TW202130867A - Polyphenylene sulfide staple fiber, and filter fabric formed from same - Google Patents

Abstract

Polyphenylene sulfide staple fiber characterized by being formed from fibers having at least two different single-fiber finenesses, and moreover characterized in that the mixed fiber uniformity is less than 3.0. Provided is PPS stable fiber for which a cotton blend step during production of a filter fabric is simplified and with which it is possible to improve dust detachment properties, improve the efficiency of dust capture, and reduce pressure loss.

Description

Polyphenylene sulfide staple fiber and filter cloth containing the same

The present invention relates to short polyphenylene sulfide fibers and filter cloth containing the short polyphenylene sulfide fibers.

Polyphenylene sulfide (hereinafter sometimes referred to as PPS) resin has excellent heat resistance, barrier properties, chemical resistance, electrical insulation, and humidity and heat resistance, which are suitable as engineering plastics. It is used for injection molding or extrusion molding. As the center, it is used in various electrical or electronic parts, mechanical parts and auto parts, films and fibers. For example, PPS resin materials are widely used in filter cloths used in various industrial filters such as bag filters for exhaust gas dust collection. Such a filter cloth is formed on a base fabric made of spun yarns of PPS staple fibers. It is formed by layering a fiber web containing PPS staple fibers and performing needle punching. It is used to trap dust in the exhaust gas, and it will be dust-free. Exhaust gas is exhausted to the outside, and it is important to keep it unblocked for a long period of time.

In order to suppress clogging of the filter cloth and to achieve a long life of the filter cloth performance, it is effective to efficiently detach the attached dust from the filter cloth. For example, if the filter cloth of the bag filter becomes clogged, the exhaust gas cannot be discharged from the incinerator. Therefore, the incinerator must be stopped and the filter cloth must be replaced. That is, if the dust is efficiently blown off before the filter cloth is clogged, the filter cloth can be prolonged in life, and long-term continuous operation of the incinerator becomes possible.

In the bag filter, as a method of efficiently detaching the dust attached to the filter cloth, the pulse jet method is often used. The so-called pulse jet method is a method in which high-speed airflow is periodically blown onto the filter cloth before the dust adhered on the surface of the filter cloth is accumulated to vibrate the filter cloth, and the dust adhered on the surface of the filter cloth is blown off. . Although such a pulse jet method can remove dust, in this method, the high-speed air flow applied as an external force is of course easy to reduce the mechanical strength of the filter cloth over time. In addition, when external force is periodically applied, when the mechanical strength of the filter cloth is insufficient, the filter cloth breaks and the function as a bag filter cannot be achieved.

On the other hand, under the current trend of stricter environmental regulations in the world, especially in the trend set by the United States, the control of particulate matter floating in the atmosphere, especially the small particle size (PM2.5 control), is in Japan There is also the possibility of application. In response to such a trend, I hope for an excellent filter with higher dust collection efficiency and less clogging.

In response to this, a filter cloth in which PPS fibers having a single fiber fineness of 1.8 d (2.0 dtex) or less are arranged on a fiber web on the air inflow side has been proposed (Patent Document 1).

In addition, Patent Document 2 proposes a filter cloth including at least two layers of fiber webs, and the fiber web on the air inflow side includes 50% by mass or more of PPS fibers with a fiber diameter of 15 μm or less (single fiber fineness of 2.2 dtex or less). In this proposal, by controlling the fiber weight below 15 μm, certain effects can be obtained with regard to dust peeling performance, dust collection efficiency, and pressure loss caused by clogging of the filter cloth.

In addition, Patent Document 3 proposes a method of blending fibers having different deniers during spinning. [Prior Technical Literature] [Patent Literature]

Patent Document 1: Japanese Patent Application Laid-Open No. 10-165729 Patent Document 2: International Publication No. 2004/087293 Patent Document 3: Japanese Patent Application Publication No. 2014-152407

[The problem to be solved by the invention]

However, in the proposal of Patent Document 1, although the peeling performance of dust and the efficiency of dust collection do have a tendency to be improved, there is a problem of large pressure loss due to clogging of the filter cloth. In the proposal of Patent Document 2, in order to blend PPS fibers with a fiber diameter of 15 μm or less with other PPS fibers, it is necessary to blend the two raw cottons when the filter cloth is made. At the same time, when the blending is uneven , There are concerns about the effect of dust stripping, dust collection efficiency and pressure loss effect. Therefore, this cotton blending step is a step that greatly affects the performance of the filter cloth, and more uniform cotton blending is necessary. In addition, the proposal of Patent Document 3 improves the uniformity of the blending in each stage compared to the method of blending raw cotton with different deniers after the raw cotton is made. However, in the content described in this patent, the fact is that because the binding force between the fibers in the spindle unit is strong, the blending of the single fiber units is insufficient only by the blending of the fibers during spinning.

