WO2000057989A1

WO2000057989A1 - Filter cartridge

Info

Publication number: WO2000057989A1
Application number: PCT/JP2000/001999
Authority: WO
Inventors: Osamu Yamaguchi; Shigenori Fukuda
Original assignee: Chisso Corporation
Priority date: 1999-03-30
Filing date: 2000-03-30
Publication date: 2000-10-05
Also published as: KR20010110463A; DE10084397T1; JP4604351B2

Abstract

A filter cartridge which comprises a porous cylindrical body and, wound cylindrically in a twill manner around it, a strap of non-woven fabric comprising melt blown thermoplastic fibers or a strap of non-woven fabric prepared by laminating at least one layer of a collection of non-woven fibers comprising melt blown thermoplastic fibers and at least one layer of a collection of non-woven long fibers and bonding them together. The filter cartridge is excellent in liquid permeability, filtration life, the stability in precision of filtration and the like.

Description

Description Filter technology

The present invention relates to a filter cartridge for liquid filtration, more specifically, a band-shaped nonwoven fabric (hereinafter, abbreviated as a band-shaped melt-pro-nonwoven fabric) made of melt-produced thermoplastic fiber (hereinafter, abbreviated as a melt-pro-fiber), or melt-blown. A nonwoven fabric (hereinafter, abbreviated as a belt-shaped melt-blown nonwoven fabric) formed by laminating and bonding at least one layer each of a nonwoven fiber aggregate made of thermoplastic fibers and a long-fiber nonwoven fiber aggregate into a perforated tube The present invention relates to a filter that can be wound around a filter in a tubular shape by traversing.

At present, various filters for purifying fluids are being developed and manufactured. Above all, cartridge type filters (hereinafter abbreviated as filter cartridges), in which filter media can be easily replaced, are used to remove suspended particles in industrial liquid raw materials and to remove cake flowing out of a cake filtration device. It is used in a wide range of industrial fields such as industrial water purification.

Several types of filter-cartridge structures have been proposed. Among them, the most typical is a wound filter and a cartridge. This is a cylindrical cartridge that is made by winding a spun yarn as a filter material around a perforated cylindrical core in a twill shape, and then fluffing the spun yarn. It's being used. Other than that, there is a non-woven fabric laminated filter cartridge. This is a cylindrical filter cartridge made by winding several types of nonwovens, such as carding nonwovens, into a perforated cylindrical core and stepwise concentrically winding them. Has been

However, these filters have several disadvantages. For example, the method of collecting particles in a wound-type filler cartridge is based on the spun yarn. Particles are collected by the fluff, and the particles are trapped in the gap between the spun yarns.However, it is difficult to adjust the size and shape of the fluff and the gap, so the size and amount of particles that can be collected are limited. There is a disadvantage that there is. In addition, since spun yarn is made from short fibers, there is a disadvantage that constituent fluids of the spun yarn fall off when a fluid flows through the filter force cartridge. Furthermore, when producing spun yarn, a small amount of a surfactant is often applied to the surface of the spinning machine in order to prevent the short fibers from being attached to the spinning machine due to static electricity or the like. Filter made from spun yarn coated with such a surfactant

— Filtering the liquid with a cartridge may adversely affect the cleanliness of the liquid, including bubbling of the liquid, an increase in TOC (total organic carbon), COD (chemical oxygen demand), and electrical conductivity. Further, as described above, since spun yarn is made by spinning short fibers, it requires at least two steps of spinning short fibers and spinning, and as a result, the price may increase.

Also, as shown in Fig. 1, a so-called non-woven laminated filter cartridge, which has a structure in which a wide non-woven fabric is wound around a perforated tubular body as it is, is called a non-woven laminated filter cartridge. Decided. Non-woven fabrics are produced by entanglement of short fibers with a carding machine or air laid machine, followed by heat treatment with a hot air heater or heating roll, if necessary, or by a direct method such as melt blow method or spun bond method. Often done by non-woven fabric. However, any machine used for nonwoven fabric production, such as a card machine, an air laid machine, a hot air heater, a heating roll, a melt blow machine, a spun bond machine, etc., often has uneven nonwoven fabric properties such as basis weight in the machine width direction. This can result in poor quality filter cartridges or higher manufacturing costs if advanced manufacturing techniques are used to eliminate unevenness. In addition, it is necessary to use about 2 to 6 types of non-woven fabric for each type of non-woven fabric laminated filter cartridge.Furthermore, it is necessary to use different non-woven fabrics for each type of filter. May also increase manufacturing costs.

Several methods have been proposed to solve such problems of the conventional fill cartridge. For example, Japanese Utility Model Publication No. 6-777067 has a porosity. A filter cartridge has been proposed in which a filter material, which is squeezed and squeezed while twisting a tape-shaped paper while restricting its diameter to about 3 mm, is closely wound around a porous inner cylinder. This method has the advantage that the winding bit of the winding can be increased outward from the porous inner cylinder. However, it is necessary to squeeze the filter material to narrow it down.Therefore, the collection of particles is mainly carried out between the pitches of the filter material. It is difficult to expect the collection of particles by the filtration material itself, as was the case. As a result, the surface of the filter may be clogged and the filtration life may be shortened, or the permeability may be poor.

As another method, Japanese Unexamined Patent Publication (Kokai) No. Hei 11-1543 discloses a method of cutting a cellulose spunbond non-woven fabric into a band-shaped body on a bobbin having a large number of fine holes and twisting the narrow hole through a narrow hole. Fil Yuichi has been proposed in which the added string is wound. By using this method, mechanical strength is higher than that of a conventional tissue filter made of refined soft cellulose knives made of thin cellulose paper and wound in a roll, and there is no dissolution by water or elution of binder. It is thought that we can make Phil Yuichi. However, the cellulose spunbonded nonwoven fabric used for this filter has a paper-like form, so it is too rigid, and the conventional thread-wound filter traps particles with its fluff. It is difficult to expect the collection of particles by the filtration material itself. In addition, cellulose 'spunbond nonwoven fabric has a paper-like form and therefore easily swells in the liquid.Swelling reduces the strength of the filter, changes the filtration accuracy, deteriorates liquid permeability, reduces filtration life, etc. Problems can arise. In addition, the bonding of fiber intersections of cellulose spunbonded nonwoven fabrics is often performed by chemical treatment or the like, but the bonding is often inadequate, causing a change in filtration accuracy or fiber. It often causes debris to fall off, making it difficult to obtain stable filtration performance.

As another method, Japanese Patent Publication No. Hei 4-45810 discloses a slit nonwoven fabric composed of a conjugate fiber in which 10% by weight or more of the constituent fibers is divided into 0.5 denier or less. Wound on the core tube so that the fiber density is 0.18 to 0.30 (g / cm ³ ) Phil Yuichi has been suggested. By using this method, it is said that fine particles in liquid can be captured by fibers with small fineness. However, it is necessary to use physical stress such as high-pressure water to divide the composite fiber, and it is difficult to uniformly divide the entire nonwoven fabric by high-pressure water. If it is not uniformly divided, there is a difference in the collection particle diameter between a well-divided portion and an insufficiently-divided portion in the nonwoven fabric, so that filtration accuracy may be coarse. In addition, the strength of the non-woven fabric may decrease due to the physical stress used during splitting, so the strength of the manufactured filter will decrease and it will be easily deformed during use, or the porosity of the filter will change Liquid permeability may be reduced. Further, when the strength of the nonwoven fabric is low, it is difficult to adjust the tension when wound around the porous core tube, so that it may be difficult to finely adjust the porosity. Furthermore, the spinning technology required to produce easily splittable fibers and the increase in operating costs during production increase the cost of manufacturing filters. It can be used in some fields where a high level of filtration performance is required, such as industry.However, pool water filtration It seems that it is difficult to use for applications that require.

As a result of studying to solve the above problem, a non-woven fiber aggregate made of melt-pro fibers, or a non-woven fiber aggregate made of melt-blown fibers and a long-fiber non-woven fiber aggregate, are wrapped in a perforated cylindrical body. The present inventors have found that it is possible to obtain a cylindrical filter cartridge excellent in liquid permeability, filtration life, stability of filtration accuracy, and the like by using the filter cartridge wound around the present invention, and arrived at the present invention. Disclosure of the invention

The present invention has the following configuration.

(1) A filament cartridge comprising a band-shaped nonwoven fabric made of melt-blown thermoplastic fiber wound around a perforated cylindrical body in a twill pattern.

