JPH06205915A - Composite sheet and its production - Google Patents

Composite sheet and its production

Info

Publication number
JPH06205915A
JPH06205915A JP118893A JP118893A JPH06205915A JP H06205915 A JPH06205915 A JP H06205915A JP 118893 A JP118893 A JP 118893A JP 118893 A JP118893 A JP 118893A JP H06205915 A JPH06205915 A JP H06205915A
Authority
JP
Japan
Prior art keywords
fiber
fibers
composite sheet
sheet
heat
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
JP118893A
Other languages
Japanese (ja)
Other versions
JP3331651B2 (en
Inventor
Ryoichi Togashi
良一 富樫
Hiroyasu Kato
博恭 加藤
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toray Industries Inc
Original Assignee
Toray Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Toray Industries Inc filed Critical Toray Industries Inc
Priority to JP00118893A priority Critical patent/JP3331651B2/en
Publication of JPH06205915A publication Critical patent/JPH06205915A/en
Application granted granted Critical
Publication of JP3331651B2 publication Critical patent/JP3331651B2/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Abstract

PURPOSE:To obtain a composite sheet having low pressure loss property, pleated property and dust holding property by integrally laminating a melt blow fiber along the uneven surface of a sheet consisting mainly of an inorganic fiber having thermal adhesive components or tacky adhesive components at least on the surface. CONSTITUTION:A melt blow fiber carried together with heated air is collected by the surface of a sheet consisting mainly of an inorganic fiber having thermal adhesive components or tacky adhesive components at least on the surface. The melt blow fiber is integrally laminated, biting into a space between fiber and fiber, between resin and resin or between fiber and resin to obtain a composite sheet of low pressure loss and long service life. To make adhere to the melt blow fiber to obtain the integrity as a filter medium, resin or fiber of the same system as the melt blow fiber having the melting point >=20 deg.C lower than that of time melt blow fiber is used as the thermal adhesive components. The melt blow fiber is made an electret and to which an adhesive component having tacky adhesive property at room temperature is stuck.

Description

【発明の詳細な説明】Detailed Description of the Invention

【0001】[0001]

【産業上の利用分野】本発明は、無機繊維を主体とする
シートとメルトブロー繊維が積層一体化された複合シー
トに関し、好適には、濾過材料として良好な低圧損性、
プリーツ性およびダストホールディング性を備えた複合
シートおよびその製造方法に関するものである。
BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite sheet in which a sheet mainly composed of inorganic fibers and a melt-blown fiber are laminated and integrated, and preferably has a low pressure loss property as a filtering material,
The present invention relates to a composite sheet having pleating properties and dust holding properties and a method for manufacturing the same.

【0002】[0002]

【従来技術】濾過材料に要求される特性としてフィルタ
ー特性のほかに難燃性、シートを山谷折りするためのプ
リーツ性や濾過圧に耐える剛性が求められる。無機繊維
シートと不織布を組み合わせたシートに関する従来技術
には、例えば特公昭63−22847号や実開昭57−
119720号がある。特公昭63−22847号公報
は、NB95やHEPAクラスの極めて捕集効率の高い
ガラス濾材(捕集効率が,粒子径0.3μmに対して9
5%〜99.97%)とエレクトレット素材を後工程で
積層してプリーツ化したクリーンルーム用の超高性能フ
イルターエレメントに関するもので、クリーンルーム用
の超高性能シートとして用いるため、高い捕集効率の高
性能ガラスシートとエレクトレットシートを併用するこ
とで捕集効率の安定性向上を目的としたものである。ま
た、防炎性について着目した実開昭57−119720
号公報には、ガラスシートや金属ネットとエレクトレッ
トシートを層重して防炎性とする技術が示されている。
いづれの公知例も、2つの素材シートを重ね合わせたも
のであって一体化方法を示唆するものではないが、例え
ば、接着剤を用いて一体化する場合には、加熱状態で加
圧する必要があるのでメルトブロー不織布が潰れ、圧力
損失の上昇や寿命低下などのフィルター特性の低下は避
けられないものであった。また後加工となるのでコスト
アップが避けられないものであった。さらに、実開昭5
7−119720号公報での防炎性を評価した結果、5
0g/m2 目付のガラスシート(アクリルバインダー5
gを含む)と50g/m2 目付のメルトブロー不織布を
エチレン酢酸ビニルアクリレート(EVA)系の低融点
パウダー4g/m2 を用いてシンタリング加工によって
2層を接着したものは、防炎性が得られないことがわか
った。
2. Description of the Related Art In addition to filter characteristics, flame retardancy, pleating characteristics for folding a sheet into ridges and valleys, and rigidity to withstand filtration pressure are required as characteristics required for a filtration material. Prior art relating to a sheet in which an inorganic fiber sheet and a non-woven fabric are combined includes, for example, Japanese Patent Publication No. 63-22847 and Japanese Utility Model Publication No. 57-
There is No. 119720. Japanese Examined Patent Publication No. 63-22847 discloses a glass filter medium of NB95 or HEPA class having extremely high collection efficiency (collection efficiency is 9 μm for a particle size of 0.3 μm).
(5% to 99.97%) and an electret material are laminated in a post process to form a pleated ultra-high performance filter element for a clean room. Since it is used as an ultra-high performance sheet for a clean room, it has a high collection efficiency. It is intended to improve the stability of the collection efficiency by using the performance glass sheet and the electret sheet together. Moreover, the actual exploitation 57-119720 which paid its attention to the flameproof property.
The publication discloses a technique of layering a glass sheet or a metal net and an electret sheet to make them flameproof.
None of the known examples is a stack of two material sheets and does not suggest an integration method. For example, when integrating using an adhesive, it is necessary to apply pressure in a heated state. Therefore, the melt-blown nonwoven fabric is crushed, and it is inevitable that the filter characteristics are deteriorated such as an increase in pressure loss and a decrease in life. Further, since it is post-processing, cost increase is inevitable. In addition, the actual Kaisho 5
As a result of evaluating the flameproof property in JP-A 7-119720, 5
Glass sheet with 2 g / m 2 (Acrylic binder 5
g)) and a melt blown nonwoven fabric with a basis weight of 50 g / m 2 using ethylene vinyl acetate acrylate (EVA) low melting point powder 4 g / m 2 by a sintering process to bond two layers to each other I knew I couldn't.

