JP5362561B2 - 二峰性単層単成分媒体を用いたプリーツ状フィルタ - Google Patents
二峰性単層単成分媒体を用いたプリーツ状フィルタ Download PDFInfo
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- B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
- B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B01D35/00—Filtering devices having features not specifically covered by groups B01D24/00 - B01D33/00, or for applications not specifically covered by groups B01D24/00 - B01D33/00; Auxiliary devices for filtration; Filter housing constructions
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- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
- B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
- B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
- B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
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- D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
- D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
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Description
a)同一高分子組成の、大寸法及び小寸法が混ざり合った連続単成分高分子繊維の二峰性質量分率/繊維寸法混合物を含む、単成分単層不織布ウェブを形成する工程であって、該ウェブは少なくとも100mgのガーレー剛性を有する工程と、
b)該不織布ウェブにプリーツの列を形成する工程と、
c)該プリーツ状ウェブを所望の寸法及び形状に切断し、少なくともいくつかの繊維交点で互いに固着される繊維の自己支持型多孔質単成分単層マトリックスを含み、前面風速1.52m/秒で少なくとも15%の平均初期サブミクロン効率を有する、プリーツ状フィルタ要素を形成する工程と、を含むプロセスを提供する。
図2〜図5に示す装置を用い、ポリプロピレン溶融紡糸繊維及びポリプロピレンメルトブローマイクロファイバーから、9つのウェブを調製した。溶融紡糸繊維は、チバスペシャルティケミカルズ(Ciba Specialty Chemicals)から市販の0.75重量%のCHIMASSORB 944ヒンダードアミン光安定剤を添加し、メルトフローインデックス(melt flow index)70を有するトータルペトロケミカルズ(Total Petrochemicals)から市販のFINA(商標)3860ポリプロピレンから調製された。押出ヘッド10は、合計で512個の開口部、一列あたり32個の開口部を備える16列の開口部を有する。開口部は、6.4mm(0.25インチ)間隔で、正方形模様に配列された(開口部は、長手方向に加えて横方向に配列され、横方向及び長手方向の双方に等間隔であることを意味する)。ポリマーは、0.8g/穴/分で押出ヘッドに与えられ、ポリマーは、235℃(455°F)の温度まで加熱された。2つの急冷空気流(図2の18b;流れ18aは用いず)を、約0.47m/秒(93フィート/分)の表面速度で、7.2℃(45°F)の温度で、急冷ボックスの高さ406mm(16インチ)からの上流、及び約0.22m/秒(43フィート/分)の表面速度で、周辺室温にて、急冷ボックスの高さ197mm(7.75インチ)からの下流として供給した。米国特許第6,607,624(B2)号(ベリガン(Berrigan)ら)に示されているような移動可能な壁減衰器を採用して、0.76mm(0.030インチ)のエアーナイフ間隙(ベリガン(Berrigan)らでは30)を用い、空気は、0.1MPa(14psig)の圧力、5mm(0.20インチ)の減衰器上部間隙幅、4.7mm(0.185インチ)の減衰器底部間隙幅、及び152mm(6インチ)の減衰器の長い側面(ベリガン(Berrigan)らでは36)でエアーナイフに供給した。押出ヘッド10から減衰器16までの距離(図2の17)は、78.7cm(31インチ)であり、減衰器16から回収ベルト19までの距離(図3の524及び522)は、68.6cm(27インチ)であった。溶融紡糸繊維流は、約36cm(約14インチ)の幅で、回収ベルト19上に付着させた。回収ベルト19は、20メッシュのステンレスで作られ、約14.3m/分(47フィート/分)の速度で除去された。回収ベルト19は、20メッシュのステンレスで作られ、約14.3m/分(47フィート/分)の速度で除去された。
試験番号1−8の帯電したウェブを評価し、下表2Aに示すように、付加的なフラットウェブ特性を判定した。