(2) A belt-shaped nonwoven fabric obtained by laminating and joining at least one layer each of a nonwoven fiber aggregate made of melt-processed thermoplastic fiber and a long fiber nonwoven fiber aggregate is perforated. A fill-filled ridge that is wrapped in a twill shape around a cylindrical body.

(3) The melt-blown thermoplastic fiber is a mixed fiber or a composite fiber comprising a low melting point resin and a high melting point resin, and the melting point difference between the two resins is 10 ° C or more.

1) or 1st fill cartridge as described in (2).

(4) The thermoplastic fiber constituting the long-fiber nonwoven fiber aggregate is a heat-adhesive conjugate fiber comprising a low-melting resin and a high-melting resin, and a difference in melting point between the two resins is 1 ° C or more. (2) Phil's power cartridge as described in paragraph (2).

(5) The filler cartridge according to (3) or (4), wherein the low-melting resin is a linear low-density polyethylene, and the high-melting resin is polypropylene.

(6) The filter according to (1) to (5), wherein the air permeability of the nonwoven fabric is in the range of 1 to 500 cm ³ / cm ² / sec.

(7) The filler cartridge according to any one of (1) to (5), wherein the bonding of the nonwoven fabric is thermocompression-bonded with a hot embossing roll.

(8) The filler according to item (2), wherein the bond of the nonwoven fabric is heat-bonded with hot air.

(9) The filter according to any one of (1) to (5), wherein the band-shaped nonwoven fabric is twisted.

(10) The fill cartridge according to any one of (1) to (5), wherein the porosity of the fill cartridge is 65 to 85%.

(11) The filter cartridge according to any one of (1) to (5), wherein the band-shaped nonwoven fabric is a pleated material having 4 to 50 folds, and is wound around a perforated tubular body in a twill shape.

(12) The fill cartridge according to (11), wherein at least a part of the fold of the fold is non-parallel.

(13) The filter according to (11), wherein the porosity of the pleated material is 60 to 95%.

(14) The slit width of the band-shaped nonwoven fabric is 0.5 cm or more, and the product of the slit width (cm) and the basis weight (g / m ² ) is 200 or less (1) to (5). File evening cartridge. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 illustrates a state in which the nonwoven fabric is wound in a paste shape.

FIG. 2 is an explanatory diagram showing the state of particle collection by an emboss pattern of a long-fiber nonwoven fabric.

FIG. 3 is an explanatory view showing a state in which the long continuous fiber nonwoven fabric is wound as it is without processing.

FIG. 4 is an explanatory diagram showing a state in which the belt-shaped long-fiber nonwoven fabric is wound while being twisted.

FIG. 5 is an explanatory view showing a state in which the long nonwoven fabric band is passed through small holes to be bundled, and then wound.

FIG. 6 is a view showing a state in which the band-shaped long-fiber nonwoven fabric is processed into a pleated material using a pleated guide.

FIG. 7 is a cross-sectional view showing an example of a fold forming guide used in the present invention. FIG. 8 is a cross-sectional view showing an example of a fold forming guide used in the present invention. FIG. 9 is an explanatory diagram illustrating an example of a cross-sectional shape of a non-parallel pleat. FIG. 10 is an explanatory diagram showing an example of the cross-sectional shape of a pleated parallel fold. FIG. 11 is an explanatory view showing a positional relationship between a fold forming guide, a narrow rectangular hole, and a small hole. FIG. 12 is a partially cutaway perspective view showing an example of a fold according to the present invention. FIG. 13 is a perspective view of a file cartridge according to the present invention.

FIG. 14 is a cross-sectional view of a fill-in-a-box as per the present invention.

FIG. 15 is a conceptual diagram of a spunbond nonwoven fabric.

FIG. 16 is a conceptual diagram of a short fiber nonwoven fabric.

The description of the reference numerals is given below.

1 Area with strong thermocompression bonding by emboss pattern

2 Part with only weak thermocompression bonding without emboss pattern

3 particles

4 Particles that have passed through a part with only weak thermocompression bonding without emboss pattern 5 Strip-shaped long-fiber nonwoven fabric or its bundle

6 Narrow hole traverse guide

7 bobbins

8 Perforated cylindrical body

9 Filter cartridge

1 0 Traverse Guide

1 1 Traverse Guide

1 2 External Regulation Guide

1 3 Internal Regulation Guide

1 4 Small hole

1 5 folds

16 Fold formation guide

1 7 Comb-shaped fold formation guide

1 8 Narrow rectangular hole

1 9 Oval shape with minimum area containing bundled long-fiber nonwoven fabric bundle

20 0 Spacing between a certain bundle of long-fiber non-woven fabric bundle and one of the bundle of long-fiber non-woven fabric wound on the layer below

2 1 Inner layer

2 2 Microfiltration layer

2 3 Outer layer

2 4 Banded long-fiber nonwoven fabric bundle

2 5 Long fibers constituting spunbond nonwoven fabric

2 6 particles

2 7 Short fibers constituting short fiber non-woven fabric Best mode for carrying out the invention

Hereinafter, embodiments of the present invention will be described specifically.

The melt blown fiber used in the present invention is a fiber obtained by a melt-pro method. It is a fiber. The melt blow method is a method in which a molten thermoplastic resin extruded from a spinning hole is sprayed onto a collecting compartment or the like by a high-temperature, high-speed gas blown from the periphery of the spinning hole to obtain a fibrous web. 3, 5, 32, 800.

As the thermoplastic fiber used in the present invention, any thermoplastic resin that can be melt-spun can be used. Examples include polypropylene, low-density polyethylene, high-density polyethylene, linear low-density polyethylene, and copolymerized polypropylene (for example, propylene as the main component, and binary with ethylene, butene-11, 4-methylpentene-11, etc.). Or low-melting polyesters obtained by copolymerizing the acid component with terephthalic acid in addition to terephthalic acid, and polyolefin-based resins such as polyolefin resin, etc. Polyester resin such as polyester resin, nylon 6, nylon 66, etc., polystyrene resin (atactic polystyrene, syndiotactic polystyrene), polyurethane elastomer, polyester elastomer, polytetrafluoroethylene Etc. Thermoplastic Resin can be presented. In addition, a functional resin can be used, for example, by using a biodegradable resin such as lactic acid-based polyester to make the filter cartridge biodegradable. Also, when using a resin that can be polymerized with a metallocene catalyst, such as a polyolefin-based resin or a polystyrene-based resin, using a resin polymerized with a metallocene catalyst can improve nonwoven fabric strength, improve chemical resistance, reduce production energy, etc. This is preferable because the properties of the meta-mouth resin are utilized in the filter cartridge. These resins may be blended and used to adjust the thermal adhesiveness and rigidity of the long-fiber nonwoven fabric. Among these, when filter cartridges are used for filtration of aqueous liquids at room temperature, polyolefin resins such as polypropylene are preferable from the viewpoint of chemical resistance and price, and they are used for liquids at relatively high temperatures. In this case, a polyester resin, a polyamide resin, or a syndiotactic polystyrene resin is preferable.

Further, the melt blown fiber used in the present invention may be composed of two components, a low melting point resin and a high melting point resin having a melting point difference of 10 ° C. or more. Of course, of the present invention It may be composed of a resin of three or more components as long as the effect is not impaired. In the case of a resin having no melting point, the flow start temperature is regarded as the melting point. As a method of using one melt fiber as two components, each fiber may be a two-component composite fiber having a cross-sectional shape such as a sheath-core type or a side-by-side type, or a two-component resin may be alternately applied from each hole of a melt blow nozzle. The fibers may be discharged to form a mixed state. Specific examples of these methods are disclosed in, for example, Japanese Patent Application Laid-Open No. Hei 7-82649, Japanese Patent Application Laid-Open No. H11-256008, and the like. When the thermal bonding at the fiber junction is stable, when used as a filter cartridge, the possibility of particles trapped near the fiber junction flowing out when the filtration pressure or water flow increases is reduced, and the filter This is preferable because the deformation of the cartridge is reduced and the probability that the fiber is dropped is reduced even if the fiber is deteriorated by a substance contained in the filtrate.