Therefore, the object of the present invention is to provide polyphenylene sulfide staple fiber and filter cloth containing the same, which can particularly simplify the cotton blending step when the filter cloth is made, and improve the uniformity of blending fiber than before. [Means to solve the problem]

In order to solve the above-mentioned problems, the present invention is a polyphenylene sulfide staple fiber characterized by including at least two types of fibers with different single fiber deniers, and the blending uniformity is less than 3.0. Furthermore, it is a filter cloth containing the polyphenylene sulfide short fiber described above. Furthermore, it is a method for producing polyphenylene sulfide staple fiber, which simultaneously spins at least two types of fibers having a single fiber fineness of 0.5 dtex or more and 3.0 dtex or less and a maximum thickness of 1.0 dtex or more of different single fiber deniers. Mixed fiber, the uniformity of mixed fiber is less than 3.0. [Effects of Invention]

According to the present invention, it is possible to provide polyphenylene sulfide staple fibers that can simplify the cotton blending step when the filter cloth is made, and to provide blended fibers by spinning blending fibers, and further by blending fibers during stretching. Polyphenylene sulfide staple fiber that can improve the uniformity of fiber mixing, improve dust peelability, improve dust collection efficiency, and reduce pressure loss.

[Form to implement the invention]

The polyphenylene sulfide staple fiber of the present invention is a polyphenylene sulfide staple fiber obtained by spinning and blending at least two types of fibers with different single fiber deniers simultaneously.

The polyphenylene sulfide (PPS) resin used in the polyphenylene sulfide staple fiber of the present invention means a resin containing paraphenylene sulfide units or metaphenylene sulfide units represented by the following structural formula (I) The phenylene sulfide unit is a polymer of repeating units.

The PPS resin may be a homopolymer, or a copolymer having both para-phenylene sulfide units and meta-phenylene sulfide units, and as long as the effect of the present invention is not impaired, it may also be a copolymer with other aromatic sulfur Copolymers or mixtures of ethers.

In addition, the melt flow rate (MFR) of the PPS resin at 320° C. measured with an extrusion plastometer in accordance with JIS K7210: 2014 Thermoplastic Flow Test is preferably 200 to 600 g/10 minutes. In the case of melt spinning using PPS resin with MFR exceeding 600g/10min, the spinning tension is low, and thread breakage occurs frequently during spinning; in addition, if PPS resin with MFR less than 200g/10min is used, the stretch cannot be maintained. The required elongation of the undrawn yarn is disadvantageous in the production of extremely fine fineness. A more preferable MFR is 200 to 400 g/10 minutes.

As a commercially available product of the PPS resin used in the present invention, "Torelina" (registered trademark) manufactured by Toray Co., Ltd. or "Fortron" (registered trademark) manufactured by POLYPLASTICS (registered trademark), etc. can be cited.

The polyphenylene sulfide staple fiber of the present invention is a staple fiber obtained by spinning the above-mentioned PPS resin, and the fiber length is preferably 38 to 64 mm.

The polyphenylene sulfide staple fiber of the present invention is a polyphenylene sulfide staple fiber with a blending uniformity of less than 3.0. The so-called blending uniformity is an index used to quantitatively judge the deviation of the blending condition of the raw cotton obtained by blending, and it is measured as follows. First, 300 g of the polyphenylene sulfide raw cotton obtained by blending fibers is preliminarily opened with an opener, and processed by carding to make a fiber web. The net is randomly extracted from the obtained fiber net, and cut so that the cross section of the fiber can be seen. The fiber cutting method is not limited, but for example, there is a method of inserting the obtained net into a copper plate with a hole of 1 mm to 2 mm in diameter and cutting it along the copper plate. Using an optical microscope camera, five fiber cross-sections were taken at a magnification of 1000 times to obtain fiber cross-section photos. At this time, the image is taken so that the total number of fiber sections can be confirmed to be 600 or more. From the number of randomly selected 600 cross-sections in each of the 5 photos taken, confirm the number of the thinnest fiber among at least 2 types of fibers with different single fiber deniers, and find at least 2 in each photo The mixing ratio (number ratio, %) of the thinnest fiber among fibers with different types of single fiber deniers is calculated from the standard deviation, and the value is regarded as the mixing uniformity.

Next, the method of manufacturing the polyphenylene sulfide staple fiber of the present invention will be explained.

