WO2012086820A1 - 膜の支持体 - Google Patents
膜の支持体 Download PDFInfo
- Publication number
- WO2012086820A1 WO2012086820A1 PCT/JP2011/079950 JP2011079950W WO2012086820A1 WO 2012086820 A1 WO2012086820 A1 WO 2012086820A1 JP 2011079950 W JP2011079950 W JP 2011079950W WO 2012086820 A1 WO2012086820 A1 WO 2012086820A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- nonwoven fabric
- tensile strength
- support
- membrane
- width direction
- Prior art date
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- 239000012528 membrane Substances 0.000 title claims abstract description 113
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 152
- 239000000835 fiber Substances 0.000 claims abstract description 72
- 239000000853 adhesive Substances 0.000 claims description 56
- 230000001070 adhesive effect Effects 0.000 claims description 56
- 238000000926 separation method Methods 0.000 claims description 49
- 230000035699 permeability Effects 0.000 claims description 11
- 238000010030 laminating Methods 0.000 claims description 9
- 229920000728 polyester Polymers 0.000 claims description 9
- 229920000098 polyolefin Polymers 0.000 claims description 3
- 238000000034 method Methods 0.000 abstract description 47
- 238000004519 manufacturing process Methods 0.000 abstract description 11
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- ZMXDDKWLCZADIW-UHFFFAOYSA-N N,N-Dimethylformamide Chemical compound CN(C)C=O ZMXDDKWLCZADIW-UHFFFAOYSA-N 0.000 description 10
- 229920000642 polymer Polymers 0.000 description 9
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 9
- 238000003825 pressing Methods 0.000 description 8
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- 229920002492 poly(sulfone) Polymers 0.000 description 5
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- 239000000463 material Substances 0.000 description 4
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- 238000001035 drying Methods 0.000 description 3
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- FFBHFFJDDLITSX-UHFFFAOYSA-N benzyl N-[2-hydroxy-4-(3-oxomorpholin-4-yl)phenyl]carbamate Chemical compound OC1=C(NC(=O)OCC2=CC=CC=C2)C=CC(=C1)N1CCOCC1=O FFBHFFJDDLITSX-UHFFFAOYSA-N 0.000 description 2
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- 238000001223 reverse osmosis Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000000108 ultra-filtration Methods 0.000 description 2
- 239000004642 Polyimide Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 239000002518 antifoaming agent Substances 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
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- 239000013505 freshwater Substances 0.000 description 1
- 239000000499 gel Substances 0.000 description 1
- 238000001879 gelation Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
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- 229920001778 nylon Polymers 0.000 description 1
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Images
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
- B01D69/105—Support pretreatment
-
- 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
- B01D69/1213—Laminated layers
-
- 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
-
- 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
- B01D71/48—Polyesters
-
- 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
- B32B5/265—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 characterised by one fibrous or filamentary layer being a non-woven fabric layer
- B32B5/266—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 characterised by one fibrous or filamentary layer being a non-woven fabric layer next to one or more non-woven fabric layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2325/00—Details relating to properties of membranes
- B01D2325/04—Characteristic thickness
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2325/00—Details relating to properties of membranes
- B01D2325/20—Specific permeability or cut-off range
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2325/00—Details relating to properties of membranes
- B01D2325/24—Mechanical properties, e.g. strength
-
- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0253—Polyolefin fibres
-
- 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
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24628—Nonplanar uniform thickness material
Definitions
- the present invention relates to a membrane support that adheres a membrane to one adhesive surface, and more particularly to a membrane support that is optimal for attaching a separation membrane to an adhesive surface.
- Patent Document 1 a support having a two-layer structure in which a high-density nonwoven fabric and a low-density nonwoven fabric are laminated has been proposed as a support for a separation membrane.
- Patent Document 3 a support having a single-layer structure in which a high-density nonwoven fabric and a low-density nonwoven fabric are laminated.
- the rigidity of the support becomes weaker, and when the separation membrane is applied to one side of the support and provided, Due to the contraction, there is a problem that the curve in the width direction is large, that is, the curve is bent so that the central portion is concave. If the curvature in the width direction becomes large, it may cause problems such as inability to pass the line successfully in the next step of cutting the separation membrane into a flat plate and stacking it with the channel material.
- JP 60-238103 A Japanese Patent Laid-Open No. 61-222506 JP-A-10-225630 JP 2002-95937 A
- the present invention has been made to solve such conventional problems.
- the main object of the present invention is to support a membrane capable of reducing defects in the production line by suppressing the bending in the width direction in a state where the membrane is formed on the adhesive surface while reducing the basis weight of the support and reducing the basis weight.
- Another object of the present invention is to effectively prevent the film from being curled into a cylindrical shape due to the contraction of the film in a state where the film is formed on the adhesive surface, and to solve the problem in the next process of the production line. It is to provide a support.
- the support of the membrane of the present invention is a support in which the membrane 2 is attached to the adhesive surface 12, and a plurality of nonwoven fabric sheets 1 formed by three-dimensionally gathering fibers are laminated, and by heat and pressure treatment, The fibers of the nonwoven fabric sheet 1 are combined to form a sheet.
- the support is formed by laminating a plurality of nonwoven fabric sheets 1 having different tensile strength aspect ratios (k), which is the ratio (f2 / f1) of the tensile strength (f2) in the length direction to the tensile strength (f1) in the width direction.
- k tensile strength aspect ratios
- the length direction of a nonwoven fabric sheet is the length direction of the nonwoven fabric sheet manufactured by the sheet form of predetermined width
- the transfer direction of the nonwoven fabric sheet conveyed along a line is meant It shall be.
- the aspect ratio (k) of the tensile strength of the nonwoven fabric sheet is the tensile strength (f2) in the length direction (longitudinal direction) with respect to the tensile strength (f1) in the width direction (lateral direction) of the nonwoven fabric sheet. Ratio (f2 / f1).
- the above support is characterized in that, while reducing the basis weight of the support and making it thin, it suppresses bending in the width direction and reduces defects in the production line in a state where a film is formed on the adhesive surface. That is, the above-mentioned support is a state in which a plurality of laminated nonwoven fabric sheets are heat-pressed and bonded into a sheet shape, and the adhesive surface of the membrane is a plurality of nonwoven fabrics having different tensile strength ratios (f2 / f1). This is because by laminating the sheets, the sheet is curved in advance in the width direction so that the central portion is convex. This support is curved in the width direction by the heat and pressure treatment.
- the aspect ratio of the tensile strength which is the ratio (f2 / f1) of the tensile strength (f2) in the length direction to the tensile strength (f1) in the width direction. It is because the several nonwoven fabric sheet 1 from which (k) differs is laminated
- the ratio (f2 / f1) of the tensile strength (f2) in the length direction to the tensile strength (f1) in the width direction of the nonwoven fabric sheet is increased, the shrinkage force in the width direction due to the heat and pressure treatment increases.