The combination of the low melting point resin and the high melting point resin of the composite fiber is not particularly limited as long as the melting point difference is 10 ° C or more, preferably 15 ° C or more, and linear low-density polyethylene / polypropylene, High-density polyethylene / polypropylene, low-density polyethylene / polypropylene, copolymer of propylene with other polyolefins / polypropylene, linear low-density polyethylene, high-density polyethylene, low-density polyethylene / high-density polyethylene, various polyethylenes Thermoplastic polyester, propylene thermoplastic polyester, copolymerized polyester / thermoplastic polyester, polyethylene / nylon 6, polypropylene / nylon 6, nylon 6 / nylon 66, nylon 6 / thermoplastic polyester, etc. Can be. Among them, the use of a combination of linear low-density polyethylene Z polypropylene is preferable because the rigidity and porosity of the long-fiber nonwoven fabric can be easily adjusted in the process of fusing the fiber intersections during the production of the nonwoven fabric. In addition, when used in a liquid having a relatively high temperature, a low-melting-point polyester / polyethylene terephthalate combination obtained by copolymerizing terephthalic acid and isophthalic acid with ethylene glycol can also be suitably used.

The average fiber diameter of the melt-pro fibers used in the present invention varies depending on the use of the filter and the type of resin, and is generally unpredictable. Is desirable. When the fineness is less than 0.5 μm, the filter of the present invention is used. Although it can theoretically be used for a cartridge, it is actually difficult to manufacture. On the other hand, if the fiber diameter exceeds 100 μm, the formation of the nonwoven fabric may become uneven when the nonwoven fabric is used later. If the average fiber diameter exceeds 50 μm, adjacent fibers may be fused together. However, there is no particular problem as long as the effect of the present invention is not impaired.

In addition, the melt-blown fibers do not necessarily have to have a circular cross section, and may have an irregular cross-sectional shape. In that case, the collection of fine particles increases as the surface area of the filter increases, so that it is possible to obtain the same liquid-permeability and high-precision filter cartridge than in the case of using a fiber having a circular cross section.

In addition, by mixing a hydrophilic resin such as polyvinyl alcohol with the raw resin of the melt-pro fibers or by plasma processing, the melt-blown fibers are made hydrophilic to improve the liquid permeability when used in aqueous liquids. Is preferred.

In addition, the melt-blown fibers are usually bonded at a weak point due to the residual heat of the fibers themselves when they are sprayed onto the collecting conveyor net, etc., but then the heat bonding is further strengthened by appropriate heat treatment. Is also good. The methods include thermocompression bonding using a device such as a hot embossing hole and a hot flat calender roll, and heat treatment such as a hot air circulation type, a heat through air type, an infrared heater type, and a vertical hot air jet type. You can use the machine. Above all, a method using a heat-through-air heat treatment machine is preferable because the production speed can be improved, the productivity is good, and the cost can be reduced. On the other hand, the first nonwoven fabric used in the present invention is a meltblown nonwoven fabric. As described above, the melt-blown non-woven fabric is an excellent non-woven fabric in terms of microfiltration, but has the disadvantage that the strength of the non-woven fabric is weaker than other non-woven fabrics. The temporal change of the particle size is large.See Comparative Example 4 described later). In this respect, the filtration life is improved by winding the filter in a twill shape on a perforated cylindrical body (Example 1). Simply increasing the life of the filtration may be considered to increase the porosity of the filter, but doing so is not preferable because the strength of the filter is reduced and the filtration accuracy is reduced.

However, while maintaining the filtration accuracy characteristic of melt-blown nonwoven fabric, A nonwoven fabric made by laminating a nonwoven fiber aggregate consisting of thermoplastic fibers melt-blown to withstand a high filtration pressure with a long-fiber nonwoven fiber aggregate, and bonding both together (that is, a strip-shaped laminated meltblown nonwoven fabric) There is a second nonwoven fabric used in the invention. The non-woven fiber aggregate referred to here is a concept that includes a nonwoven fabric where fiber intersections are bonded and a fiber aggregate where the fibers are entangled differently but not bonded. is there. Non-woven fiber aggregates instead of non-woven fabrics are used as ribbon-shaped melt-melt openings. When manufacturing non-woven fabrics, not only the bonding between the fibers constituting different types of non-woven fiber aggregates, but also the same type of non-woven fiber aggregates This is because the bonding between the fibers constituting the body is also performed, and it is not always necessary to make a nonwoven fabric in advance. Here, the term "bonding" is preferably a bonding of fiber intersections by thermal bonding.

The long-fiber nonwoven fabric used in the present invention is a long-fiber nonwoven fabric obtained by a spun bond method or the like. The long fibers obtained by the spun bond method are dispersed on the collection conveyor to form long fibers. Any kind of thermoplastic resin that can be melt-spinnable can be used for the long fiber as in the case of the melt-pro-fibre described above, and the two components can be formed into a composite fiber or a mixed fiber, similarly to the melt-pro-fibre. . This resin may be the same as or different from the melt-pro-fiber, but it may be the same as the melt-blown resin (or its low-melting resin if two components are used in the melt-blown nonwoven). The use of a resin having high compatibility is desirable because the fiber intersection is stably bonded when the resin is bonded to the meltblown fiber in a later step.

As shown in Fig. 15, the long-fiber nonwoven fabric made by the spunbonding method or the like has the same fiber direction as the machine direction. It will be small. On the other hand, in the case of a nonwoven fabric made of short fibers obtained by the card method, etc., the fiber direction is not constant as shown in Fig. 16, so the holes formed by the fibers 27 have a shape close to a circle or square. Even if the porosity is the same as that of the long-fiber nonwoven fabric made by the spunbonding method or the like, the maximum passing particle diameter 26 is large. Since the water permeability of the filter medium is almost determined by the porosity when the fiber diameter is the same, a filter with excellent water permeability can be obtained by using a long-fiber nonwoven fabric made by the spun bond method or the like. This effect closes the pores of filter media such as adhesive Use of a cellulose spunbond nonwoven fabric is not preferable because a small binder is used when the binder is used. In addition, the use of cellulose spunbonded nonwoven fabrics reduces the strength of the nonwoven fabrics, so that when the filtration pressure is increased due to clogging of the filler, the pores composed of fibers are easily deformed. There is.

In the case where the long fibers are used in the present invention, the fiber diameter of the long fibers varies depending on the use of the filter cartridge and the type of the resin, so that it is generally difficult to specify a single fiber fineness of 0.6 dtex to 1 dtex. A range of 0 dtex is desirable. If the fineness exceeds 100 dtex, the strength of the nonwoven fabric will decrease when a laminated nonwoven fabric is formed later. Conversely, it is considered that there is no problem in the use of the present invention even if the single yarn fineness is less than 0.6 dtex, but when spinning a fiber having a fineness smaller than 0.6 dtex by the current spunbonding method. The production efficiency is reduced, is not practical.

Further, the cross-sectional shape of the long fiber is not necessarily required to be a circular cross-section, and may be an irregular cross-sectional shape.

Next, when a band-shaped laminated melt-blown non-woven fabric is used for the band-shaped non-woven fabric of the present invention, at least one layer of each of a non-woven fiber aggregate made of melt-blown thermoplastic fiber and a long-fiber non-woven fiber aggregate is laminated. A method of combining the two will be described.

First, a method of stacking will be described. The method of laminating is not particularly limited, and the melt-blown nonwoven fiber aggregate and the long-fiber nonwoven fiber aggregate may be manufactured in separate steps by an appropriate method, and then they may be laminated. Alternatively, the thermoplastic resin may be directly melt-blown and laminated on the long-fiber nonwoven fabric or long-fiber web. As a combination to be laminated, two layers of melt blown fiber / long fiber, or three layers of long fiber / melt blown fiber / long fiber, or two types of melt-blown non-woven fabrics having different fiber diameters can be used. Examples include three layers of long fibers or four layers of long fibers / melt blown fibers / melt blown fibers, but are not limited thereto. The upper limit of the number of layers is not particularly limited, but an increase in the number of layers increases the manufacturing cost, and a corresponding effect is required.

Next, the laminated nonwoven fabric or web is combined to form a laminated meltblown nonwoven fabric. Explain how to do this. Examples of the bonding method include thermal bonding and chemical bonding, but thermal bonding is preferred, which has excellent chemical resistance and does not cause outflow of low molecular components. Examples of the method of performing this heat bonding include a method of thermocompression bonding using a device such as a hot embossing nozzle, a heat flat calendar roll, a hot air circulation type, a heat through air type, an infrared heater type, a vertical hot air jet type, etc. And a method using a heat treatment machine. Among them, the method using a hot embossing nozzle is preferable because the production speed of the nonwoven fabric can be improved, the productivity is high, and the cost is low. Furthermore, as shown in Figure 2, the nonwoven fabric made by the method using the hot embossed mouth has a part 1 with strong thermocompression bonding by emboss pattern and a part 2 with only weak thermocompression bonding without embossing pattern And exists. As a result, a large number of particles 3 and 4 can be collected in the part 1 where strong thermocompression bonding is performed. On the other hand, in part 2 where only weak thermocompression bonding is performed, some of the particles are collected, but the remaining particles can pass through the non-woven fabric and move to the next layer, so that the A filtering structure is preferable. In this case, it is desirable that the area of the emboss pattern is 5 to 25%. By setting this area to 5% or more, the effect of the thermal bonding at the fiber intersection as described above can be improved, and by setting the area to 25% or less, the rigidity of the nonwoven fabric can be suppressed, or particles can be reduced. It can be easier to pass through the nonwoven.

