TW201822868A - 無機纖維片材、蜂巢式成形體及蜂巢式過濾器 - Google Patents
無機纖維片材、蜂巢式成形體及蜂巢式過濾器 Download PDFInfo
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- TW201822868A TW201822868A TW106136469A TW106136469A TW201822868A TW 201822868 A TW201822868 A TW 201822868A TW 106136469 A TW106136469 A TW 106136469A TW 106136469 A TW106136469 A TW 106136469A TW 201822868 A TW201822868 A TW 201822868A
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Classifications
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- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
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- B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
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Abstract
本發明係關於一種無機纖維片材,其包含玻璃纖維作為主成分,且相對於無機纖維片材之總量而含有3~20質量%之縱橫比為300~2000之有機纖維。
Description
本發明係關於一種無機纖維片材、蜂巢式成形體及蜂巢式過濾器。 本申請係基於2016年10月24日在日本提出申請之日本專利特願2016-207709號而主張優先權,並將其內容引用至本文中。
陶瓷纖維由於具有高耐熱性、高隔熱性、不燃性等特徵,故而使用陶瓷纖維之無機纖維片材被廣泛地使用。例如,該無機纖維片材用於隔熱材料、耐熱緩衝材料、耐熱遮蔽材料、隔片、觸媒等功能材料之擔載體等。又,對無機纖維片材進行波浪形加工而獲得之蜂巢式成形體係製成擔載有吸附材料等功能材料之熱交換用蜂巢式過濾器、或氣體吸附用蜂巢式過濾器而使用。 例如專利文獻1及2中揭示有一種無機纖維片材之製造方法,其係製備包含陶瓷纖維、有機黏合劑、石鞣皮等之原料漿料,並利用該原料漿料進行抄紙而製成無機纖維片材。此處,所謂石鞣皮係指天然出產之一種黏土礦物,為含水矽酸鎂。石鞣皮係用作無機黏合劑。又,專利文獻2中揭示有於對無機纖維片材進行波浪形加工而製成蜂巢式成形體後進行焙燒,並將吸附材料等擔載於所獲得之焙燒體,而製成氣體吸附元件(蜂巢式過濾器)。 然,陶瓷纖維於由EU(歐盟)制定之針對人造非晶質纖維之EU指令97/69EC中被分類為2類(有致癌嫌疑)。因此,就對人體之安全方面而言,趨向於脫陶瓷化,例如正研究使用玻璃纖維、或生物可溶性纖維代替陶瓷纖維。作為脫陶瓷化所使用之玻璃纖維之纖維直徑,據稱較佳為3 μm以上者。 基於此種情況,例如專利文獻3中揭示有一種使用以生物可溶性陶瓷纖維作為主體且包含玻璃纖維、有機纖維、陽離子性無機黏合劑及作為石鞣皮之一種之海泡石的漿料進行抄紙,而獲得無機纖維片材之方法。 然而,生物可溶性陶瓷纖維存在難以獲得強度而難以輕量化或薄片化之課題。 [先前技術文獻] [專利文獻] [專利文獻1]日本專利特開昭60-33250號公報 [專利文獻2]日本專利第2925127號公報 [專利文獻3]日本專利第5558518號公報
