WO2011158324A1 - Filter support body and filter using same - Google Patents

Filter support body and filter using same Download PDF

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Publication number
WO2011158324A1
WO2011158324A1 PCT/JP2010/060069 JP2010060069W WO2011158324A1 WO 2011158324 A1 WO2011158324 A1 WO 2011158324A1 JP 2010060069 W JP2010060069 W JP 2010060069W WO 2011158324 A1 WO2011158324 A1 WO 2011158324A1
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WO
WIPO (PCT)
Prior art keywords
filter
adhesive component
support
thermal adhesive
porous membrane
Prior art date
Application number
PCT/JP2010/060069
Other languages
French (fr)
Japanese (ja)
Inventor
貴史 恋田
山本　俊也
Original Assignee
東洋紡績株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 東洋紡績株式会社 filed Critical 東洋紡績株式会社
Priority to PCT/JP2010/060069 priority Critical patent/WO2011158324A1/en
Publication of WO2011158324A1 publication Critical patent/WO2011158324A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B01D69/107—Organic support material
    • B01D69/1071—Woven, non-woven or net mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1692—Other shaped material, e.g. perforated or porous sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
    • B01D53/228—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion characterised by specific membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/12—Composite membranes; Ultra-thin membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/12—Composite membranes; Ultra-thin membranes
    • B01D69/1216—Three or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/26—Polyalkenes
    • B01D71/261—Polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/26—Polyalkenes
    • B01D71/262—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/30—Polyalkenyl halides
    • B01D71/32—Polyalkenyl halides containing fluorine atoms
    • B01D71/36—Polytetrafluoroethene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/76—Macromolecular material not specifically provided for in a single one of groups B01D71/08 - B01D71/74
    • 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
    • B01D2239/065—More than one layer present in the filtering material
    • 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
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0654—Support layers
    • 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
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0668—The layers being joined by heat or melt-bonding
    • 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
    • B01D2239/069—Special geometry of layers
    • 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
    • B01D2239/08—Special characteristics of binders
    • B01D2239/083—Binders between layers of the filter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2325/00—Details relating to properties of membranes
    • B01D2325/32—Melting point or glass-transition temperatures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/26—Polyalkenes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/28—Polymers of vinyl aromatic compounds

Definitions

  • the present invention relates to a filter support and a high-performance porous membrane filter using the support. More specifically, the present invention relates to a support for a porous membrane material for high-performance filters such as a HEPA filter and a ULPA filter, and a high-performance porous membrane filter using the same.
  • a microporous membrane has been used as a filter for high-performance filtration.
  • the microporous membrane is used as it is, it is easily damaged, and the form retainability is poor. Therefore, the microporous membrane is held by a support and used for a filter for microfiltration.
  • the proposal which uses the polyester long fiber spun bond nonwoven fabric which does not contain polyolefin for a support body is made.
  • the heat-adhesive polyester composite fiber used has a melting point of the heat-adhesive component of 120 ° C. or higher, preferably 180 ° C. or higher.
  • Patent Document 1 also describes an example in which no thermal bonding fiber is used.
  • thermocompression bonding in order to prevent damage to the microporous membrane due to thermocompression bonding, a thermobonded composite fiber nonwoven fabric is used as a support, and for example, thermocompression bonding is performed with a release-treated roller at 160 ° C. to prevent adhesion. Proposals have been made. However, it is disclosed that it is necessary to apply a spacer because the shape retention of the folded filter is insufficient.
  • Patent Document 3 discloses that it is necessary to use a spacer made of a polyamide heat-bonding resin when laminating a nonwoven fabric made of heat-bonding fibers on a support on a fine porous film and folding it.
  • Patent Document 4 when a core-sheath fiber nonwoven fabric is used as a support for a microporous membrane, it is preferable to perform sealing by a method of applying an adhesive or heating and re-fixing the bent portion of the fold. It is disclosed that the microporous membrane is damaged when the sealing process is not performed.
  • a spacer is not used is disclosed, a sealing process is necessary and a large amount of a thermal adhesive component is contained, so that the problem of insufficient outgas reduction has not been solved.
  • an object of the present invention is to provide a filter support using a fine porous membrane with little outgas and excellent shape retention of a folded product and a porous membrane filter using the same.
  • this invention consists of the following structures. 1.
  • a long-fiber non-woven fabric having a basis weight of 20 to 100 g / m 2 and an embossing process with a crimp area ratio of 8 to 18%, and at least one surface of the long-fiber non-woven fabric is coated with ethylene vinyl acetate
  • the polyester is a polyester containing at least 95 mol% of any one of polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, or polycyclohexylene diterephthalate, and the filter substrate has an apparent density of 100 to 155 kg / m. 3.
  • the filter support according to 1 above which is 3 . 3.
  • a porous membrane filter in which a surface to which a thermal adhesive component of the filter support according to any one of the above 1 to 3 is applied is bonded to the porous membrane. 5.
  • a porous membrane filter in which the surfaces to which the thermal adhesive component of the filter support according to any one of the above 1 to 3 is applied are bonded to both surfaces of the porous membrane. 6). 6. The porous membrane filter as described in 4 or 5 above, wherein the filter is folded.
  • the present invention reduces the amount of outgassing by reducing the amount of thermal adhesive component applied to the limit, and at the same time, optimizes the material of the long-fiber nonwoven fabric used, various physical properties and the composition of the thermal adhesive component, and is flexible and suitable for the support. By imparting a high rigidity, it is possible to provide a filter having excellent shape retention of the folding process.
  • the present invention provides a long-fiber nonwoven fabric made of polyester and having a basis weight of 20 to 100 g / m 2 and an embossed crimp area ratio of 8 to 18%, on at least one surface of the long-fiber nonwoven fabric.
  • a filter support in which 0.7 to 5.0 g / m 2 of a thermoadhesive component containing an ethylene vinyl acetate copolymer is applied to a thermoplastic resin having a melting point of 100 ° C. to 140 ° C. Furthermore, it is a filter in which the surface to which the thermal adhesive component of the support is applied is bonded to the porous membrane.
  • the polyester in the present invention is a polyester resin having a melting point of 220 ° C. or higher, preferably polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polycyclohexanedimethyl terephthalate (PCHT), etc. it can.
  • PET polyethylene terephthalate
  • PBT polybutylene terephthalate
  • PEN polyethylene naphthalate
  • PCHT polycyclohexanedimethyl terephthalate
  • the copolymer polyester has more oligomers than the homopolyester, so containing 95 mol% or more of the homopolyester can reduce the heat resistance, durability, and outgas generation amount.
  • it is 100 mol% of polyethylene terephthalate with high versatility.
  • resins and agents other than polyester can be kneaded or mixed.
  • resins and agents other than polyester can be kneaded or mixed.
  • titanium oxide, an antibacterial agent, an antifungal agent, a ceramic having a far-infrared radiation function and the like can be mentioned, and the amount is preferably less than 3% by weight so as not to affect the mechanical strength.
  • the non-woven fabric used in the present invention is preferably a long-fiber non-woven fabric in order to prevent the generation of dust that is indispensable for a high-performance filter, and the short-fiber non-woven fabric is not preferable because dust is generated.
  • a spunbonded nonwoven fabric is preferred as an industrial material that is stable in quality, has high homogeneity, is relatively inexpensive, and is mass-produced.
  • the long fiber nonwoven fabric of the present invention is preferably embossed with a basis weight of 20 to 100 g / m 2 and a crimp area ratio of 8 to 18%.
  • a basis weight of less than 20 g / m 2 is not preferable because the support function of the support is reduced and the preliminary filtration function is also reduced. If the weight per unit area exceeds 100 g / m 2 , the deformation difference of the bent portion at the time of the folding process becomes large, and it becomes difficult to perform the folding process unless the mechanical force is increased. When the mechanical force is greatly applied, the bonded porous membrane may be damaged, which is not preferable.
  • a more preferred basis weight is 25 to 70 g / m 2 , and further preferably 25 to 50 g / m 2 .
  • the single fiber fineness of the fibers constituting the long-fiber nonwoven fabric used in the present invention is not particularly limited, but it is preferably 1.0 to 5.0 dtex, and preferably 1.5 to 3 in which coverage and rigidity can be realized with a low basis weight. 0.0 dtex is more preferred.
  • embossing is necessary to maintain rigidity and smoothness of the surface evenly with a low basis weight, to provide a uniform heat-adhesive component, and to maintain air permeability and filterability.
  • the rigidity is inferior
  • the support function as a support is inferior
  • the surface is not smooth.
  • the area ratio of crimping by embossing is preferably 8 to 18%. If it is less than 8%, the shape retention function at low weight is inferior, and the smoothness of the surface also deteriorates, which is not preferable. If it exceeds 18%, the bending rigidity becomes too high, the mechanical force at the time of folding is increased, and the bonded porous membrane may be damaged, which is not preferable.
  • a more preferable crimp area ratio is 10 to 15%.
  • the embossed pattern is not particularly limited, but a dot-shaped embossed pattern in which rigid points are dispersed is preferable, and the dot point has a crimping area of 0.2 to 0.5 mm 2 and has a small shape. A mold having a staggered arrangement is particularly preferred.
  • the apparent density of the long-fiber nonwoven fabric used in the present invention is preferably 100 to 155 kg / m 3, and more preferably 110 to 150 kg / m 3, which can satisfy both rigidity and air permeability.
  • the filter support of the present invention reduces the heat-adhesive component used by applying a heat-adhesive component to at least one surface of the long-fiber nonwoven fabric.
  • a thermal adhesive component is also present inside, the thermal adhesive component used cannot be reduced, and the amount of outgas generation increases.
  • the thermal adhesive component penetrates into the long-fiber nonwoven fabric during the bonding with the porous membrane, so that the thermal adhesive component reaches the surface opposite to the bonding surface (thermal adhesive component-giving surface) with the porous membrane of the long-fiber nonwoven fabric. It may penetrate and the thermal adhesive component may ooze out from the surface.
  • the heat-adhesive component that has oozed out is not preferable because a problem occurs in workability such as the product after joining is wound around the calendar roller.
  • the thermal adhesive component of the present invention is a thermoplastic resin containing an ethylene-vinyl acetate copolymer and having a melting point of 100 ° C. to 140 ° C. in order to maintain shape stability when used in a temperature range below 80 ° C. Use is preferred.
  • thermoplastic resins other than the ethylene vinyl acetate copolymer polyolefins such as polyethylene and polypropylene may be contained. If the melting point of the thermoplastic resin is less than 100 ° C., the form durability is inferior, which is not preferable. When the melting point exceeds 140 ° C., the heat conduction becomes insufficient at the time of calendering for bonding to the porous film, and the bonding may not be performed properly.
  • the melting point of the preferred thermal adhesive component of the present invention is 105 to 135 ° C, more preferably 110 to 130 ° C.
  • the thermal adhesive component of the present invention preferably contains an ethylene vinyl acetate copolymer in order to maintain flexibility and bonding strength. This is because the adhesiveness is good even when the porous film is polytetrafluoroethane or the like.
  • the vinyl acetate content of the ethylene vinyl acetate copolymer is preferably 5 to 35% by weight. If it is less than 5% by weight, the bonding strength with the polyester may be reduced. If it is 35% by weight or more, there will be no problem in a sufficiently dispersed state. In some cases, the form retainability may decrease due to a decrease in stability.
