US20050077646A1 - Process for producing electret and production apparatus - Google Patents

Process for producing electret and production apparatus Download PDF

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Publication number
US20050077646A1
US20050077646A1 US10/501,265 US50126504A US2005077646A1 US 20050077646 A1 US20050077646 A1 US 20050077646A1 US 50126504 A US50126504 A US 50126504A US 2005077646 A1 US2005077646 A1 US 2005077646A1
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Prior art keywords
thermoplastic resin
droplets
fibers
melt
process according
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Osamu Akiba
Akihiro Matsubayashi
Masaaki Nagashima
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Japan Vilene Co Ltd
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Japan Vilene Co Ltd
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Assigned to JAPAN VILENE CO., LTD. reassignment JAPAN VILENE CO., LTD. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: AKIBA, OSAMU, MATSUBAYASHI, AKIHIRO, NAGASHIMA, MASAAKI
Publication of US20050077646A1 publication Critical patent/US20050077646A1/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/01—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with hydrogen, water or heavy water; with hydrides of metals or complexes thereof; with boranes, diboranes, silanes, disilanes, phosphines, diphosphines, stibines, distibines, arsines, or diarsines or complexes thereof
    • D06M11/05—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with hydrogen, water or heavy water; with hydrides of metals or complexes thereof; with boranes, diboranes, silanes, disilanes, phosphines, diphosphines, stibines, distibines, arsines, or diarsines or complexes thereof with water, e.g. steam; with heavy water

Definitions

  • the present invention relates to a process and an apparatus for manufacturing an electret article.
  • a nonwoven fabric filter has been used to capture dust in a gas.
  • Nonwoven fabric filters capture dust or the like mainly by physical functions such as Brownian diffusion, an interruption, or an inertial impaction. Therefore, a nonwoven fabric filter made of finer fibers can capture and remove finer dust, and thus improve the dust collection efficiency. Nevertheless, there is a problem in that the pressure loss is increased as the fiber diameter of the nonwoven fabric filter is reduced, and thus, the lifetime of the nonwoven fabric filter is shortened.
  • Patent Document 1 discloses a method and an apparatus for electrical charging of the individual fibers by spraying a sufficient amount of polar liquid onto a nonconductive polymer before forming a fiber web, collecting the fibers to form a nonwoven web, and then drying the web. According to this method and the apparatus, an electret article can be obtained without applying an electric field, by spraying of the polar liquid directly onto the individual fibers before forming the fiber web and drying the individual fibers.
  • the method and the apparatus disclosed in the Patent Document 1 has advantageous effects in that a large amount of electrical charge can be acquired, and after the fiber web is formed, a procedure for electrically charging the resulting fiber web is not required to obtain an electret web. Nevertheless, in the method and the apparatus, the nonconductive polymer must be thoroughly saturated with the polar liquid to be electrically charged, and thus, the drying step is required. This means that a large amount of energy is required for the drying.
  • the inventors of the present invention engaged in intensive research to overcome the above disadvantages of the prior art and, as a result, found that an electret article having a large amount of electrical charge can be produced through a simple process without the need of a large amount of energy for drying.
  • the present invention is based on the above findings.
  • the present invention relates to a process for manufacturing an electret article, comprising passing melt-extruded thermoplastic resin fibers through a mist space substantially formed from droplets of a polar liquid, and then collecting the fibers, wherein the thermoplastic resin fibers contain electrical-chargeability enhancing agents, and the average diameter of the droplets is less than 20 ⁇ m.
  • thermoplastic resin fibers containing electrical-chargeability enhancing agents a large amount of electrical charge can be imparted by passing the extruded thermoplastic resin fibers containing electrical-chargeability enhancing agents through the mist space formed from the droplets of a polar liquid, and a drying procedure becomes unnecessary because an average diameter of the droplets used is less than 20 ⁇ m, and thus, the thermoplastic resin fibers are not wetted. It is believed that smaller droplets have a higher surface tension, and thus, do not wet the thermoplastic resin fibers.
  • thermoplastic resin fibers are not subjected to a drying step after passing through the mist space.