Further, air permeability of the Merutopuro one nonwoven or laminate meltblown ^{nonwoven, 1~ 5 0 0 cm 3 /} cm 2 / range of sec is desirable. If the air permeability is less than 1 cm ³ / cm ² Z seconds, the liquid permeability of the non-woven fabric will be extremely poor, and the liquid permeability of the manufactured film may be poor. Conversely, if the air permeability is greater than 500 cm ³ / cm ² / sec, spunbonded nonwoven fabric, short fiber nonwoven fabric, etc. can be substituted without using melt-processed nonwoven fabric, which is generally lower. Because it is costly, the value of using melt-pro-woven is reduced.

The weight per unit area of the melt-produced nonwoven fabric or the laminated melt-produced nonwoven fabric is preferably 5 to ²⁰⁰ g / m ² . If this value is less than 5 g / m ² , the non-woven fabric becomes uneven due to the reduced amount of fiber, or the strength of the non-woven fabric decreases, or the heat at the fiber intersection as described above. Joining may be difficult. On the other hand, if the value is more than ²⁰⁰ g / m ² , the rigidity of the nonwoven fabric becomes too large, and it may be difficult to wind the nonwoven fabric around the perforated tubular body later.

Next, the melt-produced nonwoven fabric or the laminated meltblown nonwoven fabric is formed into a belt shape. In order to form a band, a method of directly forming a band-shaped non-woven fabric by adjusting the spinning width can be used, but a method of slitting a wide-width non-woven fabric into a band is preferable because an inexpensive and uniform product can be obtained. The slit width at this time varies depending on the basis weight of the nonwoven fabric used, but is preferably 0.5 cm or more. If the width is smaller than 5 cm, the nonwoven fabric may be cut at the time of slitting, and it may be difficult to adjust the tension when winding the band-shaped nonwoven fabric later in a twill shape. If it is made, the winding time will be longer and the productivity will be lower. On the other hand, the upper limit of the slit width differs depending on the basis weight, and the value of the slit width X basis weight is preferably ²⁰⁰ cm · g / m ² or less. If this value exceeds ²⁰⁰ cmg / m2, the rigidity of the nonwoven fabric becomes too strong, and it becomes difficult to wind the nonwoven fabric around the perforated tubular body later, and the amount of fibers increases. It can be difficult to wind tightly because it is too long. In the case where a band-shaped nonwoven fabric is directly produced by adjusting the spinning width, the preferable ranges of the basis weight and the nonwoven fabric width are the same as in the case where the band is formed by slitting.

The belt-shaped melt-pro nonwoven fabric or laminated melt-produced nonwoven fabric (hereinafter abbreviated as “band-shaped nonwoven fabric”) may be processed by a method described later and then wound in a twill shape. It may be wound as it is without. Figure 3 shows an example of the manufacturing method in this case. The winder used for a normal wound filter or cartridge can be used for the winding machine. The supplied nonwoven fabric 5 passes through a traverse guide 6 having a narrow hole that moves while traversing, and then is wound up on a perforated cylindrical body 8 attached to a bobbin 7 to fill a cartridge 9. Becomes The filters created by this method will be very dense, and will be a very accurate filter. However, in this method, it is difficult to adjust the filtration accuracy by changing the manufacturing conditions.

On the other hand, it is also possible to twist the band-shaped nonwoven fabric and then wind it up. In this case Fig. 4 shows an example of the manufacturing method. Also in this case, a winder used for a normal thread-wound fill cartridge can be used for the winding machine. Since the band-shaped nonwoven fabric becomes apparently thick due to twisting, the traverse guide 10 preferably has a larger pore diameter than that shown in FIG. When the twist is applied to the belt-shaped nonwoven fabric, the apparent porosity of the nonwoven fabric can be changed by the number of twists per unit length or the twisting strength, so that the filtration accuracy can be adjusted. The number of twists at this time is preferably in the range of 50 to 100 times per lm of the band-shaped nonwoven fabric. If this value is less than 50 times, the effect of adding twist is hardly obtained. On the other hand, if the value is more than 100 times, the produced filter-cartridge becomes inferior in liquid permeability, which is not preferable.

It is further preferable that the above-mentioned band-shaped nonwoven fabric is bundled by an appropriate method and then wound around a perforated cylindrical body. As a method, the band-shaped nonwoven fabric may be simply bundled through small holes or the like, or the band-shaped nonwoven fabric may be preformed into a pleated shape through small holes or the like after being preformed with a fold forming guide. You may. By using this method, the winding pattern can be changed by adjusting the ratio of the traverse guide traverse speed to the bobbin rotation speed, so that filter cartridges with various performances can be made from the same type of nonwoven fabric. it can.

FIG. 5 shows an example of a manufacturing method in which a small hole is simply passed through as a method of converging a band-shaped nonwoven fabric. In this case as well, the winder used for the ordinary thread-wound fill cartridge can be used for the winding machine. In FIG. 5, the band-shaped nonwoven fabric is bundled by making the holes of the traverse guide 11 small. However, a small hole guide may be provided on the yarn path before the traverse guide 11. The diameter of the small holes depends on the basis weight and width of the band-shaped nonwoven fabric used, but is preferably in the range of 3 mm to 10 mm. If the diameter is smaller than 3 mm, the friction between the band-shaped nonwoven fabric and the small holes increases, and the winding tension becomes too high. If this value is larger than 10 mm, the convergence size of the band-shaped nonwoven fabric becomes unstable.

Next, Fig. 6 shows a partially cutaway perspective view of an example of a manufacturing method in the case of preforming the cross-sectional shape of the band-shaped nonwoven fabric with the fold forming guide and then processing it into a fold through small holes. lb

. In this case as well, a winder used for a normal thread-fill type cartridge can be used for the winding machine. When this method is adopted, the band-shaped nonwoven fabric 5 is preformed into a cross-sectional shape through a fold forming guide 16, and then formed into a pleated material 15 through a small hole 14. When it is taken in the direction of A and wound up into a perforated cylindrical body through a traverse guide, it becomes a filter cartridge.

Next, the fold formation guide will be described. The fold formation guide is usually made by processing a round bar with an outer diameter of about 3 mm to 10 mm, and then applying a fluororesin process to the surface to prevent friction with the nonwoven fabric. An example of the shape is shown in Figs. In the example given here, the plication guide 16 consists of an external control guide 12 and an internal control guide 13. The shape of the fold forming guide 16 is not particularly limited, but is preferably a shape in which the cross-sectional shape of the fold formed from this guide is converged so that the folds are not parallel. One example of the cross-sectional shape of the pleated material thus produced is shown in FIGS. 9A, 9B, and 9C, but is not limited thereto. In these embodiments of the present invention, the formation of folds that are converged so that at least a portion of the folds are non-parallel is the most preferred embodiment of the present invention. In other words, when some of the folds are non-parallel as in the cross-sectional shape in Fig. 9, compared to when the folds are almost parallel as shown in Figs. 10 (A) and (B). Even when the filtration pressure is applied to the pleats in a direction perpendicular to the arrow as shown by the arrow, the shape retention force of the pleats is strong, and the filtration function of the original pleats can be maintained. In other words, when the folds are non-parallel, the cross-sectional shape of the folds is non-parallel due to the superior ability to suppress the pressure drop of the fill cartridge compared to the case where the folds are parallel. Especially preferred. The number of guides is not necessarily one, but if several pieces of guides of different shapes and sizes are arranged in series to gradually change the cross-sectional shape of the band-shaped nonwoven fabric, pleated materials Since the cross-sectional shape becomes constant depending on the place, it is preferable because there is no unevenness in quality.

In the present invention, when the band-shaped nonwoven fabric is wound into a perforated tubular body after being formed into a pleated material, the final number of the pleated material is preferably 4 to 50, more preferably? ~ 45. When the number of folds is less than 4, the effect of expanding the filtration area by providing folds is poor. On the other hand, when the number of folds exceeds 50, the folds become too small, making it difficult to produce, and easily affecting the filtration function.

