JP5976351B2 - Filter media and fuel filter - Google Patents

Description

  The present invention relates to a filter medium for trapping dust, and relates to a filter medium having a compact shape, excellent carding stability, dust trapping performance, and a long filter life.

  In a fuel tank for automobiles, a fuel filter (suction filter) for removing foreign matters and carbon dust mixed in the fuel tank is installed on the suction side of the fuel pump. As the fuel filter material, for example, a material obtained by arbitrarily laminating a nonwoven fabric such as a woven fabric having a mesh structure, a spunbond nonwoven fabric, a spunlace nonwoven fabric, or a melt blown nonwoven fabric is used.

  Usually, dust is trapped between the fibers of the nonwoven layer. In recent years, further dust trapping ability has been demanded for the filter medium, and it is desired to provide a dense filter medium that can trap even fine dust of several μm to 50 μm. However, the denser the filter media, the greater the amount of dust that accumulates between the fibers as capture continues, resulting in a higher pressure loss of the filter media. Therefore, a dense filter medium between fibers that can capture minute dust has been difficult to use for a long time.

  In order to cope with the above problem, a filter medium having a gradient in the density and fiber diameter of a nonwoven fabric layer is known. For example, a filter medium for laminating a plurality of long-fiber nonwoven fabrics formed by the spunbond method, and by changing the fiber diameter forming the long-fiber nonwoven fabric or the basis weight of the nonwoven fabric, a density gradient is created between the long-fiber nonwoven fabrics, An automotive fuel filter that captures dust in stages according to its diameter is provided (Patent Document 1).

  Further, in order to cope with the problem of a decrease in liquid permeability in the intermediate layer, a filter medium in which a thermoplastic long fiber nonwoven fabric is laminated as an intermediate layer between two layers of spunlace nonwoven fabric composed of short fibers, There has been provided a filter material for a suction filter having an inclination function of sequentially capturing particles having different sizes by changing the fiber diameter in the thickness direction (Patent Document 2).

  Furthermore, a filter medium in which a spunlace nonwoven fabric and a meltblown nonwoven fabric are laminated between long fiber nonwoven fabric layers, a fineness gradient is provided between the spunlace nonwoven fabric and the meltblown nonwoven fabric, and a layer having a large fiber diameter is provided upstream of the filter. A fuel filter material that improves the filter life by arranging a small layer on the downstream side is also known (Patent Document 3).

JP 2003-236321 A JP 2011-184832 A JP 2006-187710 A

  However, since the fuel filter for automobiles described in Patent Document 1 is a nonwoven fabric in which a layer having a dust capturing ability is formed by a spunbond method, it is difficult to control the fiber diameter of the nonwoven fabric to 10 μm or less. . For this reason, the automobile fuel filter described in Patent Document 1 cannot capture extremely fine dust having a particle size of 10 μm or less.

  On the other hand, in the filter material for the suction filter described in Patent Document 2, fibers having a fiber diameter of 10 μm or less are used as the raw material of the spunlace nonwoven fabric, but the fiber diameter is too thin, so that carding cannot be stably performed. It was difficult to uniformly disperse the fibers.

  Although the filter material for fuel described in Patent Document 3 is laminated with a spunlace nonwoven fabric and a meltblown nonwoven fabric, when the fiber diameter of the fibers constituting the meltblown nonwoven fabric is controlled to 10 μm or less, the bonding force between the fibers is weak, There was a problem that the fibers were worn by contact with the dust and fiber waste was generated. In order to suppress the generation of fiber waste, the melt blown nonwoven fabric must be heat-sealed or physically pressure-bonded, which has the disadvantage of shortening the filter life.

  As described above, in the prior art, the fiber diameter is reduced in order to capture minute dust, but this causes difficulties in carding and filter life. Furthermore, since the filter described in any literature changes the fiber diameter which comprises a nonwoven fabric, since the gradient is provided between the nonwoven fabrics and the dust is captured step by step, in these methods, the diameter of the raw material is used as a raw material. A large number of different fibers had to be prepared, and procurement and inventory management were complicated.

  Under such circumstances, the present invention provides a filter medium capable of simultaneously stabilizing carding and extending the life of the filter while reducing the efficiency of capturing fine dust and reducing the types of raw fiber. Listed as a purpose.

  As a result of intensive research to solve the above problems, the present inventor laminated two or more short fiber layers including one or more of divided fibers and non-divided fibers, and from the front side of the filter medium between the short fiber layers. It discovered that the said subject could be solved by increasing the mixture ratio of a split fiber toward the back side. When split fibers are used as the raw material of the short fiber layer, the split fibers are large-diameter fibers during carding, so that a web in which the split fibers are uniformly dispersed can be formed. Then, by dividing the fiber in the subsequent steps, the fiber diameter can be reduced and the capture efficiency of the fine dust can be increased. Furthermore, since this diameter reduction is achieved by the blending of split fibers and non-split fibers, both the fine and coarse portions exist in the short fiber layer, and thus the filter eyes. It becomes possible to prevent clogging. In addition, by changing the blending amount of the split fibers stepwise, even if a single type of split fiber is used as the raw material, the desired gradient characteristics can be given, and the type of raw fiber can be reduced. I understood.

