WO2011138951A1 - 帯電フィルタ及びマスク - Google Patents
帯電フィルタ及びマスク Download PDFInfo
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- WO2011138951A1 WO2011138951A1 PCT/JP2011/060546 JP2011060546W WO2011138951A1 WO 2011138951 A1 WO2011138951 A1 WO 2011138951A1 JP 2011060546 W JP2011060546 W JP 2011060546W WO 2011138951 A1 WO2011138951 A1 WO 2011138951A1
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- WIPO (PCT)
- Prior art keywords
- nonwoven fabric
- charged
- liquid
- charging
- filter
- Prior art date
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- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
- A62B23/00—Filters for breathing-protection purposes
- A62B23/02—Filters for breathing-protection purposes for respirators
- A62B23/025—Filters for breathing-protection purposes for respirators the filter having substantially the shape of a mask
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C3/00—Separating dispersed particles from gases or vapour, e.g. air, by electrostatic effect
- B03C3/28—Plant or installations without electricity supply, e.g. using electrets
- B03C3/30—Plant or installations without electricity supply, e.g. using electrets in which electrostatic charge is generated by passage of the gases, i.e. tribo-electricity
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
- B03C3/00—Separating dispersed particles from gases or vapour, e.g. air, by electrostatic effect
- B03C3/34—Constructional details or accessories or operation thereof
- B03C3/40—Electrode constructions
- B03C3/60—Use of special materials other than liquids
- B03C3/64—Use of special materials other than liquids synthetic resins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/04—Additives and treatments of the filtering material
- B01D2239/0435—Electret
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
- B01D2239/0604—Arrangement of the fibres in the filtering material
- B01D2239/0618—Non-woven
Definitions
- the present invention relates to a charging filter and a mask including the charging filter.
- Such a non-woven fabric filter has been required to have as high a collection efficiency as possible.
- Dust collection in non-woven fabric filters is mainly due to Brownian diffusion, shielding, and inertial collision due to physical action. Therefore, if the diameter of the fibers that make up the filter is reduced, smaller dust can be captured. Therefore, dust collection efficiency can be increased.
- Patent Document 1 an electret body obtained by applying ultrasonic waves to a structure made of a thermoplastic resin via a polar liquid is known.
- the electret body of Example 1 disclosed in Patent Document 1 is obtained by applying ultrasonic waves to a non-woven fabric prepared by a melt blow technique via a polar liquid, and is excellent in the collection efficiency of atmospheric dust. It is disclosed.
- JP 2005-29944 A (claims, 0009, 0024, 0036-0040)
- the dust collection mainly depends on the physical action of the charging filter, the filter gap is clogged, and the pressure loss increases.
- the applicant of the present application has continued to intensively study to obtain a charging filter that has a higher initial collection efficiency than the prior art and is less likely to cause a decrease in collection efficiency.
- the applicant of the present application has continued diligently studying to obtain a charging filter suitable for collecting oil mist, as compared with the prior art.
- the present invention has been made to exceed the above-mentioned limitations of the prior art, and an object of the present invention is to provide a charging filter and a mask that have a high initial collection efficiency and are unlikely to cause a decrease in the collection efficiency.
- the charging filter of the present invention has a liquid-charged nonwoven fabric layer charged by applying a force through a polar liquid and a frictionally charged nonwoven fabric layer charged by rubbing a plurality of types of fiber components. .
- the charging filter may have a plurality of liquid-charged nonwoven fabric layers and / or friction-charged nonwoven fabric layers.
- the liquid-charged non-woven fabric layer may be present on the upstream side in the ventilation direction with respect to the friction-charged non-woven fabric layer.
- ⁇ Charging filter can be used for oil mist collection.
- the mask of the present invention includes the above charging filter.
- the charging filter according to the present invention includes a liquid-charged non-woven fabric layer charged by applying a force via a polar liquid and a friction charge charged by rubbing a plurality of types of fiber components with each other. It has been found that by having a non-woven fabric layer, the charging filter has a high initial collection efficiency and is unlikely to cause a decrease in the collection efficiency.
- the inventors of the present invention have a plurality of the liquid-charged nonwoven fabric layer and / or the frictionally-charged nonwoven fabric layer so that the initial collection efficiency is higher and the collection efficiency is lowered. It was found that the filter is a charging filter that is difficult to cause.
- the inventors of the present invention provide a charging filter in which the liquid-charged nonwoven fabric layer is present on the upstream side in the ventilation direction with respect to the friction-charged nonwoven fabric layer, so that further reduction in collection efficiency is unlikely to occur. I found out.
- the charging filter is a charging filter that has a high initial collection efficiency and is unlikely to cause a reduction in the collection efficiency even when the object of filtration is oil mist.
- a mask provided with a charging filter according to the present invention is a mask that has a high initial collection efficiency and is unlikely to cause a decrease in collection efficiency.
- the present invention comprises a liquid-charged nonwoven fabric layer (11) charged by applying a force through a polar liquid and a frictionally charged nonwoven fabric layer (12) charged by rubbing a plurality of types of fiber components.
- a charging filter according to one embodiment will be described with reference to FIGS.
- 1 is a mode in which a liquid-charged nonwoven fabric layer (11) and a friction-charged nonwoven fabric layer (12) are laminated one by one.
- Another charging filter (10) in FIG. 2 has two liquid-charged nonwoven layers composed of a liquid-charged nonwoven layer (11) and another liquid-charged nonwoven layer (13), and one friction-charged nonwoven layer (12). It is the aspect formed by laminating.
- the liquid charging nonwoven fabric layer (11, 13) is disposed upstream (upward in the drawing) of the ventilation direction (a) from the friction charging nonwoven fabric layer (12).
- the liquid-charged non-woven fabric layer (11) is configured based on a liquid-charged non-woven fabric that is charged by applying a force via a polar liquid.
- the liquid-charged non-woven fabric is subjected to a non-woven fabric composed of fibers described below in a charging process (hereinafter referred to as a liquid charging process) in which force is applied via a polar liquid described later, or the fibers described below are liquid It is obtained by charging the fiber by subjecting it to a charging process and then making it into a non-woven fabric.
- a liquid charging process a charging process in which force is applied via a polar liquid described later, or the fibers described below are liquid It is obtained by charging the fiber by subjecting it to a charging process and then making it into a non-woven fabric.
- polyolefin resin polyethylene resin, polypropylene resin, polymethylpentene, polyolefin resin having a structure in which a part of hydrocarbon is substituted with a cyano group or halogen such as fluorine or chlorine, etc.
- Styrene resin polyvinyl alcohol resin
- polyether resin polyether ether ketone, polyacetal, modified polyphenylene ether, aromatic polyether ketone, etc.
- polyester resin polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, Polyethylene naphthalate, polybutylene naphthalate, polycarbonate, polyarylate, wholly aromatic polyester resin, etc.
- polyimide resin polyamideimide resin
- Polyamide resins for example, aromatic polyamide resins, aromatic polyetheramide resins, nylon resins
- resins having a nitrile group for example, polyacrylonitrile
- urethane resins epoxy resins, polys
- organic polymers may be either linear polymers or branched polymers, and the polymer may be a block copolymer, a random copolymer, or a mixture of multiple organic polymers.
- the polymer may be a block copolymer, a random copolymer, or a mixture of multiple organic polymers.
- organic polymers having a volume resistivity of 10 14 ⁇ ⁇ cm or more include, for example, polyolefin resins (for example, polyethylene resins, polypropylene resins, polymethylpentene resins, polystyrene resins, etc.), polytetrafluoroethylene, Examples thereof include polyvinylidene chloride, polyvinyl chloride, and polyurethane.
- volume specific resistance value in this specification refers to a value obtained by measurement according to “General Thermosetting Plastic Test Method” defined in JIS K-6911.
- the hindered amine compound, aliphatic metal salt eg, magnesium salt of stearic acid, aluminum salt of stearic acid, etc.
- One or more compounds selected from among acid-modified polymers can be added as additives.
- a hindered amine compound may be added to the organic polymer because the charge amount of the fiber or the nonwoven fabric can be further increased.
- hindered amine compounds include 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 ⁇ , dimethyl-1- (2-hydroxyethyl) succinate -4-hydroxy-2,2,6,6-tetramethylpiperidine polycondensate, 2- (3,5-di-t-butyl-4-hydroxybenzyl) -2-n-butylmalonate bis (1, 2,2,6,6-pentamethyl-4-piperidyl) and the like.