【0003】また特開昭62−289661号では、多
列に並べたメルトブロー口金を用いて繊度の違う繊維を
順次紡糸して捕集/積層して複合化する技術が示されて
いるが、無機繊維を含まない有機繊維100%、しかも
メルトブロー繊維と捕集面の繊維組成を同一に組み合わ
せることによる一体化の構成要件となっている。しかし
ながらこの方法においては、メルトブローが繊維同士を
組合わせて用いるため、メルトブロー繊維はもともと強
度が弱く、破損が生じたり、プリーツに必要な高い剛性
と賦形性が得られないなどの実用上の問題があった。
Further, Japanese Patent Application Laid-Open No. 62-289661 discloses a technique in which fibers having different fineness are sequentially spun and collected / laminated to form a composite by using melt-blow nozzles arranged in multiple rows. It is a constituent element of integration by combining 100% of organic fibers containing no fiber and the same composition of the melt blown fiber and the collecting surface. However, in this method, since the melt-blown fibers are used in combination with each other, the melt-blown fibers are originally weak in strength, breakage occurs, and practical problems such as high rigidity and shapeability required for pleats cannot be obtained. was there.

【0004】このように従来技術には、メルトブロー不
織布の製造において、低圧損性、プリーツ加工性(剛
性)、難燃性を十分に満たす複合シートが求められてい
た。
As described above, in the prior art, there has been a demand for a composite sheet which sufficiently satisfies the low pressure loss property, the pleating processability (rigidity) and the flame retardancy in the production of the melt blown nonwoven fabric.

【0005】[0005]

【発明が解決しようとする課題】本発明の目的は、上述
したような点に鑑み、寿命、低圧損性、プリーツ加工性
(剛性)、難燃性に優れたシートを低コストで提供せん
とするものである。
In view of the above points, an object of the present invention is to provide a sheet excellent in life, low pressure loss property, pleating workability (rigidity) and flame retardancy at low cost. To do.

【0006】[0006]

【課題を解決するための手段】本発明は、次の構成を有
する。すなわち、熱接着性成分または粘着性成分を少な
くとも表面に有する無機繊維を主体とするシート表面の
凹凸に実質的に添うように、メルトブロー繊維が積層一
体化されてなることを特徴とする複合シートである。ま
た、加熱空気とともに搬送されるメルトブロー繊維を、
熱接着性成分または粘着性成分を少なくとも表面に有す
る無機繊維を主体とするシート表面で捕集して一体化す
ることを特徴とする複合シートの製造方法である。
The present invention has the following configuration. That is, in a composite sheet characterized in that the melt-blown fibers are laminated and integrated so as to substantially conform to the irregularities of the sheet surface mainly composed of inorganic fibers having at least the surface of the heat-adhesive component or the tacky component. is there. In addition, the melt blown fiber conveyed with heated air,
A method for producing a composite sheet, comprising collecting and integrating a sheet mainly composed of inorganic fibers having at least a heat-adhesive component or a tacky component on the surface thereof.

【0007】以下に詳細を説明する。The details will be described below.

【0008】本発明においては、無機繊維を主体とする
シートとメルトブロー不織布との積層一体化を図るため
鋭意研究を重ねた結果、無機繊維を主体とするシート表
面に、熱接着性または粘着性を示す部分を形成し、嵩高
な構造のものにすることが最適であることを見出だし
た。さらには、熱接着性または粘着性を示す樹脂および
/または繊維を少なくとも表面に有する無機繊維を主体
とするシート表面で、メルトブロー繊維を捕集する方法
を見い出した。この場合の捕集とは、流体で搬送される
メルトブロー繊維を、嵩高で通気性を有する無機繊維を
主体とするシート表面で流体と該メルトブロー繊維を分
離・濾過して、無機繊維を主体とするシート表面に積層
することを意味する。また、本発明において流体として
は、加熱空気が用いられる。加熱空気の温度としては、
特に限定されるものではないが、メルトブロー繊維を捕
集する面における温度を、メルトブロー繊維素材の融点
の−120℃以上、+50℃以下とすることが好まし
い。。この方法を用いることにより、得られる複合シー
トは、熱接着性または粘着性を有する無機繊維を主体と
するシート表面の繊維および/または樹脂に、メルトブ
ロー繊維が軟着または固着あるいは接着し、無機繊維を
主体とするシート表面の凹凸に実質的に添うように、メ
ルトブロー繊維が積層一体化されたものである。また、
シート表面の凹凸とは、シート表面の繊維または樹脂に
よって形成される凹凸であり、メルトブロー繊維は、繊
維と繊維の間の空間や樹脂と樹脂の間の空間あるいは繊
維と樹脂の間の空間にメルトブロー繊維がやや食い込ん
で積層され、メルトブロー繊維の少なくとも一部の繊維
が熱接着性成分または粘着性成分によって一体化してい
るものである。このため、得られた複合シートは、嵩高
性に優れ、ソフトに積層一体化されているため、従来か
ら知られている積層接着方法、すなわち低融点接着剤を
介して2つのシートを加熱ゾーンで加圧して一体化した
従来加工品にくらべ、特に低圧力損失で長寿命な複合シ
ートが得られるといった特徴を有している。
[0008] In the present invention, as a result of intensive studies for the purpose of laminating and integrating a sheet mainly composed of inorganic fibers and a melt blown nonwoven fabric, as a result, the surface of the sheet mainly composed of inorganic fibers is provided with thermal adhesiveness or tackiness. It has been found that it is optimal to form the part shown and to have a bulky structure. Further, they have found a method of collecting meltblown fibers on the surface of a sheet mainly composed of inorganic fibers having at least a resin and / or fibers exhibiting thermal adhesiveness or tackiness on the surface. The collection in this case means that the melt-blown fibers carried by the fluid are separated from the fluid and the melt-blown fibers on the surface of the sheet mainly composed of bulky and air-permeable inorganic fibers and filtered to mainly contain the inorganic fibers. It means to be laminated on the surface of the sheet. Further, in the present invention, heated air is used as the fluid. As the temperature of the heated air,
Although not particularly limited, it is preferable that the temperature at the surface for collecting the meltblown fibers is −120 ° C. or more and + 50 ° C. or less of the melting point of the meltblown fiber material. . By using this method, the resulting composite sheet has a structure in which the meltblown fibers are softly adhered, fixed or adhered to the fibers and / or the resin on the surface of the sheet, which is mainly composed of the inorganic fibers having thermal adhesiveness or tackiness, and the inorganic fibers are The melt-blown fibers are laminated and integrated so as to substantially conform to the unevenness of the sheet surface mainly composed of. Also,
The unevenness of the sheet surface is the unevenness formed by the fiber or resin on the sheet surface, and the melt blown fiber is melt blown into the space between the fibers, the space between the resins or the resin or the space between the fibers. The fibers are slightly bitten and laminated, and at least a part of the fibers of the meltblown fibers are integrated by a heat-adhesive component or a tacky component. For this reason, the obtained composite sheet has excellent bulkiness and is softly laminated and integrated. Therefore, two sheets are laminated in a heating zone through a conventionally known lamination adhesion method, that is, a low melting point adhesive. Compared to the conventional processed product that is pressed and integrated, it has a feature that a composite sheet with low pressure loss and long life can be obtained.

