. On the other hand, a more preferable wet heat treatment temperature is a melting point of the wet heat gelled resin of −30 ° C. or lower. An even more preferable wet heat treatment temperature is a melting point of the wet heat gelled resin of −40 ° C. or lower. If the wet heat treatment temperature is lower than the gelation temperature of the wet heat gelled resin, the functional filler may not be effectively fixed. When the wet heat treatment temperature exceeds the melting point of the wet heat gelled resin −20 ° C., the wet heat heat gelled resin becomes close to the melting point of the wet heat gelled resin, which may cause shrinkage when the fiber structure is fixed with the functional filler.

  The fiber structure subjected to the wet heat treatment may be 1) dried as it is, 2) washed once with water, then dried, or 3) once dried, washed with water. After that, a drying process may be performed. When washing with water, the above method 3) is convenient because the amount of the functional filler to be fixed increases.

  The drying treatment temperature is not particularly limited as long as the functional filler-fixed fiber structure is dried. In this drying process, the functional filler-fixed fiber structure may be dried while being widened in the width direction (direction perpendicular to the machine base). By widening in the width direction, the basis weight can be adjusted and the dimensional stability in the length direction and the width direction can be achieved.

Examples of wet heat treatment methods include the following methods, and the respective production methods will be described.
(1) A method of performing a steam treatment after applying a filler dispersion solution to a treated fiber structure (hereinafter referred to as a steam treatment method).
(2) A method in which a filler dispersion solution is applied to a fiber structure to be treated and then brought into contact with a heating body (hereinafter referred to as a heating body contact method).
(3) A method of bringing the fiber structure to be treated into contact with the heated filler dispersion solution (hereinafter referred to as heating liquid contact method)
The steam treatment method is suitable for imparting bulkiness and / or flexibility to the fiber structure to be obtained, and a filler dispersion solution is applied to the fiber structure to be treated comprising the fiber and the web containing the wet heat gelled resin. Then, after adjusting to a predetermined moisture content, by performing a steam treatment, a gelled product in which the wet heat gelled resin is gelled is formed to fix the functional filler.

  Examples of the steam treatment method include, for example, a method of spraying steam from above and / or below a treated fiber structure adjusted to a predetermined moisture content, and steam on a treated fiber structure in a chamber filled with steam. Examples thereof include a contact method (pad steamer method) and a method of exposing the fiber structure to be treated to steam using an autoclave or the like. According to such a method, pressure is not applied to the treated fiber structure more than necessary during gel processing. As a result, while maintaining the fiber form of the fiber structure to be treated, the functional filler can be fixed while being exposed on the fiber surface of the fiber structure to be treated. Furthermore, by adjusting the conditions of the steam treatment, the treated fiber structure can be covered with a gelled product (hereinafter referred to as a film-like gelled product) spread in a film shape at the entangled portion between the fibers. As a result, the effective area for adhering is increased, and the functional performance can be further improved.

  In the pad steamer method, the steam discharged from the steam outlet is not directly brought into contact with the fiber structure to be treated, and the steam heat treatment is performed in a uniform steam atmosphere, so that the wet heat gelled resin is wet heat gelled. It is particularly preferable because a gelled product can be formed. It is also convenient for continuous operation. Furthermore, according to the pad steamer method, since the temperature can be easily controlled, the strength and air permeability of the fiber structure can be controlled according to the purpose while maintaining the function of the functional filler. A gelled product that spreads into a film can also be formed, which is particularly preferable. For example, if the functional filler on the gelled resin that maintains the fiber shape is insufficiently fixed, increasing the temperature of the pad steamer will improve the fluidity of the gelled resin and firmly fix the functional filler. Can be made. Moreover, since the pad steamer method plays the role of the preliminary process of a drying process simultaneously with gel processing, the efficiency of a drying process can also be aimed at.

  The temperature of the filler dispersion solution may be a temperature at which the wet heat gelling resin does not gel, or a temperature at which gelation starts, the type of functional filler or functional compound, particle diameter, short fiber length Alternatively, it may be set as appropriate depending on the concentration and viscosity of the filler dispersion solution. For example, when the moisture content of the fiber structure to be treated is high, the fiber structure to be treated may be heated in a temperature range in which the fiber structure to be treated does not gel so that the wet heat gelled resin is easily gelled during the wet heat treatment. If the wet heat gelled resin is at or above the temperature at which gelation starts, it becomes a method combined with the heating liquid contact method described later, and is effective in fixing the functional filler more firmly.

  The steam treatment temperature is not particularly limited as long as the temperature in the vicinity of the fiber structure to be treated is not less than the gelation temperature of the wet heat gelled resin or the wet heat gelled resin fiber component and the melting point is -20 ° C or lower. A preferable temperature range is 80 to 120 ° C, and a more preferable temperature range is 90 to 110 ° C.

