JP7031577B2 - 多孔質繊維および吸着カラム - Google Patents
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Description
(1)直径200μm以下の粉粒体を有するものであり、前記直径200μm以下の粉粒体の、前記3次元細孔構造の横断面における面積占有率が3.0%以上である
(2)最表面から深さ方向に1.0μm以内の領域には前記直径200μm以下の粉粒体を含まないものである
(1)直径200μm以下の粉粒体を有するものであり、前記直径200μm以下の粉粒体の、前記3次元細孔構造の横断面における面積占有率が3.0%以上である
(2)最表面から深さ方向に1.0μm以内の領域には前記直径200μm以下の粉粒体を含まないものである。
式1
1次平均細孔半径[nm]=(33.30-0.3181×融点降下量[℃])/融点降下量[℃]
本発明の多孔質繊維は、除去対象物質を吸着するために、細孔の比表面積を大きくすることで、吸着性能をより向上させることができる。そのため、本発明の多孔質繊維において、前記3次元細孔構造における細孔の比表面積が10m2/g以上であることが好ましい。前記細孔の比表面積の下限として、好ましくは10m2/gであり、より好ましくは20m2/g、さらに好ましくは30m2/g、さらにより好ましくは40m2/g、特に好ましくは50m2/gである。一方で、細孔比表面積が大きすぎると多孔質繊維の機械的強度が不足することから、細孔の比表面積の上限としては、好ましくは1000m2/gであり、より好ましくは800m2/g、さらに好ましくは650m2/g、さらにより好ましくは500m2/gである。
まず、多孔質繊維を十分に湿らせた後に液体窒素に浸し、細孔内の水分を液体窒素で瞬間的に凍結させる。その後、速やかに多孔質繊維を折り、多孔質繊維断面を露出させた状態で、0.1torr以下の真空乾燥機内で凍結させた水分を除去して乾燥試料を得る。その後、スパッタリングにより、白金(Pt)や白金-パラジウム(Pt-Pd)などの薄膜を多孔質繊維表面に形成して、観察試料とする。該試料の断面を走査型電子顕微鏡(たとえば株式会社日立ハイテクノロジーズ社製、S-5500)にて観察する。走査型電子顕微鏡(400倍)で任意の繊維断面の電子顕微鏡像を印刷したものの上に透明シートを重ね、黒いペンなどを用いて粉粒体を黒く塗りつぶす。また、定規と黒いペンを用いて、スケールバーも正確に写す。その後、透明シートを白紙にコピーすることにより、粉粒体は黒、非粉粒体部分は白と明確に区別することができる。その後、画像解析ソフトを用いて、粉粒体の面積占有率(%)を求めることができる。画像解析ソフトとしては例えば、「Image J」(開発元Wayne Rasband (NIH))の「Analyze Particles」を用いて計測および粉粒体の総面積を求めることができる。粉粒体が占める面積割合、すなわち面積占有率(%)は、以下式2にて求める。なお、多孔質繊維断面の電子顕微鏡像は任意の多孔質繊維断面を30個撮影し、平均値で算出するものとする。
式2 粉粒体の面積占有率(%)=粉粒体総面積/繊維断面積×100%
また、本発明の多孔質繊維は、最表面から深さ方向に1.0μm以内の領域には前記直径200μm以下の粉粒体を含まないものであることが重要である。
式3 pH変化=pH(4H)-pH(スタート)
本発明の多孔質繊維は、表面開孔率が0.5%以上30.0%以下の範囲内であることが好ましい。多孔質繊維の表面開孔率は0.5%以上であることが好ましく、より好ましくは1.5%以上、特に好ましくは2.0%以上である。開孔率が高くなると、処理液中の除去対象物質が繊維内部の吸着サイトに拡散しやすいため好ましい。一方で、上限としては、30%であることが好ましく、16%であることがより好ましく、12%であることがさらに好ましい。開孔率が30%以下であれば、繊維強度を向上させることができ、また表面粗さの増大を抑制できるため好ましい。また、細孔内部で発生した微粒子が繊維外部へ流出することを抑制しやすくなる。