[發明所欲解決之問題] 另一方面,陶瓷纖維代替品之玻璃纖維由於纖維直徑或纖維長度較大,故而以其作為原料而製造之無機纖維片材較硬,而變得難以追隨形狀。因此,存在難以賦予波浪型,且於波浪之頂點纖維容易折斷而形成不均勻之巢室形狀等波浪形加工性問題。波浪形加工性問題於較小之巢室形狀之情形時尤其明顯。 作為使無機纖維片材變得柔軟、或變得容易追隨形狀之方法,已知有黏合劑量之減少、有機纖維之增量、及薄片化等。然而,若過度減少無機纖維片材中之黏合劑量,則有如下擔憂:於波浪形加工時,於齒輪間賦予波浪型時波浪形山部破裂,或纖維間之結合或表面強度降低而產生紙粉。 又,於增加無機纖維片材中之有機纖維量之情形時,進行焙燒處理之蜂巢式成形體存在因焙燒而燒除之有機成分較多,導致強度降低之虞。又,於藉由薄片化而進行柔軟化之情形時,由於片材之空隙變小,故而存在吸附材料等功能材料之擔載量大幅度降低之問題。 如此,於自先前之陶瓷纖維替代為玻璃纖維之情形時,難以製造出波浪形加工性優異,於該波浪形加工時亦不產生紙粉,且功能材料之擔載量亦優異之無機纖維片材。 本發明係鑒於上述情況而成者,其課題在於提供一種波浪形加工適性優異且具有充分之強度與功能材料之擔載量的無機纖維片材、使用該無機纖維片材之蜂巢式成形體、及具備該等之蜂巢式過濾器。 [解決問題之技術手段] 本發明具有以下構成。 [1]一種無機纖維片材,其係包含玻璃纖維作為主成分者,並且 相對於該無機纖維片材之總量而含有3~20質量%之縱橫比為300~2000之有機纖維。 [2]如[1]所記載之無機纖維片材,其中上述有機纖維之平均纖維直徑為上述玻璃纖維之平均直徑之3倍以下。 [3]如[1]或[2]所記載之無機纖維片材,其於空氣中以500℃焙燒2小時後之灰分量為60質量%以上。 [4]如[1]至[3]中任一項所記載之無機纖維片材,其於1.0 kg負載下之抄紙方向之耐折次數為5次以上。 [5]一種蜂巢式成形體,其係將如[1]至[4]中任一項所記載之無機纖維片材加工為蜂巢狀者。 [6]一種蜂巢式過濾器,其係於如[5]所記載之蜂巢式成形體上擔載有選自由矽膠、沸石、海泡石、活性碳及離子交換樹脂所組成之群中之一種以上之功能材料者。 [發明之效果] 根據本發明,可提供一種波浪形加工適性優異且具有充分之強度與功能材料之擔載量的無機纖維片材、使用該無機纖維片材之蜂巢式成形體、及具備該等之蜂巢式過濾器。
以下,對作為將本發明加以應用之一實施形態的無機纖維片材、使用該無機纖維片材之蜂巢式成形體、及具備該等之蜂巢式過濾器進行詳細說明。 <無機纖維片材> 首先,對作為將本發明加以應用之一實施形態的無機纖維片材之構成之一例進行說明。本實施形態之無機纖維片材包含作為主成分之玻璃纖維、與特定之有機纖維作為主體纖維。 (玻璃纖維) 無機纖維片材中之玻璃纖維之含量相對於該無機纖維片材整體之質量而超過50質量%。無機纖維片材中之玻璃纖維之含量相對於該無機纖維片材整體之質量較佳為70質量%以上,更佳為75質量%以上。若無機纖維之含量超過上述範圍之下限值,則於焙燒該無機片材時,因焙燒而燒除之有機成分不會變得過多,焙燒後容易維持所需之強度。玻璃纖維之含量之上限並無特別限制,較佳為95質量%以下,更佳為90質量%以下。若為上述範圍之上限值以下,則可確保所需之機械強度或處理性。 玻璃纖維之種類並無特別限制,除了可使用生產量較多之E玻璃以外,亦可使用高強度之S玻璃、耐酸性優異之C玻璃等。就成本觀點而言,較佳為使用廉價之E玻璃。又,玻璃纖維可單獨使用一種,亦可將兩種以上併用。 玻璃纖維之纖維長度無特別限制,較佳為玻璃纖維之長度加權平均纖維長度為1~15 mm,更佳為1~10 mm。若長度加權平均纖維長度為上述範圍之下限值以上,則有所獲得之無機纖維片材之強度更優異之傾向。若長度加權平均纖維長度為上述範圍之上限值以下,則有所獲得之無機纖維片材之質地優異之傾向。再者,長度加權平均纖維長度係藉由顯微鏡觀察對100根纖維之纖維長度進行測定而算出。 