  • the present inventors also found that, when the resin-droplet percentage is 500 or more, that is, the amount of the droplets in the mist space is relatively large with respect to the amount of the thermoplastic resin, a large amount of electrical charge can be imparted.
  • a heated gas is blown onto the melt-extruded thermoplastic resin fibers.
  • the fibers are drawn and become finer.
  • an electret article formed from finer fibers, and accordingly having enhanced properties can be obtained.
  • an electret article having a high collection efficiency, an electret article having an excellent feeling, an electret article having an excellent separating performance, or an electret article having an excellent masking property can be produced.
  • a volume specific resistivity of the thermoplastic resin is 10 14 ⁇ cm or higher, particularly 10 16 ⁇ cm or higher.
  • the amount of electrical charge can be increased.
  • the polar liquid is water.
  • the environment wherein the electret article is produced becomes good.
  • the electrical-chargeability enhancing agent is at least one compound selected from a group consisting of a hindered amine compound, a metallic salt of a fatty acid, a metallic oxide, and an unsaturated carboxylic acid-modified high-molecular compound.
  • the amount of electrical charge can be remarkably increased.
  • the average diameter of the droplets is 15 ⁇ m or less.
  • the amount of electrical charge can be further increased. This is because the number of droplets can be increased under the condition of the same total amount of droplets.
  • the present invention also relates to an apparatus for manufacturing an electric article, comprising (1) a means for melt-extruding a thermoplastic resin containing an electrical-chargeability enhancing agent to form thermoplastic resin fibers; (2) a means for spraying droplets consisting essentially of a polar liquid to a space downstream of a direction of said thermoplastic resin extruded from said means for melt-extruding said thermoplastic resin, to thereby form a mist space, the average diameter of said droplets being less than 20 ⁇ m; and (3) a means for collecting said thermoplastic resin fibers which have been passed through said mist space.
  • FIG. 1 is a schematic sectional view of an apparatus for manufacturing an electret article according to the present invention.
  • FIG. 1 i.e., a schematic sectional view of an apparatus for manufacturing an electret article according to the present invention.
  • thermoplastic resin fibers 20 contain the electrical-chargeability enhancing agents.
  • the thermoplastic resin contains the electrical-chargeability enhancing agents, it is not necessary to supply the electrical-chargeability enhancing agents to the thermoplastic resin.
  • the thermoplastic resin can be mixed with the electrical-chargeability enhancing agents before or after supplied to the melt-extruding apparatus 10 .
  • thermoplastic resin fibers 20 contain the electrical-chargeability enhancing agents. Therefore, an electret article 60 having a large amount of electrical charge can be produced, according to the present invention.
  • the thermoplastic resin fibers 20 are supplied to and passed through a mist space 30 formed from droplets 31 of a polar liquid.
  • the thermoplastic resin fibers 20 are electrically charged when passed through the mist space 30 . It is believed that the droplets 31 of a polar liquid which droplets form the mist space 30 have an average diameter of 20 ⁇ m or less and so have a higher surface tension, and thus, the thermoplastic resin fibers 20 are not wetted. Therefore, it is possible to omit a procedure for drying the thermoplastic resin fibers 20 in the present invention.
  • the mist space 30 is formed from the droplets 31 sprayed from a droplets-spraying apparatus 40 .
  • an electret article 60 having a larger amount of electrical charge can be produced.
  • the resulting electrically-charged thermoplastic resin fibers 21 are collected by a belt conveyer 50 located under the melt-extruding apparatus 10 , whereby the electret article 60 is formed thereon.
  • the electret article 60 is not wetted, and thus can be used as an electret product without being dried, or can be supplied to subsequent steps for processing for other applications without being dried.
  • thermoplastic resin which may be used in the present invention is not particularly limited, so long as it may be extruded.
  • the thermoplastic resin is made of a resin having a volume specific resistivity of 10 14 ⁇ cm or higher, more preferably 10 16 ⁇ cm or higher.
  • a resin can result in the increase of the amount of electrical charge.
  • volume specific resistivity as used herein is a value determined by a measuring apparatus of a volume specific resistivity, which apparatus is used in an insulation resistance test by a three-terminals method in accordance with a “Testing method for thermosetting plastics” prescribed in JIS K6911.
