WO2014156398A1 - Method for producing air filter material, air filter material, and air filter pack - Google Patents
Method for producing air filter material, air filter material, and air filter pack Download PDFInfo
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- WO2014156398A1 WO2014156398A1 PCT/JP2014/054118 JP2014054118W WO2014156398A1 WO 2014156398 A1 WO2014156398 A1 WO 2014156398A1 JP 2014054118 W JP2014054118 W JP 2014054118W WO 2014156398 A1 WO2014156398 A1 WO 2014156398A1
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- air filter
- nonwoven fabric
- porous membrane
- filter medium
- ptfe porous
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- 238000004519 manufacturing process Methods 0.000 title claims description 22
- 239000000463 material Substances 0.000 title abstract description 16
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 109
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims abstract description 84
- 239000004810 polytetrafluoroethylene Substances 0.000 claims abstract description 84
- 238000010438 heat treatment Methods 0.000 claims abstract description 35
- -1 polytetrafluoroethylene Polymers 0.000 claims abstract description 18
- 239000012528 membrane Substances 0.000 claims description 74
- 238000004049 embossing Methods 0.000 claims description 28
- 238000003825 pressing Methods 0.000 claims description 4
- 238000000034 method Methods 0.000 description 12
- 239000000835 fiber Substances 0.000 description 9
- 239000002245 particle Substances 0.000 description 8
- 238000003475 lamination Methods 0.000 description 5
- 238000002844 melting Methods 0.000 description 5
- 230000008018 melting Effects 0.000 description 5
- 238000004364 calculation method Methods 0.000 description 4
- 239000010687 lubricating oil Substances 0.000 description 4
- 238000000879 optical micrograph Methods 0.000 description 4
- 239000004698 Polyethylene Substances 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 239000000306 component Substances 0.000 description 3
- 239000002131 composite material Substances 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 description 3
- 239000005020 polyethylene terephthalate Substances 0.000 description 3
- 238000005096 rolling process Methods 0.000 description 3
- 238000009823 thermal lamination Methods 0.000 description 3
- MQIUGAXCHLFZKX-UHFFFAOYSA-N Di-n-octyl phthalate Natural products CCCCCCCCOC(=O)C1=CC=CC=C1C(=O)OCCCCCCCC MQIUGAXCHLFZKX-UHFFFAOYSA-N 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- BJQHLKABXJIVAM-UHFFFAOYSA-N bis(2-ethylhexyl) phthalate Chemical compound CCCCC(CC)COC(=O)C1=CC=CC=C1C(=O)OCC(CC)CCCC BJQHLKABXJIVAM-UHFFFAOYSA-N 0.000 description 2
- 238000004140 cleaning Methods 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000006378 damage Effects 0.000 description 2
- SNRUBQQJIBEYMU-UHFFFAOYSA-N dodecane Chemical compound CCCCCCCCCCCC SNRUBQQJIBEYMU-UHFFFAOYSA-N 0.000 description 2
- 239000000428 dust Substances 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000000843 powder Substances 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 125000006850 spacer group Chemical group 0.000 description 2
- 229920001410 Microfiber Polymers 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000000443 aerosol Substances 0.000 description 1
- 238000004378 air conditioning Methods 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000006866 deterioration Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000010410 dusting Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000003658 microfiber Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 230000001954 sterilising effect Effects 0.000 description 1
- 238000004659 sterilization and disinfection Methods 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
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
- B01D69/12—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
- 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
- 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
- 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
- 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
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Filtering Materials (AREA)
- Separation Using Semi-Permeable Membranes (AREA)
Abstract
The present invention is an air filter material or the like, which comprises: a step (a) wherein a first nonwoven fabric is disposed on one surface of a polytetrafluoroethylene porous film and a second nonwoven fabric is disposed on the other surface of the polytetrafluoroethylene porous film; and a step (b) wherein a heating roll is brought into contact with the second nonwoven fabric, while maintaining the polytetrafluoroethylene porous film, the first nonwoven fabric and the second nonwoven fabric in the laminated state, and the heating roll is pressed against the polytetrafluoroethylene porous film, the first nonwoven fabric and the second nonwoven fabric.
Description
本願は、日本国特願２０１３－７２８０５号及び日本国特願２０１４－２７５２４号の優先権を主張し、引用によって本願明細書の記載に組み込まれる。
This application claims the priority of Japanese Patent Application No. 2013-72805 and Japanese Patent Application No. 2014-27524, and is incorporated herein by reference.
本発明は、ポリテトラフルオロエチレン（ＰＴＦＥ）多孔質膜を備えるエアフィルタ濾材の製造方法、エアフィルタ濾材及びエアフィルタパックに関する。
The present invention relates to a method for producing an air filter medium including a polytetrafluoroethylene (PTFE) porous membrane, an air filter medium, and an air filter pack.
従来、空気清浄装置やクリーンルーム用などに用いられるエアフィルタ濾材には、ポリテトラフルオロエチレン（ＰＴＦＥ）多孔質膜等のフッ素樹脂多孔質膜を備える濾材、ガラス繊維にバインダーを加えて抄紙した濾材（ガラス濾材）、メロトブローン不織布をエレクトレット化した濾材（エレクトレット濾材）などが用いられている。
Conventionally, air filter media used for air purifiers and clean rooms include filter media comprising a fluororesin porous membrane such as polytetrafluoroethylene (PTFE) porous membrane, filter media made by adding a binder to glass fibers ( Glass filter media), filter media obtained by electretizing merotoblon nonwoven fabric (electret filter media), and the like are used.
なかでも、ＰＴＦＥ多孔質膜を備えるエアフィルタ濾材は、微小繊維の発生や自己発塵といった問題が少なく、使用に伴う圧力損失の上昇が少ないなどの特徴を有している。また、フッ素樹脂の性質として、摩擦係数が小さく滑り性が良好であり、捕集した塵を、多孔質膜に衝撃を与えることにより容易に除塵することができるといった性質なども有している。
Among them, the air filter medium provided with a porous PTFE membrane has the characteristics that there are few problems such as generation of microfibers and self-dusting, and there is little increase in pressure loss due to use. Further, as a property of the fluororesin, there is a property that the friction coefficient is small and the slip property is good, and the collected dust can be easily removed by giving an impact to the porous film.
ＰＴＦＥ多孔質膜は、一般に柔軟性に富む極めて薄い材料である。一方で、大きな風量が透過するエアフィルタユニットにおいては、その風量によってエアフィルタ濾材が大きく変形しないように、エアフィルタ濾材にある程度の剛性が要求される。また、ＰＴＦＥ多孔質膜は、柔軟性に富む極めて薄い材料であるがゆえに、ハンドリング性が非常に難しい。このため、ＰＴＦＥ多孔質膜を備えるフィルタ濾材は、例えば、特許文献１に記載されているように、通気部材としてのＰＴＦＥ多孔質膜に、補強材としての通気性支持材が、一般に加熱により積層（熱ラミネート）される。
PTFE porous membrane is generally an extremely thin material rich in flexibility. On the other hand, in an air filter unit through which a large air volume permeates, the air filter medium is required to have a certain degree of rigidity so that the air filter medium is not greatly deformed by the air volume. Moreover, since the PTFE porous membrane is an extremely thin material rich in flexibility, it is very difficult to handle. For this reason, as described in, for example, Patent Document 1, a filter medium including a PTFE porous membrane is generally laminated with a breathable support material as a reinforcing material on a PTFE porous membrane as a ventilation member by heating. (Thermal lamination).
上記従来の技術の熱ラミネート法の一例を、図５を用いて説明する。
An example of the conventional thermal laminating method will be described with reference to FIG.
