JP5586408B2 - Non-woven filter medium for filter, method for producing the same, and air filter - Google Patents
Non-woven filter medium for filter, method for producing the same, and air filter Download PDFInfo
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- Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)
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Description
本発明は、フィルタ用不織布濾材、その製造方法およびエアフィルタに関し、より詳しくは、塗装ブースに提供される空気を清浄するために使用する塗装ブース用エアフィルタに用いられる不織布濾材、その製造方法および塗装ブース用エアフィルタに関する。 The present invention relates to a non-woven filter medium for a filter, a method for producing the same, and an air filter, and more particularly, a non-woven filter medium used for an air filter for a painting booth used for cleaning air provided to a painting booth, a method for producing the same, and The present invention relates to an air filter for a painting booth.
従来、塗装ブース用エアフィルタの流入面に、スプレー方式やローラー接触方式でオイル剤やリン系難燃剤を塗布して、粉塵を捕集させるとともに、粉塵の再飛散の防止にある程度の効果を挙げている。しかし、未だ性能的に十分でなく、改良が要望されている。 Conventionally, an oil agent or phosphorus flame retardant is applied to the inflow surface of a paint booth air filter by a spray method or roller contact method to collect dust and to some extent prevent dust from re-scattering. ing. However, it is still not sufficient in terms of performance, and improvements are desired.
また、フィルタに粘着剤を塗布して、粉塵を捕捉する方法も、検討され、種々の技術が開示されている（例えば、特許文献１〜３等参照。）。
上記特許文献１には、低密度層から高密度層へと密度勾配を有した、少なくとも２層以上の繊維層から成るエアフィルタ用ろ材であって、上記高密度層の主として最上部分に、粘着性を有する水系熱可塑性樹脂からなる多孔質膜状の粘着部が設けられたことを特徴とするエアフィルタ用ろ材が開示されている。
また、特許文献２には、自動車、精密機械、電気部品、食品等の製造工場で発生するダスト、粉塵、塗料ミスト等を捕捉するためのダスト等吸着用フィルタにおいて、前記ダスト等吸着用フィルタは、平板状の不織布からなるフィルタ状基材の少なくとも片面に粘着層が形成されてあることを特徴とするダスト等吸着用フィルタが開示されている。
さらに、特許文献３には、平均空隙率が９４〜９７％であって、その全部に０．４〜５．０重量％のシリコーン系樹脂が固着された繊維層と、平均密度が０．１〜０．２７ｇ／ｃｍ３の繊維基材層とを備え、前記繊維層と前記繊維基材層とを熱融着性接着剤により貼合わせて２層の濾材となしたことを特徴とする空気清浄器用濾材が開示されている。
Moreover, the method of apply | coating an adhesive to a filter and catching dust is also examined, and various techniques are disclosed (for example, refer patent documents 1-3 etc.).
Patent Document 1 discloses an air filter medium composed of at least two or more fiber layers having a density gradient from a low density layer to a high density layer, and is mainly attached to the uppermost portion of the high density layer. An air filter medium is disclosed, which is provided with a porous membrane-like pressure-sensitive adhesive portion made of a water-based thermoplastic resin.
Patent Document 2 discloses a dust adsorption filter for capturing dust, dust, paint mist, etc. generated in a manufacturing plant for automobiles, precision machinery, electrical parts, foods, etc. A filter for adsorbing dust or the like is disclosed, in which an adhesive layer is formed on at least one surface of a filter-like substrate made of a flat nonwoven fabric.
Furthermore, in Patent Document 3, the average porosity is 94 to 97%, and a fiber layer in which 0.4 to 5.0% by weight of a silicone resin is fixed to the whole, and the average density is 0.1. a ~0.27g / cm 3 of fibrous substrate layer, characterized in that the said fibrous layer said fibrous substrate layer has no the filter medium of two layers laminated by heat fusion adhesive air A purifier filter medium is disclosed.
しかしながら、上記の従来技術には、次のような問題点があった。
（ｉ）塗装ブース用フィルタには、空気の整流と粉塵の捕捉といった機能が要求されている。そして、空気の整流は、塗装時の気流を安定させ塗装ムラを少なくするために、必用であり、また、粉塵の捕捉は、塗装表面に異物が付着するのを防ぐために、必用である。
空気の整流については、従来技術でも問題はないが、粉塵の捕捉については、振動により粉塵が流出するという問題があった。つまり、通常使用時でも、風圧による振動や、モーターなどの設備に由来する振動が、塗装ブース用フィルタには常に加えられており、これらの振動に対して十分な対策ができていないため、捕捉された粉塵が振動によって徐々に流出側に移動してしまい、最終的に粉塵が流出してしまう問題があった。
（ｉｉ）塗装ブース用フィルタのように密度が高く、厚みがあるフィルタにスプレー方式やローラー接触方式で粘着剤を塗布した場合、不織布の表面層に最も多くの粘着剤が付着してしまう。そのため、不織布表面の粘着性が著しく増大して、不織布表面にベタツキが起こり、取り扱いが困難になる上、離型紙やフィルム等が必用となる。また、粘着剤が不織布内部まで浸透しないので、不織布表面の粘着部分から内部へ移動した粉塵は、振動によって簡易に流出側へ抜けてしまうという問題があった。
（ｉｉｉ）特許文献２、３の方法では、二種類以上のシートを張り合わせるため、最低でも二工程以上を有し、また、二種類以上の材料が要求されるため、生産費用が高くなるという問題があった。
そのため、塗装ブース用フィルタとして、上記の問題点を解消した塗装ブース用フィルタが要望されている。
However, the above prior art has the following problems.
(I) The coating booth filter is required to have functions such as air rectification and dust trapping. Air rectification is necessary to stabilize the air flow during painting and reduce coating unevenness, and capturing dust is necessary to prevent foreign matter from adhering to the coating surface.