- the amount of these additives added to the organic polymer is not particularly limited, but may be added in a mass of 0.01 to 5% by mass with respect to the mass of the organic polymer. If the content of the additive is less than 0.01% by mass, the charging effect on the fiber or the nonwoven fabric tends to be small in the liquid charging process, so the additive amount may be 0.05% by mass or more. Moreover, when the said content exceeds 5 mass%, since the intensity
- additives such as activated carbon, antibacterial agent, deodorant and the like may be added to the organic polymer.
- the above-mentioned fibers include, for example, a melt spinning method, a dry spinning method, a wet spinning method, a direct spinning method (melt blow method, spun bond method, electrostatic spinning method, etc.), a method of extracting fibers from a composite fiber, and beating the fibers.
- a melt spinning method for example, a melt spinning method, a dry spinning method, a wet spinning method, a direct spinning method (melt blow method, spun bond method, electrostatic spinning method, etc.), a method of extracting fibers from a composite fiber, and beating the fibers.
- a direct spinning method melt blow method, spun bond method, electrostatic spinning method, etc.
- the fibers constituting the liquid-charged nonwoven fabric may be composed of one type of organic polymer or may be composed of a plurality of types of organic polymers.
- the fiber composed of a plurality of types of organic polymers can be generally referred to as a composite fiber, for example, a core-sheath type, a sea-island type, a side-by-side type, an orange type, a bimetal type, or the like.
- the liquid-charged nonwoven fabric layer (11) can have a dense structure, and therefore, a charge filter with a high ability to collect physical dust or oil mist. (10) can be obtained.
- the average fiber diameter of the fibers constituting the liquid-charged nonwoven fabric may be 20 ⁇ m or less, 10 ⁇ m or less, or 6 ⁇ m or less.
- the lower limit value of the average fiber diameter may be 1 ⁇ m or more, 2 ⁇ m or more, or 3 ⁇ m or more so that the initial pressure loss when the charging filter is used can be kept low.
- average fiber diameter refers to a photomicrograph magnified 1 to 50,000 times the cross-section in the thickness direction of the nonwoven fabric, and 40 fibers are selected from the photomicrograph.
- the diameter of a circle having the same cross-sectional area is defined as the fiber diameter.
- the apparent density of the liquid-charged nonwoven fabric may be 100 kg / m 3 or less, 80 kg / m 3 or less, or 60 kg / m 3 or less so that the increase in pressure loss due to dust collection is suppressed. It is good.
- the “apparent density” is a value obtained by calculating the mass per 1 m 3 of the liquid charged nonwoven fabric layer (11).
- non-woven fabric comprising the above-described fibers
- examples of the non-woven fabric comprising the above-described fibers include, for example, a dry non-woven fabric in which a fiber is used as a non-woven fabric without using a solvent, a wet non-woven fabric in which a fiber is used in a non-woven fabric using a solvent, a direct method (melt blow method, spunbond method, static Examples thereof include a nonwoven fabric obtained by spinning a fiber using an electrospinning method or the like and collecting the fiber.
- the amount of additives that inhibit the charging effect (fiber oils, dispersants, surfactants, etc.) added to the fiber or nonwoven fabric can be reduced, and the contacts between the fibers can be integrated without using a binder.
- the non-woven fabric may be prepared using a melt blow method, an electrostatic spinning method, or the like.
- the liquid-charged non-woven fabric is prepared by applying the fiber or non-woven fabric obtained as described above to the liquid-charging process described below.
- the liquid charging process is a charging process of a fiber or a nonwoven fabric having at least one charging method selected from the following.
- (1) A method in which a polar liquid is applied to a fiber or non-woven fabric and then charged by applying a force via the polar liquid.
- (2) A method in which a polar liquid is applied to a fiber or a non-woven fabric, and at the same time, a force is applied via the polar liquid to cause charging.
- (3) A method in which a fiber or a non-woven fabric is charged by applying a force through a polar liquid while being immersed in a polar liquid filled in a container.
- polar liquid for example, a liquid having low electrical conductivity such as water, alcohol, acetone, or water in which ammonia is dissolved can be used.
- the electric conductivity referred to here is one measured by JIS K 0101 “Industrial water test method”.
- JIS K 0101 Industry Standard water test method
- the temperature of the polar liquid used in the liquid charging process is not limited as long as the fiber or the nonwoven fabric can be suitably charged, but may be 40 ° C. or lower.
- Examples of the method of applying the polar liquid to the fiber or the nonwoven fabric include a method of applying the polar liquid as a mist, liquid droplet, liquid flow, or the like using a spray, a shower, a nozzle, or the like.
- Examples of the method for immersing the fiber or the nonwoven fabric include a method using an impregnation apparatus (for example, a saturator manufactured by Rodney Hunt).
- the method of applying or impregnating the polar liquid at this time is not limited as long as it can suitably charge the fiber or the nonwoven fabric, and can be appropriately selected.
- Examples of the method of applying a force include a method of causing ultrasonic waves, vibration, and a polar liquid to collide as a liquid flow.
- a method of causing a polar liquid to collide as a liquid flow such as a method of causing a water flow to collide, a force can be applied to the fiber or the nonwoven fabric at the same time as applying the polar liquid.
- the strength and time of the force acting on the fiber or the nonwoven fabric can be appropriately adjusted so that the amount of charge of the fiber or the nonwoven fabric can be increased.
- the fiber or the nonwoven fabric applied with a force through the polar liquid in this way is subjected to a drying process in order to remove the polar liquid.
- Examples of the apparatus used for drying the fiber or non-woven fabric include known apparatuses such as a heating roller such as a can dryer and calendar, a hot air dryer, a hot air dryer, an electric furnace, and a heat plate.
- the temperature in the drying process may be 120 ° C. or lower, 105 ° C. or lower, or 90 ° C. or lower.
- the fiber or the nonwoven fabric is naturally dried, or the fiber or the nonwoven fabric is subjected to an ultrasonic wave or vibration to remove the polar liquid, so that the fiber or the nonwoven fabric is not heated. May be.
- the liquid-charged non-woven fabric can be obtained by subjecting the non-woven fabric to the above liquid charging process.
- the liquid-charged non-woven fabric can be obtained by preparing the non-woven fabric after the fibers are charged by the above liquid charging process.
- the liquid-charged nonwoven fabric obtained in this way can be used as the liquid-charged nonwoven fabric layer (11) as it is.
- the liquid-charged nonwoven fabric layer (11) is subjected to post-processing such as punching, slitting or corrugating. ).
- a liquid-charged nonwoven fabric layer (11) may be formed by laminating a reinforcing material such as a nonwoven fabric, net, woven fabric or knitted fabric on the liquid-charged nonwoven fabric and then post-processing.
- the form stability of the liquid-charged nonwoven fabric in the subsequent process is increased, and the strength of the obtained liquid-charged nonwoven fabric is also improved, making it easy to handle.
- the reinforcing material is laminated on the upstream side (upward in the drawing) of the liquid charging nonwoven fabric (a)
- the reinforcing material is laminated on the downstream side (downward on the drawing) of the liquid charging nonwoven fabric (a).
- the charging filter (10) can be suitably prepared, either of them may be used.
- the reinforcing material it is possible to use a reinforcing material that is less likely to cause a decrease in the collection efficiency of the charging filter due to a small amount of the surfactant or the like that deteriorates the charging characteristics.
- a spunbonded nonwoven fabric can be used as a reinforcing material because it has a small amount of adhesion of a surfactant or the like.
- the thickness of the liquid-charged nonwoven fabric layer (11) is not limited as long as the charge filter (10) can be suitably prepared, and can be appropriately adjusted.
- the high collection efficiency of the charge filter (10) and the difficulty in reducing the collection efficiency due to electrostatic collection action are affected by the amount of charge in the liquid-charged nonwoven fabric layer (11).
- the charge amount of the charged nonwoven fabric layer (11) is affected by the mass (weight per unit area) and the surface area of the liquid charged nonwoven fabric.
- the initial pressure loss of the charged filter (10) is high.
- the basis weight of the liquid charged nonwoven fabric layer (11) may be in the range of 10 to 120 g / m 2 , in the range of 30 to 100 g / m 2 , or in the range of 50 to 80 g / m 2 .