- the adhesion surface is centered in the width direction.
- the support body in which the adhesive surface of the film is curved in the center convex in the width direction in advance is formed by forming a film on the adhesive surface which is the convex surface, and thereby shrinks when the applied film is cured.
- the bending in the width direction is offset, that is, the bending provided in the reverse direction by the heating and pressurizing treatment can suppress the bending in the width direction due to the contraction of the film, and reduce problems in the next process.
- the above support is curved by the difference in shrinkage in the width direction of the nonwoven fabric sheet, like a bimetal that is deformed by expansion and contraction, the difference in the aspect ratio (k) of the tensile strength of each nonwoven fabric sheet is adjusted.
- the bending in the width direction in the heat-pressed state can be controlled more precisely and the direction in which the bending is performed can be reliably and stably specified.
- the membrane 2 provided on the adhesive surface 12 can be a separation membrane.
- this support can suppress the inconvenience at the time of manufacturing the separation membrane by suppressing the adhesion surface from being bent into the central recess by contraction of the formed separation membrane.
- the nonwoven fabric sheet 1 can be laminated on the membrane support of the present invention.
- the above support body has the simplest structure, and the adhesive surface of the film can be curved in the central direction in the width direction while the basis weight of the support body is light and thin.
- the support of the film of the present invention can be obtained by making the nonwoven fabric sheet 1 into a wet papermaking nonwoven fabric.
- the above support has a feature that the fibers can be uniformly distributed over the entire support since the nonwoven sheet is subjected to wet papermaking.
- the support of the membrane of the present invention can make the nonwoven fabric sheet 1 a dry and three-dimensionally assembled nonwoven fabric.
- the above support has a feature that the strength of the entire support can be increased because the non-woven fabric sheet is three-dimensionally assembled in a dry manner.
- the membrane support of the present invention may include a nonwoven fabric in which the nonwoven fabric sheet 1 is wet-made and a nonwoven fabric that is three-dimensionally assembled in a dry manner.
- the difference in aspect ratio (k) of the tensile strength of the nonwoven fabric sheet 1 can be 1.5 or more, preferably 2.5 or more.
- the nonwoven fabric sheet 1 can be composed of polyester fibers or polyolefin fibers.
- the membrane support of the present invention has a basis weight of 50 to 100 g / m 2 , a thickness of 50 to 150 ⁇ m, and an air permeability of 0.3 to 6.0 cc / layer. It can be set to cm 2 / sec.
- a separation membrane in which a polymer membrane made of a polymer resin layer is provided on the adhesive surface of the support, for example, a microfiltration membrane, an ultrafiltration membrane, a nanofiltration membrane, a reverse osmosis membrane, or the like is optimal.
- These separation membranes are a process in which a polymer membrane is formed on the adhesive surface, and a force that curves the adhesive surface to a central recess acts due to shrinkage during curing of the applied polymer resin.
- the body has an adhesive surface that forms a polymer film curved in advance to the central convexity, a polymer resin layer is formed on this surface, and the adhesive surface becomes centrally concave due to shrinkage during curing of the polymer resin. Even if a bending force is applied to the substrate, the separation membrane is curved in the opposite direction, i.e., it is counteracted by the tensile force of the support that has the adhesive surface curved in the center, preventing the separation membrane from bending in the width direction.
- the support of the present invention does not necessarily need to be provided with a separation membrane on the adhesive surface, and a non-separation membrane, for example, an uncured paste-like plastic is applied and the plastic is cured.
- a film can be provided on the adhesive surface, and the support can be reinforced with this film, or the surface can be smoothed, or can be used for a support that is easy to slip.
- the support of the membrane is formed by three-dimensionally gathering the fibers in a wet or dry manner to form a nonwoven sheet, laminating a plurality of nonwoven sheets, and heating and pressurizing the laminated sheets to form the nonwoven sheet fibers. Combined to form a sheet.
- the nonwoven fabric sheet to be laminated so that the support body is curved in the width direction in a state in which a laminated sheet in which a plurality of nonwoven fabric sheets are laminated is heated and pressurized and processed into a sheet shape
- k aspect ratios of the tensile strength
- the tensile strength aspect ratio (k) is the tensile strength (f2) in the length direction / width direction. It is specified by the tensile strength (f1).
- the use of nonwoven fabric sheets with different tensile strength aspect ratios (k) results in a difference in shrinkage in the width direction of the nonwoven fabric sheets laminated by heat and pressure treatment. Is curved in the width direction.
- the nonwoven fabric sheet having a low tensile strength in the width direction that is, the aspect ratio (k) of the tensile strength is large.
- the nonwoven fabric sheet has a large shrinkage
- the nonwoven fabric sheet having a small tensile strength aspect ratio (k) has a small shrinkage and bends in the width direction due to the difference in shrinkage.
- a support in which a plurality of non-woven sheets are laminated and heat-pressed can control the curvature in the width direction more accurately by controlling the difference in the aspect ratio (k) of the tensile strength of each non-woven sheet. .
- the curvature in the width direction can be increased by increasing the difference in the aspect ratio (k) of the tensile strength, and conversely, the curvature can be decreased by decreasing the difference in the aspect ratio (k) of the tensile strength.
- the film attached to the adhesive surface of the support shrinks when cured, causing the support to bend.
- Nonwoven sheets are manufactured by various manufacturing methods such as dry and wet.
- the nonwoven fabric sheet is preferably produced by mixing main fibers and binder fibers.
- Synthetic fibers such as polyester fiber, polyolefin fiber, nylon fiber, aramid fiber, polyphenylene sulfide fiber, polyvinyl alcohol fiber, etc. can be used alone or in combination as the main fiber and binder fiber used in the nonwoven fabric sheet. it can.
- Nonwoven fabric sheets containing these binder fibers can be made tough by heating and pressing to bond the fibers at intersections.
- a nonwoven fabric sheet can also be manufactured without adding a binder fiber. However, the support obtained by heating and pressurizing the nonwoven fabric sheet to which the binder fiber is added improves the strength by welding the intersection of the fiber to the fiber, and the surface becomes smooth. More preferred.
- polyester fiber is preferably used.
- the use of polyester binder fibers is optimal from the comprehensive viewpoints such as mechanical strength, suitability for heat processing, and cost.
- a low melting point polyester fiber, an unstretched polyester fiber or the like can be used as the polyester binder fiber.
- the melting point of the polyester binder fiber is preferably in the range of 110 to 260 ° C. at a lower temperature than that of the main fiber.
- the amount of binder fiber to be mixed should be determined in consideration of the degree of binding of the main fibers.
- the content is preferably 20 to 80% by weight, more preferably 30 to 70% by weight.
- the fibers constituting the nonwoven fabric sheet are suitably those having a fiber diameter of 3 to 30 ⁇ m, preferably 5 to 20 ⁇ m, and a fiber length of 1 to 25 mm, preferably 3 to 15 mm.