玻璃纖維之纖維直徑較佳為玻璃纖維之加權平均纖維直徑為3 μm以上者,更佳為4 μm以上者。若為上述範圍之下限值以上,則不屬於「WHO(World Health Organization,世界衛生組織)吸入纖維」,對人體安全。該所謂「WHO吸入性纖維」係指由世界衛生組織(WHO)所定義之因呼吸被吸入至體內並到達肺部之纖維狀物質,其係長度超過5 μm、直徑未達3 μm、縱橫比超過3者。 又,玻璃纖維之纖維直徑之上限較佳為玻璃纖維之加權平均纖維直徑10 μm以下,更佳為7 μm以下。若為上述範圍之上限值以下,則無機纖維片材之強度、與對該無機纖維片材進行加工而獲得之蜂巢式成形體之強度均優異。又,可充分地擔載吸附材料等功能材料。再者,加權平均纖維直徑係藉由顯微鏡觀察對100根纖維之纖維直徑進行測定而算出。 (有機纖維) 作為能夠應用於本實施形態之無機纖維片材中之有機纖維,可列舉天然纖維、與合成纖維。作為有機纖維,可使用天然纖維與合成纖維中之任一種以上。 作為天然纖維,可列舉木漿(針葉樹紙漿、闊葉樹紙漿)等纖維素纖維;棉、羊毛、蠶絲、麻等天然纖維,可使用該等中之任一種以上。木漿可為打漿紙漿,亦可為未打漿紙漿。該等中,較佳為相對廉價之木漿。 作為合成纖維,只要為不會因無機纖維片材之製造步驟中之加熱而熔融之纖維,則無特別限制,可根據無機纖維片材之製造步驟中所設定之乾燥溫度之溫度等而適當選擇。作為合成纖維,例如可列舉:聚乙烯系纖維、聚丙烯纖維、聚丁烯纖維、尼龍纖維、嫘縈纖維、銅銨纖維、乙酸酯纖維、聚氯乙烯纖維、丙烯酸系纖維、聚酯纖維、聚胺基甲酸酯纖維、聚對伸苯基苯并二㗁唑纖維、聚醯胺醯亞胺纖維、聚醯亞胺纖維、聚芳酯纖維、聚醚醯亞胺纖維、維尼綸纖維、聚碳酸酯纖維、乙烯-乙酸乙烯酯纖維、乙烯-乙烯醇纖維、聚苯硫醚纖維、聚對苯二甲酸乙二酯纖維、聚對苯二甲酸丁二酯纖維、聚萘二甲酸乙二酯纖維、芳香族聚醯胺纖維等化學纖維等。又,合成纖維可單獨使用該等中之任一種,亦可將兩種以上併用。 關於有機纖維之纖維長度,只要下述之縱橫比為上述範圍內,則無特別限制,較佳為有機纖維之長度加權平均纖維長度為1~15 mm,更佳為1~10 mm。若長度加權平均纖維長度為上述範圍之下限值以上,則存在抄紙時良率提高之傾向。若長度加權平均纖維長度為上述範圍之上限值以下,則存在有機纖維變得不易纏繞而成為結塊等之傾向。再者,長度加權平均纖維長度係藉由顯微鏡觀察對100根纖維之纖維長度進行測定而算出。 有機纖維之加權平均纖維直徑並無特別限制,較佳為相對於玻璃纖維之加權平均纖維直徑而為3倍以下,更佳為2倍以下。若有機纖維之加權平均纖維直徑為玻璃纖維之加權平均纖維直徑之3倍以下,則有提高因有機纖維所導致之無機纖維片材之剛性之降低效果或耐折強度之提高效果的傾向。尤其由於玻璃纖維之加權平均纖維直徑較佳為3~10 μm,故而有機纖維之加權平均纖維直徑較佳為30 μm以下,更佳為20 μm以下。有機纖維之加權平均纖維直徑之下限並無特別限制,較佳為1 μm以上,更佳為3 μm以上。由於有機纖維之加權平均纖維直徑為上述下限值以上者相對容易獲得,故而較佳。再者,纖維直徑之加權平均纖維直徑係藉由顯微鏡觀察對100根纖維之纖維直徑進行測定而算出。又,有機纖維為扁平狀之情形時之纖維直徑係對短徑與長徑進行測定而算出截面面積,將相當於該截面面積之圓之直徑作為纖維直徑。 本實施形態之無機纖維片材其有機纖維之縱橫比(用上述有機纖維之長度加權平均纖維長度除以加權平均纖維直徑而得之比率)為300以上。有機纖維之縱橫比更佳為400以上者,進而較佳為500以上者。若有機纖維之縱橫比為上述範圍之下限值以上,則可獲得剛性之降低效果,且耐折強度亦變大,故而有波浪形凸部變得不易發生破裂,且變得不易產生紙粉之傾向。又,有機纖維之縱橫比之上限並無特別限制,較佳為5000以下者,更佳為2000以下者。若為上述範圍之上限值以下,則有纖維變得不易集束之傾向。 