【0009】熱接着性成分または粘着性成分を少なくと
も表面に有する無機繊維を主体とするシートの形態は、 熱接着性または粘着性を示す樹脂を無機繊維シートの
少なくとも表面に形成したもの。この場合の樹脂の付着
形態は、樹脂パウダーや樹脂の繊維を表面付着させたも
のと、無機繊維が樹脂によってバインダーされたもので
ある。
The form of the sheet mainly composed of inorganic fibers having a heat-adhesive component or a tacky component on at least the surface is a resin having a heat-adhesive or tacky property formed on at least the surface of the inorganic fiber sheet. In this case, the resin is adhered in a form in which resin powder or resin fibers are adhered to the surface or in which inorganic fibers are bound by the resin.

【0010】熱接着性を示す繊維を無機繊維に混合し
てシート化したもの。この場合の繊維の付着形態は、無
機繊維に繊維を混合して別のバインダー樹脂で一体化し
た1層構造のものと熱接着性繊維のリッチ層を形成した
2層構造のものがある。
A sheet prepared by mixing fibers having thermal adhesiveness with inorganic fibers. In this case, the form of adhesion of the fibers includes a one-layer structure in which the fibers are mixed with the inorganic fibers and integrated with another binder resin, and a two-layer structure in which a rich layer of heat-adhesive fibers is formed.

【0011】熱接着性を示す樹脂と熱接着性を示す繊
維を少なくとも表面に形成したもの。 熱接着性を示す繊維シートを無機素材シート表面層に
一体化したもの。
A resin having heat-bonding properties and fibers having heat-bonding properties formed on at least the surface. A fiber sheet with thermal adhesiveness is integrated with the surface layer of the inorganic material sheet.

【0012】が挙げられる。なお、無機繊維を主体とす
る繊維シートは、長繊維でも短繊維でもよいが、好適に
は短繊維のガラス繊維が本発明に適し、抄紙法で作成さ
れたガラス繊維シートが好ましいものである。
[0012] The following is mentioned. The fiber sheet mainly composed of inorganic fibers may be long fibers or short fibers, but short glass fibers are suitable for the present invention, and a glass fiber sheet prepared by a papermaking method is preferable.

【0013】本発明の熱接着性成分とは、加熱空気とと
もに高温でメルトブローされた冷却過程にある繊維の捕
集において、まだ熱い状態の繊維を捕集した時、メルト
ブロー繊維と接着性、固着性が得られ、濾材としての一
体性が得られるものである。具体的には、メルトブロー
繊維がオレフイン系の場合には、オレフィン系またはオ
レフィン系共重合体であり、また、ポリエステル系の場
合には、ポリエステル系またはポリエステル系共重合体
などの同一系統の樹脂または繊維が最適に用いられる。
特に樹脂の場合には、メルトブロー不織布の融点より2
0℃以上低く、かつ融点が70℃以上のEVA樹脂、ポ
リアミド系樹脂、ポリウレタン系樹脂が無機繊維及びポ
リプロピレンメルトブロー不織布との接着性も高く優れ
ている。また熱接着性成分が繊維の場合には、例えば1
成分系の化学合成繊維や低融点化した2成分系の化学合
成繊維などが用いられ、1成分系の場合、例えば、ポリ
エステル繊維、ポリアミド繊維、ポリプロピレン繊維、
ポリエチレン繊維などが用いられ、低融点化した2成分
系の場合、ポリプロピレンとポリエチレンの共重合体ポ
リマーなどが用いられる。いずれの場合もメルトブロー
繊維の融点より20℃以上低い融点のものが接着性が高
くなるので好適である。この場合の繊維とは繊維状と言
う意味でフィブリル化したパルプ状態のもの、チョップ
やステープル、フィラメントなどが該当するものであ
る。またいずれの場合も極細繊維が好適である。この場
合、無機繊維との接着は、別のバインダー樹脂で接着し
ても良いし、繊維を溶融させて無機繊維に接着させた形
で一体性を達成したものであっても良い。また繊維とし
て繊維断面の外周部を構成する成分の一部のポリマーの
融点がメルトブロー不織布の融点より20℃以上低い熱
接着性複合短繊維を用いるのが最適である。メルトブロ
ー繊維にポリプロピレンを用いた場合、芯が、特に無機
繊維との接着性にも優れる、ポリプロピレンやポリエス
テルで、鞘の少なくとも一部がポリエチレンやその共重
合体であるオレフイン系熱接着性短繊維が無機繊維との
接着性が特に良好であるこから好ましい。
The thermoadhesive component of the present invention means the adhesiveness and the adhesiveness to the meltblown fibers when the fibers which are still hot are collected in the process of collecting the fibers which are melt-blown at high temperature with heated air in the cooling process. Is obtained, and the integrity as a filter medium is obtained. Specifically, when the meltblown fibers are olefin-based, they are olefin-based or olefin-based copolymers, and when they are polyester-based, resins of the same system such as polyester-based or polyester-based copolymers or Fiber is optimally used.
Especially in the case of resin, the melting point of the melt blown nonwoven fabric is 2
EVA resins, polyamide resins, and polyurethane resins having a melting point of 70 ° C. or higher and a low melting point of 0 ° C. or higher are excellent in adhesiveness to inorganic fibers and polypropylene meltblown nonwoven fabric. When the heat-adhesive component is fiber, for example, 1
For example, polyester fibers, polyamide fibers, polypropylene fibers, etc. are used in the case of a one-component system, such as a component-system chemically synthesized fiber or a low melting point two-component system chemically synthesized fiber.
In the case of a two-component system having a low melting point such as polyethylene fiber, a copolymer polymer of polypropylene and polyethylene is used. In any case, a material having a melting point lower than the melting point of the melt-blown fiber by 20 ° C. or more is preferable because the adhesiveness becomes high. The fiber in this case means a fibrous pulp in a fibrous form, and a chop, a staple, a filament, or the like. In any case, ultrafine fibers are suitable. In this case, the inorganic fibers may be bonded with another binder resin, or the fibers may be melted and bonded to the inorganic fibers to achieve the integrity. Further, it is optimal to use, as the fiber, a heat-adhesive conjugate short fiber in which the melting point of a part of the polymer constituting the outer peripheral portion of the fiber cross section is 20 ° C. or more lower than the melting point of the meltblown nonwoven fabric. When polypropylene is used as the meltblown fiber, the core is polypropylene or polyester, which is also excellent in adhesiveness with inorganic fibers, and at least part of the sheath is olefin-based heat-adhesive short fibers which is polyethylene or a copolymer thereof. It is preferable because the adhesiveness with the inorganic fiber is particularly good.