Also, for example, after applying a large number of pleats to the band-shaped nonwoven fabric using a comb-shaped pleat formation guide 17 as shown in FIG. 11, the number of pleats is further reduced by passing through a narrower rectangular hole 18. It can be deformed to be numerous and the pleats can be made non-parallel at random.

In addition, the cross-sectional shape of the folds can be fixed by heating the folds 15 after passing through the small holes 14 with hot air or infrared rays. This step is not always necessary, but if the cross-sectional shape of the pleated material is complicated, or if a highly rigid band-shaped nonwoven fabric is used, the cross-sectional shape may collapse from the designed shape. However, it is preferable to perform such heating processing.

Next, the porosity of the bundled nonwoven fabric or pleated material used in the present invention (hereinafter collectively referred to as a bundle of nonwoven fabrics) will be described. First, as shown in Fig. 12, the cross-sectional area of the band-shaped nonwoven fabric bundle is the minimum area of an oval shape 19 containing the band-like nonwoven fabric bundle 24 ◦ Defines the area of a polygon that is within degrees. Then, the band-shaped nonwoven fabric bundle is cut into a predetermined length, for example, 100 times the square root of the cross-sectional area, and is defined by the following equation.

(Apparent volume of banded nonwoven fabric bundle) 2 (Cross-sectional area of banded nonwoven fabric bundle X cutting length of banded nonwoven fabric bundle)

(True volume of banded nonwoven fabric bundle) = (weight of cut banded nonwoven fabric bundle) / (density of raw material of banded nonwoven fabric bundle)

(Voidage of the banded nonwoven fabric bundle) = {11 (true volume of the banded nonwoven fabric bundle) / (apparent volume of the banded nonwoven fabric bundle)} X 100 (%)

The porosity of the banded nonwoven fabric bundle defined by this formula is preferably 60 to 95%, more preferably 85 to 92%. By setting this value to 60% or more, the band-shaped nonwoven fabric bundle can be prevented from becoming unnecessarily dense, and the pressure loss when used as a filler can be sufficiently suppressed. In a bundle Particle collection efficiency can be further improved. Further, by setting this value to 95% or less, it becomes easy to wind later, and when used as a filter cartridge, the deformation of the filter medium due to the load pressure can be further reduced. Examples of the method of adjusting this include adjusting the winding tension and adjusting the guide shape such as a fold forming guide.

Further, when producing the band-shaped nonwoven fabric bundle, granular activated carbon, an ion exchange resin or the like may be mixed and processed as long as the effects of the present invention are not impaired. In such a case, in order to fix the granular activated carbon or the ion exchange resin, the band-shaped nonwoven fabric may be adhered with a suitable binder before being bundled or added to the folds, or after being processed. After mixing ion-exchange resin and the like, heating may be performed to thermally bond with the constituent fibers of the band-shaped nonwoven fabric.

Next, the band-shaped nonwoven fabric bundle produced by the above-described method is not necessarily required to be a continuous process if it is devised so that the cross-sectional shape does not collapse. May be wound up.

Next, a method for winding the band-shaped nonwoven fabric will be described. A perforated cylindrical body having a diameter of about 100 to 40 mm and a length of about 100 to 100 mm is mounted on the bobbin of this winder, and the winder is attached to the end of the perforated cylindrical body. Fix the band-shaped non-woven fabric (or band-shaped non-woven fabric bundle) through the yarn path. The perforated cylindrical body serves as the core material of the filter cartridge, and its material and shape are not particularly limited unless it has strength enough to withstand the external pressure during filtration and the pressure loss is not extremely high. For example, an injection-molded product obtained by processing polyethylene or polypropylene into a net-like cylindrical shape like the core material used for ordinary filter cartridges, or ceramic or stainless steel, etc. It is not a problem if processed into Alternatively, another filter such as a filter cartridge which has been folded as a perforated cylindrical body and a non-woven wound type filter such as a filter may be used. Since the yarn path of the winder is traversed by a traverse cam installed parallel to the bobbin, a band-shaped nonwoven fabric is wrapped around the perforated tubular body in a traversing manner. The winding conditions at that time may be set according to the time of manufacture of a normal thread-wound fill cartridge. The speed may be set to 1000 to 200 rpm, and the winding speed may be adjusted while adjusting the feeding speed and applying tension. The porosity of the filter cartridge can be changed by the tension at this time. Furthermore, the porosity of the inner layer can be increased by adjusting the tension at the time of winding, and the porosity can be increased as the middle layer and the outer layer are wound. In particular, when the band-shaped nonwoven fabric is wound into a perforated cylindrical body after being formed into a pleated material, due to the difference in density between the outer layer, the middle layer, and the inner layer, together with the deep filtration structure formed by the pleated material provided by the pleated material. A filter cartridge having an ideal filtration structure can be provided. The filtration accuracy can also be changed by adjusting the ratio of the traverse cam traverse speed to the bobbin rotation speed to change the winding pattern. The pattern can be attached by using a conventional thread-wound filter, which is already known, and the pattern can be expressed by the number of winds when the filter length is constant. In addition, when the interval 20 between a certain yarn (in the case of the present invention, a band-shaped nonwoven fabric) and the yarn wound on the layer immediately below it is large, the filtration accuracy becomes coarse, and conversely, when it is small, the filtration accuracy becomes fine. By these methods, the band-shaped nonwoven fabric is wound to an outer diameter of about 1.5 to 3 times the outer diameter of the perforated tubular body 8 to form a fill-in-one-tridge shape. This may be used as it is as the filter cartridge 9 or it may be attached to the end face of the filter by attaching a gasket of foamed polyethylene of about 3 mm in thickness to the nozzle. You may increase the sex.

The porosity of the thus-filled film is preferably in the range of 65 to 85%. If this value is less than 65%, the fiber density becomes too high and the liquid permeability decreases. Conversely, if this value is greater than 85%, the filter-cartridge strength is reduced, and problems such as deformation of the filter at high filtration pressure tend to occur.

In addition, by making a cut or making a hole in the belt-shaped nonwoven fabric, the liquid permeability can be improved. In this case, the number of cuts is preferably about 5 to 100 per 10 cm of the band-shaped nonwoven fabric, and when a hole is formed, the ratio of the area of the opening is preferably about 10 to 80%. The filtration performance can be adjusted by using a plurality of strip-shaped nonwoven fabrics when winding or by winding the nonwoven fabric together with other yarns such as spun yarns. Can be Further, as shown in FIG. 14, the band-shaped nonwoven fabric 5 is wound around the perforated tubular body 8 by traversing to a certain diameter to form an inner layer 21. Subsequently, a wide nonwoven fabric is formed. A microfiltration layer 22 is formed by winding around the inner layer to form a microfiltration layer 22. Subsequently, a band-shaped nonwoven fabric 5 is wrapped around the inner layer again by traversing to form an outer layer 23, and the nonwoven fabric is wound. You can also make a bridge at Phil in the evening. If not put wind-wide nonwoven fabric of Ri to wind-shape may particle maximum outflow diameter when made coarse accuracy of the filter cartridge by widening the yarn spacing becomes extremely large force ^5, wide non When the woven fabric is wound in a wound form, the maximum particle outflow system can be fine-tuned as necessary. Example

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples, but the present invention is not limited to these Examples. In each example, evaluation of physical properties, filtration performance, and the like of the filtering material was performed by the methods described below.

Weave HS 7HS

The nonwoven fabric was cut out so that the area of the nonwoven fabric became 6 25 cm ² , the weight was measured, and the weight was converted into the weight per square meter to obtain the basis weight (g / m ² ). The thickness of the cut nonwoven fabric was arbitrarily measured at 10 points, and the average of 8 points excluding the maximum value and the minimum value was defined as the thickness (m) of the nonwoven fabric. When a laminated melt-blown non-woven fabric is used as the non-woven fabric of the present invention, the basis weight of each layer before lamination cannot be calculated depending on the manufacturing method. The calculated theoretical values were used.

Nonwoven fabric or textile

Five samples were randomly sampled from the nonwoven fabric or the web before lamination, photographed with a scanning electron microscope, and 100 fibers for melt-blown fibers and 20 fibers for other fibers were sampled. The fiber diameter was measured at random, and the average value was defined as the fiber diameter (〃 _m ) of the nonwoven fabric. The fineness (dtex) is calculated by using the obtained fiber diameter and the density (g / cubic centimeter) of the nonwoven fabric raw material resin as follows. Asked from. In the case where two or more components were used, the weight average value of the density of each component was used.