There is no problem with air rectification in the prior art, but there is a problem with dust capture that dust flows out due to vibration. In other words, even during normal use, vibrations due to wind pressure and vibrations derived from equipment such as motors are always applied to the paint booth filter, and sufficient measures are not taken against these vibrations. There is a problem that the dust that has been moved gradually moves to the outflow side due to vibration, and finally the dust flows out.
(Ii) When a pressure sensitive adhesive is applied to a filter having a high density and thickness such as a paint booth filter by a spray method or a roller contact method, most of the pressure sensitive adhesive adheres to the surface layer of the nonwoven fabric. For this reason, the tackiness of the nonwoven fabric surface is remarkably increased, stickiness occurs on the nonwoven fabric surface, and handling becomes difficult, and a release paper or film is required. Further, since the pressure-sensitive adhesive does not penetrate into the inside of the nonwoven fabric, there is a problem that the dust that has moved from the pressure-sensitive adhesive portion of the nonwoven fabric surface to the outflow side easily due to vibration.
(Iii) In the methods of Patent Documents 2 and 3, since two or more types of sheets are bonded together, at least two steps or more are required, and more than two types of materials are required. There was a problem.
Therefore, there is a demand for a paint booth filter that solves the above problems as a paint booth filter.
本発明の目的は、上記従来技術の問題点に鑑み、塗装ブースに提供される空気を清浄するために使用する塗装ブース用エアフィルタに用いられ、空気の整流効果と粉塵の捕捉性能に優れ、しかも振動によっても粉塵の付着保持性能に優れる不織布濾材、その製造方法および塗装ブース用エアフィルタを提供することにある。 The object of the present invention, in view of the above-mentioned problems of the prior art, is used in an air filter for a paint booth used to clean the air provided to the paint booth, and is excellent in the air rectifying effect and dust capturing performance, In addition, another object is to provide a non-woven filter medium that is excellent in dust adhesion and retention performance even by vibrations, a manufacturing method thereof, and an air filter for a painting booth.
本発明者は、前記課題を解決するために鋭意研究を重ねた結果、高融点ポリエステル繊維と熱融着ポリエステル繊維からなり、目付重量と厚みが特定範囲のサーマルボンド不織布を構成する繊維表面全面に、不織布作製工程における、例えば、熱カレンダー工程の前に、浸漬やスプレーなどにより、不織布バインダーとは異なる別の目的で、水系粘着性樹脂を付着させると、空気の整流効果と粉塵の捕捉性能に優れ、しかも振動によっても粉塵の付着保持性能に優れる不織布が得られることを見出し、これらの知見により、本発明を完成するに至った。 As a result of intensive research to solve the above problems, the present inventor is composed of a high-melting polyester fiber and a heat-fused polyester fiber, and is formed on the entire fiber surface constituting a thermal bond nonwoven fabric having a specific weight and thickness within a specific range. In the non-woven fabric production process, for example, before the thermal calendar process, when water-based adhesive resin is attached for another purpose different from the non-woven fabric binder by dipping or spraying, air rectifying effect and dust capturing performance are achieved. The present inventors have found that a nonwoven fabric excellent in dust adhesion and retention performance can be obtained by vibration, and based on these findings, the present invention has been completed.
すなわち、本発明の第１の発明によれば、繊度が１〜１００デシテックスの高融点ポリエステル短繊維１０〜９０重量％と、繊度が１〜１００デシテックスの熱融着ポリエステル短繊維１０〜９０重量％とからなり、かつ目付重量が１００〜５００ｇ／ｍ２、厚みが１０〜３０ｍｍのサーマルボンド不織布を構成する繊維表面全面に、水系粘着性樹脂を付着してなるフィルタ用不織布濾材の製造方法であって、次の工程（Ｉ）〜（ＩＩＩ）を順次施すことを特徴とする不織布濾材の製造方法が提供される。
（Ｉ）ウェブ形成工程：高融点ポリエステル短繊維と熱融着ポリエステル短繊維を混合し、ウェブを形成する工程
（ＩＩ）水系粘着性樹脂付着工程：形成されたウェブを、水系粘着性樹脂の水溶液もしくはエマルジョンに浸漬する工程または水系粘着性樹脂の水溶液もしくはエマルジョンをスプレーする工程
（ＩＩＩ）サーマルボンド不織布作製工程：水系粘着性樹脂が付着したウェブを、エアースルー法、加熱カレンダー法または超音波法により、熱溶融し、繊維間結合して、サーマルボンド不織布を作製する工程
That is, according to the first invention of the present invention, 10 to 90% by weight of high-melting polyester short fibers having a fineness of 1 to 100 dtex and 10 to 90% by weight of heat-fused polyester short fibers having a fineness of 1 to 100 dtex. consists of a and basis weight of the 100 to 500 g / m 2, the fiber surface entire thickness constitutes a thermal bond nonwoven fabric of 10 to 30 mm, a method of manufacturing the filter nonwoven filter medium formed by adhering a water-based adhesive resin Thus, there is provided a method for producing a non-woven filter medium characterized by sequentially performing the following steps (I) to (III) .
(I) Web forming step: a step of mixing high-melting polyester short fibers and heat-fused polyester short fibers to form a web
(II) Water-based adhesive resin adhesion step: A step of immersing the formed web in an aqueous solution or emulsion of an aqueous adhesive resin or a step of spraying an aqueous solution or emulsion of an aqueous adhesive resin
(III) Thermal bond nonwoven fabric production step: A step of producing a thermal bond nonwoven fabric by thermally fusing and bonding fibers between webs to which a water-based adhesive resin is adhered by an air-through method, a heating calendar method or an ultrasonic method.
また、本発明の第２の発明によれば、第１の発明において、前記サーマルボンド不織布を構成する繊維全量１００重量部に対して、水系粘着性樹脂１〜２０重量部を付着することを特徴とするフィルタ用不織布濾材の製造方法が提供される。
さらに、本発明の第３の発明によれば、第１又は２の発明において、前記水系粘着性樹脂がアクリル系樹脂であることを特徴とするフィルタ用不織布濾材の製造方法が提供される。
Moreover, according to the second invention of the present invention, in the first invention, 1 to 20 parts by weight of an aqueous adhesive resin is adhered to 100 parts by weight of the total fiber constituting the thermal bond nonwoven fabric. A method for producing a non-woven filter medium for a filter is provided.