The present invention melts PPS resin with an MFR of 200 to 400 g/10 minutes at 320°C, and spins at least 2 types of single fibers with different deniers from 2 to 100 spinnerets. fiber. At this time, it is preferable to spin so that the ratio of different deniers becomes at least 5% of the total short fiber spun at the same time, and more preferably at least 10%.

The ratio of different deniers mentioned here refers to the ratio of the number of fibers with the lowest mixing rate among more than two types of fibers with different deniers. For example, when 3.3T (fiber with a single fiber fineness of 3.3 dtex; similarly described below) is 80% and 6.6T is a mixed fiber of 20%, the ratio of the different fineness becomes 20%. In addition, when 3.3T is 50%, 6.6T is 40%, and 7.8T is 10%, the ratio of different deniers becomes 10%. In the present invention, by setting the ratio of different deniers to 5% or more, the resulting mixed fiber state is good and preferable. When it is less than 5%, the resulting blended fiber is in poor condition.

In order to obtain two or more types of fibers with different single fiber deniers, for example, it is only necessary to install a spinneret with a different number of spinneret holes, or to change the spun polymer ejection amount to adjust to the target denier. In addition, as long as the effects of the present invention are not impaired, there is no problem with two or more types or one type of fibers having a profiled cross section.

When installing spinnerets with different numbers of spinneret holes, the polymer discharge rate can be fixed to all the spinnerets, and the discharge rate per single hole of the spinneret can be adjusted to adjust the size. When changing the spun polymer discharge amount, it can be adjusted to the specified fineness by adjusting the discharge amount per single hole. In addition, when spinning and blending fibers of different deniers with one spinneret at the same time, by adjusting the diameter and length of the spinneret, there are multiple pores or holes in one spinneret. Long and so on, can spin at least two kinds of different fineness at the same time.

In the present invention, at the time of spinning, it is preferable to uniformly distribute spinnerets for spinning different fibers to the entire spinning machine and install them. For example, when two types of foreign finenesses are mixed at a ratio of 50% each, spinnerets with different fineness fibers are alternately installed. When the blending rate of one fiber (A) is 66%, and the blending rate of the other fiber (B) is 33% (the decimal point is rounded off), install 2 spindles side by side in the above (A) Next to the spinneret, install a spinneret of (B) side by side, and repeat it. Also, for example, in the case of blending three types of foreign fibers, when each is blended at a ratio of 33% (below the decimal point), the resulting spinnerets ((A), (B) with different fibers are installed side by side ) And (C) spinneret), repeat it. If any one type of spinneret is fixedly attached to one place of a spinning machine and spun, the mixed fiber state of the spinning becomes worse and the uniformity tends to be poor, so it is preferable to distribute them equally.

As described above, when spinning the polyphenylene sulfide fiber of the present invention, fibers of different single fiber deniers must be spun simultaneously.

The single fiber fineness of the polyphenylene sulfide staple fiber of the present invention can be a fiber of any fineness, preferably 0.5 to 3.0 dtex, and more preferably 0.5 to 2.5 dtex.

In the single fiber fineness, the single fiber fineness of the thinnest fiber among the fibers with different single fiber finenesses of at least two types, that is, the finest fineness is 0.5 to 1.0 dtex, more preferably 0.7 to 0.9 dtex.

In addition, the monofilament fineness of the thickest fiber among fibers having at least two types of different monofilament fineness, that is, the coarsest fineness, is preferably 1.0 dtex or more, more preferably 1.2 dtex or more.

When the single fiber fineness is less than 0.5 dtex, the fineness may be too fine, which may increase the possibility of occurrence of defects in the carding step. If the single fiber fineness exceeds 3.0 dtex, the atmospheric dust collection efficiency may decrease.

When the maximum fineness is less than 1.0 detx, neps (nep) and the like will occur in the carding step, and the productivity when forming the fiber web is likely to be deteriorated, which is not preferable.

Next, in the present invention, the unstretched polyphenylene sulfide yarn spun as described above is heat-stretched. Thermal stretching is usually performed in warm water at a temperature of 90 to 98°C, preferably 2 to 4 times, more preferably 3 to 4 times the stretching magnification.

After the thermal extension treatment, it is preferable to perform a fixed-length heat treatment. Fixed-length heat treatment refers to heat treatment to keep the length of the yarn substantially constant. The treatment method is generally to set a certain length between a plurality of rollers having substantially equal circumferential speeds, and heat treatment is performed by using at least a part of the rollers as a heating roller or separately providing a heating means.