- the support has a basis weight of 50 to 100 g / m 2 , a total thickness of 50 to 150 ⁇ m, and an air permeability of 0.3 in a state where a plurality of nonwoven fabric sheets are laminated and heated and pressurized. It is set to -6.0cc / cm ⁇ 2 > / sec.
- the nonwoven fabric sheet is manufactured by various manufacturing methods such as a wet type or a dry type with the above-mentioned mixing amount.
- the nonwoven fabric sheet manufactured by the wet method is characterized in that the fibers can be uniformly distributed as a whole.
- the present invention can use a nonwoven fabric sheet produced by a dry process or other methods.
- stacked mutually can also laminate
- the main fiber and binder fiber are first uniformly dispersed in water, and then the final fiber concentration is adjusted to 0.01 to 0.50% by weight through the steps of screen (removal of foreign matter, lumps, etc.). And paper making.
- chemicals such as a dispersion aid, an antifoaming agent, a hydrophilic agent, and an antistatic agent may be added in the process.
- a non-woven fabric sheet produced by a wet process can be obtained by laminating a plurality of non-woven fabric sheets produced separately by a paper machine, heat-pressing them, and combining them into a single sheet to form a support.
- stacking the several nonwoven fabric sheet manufactured by the wet has the feature which can be made more uniform.
- bonds it in the sheet form is made into the nonwoven fabric sheet to laminate
- a non-woven fabric sheet manufactured in a wet process is made by laminating and laminating a plurality of non-woven fabric sheets in a paper making process, and heating and pressurizing one non-woven fabric sheet laminated in a plurality of layers to form a support. You can also.
- This nonwoven fabric sheet can be laminated by laminating a plurality of nonwoven fabric sheets together by one or several types of systems such as a circular mesh, a short mesh, a long mesh, a slanted wire mesh, and a suction former.
- the support body in which a plurality of non-woven sheets are laminated and laminated in the paper making process and the non-woven sheet is heated and pressurized is also characterized by being uniform throughout.
- the support is provided with a difference in the aspect ratio (k) of the tensile strength in the length direction and the width direction of each nonwoven fabric sheet laminated in the paper making process in which a plurality of nonwoven fabric sheets are joined together. It is bent in the width direction by the difference in contraction force in the pressure treatment.
- the respective nonwoven fabric sheets laminated together are adjusted in the paper making process so that the aspect ratio (k) of the tensile strength becomes a predetermined value.
- the aspect ratio (k) of the tensile strength of the nonwoven fabric sheet it is suitable to make paper on an inclined wire mesh.
- the aspect ratio (k) of the tensile strength can be adjusted by adjusting the concentration of the raw material dispersion, the water flow velocity, the wire speed of the inclined wire mesh, the angle of inclination, and the like.
- the nonwoven fabric sheet gathers fibers so that the fiber orientation in the length direction is stronger than the orientation in the width direction, thereby increasing the tensile strength in the length direction and weakening the tensile strength in the width direction.
- the aspect ratio (k) of the tensile strength can be increased.
- a non-woven fabric sheet produced by a wet method can make a paper using a circular net, a short net, a long net, a suction former or the like to adjust the difference in the aspect ratio (k) of the tensile strength.
- Non-woven fabric sheet manufactured by dry process is manufactured by combining one kind or several kinds such as chemical bond, thermal bond, spun lace, needle punch, stitch bond, spun bond, and melt blow. Furthermore, a non-woven fabric sheet manufactured by a dry process is manufactured by supplying fibers without directionality on a moving belt. This nonwoven fabric sheet has a tensile strength that is the ratio (f2 / f1) of the tensile strength (f2) in the longitudinal direction to the tensile strength (f1) in the width direction due to the moving speed of the belt and the directionality of the fibers supplied to the belt. Controls the aspect ratio (k).
- the fibers are assembled so that the fiber orientation in the length direction is stronger than the orientation in the width direction, and the tensile strength in the length direction is increased,
- the aspect ratio (k) of the tensile strength can be increased.
- the nonwoven fabric sheet when the aspect ratio (k) of the tensile strength is increased, the shrinkage force in the width direction by the heat and pressure treatment is increased. This is because the tensile strength in the length direction is stronger than the tensile strength in the width direction, so that in the state where the binder fibers are joined at the intersection in the heat and pressure treatment, it becomes easier to shrink in the width direction than in the length direction. is there. Furthermore, the nonwoven fabric sheets laminated on each other are curved in the width direction in a state where they are heated and pressurized and bonded into a sheet shape by giving a difference of a predetermined value or more in the aspect ratio (k) of the tensile strength.
- the shrinkage force of each nonwoven fabric sheet is balanced and curved in the width direction in a state where the nonwoven fabric sheets are bonded together by heating and pressing. It will not be done.
- the support of the present invention heats and pressurizes the laminated nonwoven sheets by subjecting the laminated nonwoven sheets to a central convex shape in the width direction by heating and pressing the laminated nonwoven sheets. In the state of pressure treatment, a force that contracts in the width direction acts on both the bonding surface and the opposing surface.
- the shrinking force acting on the facing surface is adjusted to be larger than the shrinking force acting on the bonding surface
- the facing surface side of the support is curved in a central recess in the width direction, and the bonding surface side is widened. Curve in a central convex direction. Therefore, the nonwoven fabric sheets laminated on each other are laminated on the surface which becomes the opposite surface which is the surface opposite to the adhesive surface, rather than the aspect ratio (k1) of the tensile strength of the nonwoven fabric sheet laminated on the surface which becomes the adhesive surface.
- the aspect ratio (k2) of the tensile strength of the nonwoven fabric sheet is made larger than the shrinkage force acting on the adhesive surface.
- the support body controls the curvature in the width direction in the shrinkage that has been subjected to the heat and pressure treatment by the difference in the aspect ratio (k) of the tensile strength of the laminated nonwoven fabric sheet. If the difference in the aspect ratio (k) of the tensile strength of the nonwoven fabric sheets to be laminated is too small, the curvature in the width direction of the support itself is reduced, and the curvature due to film contraction cannot be offset. Therefore, the difference in the aspect ratio (k) of the tensile strength of the laminated nonwoven fabric sheet is preferably 1.5 or more, more preferably 2.5 or more.
- the difference in the aspect ratio (k) of the tensile strength of the nonwoven fabric sheets to be laminated is preferably 15 or less, more preferably 10 or less.
- the difference in the aspect ratio (k) of the tensile strength of the nonwoven fabric sheet is set to an optimum value in consideration of the shrinkage of the film to be formed.