  • the vinyl acetate content in the preferred ethylene vinyl acetate copolymer of the present invention is 10 to 33% by weight, more preferably 20 to 30% by weight.
  • the thermal adhesive component of the present invention must be applied in an amount of 0.7 to 5.0 g / m 2 in order to maintain sufficient bonding strength and form stability. If it is less than 0.7 g / m 2 , the bonding with the porous film becomes insufficient, and it is not preferable because it is peeled off during processing or the shape retention is poor. If it exceeds 5.0 g / m 2 , the amount of outgas generated increases, which is not preferable.
  • the preferable application amount of the present invention is 1.0 to 4.0 g / m 2 , more preferably 1.5 to 3.0 g / m 2 .
  • the method for applying the thermal adhesive component in the present invention is not particularly limited, but it is important to apply a uniform small amount so that it does not penetrate into the long fiber nonwoven fabric as much as possible.
  • a method of liquefying without including the outgas generating substance and applying by gravure printing is preferable.
  • Other methods, such as print jet coating have a problem of poor productivity, and dot coating cannot be applied uniformly.
  • the melt extrusion laminating method it is difficult to uniformly apply an amount of 5 g / m 2 or less.
  • a method of laminating and laminating a thin film is considered to be usable.
  • the support of the present invention obtained as described above is preferably a support having an outgas amount of 3.5 ⁇ g / g or less.
  • the lower limit is 0.1 ⁇ g / g or more in view of the use of the thermal adhesive component.
  • An outgas amount exceeding 3.5 ⁇ g / g is not preferable because it causes a problem when used as a support for a membrane material for a high performance filter such as a HEPA filter or a ULPA filter.
  • the filter of the present invention is a filter in which the porous membrane and the surface of the support to which the thermal adhesive component is applied are joined. Moreover, it is a filter of the support body / porous film / support body 3 layer structure which joined the surface to which the thermal-adhesion component of the said support body was provided to both surfaces of the porous film. Furthermore, it may be a multilayer filter.
  • the porous membrane in the present invention refers to a separation membrane having a large number of fine pores of less than 0.5 ⁇ m penetrating into the formed membrane.
  • a polytetrafluoroethylene (PTFE) sheet is stretched to form a membrane.
  • PTFE polytetrafluoroethylene
  • the thing etc. which formed many fine holes can be illustrated.
  • a PTFE porous membrane having heat resistance and durability against an organic gas or the like is particularly preferable.
  • the filter of the present invention is a filter in which at least one surface of the porous membrane and the surface of the support to which the thermal adhesive component is applied are thermally bonded. If the support is not bonded to the porous membrane, the porous membrane and the support are rubbed and damaged, the handling property as a sheet is inferior, and the shape retention property when folded is not preferable.
  • the filter of the present invention is a filter in which both surfaces of the porous membrane and the surface to which the thermal adhesive component of the support is applied are thermally bonded, so that the membrane can be more effectively prevented from being damaged.
  • the shape retention is remarkably improved in spite of joining with a small amount of the thermal adhesive component.
  • the filter of the present invention is particularly excellent in the shape retention of the portion that has been folded and folded when used as a method of widening the filtration area.
  • Polyethylene terephthalate having an intrinsic viscosity of 0.65 is dried by a conventional method, and discharged by a melt extruder at a spinning temperature of 285 ° C. from a nozzle having an orifice hole diameter of 0.25 mm at a single hole discharge rate of 1 g / min.
  • the web Taken at about 4500 m / min with a tow jet installed 1 m below, and shaken down on a mobile conveyor installed 50 cm below to form a web with a single fiber fineness of 2.2 dtex and a basis weight of 30 g / m 2 To do. Continuously, the web is wound while being compressed with a heat-pressing roller to maintain the form.
  • the upper roller is an embossed roller with an oval convex zigzag arrangement with a crimping density of 12%
  • the lower roller is an embossed roller composed of a flat roller, embossed at a temperature of 240-245 ° C and a linear pressure of 290-345 N / cm.
  • the thermal bonding component is prepared.
  • a predetermined amount of an ethylene vinyl acetate-polyethylene mixture having a vinyl acetate content of 28% by weight and a defoamer are added, and then a predetermined amount of water and a small amount of an emulsifier are added, followed by stirring with heating
  • a commercially available product may be used as long as the aqueous emulsion has a desired composition.
  • Toyo Ink's Aqua seal can be exemplified.
  • the resulting nonwoven fabric is coated with the gravure coater by adjusting the pick-up amount to the required coating amount, removed by moisture, and wound up by the usual method.
  • a support is obtained.
  • a porous film is prepared.
  • the porous membrane is prepared by a conventional method. For example, a plasticizing agent is added and kneaded to polytetrafluoroethylene powder and extruded into a lot shape, then formed into a tape shape with a rolling roller, and then the plasticizing agent is removed by heat treatment, and then the longitudinal direction is changed to a heating roller. The film is stretched and the transverse direction is heated and stretched with a grip tenter to obtain a porous film.
  • the prepared porous film is supplied to a heated calender roll so that the surface of the support to which the thermal adhesive component is applied can be bonded.
  • a heated calender roll When joining both surfaces with a support, supply the support from the top and bottom of the porous membrane, and press-bond at a linear pressure that does not damage the porous membrane, for example, less than 9.8 N / cm, and immediately cool down to generate wrinkles.
  • the filter material in which the support is bonded to the porous membrane is wound up while preventing.
  • the filter thus obtained has very few outgas generation sources and is excellent in maintaining the folded shape, so that a filter particularly suitable for a high-performance air filter system can be provided.
  • Non-woven fabric weight Ms (g / m 2 ) It is the mass (Ms) per unit area measured according to JIS L1906 (2000).
  • Adhesion amount of thermal adhesive component (g / m 2 )
  • the amount obtained by subtracting the basis weight (Ms) of the nonwoven fabric alone from the basis weight (Mt) of the nonwoven fabric provided with the thermal adhesive component is defined as the adhesion amount of the thermal adhesive component.
  • the distribution ratio of the thermal adhesive component and the non-thermal adhesive component is determined from the phase contrast micrograph of the nonwoven fabric cross section, and the basis weight of the thermal adhesive component is determined from the total nonwoven fabric basis weight. .
  • Melting point of heat bonding component (°C)
  • the thermal adhesive component of the nonwoven fabric provided with the thermal adhesive component was peeled off, and 5 mg of the peeled thermal adhesive component sample was collected, and at 20 ° C. to 10 ° C./min with a differential scanning calorimeter (TA instruments Q100).
  • the temperature at the endothermic peak position when the temperature is raised to 290 ° C. is evaluated as the melting point. In the case of two components, the endothermic peak position on the low temperature side is the melting point of the heat bonding component.
  • Outgas amount of support ( ⁇ g / g) The sum total of the component measured by the following method and an unidentified component is shown per 1g of samples.
  • ⁇ TCT conditions Collection tube heating temperature: 250 ° C Rod heating temperature: 280 ° C Trap temperature: -100 ° C Evaporation temperature at sample introduction: 280 ° C Carrier gas: He Pressure: 100 psi ⁇ GC / MS conditions> Column: HP-1MS (length 30 m, inner diameter 0.25 mm, film thickness 1 ⁇ m) Oven temperature: 50 ° C. (5 minutes keep) ⁇ 10 ° C./min gradient up to 280 ° C. ⁇ 280 ° C.
  • the outgas specified in the evaluation of the present invention is the identified outgas composition: n-dodecane, n-tridecane, n-tetradecane, 2,4-di-t-butylphenol, n-pentadecane, di-t- These are butylhydroxytoluene, hexadecene, n-heptadecane, and n-octadecane. The total amount of each component including unidentified substances is determined per gram, and the total amount is evaluated.
  • the sample folded at 3.5 cm pitch is cut to about 40 cm in length and 2 cm in width and hung in a free state, and the length (L1) between five points on the peak is measured. Then, after applying a load of 0.1 g / m 2 ⁇ cm to the lower end and leaving it at room temperature for 60 minutes, with the load removed, the length (L2) between the five peaks was measured.
  • Example 1 Polyethylene terephthalate having an intrinsic viscosity of 0.65 at a spinning temperature of 285 ° C. in a conventional manner, by a single-hole discharge rate 1 g / minute holes, consisting of long fibers having a fineness 2dtex spunbond method, the temporary pressure bonding of basis weight 30 g / m 2
  • the web was wound up, and then embossed at a roller temperature of 245 ° C. and a linear pressure of 294.2 N / cm with a dot embossed pattern roller corresponding to a crimp area ratio of 15%, with a basis weight of 30 g / m 2 and a crimp area ratio of 12%.
  • a nonwoven fabric having an apparent density of 135 kg / m 3 was obtained.
  • an ethylene vinyl acetate copolymer-polyethylene aqueous dispersion with a vinyl acetate content of 28% by weight (Toyo Ink Aqua Seal: solid content weight ratio: 45% by weight, solid content melting point: 120 ° C.) as a thermal adhesive component, gravure 2 g / m 2 was applied to one side of the nonwoven fabric by a coating method to obtain a porous membrane support.
  • the evaluation results of the support are shown in Table 1.
  • a Teflon (registered trademark) film having a thickness of 300 ⁇ m and a width of 100 mm was continuously dried with a hot air dryer at 250 ° C., and then stretched 10 times using a hot roller having a surface temperature of 300 ° C.
  • a Teflon (registered trademark) porous film having a thickness of 30 ⁇ m and an average pore diameter of 0.4 ⁇ m was prepared by repeating twice the stretching in the width direction 5 times with a grip tenter at 210 ° C.
  • the filter material is prepared by calendering using a plain roller with the upper and lower roller surface temperature of 140 ° C. did.
  • the produced filter material was an air filter for microfiltration having a folding structure with a pitch of 3.5 cm using a crease folding machine. Table 1 shows the shape retention of the obtained fold-folded filter.
  • Table 1 shows the performance of the filter support and the folded filter material obtained in the same manner as in Example 1 except that 3 g / m 2 of the thermal adhesive component was applied.
  • Table 1 shows the performance of the filter support and the folded filter material obtained in the same manner as in Example 1 except that 0.5 g / m 2 of the thermal adhesive component was applied.
  • ⁇ Comparative Example 2> Using polyethylene terephthalate having an intrinsic viscosity of 0.65 and copolymer polyester having a melting point of 130 ° C. obtained by copolymerizing ethylene terephthalate and ethylene isophthalate, a copolymer spinning machine is used in a conventional method using a compound spinning machine at a seascore ratio of 50:50. A spunbonded web having a basis weight of 40 g / m 2 was obtained by spinning to a sheath component and pulling it down with a traction jet.
  • the obtained web was embossed in the same manner as in Example 1 except that the roller temperature was set to 110 ° C., and a thermal bonding fiber having a basis weight of 40 g / m 2 , a crimping area ratio of 18%, and an apparent density of 160 kg / m 3.
  • a spunbond nonwoven fabric was obtained.
  • Table 1 shows the amount of outgas of the obtained nonwoven fabric.
  • a filter material was prepared on the both surfaces of the porous membrane using the obtained non-woven fabric made of heat-bonding fibers as a support in the same manner as in Example 1, and folded to obtain a filter material that had been folded. Table 1 shows the shape retention of the obtained filter material.