Furthermore, according to the third invention of the present invention, there is provided a method for producing a non-woven filter material for a filter according to the first or second invention, wherein the water-based adhesive resin is an acrylic resin.
本発明のフィルタ用不織布濾材は、塗装ブース用エアフィルタに用いると、空気の整流効果と粉塵の捕捉性能に優れ、しかも振動によっても粉塵の付着保持性能に優れるという効果を奏する。
そのため、本発明のフィルタ用不織布濾材を用いた塗装ブース用エアフィルタは、従来の問題点を解消した優れた性能を有する。特に、塗装ブース用の供給空気の清浄化に好適なフィルタであるので、塗装表面の汚れの原因をなくし、塗装品質を向上せしめることができる。
また、本発明のフィルタ用不織布濾材の製造方法は、簡便な方法により、安価で優れた性能の不織布濾材を作製することができる。
When used in a coating booth air filter, the filter nonwoven fabric for filter of the present invention is excellent in air rectification effect and dust capturing performance, and is also excellent in dust adhesion and retention performance due to vibration.
Therefore, the coating booth air filter using the non-woven filter medium for a filter of the present invention has excellent performance that has solved the conventional problems. In particular, since the filter is suitable for cleaning the supply air for the painting booth, it is possible to eliminate the cause of contamination on the painting surface and improve the painting quality.
Moreover, the manufacturing method of the nonwoven fabric filter material for filters of this invention can produce the nonwoven fabric filter material of the cheap and the outstanding performance with a simple method.
本発明のフィルタ用不織布濾材は、繊度が１〜１００デシテックスの高融点ポリエステル短繊維１０〜９０重量％と、繊度が１〜１００デシテックスの熱融着ポリエステル短繊維１０〜９０重量％とからなり、かつ目付重量が１００〜５００ｇ／ｍ２、厚みが１０〜３０ｍｍのサーマルボンド不織布を構成する繊維表面全面に、水系粘着性樹脂を付着してなることを特徴とする。
以下、不織布濾材、その製造方法および塗装ブース用エアフィルタなどについて、項目毎に、説明する。
The non-woven filter medium for a filter of the present invention comprises 10 to 90% by weight of high-melting polyester short fibers having a fineness of 1 to 100 dtex, and 10 to 90% by weight of heat-fused polyester short fibers having a fineness of 1 to 100 dtex, And water-based adhesive resin adheres to the fiber surface whole surface which comprises the thermal bond nonwoven fabric whose fabric weight is 100-500 g / m < 2 > and thickness is 10-30 mm, It is characterized by the above-mentioned.
Hereinafter, the nonwoven fabric filter material, the manufacturing method thereof, and the air filter for the painting booth will be described for each item.
１．サーマルボンド不織布
本発明に係るサーマルボンド不織布は、繊度が１〜１００デシテックスの高融点ポリエステル短繊維１０〜９０重量％と、繊度が１〜１００デシテックスの熱融着ポリエステル短繊維１０〜９０重量％とからなり、好ましくは、高融点繊維が４０重量％〜８５重量％の範囲を構成し、かつ高融点繊維の融点が熱融着性複合繊維の低融点成分の融点より５０℃以上高いものである。
1. Thermal Bond Nonwoven Fabric The thermal bond nonwoven fabric according to the present invention has a high-melting polyester short fiber having a fineness of 1 to 100 dtex, 10 to 90% by weight, and a hot-melt polyester short fiber having a fineness of 1 to 100 dtex and 10 to 90% by weight. Preferably, the high melting point fiber constitutes a range of 40% to 85% by weight, and the melting point of the high melting point fiber is 50 ° C. or more higher than the melting point of the low melting point component of the heat-fusible composite fiber. .
（１）高融点ポリエステル短繊維
上記の高融点ポリエステル短繊維としては、特に制限はなく、熱融着性ポリエステル繊維以外の一般に製造販売されているポリエステル系短繊維を用いることができる。また、高融点繊維としては、ポリエステル以外のナイロンや、ポリプロピレン等の合成繊維を用いてもよい。
ただし、熱融着ポリエステル短繊維との接着性を考慮すれば、熱融着ポリエステル短繊維と接着性の良い材料が好ましい。
また、繊度は、１〜１００デシテックスが好ましく、この範囲を外れると、フィルタ濾材としての性能が落ちる。
(1) High-melting-point polyester short fiber The high-melting-point polyester short fiber is not particularly limited, and polyester-based short fibers that are generally manufactured and sold other than heat-fusible polyester fibers can be used. Further, as the high melting point fiber, nylon other than polyester or synthetic fiber such as polypropylene may be used.
However, considering the adhesiveness with the heat-fused polyester short fiber, a material having good adhesiveness with the heat-fused polyester short fiber is preferable.
Further, the fineness is preferably 1 to 100 dtex, and if it is out of this range, the performance as a filter medium decreases.