  Since the functional filler is fixed in a state of being exposed on the surface of the wet heat gelled resin or wet heat gelled resin fiber by the steam treatment, an excellent effect is exhibited with a small amount of the functional filler. When the filler dispersion solution further contains a functional compound, the functional compound is fixed not only on the surface of the functional filler but also on the surface of the wet heat gelled resin or the wet heat gelled resin fiber. Compared with the case where only an adsorbing compound is used as a gas adsorbing component, a further excellent effect is exhibited.

  The fiber structure after the drying treatment may be pressed through a pair of press rolls at the outlet after the drying treatment. By performing press working at the outlet after the drying treatment, the functional filler is firmly fixed while maintaining flexibility.

  Next, the heating body contact method will be described. In the heating body contact method, in the case where the functional filler is firmly fixed, the filler dispersion solution is applied to the fiber structure to be treated including the fiber and the web containing the wet heat gelled resin, and then the predetermined moisture content is obtained. By adjusting and bringing this into contact with a heating body, a gelled product obtained by gelling the wet heat gelled resin is formed, and the functional filler is fixed. Examples of the method for bringing the fiber structure to be treated into contact with the heating body include a method for bringing it into contact with a hot roll, a method for bringing it into contact with a hot press plate, and the like. According to this method, the wet heat gelled resin fiber component can be instantaneously wet heat gelled, and at the same time the gelled product can be expanded, so that the functional filler can be fixed over a wide area. Moreover, according to this method, when it heats and gelates, the functional filler is pushed into the gelled product, and the functional filler can be more firmly fixed to the fiber surface.

  When the said heating body is planar things like a hot press board, it is preferable that the surface pressure at the time of making a to-be-processed fiber structure contact is 0.01-3 Mpa. A more preferable lower limit of the surface pressure is 0.02 MPa. A more preferable upper limit of the surface pressure is 2.5 MPa. When the surface thickness is less than 0.01 Mpa, the functional filler may not be sufficiently fixed, and when the surface pressure exceeds 3 Mpa, the texture may become hard.

  Moreover, when the said heating body contact method is the method of compression-molding processing with a hot roll, it is preferable that the linear pressure of a hot roll is 10-400 N / cm. A more preferable lower limit of the linear pressure of the hot roll is 50 N / cm. A more preferable upper limit of the linear pressure of the hot roll is 200 N / cm. When the linear pressure is less than 10 N / cm, the functional filler may not be sufficiently fixed, and when the linear pressure exceeds 400 N / cm, the texture may become hard.

  The set temperature of the heating body (for example, the set temperature of the wet heat treatment machine) is not particularly limited as long as it is not less than the gelation temperature of the wet heat gelled resin or the wet heat gelled resin fiber component and the melting point is -20 ° C or lower. A preferable temperature range is 50 to 160 ° C, and a more preferable temperature range is 80 to 150 ° C. Note that when the set temperature is set to 100 ° C. or higher in order to gel the fiber structure to be treated containing moisture, the moisture in the fiber structure to be treated first evaporates. At that time, since the gelation of the wet heat gelled resin proceeds, the actual temperature of the gel processing tends to be lower than the set temperature. Therefore, even when the melting point of the other fiber is lower than the set temperature, it may not melt or shrink substantially, and the gel processing temperature is a temperature at which the other fiber does not substantially shrink. It is preferable to process.

  By treating with a heated body, the functional filler is firmly fixed in a state exposed on the surface of the wet heat gelled resin or wet heat gelled resin fiber, so when using a small amount of the functional filler, be sure. Even when a large amount of functional filler is used, most of the functional filler can be firmly fixed, so that the amount of the functional filler falling off is small and the effect is excellent. Further, when the filler dispersion solution further contains a functional compound, the functional compound is fixed not only on the surface of the functional filler but also on the surface of the wet heat gelled resin or the wet heat gelled resin fiber. Compared with the case where only an adsorbing compound is used as a gas adsorbing component, a further excellent effect is exhibited. Therefore, for example, in a conventional functional separation material, a remarkable effect is exhibited even for gases such as formaldehyde and acetaldehyde that are difficult to remove.

  Next, the heating liquid contact method will be described. In the heating liquid contact method, the treated fiber structure is brought into contact with a heated filler dispersion solution to form a gelled product in which the wet heat gelled resin is gelled, and the functional filler is fixed. Examples of the method of bringing the fiber structure to be treated into contact with the heating liquid include a method of immersing in a heated filler dispersion solution, and a method of spraying the heated filler dispersion solution onto the fiber structure to be processed. According to this method, since the surface pressure is not applied more than necessary to the fiber structure to be treated at the time of gelation, the fluidity of the gelled wet heat gelled fiber is reduced, and the fiber form of the fiber structure to be treated In the entangled portion between the fibers, the gelled product adheres without spreading in a film shape, and can be fixed in a state where the functional filler is exposed on the fiber surface, and the obtained functional filler-fixed fiber The structure can be given bulkiness and / or flexibility. Further, when the wet heat gelled resin is gelled, the gelation of the wet heat gelled fiber proceeds simultaneously with the application of moisture, so the concentration of the functional filler in the filler dispersion solution and the temperature of the filler dispersion solution are set. It is only necessary to adjust the amount of the functional filler to be fixed. Specifically, the functional filler can be fixed to the fiber surface by impregnating the fiber or fiber structure to be treated into hot water (85 ° C. or higher) containing the functional filler. In particular, the method of immersing in a heated filler dispersion solution is preferable because the wet heat gelled fiber can be uniformly gelled.