帯状の通気性支持材２１と、同じく帯状のＰＴＦＥ多孔質膜２２とを、通気性支持材２１がＰＴＦＥ多孔質膜２２を挟み込むように、ガイドロールを通して重ね、続けて全体を加熱ロール２４に接触させて所定の温度にまで加熱する。そのまま加熱ロール２４上で通気性支持材２１とＰＴＦＥ多孔質膜２２を接着、積層させ、その後、得られた積層体をロール２５に引き取ることで、加熱ロール２４から分離し、エアフィルタ濾材を得ることができる。
The belt-like breathable support material 21 and the belt-like PTFE porous membrane 22 are overlapped through the guide roll so that the breathable support material 21 sandwiches the PTFE porous membrane 22, and then the whole contacts the heating roll 24. And heated to a predetermined temperature. The breathable support material 21 and the PTFE porous membrane 22 are bonded and laminated on the heating roll 24 as they are, and then the obtained laminate is taken up by the roll 25 to be separated from the heating roll 24 to obtain an air filter medium. be able to.
上述の通り、通気性支持材を、ＰＴＦＥ多孔質膜の両面側に重ねた場合には、エアフィルタ濾材の剛性およびハンドリング性を向上させる。しかしながら、熱ラミネートによる通気性支持材のＰＴＦＥ多孔質膜への積層を行うと、積層前のＰＴＦＥ多孔質膜そのものの性能に比べて、積層後に得られるエアフィルタ濾材の性能が低下する不具合が生じる。
As described above, when the air-permeable support material is stacked on both sides of the PTFE porous membrane, the rigidity and handling properties of the air filter medium are improved. However, when the breathable support material is laminated on the PTFE porous membrane by thermal lamination, there is a problem that the performance of the air filter medium obtained after the lamination is lower than the performance of the PTFE porous membrane itself before lamination. .
本発明は、上記事情を鑑みてなされたものであり、良好な濾材の剛性およびハンドリング性を保ちつつ、加熱による積層後に得られるエアフィルタ濾材の性能低下を抑制することを課題とする。
This invention is made | formed in view of the said situation, and makes it a subject to suppress the performance fall of the air filter medium obtained after lamination | stacking by heating, maintaining the rigidity and handling property of favorable filter medium.
すなわち、本発明は、
ポリテトラフルオロエチレン多孔質膜の一面側に第１不織布を重ね、前記ポリテトラフルオロエチレン多孔質膜の他面側に第２不織布を重ねる工程（ａ）と、
前記ポリテトラフルオロエチレン多孔質膜、前記第１不織布および前記第２不織布を重ねた状態で、前記第２不織布に加熱ロールを接触させ、前記ポリテトラフルオロエチレン多孔質膜、前記第１不織布および前記第２不織布に前記加熱ロールを押圧する工程（ｂ）と、を含むエアフィルタ濾材の製造方法であって、
前記第１不織布として前記一面側に接する面のエンボス比率が１２％以上１８％以下である不織布を用い、
前記第２不織布として前記他面側に接する面のエンボス比率が１８％よりも大きい不織布を用いるエアフィルタ濾材の製造方法を提供する。 That is, the present invention
A step (a) of superposing a first non-woven fabric on one side of the polytetrafluoroethylene porous membrane and superposing a second non-woven fabric on the other side of the polytetrafluoroethylene porous membrane;
In a state where the polytetrafluoroethylene porous membrane, the first nonwoven fabric and the second nonwoven fabric are stacked, a heating roll is brought into contact with the second nonwoven fabric, the polytetrafluoroethylene porous membrane, the first nonwoven fabric and the A step (b) of pressing the heating roll against the second nonwoven fabric, and a method for producing an air filter medium,
Using a non-woven fabric having an embossing ratio of 12% or more and 18% or less as the first non-woven fabric in contact with the one surface side,
Provided is a method for producing an air filter medium using a nonwoven fabric having an embossing ratio of a surface in contact with the other surface as the second nonwoven fabric that is greater than 18%.
ポリテトラフルオロエチレン多孔質膜の一面側に第１不織布を重ね、前記ポリテトラフルオロエチレン多孔質膜の他面側に第２不織布を重ねる工程（ａ）と、
前記ポリテトラフルオロエチレン多孔質膜、前記第１不織布および前記第２不織布を重ねた状態で、前記第２不織布に加熱ロールを接触させ、前記ポリテトラフルオロエチレン多孔質膜、前記第１不織布および前記第２不織布に前記加熱ロールを押圧する工程（ｂ）と、を含むエアフィルタ濾材の製造方法であって、
前記第１不織布として前記一面側に接する面のエンボス比率が１２％以上１８％以下である不織布を用い、
前記第２不織布として前記他面側に接する面のエンボス比率が１８％よりも大きい不織布を用いるエアフィルタ濾材の製造方法を提供する。 That is, the present invention
A step (a) of superposing a first non-woven fabric on one side of the polytetrafluoroethylene porous membrane and superposing a second non-woven fabric on the other side of the polytetrafluoroethylene porous membrane;
In a state where the polytetrafluoroethylene porous membrane, the first nonwoven fabric and the second nonwoven fabric are stacked, a heating roll is brought into contact with the second nonwoven fabric, the polytetrafluoroethylene porous membrane, the first nonwoven fabric and the A step (b) of pressing the heating roll against the second nonwoven fabric, and a method for producing an air filter medium,
Using a non-woven fabric having an embossing ratio of 12% or more and 18% or less as the first non-woven fabric in contact with the one surface side,
Provided is a method for producing an air filter medium using a nonwoven fabric having an embossing ratio of a surface in contact with the other surface as the second nonwoven fabric that is greater than 18%.
本発明において、前記第２不織布の前記他面側に接する面のエンボス比率が１９％以上５０％以下であってもよい。
In the present invention, the embossing ratio of the surface in contact with the other surface side of the second nonwoven fabric may be 19% or more and 50% or less.
本発明にかかるエアフィルタ濾材は、前記エアフィルタ濾材の製造方法で得られる。
The air filter medium according to the present invention is obtained by the method for producing an air filter medium.
本発明にかかるエアフィルタパックは、前記エアフィルタ濾材を備える。
The air filter pack according to the present invention includes the air filter medium.
以下、本発明の好ましい実施形態について、図面を参照しながら説明する。
Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
本発明のエアフィルタ濾材の製造方法は、ポリテトラフルオロエチレン多孔質膜（以下、ＰＴＦＥ多孔質膜ともいう。）の一面側に第１不織布を重ね、前記ＰＴＦＥ多孔質膜の他面側に第２不織布を重ねる工程（ａ）と、前記ＰＴＦＥ多孔質膜、前記第１不織布および前記第２不織布を重ねた状態で、前記第２不織布に加熱ロールを接触させ、前記ＰＴＦＥ多孔質膜、前記第１不織布および前記第２不織布に前記加熱ロールを押圧する工程（ｂ）と、を含むエアフィルタ濾材の製造方法であって、前記第１不織布として前記一面に接する面のエンボス比率が１２％以上１８％以下である不織布を用い、前記第２不織布の前記他面に接する面のエンボス比率が１８％よりも大きい不織布を用いる方法である。
In the method for producing an air filter medium of the present invention, a first non-woven fabric is stacked on one side of a polytetrafluoroethylene porous membrane (hereinafter also referred to as PTFE porous membrane), and the first non-woven fabric is placed on the other side of the PTFE porous membrane. (2) stacking the nonwoven fabric (a), in a state where the PTFE porous membrane, the first nonwoven fabric and the second nonwoven fabric are stacked, a heating roll is brought into contact with the second nonwoven fabric, the PTFE porous membrane, And a step (b) of pressing the heating roll against one nonwoven fabric and the second nonwoven fabric, wherein the embossing ratio of the surface in contact with the one surface as the first nonwoven fabric is 12% or more 18 % Is a method using a non-woven fabric having an embossing ratio greater than 18% on the surface contacting the other surface of the second non-woven fabric.