  • Example 3 The emulsion used in Example 1 was dried and solidified to obtain a thermal adhesive component resin. The obtained resin was extrusion laminated to the spunbond nonwoven fabric embossed surface obtained in Example 1 with a film laminator at a melting temperature of 230 ° C. so as to be 12 g / m 2 to obtain a support. Next, a filter material was prepared from the obtained support in the same manner as in Example 1, and the filter was formed by folding. Table 1 shows the evaluation results of the obtained support and filter.
  • Example 5 The non-woven fabric obtained in Example 1 was copolymerized with 20% by weight of a vinyl acetate component, and an ethylene vinyl acetate copolymer having a melting point of 75 ° C. was used as a thermal bonding component, resulting in a melting temperature of 200 ° C. and an applied amount of 6 g / m 2.
  • Table 1 shows the evaluation results of the support and the filter obtained in the same manner as in Comparative Example 3 except as described above.
  • Table 1 shows the evaluation results of the support and the filter obtained in the same manner as in Example 1 except that the take-up net speed was increased so as to obtain a nonwoven fabric web having a basis weight of 10 g / m 2 .
  • Table 1 shows the evaluation results of the support and the filter obtained in the same manner as in Example 1 except that the take-up net speed was reduced so as to obtain a nonwoven fabric web having a basis weight of 150 g / m 2 .
  • Example 3 Using a polybutylene terephthalate having an intrinsic viscosity of 1.1, a fineness of 2.2 dtex obtained in the same manner as in Example 1 except that the spinning temperature was 260 ° C., and a basis weight of 30 g / m 2 were used.
  • a support for a filter coated with 2 g / m 2 of a thermal adhesive component was obtained in the same manner as in Example 1 except that the embossing roller was 210 ° C.
  • the outgas generation amount of the obtained support was 2.1 ⁇ g / g.
  • a support was joined to the porous membrane to obtain a filter that was folded.
  • the shape retention of the obtained filter in the folding process was a passing score.
  • the support bodies of Examples 1 and 2 have a small amount of heat-adhesive components, it is possible to obtain a filter having excellent shape retention while being a support body having a low outgas amount. Since the support of Comparative Example 1 is a low outgas amount support because the amount of the thermal adhesive component is small, it is not preferable because only a filter having poor shape retention can be obtained. Since the support of Comparative Example 2 contains a large amount of a thermal adhesive component, it generates a large amount of outgas and is not preferable for high performance filter applications.
  • the support of Comparative Example 3 is very excellent in form retention because there are many thermal bonding components on the joint surface, but since it contains a large amount of thermal bonding components, the amount of outgas generated increases, and it is suitable for high performance filter applications. Is not preferred. Since the support of Comparative Example 4 has a large amount of heat bonding components, the amount of outgas generated is large, and since a brittle heat bonding component is used, the shape retention is poor, which is not preferable for high performance filter applications. Since the support of Comparative Example 5 uses a soft thermal adhesive component, the shape retention is good, but the melting point of the thermal adhesive component is low and the amount of outgas generated increases, which is not preferable for high performance filter applications.
  • the support of Comparative Example 6 is not preferable because the basis weight of the long-fiber nonwoven fabric is low, so that only a filter having poor fold-folding property and poor shape retention can be obtained. Since the support of Comparative Example 7 has a high basis weight of the long-fiber non-woven fabric, it is not preferable because only a filter having inferior form-retaining property can be obtained.
  • the support of Example 3 has a small amount of outgas generation and is excellent in the shape retention of the folded filter.
  • the present invention by reducing the amount of thermal adhesive component applied to the limit, the amount of outgas is reduced, and at the same time, the material of the long-fiber nonwoven fabric to be used, various physical properties and the composition of the thermal adhesive component are optimized, and the support is flexible and moderate.
  • By imparting a high degree of rigidity it is possible to provide a filter having excellent shape retention of the folding process, it is possible to construct a higher performance clean system, and the durability of the filter is excellent. Clean system maintenance is also very easy, which is expected to make a significant contribution to the industry.

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Abstract

Provided is a filter support body that uses a porous membrane with low outgassing and excellent shape retention of pleat folded products and a filter that uses said support body. The filter support body provides a continuous non-woven fabric formed from polyester, which has a mass per unit area of 20-100 g/m2, and to which an embossing process with a bonding area ratio of 8-18% has been applied, and 0.7-5.0 g/m2 of a thermoplastic resin that includes an ethylene vinyl acetate copolymer on the surface of at least one side of the continuous non-woven fabric and has a melting point of 100-140 ºC, as a thermal adhesive component.

Description

フィルター用支持体およびそれを用いたフィルターFilter support and filter using the same
　本発明は、フィルター用支持体およびその支持体を用いた高性能多孔膜フィルターに関する。更に詳しくは、ＨＥＰＡフィルター、ＵＬＰＡフィルターなどの高性能フィルター用多孔膜材の支持体およびそれを用いた高性能多孔膜フィルターに関する。 The present invention relates to a filter support and a high-performance porous membrane filter using the support. More specifically, the present invention relates to a support for a porous membrane material for high-performance filters such as a HEPA filter and a ULPA filter, and a high-performance porous membrane filter using the same.
　従来、高性能ろ過用フィルターとして、微細多孔膜が用いられている。しかし、微細多孔膜はそのまま使用すると損傷しやすく、又、形態保持性が劣るため、微細多孔膜は、支持体で保持して精密ろ過用フィルターに用いられている。例えば、特許文献１では、アウトガス発生を抑えるため、ポリオレフィンを含まないポリエステル長繊維スパンボンド不織布を支持体に用いる提案がされている。用いる熱接着性ポリエステル複合繊維は、熱接着成分の融点が１２０℃以上、好ましくは１８０℃以上である。特許文献１には、熱接着繊維を用いない事例も記載されている。この場合、微細多孔膜と不織布の接合は、ポリエステル系熱接着剤を例えば６ｇ／ｍ２塗布して、１６０～２００℃で加熱接着する方法が提案されている。しかし、熱接着成分は比較的脆く、襞折り加工する場合、割れなどを生じ、微細多孔膜を損傷したり、襞折りフィルターの形態保持性が劣る問題がある。 Conventionally, a microporous membrane has been used as a filter for high-performance filtration. However, if the microporous membrane is used as it is, it is easily damaged, and the form retainability is poor. Therefore, the microporous membrane is held by a support and used for a filter for microfiltration. For example, in patent document 1, in order to suppress outgas generation, the proposal which uses the polyester long fiber spun bond nonwoven fabric which does not contain polyolefin for a support body is made. The heat-adhesive polyester composite fiber used has a melting point of the heat-adhesive component of 120 ° C. or higher, preferably 180 ° C. or higher. Patent Document 1 also describes an example in which no thermal bonding fiber is used. In this case, for joining the fine porous film and the nonwoven fabric, there has been proposed a method in which a polyester-based thermal adhesive is applied at, for example, 6 g / m 2 and heat-bonded at 160 to 200 ° C. However, the heat-bonding component is relatively brittle, and when folding is performed, there are problems such as cracking, damage to the microporous membrane, and poor shape retention of the folded filter.
　また、特許文献２には、熱圧着接合による微細多孔膜の損傷を防止するため、支持体として熱接着複合繊維不織布を用い、例えば１６０℃で粘着防止のため離型処理したローラーで熱圧着接合する提案がされている。しかし、襞折り加工したフィルターの形態保持性が不充分なため、スペーサーを塗布する必要があることが開示されている。 Further, in Patent Document 2, in order to prevent damage to the microporous membrane due to thermocompression bonding, a thermobonded composite fiber nonwoven fabric is used as a support, and for example, thermocompression bonding is performed with a release-treated roller at 160 ° C. to prevent adhesion. Proposals have been made. However, it is disclosed that it is necessary to apply a spacer because the shape retention of the folded filter is insufficient.
　特許文献３には、支持体に熱接着繊維からなる不織布を微細多孔膜にラミネートして襞折り加工する際、ポリアミド熱接着樹脂からなるスペーサーを用いる必要があることが開示されている。
　特許文献４には、芯鞘構造繊維不織布を微細多孔膜の支持体に用いて襞折り加工する際、襞折りの屈曲部を接着剤塗布または加熱再固定する方法で目止め加工することが好ましく、目止め加工しない場合、微細多孔膜が損傷すると開示されている。スペーサーを使用しない事例は開示されているが、目止め加工が必要であり、熱接着成分を多量に含有するので、アウトガス低減化は不十分な問題は解決されていない。 Patent Document 3 discloses that it is necessary to use a spacer made of a polyamide heat-bonding resin when laminating a nonwoven fabric made of heat-bonding fibers on a support on a fine porous film and folding it.
In Patent Document 4, when a core-sheath fiber nonwoven fabric is used as a support for a microporous membrane, it is preferable to perform sealing by a method of applying an adhesive or heating and re-fixing the bent portion of the fold. It is disclosed that the microporous membrane is damaged when the sealing process is not performed. Although an example in which a spacer is not used is disclosed, a sealing process is necessary and a large amount of a thermal adhesive component is contained, so that the problem of insufficient outgas reduction has not been solved.
国際公開第９８／６４７７号パンフレットInternational Publication No. 98/6477 Pamphlet 特開２００２－６６２２６号公報JP 2002-66226 A 特開２００４－９９０号公報JP 2004-990 A 特開２００７－１６０２７５号公報JP 2007-160275 A
　本発明は、かかる従来技術の課題を背景になされたものである。すなわち、本発明の目的は、アウトガスが少なく、襞折り加工品の形態保持性に優れた微細多孔膜を用いたフィルター用支持体およびそれを用いた多孔膜フィルターを提供することにある。 The present invention has been made against the background of the problems of the prior art. That is, an object of the present invention is to provide a filter support using a fine porous membrane with little outgas and excellent shape retention of a folded product and a porous membrane filter using the same.
　本発明者らは鋭意検討した結果、以下に示す手段により、上記課題を解決できることを見出し、本発明に到達した。
　すなわち、本発明は、以下の構成からなる。
１．ポリエステルからなる目付量が２０～１００ｇ／ｍ２で、圧着面積率が８～１８％の
エンボス加工が施された長繊維不織布と、前記長繊維不織布の少なくとも片側の表面に、エチレン酢酸ビニル共重合体を含有した融点が１００℃～１４０℃である熱可塑性樹脂を熱接着成分として０．７～５．０ｇ／ｍ２付与したフィルター用支持体。
２．ポリエステルが、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリナフタレンテレフタレート、またはポリシクロヘキレンジメチルテレフタレートのいずれか１種を少なくとも９５モル％以上含有したポリエステルであり、フィルター用支持体の見掛け密度が１００～１５５ｋｇ／ｍ３である上記１に記載のフィルター用支持体。
３．熱接着成分が、１．０～３．０ｇ／ｍ２付与されている上記１または２に記載のフィルター用支持体。
４．多孔膜に、上記１～３のいずれかに記載のフィルター用支持体の熱接着成分が付与された面が接合された多孔膜フィルター。
５．多孔膜の両面に、上記１～３のいずれかに記載のフィルター用支持体の熱接着成分が付与された面が接合された多孔膜フィルター。
６．フィルターが襞折り加工された上記４または５に記載の多孔膜フィルター。 As a result of intensive studies, the present inventors have found that the above problems can be solved by the following means, and have reached the present invention.