（２）熱融着ポリエステル短繊維
また、上記の熱融着ポリエステル短繊維としては、低融点樹脂と高融点樹脂の融点差のある二種類の樹脂からなる芯鞘型、サイドバイサイド型構造の複合繊維などを用いることができる。また、熱融着性繊維、特に熱融着性複合繊維としては、芯鞘型、サイドバイサイド型構造で、ポリエステル系樹脂以外の、例えば、ポリエチレン系樹脂、ポリプロピレン系樹脂、ポリアミド系樹脂のいずれかの熱可塑性樹脂の高融点成分と低融点成分からなる複合繊維を用いることもできる。
具体例としては、ポリエステル繊維（融点２５０℃〜２７０℃程度）と、低融点ポリエステル繊維（融点１００℃〜２３０℃程度）の複合繊維、エステル／ナイロン複合繊維、ポリエステル／ポリエチレン複合繊維、ポリプロピレン／ポリエチレン複合繊維などが挙げられ、特に高融点ポリエステルと、低融点ポリエステルとの複合繊維は、最も実用的である。この場合、複合繊維を構成する高融点成分の融点が低融点成分の融点より５０℃以上、高いこと、また、低融点成分の融点が１００℃〜２００℃の範囲にあることが好ましい。
高融点成分の融点が低融点成分の融点より５０℃未満であると、短繊維間の接着時に高融点繊維側も軟化して、所望のフィルタを得ることができない。また、低融点成分の融点が１００℃未満であると、繊維間の接着を実施する処理条件が難しく、耐熱性の点から好ましくない。さらに、低融点成分の融点が２００℃を超えると、高融点繊維の熱特性に影響し、フィルタ特性が変動するので好ましくない。
(2) Thermally-bonded polyester short fibers The above-mentioned heat-fused polyester short fibers include core-sheath type and side-by-side type composite fibers composed of two types of resins having a melting point difference between a low melting point resin and a high melting point resin. Etc. can be used. In addition, the heat-fusible fiber, particularly the heat-fusible composite fiber, has a core-sheath type, side-by-side structure, and other than polyester resin, for example, any of polyethylene resin, polypropylene resin, polyamide resin A composite fiber composed of a high melting point component and a low melting point component of a thermoplastic resin can also be used.
Specific examples include polyester fibers (melting point: about 250 ° C. to 270 ° C.) and low melting point polyester fibers (melting point: about 100 ° C. to 230 ° C.), ester / nylon composite fibers, polyester / polyethylene composite fibers, polypropylene / polyethylene. Examples include composite fibers, and in particular, composite fibers of high-melting polyester and low-melting polyester are most practical. In this case, the melting point of the high melting point component constituting the composite fiber is preferably 50 ° C. or more higher than the melting point of the low melting point component, and the melting point of the low melting point component is preferably in the range of 100 ° C. to 200 ° C.
When the melting point of the high melting point component is less than 50 ° C. than the melting point of the low melting point component, the high melting point fiber side is also softened when the short fibers are bonded, and a desired filter cannot be obtained. Moreover, when the melting point of the low melting point component is less than 100 ° C., the treatment conditions for carrying out adhesion between fibers are difficult, which is not preferable from the viewpoint of heat resistance. Furthermore, when the melting point of the low melting point component exceeds 200 ° C., it affects the thermal characteristics of the high melting point fiber, and the filter characteristics fluctuate.
熱融着ポリエステル繊維の混合比率は、１０〜９０重量％であり、１０重量％以上とするのは、熱融着ポリエステル繊維の混合比率が１０重量％未満の場合、繊維同士の接着交点が少なく、交点強力が弱く、表面が擦れると毛羽立ちが発生し易く、繊維の脱落の原因となる。そのため、熱融着ポリエステル繊維の混合比率は、１０重量％以上が好ましい。一方、熱融着ポリエステル繊維の混合比率が９０重量％を超えると、厚みが所望のものを得ることが困難になる。
特に、高融点ポリエステル短繊維の構成が４０〜８５重量％（すなわち、熱融着ポリエステル繊維の混合比率が１５〜６０重量％）であって、高融点ポリエステル短繊維の融点が熱融着性複合繊維の低融点成分の融点より５０℃以上高いことが効果的である。高融点繊維の構成が４０重量％未満であると、即ち、熱融着性複合繊維が６０質量％を超えると、嵩高性（厚いものが得にくく）が乏しく、低初期圧損のフィルタが得にくい。一方、８５質量％を超えると、熱融着性複合繊維が少ないため、嵩高いフィルタを得ても、すぐに型崩れし、へたってしまう。また、短繊維の抜けが生じ易くなり好ましくない。
The mixing ratio of the heat-sealable polyester fiber is 10 to 90% by weight, and the reason for setting it to 10% by weight or more is that when the mixing ratio of the heat-sealable polyester fiber is less than 10% by weight, there are few adhesion intersections between the fibers The strength at the intersection is weak, and when the surface is rubbed, fluffing is likely to occur, causing the fibers to fall off. Therefore, the mixing ratio of the heat-fused polyester fiber is preferably 10% by weight or more. On the other hand, when the mixing ratio of the heat-fused polyester fiber exceeds 90% by weight, it becomes difficult to obtain a desired thickness.
In particular, the composition of the high-melting polyester short fiber is 40 to 85% by weight (that is, the mixing ratio of the heat-fusion polyester fiber is 15 to 60% by weight), and the melting point of the high-melting polyester short fiber is the heat-fusible composite. It is effective to be 50 ° C. or more higher than the melting point of the low melting point component of the fiber. When the composition of the high melting point fiber is less than 40% by weight, that is, when the heat-fusible composite fiber exceeds 60% by mass, the bulkiness (thickness is difficult to obtain) is poor, and it is difficult to obtain a filter with low initial pressure loss. . On the other hand, when it exceeds 85 mass%, since there are few heat-fusible composite fibers, even if it obtains a bulky filter, it will lose shape immediately and will fall. Further, short fibers are likely to come off, which is not preferable.
また、熱融着ポリエステル繊維の繊度は、１〜１００デシテックスが好ましく、この範囲を外れると、フィルタ濾材としての性能が落ちる。特に、熱融着性複合繊維の繊度は、１〜１０デシテックスの範囲がより好ましい。繊度が１デシテックス未満であると、濾過性能を有する充分な嵩高性のあるフィルタを得ることができない。一方、繊度が１０デシテックスを超えると、繊維本数が減少し、繊維間接着点も減少して、嵩高性は得られるが、所望の濾過性能を有するフィルタを得ることができない。 Further, the fineness of the heat-fused polyester fiber is preferably 1 to 100 dtex, and if it is out of this range, the performance as a filter medium is lowered. In particular, the fineness of the heat-fusible conjugate fiber is more preferably in the range of 1 to 10 dtex. If the fineness is less than 1 dtex, a sufficiently bulky filter having filtration performance cannot be obtained. On the other hand, when the fineness exceeds 10 dtex, the number of fibers decreases and the interfiber bonding point also decreases, and bulkiness is obtained, but a filter having desired filtration performance cannot be obtained.