【0014】また粘着性成分とは、常温でメルトブロー
繊維に対して粘着性を有する樹脂で通常の粘着剤をスプ
レー法などで、無機繊維を主体とするシートの表面に付
着させたものが好ましく用いられる。
The adhesive component is preferably a resin which is adhesive to the meltblown fibers at room temperature, and which is prepared by applying an ordinary adhesive to the surface of a sheet mainly composed of inorganic fibers by a spray method or the like. To be

【0015】接着性成分または粘着性成分である樹脂お
よび/または繊維の使用量は、多量に用いた方がメルト
ブロー繊維との一体性が強化されるので好ましいが、難
燃性が得られにくくなる傾向がある。このため、難燃性
を満足させるため、可燃性成分の使用量の適正化または
難燃剤の混合量を適宜選択することにより、LOI値を
26以上とすることが好ましい。なお、LOI値の測定
方法は、JIS−K7201−1976に従って求める
ものである。
It is preferable to use a large amount of the resin and / or the fiber as the adhesive component or the tacky component because the integrity with the meltblown fiber is enhanced, but the flame retardancy becomes difficult to obtain. Tend. Therefore, in order to satisfy the flame retardancy, it is preferable to set the LOI value to 26 or more by optimizing the usage amount of the flammable component or appropriately selecting the mixing amount of the flame retardant. The LOI value is measured according to JIS-K7201-1976.

【0016】無機繊維を主体とするシートの構成は、空
調用シートとしては無機繊維の平均繊維径が2ミクロン
以上、気孔容積率が86%以上の比較的嵩高なシート構
造が、メルトブロー繊維の食い込みが良く一体性に優れ
たものが得られ、好ましい。本発明における積層一体化
のプロセスは、加熱状態にあるメルトブロー繊維を、無
機繊維を主体とするシート面に強く吹き付けることによ
って、メルトブロー繊維を固着、接着、粘着させ、また
極一部の繊維は、繊維に絡ませて積層一体化するもので
ある。この積層一体化方法は一般にメルトブロー法と呼
ばれる方法であり、加熱状態にある極細繊維や十分微細
化に至らなかった極太繊維が、加熱空気とともの捕集面
に吹き付けられることで、捕集面の熱接着成分または粘
着性成分に接着、固着、粘着、粘着し、同時に凹部分に
食い込み積層一体化するので、シート表面の凹凸に添っ
て一体化されるため高い積層一体性が得られる。さらに
従来技術のように後工程加熱ロールや加熱ベルトの間に
2枚のシートを挾んで接着するものではないので、変形
や潰れが生じないので嵩高な状態で積層一体化が可能で
あるので、特に低圧損で寿命の長い濾材を得ることが可
能である。特に強固な一体性を必要とする場合は、熱接
着性成分の融点以上、メルトブロー繊維の融点以下で熱
処理(場合により押圧も含むものである)することが好
ましい。熱処理には、熱炉や、加熱ベルト、加熱ロール
(ロールは表面状態が平滑ロールやエンボスロールの類
い)などが使用できる。また、無機繊維を主体とするシ
ートを予め加熱した状態でメルトブロー繊維を捕集する
ことで更に一体性を向上させることも可能である。
The sheet composed mainly of inorganic fibers has a relatively bulky sheet structure in which the average fiber diameter of the inorganic fibers is 2 microns or more and the pore volume ratio is 86% or more as an air-conditioning sheet. It is preferable because a product having good and excellent integration can be obtained. The process of lamination integration in the present invention, the melt-blown fibers in a heated state, by strongly blowing to the sheet surface mainly inorganic fibers, the melt-blown fibers are fixed, adhered, sticky, and a very small part of the fibers, It is entangled with fibers to be laminated and integrated. This lamination integration method is generally called a melt blow method, and ultrafine fibers in a heated state or very thick fibers that have not been sufficiently miniaturized are blown onto the collection surface together with heated air, thereby collecting the surface. Since it adheres to, adheres to, sticks to, or adheres to the heat-adhesive component or the tacky component and simultaneously bites into the concave portion to form a laminated body, it is integrated according to the unevenness of the sheet surface, so that a high degree of laminated body integration can be obtained. Further, unlike the prior art, since two sheets are not sandwiched and bonded between the heating rolls and heating belts in the post-process, deformation and crushing do not occur, so that it is possible to stack and integrate them in a bulky state. In particular, it is possible to obtain a filter medium with a low pressure loss and a long life. When particularly strong integrity is required, it is preferable to perform heat treatment (including pressing in some cases) at a temperature not lower than the melting point of the heat-adhesive component and not higher than the melting point of the meltblown fiber. For the heat treatment, a heating furnace, a heating belt, a heating roll (a roll has a smooth surface state or a kind of embossing roll) and the like can be used. It is also possible to further improve the integrity by collecting the meltblown fibers in a state where a sheet mainly composed of inorganic fibers is preheated.