  • the thermoplastic resin is, for example, a polyolefin-based resin, such as a polyethylene-based resin, polypropylene-based resin, polymethylpentene-based resin, or polystyrene-based resin, polytetrafluoroethylene, polyvinylidene chloride, polyvinyl chloride, polyurethane, or the like.
  • the polyolefin-based resin is preferably used, because it has a high volume specific resistivity, and has an easy-processing property because of a thermoplasticity thereof.
  • the polypropylene-based resin, or polymethylpentene-based resin is more preferably used, because it has an excellent heat resistance.
  • the amount of electrical charge can be increased by the electrical-chargeability enhancing agents contained in the thermoplastic resin.
  • the electrical-chargeability enhancing agent is not particularly limited, so long as it can increase the amount of electrical charge in an article containing itself. More particularly, an electret article containing a certain compound and an electret article not containing the same compound are produced by the process of the present invention. When the amount of electrical charge in the electret article containing the compound is increased in comparison with that of electrical charge in the electret article not containing the compound, the compound can be determined as the electrical-chargeability enhancing agent.
  • a preferred electrical-chargeability enhancing agent used in the present invention is, for example, a hindered amine compound, a metallic salt of a fatty acid, for example, a metallic salt of a fatty acid having 10 to 30 carbon atoms, such as magnesium stearate or aluminum stearate, or the like, a metallic oxide, such as titanium oxide, silicon dioxide, a naturally-occurring mineral, and an unsaturated carboxylic acid-modified high-molecular compound, such as polyethylene, polypropylene, or polystyrene modified by an unsaturated carboxylic acid having 3 to 10 carbon atoms, such as acrylic acid, methacrylic acid, or maleic acid.
  • the electrical-chargeability enhancing agent as above can be used alone, or in combination thereof.
  • the hindered amine compound can particularly increase the amount of electrical charge, and thus is preferable.
  • the hindered amine compound is, for example, poly[ ⁇ (6-(1,1,3,3-tetramethylbutyl)imino-1,3,5-triazine-2,4-diyl) ⁇ (2,2,6,6-tetramethyl-4-piperidyl)imino ⁇ hexamethylene ⁇ (2,2,6,6-tetramethyl-4-piperidyl)imino ⁇ ], or dimethyl succinate-1-(2-hydroxyethyl)-4-hydroxy-2,2,6,6-tetramethylpiperidine polycondensate, or 2-(3,5-di-t-butyl-4-hydroxybenzyl)-2-n-butyl malonic acid bis(1,2,2,6,6-pentamethyl-4-piperidyl).
  • the amount of the electrical-chargeability enhancing agents contained in the thermoplastic resin is not particularly limited, but is preferably 0.01 to 5 mass % with respect to the total mass of the thermoplastic resin and the electrical-changeability enhancing agent.
  • the amount of the electrical-chargeability enhancing agent is less than 0.01 mass %, the amount of electrical charge might be insufficient.
  • the amount is more preferably 0.05 mass % or more, or most preferably 0.1 mass % or more.
  • the amount of the electrical-chargeability enhancing agent is more than 5 mass %, a physical strength of the electret article might be lowered.
  • the amount is more preferably 4 mass % or less, or still more preferably 3 mass % or less, or most preferably 2.5 mass % or less.
  • the thermoplastic resin containing an electrical-chargeability enhancing agent can be melted and extruded in the form of fibers from the melt-extruding apparatus.
  • the melt-extrusion may be carried out by simple extruding of the thermoplastic resin fibers 20 from the melt-extruding apparatus 10 as shown in FIG. 1 .
  • a heated gas may be blown onto, or an electric field may be applied to, the melt-extruded thermoplastic resin fibers after extrusion from the melt-extruding apparatus 10 .
  • the blowing of the heated gas, or the application of the electric field is preferably carried out before passing the fibers through the mist space.
  • a conventional die such as that used in a spun-bonding method may be used.
  • a heated gas is blown after extrusion from the melt-extruding apparatus
  • a conventional die such as that used in a melt-blowing method may be used.
  • an electric field may be applied after extrusion from the melt-extruding apparatus
  • a conventional die such as that used in an electrostatically extruding method may be used.