That is, this invention consists of the following structures.
1. A long-fiber non-woven fabric having a basis weight of 20 to 100 g / m 2 and an embossing process with a crimp area ratio of 8 to 18%, and at least one surface of the long-fiber non-woven fabric is coated with ethylene vinyl acetate A support for a filter to which 0.7 to 5.0 g / m 2 of a thermoplastic resin containing a coalescence and having a melting point of 100 to 140 ° C. as a thermal adhesive component is applied.
2. The polyester is a polyester containing at least 95 mol% of any one of polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, or polycyclohexylene diterephthalate, and the filter substrate has an apparent density of 100 to 155 kg / m. 3. The filter support according to 1 above, which is 3 .
3. 3. The filter support according to 1 or 2 above, wherein the thermal adhesive component is applied at 1.0 to 3.0 g / m 2 .
4). A porous membrane filter in which a surface to which a thermal adhesive component of the filter support according to any one of the above 1 to 3 is applied is bonded to the porous membrane.
5. A porous membrane filter in which the surfaces to which the thermal adhesive component of the filter support according to any one of the above 1 to 3 is applied are bonded to both surfaces of the porous membrane.
6). 6. The porous membrane filter as described in 4 or 5 above, wherein the filter is folded.
　本発明は、熱接着成分付与量を極限まで低減することにより、アウトガス量を下げ、同時に、使用する長繊維不織布の素材、諸物性および熱接着成分の組成を適正化し、支持体に柔軟かつ適度な剛直性を付与せしめることで、優れた襞折り加工の形態保持を有するフィルターを提供することができる。 The present invention reduces the amount of outgassing by reducing the amount of thermal adhesive component applied to the limit, and at the same time, optimizes the material of the long-fiber nonwoven fabric used, various physical properties and the composition of the thermal adhesive component, and is flexible and suitable for the support. By imparting a high rigidity, it is possible to provide a filter having excellent shape retention of the folding process.
　以下、本発明を詳述する。
　本発明は、ポリエステルからなる、目付量が２０～１００ｇ／ｍ２で、エンボス加工が施された圧着面積率が８～１８％である長繊維不織布と、前記長繊維不織布の少なくとも片側の表面に、融点が１００℃～１４０℃である熱可塑性樹脂に、エチレン酢酸ビニル共重合体を含有した熱接着成分を、０．７～５．０ｇ／ｍ２付与したフィルター用支持体である。さらには、該支持体の熱接着成分が付与された面と多孔膜が接合されたフィルターである。 The present invention is described in detail below.
The present invention provides a long-fiber nonwoven fabric made of polyester and having a basis weight of 20 to 100 g / m 2 and an embossed crimp area ratio of 8 to 18%, on at least one surface of the long-fiber nonwoven fabric. A filter support in which 0.7 to 5.0 g / m 2 of a thermoadhesive component containing an ethylene vinyl acetate copolymer is applied to a thermoplastic resin having a melting point of 100 ° C. to 140 ° C. Furthermore, it is a filter in which the surface to which the thermal adhesive component of the support is applied is bonded to the porous membrane.
　本発明におけるポリエステルとは、融点が２２０℃以上のポリエステル樹脂で、好ましくは、ポリエチレンテレフタレート（ＰＥＴ）、ポリブチレンテレフタレート（ＰＢＴ）、ポリエチレンナフタレート（ＰＥＮ）、ポリシクロヘキサンジメチルテレフタレート（ＰＣＨＴ）などが例示できる。本発明のポリエステル成分は、共重合ポリエステルでは、オリゴマーがホモポリエステルに比べて多くなるので、ホモポリエステルを９５モル％以上含有させることが、耐熱性、耐久性、アウトガスの発生量を低減できるので、好ましく、より好ましくは汎用性の高いポリエチレンテレフタレート１００モル％である。また、用いるポリエステル樹脂に、その他の機能を付与するために、ポリエステル以外の樹脂、剤を練り込むあるいは混合することができる。例えば、酸化チタンや抗菌剤、抗カビ剤、遠赤外線放射機能を有するセラミックなどが挙げられ、機械強度などに影響がない程度に３重量％未満が好ましい。 The polyester in the present invention is a polyester resin having a melting point of 220 ° C. or higher, preferably polyethylene terephthalate (PET), polybutylene terephthalate (PBT), polyethylene naphthalate (PEN), polycyclohexanedimethyl terephthalate (PCHT), etc. it can. In the polyester component of the present invention, the copolymer polyester has more oligomers than the homopolyester, so containing 95 mol% or more of the homopolyester can reduce the heat resistance, durability, and outgas generation amount. Preferably, it is 100 mol% of polyethylene terephthalate with high versatility. Further, in order to impart other functions to the polyester resin to be used, resins and agents other than polyester can be kneaded or mixed. For example, titanium oxide, an antibacterial agent, an antifungal agent, a ceramic having a far-infrared radiation function and the like can be mentioned, and the amount is preferably less than 3% by weight so as not to affect the mechanical strength.
　本発明に使用する不織布は、高性能フィルターに不可欠のダスト発生を防止するため、長繊維不織布であることが好ましく、短繊維不織布では、ダストが発生するので、好ましくない。
　長繊維不織布であれば、特には限定されないが、品質が安定しており、均質性が高く、比較的安価で大量生産される工業材料として、スパンボンド不織布が好ましい。
　本発明の長繊維不織布は、目付量が２０～１００ｇ／ｍ２で、圧着面積率が８～１８％のエンボス加工が施されたものが好ましい。
　目付量が２０ｇ／ｍ２未満では、支持体の支持機能が低減すると共に、予備ろ過機能も低減するので好ましくない。目付量が１００ｇ／ｍ２を越えると、襞折り加工時の屈曲部の変形差が大きくなり、機械的力を大きくしないと襞折り加工しにくくなる。機械的力が大きく掛かると、接合された多孔膜を損傷する場合が発生するので好ましくない。より好ましい目付量は、２５～７０ｇ／ｍ２、さらに好ましくは、２５～５０ｇ／ｍ２である。 The non-woven fabric used in the present invention is preferably a long-fiber non-woven fabric in order to prevent the generation of dust that is indispensable for a high-performance filter, and the short-fiber non-woven fabric is not preferable because dust is generated.
Although it is not particularly limited as long as it is a long-fiber nonwoven fabric, a spunbonded nonwoven fabric is preferred as an industrial material that is stable in quality, has high homogeneity, is relatively inexpensive, and is mass-produced.
The long fiber nonwoven fabric of the present invention is preferably embossed with a basis weight of 20 to 100 g / m 2 and a crimp area ratio of 8 to 18%.
A basis weight of less than 20 g / m 2 is not preferable because the support function of the support is reduced and the preliminary filtration function is also reduced. If the weight per unit area exceeds 100 g / m 2 , the deformation difference of the bent portion at the time of the folding process becomes large, and it becomes difficult to perform the folding process unless the mechanical force is increased. When the mechanical force is greatly applied, the bonded porous membrane may be damaged, which is not preferable. A more preferred basis weight is 25 to 70 g / m 2 , and further preferably 25 to 50 g / m 2 .
　本発明に使用する長繊維不織布を構成する繊維の単繊維繊度は特には限定されないが、被覆性と剛直性を低目付で実現できる、１．０～５．０ｄｔｅｘが好ましく、１．５～３．０ｄｔｅｘがより好ましい。 The single fiber fineness of the fibers constituting the long-fiber nonwoven fabric used in the present invention is not particularly limited, but it is preferably 1.0 to 5.0 dtex, and preferably 1.5 to 3 in which coverage and rigidity can be realized with a low basis weight. 0.0 dtex is more preferred.
　本発明に使用する長繊維不織布において、エンボス加工は、低目付でも、剛直性と表面を平滑化し均質な熱接着成分付与性をもたせ、且つ通気性とろ過性も保持させるために、必要である。エンボス加工されていない場合、剛直性が劣り、支持体としての支持機能が劣り、表面が平滑ではないので、多孔膜との接合時に接着斑を生じ形態耐久性も劣るので好ましくない。 In the long-fiber non-woven fabric used in the present invention, embossing is necessary to maintain rigidity and smoothness of the surface evenly with a low basis weight, to provide a uniform heat-adhesive component, and to maintain air permeability and filterability. . When not embossed, the rigidity is inferior, the support function as a support is inferior, and the surface is not smooth.
　エンボス加工による圧着面積率は８～１８％が好ましい。８％未満では、低目付けでの形態保持機能が劣り、表面の平滑度も悪くなるので好ましくない。１８％を越えると、屈曲剛直性が高くなりすぎ、襞折り加工時の機械的力が大きくなり、接合された多孔膜の損傷を生じる場合があり好ましくない。より好ましい圧着面積率は１０～１５％である。本発明では、エンボス文様は特には限定されないが、好ましくは、剛直点が分散されているドット形状のエンボス文様が好ましく、ドット点は圧着面積が０．２～０．５ｍｍ２で、形状が小判型で、千鳥配列のものが特に好ましい。 The area ratio of crimping by embossing is preferably 8 to 18%. If it is less than 8%, the shape retention function at low weight is inferior, and the smoothness of the surface also deteriorates, which is not preferable. If it exceeds 18%, the bending rigidity becomes too high, the mechanical force at the time of folding is increased, and the bonded porous membrane may be damaged, which is not preferable. A more preferable crimp area ratio is 10 to 15%. In the present invention, the embossed pattern is not particularly limited, but a dot-shaped embossed pattern in which rigid points are dispersed is preferable, and the dot point has a crimping area of 0.2 to 0.5 mm 2 and has a small shape. A mold having a staggered arrangement is particularly preferred.
　本発明に使用する長繊維不織布の見掛け密度は、剛直性と通気性を同時に満足するできる１００～１５５ｋｇ／ｍ３とするのが好ましく、１１０～１５０ｋｇ／ｍ３とするのがより好ましい。 The apparent density of the long-fiber nonwoven fabric used in the present invention is preferably 100 to 155 kg / m 3, and more preferably 110 to 150 kg / m 3, which can satisfy both rigidity and air permeability.
　本発明のフィルター用支持体は、前記長繊維不織布の少なくとも片側の表面に、熱接着成分を付与することで、使用熱接着成分を少なくするものである。内部にも熱接着成分が存在する場合、使用熱接着成分を少なくすることができず、アウトガス発生量が多くなる。さらに、多孔膜との接合時に、熱接着成分が長繊維不織布に浸透することにより、長繊維不織布の多孔膜との接合面（熱接着成分付与面）と反対側の表面にまで熱接着成分が浸透し、該表面より熱接着成分が滲み出すことがある。その結果、滲み出した熱接着成分により、接合後の製品がカレンダーローラーに巻き付くなどの加工性に問題が発生するので好ましくない。 The filter support of the present invention reduces the heat-adhesive component used by applying a heat-adhesive component to at least one surface of the long-fiber nonwoven fabric. When a thermal adhesive component is also present inside, the thermal adhesive component used cannot be reduced, and the amount of outgas generation increases. Furthermore, the thermal adhesive component penetrates into the long-fiber nonwoven fabric during the bonding with the porous membrane, so that the thermal adhesive component reaches the surface opposite to the bonding surface (thermal adhesive component-giving surface) with the porous membrane of the long-fiber nonwoven fabric. It may penetrate and the thermal adhesive component may ooze out from the surface. As a result, the heat-adhesive component that has oozed out is not preferable because a problem occurs in workability such as the product after joining is wound around the calendar roller.