【0017】メルトブロー繊維の繊度が5デニール以上
の場合には、無機繊維を主体とするシートの凹凸に添う
能力が落ちる傾向があるので、より細繊度のものが好ま
しく、3デニール以下のものが好ましい。
When the melt-blown fiber has a fineness of 5 denier or more, the ability to conform to the irregularities of the sheet mainly composed of inorganic fibers tends to deteriorate, so that a finer fineness is preferable, and a fineness of 3 denier or less is preferable. .

【0018】メルトブロー繊維に他の素材を混ぜて搬送
捕集を行った複合シートも本発明では実施可能である。
この方法により、混入した素材の機能が加味されるので
シートの高性能化を達成できる。例えば熱接着性繊維あ
るいは低融点パウダーを混入して捕集した場合は、無機
繊維を主体とする接着性素材とより強固に接着するので
複合一体性に優れた複合シートが嵩高で低圧損で得られ
る。またエレクトレット繊維、活性炭繊維、抗菌繊維な
どを混ぜて機能を付与したものも好ましい。
A composite sheet obtained by mixing the meltblown fiber with another material and carrying and collecting the same can also be used in the present invention.
By this method, the function of the mixed material is added, so that high performance of the sheet can be achieved. For example, when heat-adhesive fibers or low-melting-point powder is mixed and collected, it will adhere more strongly to the adhesive material consisting mainly of inorganic fibers, so a composite sheet with excellent composite integrity can be obtained with high bulk and low pressure loss. To be It is also preferable to add a function by mixing electret fiber, activated carbon fiber, antibacterial fiber and the like.

【0019】また、エレクトレット化の可能なメルトブ
ロー繊維、例えばポリプロピレンやポリカーボネート繊
維を電界強度1kv/cm以上の電場内で捕集した場合
は、エレクトレット化複合シートとなるので、高捕集性
の濾材となる。
When a meltblown fiber that can be electretized, such as polypropylene or polycarbonate fiber, is collected in an electric field having an electric field strength of 1 kv / cm or more, it becomes an electretized composite sheet, and therefore a filter material having a high collecting property. Become.

【0020】また、電場内で捕集一体化した複合シート
は、静電気効果によって無機繊維を主体とするシートに
メルトブロー繊維が密着するのでさらに接着性が高まり
複合一体性に優れたシートを得られ好ましい。エレクト
レット化の工程は、複合シートになった後でもかまわな
い。
Further, the composite sheet collected and integrated in the electric field is preferable because the melt-blown fiber adheres to the sheet mainly composed of the inorganic fiber due to the electrostatic effect so that the adhesiveness is further increased and a sheet having excellent composite integrity is obtained. . The electretization process may be performed after the composite sheet is formed.

【0021】本発明によって得られた複合シートは、濾
材として広く使用でき、空気フィルター、液体フィルタ
ーなどに特に好適である。また、断熱材や、結露遮断
材、遮音材、遮水材などに好適に用いられる。
The composite sheet obtained by the present invention can be widely used as a filter medium, and is particularly suitable for air filters, liquid filters and the like. Further, it is preferably used as a heat insulating material, a dew condensation blocking material, a sound insulating material, a water blocking material, and the like.

【0022】[0022]

【実施例】実施例をもって更に詳細に本発明を説明す
る。
The present invention will be described in more detail with reference to Examples.

【0023】実施例1 ポリプロピレン繊維(0.5デニール、繊維長5mm)
を3重量%含む無機繊維を主体とするシート(ガラス繊
維;平均直径7μm,厚さ0.7mm、目付60g/m
2 、圧力損失0.2mmAq)表面にポリプロピレンを
メルトブロー紡糸(ポリマー吐出温度300℃、加熱空
気温度320℃、捕集面温度130℃)して平均繊維直
径2.5μm、目付7g/m2 のメルトブロー不織布を
捕集して一体化した複合シートを得た。得られた複合シ
ートは、SEM写真および光学顕微鏡でシート断面を観
察したところ、メルトブロー繊維とポリプロピレン短繊
維が固着した部分と接着した部分とさらの繊維間の凹部
にメルトブロー繊維が食い込んでいた。複合シートを折
りピッチ3mmでユニット化したが、ピッチの不揃いも
なくきれいなユニットが得られた。この複合シートの圧
力損失は1mmAqであった。
Example 1 Polypropylene fiber (0.5 denier, fiber length 5 mm)
A sheet mainly made of inorganic fiber containing 3% by weight (glass fiber; average diameter 7 μm, thickness 0.7 mm, basis weight 60 g / m 2
2 , pressure loss 0.2mmAq) polypropylene melt-spun on the surface (polymer discharge temperature 300 ° C, heated air temperature 320 ° C, collection surface temperature 130 ° C) and melt blown with average fiber diameter 2.5μm and basis weight 7g / m 2 . A non-woven fabric was collected to obtain an integrated composite sheet. When the cross section of the obtained composite sheet was observed with an SEM photograph and an optical microscope, it was found that the meltblown fibers had penetrated into the concave portions between the portions where the meltblown fibers and polypropylene short fibers were fixed, the portions where they were bonded, and the further fibers. The composite sheet was unitized with a folding pitch of 3 mm, but a clean unit was obtained without uneven pitch. The pressure loss of this composite sheet was 1 mmAq.