  • the method of blowing a heated gas is preferable, because the fibers are drawn and fined, and thus many properties are improved. For example, an electret article having a high collection efficiency, an electret article having an excellent feeling, an electret article having an excellent separating performance, or an electret article having an excellent masking property can be produced.
  • the temperature of the blowing gas is higher than the melting point of the thermoplastic resin, and lower than a decomposition temperature of the thermoplastic resin.
  • the amount of the heated blowing gas is not particularly limited, but is preferably 5-fold to 2000-fold (mass) larger than the mass of the thermoplastic resin extruded.
  • the gas is not particularly limited, but preferably air is used in view of the manufacturing environment of the article.
  • the thermoplastic resin fibers 20 melt-extruded from the melt-extruding apparatus 10 are electrically charged by passing through the mist space 30 formed from the droplets 31 of the polar liquid.
  • an electric field may or may not be applied to the mist space. Electrical charge may be imparted without applying an electric field.
  • the polar liquid used to form the droplets is not particularly limited, but for example, is water, alcohol, acetone, ammonia, or the like.
  • the polar liquid as above may be used alone, or in a combination thereof. From the point of view of the manufacturing environment, it is preferable to use water, particularly, only water.
  • a drying procedure can be omitted, by fining an average diameter of the droplets used to less than 20 ⁇ m.
  • the reason why the thermoplastic resin fibers are not wetted is unclear, when the average diameter of the droplets is less than 20 ⁇ m.
  • the present inventors believe that smaller droplets have a higher surface tension, and thus, do not wet the thermoplastic resin fibers when in contact therewith. Therefore, it is supposed that the tendency not to wet the thermoplastic resin fibers would be strengthened as the surface tension is increased. Therefore, the average diameter of the droplets is preferably 15 ⁇ m or less, more preferably 12 ⁇ m or less.
  • the average diameter of the droplet becomes smaller in the mist space formed from a given mass of the droplets, the number of droplets acting on the thermoplastic resin fibers is increased, and thus, the amount of electrical charge can be further increased.
  • the average diameter is suitably about 0.1 ⁇ m.
  • the average diameter is smaller than 0.1 ⁇ m, the amount of electrical charge is liable to be lowered.
  • the term “average diameter of the droplets” as used herein means a Sauter's mean diameter obtained by a measure using a laser Doppler particle size distribution measuring equipment.
  • the mist space used in the present invention may be formed from a number of droplets floating or hanging as a mass in a spatial area; preferably a mist space formed from a number of droplets moving in a given direction or in various directions; or a mist space formed from floating and moving droplets.
  • the mist space may be formed by a commercially available droplets-spraying apparatus, such as an atomizer of “AKIMist” (tradename; Ikeuchi Co., Ltd.) or “AKIJet” (tradename; Ikeuchi Co., Ltd.).
  • thermoplastic resin fibers may be passed through the mist space in any direction. However, it is preferable that the thermoplastic resin fibers are passed through the mist space in a direction perpendicular to the spraying direction of the droplets from the droplets-spraying apparatus, because the amount of electrical charge can be increased.
  • the resin-droplet percentage of the formula: (Wp/Wf) ⁇ 100 is preferably 500 or more.
  • the amount of electrical charge can be increased. It is believed that this is because the number of the droplets acting on the thermoplastic resin fibers is increased. Further, as mentioned above, if the average diameter of the droplet becomes smaller in the mist space formed from a given mass of the droplets, the number of the droplets acting on the thermoplastic resin fibers is increased, and thus, the amount of electrical charge can be increased.
  • the resin-droplet percentage is more preferably 600 or more, particularly preferably 700 or more, most preferably 1000 or more.
  • the resin-droplet percentage is more preferably 600 or more, particularly preferably 700 or more, most preferably 1000 or more.
  • There is no upper limit of the resin-droplet percentage but is preferably a value at which the thermoplastic resin fibers are not wetted. Such an upper limit of the resin-droplet percentage at which the thermoplastic resin fibers are not wetted may be experimentally determined, if necessary.
  • the resin-droplet percentage can be suitably obtained by adjusting the amount of the fibers extruded from the melt-extruding apparatus 10 and the amount of the droplets sprayed from the droplets-spraying apparatus 40 , as shown in FIG. 1 .