より具体的には、図１に示すように、まず、帯状の不織布１ａおよび１ｂがＰＴＦＥ多孔質膜２を挟み込むように、不織布１ａおよび１ｂとＰＴＦＥ多孔質膜とを重ねる。すなわち、ＰＴＦＥ多孔質膜の一面側２ａに第１不織布を重ね、前記ＰＴＦＥ多孔質膜の他面側２ｂに第２不織布をガイドロール３を通して重ねる（工程ａ）。
続けて、前記ＰＴＦＥ多孔質膜、前記第１不織布および前記第２不織布を重ねた状態で前記第２不織布に加熱ロールを接触させ、全体を加熱ロール４に沿わせて押圧する（工程ｂ）。加熱ロール４に沿わせた状態でＰＴＦＥ多孔質膜２、不織布１ａおよび１ｂを含む全体を加熱ロール４により所定の温度にまで加熱し、不織布１ａおよび１ｂとＰＴＦＥ多孔質膜２とを接着、積層させ、得られた積層体をロール５に引き取ることで、加熱ロール４から分離し、エアフィルタ濾材Ａを得ることができる。 More specifically, as shown in FIG. 1, first, the nonwoven fabrics 1a and 1b and the PTFE porous membrane are overlapped so that the strip-like nonwoven fabrics 1a and 1b sandwich the PTFE porous membrane 2. That is, the first nonwoven fabric is overlaid on one side 2a of the PTFE porous membrane, and the second nonwoven fabric is overlaid on the other surface side 2b of the PTFE porous membrane through the guide roll 3 (step a).
Subsequently, a heating roll is brought into contact with the second nonwoven fabric in a state where the PTFE porous membrane, the first nonwoven fabric and the second nonwoven fabric are stacked, and the whole is pressed along the heating roll 4 (step b). The entire structure including the PTFEporous membrane 2 and the nonwoven fabrics 1a and 1b along the heating roll 4 is heated to a predetermined temperature by the heating roll 4, and the nonwoven fabrics 1a and 1b and the PTFE porous membrane 2 are bonded and laminated. Then, the resulting laminate is taken up by the roll 5 to be separated from the heating roll 4 to obtain the air filter medium A.
続けて、前記ＰＴＦＥ多孔質膜、前記第１不織布および前記第２不織布を重ねた状態で前記第２不織布に加熱ロールを接触させ、全体を加熱ロール４に沿わせて押圧する（工程ｂ）。加熱ロール４に沿わせた状態でＰＴＦＥ多孔質膜２、不織布１ａおよび１ｂを含む全体を加熱ロール４により所定の温度にまで加熱し、不織布１ａおよび１ｂとＰＴＦＥ多孔質膜２とを接着、積層させ、得られた積層体をロール５に引き取ることで、加熱ロール４から分離し、エアフィルタ濾材Ａを得ることができる。 More specifically, as shown in FIG. 1, first, the
Subsequently, a heating roll is brought into contact with the second nonwoven fabric in a state where the PTFE porous membrane, the first nonwoven fabric and the second nonwoven fabric are stacked, and the whole is pressed along the heating roll 4 (step b). The entire structure including the PTFE
図１の例において、不織布１ａおよび１ｂの加熱温度は、加熱ロール４の温度設定や、ライン速度を調節することで制御することができる。このとき、不織布１ａおよび１ｂの加熱の温度は、不織布１ａに含まれる最も低融点な材料と、不織布１ｂに含まれる最も低融点な材料とのうち、高い方の融点以上とする。
In the example of FIG. 1, the heating temperature of the nonwoven fabrics 1a and 1b can be controlled by adjusting the temperature setting of the heating roll 4 and the line speed. At this time, the heating temperature of the nonwoven fabrics 1a and 1b is set to be equal to or higher than the higher melting point of the lowest melting point material contained in the nonwoven fabric 1a and the lowest melting point material contained in the nonwoven fabric 1b.
また、加熱ロール４の直後に設置されているガイドロール６により、加熱された不織布１ａおよび１ｂとＰＴＦＥ多孔質膜２との積層体をさらに加圧することで各層の接着力を向上させることができる。
Moreover, the adhesive force of each layer can be improved by further pressing the laminated body of the heated nonwoven fabrics 1a and 1b and the PTFE porous membrane 2 by the guide roll 6 installed immediately after the heating roll 4. .
本発明のエアフィルタ用濾材の製造方法において、不織布１ａおよび１ｂは、それぞれ少なくとも片面にエンボスが設けられており、それぞれのエンボス加工が施された面が、ＰＴＦＥ多孔質膜２との積層する際に、ＰＴＦＥ多孔質膜２と接するように配置される。
In the method for producing a filter medium for an air filter of the present invention, each of the nonwoven fabrics 1a and 1b is provided with an emboss on at least one surface, and each embossed surface is laminated with the PTFE porous membrane 2 The PTFE porous membrane 2 is disposed in contact therewith.
また、不織布１ａおよび１ｂは、ＰＴＦＥ多孔質膜２に接する面のエンボス比率が異なるものを用いる。具体的には、不織布１ａとしてＰＴＦＥ多孔質膜２に接する面のエンボス比率が１２％以上１８％以下である不織布を用い、不織布１ｂとしてＰＴＦＥ多孔質膜２に接する面のエンボス比率が１８％よりも大きい不織布を用いる。
特に、不織布１ａとしてエンボス比率が１２％以上１８％以下である不織布を用い、不織布１ｂとしてエンボス比率が１９％以上５０％以下である不織布をそれぞれ用いることが好ましい。 Nonwoven fabrics 1a and 1b are different in the embossing ratio of the surface in contact with the PTFE porous membrane 2. Specifically, a non-woven fabric having an embossing ratio of 12% or more and 18% or less on the surface in contact with the PTFE porous membrane 2 as the non-woven fabric 1a, and an embossing ratio of the surface in contact with the PTFE porous membrane 2 as the non-woven fabric 1b is from 18%. Also use a large nonwoven fabric.
In particular, it is preferable to use a nonwoven fabric with an embossing ratio of 12% or more and 18% or less as thenonwoven fabric 1a, and use a nonwoven fabric with an embossing ratio of 19% or more and 50% or less as the nonwoven fabric 1b.
特に、不織布１ａとしてエンボス比率が１２％以上１８％以下である不織布を用い、不織布１ｂとしてエンボス比率が１９％以上５０％以下である不織布をそれぞれ用いることが好ましい。
In particular, it is preferable to use a nonwoven fabric with an embossing ratio of 12% or more and 18% or less as the
本発明において、「エンボス比率」とは、単位面積当たりの不織布の凹部の面積の割合を意味する。なお、算出方法は、後述する実施例で詳細に述べる。
In the present invention, the “embossing ratio” means the ratio of the area of the concave portion of the nonwoven fabric per unit area. The calculation method will be described in detail in an example described later.
上記のように不織布１ａおよび１ｂを、前記ＰＴＦＥ多孔質膜２の一面側２ａおよび他面側２ｂに配置すると、エンボス比率が小さい、すなわち、単位面積当たりの凹部の面積が小さい不織布１ａとＰＴＦＥ多孔質膜２の一面側２ａとの間では、接触点数が不織布１ｂとＰＴＦＥ多孔質膜２の他面側２ｂとの間に比べて多くなる。図１に示す加熱ロール４によるラミネートでは、ＰＴＦＥ多孔質膜２の一面側２ａにある不織布１ａは、加熱ロール４に接触しない側に位置する。このような配置では、不織布１ａには加熱ロール４からの熱が不織布１ｂに比べて伝わりにくいため、十分なラミネート後の接着力を得るために、ガイドロール６などにより、不織布１ａには、不織布１ｂに比べて張力を大きく掛ける必要がある。
このため、不織布１ａが加熱ロール４に向かって、加熱された状態で押し付けられる圧力は、不織布１ｂが加熱ロール４に向かって押し付けられる圧力よりも高くなる。 When the non-woven fabrics 1a and 1b are arranged on the one side 2a and the other side 2b of the PTFE porous membrane 2 as described above, the embossing ratio is small, that is, the non-woven fabric 1a and the PTFE porous structure have a small area per unit area. Between the one surface side 2a of the membrane 2, the number of contact points is larger than between the nonwoven fabric 1b and the other surface 2b of the PTFE porous membrane 2. In the laminate using the heating roll 4 shown in FIG. 1, the nonwoven fabric 1 a on the one surface side 2 a of the PTFE porous membrane 2 is located on the side not in contact with the heating roll 4. In such an arrangement, since the heat from the heating roll 4 is less likely to be transmitted to the nonwoven fabric 1a compared to the nonwoven fabric 1b, the nonwoven fabric 1a is provided with the nonwoven fabric 1a by a guide roll 6 or the like in order to obtain sufficient adhesive strength after lamination. It is necessary to apply a greater tension than 1b.