- the nonwoven fabric sheet produced in a wet manner has an aspect ratio (k) of tensile strength that is greater than 1 in most cases
- the aspect ratio (k1) of tensile strength of the nonwoven fabric sheet laminated on the opposite side of the adhesive surface is 2 .5 or more, preferably 3.5 or more
- the shrinkage force in the heat-pressed state is increased
- the aspect ratio (k2) of the tensile strength of the nonwoven fabric sheet on the adhesive surface is laminated on the opposite side.
- the adhesive surface is curved in the central direction in the width direction so as to be 1.5 or more, preferably 2.5 or more smaller than the aspect ratio (k1) of the tensile strength of the nonwoven fabric sheet.
- FIG. 1 shows an example of a hot-pressure processing facility 20. This figure has shown the state which carries out a heating-pressing process continuously, conveying the two nonwoven fabric sheets 1 laminated
- a heating roll 21 and an elastic roll 22 In the hot-pressure processing equipment 20 shown in the figure, two rolls that are transported with the nonwoven fabric sheet 1 interposed therebetween are used as a heating roll 21 and an elastic roll 22.
- This hot-pressure processing equipment 20 adjusts the surface temperature of the heating roll 21, the clamping force between the heating roll 21 and the elastic roll 22, and the transfer speed of the nonwoven fabric sheet 1, that is, the degree of heating and pressing by adjusting the pressing time. I have control. However, the heat and pressure processing equipment can be transferred while being sandwiched between two heating rolls and subjected to heat and pressure treatment.
- the surface temperature of the heating roll 21 is 150 to 260 ° C., preferably 200 to 250 ° C.
- the pressure between the heating roll 21 and the elastic roll 22 is 40 to 250 kg / cm, preferably 100 to 200 kg / cm
- the transfer rate of the nonwoven fabric sheet 1 is 10 to 100 m / min, preferably 20 to 60 m / min, and is heated and pressurized.
- the surface temperature of the heating roll, the clamping force of the two rolls, and the transfer speed of the nonwoven fabric sheet are adjusted according to the required support specifications.
- the heat input becomes strong, and conversely, the surface temperature of the heating roll and the sandwiching force of the roll are low, and the nonwoven fabric
- heat input is weakened.
- An optimal support can be obtained by adjusting the above conditions well and adjusting the thickness and blending ratio of the raw material fibers used in the papermaking process.
- FIG. 2 and FIG. 3 show a state in which two nonwoven fabric sheets 1 having a difference in aspect ratio (k) of tensile strength are laminated, and this laminated sheet is heated and pressed to be combined into a sheet shape.
- molded support body 10 curves in the width direction is shown.
- the aspect ratio (k1) of the tensile strength of the first nonwoven fabric sheet 1A laminated on the surface that becomes the facing surface 11 is the tensile strength of the second nonwoven fabric sheet 1B laminated on the surface that becomes the adhesive surface 12.
- the strength is adjusted to be larger than the aspect ratio (k2), and as shown by arrows A and B in FIG.
- the contraction force (indicated by arrow A) on the facing surface 11 side is the adhesion surface 12 side. 3 and is curved in the width direction with the adhesive surface 12 as a central convex and the opposing surface 11 as a central concave, as shown in FIG. 3 (b).
- stack is made into two sheets, and the 1st nonwoven fabric sheet 1A laminated
- a state is shown in which a single support 10 is formed by pressure treatment and bonding to each other.
- the support is not shown, but three or more nonwoven fabric sheets can be laminated and subjected to heat and pressure treatment, and these can be combined with each other to form a support.
- This support has an aspect ratio (k1) of the tensile strength of the first nonwoven fabric sheet laminated on the opposite surface side and an aspect ratio (k2) of the tensile strength of the second nonwoven fabric sheet laminated on the adhesive surface side.
- the bending state in the width direction of the support can be adjusted by adjusting the aspect ratio (k3) of the tensile strength of the intermediate nonwoven fabric sheet laminated in the middle.
- the heat and pressure treatment is performed simultaneously in a state where a plurality of nonwoven fabric sheets are laminated, but the plurality of nonwoven fabric sheets laminated to each other are subjected to heat and pressure processing as a pre-process.
- a pre-process can also be used. That is, a nonwoven fabric sheet that has been preliminarily heated and pressed can be combined with a nonwoven fabric sheet that has not been heated and pressed, and then heated and pressurized.
- the support manufactured as described above is provided with the film 2 attached to the adhesive surface 12 in the film forming process.
- 4 and 5 show a process of applying a polymer solution 31 to the adhesive surface 12 and providing the semipermeable membrane 2A on this surface in a general film forming process facility 30.
- FIG. As shown in this figure, while rotating the support 10 along the drum 32, the polymer solution 31 is attached to the surface of the convex surface which is the adhesive surface 12 in the form of a film.
- the polymer solution 31 is filled in a hopper 33 disposed above the drum 32. The lower end of the hopper 33 is brought close to the adhesive surface 12 of the support 10 so that the polymer solution 31 does not leak from the boundary with the support 10.
- the support 10 In order to cure the polymer solution 31 applied to the support 10, the support 10 is separated from the drum 32 and introduced into the coagulation tank 35.
- the support 10 introduced into the coagulation tank 35 is conveyed to the transfer roll 34 and immersed in the coagulation tank 35.
- polysulfone dissolved in N, N-dimethylformamide (DMF) at a concentration of 16.5% by weight can be used. Since this polymer solution 31 has a property that polysulfone gels and solidifies when it comes into contact with water, it is immersed in a coagulation tank 35 containing water to be gelled. After that, the support 10 that has passed through the coagulation tank 35 is immersed in the cleaning tank 36 and coagulated while cleaning the remaining DMF. As described above, a 20 to 100 ⁇ m polysulfone layer is provided as the semipermeable membrane 2A on the adhesive surface 12 of the support 10.
- DMF N, N-dimethylformamide
- the support 10 is curved in the width direction on the adhesive surface 12 side by the contraction force (indicated by an arrow C) of the semipermeable membrane 2A formed on the adhesive surface 12. try to.
- the support is greatly curved in the width direction, and it may not be possible to carry the roll well.
- the film 2 is curved in advance in a direction opposite to the bending direction due to the shrinkage at the time of curing of the film 2, that is, the adhesive surface 12 is centrally convex in the width direction.
- the support 10 in which the adhesive surface 12 is curved in the reverse direction in advance is formed by forming the film 2 on the adhesive surface 12 that is a convex surface, so that the width of the applied film 2 due to shrinkage at the time of curing is applied.
- the bending in the direction is offset, and the bending in the width direction due to the contraction force of the film 2 is suppressed. That is, the bending provided in the reverse direction by the heat and pressure treatment suppresses the bending in the width direction due to the contraction of the film and prevents the support 10 from being greatly bent.
- membrane 2 can perform roll conveyance smoothly.
- an active layer (skin layer) is coated on the surface of the semipermeable membrane 2A.
- cellulose-based materials such as cellulose acetate, polyamide-based materials, polyimide-based materials, and the like are used depending on applications.