  That is, the filter medium according to the present invention is an intermediate in which two or more short fiber layers including one or more of split fibers and non-split fibers are laminated, a reinforcing material made of synthetic resin, a surface material composed of long-fiber nonwoven fabrics, and the like. A material and a backing material composed of a long-fiber nonwoven fabric are laminated in this order, and each material is partially fused. Between the short fiber layers, the mixing ratio of split fibers from the front side to the back side of the filter medium Is characterized by an increase. The split fibers exist in the state of ultrafine fibers after being peeled in the length direction, the fineness of the ultrafine fibers is 0.10 dtex or more and 0.35 dtex or less, and the fineness of the non-split fibers is 1 It is desirable that it is 0.0 dtex or more and 10 dtex or less. In addition, the ratio of the split fibers of the outermost short fiber layer is 10% by mass or more and less than 50% by mass, and the ratio of the split fibers of the outermost short fiber layer is 50% by mass or more and 100% by mass or less. It is preferable. Furthermore, it is preferable that the amount of change in the fineness of the split fibers and the fineness of the non-split fibers is maintained within ± 20% between the short fiber layers. Moreover, it is desirable that the part which is partly fused is 0.2% or more and 5.0% or less in area ratio with respect to the surface of the filter medium. Furthermore, the short fiber layer is preferably manufactured by water punching.

  The present invention also includes a fuel filter in which the filter medium is disposed.

  According to the present invention, as the short fiber layer of the filter medium, two or more short fiber layers including one or more of the split fibers and the non-split fibers are laminated, and the split fibers are disposed between the short fiber layers from the front side to the back side of the filter medium. By increasing the blending ratio, it is possible to capture dust with a small particle size and to maintain a long filter life. Moreover, in this invention, since the gradient is provided between the short fiber layers by changing the blending ratio of the split fibers, the raw material fibers can be easily procured.

FIG. 1 is an enlarged cross-sectional view showing an example of the filter medium of the present invention.

  Hereinafter, the filter medium according to the present invention will be described in detail with reference to the drawings showing the embodiments. However, the present invention is not limited to the illustrated examples, but within a range that can be adapted to the purpose described above and below. The present invention can be carried out with appropriate modifications, and all of them are included in the technical scope of the present invention.

1. Configuration of Filter Medium FIG. 1 is an enlarged sectional view showing an example of the filter medium of the present invention. FIG. 1 shows a state of a cut surface when the filter medium 10 is cut. The filter medium 10 in the illustrated example includes a reinforcing material 1 made of a synthetic resin, a surface material 2 made of a long-fiber non-woven fabric, short fiber layers (short fiber non-woven fabric) 3, 4 including one or more of split fibers and non-split fibers, An intermediate material 8 in which two or more layers of 5 are laminated (in the illustrated example, three layers) and a backing material 9 composed of a long-fiber nonwoven fabric are laminated in this order. In the filter medium 10 in the illustrated example, the layers manufactured separately are sequentially laminated, and then the layers are joined by partial fusion using an ultrasonic welding machine. When a gas or liquid containing dust flows in from the reinforcing material 1 side, the dust in the gas or liquid is captured between the fibers of each material constituting the filter medium 10 according to the particle diameter.

2. Intermediate material 8
In the filter medium 10, in the intermediate material 8, the short fiber layer (short fiber layer 3 in FIG. 1) closer to the surface material 2 has a smaller amount of split fibers and the short fiber layer (short fiber in FIG. 1) closer to the backing 9. As the layer 5), the blending ratio of the divided fibers is higher. That is, the short fiber layers 3 to 5 in the illustrated example are arranged in order from the front side to the back side of the filter medium 10 (in the order of the short fiber layer 3, the short fiber layer 4, and the short fiber layer 5). The rate is increasing. In this way, when short fiber layers with different blending amounts of split fibers are laminated with a gradient, it is possible to narrow the eyes at the split fiber portions, and thus it is possible to capture dust according to the particle size. .

  If it demonstrates in detail, the said division | segmentation fiber will peel in the length direction by the mechanical force at the time of forming a short fiber layer from a web. Therefore, the split fibers exist as ultrafine fibers after peeling in the short fiber layers 3 to 5, and due to the presence of minute gaps formed between the ultrafine fibers, the short fiber layer is a dust having a small particle diameter. It can be captured even if it exists. On the other hand, the fibers of the non-divided fibers are thicker than the ultrafine fibers, and the inter-fiber voids are likely to be large at locations where the non-divided fibers are present. Due to the presence of the large gap, it is possible to pass gas or liquid with a small resistance. Since the intermediate material 8 is formed by combining such split fibers and non-split fibers, it is possible to prevent clogging of the filter while increasing the capture efficiency of fine dust. In addition, when split fibers are used, not only can the gaps between the fibers be reduced, but it also contributes to stabilizing carding and reducing the types of raw fibers. As described above, the split fibers play an important role in the present invention. The details will be described below. In addition, in this specification, the split fiber means a short fiber that is peeled in the length direction of the fiber, and the non-split fiber means a short fiber that cannot be peeled in the length direction of the fiber.

2-1. Split fibers Split fibers used in the present invention are formed by alternately arranging first resin regions (one-component resin) and second resin regions (other component resins) different from the first resin. The fiber surface is covered with a protective film. Due to the presence of different resin regions, the peeling stress is applied to the boundary of the resin regions due to mechanical force when manufacturing the short fiber layer (details will be described later, for example, during mechanical entanglement by water punching or the like). Concentrate, break the bundling by the protective film, and the split fibers split in the length direction from the boundary. When the intermediate material 8 is formed using such a split fiber, it is not necessary to split the fiber from the beginning as long as the fiber can be split in a later manufacturing process. Carding). If it does so, the fiber to card can be made large diameter, and handling of a fiber will become easy compared with the case where carding an ultrafine fiber. Furthermore, by changing the blending amount of the non-divided fibers and the divided fibers, the degree of opening between the fibers can be adjusted, and it becomes unnecessary to prepare a large number of fibers having different diameters.

  Regarding the split fibers, the fineness before splitting (peeling) is, for example, preferably 1 dtex or more and 8 dtex or less, more preferably 2 dtex or more and 5 dtex or less. If the fineness before separation of the split fibers is within the above range, the carding process can be carried out stably.