- the “weight per unit area” is a value obtained by calculating the mass per 1 m 2 of the liquid charged nonwoven fabric layer (11).
- the frictionally charged non-woven fabric layer (12) is configured by including a plurality of types of fiber components, and is also configured based on a frictionally charged non-woven fabric in which a plurality of types of fiber components are frictionally charged.
- the frictionally charged non-woven fabric is a process of rubbing and charging a plurality of types of fibers composed of different fiber components, or a fiber composed of a plurality of types of fiber components, which will be described below (hereinafter referred to as a tribocharging process). It is obtained by preparing it in the form of a non-woven fabric after being subjected to the above, or by subjecting it to a process of charging by friction and preparing it in the form of a non-woven fabric.
- polyolefin resin polyethylene, polypropylene, polymethylpentene, polyolefin resin having a structure in which a part of hydrocarbon is substituted with a cyano group or a halogen such as fluorine or chlorine, etc.
- Styrene resin polyvinyl alcohol resin
- polyether resin polyether ether ketone, polyacetal, modified polyphenylene ether, aromatic polyether ketone, etc.
- polyester resin polyethylene terephthalate, polytrimethylene terephthalate, polybutylene terephthalate, Polyethylene naphthalate, polybutylene naphthalate, polycarbonate, polyarylate, wholly aromatic polyester resin, etc.
- polyimide resin polyamideimide resin
- Polyamide resins for example, aromatic polyamide resins, aromatic polyetheramide resins, nylon resins
- resins having a nitrile group for example, polyacrylonitrile
- urethane resins epoxy resins, polys
- organic polymers may be either linear polymers or branched polymers, and the polymers may be block copolymers or random copolymers, or those in which organic polymers are mixed in multiple components.
- polymers may be block copolymers or random copolymers, or those in which organic polymers are mixed in multiple components.
- the frictionally charged nonwoven fabric having a further increased charge amount can be obtained. That is, the amount of charge is larger when the acrylic resin fiber having a substantially circular cross section is used than when the acrylic resin fiber having a constricted irregular cross section is used.
- An acrylic resin fiber having such a substantially circular cross section is described in, for example, “Fiber Handbook-Raw Materials” (Fiber Society, published by Maruzen Co., Ltd., published in October 1970, see pages 727 to 779).
- an inorganic solvent such as nitric acid, zinc chloride aqueous solution, calcium chloride aqueous solution, and rhodan salt (sodium thiocyanate, potassium thiocyanate, calcium thiocyanate) aqueous solution.
- an acrylic resin fiber having a substantially circular cross section “Exlan” (Nippon Exlan Industry Co., Ltd., trade name), “Cresslan” (US American Cyyanamid Co., trade name), “Zephran” (The The Dow Chemical Co., USA) Product name), "Cotel” (Courtaulds Co., UK, product name).
- the fiber made of the other polyolefin resin a fiber made of a resin in which a part of the polyolefin resin is substituted with a cyano group or a halogen can be used.
- the polyolefin-based resin contains a phosphorus-based antioxidant and a sulfur-based antioxidant, a triboelectrically charged nonwoven fabric having a large charge amount can be obtained.
- additives such as activated carbon, antibacterial agents and deodorants may be added to the organic polymer.
- the above-mentioned fibers include melt spinning method, dry spinning method, wet spinning method, direct spinning method (melt blow method, spunbond method, electrostatic spinning method, etc.), method of extracting fiber from composite fiber, beating fiber and fiber It can obtain by well-known methods, such as the method of obtaining.
- the fibers constituting the frictionally charged nonwoven fabric may be composed of a plurality of types of organic polymers.
- the fiber composed of a plurality of types of organic polymers can be generally referred to as a composite fiber, for example, a core-sheath type, a sea-island type, a side-by-side type, an orange type, a bimetal type, or the like.
- the mixing ratio is not limited as long as the charge amount can be suitably increased by the triboelectric charging process, and is appropriately selected. can do.
- the triboelectric nonwoven fabric is prepared so that the mass mixing ratio of the fiber made of polyolefin resin and the fiber made of acrylic resin is in the range of 30:70 to 80:20, it is suitable for the triboelectric charging process. A triboelectrically charged non-woven fabric having a large charge amount can be obtained.
- the average fineness of the fibers constituting the frictionally charged non-woven fabric is such that dust or oil mist can be collected, and in the friction charging process described below, the charged state can be stably charged with a large amount of charge.
- the fineness may be in the range of 1 dtex to 6 dtex, may be in the range of 1 dtex to 4 dtex, and may be in the range of 1.5 dtex to 3 dtex.
- the addition ratio of the additive that inhibits the charging effect by washing the fiber or the nonwoven fabric with, for example, warm water or alcohol is 0.2% by mass or less, or 0.15% by mass or less with respect to the fiber mass. As a state, it can be subjected to a frictional charging process.
- the method is not limited as long as the fibers can be charged by friction with each other as a frictional charging treatment.
- a card machine represented by a flat card or a roller card
- a garnet machine or an air raid is used.
- the fibers are easily rubbed with each other, can be triboelectrically charged and can be prepared in the form of a nonwoven fabric, and a triboelectrically charged nonwoven fabric can be easily obtained.
- the obtained frictionally charged nonwoven fabric can be used as it is as the frictionally charged nonwoven fabric layer (12).
- a needle punch It may be processed.
- the constituting fibers may be rubbed against each other without giving the needle punching treatment or before and / or after performing the needle punching treatment by applying vibration to the frictionally charged non-woven fabric or squeezing.
- the triboelectric non-woven fabric is superior in the amount of charge is not known, but the generation of the charge depends on the friction between multiple types of organic polymers, and the friction between the organic polymers occurs only on the surface of the non-woven fabric. However, it is considered that the charge is generated in the entire frictionally charged non-woven fabric because it occurs also in the inside.
- the triboelectric charging process can more efficiently charge the nonwoven fabric than a charging method that imparts charge only to the surface of the nonwoven fabric, such as a plasma charging process or a corona charging process.
- Such a frictionally charged non-woven fabric can be used as it is as a frictionally charged non-woven fabric layer (12), but can also be used as a triboelectrically charged non-woven fabric layer (12) by post-processing such as punching, slitting or corrugating. good. Further, if necessary, a frictionally charged non-woven fabric layer (12) may be formed by laminating a reinforcing material such as a non-woven fabric, net, woven fabric or knitted fabric on the triboelectrically charged non-woven fabric, followed by post-processing.
- a reinforcing material such as a non-woven fabric, net, woven fabric or knitted fabric
- the frictionally charged nonwoven fabric is reinforced with a reinforcing material
- the form stability of the frictionally charged nonwoven fabric in the subsequent process is increased, and the strength of the obtained frictionally charged nonwoven fabric is improved, so that it is easy to handle.
- the reinforcing material is laminated on the upstream side (upward in the drawing) of the frictionally charged nonwoven fabric (a), it is laminated on the downstream side (downward in the drawing) of the frictionally charged nonwoven fabric (a).
- the charging filter (10) can be suitably prepared, either of them may be used.
- the reinforcing material it is possible to use a reinforcing material that is less likely to cause a decrease in the collection efficiency of the charging filter due to a small amount of the surfactant or the like that deteriorates the charging characteristics.
- a spunbonded nonwoven fabric can be used as a reinforcing material because it has a small amount of adhesion of a surfactant or the like.
- a charged nonwoven fabric layer (12) may be used.
- the thickness of the frictionally charged nonwoven fabric layer (12) is not limited as long as the charge filter (10) can be suitably prepared, and can be appropriately adjusted.
- the high collection efficiency of the charge filter (10) and the difficulty in reducing the collection efficiency due to the electrostatic collection action are affected by the amount of charge in the frictionally charged nonwoven fabric layer (12).
- the charge amount of the charged nonwoven fabric layer (12) is affected by the mass per unit area (weight per unit area) and the size of the surface area of the frictionally charged nonwoven fabric.
- the frictionally charged non-woven fabric layer (12) is in a mode in which the fibers are densely gathered and the basis weight is high, the initial pressure loss of the charging filter (10) becomes high, and further to the mask described later. In the case of molding, workability may be deteriorated.
- the basis weight of the frictionally charged nonwoven fabric layer (12) may be in the range of 60 to 400 g / m 2 , in the range of 100 to 320 g / m 2 , or in the range of 140 to 240 g / m 2 .