Regarding the heat treatment temperature, by setting it to preferably 190°C or higher, more preferably 200°C or higher, and still more preferably 210°C or higher, sufficient strength can be appropriately imparted to the PPS short fibers. In addition, by setting it to 270°C or lower, more preferably 240°C or lower, false adhesion between fibers can be appropriately suppressed.

The fixed-length heat treatment time is preferably set to 5 seconds or more, so that sufficient strength can be appropriately imparted to the PPS short fibers. On the other hand, when the fixed-length heat treatment time is too long, only the strength is saturated, and the upper limit of the fixed-length heat treatment time is preferably about 12 seconds.

Then, multi-stage lamination is carried out and press rolling is applied. In the method for obtaining the polyphenylene sulfide fiber of the present invention, it is important how to disperse the stretched tow into single fibers. For this reason, it is possible to cite the fiber splitting caused by the use of fiber splitting guides, and the polymerization However, in consideration of productivity, it is best to use multi-stage lamination to form bundles, and to split fibers by optimizing the amount of oil and oil. The so-called whole bundle caused by multi-stage lamination is divided into at least two stretched tows. Under the condition of tow tension of 0.5cN/dtex or more, the width of the tow is stacked at least 2 layers above and below. The fiber bundle constrained by another spindle unit is superimposed on the fiber bundle constrained by the spindle unit, and then the fiber bundle of the single fiber unit is effectively promoted by pressing and rolling. The tow tension is preferably 0.5 cN/dtex or more, more preferably 0.6 cN/dtex or more. In the case of lamination with 0.5 cN/dtex or less, it is difficult for another fiber bundle to enter into the fiber bundle constrained by the spindle unit during the lamination, and the mixing effect of the single fiber unit is poor. In addition, the oil agent has the function of reducing the friction between the fibers and maintaining the fluidity between the fibers, and plays an important role in forming a single fiber into a single fiber.

Regarding the step of applying the oiling agent, as long as it is after the fixed-length heat treatment and before the multi-stage lamination, the applying method is not particularly limited.

There are no particular limitations on the method of applying the oil agent. As an example, there is a method of applying an oil agent whose concentration has been adjusted by a spray method, a spray method, or a spray method. More preferably, a method of uniformly applying to the tow by a kiss roller method can be cited.

In order to obtain a sufficient effect, the crimp-containing tow oil is preferably added to the fiber by 0.05 to 0.30% by weight, more preferably 0.15 to 0.25% by weight. If the oil content of the crimp-containing tow is less than 0.05% by weight, it is difficult to obtain a fiber splitting effect suitable for spinning fiber splitting. If the oil content of the crimp-containing tow is 0.30% by weight or more, the adhesion amount is too large, which may cause problems such as poor step passability in the spinning step. In addition, the oiling agent is not particularly specific as long as it is an oiling agent used for fiber production, and nonionic surfactants, cationic surfactants, anionic surfactants, etc. can be preferably used.

After the above-mentioned whole bundle, it is press-rolled, crimped, heat-set, and cut into a specified length to obtain the short fiber of the present invention.

Fig. 1 is an exploded cross-sectional view of a filter material (filter cloth) using a fiber web (non-woven fabric) containing polyphenylene sulfide short fibers obtained in the present invention.

In Fig. 1, the so-called fiber web 1 forming the filter layer on the air inflow surface means the surface of the filter material for surface filtering where the air containing dust first comes into contact with the filter material. That is, it means the surface where dust is collected on the surface of the filter material to form a dust layer. In addition, the surface on the opposite side is formed by the fiber web 3 of the filter layer forming the air discharge surface, and represents the surface where the dust-removed air is discharged. As a method of making a fiber web, the short fiber is made by passing it through a cotton opener and then using a carding machine. In addition, between the fabricated fiber web 1 and the web 3, a fabric (aggregate) 2 containing heat-resistant fibers is sandwiched, and the needle-punching step becomes a felt, whereby dimensional stability, tensile strength and durability can be obtained. A filter material with excellent mechanical strength such as abrasion and dust collection efficiency. The short polyphenylene sulfide fiber of the present invention is used in the fiber web 1.

The polyphenylene sulfide staple fiber obtained by the method for producing polyphenylene sulfide staple fiber of the present invention can be temporarily made into textile yarns in addition to non-woven fabrics such as bag filters and papermaking, and the textile yarns can be used to make woven fabrics or knitted fabrics, etc. Cloth silk. [Example]

Next, the manufacturing method of the polyphenylene sulfide staple fiber of the present invention will be specifically explained with examples. However, the present invention is not limited by the following embodiments. Each characteristic value defined in the present invention is obtained by the following method.