（３）サーマルボンド不織布
本発明において、水系粘着性樹脂が付着してなるサーマルボンド不織布は、目付重量が１００〜５００ｇ／ｍ２、好ましくは２００〜５００ｇ／ｍ２、厚みが１０〜３０ｍｍ程度、好ましくは１５〜３０ｍｍ程度である。
目付重量が１００ｇ／ｍ２未満では、満足する濾過性能を得ることができず、または満足したものができても濾過寿命が短くなるので好ましくない。一方、目付重量が５００ｇ／ｍ２を超えると、低初期圧損を得るのが難しい。
また、厚みが１０ｍｍ未満では、粉塵保持容量が少なくなり、寿命が短くなる。一方、厚みが３０ｍｍを超えると、輸送に費用が掛かり、濾材を設置する枠に収まらないおそれがある。
(3) Thermal bond nonwoven fabric In the present invention, the thermal bond nonwoven fabric formed by adhering the water-based adhesive resin has a basis weight of 100 to 500 g / m 2 , preferably 200 to 500 g / m 2 , and a thickness of about 10 to 30 mm. Preferably it is about 15-30 mm.
If the weight per unit area is less than 100 g / m 2 , satisfactory filtration performance cannot be obtained, or even if it is satisfactory, the filtration life is shortened. On the other hand, when the weight per unit area exceeds 500 g / m 2 , it is difficult to obtain a low initial pressure loss.
On the other hand, if the thickness is less than 10 mm, the dust holding capacity is reduced and the life is shortened. On the other hand, if the thickness exceeds 30 mm, transportation is expensive and the filter medium may not fit in the frame.
２．水系粘着性樹脂
本発明において、水系粘着性樹脂は、水のみを分散媒とする水系エマルジョン型（または水溶性）粘着剤といわれるものであって、安価であり、臭気の問題も少なく、環境にもやさしいため、用いられる。水系エマルジョン型粘着剤の樹脂（ポリマー）としては、アクリル系ポリマー、ウレタン系ポリマー、ゴム系ポリマー、それらの変成体、それらの共重合体などが好適に用いられる。また、水系粘着性樹脂として、上記以外では、エポキシ樹脂、テルペン樹脂、フェノール樹脂などの、乾燥後に粘着性のある水系熱可塑性樹脂でもよい。
また、難燃性を付加する場合は、水系粘着性樹脂に、リン系難燃剤を混合することが望ましい。
2. Water-based adhesive resin In the present invention, the water-based adhesive resin is said to be a water-based emulsion type (or water-soluble) pressure-sensitive adhesive using only water as a dispersion medium, is inexpensive, has few odor problems, and is environmentally friendly. Used because it is easy. As the resin (polymer) of the water-based emulsion-type pressure-sensitive adhesive, acrylic polymers, urethane polymers, rubber polymers, modified products thereof, copolymers thereof, and the like are preferably used. In addition to the above, the water-based adhesive resin may be a water-based thermoplastic resin that is adhesive after drying, such as an epoxy resin, a terpene resin, or a phenol resin.
Moreover, when adding a flame retardance, it is desirable to mix a phosphorus flame retardant with water-based adhesive resin.
さらに、水系粘着性樹脂である粘着剤には、本発明の効果を阻害しない範囲で、一般に用いられる添加剤、例えば、ロジン、テルペン等の粘着付与樹脂、防腐剤、増粘剤の他、イソシアネート、エポキシ等の硬化剤などを併用してもよい。 Further, the pressure-sensitive adhesive that is a water-based pressure-sensitive adhesive resin has additives that are generally used within a range that does not impair the effects of the present invention, such as tackifier resins such as rosin and terpene, preservatives, thickeners, isocyanates, and the like. Further, a curing agent such as epoxy may be used in combination.
本発明では、水系粘着性樹脂の付着量は、サーマルボンド不織布を構成する繊維全量１００重量部に対して、１〜２０重量部程度が好適である。 In this invention, about 1-20 weight part is suitable for the adhesion amount of water-system adhesive resin with respect to 100 weight part of fiber whole quantity which comprises a thermal bond nonwoven fabric.
また、水系粘着性樹脂の付着方法は、水系粘着性樹脂を薄く繊維表面全体に付着させるため、ディップ方式またはスプレー方式にて、好ましくはディップ方式にて行うのが望ましい。
不織布ウェブ、若しくは、すでに熱処理されたサーマルボンド不織布全体に、水系粘着性樹脂を含浸させ、マングルロール等で絞って、所定量を付着させ、乾燥工程にて、水分を蒸発させる。熱処理されたサーマルボンド不織布全体より、不織布ウェブで行う方が、工程数が少なくなり、コストが低減されるので、より望ましい。
In addition, the water-based adhesive resin is attached by a dip method or a spray method, preferably a dip method, so that the water-based adhesive resin is thinly attached to the entire fiber surface.
The nonwoven web or the entire thermally bonded nonwoven fabric that has already been heat-treated is impregnated with a water-based adhesive resin, squeezed with a mangle roll or the like to deposit a predetermined amount, and moisture is evaporated in a drying step. It is more desirable to use a nonwoven web than the whole heat-bonded thermal bond nonwoven fabric because the number of steps is reduced and the cost is reduced.
３．フィルタ用不織布濾材の製造方法
本発明のフィルタ用不織布濾材の製造方法は、特に限定されないが、好ましくは、次の工程（Ｉ）〜（ＩＩＩ）を順次施すことを特徴とする。
（Ｉ）ウェブ形成工程：高融点ポリエステル短繊維と熱融着ポリエステル短繊維を混合し、ウェブを形成する工程
（ＩＩ）水系粘着性樹脂付着工程：形成されたウェブを、水系粘着性樹脂の水溶液もしくはエマルジョンに浸漬する工程または水系粘着性樹脂の水溶液もしくはエマルジョンをスプレーする工程
（ＩＩＩ）サーマルボンド不織布作製工程：水系粘着性樹脂が付着したウェブを、エアースルー法、加熱カレンダー法または超音波法により、熱溶融し、繊維間結合して、サーマルボンド不織布を作製する工程
3. The manufacturing method of the nonwoven fabric filter material for filters Although the manufacturing method of the nonwoven fabric filter material for filters of this invention is not specifically limited, Preferably, following process (I)-(III) is performed sequentially, It is characterized by the above-mentioned.