- the “weight per unit area” is a value obtained by calculating the mass per 1 m 2 of the frictionally charged nonwoven fabric layer (12).
- the charge filter (10) having a plurality of liquid-charged non-woven fabric layers is shown in FIG. ), A charge filter (10) having a larger charge amount than the charge filter (10) having a liquid charged nonwoven fabric layer (11) and a frictionally charged nonwoven fabric layer (12) one by one, as shown in FIG. It is possible to obtain a charging filter (10) having a high initial collection efficiency and hardly causing a decrease in the collection efficiency.
- liquid electrification nonwoven fabric layer (13) is comprised on the basis of a liquid electrification nonwoven fabric, and can be prepared like the liquid electrification nonwoven fabric layer (11).
- another liquid-charged nonwoven fabric layer (13) is present downstream of the liquid-charged nonwoven fabric layer (11) in the ventilation direction, as in the charge filter (10) of FIG. 2, another liquid-charged nonwoven fabric layer (13)
- the apparent density can be adjusted as appropriate, and may be 200 kg / m 3 or less, 150 kg / m 3 or less, or 100 kg / m 3 or less so as to suppress an increase in pressure loss due to dust collection. m 3 or less may be used.
- the “apparent density” referred to in this specification is a value obtained by calculating the mass per 1 m 3 of the nonwoven fabric.
- the thickness of the other liquid-charged nonwoven fabric layer (13) is not limited as long as the charge filter (10) can be suitably prepared, and can be appropriately adjusted.
- the high collection efficiency of the charging filter (10) and the difficulty in reducing the collection efficiency due to the electrostatic collection action are affected by the charge amount of another liquid-charged nonwoven fabric layer (13).
- the charge amount of the other liquid-charged nonwoven fabric layer (13) is affected by the mass (unit weight) per unit area of the liquid-charged nonwoven fabric and the size of the surface area.
- the other liquid-charged non-woven fabric layer (13) is in a mode in which fibers are densely gathered and the basis weight is high, the pressure loss of the charge filter (10) becomes high.
- the basis weight of another liquid-charged nonwoven fabric layer (13) located downstream of the layer (11) may be lighter than the basis weight of the liquid-charged nonwoven fabric layer (11).
- the average fiber diameter of the fibers constituting another liquid charged nonwoven fabric layer (13) located on the downstream side (downward direction in the drawing) of the liquid charged nonwoven fabric layer (11) is the fiber constituting the liquid charged nonwoven fabric layer (11).
- the fiber diameter can be made thinner.
- a specific numerical value may be 10.0 ⁇ m or less, 6.0 ⁇ m or less, or 4.0 ⁇ m or less.
- the lower limit value of the average fiber diameter may be 0.5 ⁇ m or more, or 1.0 ⁇ m or more so that the increase of the initial pressure loss and the pressure loss due to dust collection can be suppressed when the charging filter (10) is used. Or 1.5 ⁇ m or more.
- the liquid-charged nonwoven fabric layer (11) is used for the purpose of reducing the initial pressure loss. Even if a liquid-charged non-woven fabric with a small amount of electricity is used, the triboelectrically-charged non-woven fabric layer (12) rich in charge is provided to electrostatically collect the decrease in the physical collection ability of the charge filter (10). It can be compensated by the improvement of ability.
- the charging filter (10) having the liquid-charged nonwoven fabric layer (11) and the friction-charged nonwoven fabric layer (12) can reduce the initial pressure loss, but can reduce the initial collection efficiency. It can be increased, the decrease in the collection efficiency accompanying the collection of dust can be reduced, and the increase in pressure loss can be suppressed.
- Each charged nonwoven fabric layer may be bonded by a bonding means such as an adhesive or fiber bonding, but the charged filter (10) may be formed by laminating each charged nonwoven fabric layer without using a bonding means.
- a bonding means such as an adhesive or fiber bonding
- the charged filter (10) may be formed by laminating each charged nonwoven fabric layer without using a bonding means.
- the joining range is too wide, it may cause a reduction in the collection efficiency of the charging filter (10).
- a continuous or discontinuous linear joint having a width of 0.1 to 5 mm may be provided around the charging filter (10), and in particular a continuous or discontinuous linear joint having a width of 0.5 to 3 mm. A part may be provided.
- Joining by fiber bonding may be performed by heat fusion, but when heat is applied to the whole, the electric charge held in the fiber moves, and the electrostatic collecting action of the charging filter (10) may be reduced. Therefore, means such as ultrasonic fusion may be used.
- Each charged non-woven fabric layer can be used as it is as the charge filter (10), but it can also be used as a charge filter (10) by performing post-processing such as punching, slitting or corrugating. If necessary, add binders, paints, and functional additives (antibacterial agents, activated carbon, deodorants, etc.) to each laminated non-woven fabric layer, or reinforce non-woven fabrics, nets, fabrics, knitted fabrics, etc. It is good also as a charge filter (10) by post-processing after laminating
- the shape stability of the charging filter (10) is increased and the strength is improved, so that it is easy to handle.
- the reinforcing material is laminated on the upstream side (upward on the paper surface) of the charging filter (10) in the ventilation direction (a), the downstream side (downward on the paper surface) of the charging filter (10) in the ventilation direction (a). Even if they are laminated, any one may be used as long as the charge filter (10) can be suitably prepared.
- the reinforcing material it is possible to use a reinforcing material that is less likely to cause a decrease in the collection efficiency of the charging filter due to a small amount of the surfactant or the like that deteriorates the charging characteristics.
- a spunbonded nonwoven fabric can be used as a reinforcing material because it has a small amount of adhesion of a surfactant or the like.
- the order of stacking of the respective charged nonwoven fabric layers constituting the charging filter (10), the number of the respective charged nonwoven fabric layers to be stacked, and the like are not particularly limited and can be appropriately adjusted.
- the charging filter (10) has one liquid-charged nonwoven fabric layer (11) and one friction-charged nonwoven fabric layer (12)
- the upstream side of the charging filter (10) in the ventilation direction (a) A charging filter (10) in which the respective charged nonwoven fabric layers are laminated in the order of the frictionally charged nonwoven fabric layer (12) and the liquid charged nonwoven fabric layer (11) from the upper side of the paper surface can be obtained.
- the charging filter (10) has a ventilation direction (a) From the upstream side (upward on the paper surface), the frictionally charged nonwoven fabric layer (12), the liquid charged nonwoven fabric layer (11), and another liquid charged nonwoven fabric layer (13) may be used.
- a charging filter (10) can be comprised.
- the charging filter (10) has a plurality of liquid-charged nonwoven fabric layers and a plurality of friction-charged nonwoven fabric layers, the order of lamination of the respective charged nonwoven fabric layers can be appropriately adjusted.
- the charged filter (10) in which the liquid-charged nonwoven fabric layer (11, 13) is present upstream of the triboelectrically-charged nonwoven fabric layer (12) in the ventilation direction (a).
- the liquid charged non-woven fabric layer (11, 13) plays a role of collecting main dust or oil mist, so that neutralization of electric charge accompanying the collection of dust by the triboelectrically charged non-woven fabric layer (12) can be suppressed. Further, it is possible to further prevent the collection efficiency of the charging filter (10) from being lowered.
- one or more liquid-charged nonwoven fabric layers may be a charge filter (10) that exists upstream of the triboelectrically charged nonwoven fabric layer (12) in the ventilation direction (a).
- the charging filter (10) may be present on the upstream side in the ventilation direction (a) with respect to the frictionally charged nonwoven fabric layer (12).
- the liquid charged nonwoven fabric layer (11 in FIG. 2) existing on the upstream side may be composed of fibers having a larger fiber diameter than other liquid charged nonwoven fabric layers (13 in FIG. 2).
- the above charging filter (10) can be used as a base material for a mask.
- a method for manufacturing the mask a known method can be used.
- the charging filter (10) is used as a base material for a molding mask, the charging filter (10) is attached to one face including the mouth.
- a mask (1) as shown in FIG. 7 can be formed by forming a cup shape covering the portion.
- the reinforcing material and the charging filter (10) are laminated and then formed into a mask (1) as shown in FIG.
- a mask (1) as shown in FIG. 7 can be obtained by forming the charge filter (10) on the substrate and then forming it.
- the periphery can be joined by sewing, adhesion, or the like before molding, simultaneously with molding, or after molding.