  Further, the fineness after the division (peeling) is preferably, for example, 0.10 dtex or more and 0.35 dtex or less, and more preferably 0.15 dtex or more and 0.25 dtex or less. If the fineness after peeling is within the above range, even a dust having a small particle size can be captured, so that the collection efficiency is improved.

  As the split fiber, one-component resin and other component resin are radially composited such as a petal type, a rice character type, a hollow radiation type, etc .; a layered composite fiber; It is good to use. In the present invention, in particular, in order to increase dust capture efficiency, it is desirable to use a fiber that is compounded into a hollow radiation type that can increase the number of divisions.

  The cross-sectional shape of the split fiber is not particularly limited, and the cross-sectional shape of the fiber before peeling may be, for example, a round, oval, rectangular, hollow, or doughnut-like fiber. As the cross-sectional shape of the fiber, for example, a fiber such as a round shape, a kamaboko shape, a rectangular shape, or a triangular shape may be appropriately employed.

  As the raw material of the split fiber, a resin capable of spinning a composite fiber is used. For example, a polyester resin such as a polyethylene terephthalate resin or a polybutylene terephthalate resin; a polyamide resin such as a nylon resin or an aramid resin; a polyethylene resin or a polypropylene resin A resin selected from polyolefin resins is preferably used. The combination of the resin used as the one-component resin and the other component resin is desirably incompatible, and among them, the combination of the polyester-based resin and the polyamide-based resin, and two types of resins selected from the polyester-based resins Or a combination of two resins selected from polyolefin resins. Furthermore, a combination of polyethylene terephthalate resin and nylon resin, a combination of polyethylene resin and polypropylene resin, or a combination of polyethylene terephthalate resin and polybutylene terephthalate resin is more suitable, and a combination of polyethylene terephthalate resin and nylon resin having excellent oil resistance is preferable. Most preferred.

  Moreover, it is desirable that the split fibers can be divided into two or more in the length direction, and more preferably eight or more. Further, although there is no upper limit to the number of divisions of the divided fibers, it is preferably a fiber that can be divided into 24 or less in the length direction, and more preferably 16 or less. If the number of divisions is within the above range, the filter life can be extended while improving the dust collection efficiency.

  The fiber length of the split fibers is, for example, preferably 20 to 100 mm, more preferably 30 to 90 mm, and further preferably 40 to 80 mm.

  The split fibers may contain one or more resin regions formed from a resin different from the first and second resins. A protective film is not essential. Further, each short fiber layer may be formed of one or more types of split fibers, and the type of split fibers may be the same or different between the short fiber layers.

2-2. Next, non-divided fibers used for the short fiber layers 3 to 5 will be described in detail. As a raw material for the short fiber layers 3 to 5, in the present invention, non-divided fibers are used together with the divided fibers. When non-divided fibers are used as a raw material constituting the short fiber layer, since the fineness of the non-divided fibers is high, a relatively large inter-fiber gap is formed in the short fiber layer. The amount of gas or liquid passing through the filter medium 10 can be adjusted by the presence of the void. In addition, the bulkiness of the short fiber layers 3 to 5 can be increased while maintaining the basis weight, which leads to an improvement in the amount of dust retained. Thereby, the filter life of the filter medium 10 can be maintained longer. Moreover, it becomes possible to adjust the compounding quantity of a division | segmentation fiber suitably by mix | blending a non-partition fiber.

  The fineness of the non-divided fibers is preferably 1.0 dtex or more and 10 dtex or less, and more preferably 1.5 dtex or more and 3.0 dtex or less. If the fineness of the undivided fibers is within the above range, it is desirable because the dust holding amount is improved. When the non-divided fiber is a polyester fiber, for example, the fineness of the non-divided fiber is preferably 1.0 dtex or more and 5.0 dtex or less, and more preferably 1.5 dtex or more and 3.0 dtex or less. If the fineness of the non-divided fibers is within the above range, it is desirable because an improvement in dust collection efficiency and a longer filter life can be achieved at the same time.

  As the non-divided fibers, it is preferable to use synthetic fibers such as polyester fibers, polyamide fibers, polyolefin fibers and acrylic fibers; recycled fibers such as rayon fibers; semisynthetic fibers such as acetate fibers. Among these, it is desirable to use polyester fibers having excellent oil resistance.

  The cross-sectional shape of the non-segmented fiber is not particularly limited, but as the non-segmented fiber, a fiber having a round cross-sectional shape, or a fiber having an irregular cross-sectional shape such as a triangular shape, a star shape, a polygonal shape, a Y shape, or an L shape. Should be used.

  The fiber length of the non-divided fibers is, for example, preferably 20 to 100 mm, more preferably 30 to 90 mm, and still more preferably 35 to 80 mm.

  In particular, in a short fiber layer formed by blending both split fibers and non-split fibers, the ratio of the fiber lengths of split fibers and non-split fibers (fiber length of split fibers / fiber length of non-split fibers) is 70 / 30 to 30/70 is preferable, and 50/50 is more preferable. When the ratio of the fiber lengths is within the above range, a dense portion and a rough portion between the fibers can be uniformly formed in the short fiber layer. Therefore, the filter capture efficiency is improved, and the filter can be used for a long time.

  In addition, only 1 type may be sufficient as the non-dividing fiber used as a raw material of one short fiber layer, and what mixed multiple types may be sufficient as it. Moreover, the kind of non-dividing fiber may be the same between the short fiber layers, or may be different.