(1) Blending uniformity The so-called blending uniformity is an index used to quantitatively judge the deviation of the blending condition of the raw cotton obtained by blending, and it is measured as follows.

300g of polyphenylene sulfide raw cotton obtained by blending fiber was used on a cotton opener manufactured by Daiwa Machinery Co., Ltd. to perform preliminary fiber opening at a processing speed of 150g/min, and a carding machine manufactured by Daiwa Machinery Co., Ltd. was used at a processing speed of 100g/min. The carding process is performed in minutes to obtain a fiber web. The net is randomly extracted from the obtained fiber net, and cut so that the cross section of the fiber can be seen. The cutting method is to insert the obtained net into a copper plate with a hole of 1mm-2mm in diameter, and cut along the copper plate. For the fiber section, an optical microscope camera was used to take a picture of the section at a magnification of 1000 times. At this time, the image was taken so that the total number of fiber cross-sections in each photograph can be confirmed to be more than 600. From the number of randomly selected 600 cross-sections in each of the 5 photos taken, confirm the number of the thinnest fiber among at least 2 types of fibers with different single fiber deniers, and find at least 2 of each photo The blending ratio (number ratio, %) of the thinnest fiber among fibers with different single-fiber deniers of the type is calculated from the value of the blending ratio (%) of the fine denier varieties, and the value is regarded as the blending uniformity.

The criteria for judging the uniformity of blended fibers is that the blending uniformity is less than 3.0 as S (very good), the blending uniformity is less than 3.0 as A (good), and the blending uniformity is less than 4.0 as A (good). B (Normal), consider the case above 6.0 as C (Poor). Consider A (good) or higher as a pass.

(2) Atmospheric dust collection efficiency The air dust collection efficiency measuring device shown in Figure 2 is used to measure the dust collection efficiency of the filter material by the air dust calculation method. That is, with the air blower 8 installed on the downstream side of the filter material 5 (φ 170mm) in Fig. 2, the filter material 5 is ventilated with a filter wind speed of 1m/min for 5 minutes, and then a particle counter manufactured by RION is used ( Upstream) 4 Measure the number A of atmospheric dust (particle size: 0.3～5μm) on the upstream side of the filter material 5, and measure the atmospheric dust (particle size) on the downstream side of the filter 5 with a particle counter (downstream) 6 manufactured by the same company. Diameter: 0.3～5μm) Number B. The measurement sample was performed with n=3. From the obtained measurement results, the collection efficiency (%) is obtained by the following formula. Collection efficiency (%)=(1−(B/A))×100 In the above formula, A is the number of atmospheric dust on the upstream side, and B is the number of atmospheric dust on the downstream side.

Atmospheric dust collection efficiency is judged by taking 55% or more as S (very good) for dust collection efficiency with a particle size of 1μm or less, and A (good) as 50% or more and less than 55%, and 45% or more And less than 50% is regarded as B (normal), and less than 45% is regarded as C (bad). Consider A (good) or higher as a pass.

(3) Pressure loss after dust blowing The pressure loss measuring device of Fig. 3 is used to measure the pressure loss after dust blowing of the filter material. That is, with the vacuum pump 12 and the flow meter 10 installed on the downstream side of the filter medium 5 (φ 170 mm) in FIG. 3, the filter medium 5 is given a flow of air with a filtering wind speed of 2.0 m/min. JIS 10 types of dust are added to the air inflow surface side of the filter material 5 (filter area 100 cm ² ) with dust adjusted to a dust concentration of 20 g/m ^{3 by the dust feeder 14 and the dust disperser 15.} Every time the pressure loss measured by the digital fluid pressure gauge 13 rises to 10mmH ₂ O (980pa), the pulse jet load machine 9 located downstream of the filter 5 sets a pulse jet pressure of 3kgf/cm ² (294kpa) , 155 times of pulse injection under the condition of 0.1sec, the digital fluid pressure gauge 13 continuously monitors the pressure loss immediately after the pulse injection load.

The criterion for determining the pressure loss after dust blowing is based on the pressure loss less than 7mmH ₂ O (69pa) at the elapsed time of 30hr as S (very good), and 7mmH ₂ O (69pa) or more and less than 7.5mmH ₂ O (74pa) ) Is regarded as A (good), 7.5mmH ₂ O (74pa) or more and less than 8mmH ₂ O (78pa) is regarded as B (normal), and _{the case higher than 8mmH 2} O (78pa) is regarded as C (poor) . Consider A (good) or higher as a pass.