(Fineness) = 7Γ (fiber diameter) ² X (density) / 400

Non-woven fabric

The air permeability of the nonwoven fabric before slitting was measured at 20 points for each nonwoven fabric according to the JISL 1106-A method, and the average value was determined. (Unit: cm ³ Z cm ² / sec)

After fixing the cross-sectional shape of the pleats with an adhesive, it was cut at five locations at arbitrary positions, and the cross-section was photographed with a microscope. From the photograph, the number of folds in the band-shaped nonwoven fabric was counted as one for both the mountain fold and the valley fold, and one half of the average number of the cut five points was taken as the number of folds.

不織布の亩 m m m ^ m

After fixing the cross-sectional shape of the band-shaped nonwoven fabric bundle with an adhesive, the cross-section was cut at five arbitrary positions, and the cross-section was photographed with a microscope. The photograph was image-analyzed to determine the cross-sectional area of the band-shaped nonwoven fabric bundle. A band-shaped nonwoven fabric bundle at another location was cut to a length of 10 cm, and the porosity was calculated from the weight and the cross-sectional area obtained earlier using the following equation.

(True volume of banded nonwoven fabric bundle) = (weight of banded nonwoven fabric bundle) / (density of raw material of banded nonwoven fabric bundle)

(Void ratio of banded nonwoven fabric bundle) 2 {1 1 (True volume of banded nonwoven fabric bundle) / (apparent volume of banded nonwoven fabric bundle)} X 100 (%)

Thread spacing

The distance between the bundle of band-shaped nonwoven fabric on the surface layer (or the band-shaped nonwoven fabric, spun yarn, etc., which is wound around a perforated cylindrical body in the following examples) and the bundle of adjacent band-shaped nonwoven fabric (see FIG. 13-20). ) Were measured at 10 points on one fill cartridge and the average was taken as the yarn spacing.

Porosity of filter / cartridge The outer diameter, inner diameter, length, and weight of the filter cartridge were measured, and the porosity was determined using the following equation. In order to determine the porosity of the filter media itself, the outer diameter of the perforated tubular body is used for the inner diameter value, and the weight value is calculated by subtracting the weight of the perforated tubular body from the weight of the filter. The subtracted value was used.

(Apparent volume of the filter) 2 π {(outer diameter of the filter) ² — (inner diameter of the filter) ² } (length of the filter) / 4

(True volume of filter) = (Weight of Fill Yuichi) / (Density of Fill Yuichi ingredients)

)

(Porosity of Fill 1) = {11-1 (True volume of Fill 1) / Apparent volume of Filter 1) 1 100 (%)

wm ^ Ne τι term mosquito cattle, 、 vortex life

Attach one filter cartridge to the nozzle of the circulation type filtration performance tester and adjust the flow rate to 30 liters per minute with a pump to circulate water. The pressure loss before and after the fill cartridge at this time was defined as the initial pressure loss. Next to the circulating water

Eight types of test powder I (abbreviated as JIS 8; median diameter: 6.6 to 8.6〃m) and seven types (abbreviated as JIS 7) specified in JISZ8901 The mixture obtained by continuously adding 0.4 g / min per minute of a cake obtained by mixing the mixture of 27 to 31) at a weight ratio of 1: 1, collecting the undiluted solution and the filtrate 5 minutes after the start of the addition, and adjusting to a predetermined magnification After dilution, the number of particles contained in each liquid was measured with a light-blocking particle detector to calculate the initial collection efficiency at each particle size. Further, by interpolating the values, a particle size showing a trapping efficiency of 80% was obtained. Further, the cake was further added, and when the pressure loss of the fill cartridge reached 0.2 MPa, the stock solution and the filtrate were collected in the same manner, and the collected particle size at 0.2 MPa was measured. I asked. The time from the start of the addition of the cake to reaching 0.2 MPa was defined as the filtration life. If the pressure difference did not reach 0.2 MPa even when the filtration life reached 1000 minutes, the measurement was stopped at that point.

The 71st period of liquid and fiber

Attach one filter cartridge to the nozzle of the circulating filtration performance tester, and adjust the flow rate to 10 liters per minute with a pump to pass ion-exchanged water. Initial filtration One liter of the solution was sampled, and 25 cubic centimeters of the solution were sampled in a colorimetric bottle, stirred vigorously, and foaming was observed 10 seconds after the stirring was stopped. If the volume of the foam (the volume from the liquid surface to the top of the foam) is at least 10 cubic centimeters, X is the case where less than 10 cubic centimeters and at least 5 bubbles with a diameter of 1 mm or more are observed. Δ, when less than 5 bubbles having a diameter of l mm or more were Δ, and foaming was determined as Δ. Also, pass 500 m3 of the initial filtrate through a dinitrocellulose filter paper having a pore diameter of 0.8〃ιη, and if there are four or more fibers with a length of l mm or more per square centimeter of the filter paper, x, 1-3 The case was determined to be 8, and the case of 0 was determined to be 〇, and fiber detachment was determined.

Example 1

As a melt-pro nonwoven fabric, the basis weight is 20 gZm ² , the average fiber diameter is 3 m, the thickness is 200 m, the air permeability is 37 cm ³ / cm ² / sec, and the fiber intersection is weakly adhered due to the residual heat of spinning. A polypropylene meltblown nonwoven fabric was used. The perforated cylindrical body is 30 mm in inner diameter, 34 mm in outer diameter, 250 mm in length, and is injection molded from polypropylene with 180 holes of 6 mm square. Product was used. The meltblown nonwoven fabric was slit to a width of 50 mm to obtain a belt-like nonwoven fabric. Then, using a winder, the band-shaped nonwoven fabric is wound around the perforated tubular body without focusing, etc., and the winding number is adjusted so that the interval between the band-shaped nonwoven fabrics becomes 0 mm at the initial spindle speed of 150 rpm. Then, it was wound up to an outer diameter of 62 mm on a perforated cylindrical body to obtain a cylindrical filter cartridge 9 as shown in FIG.

Example 2

A fill cartridge was obtained in the same manner as in Example 1 except that the number of winds was changed so that the interval between the band-shaped nonwoven fabrics was 1 mm. However, the filtration performance of the filter was not much different from that of the filter shown in Example 1. The reason why there was no difference from the file shown in Example 1 is probably because the band-shaped nonwoven fabric was not bundled and the influence of the number of winds did not occur.

Example 3

The same band-shaped nonwoven fabric and perforated tubular body as in Example 1 were used. A guide with a circular hole with a diameter of 5 mm is installed in the yarn path up to the winder to make the belt-shaped nonwoven fabric approximately 5 m in diameter. m, and wound around a perforated cylindrical body in the same manner as in Example 1 to obtain a cylindrical filter. The filtration performance of this filter was almost the same as the filter shown in Example 1.

Example 4

A cylindrical filter cartridge was obtained in the same manner as in Example 3 except that the number of winds was adjusted so that the interval between the band-shaped nonwoven fabrics was 1 mm. This filter had lower accuracy, better water permeability, and longer filtration life than the filter shown in Example 3.

Example 5

Except that the number of winds was adjusted so that the interval between the belt-shaped nonwoven fabrics was 2 mm, a cylindrical fill strip was obtained in the same manner as in Example 3. This filter was a coarser filter than the filter shown in Example 4.

Example 6

A cylindrical filter cartridge was obtained in the same manner as in Example 3 except that the number of winds was adjusted so that the interval between the band-shaped nonwoven fabrics was 2 mm. This filter was a coarser filter than the filter shown in Example 5.

Example 7

The same nonwoven fabric as in Example 1 was used as the meltblown nonwoven fabric. In addition, a polypropylene spunbonded nonwoven fabric having a basis weight of 22 g / m, a thickness of 200 μm, a fineness of 2 dtex, and a fiber intersection hot-pressed with a hot embossing roll was used as the long-fiber nonwoven fabric. Each one of the melt-blown nonwoven fabric and the long-fiber nonwoven fabric was overlapped, and the nonwoven fabric intersection was adhered with an enboss roll to produce a laminated melt-blown nonwoven fabric. This laminated melt blown nonwoven fabric was slit into a width of 50 mm to obtain a belt-shaped nonwoven fabric. In all other respects, a cylindrical filter cartridge was obtained in the same manner as in Example 4. The initial collection particle size of this filter was similar to that of Example 4 shown in Example 4, but was excellent with little change in accuracy.