- the liquid charging nonwoven fabric layer and / or the frictionally charged nonwoven fabric layer are individually laminated on the reinforcing material before or after molding, and then molded.
- the mask (1) as shown in FIG. 7 can be obtained.
- A-1 Preparation method of melt-blown nonwoven fabric (A-1) subjected to liquid electrification
- polypropylene resin Principal Polymer Co., Ltd. manufactured by Prime Polymer Co., Ltd.
- CHIMASSORB 944FDL commercially available hindered amine light stabilizer
- spinning is performed using the melt blow method, and the melt blow nonwoven fabric (weight per unit: 50 g / m 2 , thickness) (Length: 0.8 mm, average fiber diameter: 6 ⁇ m).
- the resulting meltblown nonwoven fabric is pure water (corresponding to secondary distilled water that has undergone distillation and ion exchange) that is maintained as a polar liquid with an electrical conductivity of 3.2 ( ⁇ S / cm) and a temperature of 20 ⁇ 5 ° C.
- the sample was transported into the retained bath, loaded with pure water and subjected to ultrasonic waves with a frequency of 20 kHz.
- the melt blown nonwoven fabric subjected to ultrasonic waves was dried at 105 ° C. using a conveyor dryer to obtain a liquid blown melt blown nonwoven fabric (weight per unit: 50 g / m 2 , thickness: 0.8 mm, A-1). .
- melt-blown nonwoven fabric (A-2) subjected to liquid electrification Spinning was performed using the melt-blowing method, and melt-blown nonwoven fabric (weight per unit: 25 g / m 2 , thickness: 0.3 mm, average fiber diameter: 3 ⁇ m) Except for the preparation, a liquid-blown melt-blown nonwoven fabric (weight per unit: 25 g / m 2 , thickness: 0.3 mm, A-2) was obtained in the same manner as in section A-1.
- melt blown nonwoven fabric (B-1) treated with corona discharge The melt-blown nonwoven fabric obtained in Section A-1 was subjected to corona discharge treatment (DC voltage: 15 kV) as a charging treatment, and was subjected to corona discharge treatment (weight per unit: 50 g / m 2 , thickness: 0.8 mm, B- 1) got.
- the nonwoven fabric was charged by corona discharge treatment.
- melt blown nonwoven fabric (B-2) treated with corona discharge The melt-blown nonwoven fabric obtained in Section A-2 was subjected to corona discharge treatment (DC voltage: 15 kV) as a charging treatment, and the melt-blown nonwoven fabric subjected to corona discharge treatment (weight per unit: 25 g / m 2 , thickness: 0.3 mm, B- 2) got.
- the nonwoven fabric was charged by corona discharge treatment.
- C-1 Preparation method of corona discharge-treated hydroentangled nonwoven fabric (C-1) Polypropylene fiber (made by Ube Nitto Kasei Co., Ltd., NF, fineness: 2.2dtex, average fiber diameter: 18 ⁇ m, fiber length: 51mm)
- the fiber was opened by a machine and hydroentangled with a water pressure of 15 MPa to prepare a hydroentangled nonwoven fabric (weight: 50 g / m 2 , thickness: 0.6 mm).
- the obtained hydroentangled nonwoven fabric is subjected to corona discharge treatment (DC voltage: 15 kV) to obtain a corona discharge treated hydroentangled nonwoven fabric (weight per unit: 50 g / m 2 , thickness: 0.6 mm, C-1). It was.
- This mixed fiber is made into a fiber web by a card machine and triboelectrically charged, and this fiber web is laminated on a polypropylene spunbond nonwoven fabric (Mitsui Chemicals, Syntex PK103, basis weight: 15 g / m 2 ), and needle density: Under a condition of 160 / cm 2 , needle punching was performed from the fiber web side to obtain a frictionally charged needle punch composite nonwoven fabric (weight per unit: 200 g / m 2 , thickness: 2.3 mm, D-1).
- a polypropylene spunbond nonwoven fabric Mitsubishi Chemicals, Syntex PK103, basis weight: 15 g / m 2
- needle density Under a condition of 160 / cm 2 , needle punching was performed from the fiber web side to obtain a frictionally charged needle punch composite nonwoven fabric (weight per unit: 200 g / m 2 , thickness: 2.3 mm, D-1).
- D-2 Preparation Method of Frictionally Charged Needle Punch Composite Non-woven Fabric (D-2) Same as D-1 except that the fabric web weight is 250 g / m 2 laminated on the polypropylene spunbonded non-woven fabric. Thus, a needle-punch composite nonwoven fabric (weight per unit: 250 g / m 2 , thickness: 2.7 mm, D-2) subjected to friction charging was obtained.
- D-3 Preparation Method of Frictionally Charged Needle Punch Composite Non-woven Fabric (D-3) Same as D-1 except that the basis weight of the fiber web laminated on the polypropylene spunbond nonwoven fabric is 180 g / m 2 A needle-punch composite nonwoven fabric (weight per unit: 180 g / m 2 , thickness: 1.9 mm, D-3) obtained by friction charging was obtained.
- D-4 Preparation method of needle-punch composite nonwoven fabric (D-4) subjected to triboelectric charging treatment Triboelectric charging treatment was carried out in the same manner as in section D-1, except that the basis weight of the fiber web laminated on the polypropylene spunbond nonwoven fabric was prepared. Needle punch composite nonwoven fabric (weight per unit: 275 g / m 2 , thickness: 3.0 mm, D-4) was obtained.
- E-1 Preparation method of needle punch composite nonwoven fabric (E-1) treated with corona discharge Polypropylene fiber (manufactured by Ube Nitto Kasei Co., Ltd., NM, fineness: 2.2dtex, fiber length: 51mm)
- the fiber web was laminated on a polypropylene spunbonded nonwoven fabric (Mitsui Chemicals, Syntex PK103, basis weight: 15 g / m 2 ), and needle punching was performed from the fiber web side under the condition of needle density: 160 / cm 2.
- the needle punch composite nonwoven fabric (weight per unit: 200 g / m 2 , thickness: 2.4 mm) was obtained.
- the obtained needle punch composite nonwoven fabric was washed with warm water at 30 ° C., and the amount of the fiber oil agent adhering to the fiber was adjusted to 0.1% or less with respect to the fiber mass, and then dried and then subjected to corona discharge treatment (DC Voltage: 15 kV) was performed, and a needle punch composite nonwoven fabric (weight per unit: 200 g / m 2 , thickness: 2.4 mm, E-1) subjected to corona discharge treatment was obtained.
- Example 1 Each charged non-woven fabric layer was laminated without bonding to obtain a two-layered charge filter (weight per unit: 250 g / m 2 , thickness: 3.1 mm) having the following configuration.
- Upstream side of air flow direction (a): Liquid-charged melt blown nonwoven fabric (A-1) with a basis weight of 50 g / m 2
- Downstream side of air flow direction (a): Needle punch composite non-woven fabric with a weight per unit of 200g / m 2 (D-1, polypropylene spunbond non-woven fabric is downstream of air flow direction (a))
- Example 2 Lamination was performed in the same manner as in Example 1 to obtain a two-layered charge filter (weight per unit: 250 g / m 2 , thickness: 3.1 mm) having the following configuration.
- Upstream side of air flow direction (a): Needle punch composite non-woven fabric with frictional electrification with a basis weight of 200 g / m 2 (D-1, polypropylene spunbond non-woven fabric is downstream of air flow direction (a))
- Downstream side of air flow direction (a): Liquid blown non-woven fabric (A-1) with a weight per unit area of 50 g / m 2
- Example 1 Lamination was performed in the same manner as in Example 1 to obtain a two-layered charge filter (weight per unit: 250 g / m 2 , thickness: 3.1 mm) having the following configuration.
- Upstream side of air flow direction (a): Liquid-charged melt blown nonwoven fabric (A-1) with a basis weight of 50 g / m 2
- Downstream side of air flow direction (a): Needle punch composite nonwoven fabric treated with corona discharge with a basis weight of 200 g / m 2 (E-1, polypropylene spunbond nonwoven fabric is downstream of air flow direction (a))
- Example 2 Lamination was performed in the same manner as in Example 1 to obtain a two-layered charge filter (weight per unit: 250 g / m 2 , thickness: 3.1 mm) having the following configuration.
- Example 3 Lamination was performed in the same manner as in Example 1 to obtain a two-layered charge filter (weight per unit: 250 g / m 2 , thickness: 2.7 mm) having the following configuration.