無機纖維片材中之有機纖維之含量相對於該無機纖維片材整體之質量為3~20質量%,更佳為5~15質量%。若有機纖維之含量為上述範圍之下限值以上,則有進行波浪形加工時之波浪狀之賦型性良好,而波浪之形狀變得良好,從而波浪形加工適性優異之傾向。若為上述範圍之上限值以下,則有於空氣中進行焙燒時之灰分變低之傾向。 (其他成分) 本實施形態之無機纖維片材於無損本發明之效果之範圍內除可包含上述之成為主體纖維之玻璃纖維與有機纖維以外,亦可包含該玻璃纖維以外之1種以上之無機纖維、或藉由濕式抄紙而製造該無機纖維片材時所添加之1種以上之成分。 作為玻璃纖維以外之無機纖維,無特別限定,但於考慮對人體之安全性之情形時,較佳為生物可溶性無機纖維。 於本說明書中,所謂生物可溶性無機纖維係指如上所述不屬於「WHO吸入性纖維」之纖維,或依據EU指令97/69/EC之NotaQ「生物可溶性纖維判定基準」滿足以下4個條件(1)~(4)中任意1個條件之纖維。生物可溶性無機纖維包括生物可溶性陶瓷、生物可溶性岩絨等。 上述4個條件如下所述。 (1)於短期吸入暴露之動物實驗中,長度超過20 μm之纖維之半衰期未達10天者;(2)於短期氣管內注入之動物實驗中,長度超過20 μm之纖維之半衰期未達40天者; (3)於腹腔內投予之動物實驗中,無顯著之致癌性者; (4)於長期吸入暴露之動物實驗中,並無與致癌性有關之病理檢查結果或腫瘤形成者(其中,含有超過18質量%之鹼金屬及鹼土金屬之氧化物(Na2
O、K2
O、CaO、MgO、BaO)作為組成者)。 生物可溶性無機纖維中通常因其製法而含有非纖維狀物之「散粒(shot)」。若使用散粒含量較多之生物可溶性無機纖維作為玻璃纖維以外之無機纖維,則有於所獲得之無機纖維片材中開孔、落粉等成為問題之情況。因此,作為生物可溶性無機纖維,較佳為使用散粒之含有率為20質量%以下者,更佳為使用15質量%以下者。又,生物可溶性無機纖維可單獨使用一種,亦可將兩種以上併用。 再者,就對人體之安全性觀點而言,本實施形態之無機纖維片材較佳為不含有於EU指令97/69EC中被分類為2類(有致癌嫌疑)之陶瓷纖維。又,無機纖維片材中之玻璃纖維以外之無機纖維之比率相對於該無機纖維片材整體之質量較佳為45質量%以下,更佳為40質量%以下,進而較佳為30質量%以下。 關於藉由濕式抄紙而製造無機纖維片材時所添加之成分,並無特別限制,例如可列舉:有機黏合劑成分、無機黏合劑成分、助劑、添加劑、填充劑等。 有機黏合劑成分係使纖維彼此接著之成分。作為有機黏合劑成分,可列舉會因製造無機纖維片材時之加熱而至少一部分熔融之熱塑性樹脂等。用作有機黏合劑成分之熱塑性樹脂可根據製造無機纖維片材時之乾燥溫度等而適當選擇。有機黏合劑成分之形態並無限制,可為纖維狀、粒子狀、乳液、液狀等中之任一形態。 作為熱塑性樹脂,例如可列舉:聚乙烯樹脂、氯乙烯樹脂、(甲基)丙烯酸酯樹脂、苯乙烯-丙烯酸酯共聚物、乙酸乙烯酯樹脂、乙酸乙烯酯-(甲基)丙烯酸酯共聚物、乙烯-乙酸乙烯酯共聚物、聚酯系樹脂、聚乙烯醇(PVA)、乙烯-乙烯醇共聚物等。又,亦可使用苯乙烯・丁二烯橡膠(SBR)、腈橡膠(NBR)等橡膠系乳液。作為熱塑性樹脂,可使用該等中之一種以上。 又,作為有機黏合劑成分,亦可使用熔點不同之兩種以上之材料進行複合化,更低熔點之部分發生熔融而作為黏合劑發揮作用之複合纖維。作為複合纖維,可列舉芯鞘型纖維、並列型纖維等。作為芯鞘型纖維,可列舉於包含聚對苯二甲酸乙二酯、聚丙烯等之高熔點之芯部之周圍形成有包含聚乙烯等之低熔點之鞘部的纖維等。 作為有機黏合劑成分,亦可使用會因無機纖維片材之製造步驟中之加熱而發生硬化,從而使纖維彼此接著之熱硬化型樹脂。 作為熱硬化型樹脂,可列舉:酚樹脂、環氧樹脂、三聚氰胺樹脂、脲樹脂、不飽和聚酯樹脂、聚胺基甲酸酯樹脂、熱硬化性聚醯亞胺樹脂等。作為熱硬化型樹脂,可使用該等中之一種以上。 