【0024】実施例2 熱接着性複合短繊維(チッソポリプロ(株);商品名E
SGB=2デニール、繊維長5mm、LOI値27)1
0重量%とガラス繊維(平均直径7μm)をメチル・エ
チルアクリレートバインダーで一体化した目付75g/
2 (捕集効率11%、厚さ0.45mm、剛軟度30
0mg、圧力損失0.3mmAq)の無機繊維を主体と
するシート表面にポリプロピレンをメルトブロー紡糸し
て平均繊維直径1.5μm、目付10g/m2 のメルト
ブロー不織布を捕集して一体化し、複合シート(捕集効
率25%、圧力損失2.0mmAq)を得た。複合シー
トを折りピッチ3mmでユニット化したが、ピッチの不
揃いもなくきれいなユニットが得られた。難燃性をJI
S−L−1091A−1法で評価したが区分3の満足す
る結果が得られた。
Example 2 Heat-adhesive composite short fibers (Chisso Polypro Co., Ltd .; trade name E)
SGB = 2 denier, fiber length 5 mm, LOI value 27) 1
75 wt / g of 0 wt% and glass fiber (average diameter 7 μm) integrated with methyl-ethyl acrylate binder
m 2 (collection efficiency 11%, thickness 0.45 mm, bending resistance 30
Polypropylene is melt-blown on a sheet surface mainly composed of inorganic fibers of 0 mg and a pressure loss of 0.3 mmAq) to collect and integrate a melt-blown nonwoven fabric having an average fiber diameter of 1.5 μm and a basis weight of 10 g / m 2 to form a composite sheet ( A collection efficiency of 25% and a pressure loss of 2.0 mmAq) were obtained. The composite sheet was unitized with a folding pitch of 3 mm, but a clean unit was obtained without uneven pitch. Flame retardancy is JI
Evaluation was made by the SL-1091A-1 method, but satisfactory results for Category 3 were obtained.

【0025】実施例3 実施例2の複合シートを、直流電界強度7kv/cmの
電場内で、メルトブロー不織布側をアース極に接地した
状態でエレクトレット化した。この結果、捕集効率を9
0%まで向上させることができた。
Example 3 The composite sheet of Example 2 was electretized in an electric field having a DC electric field strength of 7 kv / cm while the meltblown nonwoven fabric side was grounded to a ground electrode. As a result, the collection efficiency is 9
It was possible to improve it to 0%.

【0026】実施例4 融点80℃の水系EVA樹脂4重量%が接着された硝子
繊維を主体とするシート(ガラス繊維=平均繊維直径4
μm、捕集効率32%、厚さ0.45mm、剛軟度25
0mg、圧力損失0.7mmAq)に平均繊維直径1.
5μmのポリプロピレンをメルトブロー紡糸して、目付
10g/m2 のメルトブロ−不織布を一体化した複合シ
ートを得た。複合シートを折りピッチ3mmでユニット
化したが、ピッチの不揃いもなくきれいなユニットが得
られた。
Example 4 A sheet composed mainly of glass fibers to which 4% by weight of a water-based EVA resin having a melting point of 80 ° C. was adhered (glass fiber = average fiber diameter 4
μm, collection efficiency 32%, thickness 0.45 mm, bending resistance 25
0 mg, pressure loss 0.7 mmAq) with an average fiber diameter of 1.
5 μm polypropylene was melt-blow spun to obtain a composite sheet in which a unit weight of 10 g / m 2 of melt-blown nonwoven fabric was integrated. The composite sheet was unitized with a folding pitch of 3 mm, but a clean unit was obtained without uneven pitch.

【0027】実施例5 融点80℃の水系EVA樹脂8重量%にブロム系難燃剤
を10%混合した樹脂で接着された無機繊維を主体とす
るシート(無機繊維=ガラス平均直径7μm、捕集効率
22%、厚さ0.45mm、剛軟度250mg、圧力損
失0.4mmAq、LOI値30)に平均繊維直径1.
0μmのポリプロピレンをメルトブロー紡糸して、目付
30g/m2 メルトブロー不織布を一体化した複合シー
トを得た。難燃性をJIS−L−1091A−1法で評
価したが区分3の満足する結果が得られた。
Example 5 A sheet composed mainly of inorganic fibers bonded with a resin obtained by mixing 10% of a bromine flame retardant with 8% by weight of a water-based EVA resin having a melting point of 80 ° C. (inorganic fiber = glass average diameter 7 μm, collection efficiency) 22%, thickness 0.45 mm, bending resistance 250 mg, pressure loss 0.4 mmAq, LOI value 30) and average fiber diameter 1.
Melt-blowing was performed on 0 μm polypropylene to obtain a composite sheet in which a basis weight of 30 g / m 2 melt-blown nonwoven fabric was integrated. The flame retardancy was evaluated by the JIS-L-1091A-1 method, but a satisfactory result in Category 3 was obtained.

【0028】実施例6 ガラス繊維シート(ガラス平均直径7μm、捕集効率1
8%、厚さ0.5mm、圧力損失0.2mmAq)の表
面に融点83℃のEVAパウダー樹脂4g/m2 を接着
させた無機繊維を主体とするシートに平均繊維直径1.
μmのポリプロピレンをメルトブロー紡糸して、目付6
g/m2 のメルトブロー不織布を一体化した複合シート
を得た。さらにこの複合シートをプリーツした状態で9
0℃の熱炉に放置し接着強度に優れた複合シートを得
た。この複合シートを折りピッチ2.5mmでユニット
化したが、低圧力損失に優れたユニットが得られた。
Example 6 Glass fiber sheet (glass average diameter 7 μm, collection efficiency 1
8%, thickness 0.5 mm, pressure loss 0.2 mmAq) surface-bonded EVA powder resin 4 g / m 2 having a melting point of 83 ° C. to a sheet mainly composed of inorganic fibers and having an average fiber diameter of 1.
Melt-blow spinning of polypropylene of μm, weight 6
A composite sheet in which a melt blown nonwoven fabric of g / m 2 was integrated was obtained. 9 in the pleated state of this composite sheet
It was left in a heating furnace at 0 ° C. to obtain a composite sheet having excellent adhesive strength. This composite sheet was unitized with a folding pitch of 2.5 mm, but a unit excellent in low pressure loss was obtained.