- the active layer is deposited thinner than the semipermeable membrane.
- the semipermeable membrane before coating the active layer is said to be a microfiltration membrane or ultrafiltration membrane, and the semipermeable membrane at the stage where the active layer is coated is called a nanofiltration membrane or reverse osmosis membrane. .
- nanofiltration membrane or reverse osmosis membrane There are many uses in various fields such as fresh water, dairy, food, medicine, chemistry, nuclear industry, dyeing and processing, and it can be used as a support for each semipermeable membrane.
- Nonwoven sheet making process 1 56% stretched polyethylene terephthalate (PET) fiber having a fiber diameter of 7 ⁇ m and a fiber length of 5 mm and 44% unstretched PET fiber having a fiber diameter of 11 ⁇ m and a fiber length of 5 mm were sufficiently dispersed in water in a chest, Adjusting the aspect ratio (k) of the tensile strength by adjusting the aqueous slurry with a fiber concentration of 0.05%, sending it to the inclined wire mesh paper machine, and adjusting the water flow rate of the aqueous slurry and the paper speed of the inclined wire mesh.
- a base paper A of a wet nonwoven fabric sheet formed by three-dimensionally gathering fibers was made.
- the tensile strength tester (f2) in the length direction (longitudinal direction) and the tensile strength in the width direction (transverse direction) are used in a tensile tester that cuts the produced base paper A into a width of 50 mm and sets the distance between grips to 180 mm.
- (F1) was measured, and the aspect ratio (k) of the tensile strength, which is the ratio (f2 / f1) of the tensile strength (f2) in the length direction to the tensile strength (f1) in the width direction, was obtained.
- This base paper A had a basis weight of 38 g / m 2 and an aspect ratio (k) of tensile strength of 6.7.
- Nonwoven sheet making process 2 60% stretched PET fiber having a fiber diameter of 12 ⁇ m and a fiber length of 5 mm and 40% of unstretched PET fiber having a fiber diameter of 11 ⁇ m and a fiber length of 5 mm were sufficiently dispersed in water in a chest to obtain a fiber concentration of 0.05 % Of the aqueous slurry is sent to a slanted wire mesh paper machine, and the water flow rate of the aqueous slurry and the slanted wire mesh papermaking speed are adjusted to adjust the aspect ratio (k) of the tensile strength and the three-dimensional fiber.
- the base paper F of the wet nonwoven fabric sheet formed by assembly was made.
- the tensile strength tester (f2) in the length direction (longitudinal direction) and the tensile strength in the width direction (transverse direction) are used in a tensile tester that cuts the base paper F into 50 mm width and sets the distance between grips to 180 mm.
- (F1) was measured, and the aspect ratio (k) of the tensile strength, which is the ratio (f2 / f1) of the tensile strength (f2) in the length direction to the tensile strength (f1) in the width direction, was obtained.
- This base paper F had a basis weight of 38 g / m 2 and an aspect ratio (k) of tensile strength of 1.8.
- the support of Example 1 obtained as described above had a basis weight of 78 g / m 2 , a thickness of 93 ⁇ m, and an air permeability of 0.8 cc / cm 2 / sec.
- the tensile strength tester (f2) in the length direction (longitudinal direction) and the tensile strength in the width direction (lateral direction) were measured using a tensile tester in which the support was cut to a width of 15 mm and the distance between the grips was set to 180 mm.
- (f1) was measured and the aspect ratio (k) of the tensile strength was determined, it was 3.5.
- this support was cut into a sheet having a size of 400 mm (width) ⁇ 1000 mm (length), and the degree of bending in the width direction was confirmed.
- the surface on the base paper F side was curved in a central convex in the width direction
- the surface on the base paper A side was curved in a central concave in the width direction.
- a photograph of this support is shown in FIG. However, this photograph shows a state where the support is placed on a horizontal base with the base paper F side as the bottom surface and the base paper A side as the top surface. As can be seen from this photograph, the obtained support was curved with both edges in the width direction floating about 20 mm from the upper surface of the table.
- aspect ratio of the tensile strength in m 2 and (k) 6.7 base paper a the aspect ratio of the tensile strength at a basis weight 38 g / m 2 (k) has papermaking 3.6 of base paper E.
- the obtained two non-woven sheets (base paper A and base paper E) are laminated, and the heat and pressure processing equipment 20 in which the heating roll 21 and the elastic roll 22 are combined is subjected to heat and pressure treatment under the same conditions as in Example 1.
- the laminated nonwoven fabric sheets were combined into a sheet shape.
- the support of Example 2 obtained as described above had a basis weight of 78 g / m 2 , a thickness of 93 ⁇ m, and an air permeability of 0.7 cc / cm 2 / sec.
- the tensile strength tester (f2) in the length direction (longitudinal direction) and the tensile strength in the width direction (lateral direction) were measured using a tensile tester in which the support was cut to a width of 15 mm and the distance between the grips was set to 180 mm.
- (f1) was measured and the aspect ratio (k) of the tensile strength was determined, it was 4.5.
- this support was cut into a sheet having a size of 400 mm (width) ⁇ 1000 mm (length), and the degree of bending in the width direction was confirmed.
- the surface on the base paper E side was curved in a central convex in the width direction
- the surface on the base paper A side was curved in a central concave in the width direction.
- aspect ratio of the tensile strength in m 2 (k) and the base paper B 3.6, the aspect ratio of tensile strength at a basis weight 38g / m 2 (k) has papermaking base paper F of 1.8.
- the obtained two non-woven sheets (base paper A and base paper F) are laminated, and the heat and pressure processing equipment 20 in which the heating roll 21 and the elastic roll 22 are combined, heat and pressure treatment is performed under the same conditions as in Example 1.
- the laminated nonwoven fabric sheets were combined into a sheet shape.
- the support of Example 3 obtained as described above had a basis weight of 78 g / m 2 , a thickness of 93 ⁇ m, and an air permeability of 0.9 cc / cm 2 / sec.
- the tensile strength tester (f2) in the length direction (longitudinal direction) and the tensile strength in the width direction (lateral direction) were measured using a tensile tester in which the support was cut to a width of 15 mm and the distance between the grips was set to 180 mm.
- (f1) was measured and the aspect ratio (k) of the tensile strength was determined, it was 2.6.
- this support was cut into a sheet having a size of 400 mm (width) ⁇ 1000 mm (length), and the degree of bending in the width direction was confirmed.
- the surface on the base paper F side was curved in a central convex in the width direction
- the surface on the base paper B side was curved in a central concave in the width direction.
- the obtained two non-woven sheets (base paper A and base paper D) are laminated, and the heat and pressure processing equipment 20 in which the heating roll 21 and the elastic roll 22 are combined is subjected to heat and pressure treatment under the same conditions as in Example 1.
- the laminated nonwoven fabric sheets were combined into a sheet shape.