　本発明の熱接着成分は、８０℃未満の温度域で使用する場合の形態安定性を保持するために、エチレン酢酸ビニル共重合体を含有した、融点が１００℃～１４０℃の熱可塑性樹脂の使用が好ましい。エチレン酢酸ビニル共重合体以外の熱可塑性樹脂としてはポリエチレン、ポリプロピレン等のポリオレフィンが含有されていていても良い。熱可塑性樹脂の融点が１００℃未満では、形態耐久性が劣るので好ましくない。融点が１４０℃を越えると多孔膜との接合のためのカレンダー加工時に、熱伝導が不充分となり接合がうまくできない場合があり好ましくない。本発明の好ましい熱接着成分の融点は１０５～１３５℃であり、より好ましくは１１０～１３０℃である。 The thermal adhesive component of the present invention is a thermoplastic resin containing an ethylene-vinyl acetate copolymer and having a melting point of 100 ° C. to 140 ° C. in order to maintain shape stability when used in a temperature range below 80 ° C. Use is preferred. As thermoplastic resins other than the ethylene vinyl acetate copolymer, polyolefins such as polyethylene and polypropylene may be contained. If the melting point of the thermoplastic resin is less than 100 ° C., the form durability is inferior, which is not preferable. When the melting point exceeds 140 ° C., the heat conduction becomes insufficient at the time of calendering for bonding to the porous film, and the bonding may not be performed properly. The melting point of the preferred thermal adhesive component of the present invention is 105 to 135 ° C, more preferably 110 to 130 ° C.
　本発明の熱接着成分は、柔軟性と接合力維持のため、エチレン酢酸ビニル共重合体を含有していることが好ましい。多孔膜がポリテトラフルオロエタンなどの場合などでも接着性が良好なためである。エチレン酢酸ビニル共重合体の酢酸ビニル含有量は５～３５重量％が好ましい。５重両％未満では、ポリエステルとの接合力が低下する場合があり、３５重量％以上では、十分な分散状態では問題を生じないが、分散状態が不十分な場合、融点降下を生じて熱安定性の低下による形態保持性が低下する場合がある。本発明の好ましいエチレン酢酸ビニル共重合体中での酢酸ビニル含有量は１０～３３重量％、より好ましくは２０～３０重量％である。 The thermal adhesive component of the present invention preferably contains an ethylene vinyl acetate copolymer in order to maintain flexibility and bonding strength. This is because the adhesiveness is good even when the porous film is polytetrafluoroethane or the like. The vinyl acetate content of the ethylene vinyl acetate copolymer is preferably 5 to 35% by weight. If it is less than 5% by weight, the bonding strength with the polyester may be reduced. If it is 35% by weight or more, there will be no problem in a sufficiently dispersed state. In some cases, the form retainability may decrease due to a decrease in stability. The vinyl acetate content in the preferred ethylene vinyl acetate copolymer of the present invention is 10 to 33% by weight, more preferably 20 to 30% by weight.
　本発明の熱接着成分は、十分な接合強度と形態安定性を維持するために、０．７～５．０ｇ／ｍ２付与する必要がある。０．７ｇ／ｍ２未満では、多孔膜との接合が不十分になり、加工時に剥離したり、形態保持性が劣るので好ましくない。５．０ｇ／ｍ２を越えるとアウトガスの発生量が増加するので好ましくない。本発明の好ましい付与量は、１．０～４．０ｇ／ｍ２、より好ましくは１．５～３．０ｇ／ｍ２である。 The thermal adhesive component of the present invention must be applied in an amount of 0.7 to 5.0 g / m 2 in order to maintain sufficient bonding strength and form stability. If it is less than 0.7 g / m 2 , the bonding with the porous film becomes insufficient, and it is not preferable because it is peeled off during processing or the shape retention is poor. If it exceeds 5.0 g / m 2 , the amount of outgas generated increases, which is not preferable. The preferable application amount of the present invention is 1.0 to 4.0 g / m 2 , more preferably 1.5 to 3.0 g / m 2 .
　本発明での熱接着成分を付与方法は、特には限定されないが、均一に少量を、しかも出来る限り長繊維不織布内に浸透しないよう付与することが重要であり、その方法として、熱接着成分をアウトガス発生原因物質を含めず液状化して、グラビア印刷法で塗布する方法が好適である。他の方法、例えばプリントジェット塗布では、生産性が劣る課題があり、ドット塗布では均一に塗布できない。また、溶融押出しラミネート法では、５ｇ／ｍ２以下の量を均一に付与することが困難である。薄膜化したフィルムを積層ラミネートする方法は利用可能であると考えられる。 The method for applying the thermal adhesive component in the present invention is not particularly limited, but it is important to apply a uniform small amount so that it does not penetrate into the long fiber nonwoven fabric as much as possible. A method of liquefying without including the outgas generating substance and applying by gravure printing is preferable. Other methods, such as print jet coating, have a problem of poor productivity, and dot coating cannot be applied uniformly. Further, in the melt extrusion laminating method, it is difficult to uniformly apply an amount of 5 g / m 2 or less. A method of laminating and laminating a thin film is considered to be usable.
　前記により得られた本発明の支持体は、アウトガス量が３．５μｇ／ｇ以下の支持体でであることが好ましい。アウトガス量は少なければ少ないほど好ましいが、熱接着成分を使用することを鑑みると、その下限値は０．１μｇ／ｇ以上である。アウトガス量が３．５μｇ／ｇを超えると、ＨＥＰＡフィルター、ＵＬＰＡフィルターなどの高性能フィルター用膜材の支持体に使用する際に、問題となるため好ましくない。 The support of the present invention obtained as described above is preferably a support having an outgas amount of 3.5 μg / g or less. The smaller the amount of outgas, the better. However, the lower limit is 0.1 μg / g or more in view of the use of the thermal adhesive component. An outgas amount exceeding 3.5 μg / g is not preferable because it causes a problem when used as a support for a membrane material for a high performance filter such as a HEPA filter or a ULPA filter.
　本発明のフィルターは、多孔膜と、前記支持体の熱接着成分が付与された面が接合されたフィルターである。また、多孔膜の両面に、前記支持体の熱接着成分が付与された面を接合した支持体／多孔膜／支持体３層構造のフィルターである。さらに、多層構造のフィルターとしても構わない。 The filter of the present invention is a filter in which the porous membrane and the surface of the support to which the thermal adhesive component is applied are joined. Moreover, it is a filter of the support body / porous film / support body 3 layer structure which joined the surface to which the thermal-adhesion component of the said support body was provided to both surfaces of the porous film. Furthermore, it may be a multilayer filter.
　本発明における多孔膜とは、製膜された膜に、貫通する０．５μｍ未満の微細な孔を多数有する分離膜をいい、例えば、ポリテトラフルオロエチレン（ＰＴＦＥ）シートを延伸して、膜に多数の微細孔を形成したものなどが例示できる。本発明では、耐熱性を有し、有機ガスなどに耐久性を有するＰＴＦＥ多孔膜が特に好ましい。 The porous membrane in the present invention refers to a separation membrane having a large number of fine pores of less than 0.5 μm penetrating into the formed membrane. For example, a polytetrafluoroethylene (PTFE) sheet is stretched to form a membrane. The thing etc. which formed many fine holes can be illustrated. In the present invention, a PTFE porous membrane having heat resistance and durability against an organic gas or the like is particularly preferable.
　本発明のフィルターは、多孔膜の少なくとも片面と前記支持体の熱接着成分が付与された面とが熱接合されたフィルターである。支持体が多孔膜と接合していないと、多孔膜と支持体が擦れて損傷したり、シートとしての取り扱い性が劣り、更には、襞折り加工した場合の形態保持性が劣り好ましくない。 The filter of the present invention is a filter in which at least one surface of the porous membrane and the surface of the support to which the thermal adhesive component is applied are thermally bonded. If the support is not bonded to the porous membrane, the porous membrane and the support are rubbed and damaged, the handling property as a sheet is inferior, and the shape retention property when folded is not preferable.
　また、本発明のフィルターは、多孔膜の両面と前記支持体の熱接着成分が付与された面とが熱接合されたフィルターであることが、膜の損傷をより効果的に防止でき好ましい。襞折り加工した場合、少量の熱接着成分で接合したにもかかわらず、形態保持性が著しく向上する効果もある。 In addition, it is preferable that the filter of the present invention is a filter in which both surfaces of the porous membrane and the surface to which the thermal adhesive component of the support is applied are thermally bonded, so that the membrane can be more effectively prevented from being damaged. In the case of the folding process, there is also an effect that the shape retention is remarkably improved in spite of joining with a small amount of the thermal adhesive component.
　本発明のフィルターは、ろ過面積を広くする方法である襞折り加工して使用する際に、襞折り加工された部分の形態保持性が特に優れている。 The filter of the present invention is particularly excellent in the shape retention of the portion that has been folded and folded when used as a method of widening the filtration area.
　以下に、本発明の多孔膜フィルター用支持体およびそれを用いたフィルターの製造方法の一例を示す。なお、この開示で、本発明が限定されるものではない。
　固有粘度０．６５のポリエチレンテレフタレートを常法により、乾燥して、溶融押出機にて、紡糸温度２８５℃にて、オリフィス孔径０．２５ｍｍのノズルより、単孔吐出量１ｇ／分にて吐出し、下方１ｍに設置した牽引ジェットにて約４５００ｍ／分相当にて引取り、下方５０ｃｍに設置された移動式コンベア上に振落し、単繊維繊度２．２ｄｔｅｘ、目付３０ｇ／ｍ２のウエッブを形成する。連続して、形態保持のため加熱押さえローラー
で圧縮しつつウエッブは巻き取られる。次いで、上ローラーが小判型凸形状千鳥配列の圧着密度１２％のエンボスローラー、下ローラーがフラットローラーで構成されたエンボスローラーにて、温度２４０～２４５℃、線圧２９０～３４５N／ｃｍにてエンボス加工を
行い、見掛け密度１３０ｋｇ／ｍ３の不織布を巻き取った。
　次いで、熱接着成分の準備を行う。高圧のオートクレーブにて、例えば、酢酸ビニル含有量２８重量％のエチレン酢酸ビニル－ポリエチレン混合物と消泡材を所定量投入し、次いで、所定量の水と少量の乳化剤等を添加して、加熱攪拌することで、水性エマルジョンを作成する。水性エマルジョンは、所望組成のものであれば、市販品を使用してもかまわない。本発明では、たとえば、東洋インキ製アクワシールなどが例示できる。
　熱接着成分が準備できれば、得られた不織布を常法により、グラビアコート機にて、必要な塗布量にピックアップ量を調整してコーティングし、水分を除去して巻き取られ、本発明のフィルター用支持体が得られる。
　次いで、多孔膜を準備する。多孔膜は、常法により作成する。たとえばポリテトラフルオロエチレン粉末に塑性化剤を添加混練してロット状に押出し、ついで、圧延ローラーにてテープ状に形成、次に熱処理にて、塑性化剤を除去後、縦方向を加熱ローラーにて延伸し、横方向をグリップテンターにて加熱延伸して、多孔膜を得られる。
　準備した多孔膜と支持体の熱接着成分が付与された面側を接合できるように加熱カレンダーロールに供給する。両面を支持体で接合する場合、多孔膜の上下から支持体を供給して、多孔膜を損傷させない線圧、たとえば、９．８N／ｃｍ未満で圧着接合してすぐ冷却
して皺発生などを防止しつつ、多孔膜に支持体が接合されたフィルター材を巻き取る。本発明の熱接着成分を付与した支持体を用いる場合、加熱ローラーは上下ローラー温度１５０℃に設定して接合させるのが好ましい。
　次いで、常法により、襞折り加工処理を行い、本発明のフィルターが得られる。 Below, an example of the manufacturing method of the support body for porous membrane filters of this invention and a filter using the same is shown. It should be noted that the present invention is not limited by this disclosure.