- Upstream side of air flow direction (a): Hydroentangled nonwoven fabric treated with corona discharge with a basis weight of 50 g / m 2 (C-1)
- Downstream side of air flow direction (a): Needle punch composite non-woven fabric with a weight per unit of 200g / m 2 (D-1, polypropylene spunbond non-woven fabric is downstream of air flow direction (a))
- Example 5 Lamination was performed in the same manner as in Example 1 to obtain a two-layered charge filter (weight per unit: 75 g / m 2 , thickness: 1.1 mm) having the following configuration.
- Upstream side of air flow direction (a): Liquid-charged melt blown nonwoven fabric (A-1) with a basis weight of 50 g / m 2
- Downstream of the air flow direction (a): Liquid-blown melt blown nonwoven fabric (A-2) with a basis weight of 25 g / m 2
- Example 6 Lamination was performed in the same manner as in Example 1 to obtain a two-layered charge filter (weight per unit: 250 g / m 2 , thickness: 3.1 mm) having the following configuration.
- Upstream side of air flow direction (a): Needle punch composite non-woven fabric with triboelectric treatment with a basis weight of 200 g / m 2 (D-1, polypropylene spunbond non-woven fabric is downstream of air flow direction (a))
- Downstream side of air flow direction (a): Melon blown nonwoven fabric treated with corona discharge with a basis weight of 50g / m 2 (B-1)
- the charged filter was cut out as a circular sample with a diameter of 145 mm and mounted on a specified measuring device (AP-9000, manufactured by Shibata Kagaku).
- the effective filtration area of the charged filter circular sample at this time was 124 cm 2 .
- NaCl particles having a median particle size distribution of 0.06 to 0.10 ⁇ m and a geometric standard deviation of 1.8 or less are used, and the particle concentration is 50 mg / m 3 or less (concentration variation: ⁇ 15% or less).
- the test flow rate was 85 liters per minute, and air containing NaCl particles was supplied from the upstream of the measurement sample.
- the particle concentration was measured with a light scattering dust concentration meter on the upstream side and downstream side of the measurement sample until the supply amount of NaCl particles reached 100 mg in total. From this measurement result, the collection efficiency in the supply amount of NaCl particles was determined and recorded as a change in the collection efficiency over time. The closer the value of collection efficiency is to 100%, the higher the dust collection efficiency. In addition, the smaller the difference between the initial value of the collection efficiency of the charging filter and the minimum value of the collection efficiency recorded until the total supply amount of NaCl particles reaches 100 mg, the more collected by the collection of dust. It shows that the charging filter has a small amount of decrease in efficiency.
- DOP dioctyl phthalate
- the DOP mist concentration was measured with a light scattering dust concentration meter on the upstream and downstream sides of the measurement sample until the total amount of DOP supplied reached 200 mg. From this measurement result, the collection efficiency at the DOP supply amount was determined and recorded as a change in the collection efficiency over time. The closer the value of the collection efficiency is to 100%, the higher the collection efficiency of the oil mist is. In addition, the smaller the difference between the initial value of the collection efficiency of the charging filter and the minimum value of the collection efficiency recorded until the total amount of DOP mist supplied reaches 200 mg, the smaller the collection efficiency due to oil mist collection. This indicates that the charging filter has a small amount of decrease.
- MB melt blown nonwoven fabric
- NP needle punch composite nonwoven fabric
- HE hydroentangled nonwoven fabric
- the charging filter of Example 1 shows that the “initial value of the collection efficiency” and the “minimum value of the collection efficiency” in the collection of NaCl particles and DOP mist are any of the charge filters of Comparative Examples 1 to 6. It was found that both showed the highest value, and the decrease in collection efficiency (“initial value of collection efficiency” ⁇ “minimum value of collection efficiency”) showed the smallest value.
- the “initial value of the collection efficiency” and the “minimum value of the collection efficiency” in the collection of NaCl particles and DOP mist are the charging filters of Comparative Example 1 and Comparative Examples 3 to 6. It was found that both showed the highest value, and the decrease in collection efficiency (“initial value of collection efficiency” ⁇ “minimum value of collection efficiency”) showed the smallest value. In addition, the charging filter of Example 2 is lower than the charging filter of Comparative Example 2 in terms of “initial value of collection efficiency” and “minimum value of collection efficiency” and lowering of collection efficiency (“ It was found that the “initial value of collection efficiency” ⁇ “minimum value of collection efficiency”) was small.
- the charging filter of Example 2 is the same as the charging filter of Comparative Example 2, but the “initial value of collection efficiency” and “minimum value of collection efficiency” in the collection of NaCl particles are the same, but the collection of NaCl. From FIG. 3 and FIG. 4, it was found that the charging filter was able to suppress the increase in pressure loss due to.
- the charging filters of Examples 1 and 2 are characterized by having a liquid-charged nonwoven fabric layer and a friction-charged nonwoven fabric layer, so that the initial collection efficiency is high and the collection efficiency is hardly reduced. It is a charging filter.
- the charging filter of Example 1 was compared with the charging filter of Example 2 in terms of “initial value of collection efficiency” and “minimum value of collection efficiency” in the collection of NaCl particles and DOP mist.
- initial value of collection efficiency ⁇ “minimum value of collection efficiency”
- the charging filter of Example 1 is characterized in that the liquid-charged nonwoven fabric layer is present on the upstream side in the ventilation direction from the frictionally charged nonwoven fabric layer. Furthermore, it turned out that it is a charging filter which a fall of collection efficiency does not produce easily.
- the charged filters of Examples 1 and 2 collect oil mist that has high initial collection efficiency and is unlikely to cause a decrease in collection efficiency. It was a charging filter suitable for the above.
- Example 3 The respective charged non-woven fabric layers were laminated without bonding to obtain a three-layer charged filter (weight per unit: 275 g / m 2 , thickness: 3.4 mm) having the following configuration.
- Upstream side of air flow direction (a): Liquid-charged melt blown nonwoven fabric (A-1) with a basis weight of 50 g / m 2 Middle stream in the air flow direction (a): Melt blown nonwoven fabric with a basis weight of 25 g / m 2 treated with liquid charging (A-2)
- Downstream side of air flow direction (a): Needle punch composite non-woven fabric with a weight per unit of 200g / m 2 (D-1, polypropylene spunbond non-woven fabric is downstream of air flow direction (a))
- Example 4 Lamination was performed in the same manner as in Example 1 to obtain a three-layered charge filter (weight per unit: 275 g / m 2 , thickness: 3.4 mm) having the following configuration.
- Upstream side of air flow direction (a): Liquid-charged melt blown non-woven fabric with a basis weight of 25 g / m 2 (A-2)
- Middle flow in the ventilation direction (a): Melt blown non-woven fabric (A-1) with a liquid weight treatment with a basis weight of 50 g / m 2
- Downstream side of air flow direction (a): Needle punch composite non-woven fabric with a weight per unit of 200g / m 2 (D-1, polypropylene spunbond non-woven fabric is downstream of air flow direction (a))
- Example 5 Lamination was performed in the same manner as in Example 1 to obtain a three-layer charged filter (weight per unit: 275 g / m 2 , thickness: 3.2 mm) having the following configuration.
- Upstream side of air flow direction (a): Hydroentangled nonwoven fabric treated with corona discharge with a basis weight of 50 g / m 2 (C-1)
- Middle stream in the air flow direction (a): Melt blown nonwoven fabric with a basis weight of 25 g / m 2 treated with liquid charging (A-2)
- Downstream side of air flow direction (a): Needle punch composite non-woven fabric with a weight per unit of 200g / m 2 (D-1, polypropylene spunbond non-woven fabric is downstream of air flow direction (a))
- Example 7 Lamination was performed in the same manner as in Example 1 to obtain a three-layered charge filter (weight per unit: 275 g / m 2 , thickness: 3.4 mm) having the following configuration.