- the support of Comparative Example 1 obtained as described above had a basis weight of 79 g / m 2 , a thickness of 92 ⁇ m, and an air permeability of 0.5 cc / cm 2 / sec.
- the tensile strength tester (f2) in the length direction (longitudinal direction) and the tensile strength in the width direction (lateral direction) were measured using a tensile tester in which the support was cut to a width of 15 mm and the distance between the grips was set to 180 mm.
- (f1) was measured and the aspect ratio (k) of the tensile strength was determined, it was 5.7.
- the support was cut into a sheet having a size of 400 mm (width) ⁇ 1000 mm (length), and the degree of bending in the width direction was confirmed, but this support was bent in the width direction. It wasn't.
- the base sheet B of the wet non-woven sheet is made by adjusting the aspect ratio (k) of the tensile strength to 3.6, and in the non-woven sheet making process 2, the aspect ratio of the tensile strength
- the aspect ratio (k) of the tensile strength is 3 at a basis weight of 38 g / m 2 in the same manner as in Example 1 except that the base paper E of the wet nonwoven fabric sheet is prepared by adjusting so that (k) is 3.6.
- a base paper B having a basis weight of 38 g / m 2 and a tensile strength aspect ratio (k) of 3.6 was made.
- the obtained two non-woven sheets (base paper B and base paper E) are laminated, and the heat and pressure processing equipment 20 in which the heating roll 21 and the elastic roll 22 are combined is subjected to heat and pressure treatment under the same conditions as in Example 1.
- the laminated nonwoven fabric sheets were combined into a sheet shape.
- the support of Comparative Example 2 obtained as described above had a basis weight of 78 g / m 2 , a thickness of 92 ⁇ m, and an air permeability of 0.8 cc / cm 2 / sec.
- the tensile strength tester (f2) in the length direction (longitudinal direction) and the tensile strength in the width direction (lateral direction) were measured using a tensile tester in which the support was cut to a width of 15 mm and the distance between the grips was set to 180 mm.
- (f1) was measured and the aspect ratio (k) of tensile strength was determined, it was 3.7.
- the support was cut into a sheet having a size of 400 mm (width) ⁇ 1000 mm (length), and the degree of bending in the width direction was confirmed, but this support was bent in the width direction. It wasn't.
- aspect ratio of the tensile strength in m 2 (k) and the base paper C of 1.8, the aspect ratio of tensile strength at a basis weight 38g / m 2 (k) has papermaking base paper F of 1.8.
- the obtained two non-woven sheets (base paper C and base paper F) are laminated, and heat and pressure processing equipment 20 in which the heating roll 21 and the elastic roll 22 are combined is subjected to heat and pressure treatment under the same conditions as in Example 1.
- the laminated nonwoven fabric sheets were combined into a sheet shape.
- the support of Comparative Example 3 obtained as described above had a basis weight of 79 g / m 2 , a thickness of 94 ⁇ m, and an air permeability of 1.0 cc / cm 2 / sec.
- the tensile strength tester (f2) in the length direction (longitudinal direction) and the tensile strength in the width direction (lateral direction) were measured using a tensile tester in which the support was cut to a width of 15 mm and the distance between the grips was set to 180 mm.
- (f1) was measured and the aspect ratio (k) of the tensile strength was determined, it was 1.8.
- the support was cut into a sheet having a size of 400 mm (width) ⁇ 1000 mm (length), and the degree of bending in the width direction was confirmed, but this support was bent in the width direction. It wasn't.
- Table 1 shows the physical properties of the supports obtained in Examples 1 to 3 and Comparative Examples 1 to 3.
- a separation membrane was provided on the adhesive surfaces of the supports obtained in Examples 1 to 3 and Comparative Examples 1 to 3 as follows.
- the supports of Examples 1 and 3 have the surface on the base paper F side as the adhesive surface
- the support of Example 2 has the surface on the base paper E side as the adhesive surface
- the support of Comparative Examples 1 to 3 The body was provided with a separation membrane by the general film forming process equipment 30 shown in FIG. 4 with the surfaces of the base paper D side, base paper E side, and base paper F side as adhesive surfaces.
- a polymer solution in which polysulfone is dissolved in N, N-dimethylformamide (DMF) at a concentration of 16.5% is applied to the adhesive surface of the support, and immersed in a coagulation tank containing water. Gelation was then performed, and the remaining DMF was immersed in a washing tank and solidified while washing, and a separation membrane was provided on the adhesive surface.
- a polysulfone layer having a thickness of 35 ⁇ m was laminated on the adhesive surfaces of the supports of Examples 1 to 3 and Comparative Examples 1 to 3 to provide a separation membrane.
- Example 1 As can be seen from the photograph of FIG. 7, the support of Example 1 is in a state where both edges in the width direction are lifted by about 20 mm from the upper surface of the table, with the separation membrane stacking surface as the upper surface. It was only curved. This support was able to pass through the next process without any problems, and no problems occurred.
- Example 2 The support of Example 2 was curved in such a manner that both edges in the width direction floated about 25 mm from the top surface of the table with the separation membrane stacking surface as the top surface and placed on a horizontal table. I was able to pass through and there was no problem.
- Example 3 The support of Example 3 was curved in a state where both edges in the width direction floated about 30 mm from the upper surface of the table with the separation membrane stacking surface as the upper surface and placed on a horizontal table. I was able to pass through and there was no problem.
- the support of Comparative Example 1 was placed on a horizontal table with the separation membrane stacking surface as the upper surface, and the separation membrane contracted to move from both ends in the width direction toward the center. Then, it was curled into a cylinder having a diameter of about 30 mm with the separation membrane inside. This support was curled into a cylindrical shape, and thus failed to pass the next process well, resulting in problems.
- the support of Comparative Example 2 was placed on a horizontal table with the separation membrane stacking surface as the upper surface, and the separation membrane contracted to move from both ends in the width direction toward the center. Then, it was curled into a cylinder having a diameter of about 35 mm with the separation membrane inside. This support was curled into a cylindrical shape, and thus failed to pass the next process well, resulting in problems.
- the support of Comparative Example 3 was placed on a horizontal table with the separation membrane stacking surface as the upper surface, and the separation membrane contracted to move from both ends in the width direction toward the center. Then, it was curled into a cylinder having a diameter of about 40 mm with the separation membrane inside. This support was curled into a cylindrical shape, and thus failed to pass the next process well, resulting in problems.
- the degree of curvature in the width direction of the supports of Examples 1 to 3 and Comparative Examples 1 to 3 on which the separation membrane was formed hardly occurred in the supports of Examples 1 to 3.
- Comparative Examples 1 to 3 the curl increased in the order of Comparative Example 3, Comparative Example 2, and Comparative Example 1.
- the support of the example has a tensile strength higher than that of the support of comparative example 3.