単一の押出成形機、図8に示されるような複数の大開口部及び小開口部を有するメルトブローダイチップ、及び「超微細熱可塑性繊維(Superfine Thermoplastic Fiber)」、産業応用化学(Industrial Engineering Chemistry)、第48巻、第8号、1342〜1346頁(1956年)、及び海軍研究試験所(Naval Research Laboratory)の報告書番号111437(1954年4月15日)に記載されるような工程を用い、単成分単層メルトブロウン・ウェブを、TOTAL(商標)EOD−12ポリプロピレン、エレクトレット帯電増大添加剤として1%のトリステアリルメラミンを添加したトータルペトロケミカルズ(Total Petrochemicals)から市販の1200メルトフローレートポリマーから形成した。ポリマーは、クロンプトン・アンド・ノールズ社(Crompton & Knowles Corp)のデービス基準部(Davis Standard Division)から50.8mm(2インチ)の単軸押出成形機のモデル20 DAVIS STANDARD(商標)に供給した。押出成形機は、全長152cm(60インチ)、長さ/直径の比率30/1を有した。頂点10cc/revの融解ポンプは、元の0.3mm(0.012インチ)の開口部を、すべての21番目の開口部に0.8mm(0.033インチ)の穴を開けることにより変性した25.4cm(10インチ)の幅広く穴あけした開口部のメルトブローダイへのポリマーの流量を測定し、それにより、小寸法と大寸法の穴の数に比率を20:1、大穴寸法と小穴寸法の比率を2.67:1に提供する。開口部の線は、10穴/cm(25穴/インチ)の穴隙を有した。加熱した空気は、ダイチップで、繊維を減衰した。エアーナイフには、0.51mm(0.020インチ)の負の戻り及び0.76mm(0.030インチ)の空隙を用いた。ゼロから中程度の真空は、ウェブ成形の時点で、中型のメッシュコレクタスクリーンを貫通した。押出成形機からのポリマー出力率は、0.36kg/cm/時間(2.0ポンド/インチ/時間)であり、DCD(ダイからコレクタの距離)は、58.4cm(23.0インチ)及び気圧は、必要に応じて調整され、ウェブに約93gsmの坪量及び約22μmのEFDを提供された。ウェブは、米国特許第5,496,507号(アンガドジバンド(Angadjivand)ら’507)に教示された技法に従い、脱イオン水でハイドロチャージされ、乾燥させ、評価し、下表3Aに示されるフラットウェブ特性を確定した。8つのサンプルを試験し、ガーレー剛性、NaCl透過率及びDOP透過率を測定して平均化した。
図6に示すような装置及びウェンテ・バンA(Wente, Van A.)、「超微細熱可塑性繊維(Superfine Thermoplastic Fiber)」、産業応用化学(Industrial and Engineering Chemistry)、第48巻、第8号、1342〜1346頁(1956年)及び海軍研究試験所(Naval Research Laboratoriy)の報告書番号111437(1954年4月15日)に記載されるような工程を用いて、単成分単層ウェブを、同一高分子組成からなる大寸法繊維及び個々に調製された小寸法繊維のメルトブローを用いて形成した。トータルペトロケミカルズ(Total Petrochemicals)から入手可能なメルトフローインデックス(melt flow index)350を有するTOTAL 3960を用いて、大寸法繊維を形成し、エレクトレット帯電増大添加剤として0.8%のCHIMASSORB 944ヒンダードアミン光安定剤及びポリワン社(PolyOne Corp.)から入手可能な1%のPOLYONE(商標)番号CC10054018WEの青色の色素に添加し、ウェブ内の大寸法繊維の分布を評価するために役立てた。得られた青色のポリマーブレンドをクロンプトン・アンド・ノールズ社(Crompton & Knowles Corp.)のデービス基準部(Davis Standard Division)からモデル20 Davis Standard(商標)50.8mm(2インチ)の単軸押出成形機に供給した。押出成形機は、全長152cm(60インチ)及び30/1の長さ/直径比を有した。0.8%のCHIMASSORB 944ヒンダードアミン光安定剤に添加し、エクソンモービル社(Exxon Mobil Corporation)製のメルトフローインデックス(melt flow index)1475を有するExxon PP3746ポリプロピレンを用いて小寸法繊維を形成した。後者のポリマーは、白色であり、クロンプトン・アンド・ノールズ社(Crompton & Knowles Corp.)のデービス基準部(Davis Standard Division)からKILLION(商標)19mm(0.75インチ)単軸押出成形機に供給した。ゼニスポンプ(Zenith Pump)からの10cc/revZENITH(商標)融解ポンプを用いて、それぞれのポリマーの流量を測定し、それぞれのダイ空洞に供給される交互の開口部を有する10穴/cm(25穴/インチ)の空隙部で、直径0.38mm(0.015インチ)の開口部を用いて、50.8cm(20インチ)の広い穴があいた開口部メルトブローダイにダイ空洞を分離した。加熱した空気は、ダイチップで繊維を減衰した。エアーナイフには、0.25mm(0.010インチ)の正の戻り及び0.76mm(0.030インチ)の空隙を用いた。中程度の真空は、ウェブ成形の時点で、中型のメッシュコレクタスクリーンを貫通した。押出成形機からのポリマー出力率は、0.18kg/cm/時間(1.0ポンド/インチ/時間)であり、DCD(ダイからコレクタの距離)は、57.2cm(22.5インチ)及びコレクタ速度は、必要に応じて調整され、ウェブに208gsmの坪量が提供された。必要に応じて、押出し流量、押出し温度及び加熱された空気圧を変えることにより、20μmの標的EFDを達成した。それぞれの押出成形機からのポリマー率を調整することにより、75%の大寸法繊維及び25%の小寸法繊維を有するウェブを製造した。ウェブは、米国特許第5,496,507号(アンガドジバンド(Angadjivand)ら’507)に教示された手法に従い、脱イオン水でハイドロチャージされ、乾燥させた。13.8cm/秒の前面風速で、坪量、厚さ、EFD、ガーレー剛性、初期圧力低下、NaClの初期透過率及びフラットウェブのための線質係数QFを下表4Aに設定した。