Polyethylene terephthalate having an intrinsic viscosity of 0.65 is dried by a conventional method, and discharged by a melt extruder at a spinning temperature of 285 ° C. from a nozzle having an orifice hole diameter of 0.25 mm at a single hole discharge rate of 1 g / min. Taken at about 4500 m / min with a tow jet installed 1 m below, and shaken down on a mobile conveyor installed 50 cm below to form a web with a single fiber fineness of 2.2 dtex and a basis weight of 30 g / m 2 To do. Continuously, the web is wound while being compressed with a heat-pressing roller to maintain the form. Next, the upper roller is an embossed roller with an oval convex zigzag arrangement with a crimping density of 12%, and the lower roller is an embossed roller composed of a flat roller, embossed at a temperature of 240-245 ° C and a linear pressure of 290-345 N / cm. Processing was performed to wind up a nonwoven fabric with an apparent density of 130 kg / m 3 .
Next, the thermal bonding component is prepared. In a high-pressure autoclave, for example, a predetermined amount of an ethylene vinyl acetate-polyethylene mixture having a vinyl acetate content of 28% by weight and a defoamer are added, and then a predetermined amount of water and a small amount of an emulsifier are added, followed by stirring with heating This creates an aqueous emulsion. A commercially available product may be used as long as the aqueous emulsion has a desired composition. In the present invention, for example, Toyo Ink's Aqua seal can be exemplified.
Once the thermal adhesive component is ready, the resulting nonwoven fabric is coated with the gravure coater by adjusting the pick-up amount to the required coating amount, removed by moisture, and wound up by the usual method. A support is obtained.
Next, a porous film is prepared. The porous membrane is prepared by a conventional method. For example, a plasticizing agent is added and kneaded to polytetrafluoroethylene powder and extruded into a lot shape, then formed into a tape shape with a rolling roller, and then the plasticizing agent is removed by heat treatment, and then the longitudinal direction is changed to a heating roller. The film is stretched and the transverse direction is heated and stretched with a grip tenter to obtain a porous film.
The prepared porous film is supplied to a heated calender roll so that the surface of the support to which the thermal adhesive component is applied can be bonded. When joining both surfaces with a support, supply the support from the top and bottom of the porous membrane, and press-bond at a linear pressure that does not damage the porous membrane, for example, less than 9.8 N / cm, and immediately cool down to generate wrinkles. The filter material in which the support is bonded to the porous membrane is wound up while preventing. When using the support body which provided the heat-adhesive component of this invention, it is preferable to set a heating roller to the upper and lower roller temperature of 150 degreeC, and to make it join.
Subsequently, a folding process is performed by a conventional method to obtain the filter of the present invention.
　かくして得られたフィルターは、アウトガス発生源が非常に少なく、襞折りの形態保持性も優れているので、高性能空気フィルターシステムに特に適したフィルターを提供できる。 The filter thus obtained has very few outgas generation sources and is excellent in maintaining the folded shape, so that a filter particularly suitable for a high-performance air filter system can be provided.
　以下に実施例を示して本発明を具体的に説明するが、本発明は実施例に限定されるものではない。
　なお、本発明における実施例で記載する評価は以下の方法による。 EXAMPLES The present invention will be specifically described below with reference to examples, but the present invention is not limited to the examples.
In addition, evaluation described in the Example in this invention is based on the following method.
不織布の目付量：Ｍｓ（ｇ／ｍ２）
　ＪＩＳ　Ｌ１９０６（２０００）に準じて測定した単位面積あたりの質量（Ｍｓ）である。 Non-woven fabric weight: Ms (g / m 2 )
It is the mass (Ms) per unit area measured according to JIS L1906 (2000).
不織布の見掛け密度：ρ（ｋｇ／ｍ３）
　ＪＩＳ　Ｌ１９０６（２０００）に準じてＪＩＳ　Ｌ１０９６　８．９により測定した厚み（ｔ）：ｍｍ　より、以下の計算で求める。
　ρ＝Ｍｓ／ｔ Apparent density of nonwoven fabric: ρ (kg / m 3 )
The thickness (t) measured in accordance with JIS L1906 (2000) according to JIS L1096 8.9: mm.
ρ = Ms / t
不織布の圧着面積率：Ｐ（％）
　任意の２０箇所で３０ｍｍ角に裁断し、ＳＥＭにて５０倍の写真を撮る。撮影写真をＡ３サイズに印刷して圧着単位面積を切り抜き、面積（Ｓ０）を求める。次いで圧着単位面積内において圧着部のみを切り抜き圧着部面積（Ｓｐ）を求め、圧着面積率（Ｐ）を算出する。その圧着面積率Ｐ
２０点の平均値を求めた。
　Ｐ＝Ｓｐ／Ｓ０　（ｎ＝２０） Non-woven fabric crimp area ratio: P (%)
Cut into 30mm squares at any 20 locations and take 50x pictures with SEM. The photographed photograph is printed in A3 size, the crimping unit area is cut out, and the area (S0) is obtained. Next, only the crimping part is cut out within the crimping unit area to obtain the crimping part area (Sp), and the crimping area ratio (P) is calculated. Crimp area ratio P
The average value of 20 points was obtained.
P = Sp / S0 (n = 20)
熱接着成分の付着量（ｇ／ｍ２）
　熱接着成分を付与した不織布の目付量（Ｍｔ）から不織布単独の目付量（Ｍｓ）を差し引いた量を熱接着成分の付着量とする。但し、熱接着複合繊維から構成される不織布は、不織布断面の位相差顕微鏡写真より、熱接着成分と非熱接着成分の分布比率を求め、全不織布目付量から、熱接着成分の目付量を求める。 Adhesion amount of thermal adhesive component (g / m 2 )
The amount obtained by subtracting the basis weight (Ms) of the nonwoven fabric alone from the basis weight (Mt) of the nonwoven fabric provided with the thermal adhesive component is defined as the adhesion amount of the thermal adhesive component. However, for nonwoven fabrics composed of thermally bonded conjugate fibers, the distribution ratio of the thermal adhesive component and the non-thermal adhesive component is determined from the phase contrast micrograph of the nonwoven fabric cross section, and the basis weight of the thermal adhesive component is determined from the total nonwoven fabric basis weight. .
熱接着成分の融点（℃）
　熱接着成分を付与した不織布の熱接着成分を剥離し、剥離した熱接着成分サンプル５ｍｇを採取し、示差走査型熱量計（ＴＡ　ｉｎｓｔｒｕｍｅｎｔｓ社製Ｑ１００）にて、２０℃から１０℃／分にて２９０℃まで昇温させたときの吸熱ピーク位置の温度を融点として評価する。なお、２成分の場合、低温側の吸熱ピーク位置を熱接着成分の融点とする。 Melting point of heat bonding component (℃)
The thermal adhesive component of the nonwoven fabric provided with the thermal adhesive component was peeled off, and 5 mg of the peeled thermal adhesive component sample was collected, and at 20 ° C. to 10 ° C./min with a differential scanning calorimeter (TA instruments Q100). The temperature at the endothermic peak position when the temperature is raised to 290 ° C. is evaluated as the melting point. In the case of two components, the endothermic peak position on the low temperature side is the melting point of the heat bonding component.
支持体のアウトガス量（μｇ／ｇ）
　以下の方法により測定した成分及び未同定成分の総計を試料１ｇ当りで示す。
（１）捕集方法
　試料０．２ｇをＭＳＴＤ－２５８Ｍ－Ｂ（ＧＬサイエンス）のパイレックス（登録商標）製チャンバー（φ１６２ｍｍ×１３０ｍｍ）内にセットした。オーブンプログラムを０℃～８０℃まで、１０℃／分の勾配で上昇させ、８０℃で１５分キープするよう設定し、試料を加熱した。加熱の間、Ｈｅパージ（１５０ｍｌ／分）にて、発生したＶＯＣ成分をＴｅｎａｘ－ＴＡ捕集管（ＧＬサイエンス）に、濃縮捕集した。
（２）ＧＣＭＳ分析方法
　捕集後のＴｅｎａｘ－ＴＡ捕集管を、ＴＣＴ（ＣＰ－４０２０：クロムパック）－ＧＣ／ＭＳ（ＨＰ－６８９０／ＨＰ－５９７３：Ａｇｉｌｅｎｔ）にて、測定し、捕集成分を定性、定量した。詳細な測定条件を以下にまとめる。
　また、標準試料として、トルエン１６８ｐｐｍメタノール溶液１μｌをＴｅｎａｘ－ＴＡ捕集管に添加し、試料と同様の方法で、ＧＣ／ＭＳ測定した。試料の測定にて、検出されたピークを、トルエン換算値として定量した。
　＜ＴＣＴ条件＞
　　捕集管加熱温度：２５０℃
　　ロッド加熱温度：２８０℃
　　トラップ温度：－１００℃
　　試料導入時気化温度：２８０℃
　　キャリアガス：Ｈｅ
　　圧力：１００ｐｓｉ
　＜ＧＣ／ＭＳ条件＞
　　カラム：ＨＰ－１ＭＳ（長さ３０ｍ、内径０．２５ｍｍ、膜厚１μｍ）
　　オーブン温度：５０℃（５分キープ）→２８０℃まで１０℃／分勾配→２８０℃（１０分キープ）
　　測定モード：ＳＣＡＮモード（ｍ／ｚ＝４０～５００）
　なお、本発明の評価で規定するアウトガスとは、同定したアウトガス組成としては、ｎ－ドデカン、ｎ－トリデカン、ｎ－テトラデカン、２・４－ジ－ｔ－ブチルフェノール、ｎ－ペンタデカン、ジ－ｔ－ブチルヒドロキシトルエン、ヘキサデセン、ｎ－ヘプタデカン、ｎ－オクタデカンであり、未同定物質を含めた各成分の総計を１ｇ当りで求めた量をいい、総量を評価している。 Outgas amount of support (μg / g)
The sum total of the component measured by the following method and an unidentified component is shown per 1g of samples.
(1) Collection method A 0.2 g sample was set in a Pyrex (registered trademark) chamber (φ162 mm × 130 mm) of MSTD-258MB (GL Science). The oven program was set from 0 ° C. to 80 ° C. with a ramp of 10 ° C./min and set to keep 15 minutes at 80 ° C., and the sample was heated. During heating, the generated VOC component was concentrated and collected in a Tenax-TA collection tube (GL Science) by He purge (150 ml / min).
(2) GCMS analysis method Tenax-TA collection tube after collection was measured with TCT (CP-4020: Chrome Pack) -GC / MS (HP-6890 / HP-5993: Agilent) and collected. Minutes were qualitatively and quantified. Detailed measurement conditions are summarized below.