  The gel processing temperature of the heating liquid contact method is not particularly limited as long as it is not less than the gelation temperature of the wet heat gelled resin or the wet heat gelled resin fiber component, and the melting point is −20 ° C. or less. It is 85-120 degreeC, and a more preferable temperature range is 90-100 degreeC. When the temperature is lower than 85 ° C., the filler may not be sufficiently fixed. When the temperature is higher than 120 ° C., the texture becomes hard and may be in the form of a film.

  The filler concentration of the filler dispersion solution in the heating liquid contact method may be set as appropriate depending on the basis weight and fixing amount of the fiber structure to be used, the temperature and viscosity of the filler dispersion solution, and the preferred range is 0.1 to 75. It is mass%, and a more preferable range is 1 to 50 mass%.

  In the heated liquid contact method, by immersing the fiber structure to be treated in a heated filler dispersion solution, the gelation of the wet heat gelled resin or the wet heat gelled resin fiber and the fixing of the functional filler are simultaneously performed in the liquid. Done. As a result, the functional filler can be fixed more uniformly and exposed on the fiber surface than when it is gelled after the functional filler is applied. To do. Further, when the filler dispersion solution further contains a functional compound, the functional compound is fixed not only on the surface of the functional filler but also on the surface of the wet heat gelled resin or wet heat gelled resin fiber. As compared with the case where only the active compound is used as the gas adsorbing component, the effect is further improved.

  As described above, the wet heat treatment method for the fiber structure to be treated includes a steam treatment method, a heating body contact method, a heating liquid contact method, etc., but the same treatment may be repeated or other treatment methods. May be performed in combination.

  The surface fiber layer is laminated on at least one side of the fiber structure (functional layer) to which the functional filler thus obtained is fixed. The lamination may be performed simply by superimposing, but it is preferable to bond the functional layer and the surface fiber layer by the method described below in order to improve processability and prevent the filler from falling off. There are various methods for bonding the functional layer and the surface fiber layer, such as bonding with an adhesive, sewing, etc., but in order to exhibit the effect of the filler more effectively so as not to hinder the adsorption performance of the functional filler, It is preferable to integrate by pressure bonding. For example, when an embossing roll is used, when an embossing roll heated to about 110 to 135 ° C, or when a metal flat roll (unengraved roll) is used as a companion to the embossing roll, the metal flat roll is heated, or both It is good to heat and roll the roll.

When crimping using an embossing roll, you may crimp it with any combination of embossing roll and embossing roll, embossing roll and metal flat roll, embossing roll and rubber flat roll, or embossing roll and cotton roll. .
Among these, the one using an embossing roll and a rubber flat roll is preferable because it becomes bulky and the surface area increases.

In the case of embossing rolls and embossing rolls, it is more preferable that the material is zigzag-shaped or zigzag folded so that the patterns bite each other and the bulkiness becomes very high.
In this case, it is preferable to heat one of the embossing rolls because it is difficult for the material to be formed into a film by pressure bonding.

  Furthermore, for embossed sculptures, if the pattern of the sculpture is flat, diamond pattern, circular pattern, triangle pattern, square pattern, rectangular pattern, oval pattern, star pattern, spade pattern, clover pattern, heart pattern, etc. The three-dimensional shape is preferably at least one pattern selected from a hemispherical pattern, a triangular pyramid pattern, a quadrangular pyramid pattern, a five-stroke pyramid pattern, and the like. Of these, a three-dimensional pattern (hereinafter referred to as a three-dimensional embossed pattern) is more preferable because the functional separating material becomes bulky. In particular, the hemispherical handle is most preferable because of its increased surface area and bulkiness.

  Above all, the embossing roll consisting of a semi-circular embossed pattern and the partial crimping process consisting of a rubber flat roll are effective in increasing the bulkiness of the functional separator, increasing the surface area, and the function of the filler. It is most preferable also from utilization.

  The embossing ratio of the embossing roll represents an area ratio between the concave part of the roll and the convex part of the roll by embossing a nonwoven fabric or the like. The embossing ratio can be measured simply by placing imitation paper on the embossing roll and transferring the embossing pattern with a pencil or the like. A preferred measurement method is to take an embossed pattern with a digital camera toward the embossing roll. Next, the image data is subjected to image processing, and binarization is performed so that the pattern portion (the convex portion of the roll) is white and the concave portion of the roll is black. As the image processing apparatus, an image processing apparatus 555 type manufactured by PIASS was used. The threshold value varies depending on the exposure, the light quantity, the degree of dirt on the embossing roll, and so on, but cannot be determined unconditionally. However, the threshold value when photographing the three-dimensional embossing must be adjusted so that the base part of the pattern is completely recognized as the convex part of the roll. If the threshold cannot be adjusted between 100 and 150 at this time, the range of 50 to 200 is allowed. What is important at this time is that pattern distortion occurs due to the angle of shooting except for the vertical portion with respect to the embossing roll, and therefore, it is necessary to perform trimming so that the shooting portion is about 10 cm except for the vertical portion. The horizontal portion should be at least 30 cm or longer.