2-3. Method for Producing Short Fiber Layer Each of short fiber layers 3 to 5 was formed after blending the above-described split fibers and / or non-split fibers and carrying out carding using a card machine or the like to form a web. Desirably, the web is manufactured by mechanical entanglement. As the mechanical entanglement method, water punching or needle punching is suitable. Especially, if it is a water punch process, a split fiber can be divided | segmented with the pressure loaded at the time of a process, and it can be made into an ultrafine fiber. The pressure of the water ejected from the nozzle is not particularly limited, 60 kg / cm ² or more 150 kg / cm ² or less is preferable. When the pressure is less than 60 kg / cm ² , the split fibers are not sufficiently peeled off, and the desired filter performance may not be obtained. On the other hand, when the pressure exceeds 150 kg / cm ² , excessive energy is required, and traces of water flow remain on the surface of the short fiber layer, and there is a possibility that the fibers are overly dense. The water pressure may be appropriately changed according to the type of split fiber.

2-4. The intermediate material 8 is formed by laminating short fiber layers 3 to 5 manufactured in the order of the mixing ratio of the divided fibers, and the short fiber layers 3 to 5 are sequentially formed from the front side to the back side of the filter medium 10. The ratio of the split fibers in the short fiber layer is higher (in the order of the short fiber layer 3, the short fiber layer 4, and the short fiber layer 5).

  The blending ratio of the split fibers between the short fiber layers is, for example, that the ratio of the split fibers of the outermost short fiber layer (short fiber layer 3 in FIG. 1) is preferably 10% by mass or more and less than 50% by mass, Moreover, it is more preferable that the ratio of the split fibers of the shortest fiber layer (short fiber layer 5 in FIG. 1) is 50% by mass or more and 100% by mass or less. As described above, by increasing the ratio of the split fibers blended in the short fiber layers 3 to 5 in order, dust can be captured according to the particle diameter when the filter medium 10 is used. Further, by capturing dust in stages, it is possible to obtain the filter medium 10 that is less likely to be clogged and has a long filter life. In the present invention, the ratio of the split fibers of the outermost short fiber layer 3 is 20% by mass or more and less than 40% by mass, and the ratio of the split fibers of the outermost short fiber layer 5 is 60% by mass or more and 70% by mass. % Is a more preferable embodiment. When the mixing ratio of the split fibers is within the above range, the filter medium 10 can achieve a longer life of the filter medium while exhibiting higher collection efficiency.

  In the intermediate material 8, the blending ratio of the split fibers is increased in order from the front side to the back side, and the short fiber layer existing on the back side is denser between the fibers, so to suppress clogging of the filter medium 10, The short fiber layers 3 to 5 are desirably thinned in order from the front side to the back side (that is, the order of the short fiber layer 3, the short fiber layer 4, and the short fiber layer 5). The relationship between the thicknesses of the outermost short fiber layer 3 and the outermost short fiber layer 5 is, for example, that the thickness of the outermost short fiber layer 5 is 0 with respect to the thickness of the outermost short fiber layer 3. It is preferably 4 times or more and 0.8 times or less, and more preferably 0.5 times or more and 0.75 times or less.

  In the present invention, since the intermediate material 8 is provided with a gradient by changing the blending amount of the split fibers, the intermediate material 8 has a gradient even if the fiber diameters of the raw material fibers are approximately the same between the short fiber layers. Can be made. That is, according to the present invention, the raw fibers of the short fiber layers 3 to 5 do not need to have a large change in fineness between the short fiber layers. For example, all the short fiber layers have the same fineness, or the short fibers Even if the difference in fineness between the fiber having the maximum fineness of the layer and the fiber having the smallest fiber is extremely small, the intermediate material 8 having the desired gradient characteristics can be formed.

  In the case of split fibers, the difference between the fineness of the fiber having the maximum fineness (maximum fineness) and the fineness of the fiber having the minimum fineness (minimum fineness) should be maintained within ± 20% of the maximum fineness, for example. It is more desirable that it is maintained within ± 10%, and it is further preferable that the fineness of the split fibers used is equal in all the short fiber layers.

  For non-divided fibers, as in the case of divided fibers, the difference between the maximum fineness and the minimum fineness with respect to the maximum fineness is desirably maintained within ± 20%, for example, and maintained within ± 10%. It is more desirable.

  The fineness of the split fibers before splitting (peeling) is applied to the fineness of the split fibers.

  In the present invention, the fineness of the split fibers and non-split fibers used as raw materials is maintained within a certain value between the fiber layers. However, since the blending amount of the split fibers is changed, the short fiber layers 3 to 5 are arranged in order from the front side to the back side (that is, the order of the short fiber layer 3, the short fiber layer 4, and the short fiber layer 5). The average fiber diameter is small. The average fiber diameter of the shortest fiber layer 5 on the backmost side is desirably 0.20 times or more and 0.85 times or less, more preferably 0.25 times the average fiber diameter of the short fiber layer 3 on the outermost side. It is more than 0.60 times. If the ratio of the average fiber diameter is within the above range, it is desirable because dust can be captured stepwise according to the particle diameter. The method for measuring the average fiber diameter will be described in detail in the Examples section.

  The average fiber diameter of the outermost short fiber layer 3 is preferably 5.0 μm to 20 μm, more preferably 8.0 μm to 15 μm. Moreover, it is preferable that the average fiber diameter of the short fiber layer 5 of the backmost side is 1.0 micrometer-15 micrometers, More preferably, they are 2.0 micrometers-10 micrometers.

  The thickness of the outermost short fiber layer 3 is preferably 0.5 mm to 1.0 mm, more preferably 0.6 mm to 0.8 mm.

  The thickness of the shortest fiber layer 5 on the backmost side is preferably 0.3 mm to 0.8 mm, and more preferably 0.4 mm to 0.7 mm.

Aeration rate of the short fiber layer 3 top front ^{of, 50cc / (sec · cm 2} ) ~120cc / is preferably (sec · cm ²⁾ is, more preferably ^{65cc / (sec · cm 2)} ~100cc / ( sec · cm ² ).