As a standard sample, 1 μl of a toluene 168 ppm methanol solution was added to a Tenax-TA collection tube, and GC / MS measurement was performed in the same manner as the sample. In the measurement of the sample, the detected peak was quantified as a toluene equivalent value.
<TCT conditions>
Collection tube heating temperature: 250 ° C
Rod heating temperature: 280 ° C
Trap temperature: -100 ° C
Evaporation temperature at sample introduction: 280 ° C
Carrier gas: He
Pressure: 100 psi
<GC / MS conditions>
Column: HP-1MS (length 30 m, inner diameter 0.25 mm, film thickness 1 μm)
Oven temperature: 50 ° C. (5 minutes keep) → 10 ° C./min gradient up to 280 ° C. → 280 ° C. (10 minutes keep)
Measurement mode: SCAN mode (m / z = 40-500)
The outgas specified in the evaluation of the present invention is the identified outgas composition: n-dodecane, n-tridecane, n-tetradecane, 2,4-di-t-butylphenol, n-pentadecane, di-t- These are butylhydroxytoluene, hexadecene, n-heptadecane, and n-octadecane. The total amount of each component including unidentified substances is determined per gram, and the total amount is evaluated.
フィルターの襞折り加工の形態保持性
　３．５ｃｍピッチで襞折り加工したサンプルを、長さ約４０ｃｍ、幅２ｃｍに切断してフリー状態でぶら下げ、山部５点間の長さ（Ｌ１）を計測し、次いで、０．１ｇ／ｍ２・ｃｍの荷重を下端に掛けて６０分室温にて放置した後、荷重を除去した状態で、山部５点間の長さ（Ｌ２）を測定して、下記式にて伸張率を求める。（ｎ＝５）
　伸張率＝Ｌ２／Ｌ１
伸張率が１．５未満：◎、１．５～２：○、２を越える：×で評価した。
なお、○までが形態保持性がよいとした。 Preserving the shape of filter folds The sample folded at 3.5 cm pitch is cut to about 40 cm in length and 2 cm in width and hung in a free state, and the length (L1) between five points on the peak is measured. Then, after applying a load of 0.1 g / m 2 · cm to the lower end and leaving it at room temperature for 60 minutes, with the load removed, the length (L2) between the five peaks was measured. The elongation rate is obtained by the following formula. (N = 5)
Expansion rate = L2 / L1
The elongation ratio was evaluated as less than 1.5: １．５, 1.5-2: ◯, exceeding 2: x.
It should be noted that the shape retention is good up to ○.
＜実施例１＞
　固有粘度０．６５のポリエチレンテレフタレートを常法により紡糸温度２８５℃にて、単孔吐出量１ｇ／分孔にて、スパンボンド方式で繊度２ｄｔｅｘの長繊維からなる、目付３０ｇ／ｍ２の仮圧着ウエッブを巻取り、次いで、圧着面積率１５％相当のドットエンボスパターンローラーにて、ローラー温度２４５℃、線圧２９４．２N／ｃｍでエンボス加
工を施し、目付３０ｇ／ｍ２、圧着面積率１２％、見掛け密度１３５ｋｇ／ｍ３の不織布を得た。
　次いで、熱接着成分として、酢酸ビニル含有量２８重量％のエチレン酢酸ビニル共重合体－ポリエチレン水分散液（東洋インク製アクワシール：固形分重量比率４５重量％、固形分融点は１２０℃）を、グラビアコート法にて該不織布片面に２ｇ／ｍ２塗布して、多孔膜用支持体を得た。支持体の評価結果を表１に示す。 <Example 1>
Polyethylene terephthalate having an intrinsic viscosity of 0.65 at a spinning temperature of 285 ° C. in a conventional manner, by a single-hole discharge rate 1 g / minute holes, consisting of long fibers having a fineness 2dtex spunbond method, the temporary pressure bonding of basis weight 30 g / m 2 The web was wound up, and then embossed at a roller temperature of 245 ° C. and a linear pressure of 294.2 N / cm with a dot embossed pattern roller corresponding to a crimp area ratio of 15%, with a basis weight of 30 g / m 2 and a crimp area ratio of 12%. A nonwoven fabric having an apparent density of 135 kg / m 3 was obtained.
Next, an ethylene vinyl acetate copolymer-polyethylene aqueous dispersion with a vinyl acetate content of 28% by weight (Toyo Ink Aqua Seal: solid content weight ratio: 45% by weight, solid content melting point: 120 ° C.) as a thermal adhesive component, gravure 2 g / m 2 was applied to one side of the nonwoven fabric by a coating method to obtain a porous membrane support. The evaluation results of the support are shown in Table 1.
　次いで、厚み３００μｍ、幅１００ｍｍのテフロン（登録商標）フィルムを、２５０℃熱風乾燥機にて連続乾燥し、次いで、表面温度３００℃の熱ローラーを用い、１０倍延伸した。続いて、２１０℃のグリップテンターで、幅方向に２倍延伸を５回繰返し、厚み３０μｍ、平均孔径０．４μｍのテフロン（登録商標）多孔膜を作成した。
　引き続き、支持体の熱接着成分が多孔膜面に接するように、多孔膜の上下両面に支持体を供給しつつ、上下ローラー表面温度１４０℃のプレーンローラーを用いてカレンダー加工してフィルター材を作成した。
　作成したフィルター材は、襞折り加工機にて３．５ｃｍピッチの折り畳み構造を有する精密濾過用空気フィルターを作成した。得られた襞折り加工フィルターの形態保持性を表１に示す。 Next, a Teflon (registered trademark) film having a thickness of 300 μm and a width of 100 mm was continuously dried with a hot air dryer at 250 ° C., and then stretched 10 times using a hot roller having a surface temperature of 300 ° C. Subsequently, a Teflon (registered trademark) porous film having a thickness of 30 μm and an average pore diameter of 0.4 μm was prepared by repeating twice the stretching in the width direction 5 times with a grip tenter at 210 ° C.
Subsequently, while supplying the support to the upper and lower surfaces of the porous film so that the thermal adhesive component of the support is in contact with the porous film surface, the filter material is prepared by calendering using a plain roller with the upper and lower roller surface temperature of 140 ° C. did.
The produced filter material was an air filter for microfiltration having a folding structure with a pitch of 3.5 cm using a crease folding machine. Table 1 shows the shape retention of the obtained fold-folded filter.
＜実施例２＞
　熱接着成分を３ｇ／ｍ２付与した以外、実施例１と同様にして得られたフィルター用支持体及び襞折り加工したフィルター材の性能を表１に示す。 <Example 2>
Table 1 shows the performance of the filter support and the folded filter material obtained in the same manner as in Example 1 except that 3 g / m 2 of the thermal adhesive component was applied.
＜比較例１＞
　熱接着成分を０．５ｇ／ｍ２付与した以外、実施例１と同様にして得られたフィルター用支持体及び襞折り加工したフィルター材の性能を表１に示す。 <Comparative Example 1>
Table 1 shows the performance of the filter support and the folded filter material obtained in the same manner as in Example 1 except that 0.5 g / m 2 of the thermal adhesive component was applied.
＜比較例２＞
　固有粘度０．６５のポリエチレンテレフタレート及びエチレンテレフタレートとエチレンイソフタレートを共重合した融点１３０℃の共重合ポリエステルを用い、常法により複合紡糸機を用い、シースコア比５０：５０にて共重合ポリエステルをシース成分になるように紡糸し牽引ジェットにて牽引振り落として、目付４０ｇ／ｍ２のスパンボンドウエッブを得た。続いて、得られたウエッブは、ローラー温度１１０℃とした以外、実施例１と同様にしてエンボス加工し、目付４０ｇ／ｍ２、圧着面積率１８％、見掛け密度１６０ｋｇ／ｍ３の熱接着繊維からなるスパンボンド不織布を得た。
　得られた不織布のアウトガス量を表１に示す。
　次いで、多孔膜の両面に、得られた熱接着繊維からなる不織布を支持体として、実施例１と同様にフィルター材を作成し、襞折り加工して、襞折り加工したフィルター材を得た。　得られたフィルター材の形態保持性を表１に示す。 <Comparative Example 2>
Using polyethylene terephthalate having an intrinsic viscosity of 0.65 and copolymer polyester having a melting point of 130 ° C. obtained by copolymerizing ethylene terephthalate and ethylene isophthalate, a copolymer spinning machine is used in a conventional method using a compound spinning machine at a seascore ratio of 50:50. A spunbonded web having a basis weight of 40 g / m 2 was obtained by spinning to a sheath component and pulling it down with a traction jet. Subsequently, the obtained web was embossed in the same manner as in Example 1 except that the roller temperature was set to 110 ° C., and a thermal bonding fiber having a basis weight of 40 g / m 2 , a crimping area ratio of 18%, and an apparent density of 160 kg / m 3. A spunbond nonwoven fabric was obtained.
Table 1 shows the amount of outgas of the obtained nonwoven fabric.
Next, a filter material was prepared on the both surfaces of the porous membrane using the obtained non-woven fabric made of heat-bonding fibers as a support in the same manner as in Example 1, and folded to obtain a filter material that had been folded. Table 1 shows the shape retention of the obtained filter material.
＜比較例３＞
　実施例１で使用したエマルジョンを乾燥固化させ、熱接着成分樹脂を得た。得られた樹脂を溶融温度２３０℃でフィルムラミネート装置にて、実施例１で得たスパンボンド不織
布エンボス面に、１２ｇ／ｍ２となるよう押出ラミネートして、支持体を得た。次いで、得られた支持体を実施例１と同様にしてフィルター素材を作成し、襞折り加工してフィルターを作成した。得られた支持体及びフィルターの評価結果を表１に示す。 <Comparative Example 3>
The emulsion used in Example 1 was dried and solidified to obtain a thermal adhesive component resin. The obtained resin was extrusion laminated to the spunbond nonwoven fabric embossed surface obtained in Example 1 with a film laminator at a melting temperature of 230 ° C. so as to be 12 g / m 2 to obtain a support. Next, a filter material was prepared from the obtained support in the same manner as in Example 1, and the filter was formed by folding. Table 1 shows the evaluation results of the obtained support and filter.
＜比較例４＞
　比較例２で用いた共重合ポリエステルを熱接着成分として、溶融温度２００℃、付与量６ｇ／ｍ２となるようにした以外、比較例３と同様にして得られた支持体及びフィルターの評価結果を表１に示す。 <Comparative Example 4>
Evaluation results of the support and filter obtained in the same manner as in Comparative Example 3 except that the copolymerized polyester used in Comparative Example 2 was used as a thermal adhesive component and the melting temperature was 200 ° C. and the applied amount was 6 g / m 2. Is shown in Table 1.
＜比較例５＞
　実施例１で得た不織布に、酢酸ビニル成分が２０重量％共重合した、融点が７５℃のエチレン酢酸ビニル共重合体を熱接着成分として、溶融温度２００℃、付与量６ｇ／ｍ２となるようにした以外比較例３と同様にして得られた支持体及びフィルターの評価結果を表１に示す。 <Comparative Example 5>
The non-woven fabric obtained in Example 1 was copolymerized with 20% by weight of a vinyl acetate component, and an ethylene vinyl acetate copolymer having a melting point of 75 ° C. was used as a thermal bonding component, resulting in a melting temperature of 200 ° C. and an applied amount of 6 g / m 2. Table 1 shows the evaluation results of the support and the filter obtained in the same manner as in Comparative Example 3 except as described above.