The area of the embossed pattern obtained above is expressed as a ratio based on the area of the convex part of the roll. That is, emboss ratio = area of convex part of roll / area of concave part of roll.

  The embossing ratio is preferably 0.02 to 0.67. More preferably, it is 0.05 to 0.42. More preferably, it is 0.1-0.3. This is because if the embossing ratio is less than 0.02 or exceeds 0.67, the surface area cannot be increased.

The embossing ratio of the sheet is used when the embossing ratio of the embossing roll cannot be measured. This represents the area ratio of the unevenness of the embossed sheet, and the embossing ratio of the sheet is measured as follows. Basically, flat parts (here, flats do not include those with a surface that is not embossed and that are 10 cm square or more on a flat surface without folds or warpage) are placed on the ground horizontally. Place anti-reflective glass on top of it, but be careful not to crush the embossed pattern. Next, adjust the light source so that the angle of incidence is 45 degrees and the distance from the light source is 30 cm (the light source at this time should be one daylight fluorescent lamp without any reflection on the umbrella. You can use a general desk lamp by painting it in black without any flash.) With the digital camera's strobe turned off, the camera and the subject are placed at a distance of 30 cm. The subsequent area ratio measurement method is the same as the embossing roll measurement method, but the embossing roll needs to be the reciprocal of the calculated ratio because the convex portion of the embossing roll becomes concave on the sheet. That is, the embossing ratio of the sheet = 1 / (area of the convex portion of the sheet / the area of the concave portion of the sheet) or the embossing ratio of the sheet = the area of the concave portion of the sheet / the area of the convex portion of the sheet.

  The embossing ratio of the sheet is preferably 0.02 to 0.67. More preferably, it is 0.05 to 0.42. More preferably, it is 0.1-0.3. This is because if the embossing ratio of the sheet is less than 0.02 or exceeds 0.67, the surface area cannot be increased.

A large ratio between the apparent thickness of the functional separator and the thickness of the embossed and pressure-bonded portion is advantageous because the surface area increases.
The apparent thickness (A) was measured using a thickness measuring machine (trade name: THICKNESS GAUGE model CR-60A, manufactured by Daiei Kagaku Seisakusho Co., Ltd.) with a load of 2.94 cN per 1 cm ^{2 of} sample. Measured in state. The thickness (referred to as B) of the embossed and pressure-bonded part is obtained by cutting the functional separation material at any point using a razor or a microtome, and then observing the cross section with a scanning electron microscope (for example, a scanning electron microscope manufactured by Hitachi, Ltd.). N-5200) Observation was performed at a magnification of 60 times, and the place where the front surface and the back surface were closest to each other in the thickness direction was measured from an electron microscope photograph, and the thickness ratio was calculated by substituting the thickness into the following equation.
That is, the thickness ratio is expressed as A / B.
This was measured at 10 arbitrary cutting points, that is, n = 10 and averaged.
When the measurement magnification of the electron microscope is 60 times, and the magnification is too high or too low to measure the thickness, the magnification can be appropriately set so that the cut surface has a visual field of about 70%. .
For example, in the photograph of FIG. 6 which is an embodiment of the present invention, the illustrated portion of A is a portion corresponding to the apparent thickness measured using a thickness measuring machine, and the illustrated portion of B. Is equivalent to the thickness of the embossed and crimped portion.

The thickness ratio of the functional separating material is preferably 1.1 to 50. 2-40 are more preferable. 3-30 are more preferable. 4-20 are most preferred. If the thickness ratio is less than 1.1, an increase in surface area cannot be expected. If it exceeds 50, the convex portion is liable to be crushed by external stress, and what is processed so as to increase the surface area may block the concave portion by the crushed convex portion again.
The three-dimensional embossing is preferably given a three-dimensional pattern by an embossing machine having a three-dimensional pattern, which increases bulkiness, but the thickness ratio at that time is often in the range of 3 to 30.

  The functional separation material of the present invention is formed into, for example, a pleated fold structure or a honeycomb structure and used for an air purifier filter, an air conditioner filter, a vehicle cabin filter, a tobacco smoke filter, a factory smoke filter, etc. be able to. In this case, the honeycomb structure can also be used in combination with other filter materials such as electret filters, HEPA filters, ULPA filters and the like.