Example 8

The same nonwoven fabric used in Example 1 was used as the meltblown nonwoven fabric . As the long-fiber nonwoven fabric, a polypropylene spanbond nonwoven fabric having a basis weight of 22 g / m ² , a thickness of 200 μm, and a fineness of 2 dtex, and having a fiber intersection thermocompression-bonded with a hot boss opening was used. . These were superposed in the order of long-fiber nonwoven fabric / melt-pro-nonwoven fabric / long-fiber nonwoven fabric, and the nonwoven fabric intersections were bonded with embossing rolls to produce a laminated melt-blown nonwoven fabric. This laminated melt-produced nonwoven fabric was slit to a width of 50 mm to obtain a belt-shaped nonwoven fabric. In all other respects, a cylindrical fill cartridge was obtained in the same manner as in Example 4. Although the initial collection particle size of this filter was similar to that of the filter shown in Example 4, the change in accuracy was much smaller than that of the filter shown in Example 7 and was excellent. Was.

Example 9

Two types of nonwoven fabric were used as the melt nonwoven fabric, the same as the nonwoven fabric used in Example 1, and the same nonwoven fabric as in Example 1 except that the average fiber diameter was changed. In addition, as the long-fiber nonwoven fabric, a polypropylene spunbond nonwoven fabric with a basis weight of 22 g / thickness of 200 m, a fineness of 2 dtex, and a fiber intersection point which is thermocompression-bonded with a hot embossed mouth was used. . These were superposed in the order of long-fiber nonwoven fabric / melt-blown nonwoven fabric with an average fiber diameter of 5 μm / melt-pro-nonwoven fabric with an average fiber diameter of 3 / long-fiber nonwoven fabric, and the nonwoven fabric intersection was adhered with an enboss roll to produce a laminated melt-blown nonwoven fabric. This laminated melt blown nonwoven fabric was slit to a width of 50 mm to obtain a belt-shaped nonwoven fabric. In all other respects, a cylindrical filter cartridge was obtained in the same manner as in Example 4. The initial collection particle size of this filter was similar to that of the filter shown in Example 4, but the change in accuracy was even smaller than that of the filter shown in Example 8 and was excellent. It was a thing. In addition, the filtration life was longer than the filter shown in Example 8.

Example 10

A cylindrical filter cartridge was obtained in the same manner as in Example 8 except that the raw material resin of the melt-blown nonwoven fabric and the long-fiber nonwoven fabric was nylon 66. This filter exhibited almost the same filtration performance as the filter of Example 8.

Example 1 1 A cylindrical fill cartridge was obtained in the same manner as in Example 8 except that the raw material resin of the melt-blown nonwoven fabric and the long-fiber nonwoven fabric was polyethylene terephthalate. This filter exhibited almost the same filtration performance as the filter of Example 8.

Example 1 2

A cylindrical melt force cartridge was obtained in the same manner as in Example 8 except that the laminated melt-blown nonwoven fabric was slit to a width of 10 mm and the number of windings was adjusted so that the yarn interval was 1 mm. The performance of this fill was the same as that of Example 8. However, the time required for winding was longer than that of the filter shown in Example 4.

Example 13

A cylindrical filter cartridge was obtained in the same manner as in Example 8, except that the laminated melt-produced nonwoven fabric was slit to a width of 100 mm and the number of windings was adjusted so that the yarn interval became 0 mm. This filter 1 was a filter having a higher accuracy than the filter shown in the eighth embodiment. The reason why the accuracy of the filling was low even though the yarn spacing was 0 mm was because the banded nonwoven fabric became extremely thick. Example 14

A melt-blown non-woven fabric that uses nozzles that can alternately discharge different resins for each hole, a high-density polyethylene for the low-melting component, and a mixed-melt non-woven fabric that uses a high-melting-point component of polypropylene at a weight ratio of 5: 5 did. On the other hand, the same nonwoven fabric as the filter shown in Example 7 was used for the long-fiber nonwoven fabric. In all other respects, a cylindrical fill cartridge was obtained in the same manner as in Example 8. This filter was a finer filter than Example 8, and was an excellent filter with little change in accuracy.

Example 15

Except that linear low-density polyethylene (melting point 125 ° C) was used as the low-melting point component, a cylindrical-shaped filler was obtained in the same manner as in Example 14. This filter has the same filtering accuracy as the filter shown in Example 14 and has the same filtering accuracy. They had better water permeability than the fil of Example 14 shown in Example 14.

Example 16

The same nonwoven fabric as in Example 1 was used as the melt-produced nonwoven fabric. As the constituent fibers of the long-fiber nonwoven fabric, a sheath-core composite fiber having a low-melting-point component of high-density polyethylene and a high-melting-point component of polypropylene having a weight ratio of 5: 5 was used. In all other respects, a cylindrical fill cartridge was obtained in the same manner as in Example 8. This filter was a filter having the same filtration accuracy as the filter shown in Example 8, and the change in accuracy was smaller than that of the filter shown in Example 8.

Example 17

The same nonwoven fabric used in Example 15 was used as the meltblown nonwoven fabric. The same long-fiber nonwoven fabric as that of Example 16 was used. In all other respects, a cylindrical filter cartridge was obtained in the same manner as in Example 8. This filter has the same filtration accuracy as the filters shown in Examples 15 and 16 and has less change in accuracy than the filters shown in Examples 15 and 16. Was.

Example 18

A cylindrical filter cartridge was obtained in the same manner as in Example 16 except that a strong linear pressure was applied during winding of the filter cartridge to make the porosity of the filter 63%. Although the filtration performance of this filter was superior to that of the comparative example described later, the filter had a larger initial pressure loss and a shorter filtration life than the filter of Example 16. This is probably because the porosity was low and the fiber density was too high.

Example 19

A cylindrical filter cartridge was obtained in the same manner as in Example 16 except that the filter porosity was set to 88% by winding the band-shaped nonwoven fabric bundle with extremely low tension. Although the filtration performance of this filter was superior to the filter shown in the comparative example described later, the filter had a shorter filtration life than the filter of Example 16. The reason is that the filter porosity is high, This is probably because the filter medium was squeezed and the pressure loss increased rapidly.

Example 20

Except that the diameter of the guide of the circular hole set in the wind path of the winder was set to 1 mm, the porosity of the banded nonwoven fabric bundle was set to 58%, and all were cylindrical in the same manner as in Example 16 I got a Phil Yuichi cartridge. The filtration performance of this filter was higher than that of the comparative example described later. The initial pressure loss was higher than that of the filter shown in Example 16 and the filtration life was shorter. This is probably because the porosity of the banded nonwoven fabric bundle was low and the fiber density was too high.

Example 2 1

By setting the diameter of the guide of the circular hole installed in the wind path of the winder to 10 mm, and winding the banded non-woven fabric bundle with extremely low tension, the porosity of the banded non-woven fabric bundle is reduced to 97%. A cylindrical filter cartridge was obtained in the same manner as in Example 16 except for the above. Although the filtration performance of this filter was superior to the filter shown in Comparative Example described later, the filter had a shorter filtration life than the filter shown in Example 16. It is considered that the reason for this is that, because the porosity of the banded nonwoven fabric bundle is high, when the filtration pressure increases, the filter medium is squeezed, and the pressure loss rapidly increases.

Example 22

A cylindrical filter cartridge was obtained in the same manner as in Example 16 except that the thermocompression bonding method at the fiber intersection was changed from a hot embossing roll to a hot air circulation type heating device. This filter had the same performance as the filter shown in Example 16. Example 23

A cylindrical filter cartridge was obtained in the same manner as in Example 16 except that the band-shaped nonwoven fabric was not bundled, but instead twisted 100 times per lm. This filter was a filter having the same performance as the filter 1 shown in Example 8. Example 2 4

The band-shaped nonwoven fabric was processed into a cross-sectional shape as shown in FIG. 9 (A) to obtain a pleated material having four folds. Except that the folds were used in place of the bundled nonwoven, In the same manner as in Example 16, a cylindrical filter cartridge was obtained. This filter has the same level of accuracy as the filter shown in the embodiment 16, but the change in accuracy is smaller than that of the filter shown in the embodiment 16.

Example 2 5

The band-shaped nonwoven fabric was processed into a cross-sectional shape as shown in FIG. 8 (A) to obtain a pleated material having seven folds. A cylindrical filter cartridge was obtained in the same manner as in Example 16 except that the pleated material was used. This filter 1 had the same initial collection particle size as the filter 1 shown in Example 16 but had little change in accuracy.

Example 26

The band-shaped nonwoven fabric was processed into a cross-sectional shape as shown in FIG. 8 (C) to obtain a pleated material having 15 folds. A cylindrical fill cartridge was obtained in the same manner as in Example 16 except that the pleated material was used. This filter had the same initial collection particle size as the filter shown in Example 16 but had little change in accuracy and little pressure loss.