作為有機黏合劑成分,並無特別限制,就接著力優異之觀點而言,較佳為使用聚乙烯醇(polyvinyl alcohol,PVA)。又,於期待提高耐水性之情形時,較佳為併用丙烯酸樹脂作為有機黏合劑成分,更佳為藉由噴霧塗佈等而添加塗佈丙烯酸樹脂乳液等。 有機黏合劑成分相對於無機纖維片材之含量較佳為1~25質量%,更佳為3~20質量%,進而較佳為5~15質量%。若有機黏合劑成分之含量為上述範圍之下限值以上,則可使纖維彼此充分地結合。若為上述範圍之上限值以下,則於焙燒無機纖維片材時所燒除之有機黏合劑成分之量較少,而可製造優異之過濾器。 於使用PVA作為有機黏合劑成分之情形時,PVA相對於有機黏合劑成分之總量之含量較佳為20質量%以上,更佳為40質量%以上,亦可為100質量%。於使用丙烯酸樹脂乳液作為有機黏合劑成分之情形時,丙烯酸樹脂(固形物成分)相對於有機黏合劑成分之總量之含量較佳為5~70質量%。 無機黏合劑成分無特別限制,例如可列舉:膠體氧化矽、水玻璃、矽酸鈣、矽溶膠、氧化鋁溶膠、海泡石、烷氧基矽烷等。作為無機黏合劑成分,可使用該等中之一種以上。但,該等無機黏合劑有在被施加摩擦、彎曲等外力時會發生落粉而處理性差之情況。因此,無機黏合劑成分之含量以相對於無機纖維片材之含量計較佳為40質量%以下,更佳為30質量%以下。 作為助劑,可列舉環氧系、異氰酸酯系、碳二醯亞胺系、㗁唑啉系等交聯劑、或具有胺基、環氧基、甲基丙烯醯氧基、丙烯醯氧基、巰基等官能基之矽烷偶合劑,可使用該等中之一種以上。矽烷偶合劑之含量相對於有機黏合劑成分之100質量份,較佳為以10質量份以下之範圍使用。 作為添加劑,可列舉:抗氧化劑、光穩定劑、紫外線吸收劑、增黏劑、成核劑、中和劑、潤滑劑、抗黏連劑、分散劑、流動性改良劑、脫模劑、阻燃劑、發泡劑、著色劑、濕潤劑、黏劑、良率提高劑、紙強度提高劑、濾水劑、pH值調節劑、消泡劑、防腐劑、瀝青控制劑等,可使用該等中之一種以上。添加劑之含量相對於無機纖維片材較佳為5質量%以下。 作為填充劑,可列舉:矽酸鈣、碳酸鈣、高嶺土、滑石、塑膠顏料、玻璃珠、空心玻璃珠、微小中空玻璃球(Shirasu-balloons)等,可使用該等中之一種以上。 再者,於包含有機黏合劑成分、無機黏合劑成分、填充劑等之情形時,較佳為以無機纖維片材中之無機纖維及有機纖維之各含量成為已於上文說明之範圍內之方式調整其使用量。 關於本實施形態之無機纖維片材之基重,無特別限定,例如可設為10~100 g/m2
,較佳為設為15~60 g/m2
。若基重為上述範圍之下限值以上,則可充分地獲得無機纖維片材及由該無機纖維片材所獲得之蜂巢式成形體之強度,若為上述範圍之上限值以下,則可抑制厚度,且亦可抑制壓力損失。 本實施形態之無機纖維片材較佳為於空氣中以500℃焙燒2小時後之灰分量為60質量%以上,更佳為75質量%以上。若灰分量為上述範圍之下限值以上,則由焙燒引起之有機成分之燒除不會過大,從而可製造強度優異之蜂巢式成形體。灰分量之上限並無特別限制,例如較佳為95質量%以下,更佳為90質量%以下。若灰分量為上述上限值以下,則可含有有機纖維或有機黏合劑之最低必需量,而可賦予片材所需之機械強度、或加工性。再者,灰分量係藉由下述實施例中所記載之方法所測得之值。 本實施形態之無機纖維片材較佳為於1.0 kg負載下之抄紙方向之耐折次數為5次以上,更佳為7次以上。若耐折次數為上述範圍之下限值以上,則可於波浪形凸頂部不產生破裂而製造巢室形狀穩定且性能優異之過濾器。耐折次數係藉由下述實施例中所記載之方法所測得之值。 (無機纖維片材之製造方法) 其次,對本實施形態之無機纖維片材之製造方法之一例進行說明。本實施形態之無機纖維片材係對含有上述無機纖維及有機纖維之原料漿料進行濕式抄紙而製造無機纖維片材而成者。 無機纖維片材之製造中所使用之原料漿料含有無機纖維(主要為玻璃纖維)及有機纖維作為主體纖維,並且含有有機黏合劑成分、無機黏合劑成分、填充劑等作為任意成分。又,作為介質,通常含有水。 