- the aspect ratio (k) is large, and the support of Example 1 is the same as the support of Example 2 although the support of Example 1 and the support of Comparative Example 2 have the same aspect ratio (k) of tensile strength.
- the bending in the width direction when the separation membrane was laminated on the adhesive surface was extremely reduced. Also from this result, it can be inferred that the adhesive surface of the support is preliminarily curved centrally in the width direction.
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- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
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- Orthopedics, Nursing, And Contraception (AREA)
Abstract
Description
しかしながら、この方法によっても、支持体の坪量および製膜条件によっては、十分に幅方向の湾曲を軽減できずに、次工程で不具合を生じる問題点があった。とくに、分離膜を所定の大きさの平板状にカットする状態では、分離膜が筒状にカールされやすくなり、これにより、次工程でラインを上手く通過できない等の不具合を解消できない場合があった。
さらに、本発明の他の目的は、接着面に膜が形成された状態で、膜の収縮によって筒状にカールされるのを有効に防止して、製造ラインの次工程における不具合を解消できる膜の支持体を提供することにある。
なお、本明細書において、不織布シートの長さ方向とは、所定の幅のシート状に製造される不織布シートの長さ方向であって、ラインに沿って移送される不織布シートの移送方向を意味するものとする。さらに、本明細書において、不織布シートの引張強度の縦横比(k)とは、不織布シートの幅方向(横方向)の引張強度(f1)に対する長さ方向(縦方向)の引張強度(f2)の比率(f2/f1)を意味している。
この支持体は、接着面に分離膜を形成する状態で、形成される分離膜の収縮によって、接着面が中央凹に湾曲するのを抑制して、分離膜の製造時における不具合を解消できる。
以上の支持体は、最も簡単な構造で、支持体の坪量を軽く、薄くしながら、膜の接着面を幅方向に中央凸に湾曲させることができる。
以上の支持体は、不織布シートを湿式抄紙するので、支持体の全体にわたって繊維を均一に分布できる特徴がある。
以上の支持体は、不織布シートを乾式で立体的に集合するので、支持体全体の強度を強くできる特徴がある。
ここで、積層される不織布シートには、引張強度の縦横比(k)が異なるものを使用するが、引張強度の縦横比(k)は、長さ方向の引張強度(f2)/幅方向の引張強度(f1)で特定される。
一般的に、活性層をコーティングする前の段階の半透膜が精密濾過膜、限外濾過膜と言われ、活性層をコーティングした段階の半透膜がナノ濾過膜、逆浸透膜と言われる。
用途としては、造水、酪農、食品、医薬、化学、原子力工業、染色加工業等、多分野に多種用途があり、各々の半透膜の支持体として使用することができる。
なお、以下の例の物性は次のようにして求めた。また、以下の例において、%は特に断らない限り、重量%を意味する。
《坪量》JIS P 8124に準拠して測定した。
《厚さ》JIS P 8118に準拠して測定した。
《引張強度》JIS P 8113に準拠して測定した。
《引張強度の縦横比(k)》JIS P 8113に準拠して不織布シートの長さ方向(縦方向)の引張強度(f2)と幅方向(横方向)の引張強度(f1)を測定し、以下の式に基づいて引張強度の縦横比(k)を求めた。
引張強度の縦横比(k)=長さ方向の引張強度(f2)/幅方向の引張強度(f1)
《通気度》JIS L 1096に準拠して、フラジール形試験機を用いて測定した。
繊維径が7μmで繊維長が5mmの延伸ポリエチレンテレフタレート(PET)繊維56%と、繊維径が11μmで繊維長が5mmの未延伸PET繊維44%を、チェスト内で水中に充分に分散させて、繊維濃度0.05%の水性スラリーを調整し、これを傾斜金網抄紙機に送り、水性スラリーの水流速度と傾斜金網の抄紙速度を調整することで、引張強度の縦横比(k)を調整しながら、繊維を立体的に集合してなる湿式不織布シートの原紙Aを抄造した。
抄造された原紙Aを50mm幅に裁断し、つかみ具の間隔を180mmにセットした引張試験機で、長さ方向(縦方向)の引張強度(f2)と、幅方向(横方向)の引張強度(f1)とを測定し、幅方向の引張強度(f1)に対する長さ方向の引張強度(f2)の比率(f2/f1)である引張強度の縦横比(k)を求めた。
この原紙Aは、坪量38g/m2で、引張強度の縦横比(k)が6.7であった。
繊維径が12μmで繊維長が5mmの延伸PET繊維60%と、繊維径が11μmで繊維長が5mmの未延伸PET繊維40%を、チェスト内で水中に充分分散させて、繊維濃度0.05%の水性スラリーを調整し、これを傾斜金網抄紙機に送り、水性スラリーの水流速度と傾斜金網の抄紙速度を調整することで、引張強度の縦横比(k)を調整しながら、繊維を立体的に集合してなる湿式不織布シートの原紙Fを抄造した。
抄造された原紙Fを50mm幅に裁断し、つかみ具の間隔を180mmにセットした引張試験機で、長さ方向(縦方向)の引張強度(f2)と、幅方向(横方向)の引張強度(f1)とを測定し、幅方向の引張強度(f1)に対する長さ方向の引張強度(f2)の比率(f2/f1)である引張強度の縦横比(k)を求めた。
この原紙Fは、坪量38g/m2で、引張強度の縦横比(k)が1.8であった。
得られた2枚の不織布シート(原紙Aと原紙F)を積層し、図1に示すように、加熱ロール21と弾性ロール22を組み合わせた熱圧加工設備20で、連続的に加熱熱圧処理した。この工程において、加熱ロール21は、表面温度を230℃とし、加熱ロール21と弾性ロール22とで狭着される圧力は、180kg/cmとし、加工される速度を27m/minとして、積層された不織布シートを加熱加圧処理してシート状に結合した。
さらに、この支持体を400mm(幅)×1000mm(長さ)の寸法のシート状に裁断して、幅方向への湾曲の程度を確認した。この支持体は、原紙F側の表面が幅方向に中央凸に湾曲し、原紙A側の表面が幅方向に中央凹に湾曲していた。この支持体の写真を図6に示す。ただし、この写真は、原紙F側を下面とし、原紙A側を上面として、支持体を水平な台の上に載せた状態を示している。この写真からも分かるように、得られた支持体は、幅方向の両端縁が台の上面から約20mm浮く状態で湾曲していた。
得られた2枚の不織布シート(原紙Aと原紙E)を積層し、加熱ロール21と弾性ロール22を組み合わせた熱圧加工設備20で、実施例1と同じ条件で加熱熱圧処理して、積層された不織布シートをシート状に結合した。