For this reason, the pressure with which thenonwoven fabric 1 a is pressed toward the heating roll 4 in a heated state is higher than the pressure with which the nonwoven fabric 1 b is pressed toward the heating roll 4.
このため、不織布１ａが加熱ロール４に向かって、加熱された状態で押し付けられる圧力は、不織布１ｂが加熱ロール４に向かって押し付けられる圧力よりも高くなる。 When the
For this reason, the pressure with which the
従って、圧力がかかる不織布１ａとＰＴＦＥ多孔質膜２との間の接触点数が多くなると、接触点にかかる圧力が分散され、不織布１ａの繊維の食い込みによるＰＴＦＥ多孔質膜２の破壊が抑制される。このため、本発明の製造方法により得られるエアフィルタ濾材の捕集効率の低下が抑制されることとなる。
特に、ＰＴＦＥ多孔質膜２として、ＨＥＰＡ、ＵＬＰＡ等のエアフィルタ濾材を構成する、より捕集効率は高いが、非常に損傷しやすいＰＴＦＥ多孔質膜を用いる場合に、本発明の効果は顕著である。
ＨＥＰＡ、ＵＬＰＡ等のエアフィルタ濾材用のＰＴＦＥ多孔質膜は、ＰＴＦＥ多孔質膜２の繊維へのダメージが、エアフィルタ濾材の捕集効率の低下に反映されやすいからである。 Therefore, when the number of contact points between thenonwoven fabric 1a and the PTFE porous membrane 2 to which pressure is applied increases, the pressure applied to the contact points is dispersed, and the destruction of the PTFE porous membrane 2 due to the biting of the fibers of the nonwoven fabric 1a is suppressed. . For this reason, the fall of the collection efficiency of the air filter medium obtained by the manufacturing method of this invention will be suppressed.
In particular, when the PTFEporous membrane 2 is used as a PTFE porous membrane constituting an air filter medium such as HEPA or ULPA, which has a higher collection efficiency but is very easily damaged, the effect of the present invention is remarkable. is there.
This is because in the PTFE porous membrane for air filter media such as HEPA and ULPA, damage to the fibers of the PTFEporous membrane 2 is easily reflected in the decrease in the collection efficiency of the air filter media.
特に、ＰＴＦＥ多孔質膜２として、ＨＥＰＡ、ＵＬＰＡ等のエアフィルタ濾材を構成する、より捕集効率は高いが、非常に損傷しやすいＰＴＦＥ多孔質膜を用いる場合に、本発明の効果は顕著である。
ＨＥＰＡ、ＵＬＰＡ等のエアフィルタ濾材用のＰＴＦＥ多孔質膜は、ＰＴＦＥ多孔質膜２の繊維へのダメージが、エアフィルタ濾材の捕集効率の低下に反映されやすいからである。 Therefore, when the number of contact points between the
In particular, when the PTFE
This is because in the PTFE porous membrane for air filter media such as HEPA and ULPA, damage to the fibers of the PTFE
また、さらに本発明者らは、不織布１ｂのエンボス比率を大きくすると、加熱ロール４上への不織布溶融成分の付着（いわゆる「糸引き」と呼ばれる不具合）が抑制されることを見出した。これは、エンボス比率を大きくすると不織布１ｂを構成する繊維同士の接着点が増え、溶融した繊維がロールに取られにくくなるからである。「糸引き」の発生が抑制されることにより、製造ラインにおける、後続のエアフィルタ濾材への溶融繊維の付着などの不具合も抑制され、加熱ロール４の清掃回数を減らすこともできるため、エアフィルタ濾材の量産において歩留まり向上に寄与する。
Furthermore, the present inventors have found that when the embossing ratio of the nonwoven fabric 1b is increased, adhesion of the nonwoven fabric melt component onto the heating roll 4 (a so-called “stringing” defect) is suppressed. This is because when the embossing ratio is increased, the adhesion points between the fibers constituting the nonwoven fabric 1b are increased, and the melted fibers are difficult to be taken by the roll. By suppressing the occurrence of “string drawing”, problems such as adhesion of molten fiber to the subsequent air filter medium in the production line can be suppressed, and the number of cleanings of the heating roll 4 can be reduced. Contributes to yield improvement in mass production of filter media.
以上のように説明した本実施形態の製造方法によって得られるエアフィルタ濾材Ａは、図２に示すようにＰＴＦＥ多孔質膜２と、当該ＰＴＦＥ多孔質膜を挟むように、当該ＰＴＦＥ多孔質膜の両面に直接設けられた不織布１ａおよび１ｂとを含む積層体である。
As shown in FIG. 2, the air filter medium A obtained by the manufacturing method of the present embodiment as described above has the PTFE porous membrane 2 and the PTFE porous membrane so as to sandwich the PTFE porous membrane. It is a laminate including nonwoven fabrics 1a and 1b provided directly on both sides.
このエアフィルタ濾材Ａを用いて、エアフィルタパックおよびエアフィルタユニットを製造する。一般に、エアフィルタユニットは、エアフィルタ濾材をひだ状にプリーツ加工してエアフィルタパックを得、これをフレームに組み込んで製造することができる。
Using this air filter medium A, an air filter pack and an air filter unit are manufactured. In general, the air filter unit can be manufactured by pleating an air filter medium into a pleated shape to obtain an air filter pack, which is incorporated into a frame.
本実施形態のエアパックは、本実施形態の製造方法によって得られるエアフィルタ濾材が所定の形状あるいは大きさに形成されてなる。
本実施形態のエアパックとしては、例えば、エアフィルタ濾材が複数箇所で屈曲されてひだ状に形成されてなるエアパック等が挙げられる。
かかるエアパックは、例えば、前記エアフィルタ濾材が一方向に沿って屈曲されて形成される屈曲部と、前記屈曲部以外の領域が板状に形成されてなる平板部と、エアフィルタ濾材の一方の面側および他方の面側における各平板部の間に形成されて隣り合う屈曲部同士の間隔を保持する複数の間隔保持部とを備えてなるものであってもよい。 The air pack of this embodiment is formed by forming an air filter medium obtained by the manufacturing method of this embodiment into a predetermined shape or size.
Examples of the air pack of the present embodiment include an air pack in which an air filter medium is bent at a plurality of locations and formed into a pleat shape.
Such an air pack includes, for example, a bent portion formed by bending the air filter medium along one direction, a flat plate formed by forming a region other than the bent portion in a plate shape, and one of the air filter medium. It may be provided with a plurality of interval holding portions that are formed between the flat plate portions on the surface side and the other surface side and hold intervals between adjacent bent portions.
本実施形態のエアパックとしては、例えば、エアフィルタ濾材が複数箇所で屈曲されてひだ状に形成されてなるエアパック等が挙げられる。
かかるエアパックは、例えば、前記エアフィルタ濾材が一方向に沿って屈曲されて形成される屈曲部と、前記屈曲部以外の領域が板状に形成されてなる平板部と、エアフィルタ濾材の一方の面側および他方の面側における各平板部の間に形成されて隣り合う屈曲部同士の間隔を保持する複数の間隔保持部とを備えてなるものであってもよい。 The air pack of this embodiment is formed by forming an air filter medium obtained by the manufacturing method of this embodiment into a predetermined shape or size.
Examples of the air pack of the present embodiment include an air pack in which an air filter medium is bent at a plurality of locations and formed into a pleat shape.
Such an air pack includes, for example, a bent portion formed by bending the air filter medium along one direction, a flat plate formed by forming a region other than the bent portion in a plate shape, and one of the air filter medium. It may be provided with a plurality of interval holding portions that are formed between the flat plate portions on the surface side and the other surface side and hold intervals between adjacent bent portions.