- Upstream side of air flow direction (a): Liquid-charged melt blown nonwoven fabric (A-1) with a basis weight of 50 g / m 2 Middle stream in the air flow direction (a): Melt blown nonwoven fabric with a basis weight of 25 g / m 2 treated with liquid charging (A-2)
- Downstream side of air flow direction (a): Corona-charged needle punch composite nonwoven fabric with a basis weight of 200 g / m 2 (E-1, polypropylene spunbond nonwoven fabric is downstream of air flow direction (a))
- MB melt blown nonwoven fabric
- NP needle punch composite nonwoven fabric
- HE hydroentangled nonwoven fabric
- the charging filters of Examples 3 to 5 show that “Initial value of collection efficiency” and “Minimum value of collection efficiency” in the collection of NaCl particles and DOP mist are the same as in Example 1 and Comparative Examples 7 to 7. Compared to any of the 12 charging filters, both show a high value, and a decrease in collection efficiency ("initial value of collection efficiency"-"minimum value of collection efficiency") shows a small value. There was found.
- the charging filters of Examples 3 to 5 have a liquid charging nonwoven fabric layer and a friction charging nonwoven fabric layer, and in particular, the charging filters of Examples 3 to 4 have two liquid charging nonwoven fabric layers,
- the liquid-charged non-woven fabric layer is also located upstream of the friction-charged non-woven fabric layer in the ventilation direction (a), so that the initial collection efficiency is higher and the collection efficiency is less likely to decrease. I found out.
- the liquid charged nonwoven fabric layer present on the most upstream side in the ventilation direction is composed of fibers having a larger fiber diameter than the liquid charged nonwoven fabric layer present on the downstream side, It was found that the charge filter is less likely to increase pressure loss than the charge filter of Example 4.
- the charged filters of Examples 3 to 5 have higher initial collection efficiency and are less likely to cause a decrease in collection efficiency. It was a charging filter suitable for carrying out.
- the charge filter according to the present invention is a charge filter and a mask that have a high initial collection efficiency and are unlikely to cause a decrease in the collection efficiency by further improving the electrostatic collection action.
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Abstract
Description
(1)繊維あるいは不織布に、極性液体を付与した後に、極性液体を介して力を作用させて、帯電させる方法。
(2)繊維あるいは不織布に、極性液体を付与すると同時に、極性液体を介して力を作用させて、帯電させる方法。
(3)繊維あるいは不織布を、容器に満たされた極性液体中に浸漬した状態で、極性液体を介して力を作用させて、帯電させる方法。
体積固有抵抗値が1016程度(Ω・cm)である市販のポリプロピレン樹脂(株式会社プライムポリマー社製、プライムポリプロ)に対して、市販のヒンダードアミン系光安定剤(チバスペシャリティーケミカルズ株式会社製、CHIMASSORB 944FDL)を樹脂全体の4mass%混合し、メルトブロー法を用いて紡糸を行い、メルトブロー不織布(目付:50g/m2、厚さ:0.8mm、平均繊維径:6μm)を調製した。得られたメルトブロー不織布を、極性液体として電気伝導度が3.2(μS/cm)、温度が20±5℃の範囲に保たれた純水(蒸留、イオン交換を経た二次蒸留水に相当)が保持された浴槽内に搬送し、純水を担持させると共に周波数20kHzの超音波を作用させた。次いで、超音波を作用させたメルトブロー不織布をコンベヤ式ドライヤーを用いて105℃で乾燥し、液体帯電処理したメルトブロー不織布(目付:50g/m2、厚さ:0.8mm、A-1)を得た。
メルトブロー法を用いて紡糸を行い、メルトブロー不織布(目付:25g/m2、厚さ:0.3mm、平均繊維径:3μm)を調製した以外は、A-1項と同様にして、液体帯電処理したメルトブロー不織布(目付:25g/m2、厚さ:0.3mm、A-2)を得た。
A-1項で得られたメルトブロー不織布に対し、帯電処理としてコロナ放電処理(直流電圧:15kV)を行い、コロナ放電処理したメルトブロー不織布(目付:50g/m2、厚さ:0.8mm、B-1)を得た。なお、該不織布はコロナ放電処理によって、帯電していた。
A-2項で得られたメルトブロー不織布に対し、帯電処理としてコロナ放電処理(直流電圧:15kV)を行い、コロナ放電処理したメルトブロー不織布(目付:25g/m2、厚さ:0.3mm、B-2)を得た。なお、該不織布はコロナ放電処理によって、帯電していた。
ポリプロピレン繊維(宇部日東化成株式会社製、NF、繊度:2.2dtex、平均繊維径:18μm、繊維長:51mm)をカード機によって開繊し、これを15MPaの水圧で水流絡合して、水流絡合不織布(目付:50g/m2、厚さ:0.6mm)を調製した。得られた水流絡合不織布に対し、コロナ放電処理(直流電圧:15kV)を行い、コロナ放電処理した水流絡合不織布(目付:50g/m2、厚さ:0.6mm、C-1)を得た。
ポリプロピレン繊維(宇部日東化成株式会社製、NM、繊度:2.2dtex、繊維長:51mm)と、アクリル系繊維(日本エクスラン工業株式会社社製、エクスランK8、繊度:1.7dtex、繊維長:51mm)を、60℃の温水で洗浄し、繊維に付着した繊維油剤の量を繊維質量に対して0.1%以下になるように調整した後、混合比が(ポリオレフィン系繊維:アクリル系繊維)=(50質量%:50質量%)となるように均一に混ぜ合わせて、乾燥させた。この混ぜ合わせた繊維をカード機によって繊維ウェブとすると共に摩擦帯電させ、この繊維ウェブをポリプロピレンスパンボンド不織布(三井化学製、シンテックスPK103、目付:15g/m2)に積層して、針密度:160本/cm2の条件下において、繊維ウェブ側からニードルパンチ処理を行い、摩擦帯電処理したニードルパンチ複合不織布(目付:200g/m2、厚さ:2.3mm、D-1)を得た。
ポリプロピレンスパンボンド不織布に積層する、繊維ウェブの目付を250g/m2とした以外は、D-1項と同様にして、摩擦帯電処理したニードルパンチ複合不織布(目付:250g/m2、厚さ:2.7mm、D-2)を得た。
ポリプロピレンスパンボンド不織布に積層する、繊維ウェブの目付を180g/m2とした以外は、D-1項と同様にして、摩擦帯電処理したニードルパンチ複合不織布(目付:180g/m2、厚さ:1.9mm、D-3)を得た。
ポリプロピレンスパンボンド不織布に積層する、繊維ウェブの目付を調製した以外は、D-1項と同様にして、摩擦帯電処理したニードルパンチ複合不織布(目付:275g/m2、厚さ:3.0mm、D-4)を得た。
ポリプロピレン繊維(宇部日東化成株式会社製、NM、繊度:2.2dtex、繊維長:51mm)を、カード機によって繊維ウェブとし、この繊維ウェブをポリプロピレンスパンボンド不織布(三井化学製、シンテックスPK103、目付:15g/m2)に積層して、針密度:160本/cm2の条件下において、繊維ウェブ側からニードルパンチ処理を行い、ニードルパンチ複合不織布(目付:200g/m2、厚さ:2.4mm)を得た。得られたニードルパンチ複合不織布を30℃の温水で洗浄し、繊維に付着する繊維油剤の量を繊維質量に対して0.1%以下になるように調製した後、乾燥させてからコロナ放電処理(直流電圧:15kV)を行い、コロナ放電処理したニードルパンチ複合不織布(目付:200g/m2、厚さ:2.4mm、E-1)を得た。
各帯電不織布層を接着せずに積層して、次の構成を有する、2層構造の帯電フィルタ(目付:250g/m2、厚さ:3.1mm)を得た。
通気方向(a)の上流側:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
通気方向(a)の下流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、2層構造の帯電フィルタ(目付:250g/m2、厚さ:3.1mm)を得た。
通気方向(a)の上流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
通気方向(a)の下流側:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
積層は実施例1と同様に行い、次の構成を有する、2層構造の帯電フィルタ(目付:250g/m2、厚さ:3.1mm)を得た。