濕式抄紙可於製備含有上述各成分與水(介質)之原料漿料後,藉由利用公知之抄紙機對該原料漿料進行抄紙之方法而進行。作為抄紙機,可列舉:圓網式抄紙機、傾斜型抄紙機、長網式抄紙機、短網式抄紙機。亦可將該等抄紙機中之同類或不同類之抄紙機組合而進行多層抄紙。 關於抄紙後之脫水及乾燥之方法,並無特別限制,例如可使用揚基烘缸、滾筒乾燥機、空氣乾燥機、紅外線乾燥機等公知之乾燥機。乾燥溫度並無特別限制,通常為100℃~200℃左右。 再者,於使用有機黏合劑成分、或無機黏合劑成分之情形時,除了添加至用以製造無機纖維片材之原料漿料中以外,亦可對於所獲得之無機纖維片材藉由噴霧塗佈、淋幕式塗佈、浸漬塗佈、棒式塗佈、輥式塗佈、刮刀塗佈等方法使包含有機黏合劑成分、或無機黏合劑成分之液體附著(添加塗佈)。作為添加塗佈之對象之不織布可為乾燥後之乾燥不織布,亦可為乾燥前之濕潤織物。 <蜂巢式成形體> 其次,對作為將本發明加以應用之一實施形態的蜂巢式成形體之構成之一例進行說明。 本實施形態之蜂巢式成形體係對上述無機纖維片材進行波浪形加工,而加工為蜂巢狀之構造體。 蜂巢式成形體首先藉由對上述無機纖維片材實施波浪形加工而賦予波浪型(凹凸)。繼而,將已進行波浪形加工之無機纖維片材(瓦楞芯紙)、與未進行波浪形加工之無機纖維片材(紙板)進行接著,而製造單邊波浪成形體。然後,藉由將複數個單邊波浪成形體進行積層或製成圓筒狀,而獲得蜂巢式成形體。 作為此時所使用之接著劑,可列舉膠體氧化矽、水玻璃、海泡石、氧化鋁溶膠等無機糊劑,可使用該等中之一種以上。又,作為接著劑,亦可併用乙烯-乙烯醇等有機糊劑。 本實施形態之蜂巢式成形體可直接使用,亦可進行焙燒後使用。 <蜂巢式過濾器> 其次,對作為將本發明加以應用之一實施形態的蜂巢式過濾器之構成之一例進行說明。 本實施形態之蜂巢式過濾器係藉由在上述蜂巢式成形體上擔載至少一種功能材料而獲得。 作為功能材料,例如可列舉:吸附材料、除濕劑。 作為吸附材料,就吸附性等觀點而言,較佳為選自由矽膠、沸石、海泡石、活性碳、離子交換樹脂所組成之群中之一種以上。除此以外,亦可使用各種吸附材料作為功能材料。 作為用作除濕劑之吸附材料,例如可列舉:氧化矽、沸石、疏水性合成沸石、天然沸石、海泡石、水滑石、氧化鋁、石灰、石膏、苦土石灰、氫氧化鎂、波來鐵、矽藻土、氯化鋰、氯化鈣、波特蘭水泥、氧化鋁水泥、坡縷石、矽酸鋁、活性白土、活性氧化鋁、膨潤土、滑石、高嶺土、雲母、活性碳、吸水性聚合物等。 作為其他功能材料之例,可列舉:將鹼性化合物擔載於具有吸附能力之載體(碳酸鉀、碳酸鈉、碳酸氫鈉、氫氧化鈣、碳酸鈣等)、或例如活性碳、氧化矽、氧化鋁、水鋁英石、海泡石、菫青石、其他黏土礦物等上而成之固體吸附材料;氫氧化鈉、氫氧化鉀、碳酸鉀、氫氧化鈣、離子交換樹脂、除臭劑等。又,亦可使用將鈦等觸媒擔載於微孔而成之多孔質吸附材料作為功能材料。 作為功能材料之擔載方法,可列舉使含有功能材料之漿料含浸於上述無機纖維片材或蜂巢式成形體中,並使之乾燥之公知方法。 上述漿料可基於功能材料之擔載性及蜂巢式成形體之強度提高之目的,而含有一種以上之膠體氧化矽、水玻璃、海泡石、氧化鋁溶膠等無機接著劑。 如以上所說明,本實施形態之無機纖維片材係以玻璃纖維作為主成分,且含有3~20質量%之縱橫比300~2000之有機纖維的構成,因此維持該片材之強度,並且被賦予柔軟性。因此,根據本實施形態之無機纖維片材,可製造波浪形加工適性優異且具有充分之強度與功能材料之擔載量的過濾器基材。 本實施形態之無機纖維片材於玻璃纖維之加權平均纖維直徑為3 μm以上之情形時,具備對人體之安全性。 本實施形態之蜂巢式成形體係對上述無機纖維片材進行波浪形加工而成者,因此具有充分之強度與吸附材料之擔載量。 本實施形態之蜂巢式過濾器為高性能之過濾器。 [實施例] 以下,藉由實施例及比較例更具體地說明本發明,但本發明並不限於以下實施例。 <測定方法及評價方法> (基重) 對於所獲得之無機纖維片材,依據JIS P8124進行測定。 (厚度) 對於所獲得之無機纖維片材,依據JIS P8118進行測定。 (拉伸強度) 對於所獲得之無機纖維片材,藉由依據JIS P 8113之方法利用Tensilon型拉伸試驗器(ORIENTEC公司製造)進行測定。 (彎曲抗力) 對於所獲得之無機纖維片材,藉由依據ISO2493之方法利用抗彎強度試驗機(BENDING RESISTANCE TESTER)(L&W公司製造)進行測定。 (耐折次數) 對於所獲得之無機纖維片材,依據JIS P 8115耐折強度試驗法,利用MIT(Massachusetts Institute of Technology,麻省理工學院)試驗機於負載1.0 kg下算出對10個試片進行測定而獲得之平均次數。 (灰分量) 對於所獲得之無機纖維片材,於500℃下而非525℃下燃燒2小時,除此以外,依據JIS P8251進行測定。 (保液量) 對於所獲得之無機纖維片材,依據JIS L1913保水率之測定而測定無機纖維片材(100 mm×100 mm)之乾燥質量A(g/m2
)。其後,將該無機纖維片材浸漬於純水中15分鐘,繼而將其取出,並進行懸吊直至水滴不再因自身重量而滴落後,測定其質量B(g/m2
)。將自質量B減去質量A而獲得之值設為保液量。再者,將保液量換算為每1 m2
,並記載於表中。 (波浪形加工適性) 對所獲得之無機纖維片材實施波浪形加工,並基於以下指標評價波浪形加工適性。 S:波浪狀之賦型性非常好,波浪之形狀非常優異。 A:波浪狀之賦型性良好,波浪之形狀良好。 B:波浪狀之賦型性稍差,波浪之形狀稍有崩塌跡象。巢室形狀稍不均勻。 C:波浪狀之賦型性差,波浪之頂點有裂紋或破裂。巢室形狀不均勻。 (落粉) 對所獲得之無機纖維片材實施波浪形加工,目視觀察捲取捲出部之地板、及波浪形齒輪間之紙粉狀況,並基於以下指標評價落粉。 A:地板、齒輪間均幾乎未產生紙粉。 B:地板、或齒輪間稍微看到紙粉,但為容許範圍。 C:地板上大量地看到紙粉,或齒輪間明顯積留有紙粉。 <實施例1> 將玻璃纖維(直徑:6 μm,長度:6 mm)84質量%、作為有機纖維之聚對苯二甲酸乙二酯纖維(直徑:3.5 μm,長度:5 mm,縱橫比:1429)8質量%、作為黏合劑之聚乙烯醇(Kuraray製造,POVAL K-17U6)8質量%進行混合而製成原料漿料,並以0.2%濃度分散至水中。藉由濕式抄紙法形成隨機排列之織物,將丙烯酸系乳液以成為0.3 g/m2
之方式進行噴霧塗佈並乾燥。對所獲得之無機纖維片材之稱重、厚度、拉伸強度、彎曲抗力、耐折次數、及保液量進行測定。將結果示於表1。 對於將所獲得之無機纖維片材於空氣中以500℃焙燒2小時後之片材,測定其灰分量。將結果示於表1。 繼而,將所獲得之無機纖維片材加工為高度1.4 mm、間距2.6 mm之波浪狀作為瓦楞芯紙,利用以矽溶膠作為主成分之無機接著劑將該瓦楞芯紙接著於包含所獲得之無機纖維片材的平面片狀紙板上,而進行波浪形加工,將其捲成捲筒而製作圓筒狀之蜂巢式成形體。 針對所獲得之蜂巢式成形體,評價波浪形加工適性、落粉。將結果示於表1。 <實施例2> 將有機纖維變更為聚對苯二甲酸乙二酯纖維(直徑:5 μm,長度:5 mm,縱橫比:1000),除此以外,藉由與實施例1相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 <實施例3> 將有機纖維變更為聚對苯二甲酸乙二酯纖維(直徑:8 μm,長度:5 mm,縱橫比:625),除此以外,藉由與實施例1相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 <實施例4> 將有機纖維變更為聚對苯二甲酸乙二酯纖維(直徑:12 μm,長度:5 