かかるエアパックの製造方法は、例えば、次のような方法が挙げられる。
まず、エアフィルタ濾材がプリーツ加工される。具体的には、帯状のエアフィルタ濾材が長手方向に直交する幅方向に沿って複数箇所で屈曲されてひだ状に形成される。これにより、エアフィルタ濾材には複数の屈曲部と複数の平板部とが形成される（プリーツ加工する工程）。
次に、ひだ状にプリーツ加工したエアフィルタ濾材が、プリーツ加工前の平らな状態に伸ばされ、エアフィルタ濾材の両面に接着剤等のスペーサー樹脂（一般に「ビード」と呼ばれる）が塗布されて間隔保持部が形成される（スペーサー樹脂を塗布する工程）。
間隔保持部は、隣り合う平板部におけるひだ状に形成された際に対向する一対の対向面の間に配置される。
さらに、エアフィルタ濾材が再度屈曲されてひだ状に形成される（再度プリーツ加工する工程）。
必要に応じて、プリーツ加工されたエアフィルタ濾材が所定の大きさに切断されてもよい（切断工程）。 Examples of a method for manufacturing such an air pack include the following methods.
First, the air filter medium is pleated. Specifically, the band-shaped air filter medium is bent at a plurality of locations along the width direction orthogonal to the longitudinal direction to form a pleat. As a result, a plurality of bent portions and a plurality of flat plate portions are formed in the air filter medium (step of pleating).
Next, the air filter medium pleated into pleats is stretched to a flat state before pleating, and spacer resin (generally called “bead”) such as adhesive is applied to both sides of the air filter medium, and the interval is applied. A holding part is formed (step of applying a spacer resin).
The interval holding portion is disposed between a pair of opposing surfaces that face each other when formed in a pleat shape in adjacent flat plate portions.
Further, the air filter medium is bent again to form a pleat (step of pleating again).
If necessary, the pleated air filter medium may be cut into a predetermined size (cutting step).
まず、エアフィルタ濾材がプリーツ加工される。具体的には、帯状のエアフィルタ濾材が長手方向に直交する幅方向に沿って複数箇所で屈曲されてひだ状に形成される。これにより、エアフィルタ濾材には複数の屈曲部と複数の平板部とが形成される（プリーツ加工する工程）。
次に、ひだ状にプリーツ加工したエアフィルタ濾材が、プリーツ加工前の平らな状態に伸ばされ、エアフィルタ濾材の両面に接着剤等のスペーサー樹脂（一般に「ビード」と呼ばれる）が塗布されて間隔保持部が形成される（スペーサー樹脂を塗布する工程）。
間隔保持部は、隣り合う平板部におけるひだ状に形成された際に対向する一対の対向面の間に配置される。
さらに、エアフィルタ濾材が再度屈曲されてひだ状に形成される（再度プリーツ加工する工程）。
必要に応じて、プリーツ加工されたエアフィルタ濾材が所定の大きさに切断されてもよい（切断工程）。 Examples of a method for manufacturing such an air pack include the following methods.
First, the air filter medium is pleated. Specifically, the band-shaped air filter medium is bent at a plurality of locations along the width direction orthogonal to the longitudinal direction to form a pleat. As a result, a plurality of bent portions and a plurality of flat plate portions are formed in the air filter medium (step of pleating).
Next, the air filter medium pleated into pleats is stretched to a flat state before pleating, and spacer resin (generally called “bead”) such as adhesive is applied to both sides of the air filter medium, and the interval is applied. A holding part is formed (step of applying a spacer resin).
The interval holding portion is disposed between a pair of opposing surfaces that face each other when formed in a pleat shape in adjacent flat plate portions.
Further, the air filter medium is bent again to form a pleat (step of pleating again).
If necessary, the pleated air filter medium may be cut into a predetermined size (cutting step).
前記エアフィルタパックは、フレームに取り付けエアフィルタユニットとして形成されてもよい。
エアフィルタユニットは、前記エアフィルタパックの四方を囲むようなフレームとエアフィルタパックとをシールすることで製造される。
このように製造されたエアフィルタユニットは、空気清浄装置やクリーンルームの空調設備などに用いられる。 The air filter pack may be attached to a frame and formed as an air filter unit.
The air filter unit is manufactured by sealing a frame surrounding the four sides of the air filter pack and the air filter pack.
The air filter unit manufactured in this way is used for an air purifier or an air conditioning facility in a clean room.
エアフィルタユニットは、前記エアフィルタパックの四方を囲むようなフレームとエアフィルタパックとをシールすることで製造される。
このように製造されたエアフィルタユニットは、空気清浄装置やクリーンルームの空調設備などに用いられる。 The air filter pack may be attached to a frame and formed as an air filter unit.
The air filter unit is manufactured by sealing a frame surrounding the four sides of the air filter pack and the air filter pack.
The air filter unit manufactured in this way is used for an air purifier or an air conditioning facility in a clean room.
本実施形態で用いるＰＴＦＥ多孔質膜２は、例えば、シート状のＰＴＦＥ成形体を作製し、これを２軸延伸して多孔質化する方法、および日本国特開平７－１９６８３１号公報などに記載）などの公知の方法により製造することができる。
The PTFE porous membrane 2 used in the present embodiment is described in, for example, a method of producing a sheet-like PTFE molded body and biaxially stretching it to make it porous, and Japanese Patent Application Laid-Open No. 7-196831. ) And the like.
また必要に応じて、ＰＴＦＥ多孔質膜２として、複数のＰＴＦＥ多孔質膜が積層した構造を持つＰＴＦＥ複層多孔質膜を用いても構わない。ＰＴＦＥ複層多孔質膜の製法としては特に限定されないが、次に示すような幾つかの方法が提案されている。
例えば、
（１）液状潤滑剤の混合された分子量の異なるＰＴＦＥファインパウダーを、層状に分布させたのちに、層構造を保ったまま押出して圧延し、さらに延伸することでＰＴＦＥ複層多孔質膜を得る方法（日本国特開平３－１７９０３８号公報に記載）、
（２）液状潤滑剤を含んだ複数のＰＴＦＥ圧延シートを重ねて圧延し、さらに延伸することでＰＴＦＥ複層多孔質膜を得る方法（日本国特開昭５９－４９９３５号公報に記載）、
（３）孔径の異なる未焼成のＰＴＦＥ多孔質膜を圧着することにより積層化し、ＰＴＦＥの融点以上の温度で焼成することでＰＴＦＥ複層多孔質膜を得る方法（日本国特開昭５４－９７６８６号公報に記載）、
などが挙げられる。 If necessary, a PTFE multilayer porous membrane having a structure in which a plurality of PTFE porous membranes are laminated may be used as the PTFEporous membrane 2. Although it does not specifically limit as a manufacturing method of a PTFE multilayer porous membrane, Several methods as shown below are proposed.
For example,
(1) A PTFE fine powder mixed with a liquid lubricant and having different molecular weights is distributed in layers, then extruded and rolled while maintaining the layer structure, and further stretched to obtain a PTFE multilayer porous membrane. Method (described in Japanese Patent Application Laid-Open No. 3-17938),
(2) A method of obtaining a PTFE multi-layer porous film by rolling a plurality of PTFE rolled sheets containing a liquid lubricant, and further stretching (described in JP-A-59-49935),
(3) A method of obtaining a PTFE multilayer porous membrane by laminating unfired PTFE porous membranes having different pore diameters by pressure bonding and firing at a temperature equal to or higher than the melting point of PTFE (Japanese Patent Laid-Open No. 54-97686). ),
Etc.