(4) Carding machine passability A. Felt productivity (carding machine neps) Under the conditions of 25°C and 65% RH, use a roller carding machine to comb a web of 20g/m ² and a width of 50cm at a speed of 30m/min. 1 Regarding the neps generation state of the net out of the carding machine, the number of neps was visually confirmed when a sample of 1 m in the length direction was collected every 10 minutes. Consider a very good state without neps as S (very good), consider 8 or less as A (good), 9 to 11 as B (normal), and 12 or more as A (good). The situation is treated as C (bad).

B. Felt productivity (carding machine fly) Under the conditions of 25°C and 65% RH, use a roller carding machine to comb a web of 20g/m ² and a width of 50cm at a speed of 30m/min for 1 hour. The amount of hair (flying) produced is less than 10g as S (very good), if it exceeds 10g and less than 25g is regarded as A (good), and if it exceeds 25g and less than 35g is regarded as B (normal) , And regard the case exceeding 35g as C (poor).

C. Carding machine passability The passability of the carding machine was evaluated from the results of the above-mentioned carding machine neps and carding machine flying. In 2 items, as long as there is 1 C is regarded as C (poor), in 2 items, B (normal) is regarded as B (normal), and both items are A (good). It is regarded as A (good). In 2 items, A (good) is 1, S (very good) is 1 or S (very good) is 2 is regarded as S (very good).

(4) Comprehensive judgment: Among the above criteria for judging fiber uniformity, air dust collection efficiency, pressure loss after dust blowing, and carding machine passability, if there is only one C (poor) judgment in the 4 items, the comprehensive judgment is taken as C (poor), 4 items are only judged as A (good) or B (normal), when S (very good) is 1 and the others are B (normal), the comprehensive judgment is regarded as B (normal) ), if S (very good) is 2 or more in 4 items, or S (very good) is 1 and the others are A (good), the comprehensive judgment is regarded as A (good), and A (good) As qualified.

[Example 1] Using single fiber fineness 3.0dtex (fiber diameter 16.2μm), cut length 76mm PPS staple fiber (Toray Co., Ltd. "Torcon" (registered trademark) S101-3.0T76mm), a single yarn count of 20s, and yarn 2 textile yarns (total fineness 600dtex). Using this textile yarn, weave a plain weave fabric to obtain a flat fabric containing PPS textile yarns with a warp yarn density of 26/2.54cm and a cotton yarn density of 18/2.54cm.

On the other hand, Toray PPS pellets with an MFR value of 240 g/10 minutes were vacuum dried at a temperature of 160°C for 5 hours, and then supplied to a pressure melter type melt spinning machine for spinning. Blended fiber. The undrawn PPS yarns with different deniers obtained at a mass ratio of 20:80 are further subjected to a fixed-length heat treatment in the stretching step, and a touch roller is used to impart 0.20% by weight of a non-ionic surfactant to the tow tension to become 0.5cN/ after the above embodiment dtex adjusted, for the entire beam caused by the two-stage laminating, nip to an air pressure 4kgf / cm ² to nip, crimping, heat setting after cut into 51mm, a single fiber fineness of 0.5dtex (Fiber diameter 6.9μm) and single fiber fineness 2.2dtex (fiber diameter 14.5μm) raw cotton. Using 300g of this raw cotton, the opener made by Daiwa Machinery Co., Ltd. is used for preliminary opening at a processing speed of 150g/min, and the carding machine made by Daiwa Machinery Co., Ltd. is used for carding processing at a processing speed of 100g/min. , And temporarily needled with a needle density of 50 needles/cm ² to obtain a fiber web with a weight per unit area of 194 g/m ^2.

The above-mentioned flat fabric is used as the bone material, and the fiber net is laminated. This fiber web forms a filter layer on the air inflow surface.

Next, 100% of PPS staple fiber ("Torcon" (registered trademark) S101-7.8T51mm manufactured by Toray Co., Ltd.) with a single fiber fineness of 7.8dtex (fiber diameter of 27.2μm) and a cut length of 76mm) was opened and carded. After the treatment, temporary needle puncturing was performed with a needle density of 50 needles/cm ² , and the obtained ^{fiber net with a unit area weight of 220 g/m 2} was laminated on the other side of the flat fabric. This fiber web forms a filter layer on the air discharge surface.

Furthermore, a flat fabric (a bone material) was entangled with the above-mentioned two kinds of fiber webs by a needle punching process to obtain a filter material ^{with a basis weight of 544 g/m 2} and a total needle density of 300 needles/cm ^2.

Table 1 shows the performance of the resulting filter material. The filter material obtained here shrinks due to the needle piercing treatment, and the weight per unit area tends to be higher than theoretically.