Further, the ventilation amount of the short fiber layer 5 uppermost backside ^{of, 20cc / (sec · cm 2} ) ~70cc / is preferably (sec · cm ²⁾ is, more preferably ^{35cc / (sec · cm 2)} ~55cc / (Sec · cm ² ).

Short fiber layer 3 of basis weight of the top front side, is preferably ^{50g / m 2 ~180g / m 2} , more preferably from ^{70g / m 2 ~150g / m 2} .

Also, the basis weight of the short fiber layer 5 uppermost backside of is preferably ^{40g / m 2 ~120g / m 2} , more preferably from ^{50g / m 2 ~100g / m 2} .

Basis weight of the intermediate member 8 is preferably ^{100g / m 2 ~600g / m 2} , more preferably from ^{120g / m 2 ~500g / m 2} , more preferably at 140g / m ² ~450g / m ² is there.

  The number of the short fiber layers 3 to 5 constituting the intermediate member 8 is 2 or more, and a more preferable embodiment is 3 or more. On the other hand, there is no upper limit to the number of short fiber layers, but it is preferably 10 or less, more preferably 6 or less, and still more preferably 4 or less. If the number of short fiber layers is within the above range, it is possible to extend the life of the filter while increasing dust capture efficiency, and further increase the bulk density of the filter medium 10 and improve the rigidity of the filter medium 10. It becomes possible. On the other hand, when the number of the short fiber layers exceeds 10, the manufacturing process of the filter medium 10 becomes complicated, which is not preferable.

  Moreover, in this invention, as long as it is possible to change the ratio of a non-divided fiber and a divided fiber between short fiber layers, it is not necessary to use both a non-divided fiber and a divided fiber by all the short fiber layers. That is, if both non-split fibers and split fibers are used in the intermediate short fiber layer, the short fiber layer of the chopsticks (the shortest fiber layer on the outermost side or the backmost side) is replaced with only the non-split fibers or only the split fibers. May be formed.

3. Other members 3-1. Reinforcing material The reinforcing material 1 made of synthetic resin is disposed as the outermost layer of the filter medium 10. By disposing the reinforcing material 1, it is possible to suppress the influence due to wear that occurs when the filter medium 10 comes into contact with the bottom of the fuel tank due to engine vibration. Further, when the fuel flows into the fuel pump, foreign matters such as relatively large dust, paint fragments, rust and the like can be prevented from being worn with the filter medium 10.

  The reinforcing material 1 is preferably formed of woven fabric, knitted fabric, lace, net, nonwoven fabric, grid or the like. Among them, it is preferable to use a woven fabric, and a mesh woven fabric is preferable.

  Examples of synthetic resins used as fiber raw materials include polyolefin resins such as polyethylene resins and polypropylene resins; polyester resins such as polyethylene terephthalate resins and polybutylene terephthalate resins; and thermoplastic resins such as nylon resins, which have good oil resistance. It is preferable to employ a polyester resin.

  The fibers used as the raw material of the reinforcing material 1 preferably have an average fiber diameter of 50 μm to 300 μm, and more preferably 150 μm to 250 μm. Moreover, it is preferable that the fiber used as the raw material of the reinforcing material 1 has a fineness of 200 dtex to 500 dtex, and more preferably 300 dtex to 400 dtex.

  The thickness of the reinforcing material 1 is preferably 0.2 mm to 1.5 mm, and more preferably 0.3 mm to 0.7 mm. If the thickness of the reinforcing material 1 is within the above range, the filter medium 10 can be protected without impairing the collection effect of the filter medium 10.

Basis weight of the reinforcing material 1 is preferably ^{40g / m 2 ~300g / m 2} , more preferably from ^{80g / m 2 ~200g / m 2} , more preferably at 120g / m ² ~170g / m ² is there.

  Moreover, when using a mesh fabric as the reinforcing material 1, it is preferable that the roughness of eyes is 30-120 by mesh count, More preferably, it is 35-60. If the mesh count is within the above range, the filter medium 10 can be protected without impairing the collection effect of the filter medium 10.

3-2. Surface material Between the reinforcing material 1 and the intermediate material 8, a surface material 2 composed of a long-fiber nonwoven fabric is disposed. By disposing the surface material 2, it is possible to capture and remove relatively large foreign matters existing in the fuel tank, for example, dust and coarse particles having a particle diameter of 100 μm or more.

  As the surface material 2, a long-fiber non-woven fabric (spun-bond non-woven fabric) formed by a spunbond method is suitably used because the fibers do not easily fall off to the inflow side. The long fiber nonwoven fabric is manufactured by melt-spinning a thermoplastic resin and mechanically entangled the formed web. As a web entanglement method, needle punching or water punching is suitable. If it is the said process, the reduction | decrease of the filtration area of gas or a liquid can be suppressed, and it can suppress that the fibers of a long-fiber nonwoven fabric become overcrowded.

  Examples of the thermoplastic resin used as the raw material for the surface material 2 include polyolefin resins such as polyethylene resin and polypropylene resin; polyester resins such as polyethylene terephthalate resin and polybutylene terephthalate resin; and thermoplastic resins such as nylon resin. Among them, like the reinforcing material 1, it is preferable to use a polyester resin having excellent oil resistance.

  It is preferable that the fiber used as the raw material of the surface material 2 has an average fiber diameter of 1 μm to 50 μm, and more preferably 7 μm to 25 μm. Moreover, the fiber used as the raw material of the surface material 2 has a fineness of 1 dtex to 10 dtex, and preferably 1.4 dtex to 6 dtex.

  The thickness of the surface material 2 is preferably 0.2 mm to 3 mm, more preferably 0.8 mm to 2 mm.