例えば、
（１）液状潤滑剤の混合された分子量の異なるＰＴＦＥファインパウダーを、層状に分布させたのちに、層構造を保ったまま押出して圧延し、さらに延伸することでＰＴＦＥ複層多孔質膜を得る方法（日本国特開平３－１７９０３８号公報に記載）、
（２）液状潤滑剤を含んだ複数のＰＴＦＥ圧延シートを重ねて圧延し、さらに延伸することでＰＴＦＥ複層多孔質膜を得る方法（日本国特開昭５９－４９９３５号公報に記載）、
（３）孔径の異なる未焼成のＰＴＦＥ多孔質膜を圧着することにより積層化し、ＰＴＦＥの融点以上の温度で焼成することでＰＴＦＥ複層多孔質膜を得る方法（日本国特開昭５４－９７６８６号公報に記載）、
などが挙げられる。 If necessary, a PTFE multilayer porous membrane having a structure in which a plurality of PTFE porous membranes are laminated may be used as the PTFE
For example,
(1) A PTFE fine powder mixed with a liquid lubricant and having different molecular weights is distributed in layers, then extruded and rolled while maintaining the layer structure, and further stretched to obtain a PTFE multilayer porous membrane. Method (described in Japanese Patent Application Laid-Open No. 3-17938),
(2) A method of obtaining a PTFE multi-layer porous film by rolling a plurality of PTFE rolled sheets containing a liquid lubricant, and further stretching (described in JP-A-59-49935),
(3) A method of obtaining a PTFE multilayer porous membrane by laminating unfired PTFE porous membranes having different pore diameters by pressure bonding and firing at a temperature equal to or higher than the melting point of PTFE (Japanese Patent Laid-Open No. 54-97686). ),
Etc.
本実施形態で用いる不織布１ａおよび１ｂは、互いにエンボス比率が異なるものを用いる。具体的には、不織布１ａは、エンボス比率が１２％以上１８％以下であり、不織布１ｂは、エンボス比率が１８％よりも大きい。特に、不織布１ａは、エンボス比率が１２％以上１８％以下であり、不織布１ｂは、エンボス比率が１９％以上５０％以下であることが好ましい。尚、これら不織布のエンボスは、少なくともＰＴＦＥ多孔質膜２と接する面に設けられている必要がある。
この条件を満たすものであれば、不織布１ａおよび１ｂは、特に限定されるものではないが、ＰＴＦＥ多孔質膜より通気性に優れているものが好ましい。
また、ＰＴＦＥ多孔質膜との接着が容易であることなどから、不織布を構成する一部あるいは全部の繊維が芯鞘構造の複合繊維であり、芯成分が鞘成分より相対的に融点が高い合成繊維であることがより好ましい。 Nonwoven fabrics 1a and 1b used in the present embodiment have different embossing ratios. Specifically, the nonwoven fabric 1a has an embossing ratio of 12% or more and 18% or less, and the nonwoven fabric 1b has an embossing ratio of more than 18%. In particular, the nonwoven fabric 1a preferably has an embossing ratio of 12% to 18%, and the nonwoven fabric 1b preferably has an embossing ratio of 19% to 50%. The embossing of these nonwoven fabrics must be provided at least on the surface in contact with the PTFE porous membrane 2.
As long as this condition is satisfied, the nonwoven fabrics 1a and 1b are not particularly limited, but are preferably superior in breathability to the PTFE porous membrane.
In addition, because it is easy to adhere to the PTFE porous membrane, some or all of the fibers constituting the nonwoven fabric are composite fibers having a core-sheath structure, and the core component has a relatively higher melting point than the sheath component. More preferably, it is a fiber.
この条件を満たすものであれば、不織布１ａおよび１ｂは、特に限定されるものではないが、ＰＴＦＥ多孔質膜より通気性に優れているものが好ましい。
また、ＰＴＦＥ多孔質膜との接着が容易であることなどから、不織布を構成する一部あるいは全部の繊維が芯鞘構造の複合繊維であり、芯成分が鞘成分より相対的に融点が高い合成繊維であることがより好ましい。
As long as this condition is satisfied, the
In addition, because it is easy to adhere to the PTFE porous membrane, some or all of the fibers constituting the nonwoven fabric are composite fibers having a core-sheath structure, and the core component has a relatively higher melting point than the sheath component. More preferably, it is a fiber.
なお、不織布の材料としては、特に限定されるものではないが、例えば、ポリオレフィン（ポリエチレン（ＰＥ）、ポリプロピレン（ＰＰ）など）、ポリアミド、ポリエステル（ポリエチレンテレフタレート（ＰＥＴ）など）、芳香族ポリアミド、またはこれらの複合材を含むものなどを用いることができる。
The material of the non-woven fabric is not particularly limited. For example, polyolefin (polyethylene (PE), polypropylene (PP), etc.), polyamide, polyester (polyethylene terephthalate (PET), etc.), aromatic polyamide, or Those containing these composite materials can be used.
本実施形態によれば、良好な濾材の剛性およびハンドリング性を保ちつつ、加熱による積層後の性能低下が抑制されたエアフィルタ濾材を提供することができる。
According to the present embodiment, it is possible to provide an air filter medium in which deterioration in performance after lamination due to heating is suppressed while maintaining good rigidity and handling properties of the filter medium.
本実施形態にかかるエアフィルタ濾材の製造方法、エアフィルタ濾材及びエアフィルタパックは以上のとおりであるが、今回開示された実施形態はすべての点で例示であって制限的なものではないと考えられるべきである。本発明の範囲は前記説明ではなくて特許請求の範囲によって示され、特許請求の範囲と均等の意味および範囲内でのすべての変更が含まれることが意図される。
The manufacturing method of the air filter medium, the air filter medium and the air filter pack according to the present embodiment are as described above. However, the embodiment disclosed this time is illustrative in all respects and is not restrictive. Should be done. The scope of the present invention is defined by the terms of the claims, rather than the description above, and is intended to include any modifications within the scope and meaning equivalent to the terms of the claims.
以下、実施例および比較例を挙げて本発明をより詳細に説明するが、本発明は、これら実施例に限定されるものではない。
Hereinafter, the present invention will be described in more detail with reference to examples and comparative examples, but the present invention is not limited to these examples.
ＰＴＦＥファインパウダー（ダイキン工業(株)製、製品名：Ｆ１０４）８０重量部に対して液状潤滑剤（ドデカン）２０重量部を加えたペースト状の混和物を予備成形し、ペースト押し出しにより丸棒状に成形した。次に、一対の金属製圧延ロール間に通して、成形物を圧延したシート状成形体（厚さ：０．２ｍｍ）を得た。次に、このシート状成形体を１５０℃に加熱して乾燥させることにより、シート状成形体から液状潤滑剤を除去した。このシート状成形体を、その長手方向に３００℃の温度で１５倍延伸し、更に１５０℃の温度で３０倍延伸して、厚さ４μｍ、気孔率９５％のＰＴＦＥ多孔質膜を得た。得られたＰＴＦＥ多孔質膜は、透過流速５．３ｃｍ／秒の条件で圧力損失は１４０Ｐａであり、透過流速５．３ｃｍ／秒の条件で、粒子径０．１～０．２μｍの粒子を対象とした捕集効率は９９．９９９５％であった。
PTFE fine powder (manufactured by Daikin Industries, Ltd., product name: F104) is preliminarily molded into a paste-like mixture in which 20 parts by weight of a liquid lubricant (dodecane) is added to 80 parts by weight. Molded. Next, the sheet-like formed body (thickness: 0.2 mm) obtained by rolling the formed product was obtained by passing between a pair of metal rolling rolls. Next, the liquid lubricant was removed from the sheet-like molded body by heating the sheet-like molded body to 150 ° C. and drying. This sheet-like molded body was stretched 15 times at a temperature of 300 ° C. in the longitudinal direction and further stretched 30 times at a temperature of 150 ° C. to obtain a PTFE porous membrane having a thickness of 4 μm and a porosity of 95%. The obtained PTFE porous membrane has a pressure loss of 140 Pa under the condition of a permeation flow rate of 5.3 cm / sec, and targets particles with a particle diameter of 0.1 to 0.2 μm under the permeation flow rate of 5.3 cm / sec. The collection efficiency was 99.9995%.