[Example 2] Except for the fibers constituting the fiber web on the air inflow side, PPS fibers with a single fiber fineness of 0.5 dtex (fiber diameter 6.9 μm) and a single fiber fineness of 2.2 dtex (fiber diameter 14.5 μm) were spun at a mass ratio of 50:50 The filter material was obtained in the same manner as in Example 1 except for the mixed fiber. Table 1 shows the performance of the resulting filter material.

[Example 3] Except for the fibers constituting the fiber web on the air inflow side, PPS fibers with a single fiber fineness of 0.8 dtex (fiber diameter of 8.7 μm) and a single fiber fineness of 3.0 dtex (fiber diameter of 16.2 μm) were spun at a mass ratio of 50:50. The filter material was obtained in the same manner as in Example 1 except for the mixed fiber. Table 1 shows the performance of the resulting filter material.

[Example 4] Except for the fibers constituting the fiber web on the air inflow side, PPS fibers with a single fiber fineness of 0.5 dtex (fiber diameter 6.9 μm) and a single fiber fineness of 1.5 dtex (fiber diameter 11.9 μm) were spun and mixed with a mass of 20:80. Except for the fiber, a filter material was obtained in the same manner as in Example 1. Table 1 shows the performance of the resulting filter material.

[Example 5] Except for the fibers constituting the fiber web on the air inflow side, the single fiber fineness 0.5 dtex (fiber diameter 6.9 μm) and single fiber fineness 1.5 dtex (fiber diameter 11.9 μm) are spun and blended at a mass of 50:50. Except for the fiber, a filter material was obtained in the same manner as in Example 1. Table 1 shows the performance of the resulting filter material.

[Example 6] In addition to the fibers constituting the fiber web on the air inflow side, the single fiber fineness is 0.5 dtex (fiber diameter 6.9 μm), the single fiber fineness is 0.8 dtex (fiber diameter 8.7 μm), and the single fiber fineness is 2.2 dtex (fiber diameter 14.5 μm). The filter material was obtained in the same manner as in Example 1, except that the PPS fiber was spun and blended at a mass ratio of 20:30:50. Table 1 shows the performance of the resulting filter material.

[Example 7] In addition to the fibers constituting the fiber web on the air inflow side, the single fiber fineness is 0.5 dtex (fiber diameter 6.9 μm), single fiber fineness 1.5 dtex (fiber diameter 11.9 μm), and single fiber fineness 3.0 dtex (fiber diameter 16.2 μm). The filter material was obtained in the same manner as in Example 1, except that the PPS fiber was spun and blended at a mass ratio of 20:30:50. Table 1 shows the performance of the resulting filter material.

[Comparative Example 1] Except for the fibers constituting the fiber web on the air inflow side, PPS fibers with a single fiber fineness of 0.5 dtex (fiber diameter 6.9 μm) and a single fiber fineness of 0.8 dtex (fiber diameter 8.7 μm) are spun at a mass ratio of 60:40 The filter material was obtained in the same manner as in Example 1 except for the mixed fiber. Table 1 shows the performance of the resulting filter material.

[Comparative Example 2] Except for the fibers constituting the fiber web on the air inflow side, PPS fibers with a single fiber fineness of 0.5 dtex (fiber diameter 6.9 μm) and a single fiber fineness of 2.2 dtex (fiber diameter 14.5 μm) are spun at a mass ratio of 20:80 For the blending, the multi-stage lamination was not performed in the stretching step, and the crimp-containing tow oil content was set to 0.03% by weight, and the filter material was obtained in the same manner as in Example 1. Table 1 shows the performance of the resulting filter material.

[Comparative Example 3] Except for the fibers constituting the fiber web on the air inflow side, PPS fibers with a single fiber fineness of 0.5 dtex (fiber diameter 6.9 μm) and a single fiber fineness of 2.2 dtex (fiber diameter 14.5 μm) were spun at a mass ratio of 50:50 The fiber blending was performed in the stretching step without multi-stage lamination, except that the crimp-containing oil content was set to 0.40% by weight, and the filter material was obtained in the same manner as in Example 1. Table 1 shows the performance of the resulting filter material.

[Comparative Example 4] Except for the fiber web on the air inflow side, no spinning and blending is performed, and multi-stage lamination is not performed in the stretching step. The crimp-containing oil content is set to 0.03% by weight, and the single fiber fineness obtained by each is 0.5dtex (fiber diameter 6.9μm) PPS staple fiber and single fiber fineness 2.2dtex (fiber diameter 14.5μm) PPS staple fiber with a mass ratio of 20:80, prepared by a cotton opener manufactured by Daiwa Machinery Co., Ltd. at a processing speed of 150g/min For the sexual fiber opening, a carding machine manufactured by Daiwa Machinery Co., Ltd. was used, and the carding process was performed at a processing speed of 100 g/min, and the cotton blending operation was performed. The filter material was obtained in the same manner as in Example 1. Table 1 shows the performance of the resulting filter material.