(I) Web forming step: a step of mixing high-melting polyester short fibers and heat-fused polyester short fibers to form a web (II) water-based adhesive resin adhesion step: an aqueous solution of a water-based adhesive resin Alternatively, a step of immersing in an emulsion or a step of spraying an aqueous solution or emulsion of a water-based adhesive resin (III) A thermal bond nonwoven fabric production step: a web to which a water-based adhesive resin is adhered is obtained by an air-through method, a heating calendar method or an ultrasonic method. , Heat melting and bonding between fibers to make a thermal bond nonwoven fabric
（Ｉ）ウェブ形成工程
本発明においては、通常、乾式法でウェブを形成する。具体的には、数ｃｍ長にカットした、高融点ポリエステル短繊維と、例えば、芯鞘型の熱融着ポリエステル短繊維とを、所望の割合で混合し、その混合繊維を、開綿機とカーディング機（カードまたはエアランダム機）を用いて、ウェブを紡出し、ウェブを形成する工程である。
(I) Web formation process In this invention, a web is normally formed by a dry process. Specifically, a high melting point polyester short fiber cut to several centimeters in length and, for example, a core-sheath type heat-fusion polyester short fiber are mixed in a desired ratio, and the mixed fiber is mixed with a cotton opening machine. This is a step of spinning a web using a carding machine (card or air random machine) to form the web.
（ＩＩ）水系粘着性樹脂付着工程
水系粘着性樹脂付着工程は、具体的には、ウェブを、濃度１〜１０％の粘着剤溶液に含浸して、所望の付着量になるように、絞りロールの圧力を調整する工程、または、スプレーにてウェブ上方から、粘着剤溶液の散布を行う工程である。
(II) Water-based adhesive resin adhering step The water-based adhesive resin adhering step is specifically a squeeze roll in which a web is impregnated with an adhesive solution having a concentration of 1 to 10% to obtain a desired amount of adhesion. Is a step of adjusting the pressure, or a step of spraying the adhesive solution from above the web by spraying.
（ＩＩＩ）サーマルボンド不織布作製工程
サーマルボンド不織布作製工程では、粘着剤の付着したウェブをコンベアでドライヤーに搬入する。そして、ドライヤーでは、ウェブを乾燥させるとともに、熱融着ポリエステル短繊維を融かして融着させる必用があるため、熱融着ポリエステル短繊維の鞘部の融点より、２０℃以上高い温度が望ましい。また、乾燥と融着を両方行うため、時間が必要である。
(III) Thermal bond nonwoven fabric production process In the thermal bond nonwoven fabric production process, the web to which the adhesive is attached is carried into a dryer by a conveyor. In the dryer, it is necessary to dry the web and melt and melt the heat-bonded polyester short fiber, so that a temperature higher by 20 ° C. or more than the melting point of the sheath of the heat-bonded polyester short fiber is desirable. . Moreover, since both drying and fusion | bonding are performed, time is required.
４．フィルタ用不織布濾材の用途（塗装ブース用エアフィルタ）
本発明のフィルタ用不織布濾材は、特定のサーマルボンド不織布と水系粘着性樹脂の効果が相俟って、例えば、塗装ブース用エアフィルタに用いると、空気の整流効果と粉塵の捕捉性能に優れ、しかも振動によっても粉塵の付着保持性能に優れるという効果を発揮する。したがって、本発明のフィルタ用不織布濾材を用いた塗装ブース用エアフィルタは、特に、塗装ブース用の供給空気の清浄化に好適なフィルタであるので、塗装表面の汚れの原因をなくし、塗装品質を向上せしめることができる。
また、本発明のフィルタ用不織布濾材は、優れた性能を有するので、塗装ブース用エアフィルタのみならず、例えば、空調機、タービン、クリーンルーム内エアーの循環用フィルタ等のエアフィルタ濾材や、自動車の車室内吸気および循環用として好適なエアフィルタ濾材にも適用できる。
4). Nonwoven filter media for filters (Air filter for painting booth)
The non-woven filter medium for a filter of the present invention combines the effects of a specific thermal bond non-woven fabric and a water-based adhesive resin, for example, when used in an air filter for a coating booth, it has excellent air rectifying effect and dust capturing performance, In addition, the effect of excellent dust adhesion and retention performance is exhibited even by vibration. Accordingly, the coating booth air filter using the non-woven filter medium for filter of the present invention is a filter particularly suitable for cleaning the supply air for the coating booth. It can be improved.
In addition, since the non-woven filter medium for filter of the present invention has excellent performance, not only an air filter for a coating booth, but also an air filter medium such as an air conditioner, a turbine, a filter for circulating air in a clean room, an automobile The present invention can also be applied to an air filter medium suitable for vehicle interior intake and circulation.
本発明を、図及び実施例により説明する。
図１、２は、本発明に基づく実施例１、２に用いた製造工程の概略図である。
The invention is illustrated by the figures and examples.
1 and 2 are schematic views of manufacturing steps used in Examples 1 and 2 according to the present invention.