このＰＴＦＥ多孔質膜と、ＰＥＴ／ＰＥ芯鞘複合繊維からなる不織布とを図１に示す装置を用いて熱ラミネートにより積層し、３層構造のエアフィルタ濾材を得た。なお、このとき加熱ロール４には、ロール表面にフッ素樹脂の表面コートを施したものを用い、加熱ロール４上での不織布１ａおよび１ｂの温度が１３０℃以上となるように設定した。
The PTFE porous membrane and a nonwoven fabric made of PET / PE core-sheath composite fiber were laminated by thermal lamination using the apparatus shown in FIG. 1 to obtain an air filter medium having a three-layer structure. At this time, as the heating roll 4, a roll surface coated with a fluororesin was used, and the temperature of the nonwoven fabrics 1a and 1b on the heating roll 4 was set to 130 ° C. or higher.
本実施例および比較例で用いた不織布の特性、および作製したエアフィルタ濾材の特性を表１および表２に示す。
Tables 1 and 2 show the characteristics of the nonwoven fabric used in this example and the comparative example, and the characteristics of the produced air filter medium.
なお、本実施例における不織布のエンボス比率、圧力損失および捕集効率の測定、ならびにエアフィルタ濾材のＰＦ値の算出は以下に示す方法で行った。
In addition, the embossing ratio, pressure loss, and collection efficiency of the nonwoven fabric in this example, and the calculation of the PF value of the air filter medium were performed by the following methods.
（不織布のエンボス比率）
不織布のエンボス比率は、単位面積当たりの不織布の凹部の面積の割合として求めた。算出方法は、倍率５倍で不織布表面（例えば、図３および図４を参照）の光学顕微鏡写真を撮影して、この写真を印刷し、印刷された写真全体の重量を測定した後、印刷された写真から凹部を切り抜き、切り抜かれた紙片の重量を測定することで計算する。なお、図３は実施例１の不織布１ａ、図４は実施例１の不織布１ｂの表面の光学顕微鏡写真である。 (Non-woven embossing ratio)
The embossing ratio of the nonwoven fabric was determined as a ratio of the area of the concave portion of the nonwoven fabric per unit area. The calculation method is to take an optical micrograph of the surface of the nonwoven fabric (for example, see FIGS. 3 and 4) at a magnification of 5 times, print this photo, measure the weight of the entire printed photo, and then print it. The calculation is performed by cutting out the concave portion from the photograph and measuring the weight of the cut paper piece. 3 is an optical micrograph of the surface of thenonwoven fabric 1a of Example 1, and FIG. 4 is the surface of the nonwoven fabric 1b of Example 1.
不織布のエンボス比率は、単位面積当たりの不織布の凹部の面積の割合として求めた。算出方法は、倍率５倍で不織布表面（例えば、図３および図４を参照）の光学顕微鏡写真を撮影して、この写真を印刷し、印刷された写真全体の重量を測定した後、印刷された写真から凹部を切り抜き、切り抜かれた紙片の重量を測定することで計算する。なお、図３は実施例１の不織布１ａ、図４は実施例１の不織布１ｂの表面の光学顕微鏡写真である。 (Non-woven embossing ratio)
The embossing ratio of the nonwoven fabric was determined as a ratio of the area of the concave portion of the nonwoven fabric per unit area. The calculation method is to take an optical micrograph of the surface of the nonwoven fabric (for example, see FIGS. 3 and 4) at a magnification of 5 times, print this photo, measure the weight of the entire printed photo, and then print it. The calculation is performed by cutting out the concave portion from the photograph and measuring the weight of the cut paper piece. 3 is an optical micrograph of the surface of the
（ＰＴＦＥ多孔質膜およびエアフィルタ濾材の圧力損失の測定）
圧力損失（Ｐａ）の測定は、ＪＩＳ Ｋ ０９０１の「気体中のダスト試料補集用濾過材」に準じ、ＰＴＦＥ多孔質膜およびエアフィルタ濾材の測定サンプルを、面積１００ｍｍ2のホルダーにセットし、コンプレッサーで入口側を加圧し、流量計で空気の透過する流量を５．３ｃｍ／秒に調整した。この時の圧力損失をマノメーターで測定した。結果を表１及び２に示す。 (Measurement of pressure loss of PTFE porous membrane and air filter medium)
The pressure loss (Pa) is measured according to JIS K 0901 “filtering material for collecting dust sample in gas”, and a PTFE porous membrane and a measuring sample of air filter medium are set in a holder having an area of 100 mm 2 . The inlet side was pressurized with a compressor, and the flow rate of air through the flow meter was adjusted to 5.3 cm / sec. The pressure loss at this time was measured with a manometer. The results are shown in Tables 1 and 2.
圧力損失（Ｐａ）の測定は、ＪＩＳ Ｋ ０９０１の「気体中のダスト試料補集用濾過材」に準じ、ＰＴＦＥ多孔質膜およびエアフィルタ濾材の測定サンプルを、面積１００ｍｍ2のホルダーにセットし、コンプレッサーで入口側を加圧し、流量計で空気の透過する流量を５．３ｃｍ／秒に調整した。この時の圧力損失をマノメーターで測定した。結果を表１及び２に示す。 (Measurement of pressure loss of PTFE porous membrane and air filter medium)
The pressure loss (Pa) is measured according to JIS K 0901 “filtering material for collecting dust sample in gas”, and a PTFE porous membrane and a measuring sample of air filter medium are set in a holder having an area of 100 mm 2 . The inlet side was pressurized with a compressor, and the flow rate of air through the flow meter was adjusted to 5.3 cm / sec. The pressure loss at this time was measured with a manometer. The results are shown in Tables 1 and 2.
（ＰＴＦＥ多孔質膜およびエアフィルタ濾材の捕集効率の測定）
捕集効率は、ＪＩＳ Ｋ ３８０３の「除菌用空気濾過デプスフィルタのエアロゾル捕集性能試験方法」により、粒子径０．３～０．５μｍのＤＯＰ（ジオクチルフタレート）の粒子を、粒子の濃度が約１０8個／リットルとなるように混入して測定し、次式(１)で計算した。なお、式（１）中の、ＮＬは下流側の粒子数（個／Ｌ）、ＮＵは上流側の粒子数（個／Ｌ）、Ｐは粒子捕集効率（％）を表す。結果を表１及び２に示す。
Ｐ＝（１－ＮＬ／ＮＵ）×１００ ・・・（１） (Measurement of collection efficiency of PTFE porous membrane and air filter medium)
The collection efficiency is determined according to JIS K 3803 “Method for testing aerosol collection performance of an air filtration depth filter for sterilization” with DOP (dioctyl phthalate) particles having a particle size of 0.3 to 0.5 μm and a particle concentration of It mixed and measured so that it might become about 10 < 8 > piece / liter, and calculated by following Formula (1). In the formula (1), NL represents the number of particles on the downstream side (number / L), NU represents the number of particles on the upstream side (number / L), and P represents the particle collection efficiency (%). The results are shown in Tables 1 and 2.
P = (1-NL / NU) × 100 (1)
捕集効率は、ＪＩＳ Ｋ ３８０３の「除菌用空気濾過デプスフィルタのエアロゾル捕集性能試験方法」により、粒子径０．３～０．５μｍのＤＯＰ（ジオクチルフタレート）の粒子を、粒子の濃度が約１０8個／リットルとなるように混入して測定し、次式(１)で計算した。なお、式（１）中の、ＮＬは下流側の粒子数（個／Ｌ）、ＮＵは上流側の粒子数（個／Ｌ）、Ｐは粒子捕集効率（％）を表す。結果を表１及び２に示す。
Ｐ＝（１－ＮＬ／ＮＵ）×１００ ・・・（１） (Measurement of collection efficiency of PTFE porous membrane and air filter medium)
The collection efficiency is determined according to JIS K 3803 “Method for testing aerosol collection performance of an air filtration depth filter for sterilization” with DOP (dioctyl phthalate) particles having a particle size of 0.3 to 0.5 μm and a particle concentration of It mixed and measured so that it might become about 10 < 8 > piece / liter, and calculated by following Formula (1). In the formula (1), NL represents the number of particles on the downstream side (number / L), NU represents the number of particles on the upstream side (number / L), and P represents the particle collection efficiency (%). The results are shown in Tables 1 and 2.