[Comparative Example 5] Except for the fiber web on the air inflow side, no spinning and blending is performed, and multi-stage lamination is not performed in the stretching step. The crimp-containing oil content is set to 0.03% by weight, and the single fiber fineness obtained by each is 0.5dtex (fiber diameter 6.9μm) PPS staple fiber and single fiber fineness 2.2dtex (fiber diameter 14.5μm) PPS staple fiber with a mass ratio of 50:50, prepared by a cotton opener manufactured by Daiwa Machinery Co., Ltd. at a processing speed of 150g/min For the sexual fiber opening, a carding machine manufactured by Daiwa Machinery Co., Ltd. was used, and the carding process was performed at a processing speed of 100 g/min, and the cotton blending operation was performed. The filter material was obtained in the same manner as in Example 1. Table 1 shows the performance of the resulting filter material.

[Table 1] Example 1 Example 2 Example 3 Example 4 Example 5 Example 6 Example 7 Comparative example 1 Comparative example 2 Comparative example 3 Comparative example 4 Comparative example 5 Implementation of spinning and blending With or without Have Have Have Have Have Have Have Have Have Have without without Implementation of extended blending With or without Have Have Have Have Have Have Have Have without without without without Air inflow surface PPS0.5T % 20 50 20 50 20 20 60 20 50 20 50 PPS0.8T % 50 30 40 PPS1.5T % 80 50 30 PPS2.2T % 80 50 50 80 50 80 50 PPS3.0T % 50 50 Air discharge surface PPS7.8T % 100 100 100 100 100 100 100 100 100 100 100 100 Blending uniformity - 2.0 2.2 2.3 1.9 2.0 2.7 2.7 3.0 3.6 3.8 10.2 11.3 determination S S S S S S S A A A B B Atmospheric dust capture efficiency % 55 62 48 59 68 60 51 71 46 54 44 49 determination S S B S S S A S B A B B Pressure loss after dust blowing mmH ₂ O 7.3 7.7 5.8 7.4 7.8 7.4 5.7 7.9 7.7 7.8 7.6 7.8 determination A B S A B A S B B B B B Carding machine passability - S S S B B A A C A B B B Overview - A A A A A A A C B B C C

1: The fiber web (fiber web 1) that forms the filter layer on the air inflow surface 2: Fabrics containing heat-resistant fibers (aggregates) 3: The fiber web (fiber web 3) that forms the filter layer on the air discharge surface 4: Particle counter (upstream) 5: Filter material 6: Particle counter (downstream) 7: Fluid pressure gauge 8: Blower 9: Pulse jet load machine 10: Flow meter 11: Dust collection filter 12: Vacuum pump 13: Digital fluid pressure gauge 14: Dust supply machine 15: Dust dispersion machine 16: Whistling dust collection part 17: Atmospheric dust air 18: Air to remove atmospheric dust 19: Measuring dust 20: Air containing dust 21: Air to remove dust

Fig. 1 is an exploded cross-sectional view of a filter material (filter cloth) using a non-woven fabric containing polyphenylene sulfide short fibers of the present invention. Fig. 2 is a schematic side view of an air dust collection efficiency measuring device using a filter material (filter cloth) containing polyphenylene sulfide short fibers of the present invention. Fig. 3 is a schematic side view of a pressure loss measuring device using a filter material (filter cloth) containing polyphenylene sulfide short fibers obtained in the present invention after dust is blown.

without.

Claims (5)

A polyphenylene sulfide staple fiber is characterized by comprising at least two types of fibers with different single fiber deniers, and the uniformity of the mixed fiber is less than 3.0. Such as the polyphenylene sulfide staple fiber of claim 1, wherein the single fiber fineness is 0.5 dtex or more and 3.0 dtex or less, and at least two types of fibers with different single fiber deniers have the thickest fineness of 1.0 dtex or more, including crimped tow The oil content is 0.05 to 0.30% by weight. A filter cloth comprising the polyphenylene sulfide staple fiber as claimed in claim 1 or 2. A manufacturing method of polyphenylene sulfide staple fiber is characterized in that at least two types of fibers with different single fiber deniers are spun and blended simultaneously, and the blending uniformity is less than 3.0. According to the method for producing polyphenylene sulfide staple fiber of claim 4, the melt flow rate (MFR) of the polyphenylene sulfide resin used therein is 200-400 g/10 min at 320°C.

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