［実施例１］
次の繊維構成で、表面が平滑なサーマルボンド法の不織布濾材を作製した。
高融点ポリエステル繊維として、ポリエチレンテレフタレート系ポリエステル繊維（繊度＝６．６デシテックス、融点２７０℃）を８０重量％用い、熱融着ポリエステル繊維として、芯成分が融点２５５℃のポリエステル樹脂で、鞘成分が融点１１０℃のポリエステル樹脂から形成された芯鞘型の熱融着ポリエステル系繊維（繊度＝２．２デシテックス）を２０重量％用い、混合した。
次に、開綿機とカーディング機１０を用いて、ウェブ１を紡出し、さらに、これを重ね合わせて目的の重量とし、ディップ加工機１１を用いて、粘着剤として、（丸菱油化工業（株）製の「コアッテクス」）である変性アクリル樹脂５％濃度液に、ウェブ１を含浸させ、絞りロール１２で絞り、搬送コンベアを用いて加熱炉１３内に導入した。
濾材の厚み方向の中心温度が１４０℃になる温度で加熱炉１３内にて加熱し、目付重量３５０ｇ／ｍ２（内、粘着剤２０ｇ／ｍ２）、厚み２０ｍｍのサーマルボンド不織布濾材２を得た。
[Example 1]
A thermal bond non-woven filter medium having the following fiber configuration and a smooth surface was produced.
80% by weight of polyethylene terephthalate polyester fiber (fineness = 6.6 dtex, melting point 270 ° C.) is used as the high melting polyester fiber, and the core component is a polyester resin having a melting point of 255 ° C. A core-sheath type heat-sealable polyester fiber (fineness = 2.2 decitex) formed from a polyester resin having a melting point of 110 ° C. was used in an amount of 20% by weight and mixed.
Next, the web 1 is spun using a cotton opening machine and a carding
Heating is performed in the
この不織布濾材を２０ｃｍ角にカットして、流入側にＪＩＳ １５種粉塵０．１ｇを直径２ｃｍ円状に均一に散布して、１ｃｍの高さから３００回の落下振動試験を行った結果、粉塵の流失は見られなかった。
ここで、上記の落下振動試験は、以下の要領で実施した。
落下振動試験は、試験フィルタに強弱の振動を一定のサイクルを繰り返し、加えた。そして、この振動は、一定間隔で自動的に動くアームがある試験装置により行った。また、このアームは、連続したストレスを１分間に２００回の上下に動き、予め決められたサイクル迄（今回は、３００回）まで振動させて通過した粉末（フィルタを通り抜けた粉末の粒子の数）を数えることにより、評価したものである。
This non-woven filter medium was cut into a 20 cm square, and 0.1 g of
Here, the above drop vibration test was performed as follows.
In the drop vibration test, strong and weak vibrations were repeatedly applied to the test filter in a certain cycle. This vibration was performed by a test apparatus having an arm that automatically moves at regular intervals. In addition, the arm moves up and down a continuous stress 200 times per minute and vibrates up to a predetermined cycle (this time 300 times) (the number of powder particles that have passed through the filter). ) Is counted and evaluated.
また、ＪＩＳ Ｂ−９９０８形式３に準じた試験方法において評価すると、質量法による粒子捕集平均効率が９４．４％であり、濾過寿命は、粉塵捕集量６５１ｇ／ｍ２であった。
なお、試験条件は、風速０．５ｍ／ｓｅｃ、最終の圧力損失３９０Ｐａとした。また、この不織布の初期の圧力損失は、２３．５Ｐａであった。
また、この不織布をＪＩＳ Ｌ−１０９１ Ａ−１法に準じた難燃試験法で評価すると、難燃性の評価値が区分３であり、塗装ブース用フィルタとして要求される難燃性を有していた。
このように、実施例１で得られた不織布濾材は、塗装ブース用フィルタとして好適な塗装ブース用フィルタであった。
Moreover, when evaluated in the test method according to JIS B-9908 type 3, the particle collection average efficiency by the mass method was 94.4%, and the filtration life was 651 g / m 2 of dust collection amount.
The test conditions were a wind speed of 0.5 m / sec and a final pressure loss of 390 Pa. Moreover, the initial pressure loss of this nonwoven fabric was 23.5 Pa.
Moreover, when this nonwoven fabric is evaluated by the flame retardancy test method according to JIS L-1091 A-1, the flame retardancy evaluation value is Category 3, and has the flame retardancy required as a filter for coating booths. It was.
Thus, the nonwoven fabric filter material obtained in Example 1 was a coating booth filter suitable as a coating booth filter.
［実施例２］
高融点ポリエステル繊維として、ポリエチレンテレフタレート系ポリエステル繊維（繊度＝６．６デシテックス、融点２７０℃）を８０重量％用い、熱融着ポリエステル繊維として、芯成分が融点２５５℃のポリエステル樹脂で、鞘成分が融点１１０℃のポリエステル樹脂から形成された芯鞘型の熱融着ポリエステル系繊維（繊度＝２．２デシテックス）を２０重量％用い、混合した。
次に、開綿機とカーディング機１０を用いて、ウェブ１を紡出し、さらにこれを重ね合わせて目的の重量とし、スプレー加工機１４を用いて、粘着剤として、（丸菱油化工業（株）製の「コアッテクス」）である変性アクリル樹脂５％濃度液をウェブ１上に散布し、搬送コンベア１２を用いて加熱炉１３内に導入した。
濾材の厚み方向の中心温度が１４０℃になる温度で加熱炉１３内にて加熱し、重量３５０ｇ／ｍ２（内、粘着剤２０ｇ／ｍ２）、厚みが２０ｍｍのサーマルボンド不織布濾材３を得た。
[Example 2]
80% by weight of polyethylene terephthalate polyester fiber (fineness = 6.6 dtex, melting point 270 ° C.) is used as the high melting polyester fiber, and the core component is a polyester resin having a melting point of 255 ° C. A core-sheath type heat-sealable polyester fiber (fineness = 2.2 decitex) formed from a polyester resin having a melting point of 110 ° C. was used in an amount of 20% by weight and mixed.