mm,縱橫比:417),除此以外,藉由與實施例1相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 <實施例5> 將有機纖維變更為扁平狀聚對苯二甲酸乙二酯纖維(短直徑:8 μm,長徑:32 μm(16 μm圓當量徑),長度:5 mm,縱橫比:313),除此以外,藉由與實施例1相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 <實施例6> 將有機纖維變更為聚對苯二甲酸乙二酯纖維(直徑:17 μm,長度:10 mm,縱橫比:588),除此以外,藉由與實施例1相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由在實施例1相同之方式進行測定、評價。將結果示於表1。 <比較例1> 將有機纖維變更為聚對苯二甲酸乙二酯纖維(直徑:17 μm,長度:5 mm,縱橫比:294),除此以外,藉由與實施例1相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 <比較例2> 將有機纖維變更為聚對苯二甲酸乙二酯纖維(直徑:24 μm,長度:5 mm,縱橫比:208),除此以外,藉由與實施例1相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 <比較例3> 將有機纖維變更為N紙漿(直徑:23 μm,長度:0.7 mm,縱橫比:30),除此以外,藉由與實施例1相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 <比較例4> 將有機纖維變更為2質量%之聚對苯二甲酸乙二酯纖維之組成,除此以外,藉由與實施例3相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 <比較例5、6> 將玻璃纖維變更為陶瓷纖維(直徑:2.2 μm,長度:6 mm)84質量%,除此以外,藉由與實施例3相同之方式獲得表1所示之基重、厚度之無機纖維片材。 其後,藉由與實施例1相同之方式進行測定、評價。將結果示於表1。 [表1]
如表1所示,比較例1之巢室之形狀不均勻,且亦產生紙粉。 比較例2之巢室凸部產生裂紋,且亦產生紙粉。 比較例3之巢室之形狀不均勻。 比較例4難以賦予波浪狀之型,而產生不成為波浪狀之部分。 比較例5、6雖然產生紙粉,但加工性無問題,然而與實施例1~6相比,比較例5之保液量較少,比較例6之厚度較大。 實施例1~6之波浪形加工適性優異。又,具有充分之強度,無落粉,且保液量亦充分。 [產業上之可利用性] 本發明之無機纖維片材由於波浪形加工適性優異,且具有充分之強度,故而於隔熱材料、耐熱緩衝材料、耐熱遮蔽材料、隔片、觸媒等功能材料之擔載體等領域具有產業上之可利用性。又,本發明之蜂巢式成形體於擔載有吸附材料等功能材料之熱交換用蜂巢式過濾器、或氣體吸附用蜂巢式過濾器領域具有產業上之可利用性。
Claims (6)
- 一種無機纖維片材,其係包含玻璃纖維作為主成分者,並且 相對於該無機纖維片材之總量而含有3~20質量%之縱橫比為300~2000之有機纖維。
- 如請求項1之無機纖維片材,其中上述有機纖維之平均纖維直徑為上述玻璃纖維之平均直徑之3倍以下。
- 如請求項1或2之無機纖維片材,其於空氣中以500℃焙燒2小時後之灰分量為60質量%以上。
- 如請求項1至3中任一項之無機纖維片材,其於1.0 kg負載下之抄紙方向之耐折次數為5次以上。
- 一種蜂巢式成形體,其係將如請求項1至4中任一項之無機纖維片材加工為蜂巢狀者。
- 一種蜂巢式過濾器,其係於如請求項5之蜂巢式成形體上擔載有選自由矽膠、沸石、海泡石、活性碳及離子交換樹脂所組成之群中之一種以上之功能材料者。
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