Aeration rate of surface material ^{2, 50cc / (sec · cm 2} ) ~300cc / is preferably (sec · cm ²⁾ is, more preferably ^{100cc / (sec · cm 2)} ~200cc / (sec · cm 2 ).

Basis weight of the surface material. 2 is intended to be determined in relation to the raw material fibers, for example, it is preferably 50 g / m ² to 200 g / m ^2, more preferably 80g / m ² ~150g / m ² , and still more preferably from ^{100g / m 2 ~140g / m 2} .

3-3. Backing In the outermost layer of the filter medium 10, a backing 9 made of a long fiber nonwoven fabric is disposed. The backing material 9 is laminated on the short fiber layer side where the blending amount of the divided fibers is the largest in the intermediate material 8. When the filter medium 10 is used, the ultrafine fibers present in the intermediate material 8 gradually move to the suction pump side with the inflow of gas or liquid. Therefore, by arranging the backing material 9 as a fiber drop-off preventing layer, the fine fibers are prevented from flowing out to the fuel pump.

  As the backing material 9, similarly to the front material 2, a long fiber nonwoven fabric (spunbond nonwoven fabric) formed by a spunbond method is used. The long fiber nonwoven fabric used for the backing 9 is desirably manufactured by embossing the formed web after preventing the thermoplastic resin from melting. By embossing and thermocompression bonding the fibers of the backing 9, the spaces between the fibers become dense, so that the fine fibers can be prevented from coming off. The partial thermocompression bonding rate of the backing material 9 is preferably, for example, 5% to 25%, and more preferably 7% to 15%. The method for measuring the partial thermocompression bonding rate will be described in detail in the column of Examples.

  Examples of the thermoplastic resin used as the raw material for the backing 9 include polyolefin resins such as polyethylene resin and polypropylene resin; polyester resins such as polyethylene terephthalate resin and polybutylene terephthalate resin; and thermoplastic resins such as nylon resin. Among them, as with the reinforcing material 1 and the surface material 2, it is preferable to use a polyester resin having excellent oil resistance.

  The fibers used as the raw material for the backing 9 preferably have an average fiber diameter of 1 μm to 50 μm, more preferably 7 μm to 25 μm. Moreover, the fiber used as the raw material of the backing material 9 has a fineness of 0.5 dtex to 10 dtex, and preferably 0.9 dtex to 3 dtex.

  The thickness of the backing 9 is preferably 0.05 mm to 1.5 mm, more preferably 0.1 mm to 0.5 mm.

Aeration rate of the backing ^{9, 50cc / (sec · cm 2} ) ~300cc / is preferably (sec · cm ²⁾ is, more preferably ^{80cc / (sec · cm 2)} ~150cc / (sec · cm 2 ).

Basis weight of the backing 9, but is to be determined in relation to the raw material fibers, for example, preferably from ^{10g / m 2 ~150g / m 2} , more preferably 20g / m ² ~100g / m ² , and still more preferably from ^{30g / m 2 ~70g / m 2} .

  The backing material 9 may be laminated as necessary, and is not essential in the present invention.

4). Manufacturing method of filter medium The filter medium 10 of the present invention includes a reinforcing material 1, a surface material 2, an intermediate material 8, and a backing material 9 that are laminated in this order, and each material is joined by partial fusion. Has been. Since the raw material of each material constituting the filter medium 10 is a thermoplastic resin, it is possible to join the materials while reducing the joining area by adopting an ultrasonic fusion method or the like.

  The part that is partially fused when observed from the reinforcing material 1 side (hereinafter, also referred to as a partially fused part) is 0.2% or more and 5.0% by area ratio with respect to the surface of the filter medium 10. Or less, more preferably 0.4% or more and 2.0% or less. When the partially fused portion is less than 0.2%, the materials are not sufficiently bonded to each other, and there is a possibility of causing peeling, which is not desirable. On the other hand, if the partially fused portion exceeds 5.0%, the pressure loss of the filter medium 10 increases, and the filter life may be shortened.

Basis weight of the filter medium 10 is preferably ^{400g / m 2 ~1000g / m 2} , more preferably from ^{500g / m 2 ~900g / m 2} , even more preferably at 600g / m ² ~800g / m ² .

Aeration rate of the filter medium ^{10, 4cc / (sec · cm 2} ) ~20cc / is preferably (sec · cm ²⁾ is, more preferably ^{5cc / (sec · cm 2)} ~15cc / (sec · cm 2) It is.

  The thickness of the filter medium 10 is preferably 1 mm to 8 mm, more preferably 2 mm to 6 mm, and still more preferably 3 mm to 5 mm.

5. Fuel Filter The filter medium 10 of the present invention can be suitably used as a filter material for an automobile fuel filter mounted on an automobile or the like. For example, the filter medium 10 may be cut into a rectangular shape, then folded in half, and the outer periphery may be ultrasonically fused and processed into a bag shape to be placed inside the fuel tank.

  EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited by the following examples, but may be appropriately modified within a range that can meet the purpose described above and below. Of course, it is possible to implement them, and they are all included in the technical scope of the present invention.

The characteristics measurement and performance evaluation method of the filter medium are as follows.
(1) Thickness: According to JIS L1913 6.1A method (2) Weight per unit: According to JIS L1913 6.2 method (3) Air flow rate (breathability); Three places of the filter medium were measured using a shape tester, and the average value was used for the evaluation of the air flow rate.