Next, the web 1 is spun using a cotton spreader and a carding
Heating is performed in the
この不織布を２０ｃｍ角にカットして、実施例１と同様に、流入側にＪＩＳ １５種粉塵０．１ｇを直径２ｃｍ円状に均一に散布して、１ｃｍの高さから３００回の落下振動試験を行った結果、微量ではあるが粉塵の流失がみられた。
また、ＪＩＳ Ｂ−９９０８形式３に準じた試験方法において評価すると、質量法による粒子捕集平均効率が９４．４％であり、濾過寿命は、粉塵捕集量６５１ｇ／ｍ２であった。
なお、試験条件は、風速０．５ｍ／ｓｅｃ、最終の圧力損失３９０Ｐａとした。また、この不織布の初期の圧力損失は２３．５Ｐａであった。
また、この不織布をＪＩＳ Ｌ−１０９１ Ａ−１法に準じた難燃試験法で評価すると、難燃性の評価値が区分３であり、塗装ブース用フィルタとして要求される難燃性を有していた。
このように、比較例１で得られた不織布は、総合的に判断して、塗装ブース用フィルタとして好適な塗装ブース用フィルタであった。
This non-woven fabric was cut into 20 cm square, and in the same manner as in Example 1, 0.1 g of
Moreover, when evaluated in the test method according to JIS B-9908 type 3, the particle collection average efficiency by the mass method was 94.4%, and the filtration life was 651 g / m 2 of dust collection amount.
The test conditions were a wind speed of 0.5 m / sec and a final pressure loss of 390 Pa. Moreover, the initial pressure loss of this nonwoven fabric was 23.5 Pa.
Moreover, when this nonwoven fabric is evaluated by the flame retardancy test method according to JIS L-1091 A-1, the flame retardancy evaluation value is Category 3, and has the flame retardancy required as a filter for coating booths. It was.
Thus, the nonwoven fabric obtained in Comparative Example 1 was a coating booth filter suitable as a coating booth filter, comprehensively judged.
［比較例１］
粘着剤を付加しないこと以外、実施例１と同様の加工により、不織布を作製した。
この不織布を２０ｃｍ角にカットして、実施例１と同様に、流入側にＪＩＳ １５種粉塵０．１ｇを直径２ｃｍ円状に均一に散布して、１ｃｍの高さから３００回の落下振動試験を行った結果、著しい粉塵の流失がみられた。
よって、比較例２で得られた不織布は、塗装ブース用フィルタとして不適な塗装ブース用フィルタであった。
実施例１、２及び比較例１の概要と、評価結果を表１に示す。
[Comparative Example 1]
A nonwoven fabric was produced by the same processing as in Example 1 except that no adhesive was added.
This non-woven fabric was cut into 20 cm square, and in the same manner as in Example 1, 0.1 g of
Therefore, the nonwoven fabric obtained in Comparative Example 2 was a coating booth filter that was not suitable as a coating booth filter.
Table 1 shows the outline and evaluation results of Examples 1 and 2 and Comparative Example 1.
本発明のフィルタ用不織布濾材は、好ましくは、塗装ブース用フィルタに用いられ、使用時に粉塵離脱による粉塵の飛散が防止されるように、加工されたものである。そのため、塗装ブース用フィルタ以外にも、空調機、タービン、クリーンルーム内エアーの循環用フィルタ等のエアフィルタ濾材として利用可能である。
また、本発明のフィルタ用不織布濾材の製造方法では、その製造工程が不織布生産に連結一貫し、且つ、単一層構成であるので、工程が簡略化される点において、産業上の利用の可能性が高い。
The non-woven filter medium for a filter of the present invention is preferably used for a filter for a coating booth, and is processed so as to prevent dust scattering due to dust detachment during use. Therefore, in addition to the paint booth filter, it can be used as an air filter medium such as an air conditioner, a turbine, and a filter for circulating air in a clean room.
Further, in the method for producing a nonwoven filter medium for a filter according to the present invention, since the production process is consistently linked to the production of nonwoven fabric and has a single layer structure, the industrial process is possible in that the process is simplified. Is expensive.
１ 短繊維ウェブ
２ ディップ加工で粘着剤を付着させたサーマルボンド短繊維不織布
３ スプレー加工で粘着剤を付着させたサーマルボンド短繊維不織布
１０ カーディング紡出機（またはカーディング機）
１１ ディップ加工機
１２ 絞りロール
１３ 乾燥・加熱炉
１４ スプレー加工機
１５ 巻き取り製品（ロール）
DESCRIPTION OF SYMBOLS 1 Short fiber web 2 Thermal bond short fiber nonwoven fabric which adhered adhesive by dip processing 3 Thermal bond short fiber nonwoven fabric which adhered adhesive by
11
Claims (3)
（Ｉ）ウェブ形成工程：高融点ポリエステル短繊維と熱融着ポリエステル短繊維を混合し、ウェブを形成する工程
（ＩＩ）水系粘着性樹脂付着工程：形成されたウェブを、水系粘着性樹脂の水溶液もしくはエマルジョンに浸漬する工程または水系粘着性樹脂の水溶液もしくはエマルジョンをスプレーする工程
（ＩＩＩ）サーマルボンド不織布作製工程：水系粘着性樹脂が付着したウェブを、エアースルー法、加熱カレンダー法または超音波法により、熱溶融し、繊維間結合して、サーマルボンド不織布を作製する工程 It consists of 10 to 90% by weight of high-melting polyester short fibers having a fineness of 1 to 100 dtex, and 10 to 90% by weight of heat-bonded polyester short fibers having a fineness of 1 to 100 dtex, and a basis weight of 100 to 500 g / m. 2. A method for producing a nonwoven filter medium for a filter comprising a water-based adhesive resin attached to the entire surface of a fiber constituting a thermal bond nonwoven fabric having a thickness of 10 to 30 mm, comprising the following steps (I) to (III): A method for producing a non-woven filter medium, which is sequentially applied.
(I) Web forming step: a step of mixing high-melting polyester short fibers and heat-fused polyester short fibers to form a web (II) water-based adhesive resin adhesion step: an aqueous solution of a water-based adhesive resin Alternatively, a step of immersing in an emulsion or a step of spraying an aqueous solution or emulsion of a water-based adhesive resin (III) A thermal bond nonwoven fabric production step: a web to which a water-based adhesive resin is adhered is obtained by an air-through method, a heating calendar method or an ultrasonic method. , Heat melting and bonding between fibers to make a thermal bond nonwoven fabric
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