通気方向(a)の上流側:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
通気方向(a)の下流側:目付が200g/m2のコロナ放電処理したニードルパンチ複合不織布(E-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、2層構造の帯電フィルタ(目付:250g/m2、厚さ:3.1mm)を得た。
通気方向(a)の上流側:目付が50g/m2のコロナ放電処理したメルトブロー不織布(B-1)
通気方向(a)の下流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、2層構造の帯電フィルタ(目付:250g/m2、厚さ:2.7mm)を得た。
通気方向(a)の上流側:目付が50g/m2のコロナ放電処理した水流絡合不織布(C-1)
通気方向(a)の下流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
目付が250g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-2)のみを用いて、1層構造の帯電フィルタ(目付:250g/m2、厚さ:2.9mm、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)とした。
積層は実施例1と同様に行い、次の構成を有する、2層構造の帯電フィルタ(目付:75g/m2、厚さ:1.1mm)を得た。
通気方向(a)の上流側:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
通気方向(a)の下流側:目付が25g/m2の液体帯電処理したメルトブロー不織布(A-2)
積層は実施例1と同様に行い、次の構成を有する、2層構造の帯電フィルタ(目付:250g/m2、厚さ:3.1mm)を得た。
通気方向(a)の上流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
通気方向(a)の下流側:目付が50g/m2のコロナ放電処理したメルトブロー不織布(B-1)
防じんマスクに適用されている「防じんマスクの規格」(平成12年9月11日労働省告示第88号)第6条に記載されている試験方法に準じて行った。ここにはNaCl粒子による方法とフタル酸ジオクチルのミストによる方法とが記載されているが、ここではその双方による方法で評価した。
帯電フィルタを直径145mmの円形サンプルとして切り出し、規定の測定装置(柴田科学製、AP-9000型)に装着した。このときの帯電フィルタ円形サンプルにおける、有効濾過面積は124cm2であった。粒子には粒径分布の中央値が0.06~0.10μmで、その幾何標準偏差が1.8以下であるNaCl粒子を使用し、粒子濃度が50mg/m3以下(濃度変動:±15%以下)となる条件で、試験流量を毎分85リットルとして、NaCl粒子を含有する空気を測定サンプル上流から供給した。NaCl粒子の供給量が計100mgになるまで、測定サンプル上流側と下流側で粒子濃度を光散乱式粉じん濃度計で測定した。この測定結果からNaCl粒子の供給量における捕集効率を求め、捕集効率の経時的変化として記録した。捕集効率の値が100%に近いほど、じん埃の捕集効率が高い帯電フィルタであることを示している。また、帯電フィルタにおける捕集効率の初期値と、NaCl粒子の供給量が計100mgとなるまでに記録された、捕集効率の最低値との差が小さいほど、じん埃の捕集による捕集効率の低下量が少ない帯電フィルタであることを示している。
帯電フィルタを直径145mmの円形サンプルとして切り出し、規定の測定装置(TSI社製 AFT model-8130)に装着した。このときの帯電フィルタ円形サンプルにおける、有効濾過面積は124cm2であった。粒子には粒径分布の中央値が0.15~0.25μmで、その幾何標準偏差が1.6以下であるDOPミストを使用し、ミスト濃度が100g/m3以下(濃度変動:±15%以下)となる条件で、試験流量を毎分85リットルとして、DOPミストを含有する空気を測定サンプル上流から供給した。DOPの供給量が計200mgになるまで、測定サンプル上流側と下流側でDOPミスト濃度を光散乱式粉じん濃度計で測定した。この測定結果からDOP供給量における捕集効率を求め、捕集効率の経時的変化として記録した。捕集効率の値が100%に近いほど、オイルミストの捕集効率が高い帯電フィルタであることを示している。また、帯電フィルタにおける捕集効率の初期値と、DOPミストの供給量が計200mgとなるまでに記録された、捕集効率の最低値との差が小さいほどオイルミストの捕集による捕集効率の低下量が少ない帯電フィルタであることを示している。
NaCl粒子およびDOP粒子による捕集効率の測定を行っている際、その各測定点での試験流量を毎分40リットルとした時の圧力損失を微差圧計で測定し、NaCl粒子およびDOP粒子の捕集量における圧力損失を求め、圧力損失(吸気抵抗値)の経時的変化として記録した。圧力損失の初期値が低く、NaCl粒子およびDOP粒子の捕集に伴う圧力損失の上昇(「圧力損失の最終値」-「圧力損失の初期値」)が低いほど、通気性に優れることを示している。
各帯電不織布層を接着せずに積層して、次の構成を有する、3層構造の帯電フィルタ(目付:275g/m2、厚さ:3.4mm)を得た。
通気方向(a)の上流側:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
通気方向(a)における中流:目付が25g/m2の液体帯電処理したメルトブロー不織布(A-2)
通気方向(a)の下流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、3層構造の帯電フィルタ(目付:275g/m2、厚さ:3.4mm)を得た。
通気方向(a)の上流側:目付が25g/m2の液体帯電処理したメルトブロー不織布(A-2)
通気方向(a)における中流:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
通気方向(a)の下流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、3層構造の帯電フィルタ(目付:275g/m2、厚さ:3.2mm)を得た。
通気方向(a)の上流側:目付が50g/m2のコロナ放電処理した水流絡合不織布(C-1)
通気方向(a)における中流:目付が25g/m2の液体帯電処理したメルトブロー不織布(A-2)
通気方向(a)の下流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、3層構造の帯電フィルタ(目付:275g/m2、厚さ:3.4mm)を得た。
通気方向(a)の上流側:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
通気方向(a)における中流:目付が25g/m2の液体帯電処理したメルトブロー不織布(A-2)
通気方向(a)の下流側:目付が200g/m2のコロナ帯電処理したニードルパンチ複合不織布(E-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、3層構造の帯電フィルタ(目付:275g/m2、厚さ:3.4mm)を得た。
通気方向(a)の上流側:目付が50g/m2のコロナ放電処理したメルトブロー不織布(B-1)
通気方向(a)における中流:目付が25g/m2のコロナ放電処理したメルトブロー不織布(B-2)
通気方向(a)の下流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、3層構造の帯電フィルタ(目付:275g/m2、厚さ:3.2mm)を得た。
通気方向(a)の上流側:目付が50g/m2のコロナ放電処理した水流絡合不織布(C-1)
通気方向(a)における中流:目付が25g/m2のコロナ放電処理したメルトブロー不織布(B-2)
通気方向(a)の下流側:目付が200g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-1、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
積層は実施例1と同様に行い、次の構成を有する、3層構造の帯電フィルタ(目付:280g/m2、厚さ:3.3mm)を得た。
通気方向(a)の上流側:目付が50g/m2のコロナ放電処理した水流絡合不織布(C-1)
通気方向(a)における中流:目付が50g/m2のコロナ放電処理したメルトブロー不織布(B-1)
通気方向(a)の下流側:目付が180g/m2の摩擦帯電処理したニードルパンチ複合不織布(D-3、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)
目付が275g/m2の摩擦帯電処理したニードルパンチ不織布(D-4)のみを用いて、1層構造の帯電フィルタ(目付:275g/m2、厚さ:3.1mm、ポリプロピレンスパンボンド不織布が通気方向(a)の下流側)とした。
積層は実施例1と同様に行い、次の構成を有する、3層構造の帯電フィルタ(目付:125g/m2、厚さ:1.6mm)を得た。
通気方向(a)の上流側:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
通気方向(a)における中流:目付が25g/m2の液体帯電処理したメルトブロー不織布(A-2)
通気方向(a)の下流側:目付が50g/m2の液体帯電処理したメルトブロー不織布(A-1)
Claims (5)
- 極性液体を介して力を作用させて帯電された液体帯電不織布層と、
複数種類の繊維成分同士を摩擦させて帯電された摩擦帯電不織布層を有することを特徴とする、帯電フィルタ。 - 前記液体帯電不織布層及び/又は摩擦帯電不織布層を、複数層有していることを特徴とする、請求項1に記載の帯電フィルタ。
- 前記液体帯電不織布層が、前記摩擦帯電不織布層よりも通気方向の上流側に存在していることを特徴とする、請求項1または請求項2に記載の帯電フィルタ。
- オイルミストの捕集に使用することを特徴とする、請求項1~請求項3のいずれかに記載の帯電フィルタ。
- 請求項1~請求項4のいずれかに記載の帯電フィルタを備えるマスク。
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US9289632B2 (en) | 2016-03-22 |
JP2011235219A (ja) | 2011-11-24 |
EP2567744B1 (en) | 2019-08-14 |
KR20170128636A (ko) | 2017-11-22 |
CN102883789B (zh) | 2015-04-22 |
US20130047856A1 (en) | 2013-02-28 |
EP2567744A1 (en) | 2013-03-13 |
EP2567744A4 (en) | 2016-07-13 |
JP5475541B2 (ja) | 2014-04-16 |
KR20130086939A (ko) | 2013-08-05 |
CN102883789A (zh) | 2013-01-16 |
KR101910312B1 (ko) | 2018-10-19 |
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