さらに、この支持体を400mm(幅)×1000mm(長さ)の寸法のシート状に裁断して、幅方向への湾曲の程度を確認した。この支持体は、原紙E側の表面が幅方向に中央凸に湾曲し、原紙A側の表面が幅方向に中央凹に湾曲していた。この支持体を、原紙E側を下面とし、原紙A側を上面として、水平な台の上に載せると、幅方向の両端縁が台の上面から約12mm浮く状態で湾曲していた。
得られた2枚の不織布シート(原紙Aと原紙F)を積層し、加熱ロール21と弾性ロール22を組み合わせた熱圧加工設備20で、実施例1と同じ条件で加熱熱圧処理して、積層された不織布シートをシート状に結合した。
さらに、この支持体を400mm(幅)×1000mm(長さ)の寸法のシート状に裁断して、幅方向への湾曲の程度を確認した。この支持体は、原紙F側の表面が幅方向に中央凸に湾曲し、原紙B側の表面が幅方向に中央凹に湾曲していた。この支持体を、原紙F側を下面とし、原紙B側を上面として、水平な台の上に載せると、幅方向の両端縁が台の上面から約7mm浮く状態で湾曲していた。
得られた2枚の不織布シート(原紙Aと原紙D)を積層し、加熱ロール21と弾性ロール22を組み合わせた熱圧加工設備20で、実施例1と同じ条件で加熱熱圧処理して、積層された不織布シートをシート状に結合した。
さらに、この支持体を400mm(幅)×1000mm(長さ)の寸法のシート状に裁断して、幅方向への湾曲の程度を確認したが、この支持体は、幅方向への湾曲が生じていなかった。
得られた2枚の不織布シート(原紙Bと原紙E)を積層し、加熱ロール21と弾性ロール22を組み合わせた熱圧加工設備20で、実施例1と同じ条件で加熱熱圧処理して、積層された不織布シートをシート状に結合した。
さらに、この支持体を400mm(幅)×1000mm(長さ)の寸法のシート状に裁断して、幅方向への湾曲の程度を確認したが、この支持体は、幅方向への湾曲が生じていなかった。
得られた2枚の不織布シート(原紙Cと原紙F)を積層し、加熱ロール21と弾性ロール22を組み合わせた熱圧加工設備20で、実施例1と同じ条件で加熱熱圧処理して、積層された不織布シートをシート状に結合した。
さらに、この支持体を400mm(幅)×1000mm(長さ)の寸法のシート状に裁断して、幅方向への湾曲の程度を確認したが、この支持体は、幅方向への湾曲が生じていなかった。
さらに、実施例1~3、及び比較例1~3で得られた支持体の接着面に、以下のようにして分離膜を設けた。実施例1と3の支持体は、原紙F側の表面を接着面として、また、実施例2の支持体は、原紙E側の表面を接着面として、さらにまた、比較例1~3の支持体は、それぞれ原紙D側、原紙E側、原紙F側の表面を接着面として、図4に示す一般的な製膜工程設備30で分離膜を設けた。この製膜工程において、ポリスルフォンを16.5%の濃度でN,N-ジメチルホルムアミド(DMF)に溶解したポリマー溶液を支持体の接着面に塗布し、水を入れた凝固槽に浸漬してゲル化させ、その後、洗浄槽に浸漬し残留しているDMFを洗浄しながら凝固させて、接着面に分離膜を設けた。
以上のようにして、実施例1~3、及び比較例1~3の支持体の接着面上に、厚さ35μmのポリスルフォン層を積層して分離膜を設けた。
とくに、実施例の支持体と比較例の支持体の加熱加圧処理後の引張強度の縦横比(k)を比較すると、実施例の支持体は、比較例3の支持体よりも引張強度の縦横比(k)が大きく、また、実施例1の支持体と比較例2の支持体とは引張強度の縦横比(k)が同等であるにも関わらず、実施例の支持体の方が、接着面に分離膜を積層した際の幅方向の湾曲が極めて少なくなった。この結果からも、支持体の接着面を、予め幅方向に中央凸に湾曲させた効果だと推察できる。
1B…第2の不織布シート
2…膜 2A…半透膜
10…支持体
11…対向面
12…接着面
20…熱圧加工設備
21…加熱ロール
22…弾性ロール
30…製膜工程設備
31…ポリマー溶液
32…ドラム
33…ホッパー
34…移送ロール
35…凝固槽
36…洗浄槽
Claims (10)
- 繊維を立体的に集合してなる複数の不織布シート(1)が積層されると共に、加熱加圧処理によって、不織布シート(1)の繊維を結合してシート状としてなる、接着面(12)に膜(2)を付着する膜の支持体であって、
幅方向の引張強度(f1)に対する長さ方向の引張強度(f2)の比率(f2/f1)である引張強度の縦横比(k)が異なる複数の不織布シート(1)が積層され、加熱加圧処理された状態において、膜(2)の接着面(12)を幅方向に、中央凸に湾曲させてなる膜の支持体。 - 前記接着面(12)に設けられる膜(2)が分離膜である請求項1に記載される膜の支持体。
- 2枚の不織布シート(1)が積層されてなる請求項1又は2に記載される膜の支持体。
- 前記不織布シート(1)が、湿式抄紙された不織布である請求項1ないし3のいずれかに記載される膜の支持体。
- 前記不織布シート(1)が、乾式で立体的に集合された不織布である請求項1ないし3のいずれかに記載される膜の支持体。
- 前記不織布シート(1)が、湿式抄紙された不織布と乾式で立体的に集合された不織布とを含む請求項1ないし3のいずれかに記載される膜の支持体。
- 積層される前記不織布シート(1)の引張強度の縦横比(k)の差が1.5以上である請求項1ないし6のいずれかに記載される膜の支持体。
- 積層される前記不織布シート(1)の引張強度の縦横比(k)の差が2.5以上である請求項7に記載される膜の支持体。
- 前記不織布シート(1)の繊維が、ポリエステル繊維またはポリオレフィン繊維で構成されてなる請求項1ないし8のいずれかに記載される膜の支持体。
- 複数の不織布シート(1)を積層してなる支持体の坪量が50~100g/m2、厚さが50~150μm、通気度が0.3~6.0cc/cm2/secである請求項1ないし9のいずれかに記載される膜の支持体。
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JP5809588B2 (ja) * | 2012-03-15 | 2015-11-11 | 三菱製紙株式会社 | 半透膜支持体 |
DK2959509T3 (en) | 2013-02-14 | 2018-08-13 | Nanopareil Llc | Electrospun hybrid nanofiber felt, method of making it and method of purifying biomolecules |
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CN105040275B (zh) * | 2015-08-31 | 2017-03-29 | 常州市康捷特种无纺布有限公司 | 用于反渗透膜的湿法基材无纺布及其制备方法 |
JP6612664B2 (ja) * | 2016-03-16 | 2019-11-27 | 株式会社東芝 | 繊維配向シート |
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CN112619427B (zh) * | 2020-12-14 | 2023-04-07 | 宁波日新恒力科技有限公司 | 一种半透膜支撑体及其制备方法 |
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