(4) Evaluation of Filtration Performance (Filtration Efficiency) Distilled water is used as a solvent for the test solution, eight types of dust of the powder for test 1 of JIS Z8901 are used in distilled water, and the dust concentration in the test solution is 0. It added so that it might become 5 g / L (0.5 weight%). A dispersion test liquid was prepared by ultrasonically vibrating the test liquid for 1 minute to uniformly disperse dust. The turbidity (T ₀ ) of the obtained dispersion test liquid was measured using a turbidimeter.
The dispersion test solution was passed through the filter medium at a flow rate of 200 cc / min for 30 seconds. At this time, the dispersion test liquid was introduced from the filter medium reinforcement to the backing. The test solution after passing through the filter medium was collected, and the turbidity (T ₁ ) of the collected test solution was measured using a turbidimeter. The filtration efficiency is calculated based on the following formula (1).
Filtration efficiency (%) = (T ₀ −T ₁ ) / T ₀ × 100 (1)

(5) Evaluation of filter life Distilled water is used as a solvent for the test solution, and eight types of dust of the powder for test 1 of JIS Z8901 are used in distilled water, and the dust concentration in the test solution is 0.5 g / L ( 0.5% by weight). A dispersion test liquid was prepared by ultrasonically vibrating the test liquid for 1 minute to uniformly disperse the dust.
The obtained dispersion test liquid was passed through the filter medium at a flow rate of 200 cc / min until the pressure loss reached 2.0 kPa. At this time, the dispersion test liquid was introduced from the filter medium reinforcement to the backing. The time required for the pressure loss to reach a predetermined value was evaluated as the filter life.

(6) Measuring method of partial thermocompression bonding rate (%) The contact surface with the embossing roll of the produced nonwoven fabric (test piece: 300 mm x 300 mm) was observed and observed with an electron microscope (magnification: 100 times) ( 10 mm × 10 mm), the ratio of the area of the thermocompression bonded portion was defined as the partial thermocompression bonding rate (%).

(7) Fineness of long fiber nonwoven fabric (spunbond nonwoven fabric) The surface of the long fiber nonwoven fabric was observed with an electron microscope, and the fiber diameter was measured. The fiber diameters at the other 10 locations were measured by the same method, and the average value was defined as the fineness of the long fiber nonwoven fabric.
In addition, the fineness of the fiber used for woven fabrics / nonwoven fabrics other than long-fiber nonwoven fabrics is a value described in the catalog.

(8) Measuring method of average fiber diameter About 30 arbitrary fibers which comprise a fabric observed with an electron microscope (magnification: 100 times), each 30 fiber diameters were measured, and the average of the measured fiber diameters Was the average fiber diameter.
In addition, the average fiber diameter of the monofilament used as a raw material of a mesh fabric is a value described in a catalog.

(9) Fusion area (%)
The surface of the filter medium (test piece: 300 mm × 300 mm) on the reinforcing material side is observed with an electron microscope (magnification: 100 times), and is ultrasonically fused to the observed filter medium surface (20 mm × 20 mm). The ratio of the area of the part was evaluated as a fusion area ratio (%).

<Production of woven fabric having mesh structure>
A mesh fabric having a mesh count of 40 made of polyethylene terephthalate (PET) monofilament (average fiber diameter 200 μm) was prepared. The characteristics of the mesh fabric are as shown in each table. The obtained mesh fabric was used as a reinforcing material for the filter medium.

<Preparation of long fiber nonwoven fabric (spunbond nonwoven fabric)>
A polyester resin (polyethylene terephthalate (PET) resin) was melt spun to form a fiber web. The obtained fiber web was subjected to needle punching, and the fibers were entangled to produce a long fiber nonwoven fabric A (spunbond nonwoven fabric; sometimes referred to as CN-A in the table). The characteristics of the long-fiber nonwoven fabric A are as shown in each table.

  A polyester resin (polyethylene terephthalate (PET) resin) was melt spun to form a fiber web. The obtained fiber web is thermocompression bonded by passing between a pair of hot rolls of an embossing roll and a smooth roll, and the partial thermocompression bonding rate is 11%. There is also. The characteristics are as shown in each table.

  A long-fiber nonwoven fabric C having the basis weight, fineness, average fiber diameter, thickness, and air permeability shown in Table 1 by the same production method as the long-fiber nonwoven fabric A (in the table, it may be described as CN-C) And long fiber nonwoven fabric D (in the table, it may be described as CN-D). The characteristics are as shown in each table.

<Production of non-woven fabric containing split fibers>
Fabrication of 0% split fiber non-woven fabric (SF0) Polyester fibers having a fineness of 1.45 dtex and a fiber length of 38 mm were formed with a card machine, and the intermediate web was then wrapped with a cross wrapper. The obtained short fiber web was water punched at a pressure of 60 to 150 kg / cm ² to obtain a non-woven fabric (SF0) containing 0% split fibers. The characteristics are as shown in each table.

Fabrication of 20% split fiber blended non-woven fabric (SF20) The split fiber is a 22 split type composed of polyester / nylon 6 (weight ratio 2/1) having a fiber length of 3.8 dtex and a fiber length of 51 mm. A hollow radiation type composite fiber was used. Further, as non-divided fibers, polyester fibers having a fineness of 1.6 dtex and a fiber length of 51 mm were used. After blending so that the mixing ratio of the split fiber and the non-split fiber was split fiber / non-split fiber = 20/80, an intermediate web was formed with a card machine, and the intermediate web was then wrapped with a cross wrapper. The obtained short fiber web was subjected to water punching at a pressure of 60 to 150 kg / cm ² to obtain a 20% split fiber blended nonwoven fabric (SF20). The characteristics are as shown in each table. In addition, in the table | surface, when a short fiber layer mix | blends a split fiber, the column of a fineness shows the fineness of the split fiber after peeling / the fineness of a non-split fiber.

Preparation of 30% split fiber blended nonwoven fabric (SF30A) Same as the split fiber 20% blended nonwoven fabric (SF20) except that the mixing ratio of split fiber and non-split fiber is changed to split fiber / non-split fiber = 30/70 By the method, a 30% split fiber blended nonwoven fabric (SF30A) was obtained. The characteristics are as shown in each table.