  • the number of the droplets-spraying apparatus used to form the mist space is not particularly limited.
  • two droplets-spraying apparatuses 40 , 41 may be placed as shown in FIG. 1 , or one apparatus or three or more apparatuses may be used.
  • various conditions such as the average diameter of the droplets, the amount of the droplets, the velocity of the droplets, or properties or kinds of the polar liquid may be applied.
  • the electret article 60 can be manufactured by passing the thermoplastic resin fibers 20 through the mist space 30 as shown above to electrically charge the fibers 20 , and collecting the electrically charged thermoplastic resin fibers 21 on a suitable support, such as a belt conveyer 50 .
  • the resulting electret article 60 is not wetted, and therefore, it is possible to omit a drying procedure after the thermoplastic resin fibers 20 are passed through the mist space, in the present invention.
  • the expression “the drying procedure is not necessary” as used herein means that, for example in the embodiment as shown in FIG.
  • thermoplastic resin fibers 21 before collecting or an electret (i.e., electrically charged) article 60 after collecting
  • an electret i.e., electrically charged
  • the above expression means that a drying procedure is not necessary after the thermoplastic resin fibers are passed through the mist space.
  • the unnecessity of the drying step may bring about additional advantageous effects. For example, if an electrically charged article is dried by heating to enhance productivity, the amount of electrical charge may be lowered. Nevertheless, the present invention does not have such a defect.
  • the collecting means are not particularly limited.
  • the belt conveyer 50 as shown in FIG. 1 , or a roller may be used.
  • the collecting means such as the belt conveyer or the roller used may be porous or nonporous.
  • a suction apparatus may be placed under the collecting means such as the belt conveyer or the roller to suck the electret (or electrically charged) thermoplastic resin fibers and prevent disturbance of the electret article.
  • the surface of the collecting means such as the belt conveyer or the roller may be a plane or curved, or alternatively have other three-dimensional shapes.
  • a porous or nonporous material may be located on the collecting means such as the belt conveyer or the roller, and it can be easily integrated with the electret article.
  • a porous or nonporous material is a sheet such as a woven fabric, knitted fabric, nonwoven fabric, or a complex thereof, a porous film such as a perforated film, a foam, or a complex thereof.
  • An example of the nonporous material is a nonporous film.
  • a shape, a form, or a condition of the electret article varies with those of the thermoplastic resin fibers.
  • the electret article may be a fibrous aggregate (or web) or a film.
  • the electret article is preferably a fibrous aggregate, more preferably a melt-blown fibers aggregate or web formed from fine fibers and having an excellent collection efficiency.
  • the electret article manufactured by the process according to the present invention contains a large amount of electrical charge, and thus may be used, for example, as a gas filter for air or the like, a liquid filter for oil, water, or the like, a filter for a mask such as a mold mask, a medical material for recovering or improving healthy, a wiping material, dust-proof clothing, a sensor element of a sonic wave or vibration, or in other applications.
  • the electret article manufactured by the process according to the present invention may be used in the various applications as above, and subsequent processing may be carried out depending on the applications.
  • the electret article is used as a gas filter, which is a preferred embodiment of the present invention, the electret article is preferably pleated to broaden a filterable area thereof.
  • a starting resin was a polypropylene pellet containing 1 mass % poly[ ⁇ (6-(1,1,3,3-tetramethylbutyl)imino-1,3,5-triazine-2,4-diyl) ⁇ (2,2,6,6-tetramethyl-4-piperidyl)imino ⁇ hexamethylene ⁇ (2,2,6,6-tetramethyl-4-piperidyl)imino ⁇ ], [a hindered amine based electrical-chargeability enhancing agent: CHIMASSORB 944FD (trade name); Chiba Specialty Chemicals Co., Ltd.] with respect to a total mass of the resin and the agent.
  • the volume specific resistivity of the polypropylene was higher than 10 14 ⁇ cm.
  • the polypropylene pellet was melt-blown by a usual melt-blowing apparatus while an air having a temperature of 300° C. was blown onto the fibers, to obtain melt-blown fibers.
  • a mass of the air blown was 1500 times (mass) the mass of polypropylene.