芯部の原料となるポリマーを適当な溶媒に溶かした後、選定した粉粒体を所定量添加し、芯液を調製する。溶媒はポリマー種類によって異なるが、ジメチルホルムアミド、ジメチルスルホキシド、ヘキサノン、キシレン、テトラリン、シクロヘキサノン、四塩化炭素などが一般的に使用されている。例えばポリマーとしてPMMAを用いる場合は、ジメチルスルホキシド(DMSO)が好ましく採用される。
本発明の吸着カラムは、本発明の多孔質繊維を充填した吸着カラムである。
Vc(cm3)=ケーシング胴部の断面積(cm2)×有効長(cm)
Vf(cm3)=繊維断面積(cm2)×繊維本数×有効長(cm)
充填率=Vf(cm3)/Vc(cm3)×100(%)
なお、ケーシング胴部の断面積については、ケーシングにテーパーがある場合は、ケーシング中央における断面積とする。
1:5hrの連続紡糸を行い、紡糸時の断糸が何ら発生せず、紡糸性が極めて良好である
2:5hrの連続紡糸を行い、紡糸時の断糸が3回よりも多く発生するか、ノズル圧力が20kPa以上となるなど紡糸性が極めて不良である。
本発明の血液浄化システムは、本発明の吸着カラムと除水カラムを連結した血液浄化システムである。
<芯液紡糸原液調製>
まず、21質量%PMMA原液の調製を行った。質量平均分子量が40万のシンジオタクティック-PMMA(syn-PMMA、三菱レイヨン株式会社製、“ダイヤナール”BR-85)を31.7質量部、質量平均分子量が140万のsyn-PMMA(住友化学株式会社製、“スミペックス”AK-150)を31.7質量部、質量平均分子量が50万のアイソタクティック-PMMA(iso-PMMA、東レ株式会社製)を16.7質量部、パラスチレンスルホン酸ソーダを1.5mol%含む分子量30万のPMMA共重合体(東レ株式会社製)20質量部をジメチルスルホキシド(DMSO)376質量部と混合し、110℃で8時間撹拌し紡糸原液を調製した。
質量平均分子量が40万のsyn-PMMAを32.4質量部、質量平均分子量が140万のsyn-PMMAを32.4質量部、質量平均分子量が50万のiso-PMMA16.7質量部をジメチルスルホキシド355質量部と混合し、110℃で8時間撹拌し紡糸原液を調製した。得られた原液の粘度は2650poiseであった。
外径/内径=2.1/1.95mmφの環状スリット型口金を用いた。口金は100℃に加温し、スリット部から鞘液を0.673g/minの割合で、中心部から、芯液を0.735g/minの割合で吐出した。吐出した原液を、空中部分を500mm走行させた後、凝固浴に導いた。凝固浴には水を用いており、水温(凝固浴温度)は42℃であった。糸は、水洗浴にて洗浄し、保湿剤としてグリセリンを70質量%含む水溶液から成る浴槽に導いた後、温度を84℃とした熱処理浴内を通過させて16m/minでカセに巻き取った。
実施例1と同様な原液組成及び口金で紡糸した。その際、口金スリット部から吐出する鞘の吐出量を0g/minとした。
実施例2と同様な原液組成及び口金で紡糸した。その際、口金スリット部から吐出する鞘の吐出量を0g/minとした。
多孔質繊維の代わりに、非多孔質繊維であるナイロンを用いた。
(1)被処理液調製方法
被処理液は、以下のように牛血液を処理して用いた。
実施例1~2、比較例1~2で得られた多孔質繊維及び比較例3のナイロンを長さ8cmの束にカットし、繊維の体積が0.0905cm3となるように、グライナー社製の15mLの遠沈管に入れた。そこへ上記被処理液12mLを入れ、シーソーシェーカー等、本実施例ではTAITEC社製Wave-SIを用いて、目盛り38、角度最大(1.7秒で1往復)と設定し、室温(20~25℃)で1h撹拌した。撹拌後の無機リンの濃度C3(mg/dL)、β2MG濃度C4(mg/mL)を測定するため、各々1.5mlずつサンプリングし、9000rpmで5分間遠心分離し、上澄みを回収した。撹拌前、撹拌後のサンプルは-20℃以下の冷凍庫で保存した。無機リン濃度はオリエンタル酵母工業株式会社の長浜ライフサイエンスラボラトリーに送付し、上澄み中の無機リン濃度を測定した。また、β2MG濃度は株式会社エスアールエルに送付し、ラテックス凝集法で測定し、式4から繊維体積あたりの無機リンの吸着量、式5から繊維表面積あたりのβ2MG吸着量を算出した。
式4 繊維体積あたりの吸着量〔mg/g〕=〔(C1-C2)×0.12(dL)〕/多孔質繊総体積(cm3)
式5 繊維表面積あたりの吸着量(μg/cm2)=(C3-C4)×12/繊維の総表面積(cm2)×1000多孔質繊維