Preparation of 30% split fiber blended nonwoven fabric (SF30B) Same as split fiber 20% blended nonwoven fabric (SF20) except that the mixing ratio of split fiber and non-split fiber is changed to split fiber / non-split fiber = 30/70 By the method, 30% split fiber blended nonwoven fabric (SF30B) having a different basis weight from SF30A was obtained. The characteristics are as shown in each table.

Preparation of split fiber 40% non-woven fabric (SF40A) Same as split fiber 20% non-woven fabric (SF20) except that the mixing ratio of split fiber and non-split fiber is changed to split fiber / non-split fiber = 40/60 By the method, a 40% split fiber blended nonwoven fabric (SF40A) was obtained. The characteristics are as shown in each table.

Preparation of split fiber 40% non-woven fabric (SF40B) Same as split fiber 20% non-woven fabric (SF20) except that the mixing ratio of split fiber and non-split fiber is changed to split fiber / non-split fiber = 40/60 By the method, a 40% split fiber blended nonwoven fabric (SF40B) having a different basis weight from SF40A was obtained. The characteristics are as shown in each table.

Preparation of 50% split fiber blended nonwoven fabric (SF50) Same as the split fiber 20% blended nonwoven fabric (SF20) except that the mixing ratio of split fiber and non-split fiber is changed to split fiber / non-split fiber = 50/50 By the method, a 50% split fiber blended nonwoven fabric (SF50) was obtained. The characteristics are as shown in each table.

Production of split fiber 60% non-woven fabric (SF60) Same as split fiber 20% non-woven fabric (SF20) except that the mixing ratio of split fiber and non-split fiber is changed to split fiber / non-split fiber = 60/40 By the method, a 60% split fiber blended nonwoven fabric (SF60) was obtained. The characteristics are as shown in each table.

Production of split fiber 100% non-woven fabric (SF100) Same as split fiber 20% non-woven fabric (SF20) except that the mixing ratio of split fiber and non-split fiber is changed to split fiber / non-split fiber = 100/0 By the method, a 100% split fiber blended nonwoven fabric (SF100) was obtained. The characteristics are as shown in each table.

Examples 1-5, Comparative Examples 1-2
The layers shown in each table (reinforcing material, front material, intermediate material (first to fifth layers), and backing material) are laminated in order from the reinforcing material, and each material is fused using an ultrasonic welding machine. Thus, a filter medium was prepared.

  The filter media of Examples 1 to 5 in which two or more short fiber layers are laminated have improved dust filtration efficiency and the filter of the filter media of Comparative Examples 1 and 2 in which only one short fiber layer is laminated. Long life can be achieved at the same time.

  The filter medium produced in Example 4 has five short fiber layers in which the mixing ratio of the split fibers is increased from the front side to the back side of the filter medium. Thus, since the filter medium of Example 4 has increased the number of lamination | stacking of a short fiber layer compared with another Example, it becomes possible for each fiber layer to capture | acquire dust efficiently. Thereby, the filter medium of Example 4 can dramatically improve the filtration efficiency to 42% while keeping the filter life at 13 minutes or longer.

  Since the filter medium of Comparative Example 1 did not use the short fiber layer in which the split fibers were blended into the intermediate material, the filtration efficiency was low. This is considered to be because there were many voids between the fibers and only dust having a large particle diameter could be captured.

  Moreover, the filter medium of Comparative Example 2 uses only a short fiber layer with a blending ratio of split fibers of 100% as an intermediate material, and can capture minute dust, but dust is concentrated only on the short fiber layer. For this reason, the filter medium was quickly clogged, and the filter life was shortened.

DESCRIPTION OF SYMBOLS 1 Reinforcement material 2 Surface material 3-5 Short fiber layer 8 Intermediate material 9 Backing material 10 Filter material

Claims (7)

It is composed of a reinforcing material made of synthetic resin, a surface material composed of a long-fiber nonwoven fabric, an intermediate material in which two or more short fiber layers including one or more of split fibers and non-split fibers are laminated, and a long-fiber nonwoven fabric. Are laminated in this order, and each material is partially fused.
Between the short fiber layers, the blending ratio of the split fibers increases from the front side to the back side of the filter medium ,
Basis weight of the top front of the short fiber layer is ^{50g / m 2 ~180g / m 2} , a thickness of 0.5 mm to 1.0 mm, basis weight of the top rear side of the short fiber layer is ^{40g / m 2 ~120g / m 2} , The thickness is 0.3 mm to 0.8 mm,
A filter medium characterized in that the amount of change in the fineness of the split fibers and the fineness of the non-split fibers is maintained within ± 20% between the short fiber layers . The split fibers are present in the state of ultrafine fibers after being peeled in the length direction,
The filter medium according to claim 1, wherein the fineness of the ultrafine fiber is 0.10 dtex or more and 0.35 dtex or less, and the fineness of the non-divided fiber is 1.0 dtex or more and 10 dtex or less. The ratio of the split fibers of the outermost short fiber layer is 10% by mass or more and less than 50% by mass,
The filter medium according to claim 1 or 2, wherein a ratio of the split fibers of the shortest fiber layer on the backmost side is 50% by mass or more and 100% by mass or less. The filter medium according to any one of claims 1 to 3, wherein the number of laminated short fiber layers constituting the intermediate material is 3 or more .   The filter medium according to any one of claims 1 to 4, wherein the part that is partially fused is 0.2% or more and 5.0% or less in area ratio with respect to the surface of the filter medium.   The filter medium according to claim 1, wherein the short fiber layer is manufactured by water punching.   A fuel filter in which the filter medium according to any one of claims 1 to 6 is disposed.

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