【0029】実施例7 融点80℃の水系EVA樹脂8重量%にブロム系難燃剤
を10重量%混合した樹脂で接着された無機繊維を主体
とするシート(無機繊維=ガラス平均直径7μm、捕集
効率22%、厚さ0.45mm、剛軟度250mg、圧
力損失0.4mmAq、LOI値30)に平均繊維直径
1.0μmのポリプロピレンをメルトブロー紡糸して、
目付30g/m2 メルトブロー不織布を捕集する際に、
電界強度8kv/cmの直流電場内で実施しエレクトレ
ット化した複合シートを得た。このものの捕集効率は、
99%で高性能濾材が得られた。
Example 7 A sheet mainly composed of inorganic fibers bonded with a resin obtained by mixing 10% by weight of a bromine-based flame retardant with 8% by weight of a water-based EVA resin having a melting point of 80 ° C. (inorganic fiber = glass average diameter 7 μm, collection Melt blow-spun polypropylene with an average fiber diameter of 1.0 μm to an efficiency of 22%, a thickness of 0.45 mm, a bending resistance of 250 mg, a pressure loss of 0.4 mmAq, and an LOI value of 30).
When collecting a melt-blown nonwoven fabric with a basis weight of 30 g / m 2 ,
This was carried out in a DC electric field having an electric field strength of 8 kv / cm to obtain an electretized composite sheet. The collection efficiency of this thing is
A high performance filter material was obtained at 99%.

【0030】実施例8 ポリエチレンパルプ(三井石油化学(株)の商品名“S
WP”ULタイプ、融点125℃)を1.5重量%含む
無機繊維を主体とするシート(ガラス繊維;平均直径7
μm,厚さ0.7mm、目付60g/m2 、圧力損失
0.2mmAq)を得た。この無機繊維を主体とするシ
ートにポリプロピレンをメルトブロー紡糸して平均繊維
直径2.5μm、目付7g/m2 のメルトブロー不織布
を捕集して一体化した複合シートを得た。得られた複合
シートは、SEM写真及び光学顕微鏡でシート断面を観
察したところ、メルトブロー繊維とポリエチレンパルプ
が固着した部分と接着した部分があった。
Example 8 Polyethylene pulp (trade name "S" of Mitsui Petrochemical Co., Ltd.)
WP "UL type, melting point of 125 ° C), a sheet mainly made of inorganic fiber containing 1.5% by weight (glass fiber; average diameter 7)
μm, thickness 0.7 mm, basis weight 60 g / m 2 , pressure loss 0.2 mmAq). Polypropylene was melt-blow spun on this inorganic fiber-based sheet to collect a melt-blown nonwoven fabric having an average fiber diameter of 2.5 μm and a basis weight of 7 g / m 2 to obtain an integrated composite sheet. When the cross section of the obtained composite sheet was observed with an SEM photograph and an optical microscope, there were a portion where the melt blown fiber and polyethylene pulp were fixed and a portion where they were adhered.

【0031】実施例9 ガラス繊維シート(ガラス平均直径7μm、捕集効率1
8%、厚さ0.5mm、圧力損失0.2mmAq)の表
面に天然ゴム10重量%、アクリルゴム90重量%が配
合されてなる粘着剤を5g/m2 の割合で接着させた無
機繊維を主体とするシートに、平均繊維直径1.0μm
のポリプロピレンをメルトブロー紡糸して、目付6g/
2 のメルトブロー不織布を一体化した複合シートを得
た。この複合シートをプリーツした後、実質的にセパレ
ーターの機能を持つEVAを間欠的に筋状に塗布し、ミ
ニプリーツユニットを作成した。実用条件での試験を行
ったが問題がなかった。
Example 9 Glass fiber sheet (glass average diameter 7 μm, collection efficiency 1
8%, thickness of 0.5 mm, pressure loss of 0.2 mmAq) on the surface of which an adhesive made of 10% by weight of natural rubber and 90% by weight of acrylic rubber is adhered at a rate of 5 g / m 2 to form an inorganic fiber. Main sheet has an average fiber diameter of 1.0 μm
Melt-blow spinning polypropylene of 6g /
A composite sheet in which the melt blown nonwoven fabric of m 2 was integrated was obtained. After pleating this composite sheet, EVA having substantially the function of a separator was intermittently applied in a streak pattern to prepare a mini pleated unit. The test was conducted under practical conditions, but there was no problem.

【0032】比較例1 実施例1で用いたメルトブロー不織布と無機繊維シート
(ガラス繊維;平均直径7μm,厚さ0.7mm、目付
58g/m2 、圧力損失0.2mmAq)をEVA性の
低融点パウダー4g/m2 を用いて、加熱ロールで弱く
加圧して接着した。この複合シートの圧力損失は1.5
mmAqであった。
Comparative Example 1 The melt-blown non-woven fabric and the inorganic fiber sheet (glass fiber; average diameter 7 μm, thickness 0.7 mm, basis weight 58 g / m 2 , pressure loss 0.2 mmAq) used in Example 1 were EVA low melting point. The powder 4 g / m 2 was used and bonded by applying a weak pressure with a heating roll. The pressure loss of this composite sheet is 1.5
It was mmAq.

【0033】比較例2 熱接着性複合短繊維(チッソポリプロ(株);商品名イ
ンタック=2デニール、繊維長5mm)を0.5重量%
含む無機繊維を主体とするシート(目付65g/m2
ガラス繊維平均直径3μm、捕集効率30%、厚さ0.
45mm、剛軟度350mg)にエレクトレット化メル
トブロー不織布(平均繊維直径1.5μm、捕集効率8
5%、厚さ0.15mm、目付10g/m2 )を積層し
た状態で、120℃に加熱された熱カレンダーを用いて
加圧し、一体化したが十分な一体性が得られなかった。
Comparative Example 2 0.5% by weight of heat-adhesive composite short fibers (Chisso Polypro Co., Ltd .; trade name: Intac = 2 denier, fiber length 5 mm)
A sheet mainly composed of inorganic fibers (65 g / m 2 , basis weight,
Glass fiber average diameter 3 μm, collection efficiency 30%, thickness 0.
45 mm, bending resistance 350 mg) electretized melt blown nonwoven fabric (average fiber diameter 1.5 μm, collection efficiency 8)
5%, thickness 0.15 mm, and basis weight 10 g / m 2 ) were laminated in a laminated state by pressurizing using a thermal calender heated to 120 ° C. However, sufficient integrity was not obtained.