  • the resulting melt-blown fibers were passed through a mist space to obtain electret melt-blown fibers while being spun from the melt-blowing apparatus.
  • the mist space was formed from droplets sprayed from a droplet-spraying apparatus [AKIMist (trade name); Ikeuchi Co., Ltd.].
  • the average diameter of the droplets sprayed from the droplet-spraying apparatus was 10 ⁇ m.
  • the mist space was formed at a downstream side from the position where the heated air was blown.
  • the mist space had a resin-droplet percentage of 1150, and a variation coefficient of 0.05.
  • the electret melt-blown fibers were collected on a belt conveyer made of a stainless steel mesh without a drying step while being sucked from the opposite side of the belt conveyer, to thereby obtain electret melt-blown fibers web having an average fiber diameter of 5 ⁇ m, i.e., an electret article.
  • a starting resin was a polypropylene pellet containing 3 mass % hindered amine based electrical-chargeability enhancing agent as used in Example 1, with respect to a total mass of the resin and the electrical-chargeability enhancing agent.
  • the volume specific resistivity of the polypropylene was higher than 10 14 ⁇ cm.
  • the polypropylene pellet was melt-blown by a usual melt-blowing apparatus while an air having a temperature of 260° C. was blown onto the fibers, to obtain melt-blown fibers. A mass of the air blown was 50 times (mass) the mass of the polypropylene.
  • the resulting melt-blown fibers were passed through a mist space to obtain electret melt-blown fibers while being spun from the melt-blowing apparatus.
  • the mist space was formed from droplets sprayed from the droplet-spraying apparatus used in Example 1. An average diameter of the droplets sprayed from the droplet-spraying apparatus was 10 ⁇ m.
  • the mist space was formed at a downstream side from the position where the heated air was blown.
  • the mist space had a resin-droplet percentage of 750, and a variation coefficient of 0.05.
  • the electret melt-blown fibers were collected on a belt conveyer made of a stainless steel mesh without a drying step while being sucked from the opposite side of the belt conveyer, to thereby obtain electret melt-blown fibers web having an average fiber diameter of 7 ⁇ m, i.e., an electret article.
  • Example 2 The procedures of Example 1 were repeated except that an average diameter of the droplets sprayed from a droplet-spraying apparatus was 30 ⁇ m. However, the melt-blown fibers collected on the conveyer were thoroughly saturated with water, and a drying step was required.
  • Example 1 The procedures of Example 1 were repeated except that a polypropylene pellet without a hindered amine was used, to obtain an electret article without a drying step.
  • Example 1 The procedures of Example 1 were repeated except that a polypropylene pellet without a hindered amine was used, and the fibers were not passed through the mist space, to obtain a web of the melt-blown fibers without a drying step.
  • a pressure loss of each of the electret articles of Examples 1 and 2 and Comparative Example 2 and the melt-blown fibers web of Comparative Example 3 was measured, using an atmospheric air at an air velocity of 10 cm/second. The results are listed in Table 1.
  • the melt-blown fibers web of Comparative Example 1 were thoroughly saturated when collected, and thus, a drying step was required. Therefore, a pressure loss thereof could not be measured.
  • the electret articles produced by the process of the present invention had an excellent collection efficiency, despite a lower pressure loss in comparison with that of the melt-blown fibers web of Comparative Examples 2 and 3. Therefore, it is assumed that electret articles produced by the process of the present invention had a large amount of electrical charge.
  • an electret article having a large amount of electrical charge can be produced by a simple process without a drying step.
  • the amount of electrical charge can be increased.
  • the fibers are drawn and become fine:
  • an electret article formed from fine fibers and having enhanced properties can be obtained.
  • the amount of electrical charge can be increased.
  • the polar liquid is water in the process of the present invention, the environment wherein the electret article is produced becomes good.
  • the electrical-chargeability enhancing agent is at least one compound selected from a group consisting of a hindered amine compound, a metallic salt of a fatty acid, a metallic oxide and an unsaturated carboxylic acid-modified high-molecular compound, in the process of the present invention, the amount of electrical charge can be remarkably increased.
  • the amount of electrical charge can be further increased. This is because the number of droplets can be increased under the condition of same total amount of droplets.