  When the functional separation material of the present invention is formed into a honeycomb structure, there is a honeycomb structure in which regular hexagons are regularly arranged, a honeycomb-shaped honeycomb structure, or a corrugated structure found in corrugated cardboard, etc. It is preferable to be molded from the viewpoint of improvement in air permeability as a separating material and ease of processing of the separating material. Furthermore, the thing which shape | molded the corrugated structure what has the unevenness | corrugation which consists of the embossed pattern in which the functional separation material of this invention was partially crimped | bonded is more preferable because a surface area increases further.

  In addition, a surface fiber layer including an ultrafine fiber layer so as to prevent the filler from falling off or to cover the entire separator for the role of a prefilter for a separator made of a functional material having a honeycomb-like honeycomb structure or a corrugated honeycomb structure. Or you may cover with the fiber layer changed to it.

  The functional separating material of the present invention is obtained by subjecting the surface fiber layer or the ultrafine fiber layer contained in the surface fiber layer to electret processing, or by electret processing after laminating the functional layer and the surface fiber layer, and so on. Collectability can be improved.

  The tobacco deodorizing filter of the present invention is incorporated with the functional layer and the gas adsorbing material as a filter as they are, or in combination with a functional separating material and another separating material. In the cigarette deodorizing filter of the present invention, the functional layer and the gas adsorbing material function as a tobacco deodorizing layer, and the surface fiber layer functions as a pre-removal layer such as a spear component.

  Next, an embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view of a three-layer tobacco deodorant 1 according to an embodiment of the present invention, and a surface comprising a laminated nonwoven fabric (SMS) of a spunbond fiber layer / meltblown fiber layer / spunbond fiber layer on the outside. This is an example in which the fiber layers 2 and 2 are arranged and the functional layer 3 in which the functional filler is fixed with the wet heat gelled material is arranged on the inside.

  FIG. 2 is an example process diagram of a method for producing a functional layer (functional nonwoven fabric) (steam treatment method) according to an embodiment of the present invention. The fiber 11 (or the fiber structure 11 to be treated) is impregnated in the filler dispersion solution 13 containing the functional filler in the tank 12 (or the filler dispersion solution 13 containing the functional filler and the functional compound), and the squeezing roll 14 The pad steamer 15 in which steam is blown out from below and the steam is uniformly filled in the steam is steamed, and if necessary, dried, washed and dehydrated (not shown), and dried in the dryer 16. And wind up with the winder 17. In addition, when performing the steam process with the pad steamer 15, the blown-out steam does not directly hit the fibers 11 (or the fiber structure 11 to be processed).

  3 to 4 are scanning electron micrographs showing a functional separation material (nonwoven fabric) according to an embodiment of the present invention obtained by the steam treatment method and a state in which the functional filler is fixed to the constituent fibers. It is. Among these, FIG. 3 is a scanning electron microscope plane photograph (magnification 200) showing a nonwoven fabric, and FIG. 4 is a fiber surface enlarged photograph (magnification 2000) of the nonwoven fabric surface.

  FIG. 5 is a cross-sectional view showing a corrugated structure of a functional separating material that has been embossed in three dimensions by partial crimping according to an embodiment of the present invention.

  FIG. 6 is a cross-sectional photograph of a functional separator that has been embossed in three dimensions by partial crimping according to an embodiment of the present invention.

  Specific examples of the present invention will be described below. The functional separator of the present invention was evaluated as follows.

[Fiber diameter, average fiber diameter]
The surface of the nonwoven fabric was magnified 700 times and a photograph was taken, and the fiber diameter of each single fiber existing in a 9 cm square area of the photograph was determined. Moreover, it averaged and calculated | required the average fiber diameter.

[Air permeability]
Measured according to JIS L 1096 6.27.1 A method (Fragile method).

[Tobacco deodorization test method]
First, one main smoke and one second smoke of Mild Seven (manufactured by Japan Tobacco Inc.) were placed in a 1 m ³ capacity acrylic sealed container and stabilized in 1 hour to prepare tobacco smoke. . Next, each sample is cut into a size of 10 cm in length × 10 cm in width, put in a pollution analysis bag (trade name “Tedlar Bag”) with a capacity of 5 liters, and formulated into 1 liter of cigarette smoke and 4 liters of odorless air. Odor gas was injected. And the olfactory measurement was performed for every time based on the 6-step odor intensity display method prescribed | regulated by the malodor prevention method by making the injection | pouring time into start time.

[Gas adsorption test method]
Each sample was cut into a size of 28 cm (length) x 17.6 cm (B5 size), placed in a pollution analysis bag (trade name “Tedlar Bag”) with a capacity of 5 liters, and air and an initial concentration of 20 ppm. Each formulated harmful gas was injected. And the injection | pouring time was made into start time, and the density | concentration of each noxious gas in a bag was measured with the gas detection tube every time.

[Sample 1]
The following were prepared as functional separators.
(Production of raw material)
The sheath component is an ethylene-vinyl alcohol copolymer resin (EVOH, ethylene content 38 mol%, melting point 176 ° C.), the core component is polypropylene (PP, melting point 161 ° C.), and EVOH: PP is a ratio of 50:50. A core-sheath type composite fiber (fineness: 2.8 dtex, fiber length: 51 mm) having a (volume ratio) was prepared.