Example 2 7

A cylindrical filter was obtained in the same manner as in Example 16 except that the number of folds in the band-shaped nonwoven fabric was changed to 41. This filter had the same initial collection particle size as the filter shown in Example 16 but the change in accuracy was even smaller and the pressure loss was smaller than that of the filter shown in Example 25. Was something.

Comparative Example 1

Instead of the band-shaped nonwoven fabric, a 2 mm diameter polypropylene spun yarn spun from 3 dtex fiber was used, and the thread spacing was set to 0 mm. I got a force bridge. The initial collection particle size of this filter was much coarser than that of the filter shown in Example 3 and was almost the same as that of the filter shown in Example 6. However, the filtration life was shorter and the precision change was larger than in the case of the fill shown in Example 6. In addition, the initial filtrate had foaming, and the filter medium was also found to fall off.

Comparative Example 2 A cylindrical filter force cartridge was obtained in the same manner as in Example 3 except that one kind of filter paper specified in JISP 3801, which was cut to a width of 50 mm, was used instead of the band-shaped nonwoven fabric. The initial collection particle size of this filter was coarser than that of the filter shown in Example 3 and was about the same as that of the filter shown in Example 5, but the initial pressure loss was large, and However, the trapped particle size at the time of pressure rise also changed greatly from the initial stage. Furthermore, the filtration life was extremely short. Also, in the initial filtrate, the filter medium was found to fall off.

Comparative Example 3

Polypropylene and fineness 4 consisting of a high density polyethylene dtex, 8 split web of at type split short fibers card machine, fibers divided and fiber entanglement is the basis weight ² 2 g / m 2 divided by the high-pressure water working short fibers A non-woven fabric was obtained. Observation of this nonwoven fabric with an electron microscope and image analysis showed that 50% by weight of all the fibers were divided into a fineness of 0.5 dtex. A cylindrical fill cartridge was obtained in the same manner as in Example 3 except that this nonwoven fabric was cut to a width of 50 mm and used instead of the band-shaped nonwoven fabric. This fill filter was coarser than the filter filter shown in Example 3, and the change in accuracy was large. In addition, some bubbling was seen in the initial filtrate, and fiber shedding was also observed.

Comparative Example 4

The melt-blown nonwoven fabric used in Example 1 was slit to a width of 25 cm, and was wound around a perforated tubular body at a linear pressure of 1.5 kg / m as shown in Fig. 1 to form a cylindrical filter. Evening cartridge was obtained. Although the initial collection particle size of this filter was almost the same as that of Example 1, the collection particle size at 0.2 MPa was large. Also, the filtration life was slightly shorter than that of Example 1.

The results of the examples and comparative examples are shown in Tables 1, 2 and 3. table 1

/ 57989

32 Table 2

57989

33

Table 3

Winding performance

Filter

Yarn interval Initial collection Initial pressure 0.2 Pa

»Over-life Foaming Fiber falling off Porosity Particle size Loss Collected particle size

(mm) (%) (μm) (ΜΡβ) (βm) (min)

Example 1 0 78 2.50. 075 4 13 〇〇

¾¾Example 2 1 78 2.50 .075 413 〇〇 Example 3 0 78 2.5 0 .075 413 〇〇 Example 4 1 82 7 0 .025 9 19 〇〇 Example 5 2 83 9 0 01 5 12 25 〇〇 C

Example 6 3 83 15 0.007 20 80 〇〇 Hex Example 7 1 82 7 0.025 8.4 20 〇〇 Lol Example 8 1 82 7 0. 025 7-7 21 〇奚

¾S example 9 1 82 7 0.025 7.32 25 〇実施 Example 10 1 82 7 0.02 7.27 20 〇〇 Example 1 1 1 82 7 0.023 7.20 20 〇〇

1 2 1 82 6.5 0.027 7.2 18 〇〇 Μ Ϊ 13 1 82 10 0.01 9 1 1 30 〇笑 3S example 1 1 82 7 0. 025 7. 3 21 〇 M M example 15 1 82 7 0. 023 7. 3 21

¾¾Example 1 6 1 82 7 0.025 7.42 21 〇〇 Example 17 1 82 7 0.02 7.22 22 〇実施

H¾ 18 1 63 6.5 0. 035 7. 2 1 2 〇実施 Example 19 1 88 8 0 022 8, 8 1 5 〇〇 LOL JE example 20 1 78 6.4 0.035 7 0 1 1 〇

¾Example 21 1 0 0.022 8.8 8

ΛΒ ^ Ί 1 82 7 0.025 7.72 1〇 o Example 23 1 82 7 0.025 7.4 22 〇〇 Example 24 1 82 7 0 033 7.5 5 9 〇〇 Example 25 1 82 7 0. 023 7.4 23 〇〇 Fine 26 1 82 7 0.01 8 7.325 25 〇細 27 1 82 6 0. 021 6.3 25 〇 o Ratio ft Example 1 0 76 16 0 006 22 50 XX Comparative Example 2 0 72 10 0.024 14 1 8 〇 X Comparative Example 3 0 77 9.20, 01 1 1 3 20 ΔX Comparative Example 4 80 3 0. 063 6 12 〇. Industrial applicability

As described above, the filter cartridge of the present invention, while maintaining the excellent filtration accuracy, which is an advantage of the melt-blown nonwoven fabric, changes over time in the filtration ability based on the weakness of the fiber strength, which is its weak point, in a Taya shape. Or a non-woven fabric bonded to a long-fiber non-woven fiber aggregate, and then reduced by winding in a twill shape. This is a filter in which the non-woven fabric unevenness is reduced by winding a band-shaped non-woven fabric into a twill shape.

Therefore, compared to the conventional thread-wound filter cartridge, fine particles can be captured, the filtration life is long, the change in the initial collection particle size is hardly observed, and the pressure loss is low. In addition, when a pleated material of a band-shaped nonwoven fabric that is bundled so that at least a part of the fold is non-parallel is used, the filtering pressure in the vertical direction of the fold is lower than that of the pleated material that is parallel. Since it is hard to receive, the folds can be stably maintained without being crushed, and the filtration performance can be maintained.

Claims

The scope of the claims

1. A filter cartridge formed by winding a belt-shaped nonwoven fabric made of melt-processed thermoplastic fiber around a perforated cylindrical body in a twill shape.

2. A band-shaped nonwoven fabric formed by laminating and joining at least one layer each of a non-woven fiber aggregate made of melt-blown thermoplastic fibers and a long-fiber non-woven fiber aggregate into a perforated cylindrical body in a twill shape. One filter cartridge wound.

3. The melt-processed thermoplastic fiber is a mixed fiber or a composite fiber comprising a low-melting resin and a high-melting resin, wherein the difference between the melting points of both resins is 1 ° C. or more. A filter-cartridge as described.

4. The thermoplastic fiber constituting the long-fiber non-woven fiber aggregate is a heat-adhesive conjugate fiber comprising a low-melting resin and a high-melting resin, and a difference in melting point between the two resins is 10 ° C or more. 3. The filter according to claim 2, wherein

5. The filler cartridge according to claim 3, wherein the low-melting resin is a linear low-density polyethylene, and the high-melting resin is polyvinylene.

6-The filter cartridge according to any one of claims 1 to 5, wherein the air permeability of the nonwoven fabric is in the range of 1 to 500 cmVcmmVsec.

7. The filter cartridge according to any one of claims 1 to 5, wherein the bonding of the nonwoven fabric is thermocompression-bonded with a hot embossing roll.

8. The fill cartridge according to claim 2, wherein the bond of the nonwoven fabric is heat-bonded with hot air.

9. The filter cartridge according to claim 1, wherein the band-shaped nonwoven fabric is twisted.

10. The filter cartridge according to claim 1, wherein the porosity of the filter cartridge is 65 to 85%.

The filter cartridge according to any one of claims 1 to 5, wherein the band-shaped nonwoven fabric is a pleated material having 4 to 50 folds, and is wound around the perforated tubular body in a twill shape.

12. The method of claim 11, wherein at least a portion of the folds of the fold are non-parallel. Phil Evening Power Bridge.

13. The filter of claim 11, wherein the porosity of the pleats is 60-95%.

14. The filter according to any one of claims 1 to 5, wherein a slit width of the band-shaped nonwoven fabric is 0.5 cm or more, and a product of a slit width (cm) and a basis weight (g / m ² ) is 200 or less. Tridge.