WO2014156398A1 - Procédé pour la production de matériau de filtre à air, matériau de filtre à air et garnissage de filtre à air - Google Patents

Procédé pour la production de matériau de filtre à air, matériau de filtre à air et garnissage de filtre à air Download PDF

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Publication number
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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Prior art keywords
air filter
nonwoven fabric
porous membrane
filter medium
ptfe porous
Prior art date
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PCT/JP2014/054118
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English (en)
Japanese (ja)
Inventor
百合 堀江
将明 森
雅弘 新井
志穂 内山
Original Assignee
日東電工株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
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Application filed by 日東電工株式会社 filed Critical 日東電工株式会社
Priority to CN201480014084.2A priority Critical patent/CN105188878B/zh
Priority to KR1020157025428A priority patent/KR102255737B1/ko
Publication of WO2014156398A1 publication Critical patent/WO2014156398A1/fr

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    • 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

Definitions

  • 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.
  • PTFE polytetrafluoroethylene
  • 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.
  • PTFE polytetrafluoroethylene
  • 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 porous membrane is generally an extremely thin material rich in flexibility.
  • the air filter medium 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.
  • 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).
  • 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.
  • the rigidity and handling properties of the air filter medium are improved.
  • 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. .
  • This invention is made
  • 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;
  • 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%.
  • 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.
  • the air filter medium according to the present invention is obtained by the method for producing an air filter medium.
  • the air filter pack according to the present invention includes the air filter medium.
  • Air filter medium obtained by the production method of the present invention
  • Optical micrograph of the surface of the nonwoven fabric used in the present invention (5x magnification)
  • Optical micrograph of the surface of the nonwoven fabric used in the present invention (5x magnification)
  • 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.
  • PTFE porous membrane polytetrafluoroethylene porous membrane
  • 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 PTFE porous 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.
  • 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.
  • 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. .
  • 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.
  • Nonwoven fabrics 1a and 1b are different in the embossing ratio of the surface in contact with the PTFE porous membrane 2.
  • 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.
  • nonwoven fabric with an embossing ratio of 12% or more and 18% or less as the nonwoven fabric 1a, and use a nonwoven fabric with an embossing ratio of 19% or more and 50% or less as the nonwoven fabric 1b.
  • 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.
  • 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.
  • 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.
  • 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 the nonwoven 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.
  • 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.
  • 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.
  • an air filter pack and an air filter unit are manufactured.
  • 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.
  • 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.
  • Examples of a method for manufacturing such an air pack include the following methods.
  • spacer resin generally called “bead”
  • spacer resin such as adhesive
  • 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).
  • 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.
  • 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.
  • a PTFE multilayer porous membrane having a structure in which a plurality of PTFE porous membranes are laminated may be used as the PTFE porous membrane 2.
  • 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.
  • Nonwoven fabrics 1a and 1b used in the present embodiment have different embossing ratios.
  • the nonwoven fabric 1a has an embossing ratio of 12% or more and 18% or less
  • the nonwoven fabric 1b has an embossing ratio of more than 18%.
  • the nonwoven fabric 1a preferably has an embossing ratio of 12% to 18%
  • 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.
  • the nonwoven fabrics 1a and 1b are not particularly limited, but are preferably superior in breathability 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.
  • the material of the non-woven fabric is not particularly limited.
  • polyolefin polyethylene (PE), polypropylene (PP), etc.
  • polyamide polyamide
  • PET polyethylene terephthalate
  • aromatic polyamide or Those containing these composite materials can be used.
  • 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.
  • 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.
  • a liquid lubricant dodecane
  • 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 ⁇ m under the permeation flow rate of 5.3 cm / sec.
  • the collection efficiency was 99.9995%.
  • 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.
  • 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.
  • 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.
  • 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.
  • 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 nonwoven fabric 1a of Example 1
  • FIG. 4 is the surface of the nonwoven fabric 1b of Example 1.
  • 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.
  • 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 ⁇ m 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).
  • NL represents the number of particles on the downstream side (number / L)
  • NU represents the number of particles on the upstream side (number / L)
  • P represents the particle collection efficiency (%).
  • the results are shown in Tables 1 and 2.
  • P (1-NL / NU) ⁇ 100 (1)
  • 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.

Abstract

La présente invention porte sur un procédé de production d'un matériau de filtre à air ou similaire, qui comprend : une étape (a) dans laquelle un premier non-tissé est disposé sur une surface d'un film de polytétrafluoroéthylène poreux et un second non-tissé est disposé sur l'autre surface du film de polytétrafluoroéthylène poreux; et une étape (b) dans laquelle un rouleau chauffant est mis en contact avec le second non-tissé, tout en maintenant le film de polytétrafluoroéthylène poreux, le premier non-tissé et le second non-tissé à l'état stratifié et le rouleau chauffant est pressé contre le film de polytétrafluoroéthylène poreux, le premier non-tissé et le second non-tissé.
PCT/JP2014/054118 2013-03-29 2014-02-21 Procédé pour la production de matériau de filtre à air, matériau de filtre à air et garnissage de filtre à air WO2014156398A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
CN201480014084.2A CN105188878B (zh) 2013-03-29 2014-02-21 空气过滤器滤材的制造方法、空气过滤器滤材及空气过滤器部件
KR1020157025428A KR102255737B1 (ko) 2013-03-29 2014-02-21 에어 필터 여과재의 제조 방법, 에어 필터 여과재 및 에어 필터 팩

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
JP2013-072805 2013-03-29
JP2013072805 2013-03-29
JP2014-027524 2014-02-17
JP2014027524A JP6292920B2 (ja) 2013-03-29 2014-02-17 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

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WO2014156398A1 true WO2014156398A1 (fr) 2014-10-02

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JP (1) JP6292920B2 (fr)
KR (1) KR102255737B1 (fr)
CN (1) CN105188878B (fr)
TW (1) TWI618572B (fr)
WO (1) WO2014156398A1 (fr)

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CN107530646B (zh) 2015-05-07 2020-09-25 日东电工株式会社 过滤器滤材和过滤器单元
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KR102326322B1 (ko) * 2018-10-30 2021-11-12 주식회사 엘지화학 에어필터용 다층필름
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WO2017056508A1 (fr) * 2015-09-30 2017-04-06 日東電工株式会社 Matériau de filtre à air, bloc de filtre à air et unité de filtre à air
US10765987B2 (en) 2015-09-30 2020-09-08 Nitto Denko Corporation Air filter medium, air filter pack, and air filter unit

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JP6292920B2 (ja) 2018-03-14
KR20150138845A (ko) 2015-12-10
TW201446323A (zh) 2014-12-16
CN105188878A (zh) 2015-12-23
KR102255737B1 (ko) 2021-05-26
TWI618572B (zh) 2018-03-21
CN105188878B (zh) 2017-04-05
JP2014208326A (ja) 2014-11-06

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