The core-sheath type composite fiber was opened with a semi-random card machine to produce a card web having a basis weight of 50 g / m ² . Next, the card web is placed on a 90-mesh plain weave support, and the nozzle is arranged on the card web from a nozzle in which orifices (diameter: 0.12 mm, pitch: 0.6 mm) are arranged in a row in the width direction of the card web. The water flow was injected at a water pressure of 3 MPa, and then further injected at a water pressure of 4 MPa. Subsequently, the card web was turned upside down, and a water flow was jetted from the nozzle at a water pressure of 4 MPa to produce a hydroentangled nonwoven fabric original fabric.

(Preparation of functional filler)
As the functional filler, activated carbon particles: “Kuraray Coal PL-D” (manufactured by Kuraray Chemical Co., Ltd., coconut shell charcoal, average particle diameter of 40 to 50 μm) was used.

(Production of non-woven fabric (functional layer) containing functional filler-fixed fibers)
The hydroentangled nonwoven fabric is immersed in an aqueous dispersion (20 ° C.) containing 16% by mass of the activated carbon particles, and the pick-up rate is adjusted with the squeezing pressure of the mangle roll. It adjusted so that it might become the numerical value shown in. Next, wet heat treatment was performed in a pad steamer filled with steam adjusted so that the temperature in the vicinity of the nonwoven fabric was 100 ° C. The residence time was 20 seconds. Next, it is dried through a nonwoven fabric after wet heat treatment in a hot air circulation dryer, and further washed with water in a washing tank, and then dried in a tenter dryer adjusted to a temperature of 140 ° C., and the functional filler is fixed. A nonwoven fabric (functional layer) was obtained. In the obtained functional layer, the filler was fixed to the fiber surface with a gelled product.

(Preparation of surface fiber layer)
As a surface fiber layer, a melt-blown fiber layer (ultrafine fiber layer) having a basis weight of about 2 g / m ² was laminated between spunbond fiber layers having a basis weight of about 6.5 g / m ² and integrated by partial pressure bonding. A laminated nonwoven fabric having a basis weight of 15 g / m ² (Mitsui Chemicals Co., Ltd., trade name Syntex PQ-1153) was prepared. The fibers constituting the spunbond fiber layer were polypropylene fibers having a fiber diameter of 25 μm, and the fibers constituting the meltblown fiber layer were polypropylene fibers having an average fiber diameter of 2.5 μm. This laminated nonwoven fabric was magnified 700 times with a scanning electron microscope, and the fiber diameters of the meltblown fiber layers visible from between the fibers constituting the spunbond fiber layer were all 10 μm or less. Further, the air permeability of this laminated nonwoven fabric was 100 cm ³ / cm ² · sec.

(Production of functional separator)
Three layers of surface fiber layer / functional layer / surface fiber layer were superposed, and a pleated folding functional separating material having a ridge height of 20 mm was produced with a pleat folding machine. The air permeability when the three layers of the surface fiber layer / functional layer / surface fiber layer were superposed was 25 cm ³ / cm ² · sec. In the tobacco deodorization test, measurement was performed on a laminate in which the above three layers were stacked.

[Sample 2]
A functional separation material of the present invention was obtained by the same method as Sample 1 except that the functional compound shown below was attached by the following method. The air permeability when the three layers of the surface fiber layer / functional layer / surface fiber layer were superposed was 28 cm ³ / cm ² · sec.

(Preparation of functional compounds)
As the functional compound, a 10% by mass aqueous solution of polyallylamine was used.

(Production of non-woven fabric (functional layer) containing functional filler-fixed fibers)
The hydroentangled nonwoven fabric is immersed in an aqueous dispersion (20 ° C.) containing the functional compound adjusted to 16% by mass with the activated carbon particles and 1% by mass, and the pick-up rate is obtained with a mangle roll squeezing pressure. Was adjusted so that the adhering amount of the activated carbon particles became a numerical value shown in Table 1. Next, wet heat treatment was performed in a pad steamer filled with steam adjusted so that the temperature in the vicinity of the nonwoven fabric was 100 ° C. The residence time was 20 seconds. Next, it is dried through a nonwoven fabric after wet heat treatment in a hot air circulation dryer, and further washed with water in a washing tank, and then dried in a tenter dryer adjusted to a temperature of 140 ° C., and the functional filler is fixed. A nonwoven fabric (functional layer) was obtained.

[Sample 3]
The functional separation material of the present invention was obtained by the same method as Sample 2, except that the nonwoven fabric produced by the following method was used as the hydroentangled nonwoven fabric. The air permeability when the three layers of the surface fiber layer / functional layer / surface fiber layer were superposed was 52 cm ³ / cm ² · sec.