  • an electret article having a large amount of electrical charge can be produced by a simple apparatus without a drying means.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Filtering Materials (AREA)
  • Electrostatic Separation (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
US10/501,265 2002-01-11 2003-01-14 Process for producing electret and production apparatus Abandoned US20050077646A1 (en)

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JP2002005232 2002-01-11
JP2002-005232 2002-01-11
PCT/JP2003/000185 WO2003060216A1 (fr) 2002-01-11 2003-01-14 Procédé et dispositif de production d'électret

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EP (1) EP1471176B1 (ja)
JP (1) JP4133830B2 (ja)
WO (1) WO2003060216A1 (ja)

Cited By (8)

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US20170326485A1 (en) * 2014-12-26 2017-11-16 Toray Industries, Inc. Protective clothing
CN111560137A (zh) * 2020-05-28 2020-08-21 金发科技股份有限公司 一种用于口罩熔喷无纺布的驻极母粒及其制备方法与应用
CN112778632A (zh) * 2020-12-28 2021-05-11 银禧工程塑料（东莞）有限公司 长效熔喷聚丙烯驻极母粒及其制备方法和熔喷无纺布
CN114173904A (zh) * 2019-06-28 2022-03-11 3M创新有限公司 过滤器组件、预过滤器组件和包括它们的呼吸器
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JP2008221074A (ja) * 2007-03-09 2008-09-25 Toyobo Co Ltd エレクトレット濾材およびその製造方法
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JP6168979B2 (ja) * 2013-12-16 2017-07-26 三菱電機株式会社 フィルタ帯電処理装置およびフィルタ帯電処理方法
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JP6691874B2 (ja) * 2015-02-11 2020-05-13 日本バイリーン株式会社 濾過材、それを用いたフィルタエレメント、及び濾過材の製造方法
JP6528243B2 (ja) * 2015-08-31 2019-06-12 パナソニックＩｐマネジメント株式会社 不織布、空気清浄機、および不織布の製造方法
US20220288560A1 (en) * 2019-08-21 2022-09-15 Toyobo Co., Ltd. Electret and filter using the same
JP7359327B1 (ja) 2022-03-03 2023-10-11 東レ株式会社 エレクトレットメルトブロー不織布の製造方法および製造装置
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US20110168024A1 (en) * 2008-09-16 2011-07-14 Carl Freudenberg Kg Electret filter element and method for the production thereof
US8871011B2 (en) * 2008-09-16 2014-10-28 Carl Freudenberg Kg Electret filter element and method for the manufacture thereof
CN103348048A (zh) * 2010-08-23 2013-10-09 菲特萨德国有限公司 具有驻极体性质的非织造网和纤维、其制造工艺及其用途
US10036107B2 (en) 2010-08-23 2018-07-31 Fiberweb Holdings Limited Nonwoven web and fibers with electret properties, manufacturing processes thereof and their use
US20170326485A1 (en) * 2014-12-26 2017-11-16 Toray Industries, Inc. Protective clothing
US11396720B2 (en) * 2018-11-30 2022-07-26 The Procter & Gamble Company Methods of creating soft and lofty nonwoven webs
US11686026B2 (en) 2018-11-30 2023-06-27 The Procter & Gamble Company Methods for producing through-fluid bonded nonwoven webs
US11767622B2 (en) 2018-11-30 2023-09-26 The Procter & Gamble Company Methods of creating soft and lofty nonwoven webs
CN114173904A (zh) * 2019-06-28 2022-03-11 3M创新有限公司 过滤器组件、预过滤器组件和包括它们的呼吸器
CN111560137A (zh) * 2020-05-28 2020-08-21 金发科技股份有限公司 一种用于口罩熔喷无纺布的驻极母粒及其制备方法与应用
CN111560137B (zh) * 2020-05-28 2020-10-16 金发科技股份有限公司 一种用于口罩熔喷无纺布的驻极母粒及其制备方法与应用
CN112778632A (zh) * 2020-12-28 2021-05-11 银禧工程塑料（东莞）有限公司 长效熔喷聚丙烯驻极母粒及其制备方法和熔喷无纺布

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