P = (1-NL / NU) × 100 (1)
（エアフィルタ濾材のＰＦ値）
エアフィルタ濾材の性能を表すＰＦ値は、次式（２）により算出した。結果を表１及び２に示す。
ＰＦ値＝－Ｌｏｇ（１－捕集効率（％）／１００）／圧力損失（ｍｍＨ2Ｏ）×１００・・・（２） (PF value of air filter media)
The PF value representing the performance of the air filter medium was calculated by the following formula (2). The results are shown in Tables 1 and 2.
PF value = −Log (1−capturing efficiency (%) / 100) / pressure loss (mmH 2 O) × 100 (2)
エアフィルタ濾材の性能を表すＰＦ値は、次式（２）により算出した。結果を表１及び２に示す。
ＰＦ値＝－Ｌｏｇ（１－捕集効率（％）／１００）／圧力損失（ｍｍＨ2Ｏ）×１００・・・（２） (PF value of air filter media)
The PF value representing the performance of the air filter medium was calculated by the following formula (2). The results are shown in Tables 1 and 2.
PF value = −Log (1−capturing efficiency (%) / 100) / pressure loss (mmH 2 O) × 100 (2)
表１および表２の結果から、図１に示すラミネート工程において、不織布１ａおよび１ｂが、それぞれのエンボス加工が施された面が、ＰＴＦＥ多孔質膜２との積層する際に、ＰＴＦＥ多孔質膜２と接するように配置され、且つ、不織布１ａのエンボス比率が１２％以上１８％以下である不織布を、不織布１ｂのエンボス比率が１９％以上５０％以下である不織布をそれぞれ使用することにより、ＰＴＦＥ多孔質膜の捕集効率に比べて、得られるエアフィルタ濾材の捕集効率（もしくはＰＦ値）の低下を抑制しつつ、加熱ロール４上への不織布溶融成分の付着（糸引き）も抑制されることがわかる。
From the results shown in Table 1 and Table 2, in the laminating process shown in FIG. 1, when the nonwoven fabrics 1 a and 1 b are laminated with the PTFE porous membrane 2 on the respective embossed surfaces, the PTFE porous membrane is used. 2 and the nonwoven fabric 1a having an embossing ratio of 12% or more and 18% or less, and the nonwoven fabric 1b having an embossing ratio of 19% or more and 50% or less, respectively. Compared to the collection efficiency of the porous membrane, the decrease in the collection efficiency (or PF value) of the obtained air filter medium is suppressed, and the adhesion (string drawing) of the non-woven fabric melt component onto the heating roll 4 is also suppressed. I understand that
本発明によって提供されたエアフィルタ濾材及びエアフィルタパック、は、空気清浄装置やクリーンルームの空調設備などに用いられるエアフィルタユニットの濾材及びエアフィルタパックとして好適に使用できる。
The air filter medium and the air filter pack provided by the present invention can be suitably used as a filter medium and an air filter pack for an air filter unit used in an air cleaning device, a clean room air conditioner, and the like.
１ａ、１ｂ 不織布
２ ＰＴＦＥ多孔質膜
３ ガイドロール
４ 加熱ロール
５ 巻取ロール
６ ガイドロール
Ａ エアフィルタ濾材 1a,1b Nonwoven fabric 2 PTFE porous membrane 3 Guide roll 4 Heating roll 5 Winding roll 6 Guide roll A Air filter medium
２ ＰＴＦＥ多孔質膜
３ ガイドロール
４ 加熱ロール
５ 巻取ロール
６ ガイドロール
Ａ エアフィルタ濾材 1a,
Claims (4)
- ポリテトラフルオロエチレン多孔質膜の一面側に第１不織布を重ね、前記ポリテトラフルオロエチレン多孔質膜の他面側に第２不織布を重ねる工程（ａ）と、
前記ポリテトラフルオロエチレン多孔質膜、前記第１不織布および前記第２不織布を重ねた状態で、前記第２不織布に加熱ロールを接触させ、前記ポリテトラフルオロエチレン多孔質膜、前記第１不織布および前記第２不織布に前記加熱ロールを押圧する工程（ｂ）と、を含むエアフィルタ濾材の製造方法であって、
前記第１不織布として前記一面側に接する面のエンボス比率が１２％以上１８％以下である不織布を用い、
前記第２不織布として前記他面側に接する面のエンボス比率が１８％よりも大きい不織布を用いるエアフィルタ濾材の製造方法。 A step (a) of superposing a first non-woven fabric on one side of the polytetrafluoroethylene porous membrane and superposing a second non-woven fabric on the other side of the polytetrafluoroethylene porous membrane;
In a state where the polytetrafluoroethylene porous membrane, the first nonwoven fabric and the second nonwoven fabric are stacked, a heating roll is brought into contact with the second nonwoven fabric, the polytetrafluoroethylene porous membrane, the first nonwoven fabric and the A step (b) of pressing the heating roll against the second nonwoven fabric, and a method for producing an air filter medium,
Using a non-woven fabric having an embossing ratio of 12% or more and 18% or less as the first non-woven fabric in contact with the one surface side,
The manufacturing method of the air filter medium which uses the nonwoven fabric whose embossing ratio of the surface which contact | connects the said other surface side as said 2nd nonwoven fabric is larger than 18%. - 前記第２不織布の前記他面側に接する面のエンボス比率が１９％以上５０％以下である、請求項１に記載のエアフィルタ濾材の製造方法。 The method for producing an air filter medium according to claim 1, wherein an embossing ratio of a surface in contact with the other surface side of the second nonwoven fabric is 19% or more and 50% or less.
- 請求項１または２に記載の製造方法で得られたエアフィルタ濾材。 An air filter medium obtained by the production method according to claim 1 or 2.
- 請求項３に記載のエアフィルタ濾材を備えたエアフィルタパック。 An air filter pack comprising the air filter medium according to claim 3.
Priority Applications (2)
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| KR1020157025428A KR102255737B1 (en) | 2013-03-29 | 2014-02-21 | Method for producing air filter material, air filter material, and air filter pack |
| CN201480014084.2A CN105188878B (en) | 2013-03-29 | 2014-02-21 | The manufacture method of air filter filter medium, air filter filter medium and air filter element |
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| JP2013-072805 | 2013-03-29 | ||
| JP2013072805 | 2013-03-29 | ||
| JP2014027524A JP6292920B2 (en) | 2013-03-29 | 2014-02-17 | Air filter medium manufacturing method, air filter medium and air filter pack |
| JP2014-027524 | 2014-02-17 |
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| WO2014156398A1 true WO2014156398A1 (en) | 2014-10-02 |
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| KR (1) | KR102255737B1 (en) |
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| WO2017056508A1 (en) * | 2015-09-30 | 2017-04-06 | 日東電工株式会社 | Air filter material, air filter pack, and air filter unit |
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| WO2016178323A1 (en) * | 2015-05-07 | 2016-11-10 | 日東電工株式会社 | Filter material and filter unit |
| WO2016178324A1 (en) * | 2015-05-07 | 2016-11-10 | 日東電工株式会社 | Filter material and filter unit |
| CN105879826B (en) * | 2016-06-08 | 2018-03-13 | 河南科高辐射化工科技有限公司 | One kind is used for radiation grafted rear heating solid-liquid reaction device |
| US11338233B2 (en) * | 2017-09-22 | 2022-05-24 | Nitto Denko Corporation | Air filter medium, filter pleat pack, and air filter unit |
| TWI668046B (en) * | 2018-07-18 | 2019-08-11 | 國立臺北科技大學 | Method and device for fabricating a filter, and filter fabricated from the same |
| KR102326322B1 (en) * | 2018-10-30 | 2021-11-12 | 주식회사 엘지화학 | Multi-layer film for air purification filter |
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Also Published As
| Publication number | Publication date |
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| CN105188878A (en) | 2015-12-23 |
| TW201446323A (en) | 2014-12-16 |
| TWI618572B (en) | 2018-03-21 |
| JP6292920B2 (en) | 2018-03-14 |
| JP2014208326A (en) | 2014-11-06 |
| KR20150138845A (en) | 2015-12-10 |
| CN105188878B (en) | 2017-04-05 |
| KR102255737B1 (en) | 2021-05-26 |
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