(Production of raw material)
The core-sheath type composite fiber was opened with a semi-random card machine to produce a card web having a basis weight of 60 g / m ² . Next, the card web is placed on a 90-mesh plain weave support, and the nozzle is arranged on the card web from a nozzle in which orifices (diameter: 0.12 mm, pitch: 0.6 mm) are arranged in a row in the width direction of the card web. The water flow was injected at a water pressure of 3 MPa, and then further injected at a water pressure of 4 MPa. Subsequently, the card web was turned upside down and placed on a 25-mesh opening-forming plain weave support, and a water stream was jetted from the nozzle at a water pressure of 4 MPa to produce a hydroentangled perforated nonwoven fabric.

[Sample 4]
A functional separation material of the present invention was obtained in the same manner as in Sample 3, except that two functional layers used in Sample 3 were stacked. The air permeability when the three layers of the surface fiber layer / functional layer / surface fiber layer were superposed was 21 cm ³ / cm ² · sec.

  Table 1 shows the basis weight of the nonwoven fabric, the amount of the functional component adhered, the functional component adhesion rate, and the functional layer basis weight of the functional layers of Samples 1 to 3.

[Sample 5]
A VOC functional sheet in which activated carbon particles are fixed with a hot melt agent between two spunbond nonwoven fabrics with a deodorant fixed on the surface (trade name “Semia V”, manufactured by Asahi Kasei Fibers, weight per unit: 134 g / m ² , activated carbon A fixed amount of particles of about 40 g / m ² ) was prepared.

  Table 2 shows the results of the functional tests performed on samples 1 to 5.

  As shown in Table 2, Samples 1 to 4 show that the reduction rate of each harmful gas concentration is faster and higher in functionality than Sample 5, and formaldehyde and acetaldehyde, which are harmful gas components contained in tobacco smoke. It was able to be removed sufficiently. This is because the functional filler in the functional layer of Sample 1 is fixed by the gelled product obtained by wet heat gelation fixed to the surface of the fiber. This is thought to be due to the suppression of the decrease in the specific surface area of the filler.

[Sample 6]
As a deodorizing filter, a product name new deodorizing filter manufactured by Nissan Motor Co., Ltd. and a skyline (honeycomb structure) were prepared.

[Sample 7]
As a deodorizing filter, a product name new deodorizing filter manufactured by Nissan Motor Co., Ltd., for X-TRAIL (pleated structure) was prepared.

[Sample 8]
As a deodorizing filter, a product name deodorizing aldehyde filter for MPV (pleated structure) manufactured by Mazda Co., Ltd. was prepared.

[Sample 9]
As a deodorizing filter, a product name deodorizing antibacterial filter, ACG-T1 (pleated structure) manufactured by Bosch Corporation was prepared.

[blank]
A hydroentangled nonwoven fabric produced in Sample 1 to which a functional filler was not fixed was prepared as a blank.

  Table 3 shows the results of a cigarette deodorization test on Sample 2, Samples 6-9, and the blank.

  As shown in Table 3, sample 2 almost removed the odor component despite the small amount of the functional filler adhering. It is considered that the filler is fixed by the gelled material on the fiber surface without being buried. On the other hand, the removal of the odor component of Sample 6 was almost the same as that of Sample 2, but about 25 times as much functional filler as Sample 2 was used, which was not economical. Samples 7 to 9 were inferior in odor component removability compared to Sample 2.

[Sample 10]
A functional separation material was obtained in the same manner as Sample 1, except that a spunbonded nonwoven fabric (made by Idemitsu Unitech Co., Ltd., trade name Stratec) having a basis weight of 20 g / m ² was prepared as the surface fiber layer. The fibers constituting the spunbond fiber layer were polypropylene fibers having a fiber diameter of 25 μm. The air permeability of the spunbonded nonwoven fabric was 369 cm ³ / cm ² · sec. The air permeability when the three layers of the surface fiber layer / functional layer / surface fiber layer were superposed was 34 cm ³ / cm ² · sec.

[Sample 11]
A functional separating material was obtained in the same manner as Sample 1, except that a melt blown nonwoven fabric (trade name: Microflex, manufactured by Kuraray Co., Ltd.) having a basis weight of 25 g / m ² was prepared as the surface fiber layer. The fibers constituting the meltblown fiber layer were polypropylene fibers having an average fiber diameter of 2.5 μm. The air permeability of the melt blown nonwoven fabric was 27 cm ³ / cm ² · sec. The air permeability when the three layers of the surface fiber layer / functional layer / surface fiber layer were superposed was 15 cm ³ / cm ² · sec.

  Next, Samples 1 to 4 and Samples 10 to 11 that were pleated so that the height of the mountain was 20 mm were attached to an air purifier and used in a smoking room for one month. Samples 1-4 removed the smell of tobacco even after 1 month of use, and there was no problem with air circulation. Sample 10 had a slight odor of tobacco. In Sample 11, the surface fiber layer was discolored brown due to the tobacco component, and it was found that the outflow amount of air was small.