米国特許第6,319,865(B1)号(ミカミ(Mikami))の比較例3の方法を用いて、大寸法及び小寸法開口部の列を提供するためにチップを修正した25.4cm(10インチ)の広く穴あけした開口部ダイを用いてウェブを調製した。大開口部は、0.6mmの直径(Da)であり、小開口部は、0.4mmの直径(Db)であり、開口部の直径比R(Da/Db)は、1.5であり、大開口部のそれぞれの組の間に5つの小開口部があり、開口部を11.8開口部/cm(30開口部/インチ)で間隔をあけた。直径50mmのネジを有する単軸押出成形機及び10ccの融解ポンプを、ダイに100%のTOTAL 3868ポリプロピレンを供給するために用いた。また、ダイは、0.20mmの空気のスリット幅、60°のノズル端角、0.58mmの空気リップ開口部を有した。1〜50m/分で移動する細目スクリーンは、繊維を回収するために用いた。その他の操作パラメータを下表5Aに示す。
Claims (4)
- プリーツ状フィルタの作製プロセスであって、
a)ポリプロピレンからなる、直径が10〜60μmである大寸法繊維と直径が0.10〜10μmである小寸法繊維とが混ざり合った連続単成分高分子繊維の二峰性質量分率/繊維寸法混合物であってメルトブロー及び/又は溶融紡糸により製造される混合物を含み、少なくとも100mgのガーレー剛性を有する単成分単層不織布ウェブであって、該不織布ウェブの横断面を通して繊維直径の一様な分布を有する不織布ウェブ、を形成する工程と、
b)前記不織布ウェブにプリーツの列を形成する工程と、
c)前記プリーツ状ウェブを所望の寸法及び形状に切断し、少なくともいくつかの繊維交点で互いに固着される繊維の多孔質単成分単層マトリックスを含み、前面風速1.52m/秒で少なくとも15%の平均初期サブミクロン効率を有する自己支持型プリーツ状フィルタ要素を形成する工程と、を含む、プロセス。 - 質量分率対μm単位での繊維寸法のヒストグラムが、1〜5μmの小寸法繊維の最頻値と、12〜30μmの大寸法繊維の最頻値とを呈する、請求項1に記載のプロセス。
- プリーツ状フィルタであって、
ポリプロピレンからなる、直径が10〜60μmである大寸法繊維と直径が0.10〜10μmである小寸法繊維とが混ざり合った連続単成分高分子繊維の二峰性質量分率/繊維寸法混合物であってメルトブロー及び/又は溶融紡糸により製造される混合物を含有する、自己支持型多孔質単成分単層マトリックスを含み、
前記繊維は、少なくともいくつかの繊維交点で互いに固着され、
前記マトリックスは、襞状又は波形のプリーツの列を形成し、前面風速1.52m/秒で少なくとも15%の平均初期サブミクロン効率を有すると共に、少なくとも100mgのガーレー剛性を有し、
前記マトリックスは、横断面を通して繊維直径の一様な分布を有する、プリーツ状フィルタ。 - 小寸法繊維の数は、大寸法繊維の数の6倍以上である、請求項3に記載のプリーツ状フィルタ。
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CN101495690A (zh) | 2009-07-29 |
CN101495690B (zh) | 2013-03-27 |
EP2054136A1 (en) | 2009-05-06 |
US20100229516A1 (en) | 2010-09-16 |
US7754041B2 (en) | 2010-07-13 |
CN101495209B (zh) | 2012-12-12 |
EP2054136B1 (en) | 2013-01-02 |
WO2008016790A1 (en) | 2008-02-07 |
JP2009545440A (ja) | 2009-12-24 |
CN101495209A (zh) | 2009-07-29 |
US8372175B2 (en) | 2013-02-12 |
CA2659356C (en) | 2014-07-08 |
KR101504768B1 (ko) | 2015-03-20 |
CA2659356A1 (en) | 2008-02-07 |
EP2054136A4 (en) | 2011-12-07 |
US20080022643A1 (en) | 2008-01-31 |
KR20090038442A (ko) | 2009-04-20 |
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Free format text: JAPANESE INTERMEDIATE CODE: R250 |
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R250 | Receipt of annual fees |
Free format text: JAPANESE INTERMEDIATE CODE: R250 |
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