【0034】比較例3 アクリル樹脂4重量%で接着された無機繊維を主体とす
るシート(無機繊維=ガラス平均直径4μm、捕集効率
32%、厚さ0.45mm、剛軟度250mg、圧力損
失0.7mmAq)に平均繊維直径1.5μmのポリプ
ロピレンをメルトブロー紡糸して、目付10g/m2
メルトブロー不織布を一体化しようとしたが接着性が得
られなかった。
Comparative Example 3 A sheet mainly composed of inorganic fibers adhered with 4% by weight of acrylic resin (inorganic fiber = glass average diameter 4 μm, collection efficiency 32%, thickness 0.45 mm, bending resistance 250 mg, pressure loss). 0.7 mmAq) was melt-blown with polypropylene having an average fiber diameter of 1.5 μm to integrate a melt-blown nonwoven fabric having a basis weight of 10 g / m 2 , but no adhesiveness was obtained.

Claims (10)

【特許請求の範囲】[Claims] 【請求項1】熱接着性成分または粘着性成分を少なくと
も表面に有する無機繊維を主体とするシート表面の凹凸
に実質的に添うように、メルトブロー繊維が積層一体化
されてなることを特徴とする複合シート。
1. Melt-blown fibers are laminated and integrated so as to substantially conform to the irregularities on the surface of a sheet mainly composed of inorganic fibers having at least a heat-adhesive component or a tacky component on the surface. Composite sheet.
【請求項2】熱接着性成分がメルトブロー繊維の融点よ
り20℃以上低い低融点樹脂であることを特徴とする請
求項1記載の複合シート。
2. The composite sheet according to claim 1, wherein the heat-adhesive component is a low melting point resin which is lower than the melting point of the meltblown fibers by 20 ° C. or more.
【請求項3】熱接着性成分がメルトブロー繊維と同系統
のポリマーからなる繊維を少なくとも含むものであるこ
とを特徴とする請求項1記載の複合シート。
3. The composite sheet according to claim 1, wherein the heat-adhesive component contains at least fibers made of a polymer of the same family as the meltblown fibers.
【請求項4】熱接着性成分が、複合繊維であり、繊維断
面の外周部を構成するポリマーの少なくとも一種の融点
がメルトブロー繊維の融点より20℃以上低いことを特
徴とする請求項1または3記載の複合シート。
4. The heat-adhesive component is a composite fiber, and the melting point of at least one of the polymers constituting the outer peripheral portion of the fiber cross section is lower than the melting point of the meltblown fiber by 20 ° C. or more. The described composite sheet.
【請求項5】メルトブロー繊維がエレクトレット繊維で
あることを特徴とする請求項1記載の複合シート。
5. The composite sheet according to claim 1, wherein the meltblown fibers are electret fibers.
【請求項6】複合シートが、LOI値26以上のもので
あることを特徴とする請求項1、2、3、4または5記
載の複合シート。
6. The composite sheet according to claim 1, 2, 3, 4, or 5, wherein the composite sheet has a LOI value of 26 or more.
【請求項7】メルトブロー繊維に他の素材が含まれるこ
とを特徴とする請求項1または5記載の複合シート。
7. The composite sheet according to claim 1, wherein the meltblown fiber contains another material.
【請求項8】複合シートが濾過材料であることを特徴と
する請求項1,2,3,4,6または7記載の複合シー
ト。
8. The composite sheet according to claim 1, 2, 3, 4, 6 or 7, wherein the composite sheet is a filter material.
【請求項9】加熱空気とともに搬送されるメルトブロー
繊維を、熱接着性成分または粘着性成分を少なくとも表
面に有する無機繊維を主体とするシート表面で捕集して
一体化することを特徴とする複合シートの製造方法。
9. A composite characterized in that meltblown fibers conveyed together with heated air are collected and integrated on a sheet surface mainly composed of inorganic fibers having at least a heat-adhesive component or a tacky component on the surface. Sheet manufacturing method.
【請求項10】複合シートを熱接着性成分の融点以上で
熱処理することで一体性を増すことを特徴とする請求項
9記載の複合シートの製造方法。
10. The method for producing a composite sheet according to claim 9, wherein the composite sheet is heat-treated at a temperature equal to or higher than the melting point of the heat-adhesive component to increase the integrity.
JP00118893A 1993-01-07 1993-01-07 Composite sheet and method for producing the same Expired - Fee Related JP3331651B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
JP00118893A JP3331651B2 (en) 1993-01-07 1993-01-07 Composite sheet and method for producing the same

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
JP00118893A JP3331651B2 (en) 1993-01-07 1993-01-07 Composite sheet and method for producing the same

Publications (2)

Publication Number Publication Date
JPH06205915A true JPH06205915A (en) 1994-07-26
JP3331651B2 JP3331651B2 (en) 2002-10-07

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ID=11494483

Family Applications (1)

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Country Link
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* Cited by examiner, † Cited by third party
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JP2008155183A (en) * 2006-12-26 2008-07-10 Toyota Boshoku Corp Filter medium for air filter
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2008155183A (en) * 2006-12-26 2008-07-10 Toyota Boshoku Corp Filter medium for air filter
JP4697135B2 (en) * 2006-12-26 2011-06-08 トヨタ紡織株式会社 Air filter media
JP2009022926A (en) * 2007-07-23 2009-02-05 Toray Fine Chemicals Co Ltd Sock filter
JP2009226260A (en) * 2008-03-19 2009-10-08 Hokuetsu Paper Mills Ltd Air filter medium heat-emboss moldable and air filter using the same
JP2019204637A (en) * 2018-05-22 2019-11-28 イビデン株式会社 Heat transmission suppression sheet for battery pack and battery pack

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