[Sample 12]
The laminated body obtained in Sample 2 (laminated body in a state before pleating) is an embossed roll whose embossed pattern is a hemispherical (embossed pattern model number 7781 manufactured by Asahi Roll Co., Ltd.) and heated to 120 ° C. As a result, the lower roll was a rubber roll, and an embossing machine was used to obtain a functional separator having irregularities on the surface of the laminate.
The air permeability of the functional material having unevenness on the surface was 10 cm ³ / cm ² · sec.
The thickness ratio was 5. The apparent thickness (A) at this time was 0.86 mm, and the thickness (B) of the crimped portion was 0.172 mm.
The embossing ratio of the sheet was 0.2.

Next, the sample 12 was mounted on an air cleaner and used in a smoking room for one month. Sample 12 removed the smell of tobacco even after 1 month of use, and there was no problem with air circulation.
Since the thickness ratio and sheet embossing ratio were optimized, it was found that it had the ability to remove tobacco odor equivalent to the pleated sample.

  Next, the sample 12 was corrugated and similarly mounted in an air purifier and used in a smoking room for one month. However, the smell of tobacco was removed and air circulation was not a problem.

  The functional separation material of the present invention can be used for vehicle interior materials, building material curing sheets, wallpaper, masks, mats, carpets, filters, etc., and particularly as a gas adsorbent and tobacco deodorant filter. It can be used as a filter for equipment, a cabin filter for vehicles, a filter for smoke separators, a clothes cover, etc.

It is sectional drawing of the functional separation material of the three-layer structure which concerns on one Embodiment of this invention. It is an example process drawing of a manufacturing method (steam processing method) of a functional layer (functional nonwoven fabric) concerning one embodiment of the present invention. It is a scanning electron micrograph which shows the state which the functional filler based on one Embodiment of this invention obtained by the steam processing method, and the functional filler have adhered to the constituent fiber. It is a scanning electron micrograph which shows the state which the functional filler based on one Embodiment of this invention obtained by the steam processing method, and the functional filler have adhered to the constituent fiber. It is sectional drawing which made the corrugated structure the functionally separated material partially crimped | bonded based on one Embodiment of this invention. FIG. 3 is a cross-sectional photograph of a partially pressure-bonded functional separator according to an embodiment of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Functional separation material 2 Surface fiber layer 3 Functional layer 11 Fiber (or processed fiber structure)
12 tanks 13 filler dispersion solution 14 squeezing roll 15 pad steamer 16 dryer 17 winder

Claims (11)

It has a filler fixing fiber containing a fiber, a moist heat gelled resin on the surface thereof, and a functional filler fixed to the moist heat gelled resin, and the functional filler is subjected to steam treatment of the moist heat gelled resin. A functional layer fixed by a gelled product obtained by gelling with heat and moisture;
A surface fiber layer including an ultrafine fiber layer having a basis weight of 0.5 to 20 g / m ² including an ultrafine fiber having a fiber diameter of 10 μm or less is laminated on both surfaces of the functional layer,
The surface fiber layer is laminated with a fiber layer having a larger average fiber diameter than the ultrafine fiber layer on both sides of the ultrafine fiber layer,
Wherein the functional layer and the surface fiber layer are integrated by partial compression, the functional filler is adsorbed, and functional separation material having at least one function selected from deodorant or Ranaru group .   The functional separator according to claim 1, wherein the wet heat gelling resin is an ethylene-vinyl alcohol copolymer resin. The functional layer is a functional nonwoven fabric in which the fiber and the wet heat gelled resin contain 50% by mass or more of a wet heat gelled composite fiber including a wet heat gelled resin component and another thermoplastic synthetic fiber component,
3. The functional separator according to claim 1, wherein the basis weight of the functional nonwoven fabric is 30 to 200 g / m ² , and the fixed amount of the functional filler is ^{2 to} 200 g per 1 m ^{2 of the} nonwoven fabric.   The functional separation material according to claim 1, wherein the ultrafine fiber layer is a meltblown fiber layer, and a spunbond fiber layer is laminated on both surfaces of the meltblown fiber layer.   The functional separation material according to any one of claims 1 to 4, wherein the surface fiber layer is integrated by partial pressure bonding between an ultrafine fiber layer and a fiber layer having an average fiber diameter larger than that of the ultrafine fiber layer. The functional separation material according to claim 1, wherein the surface fiber layer has an air permeability of 50 to 250 cm ³ / cm ² · sec.   The functional separation material has a thickness ratio (A / B) of 3 to 30 when the apparent thickness of the functional separation material is A (mm) and the thickness of the partially crimped portion is B (mm). The functional separator according to any one of claims 1 to 6, which is embossed in three dimensions within a range.   The functional separator according to claim 1, wherein the functional separator is formed into a pleated structure or a honeycomb structure.   The functional separation material according to claim 1, wherein the steam treatment method is a pad steamer method.   The functional adsorbent in any one of Claims 1-9 is a gas adsorbent, The gas adsorbent which is a porous filler whose average particle diameter of the said gas adsorbent filler is 10-100 micrometers.   A filter for deodorizing a cigarette incorporating the gas adsorbent according to claim 10.