＜比較例６＞
　目付１０ｇ／ｍ２の不織布ウエッブになるように引取りネット速度を早くした以外、実施例１と同様にして得られた支持体及びフィルターの評価結果を表１に示す。 <Comparative Example 6>
Table 1 shows the evaluation results of the support and the filter obtained in the same manner as in Example 1 except that the take-up net speed was increased so as to obtain a nonwoven fabric web having a basis weight of 10 g / m 2 .
＜比較例７＞
　目付１５０ｇ／ｍ２の不織布ウエッブになるように引取りネット速度を遅くした以外、実施例１と同様にして得られた支持体及びフィルターの評価結果を表１に示す。 <Comparative Example 7>
Table 1 shows the evaluation results of the support and the filter obtained in the same manner as in Example 1 except that the take-up net speed was reduced so as to obtain a nonwoven fabric web having a basis weight of 150 g / m 2 .
＜実施例３＞
　極限粘度１．１のポリブチレンテレフタレートを用い、常法により、紡糸温度２６０℃とした以外、実施例１と同様にして得た繊度２．２ｄｔｅｘ、目付３０ｇ／ｍ２仮圧着ウエッブを、次いで、エンボスローラー２１０℃とした以外実施例１と同様にして、熱接着成分を２ｇ／ｍ２塗布したフィルター用支持体を得た。得られた支持体のアウトガス発生量は２．１μｇ／ｇであった。次いで、実施例１と同様にして、多孔膜に支持体を接合して、襞折り加工したフィルターを得た。得られたフィルターの襞折り加工の形態保持性は合格点であった。 <Example 3>
Using a polybutylene terephthalate having an intrinsic viscosity of 1.1, a fineness of 2.2 dtex obtained in the same manner as in Example 1 except that the spinning temperature was 260 ° C., and a basis weight of 30 g / m 2 were used. A support for a filter coated with 2 g / m 2 of a thermal adhesive component was obtained in the same manner as in Example 1 except that the embossing roller was 210 ° C. The outgas generation amount of the obtained support was 2.1 μg / g. Next, in the same manner as in Example 1, a support was joined to the porous membrane to obtain a filter that was folded. The shape retention of the obtained filter in the folding process was a passing score.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　実施例１、２の支持体は、熱接着成分量が少ないので、低アウトガス量の支持体でありながら、形態保持性に優れたフィルターを得ることができる。
　比較例１の支持体は、熱接着成分量は少ないので、低アウトガス量の支持体ではあるが、形態保持性が劣るフィルターしか得ることができず好ましくない。
　比較例２の支持体は、多量の熱接着成分を含むので、アウトガスの発生量が多く、高性能フィルター用途には好ましくない。
　比較例３の支持体は、接合面の熱接着成分が多いので形態保持性は非常に優れているが、多量の熱接着成分を含むので、アウトガスの発生量が多くなり、高性能フィルター用途には好ましくない。
　比較例４の支持体は、熱接着成分が多いので、アウトガスの発生量が多くなり、脆い熱接着成分を用いているので形態保持性も劣り、高性能フィルター用途には好ましくない。
　比較例５の支持体は、柔軟な熱接着成分を用いているので形態保持性は良好だが、熱接着成分の融点が低く、アウトガスの発生量が多くなり、高性能フィルター用途では好ましくない。
　比較例６の支持体は、長繊維不織布の目付が低いので、襞折り加工性が劣り、形態保持性が劣るフィルターしか得ることができず好ましくない。
　比較例７の支持体は、長繊維不織布の目付が高いため、襞折り加工の形態保持性が劣るフィルターしか得ることができず好ましくない。
　実施例３の支持体は、アウトガスの発生量が少なく、襞折り加工したフィルターの形態保持性も優れたものである。 Since the support bodies of Examples 1 and 2 have a small amount of heat-adhesive components, it is possible to obtain a filter having excellent shape retention while being a support body having a low outgas amount.
Since the support of Comparative Example 1 is a low outgas amount support because the amount of the thermal adhesive component is small, it is not preferable because only a filter having poor shape retention can be obtained.
Since the support of Comparative Example 2 contains a large amount of a thermal adhesive component, it generates a large amount of outgas and is not preferable for high performance filter applications.
The support of Comparative Example 3 is very excellent in form retention because there are many thermal bonding components on the joint surface, but since it contains a large amount of thermal bonding components, the amount of outgas generated increases, and it is suitable for high performance filter applications. Is not preferred.
Since the support of Comparative Example 4 has a large amount of heat bonding components, the amount of outgas generated is large, and since a brittle heat bonding component is used, the shape retention is poor, which is not preferable for high performance filter applications.
Since the support of Comparative Example 5 uses a soft thermal adhesive component, the shape retention is good, but the melting point of the thermal adhesive component is low and the amount of outgas generated increases, which is not preferable for high performance filter applications.
The support of Comparative Example 6 is not preferable because the basis weight of the long-fiber nonwoven fabric is low, so that only a filter having poor fold-folding property and poor shape retention can be obtained.
Since the support of Comparative Example 7 has a high basis weight of the long-fiber non-woven fabric, it is not preferable because only a filter having inferior form-retaining property can be obtained.
The support of Example 3 has a small amount of outgas generation and is excellent in the shape retention of the folded filter.
本発明により、熱接着成分付与量を極限まで低減することにより、アウトガス量を下げ、同時に、使用する長繊維不織布の素材、諸物性および熱接着成分の組成を適正化し、支持体に柔軟かつ適度な剛直性を付与せしめることで、優れた襞折り加工の形態保持を有するフィルターを提供することができき、より高性能なクリーンシステムの構築が可能となり、フィルターの耐久性が優れるので、高度なクリーンシステムのメンテナンスも非常に容易であることからも、産業界に大きく寄与することが期待される。 According to the present invention, by reducing the amount of thermal adhesive component applied to the limit, the amount of outgas is reduced, and at the same time, the material of the long-fiber nonwoven fabric to be used, various physical properties and the composition of the thermal adhesive component are optimized, and the support is flexible and moderate. By imparting a high degree of rigidity, it is possible to provide a filter having excellent shape retention of the folding process, it is possible to construct a higher performance clean system, and the durability of the filter is excellent. Clean system maintenance is also very easy, which is expected to make a significant contribution to the industry.

Claims (6)

  1. 　ポリエステルからなる目付量が２０～１００ｇ／ｍ２で、圧着面積率が８～１８％のエンボス加工が施された長繊維不織布と、前記長繊維不織布の少なくとも片側の表面に、エチレン酢酸ビニル共重合体を含有した融点が１００℃～１４０℃である熱可塑性樹脂を熱接着成分として０．７～５．０ｇ／ｍ２付与されたフィルター用支持体。 A long-fiber non-woven fabric having a basis weight of 20 to 100 g / m 2 and an embossing process with a crimp area ratio of 8 to 18%, and at least one surface of the long-fiber non-woven fabric is coated with ethylene vinyl acetate A support for a filter provided with 0.7 to 5.0 g / m 2 of a thermoplastic resin having a melting point of 100 ° C. to 140 ° C. containing a coalescence as a thermal adhesive component.
  2. 　ポリエステルが、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリナフタレンテレフタレート、またはポリシクロヘキレンジメチルテレフタレートのいずれか１種を少なくとも９５モル％以上含有したポリエステルであり、フィルター用支持体の見掛け密度が１００～１５５ｋｇ／ｍ３である請求項１に記載のフィルター用支持体。 The polyester is a polyester containing at least 95 mol% of any one of polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, or polycyclohexylene diterephthalate, and the apparent density of the filter support is 100 to 155 kg / m. The filter support according to claim 1, which is 3 .
  3. 　熱接着成分が、１．０～３．０ｇ／ｍ２付与されている請求項１または２に記載のフィルター用支持体。 The filter support according to claim 1 or 2, wherein the thermal adhesive component is applied in an amount of 1.0 to 3.0 g / m 2 .
  4. 　多孔膜に、請求項１～３のいずれかに記載のフィルター用支持体の熱接着成分が付与された面が接合された多孔膜フィルター。 A porous membrane filter in which a surface to which a thermal adhesive component of the filter support according to any one of claims 1 to 3 is applied is bonded to the porous membrane.
  5. 　多孔膜の両面に、請求項１～３のいずれかに記載のフィルター用支持体の熱接着成分が付与された面が接合された多孔膜フィルター。 A porous membrane filter in which the surfaces to which the thermal adhesive component of the filter support according to any one of claims 1 to 3 is applied are bonded to both surfaces of the porous membrane.
  6. 　フィルターが襞折り加工された請求項４または５に記載の多孔膜フィルター。 The porous membrane filter according to claim 4 or 5, wherein the filter is folded.
PCT/JP2010/060069 2010-06-15 2010-06-15 Filter support body and filter using same WO2011158324A1 (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014156398A1 (en) * 2013-03-29 2014-10-02 日東電工株式会社 Method for producing air filter material, air filter material, and air filter pack

Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6463012A (en) * 1987-09-01 1989-03-09 Toyo Boseki Electret filter medium
JPH06198108A (en) * 1992-12-28 1994-07-19 Toray Ind Inc Composite filter material
JPH10286437A (en) * 1997-04-12 1998-10-27 Daikin Ind Ltd Clean air supply device and air-permeable member used for the same
JPH11156124A (en) * 1997-11-20 1999-06-15 Toyobo Co Ltd Honeycomb-shaped air cleaning filter
JP2003275519A (en) * 2002-03-19 2003-09-30 Toray Ind Inc Filter base material and filter
JP2003299924A (en) * 2002-04-05 2003-10-21 Toray Ind Inc Pleated filter material
JP2009028617A (en) * 2007-07-26 2009-02-12 Kureha Ltd Filter nonwoven fabric
JP2010121261A (en) * 2008-10-21 2010-06-03 Asahi Kasei Fibers Corp Laminated nonwoven fabric

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6463012A (en) * 1987-09-01 1989-03-09 Toyo Boseki Electret filter medium
JPH06198108A (en) * 1992-12-28 1994-07-19 Toray Ind Inc Composite filter material
JPH10286437A (en) * 1997-04-12 1998-10-27 Daikin Ind Ltd Clean air supply device and air-permeable member used for the same
JPH11156124A (en) * 1997-11-20 1999-06-15 Toyobo Co Ltd Honeycomb-shaped air cleaning filter
JP2003275519A (en) * 2002-03-19 2003-09-30 Toray Ind Inc Filter base material and filter
JP2003299924A (en) * 2002-04-05 2003-10-21 Toray Ind Inc Pleated filter material
JP2009028617A (en) * 2007-07-26 2009-02-12 Kureha Ltd Filter nonwoven fabric
JP2010121261A (en) * 2008-10-21 2010-06-03 Asahi Kasei Fibers Corp Laminated nonwoven fabric

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2014156398A1 (en) * 2013-03-29 2014-10-02 日東電工株式会社 Method for producing air filter material, air filter material, and air filter pack
JP2014208326A (en) * 2013-03-29 2014-11-06 日東電工株式会社 Manufacturing method of air filter medium, air filter medium, and air filter pack

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