(3)粉粒体溶出量測定
実施例1~2、比較例1~2で得られた多孔質繊維及び比較例3のナイロンを10cm長さにカットし、250本をグライナー社製の50mLの遠沈管に入れ、まず大塚注射用水40mLで5回洗浄し、5回目の洗浄液をサンプルリング、撹拌前とした(N1)。その後、さらに40mLの注射用水を入れ、シーソーシェーカー等、例えばTAITEC社製Wave-SIを用いて、目盛り38、角度最大(1.7秒で1往復)と設定し、室温(20~25℃)で1h撹拌し、撹拌後の溶出液とし(N2)。洗浄液及び溶出液は、微粒子カウンター(RION社製KL-04)を用いて測定し、式6から溶出した粉粒体数を計算した。
式6 溶出した微粒子数=N2―N1
(4)糸径測定
スライドグラスとカバーガラスの間に挟み、Nikon社製V-10を用いて測定した。
示差走査熱量計(DSC)により測定した。
前述のとおりの方法で、電子顕微鏡(SEM)(株式会社日立ハイテクノロジーズ社製、S-5500)により測定し、計算した。
<吸着カラムの作製>
実施例1で得られた多孔質繊維複数本をそれぞれ内径10mm、軸方向長さ17.8mmのポリカーボネート製円筒状ケーシング内に充填した。
実施例2で得られた糸径170μmの糸を長さ17.8mmにカットしたものを実施例3と同様な吸着カラムに合計760本充填し、充填率が22.2%の吸着カラムを得た。得られた吸着カラムについて、下記<吸着カラムのリン吸着性能測定>に基づいて評価を行った。結果を表3に示す。
吸着性能評価として、吸着カラムのリン吸着性能を測定した。上記実施例1~2、比較例1~3の吸着性能評価と同様にしてウシ血漿を得た。該ウシ血漿について、総タンパク量が6.5±0.5g/dLとなるように調整した。尚、ウシ血漿は、採血後5日以内のものを用いた。次に、上記ウシ血漿100mLあたりに、7.85mgのリン酸一水素ナトリウム(Na2HPO4)及び3.45mgのリン酸二水素カリウム(KH2PO4)を溶解し、高リン血症を模倣した被処理液を作成した。
Claims (14)
- 中実形状の繊維により形成された3次元細孔構造を有し、前記3次元細孔構造における平均細孔半径が0.5nm以上100nm以下の範囲内であり、前記3次元細孔構造における細孔が、分子量1000以上の高分子化合物を選択的に吸着するものであり、次の要件をすべて満たす多孔質繊維。
(1)直径200μm以下の粉粒体を有するものであり、前記直径200μm以下の粉粒体の、前記3次元細孔構造の横断面における面積占有率が3.0%以上である
(2)最表面から深さ方向に1.0μm以内の領域には前記直径200μm以下の粉粒体を含まないものである - 表面開孔率が0.5%以上30.0%以下の範囲内である、請求項1に記載の多孔質繊維。
- 前記3次元細孔構造における細孔の比表面積が10m2/g以上である、請求項1または2に記載の多孔質繊維。
- 芯鞘型構造または海島型構造である、請求項1~3のいずれかに記載の多孔質繊維。
- 前記中実形状の繊維の糸径が20μm以上1000μm以下の範囲内である、請求項1~4のいずれかに記載の多孔質繊維。
- 前記粉粒体が、無機粒子である、請求項1~5のいずれかに記載の多孔質繊維。
- 前記粉粒体が、活性炭、カーボンナノチューブ、グラフェン、グラファイトおよび酸化グラフェンからなる群から選択される1種類以上を含む、請求項1~5のいずれかに記載の多孔質繊維。
- 前記粉粒体が、分子量1000未満の低分子化合物を選択的に吸着するものである、請求項1~7のいずれかに記載の多孔質繊維。
- 前記粉粒体が無機粒子であって、かつリン吸着性能を有する、請求項1~8のいずれかに記載の多孔質繊維。
- ポリメチルメタクリレートで構成される、請求項1~9のいずれかに記載の多孔質繊維。
- pH変化が-1以上+1以下である、請求項1~10のいずれかに記載の多孔質繊維。
- 医療用途に用いられる、請求項1~11のいずれかに記載の多孔質繊維。
- 請求項1~12のいずれかに記載の多孔質繊維を充填した吸着カラム。
- 請求項13記載の吸着カラムと除水カラムを連結した血液浄化システム。
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