WO2015151168A1 - エアフィルター材 - Google Patents
エアフィルター材 Download PDFInfo
- Publication number
- WO2015151168A1 WO2015151168A1 PCT/JP2014/059486 JP2014059486W WO2015151168A1 WO 2015151168 A1 WO2015151168 A1 WO 2015151168A1 JP 2014059486 W JP2014059486 W JP 2014059486W WO 2015151168 A1 WO2015151168 A1 WO 2015151168A1
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- WIPO (PCT)
- Prior art keywords
- polyester
- nonwoven fabric
- melting point
- air filter
- filter material
- Prior art date
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- 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
- B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
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- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/54—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
- B01D46/546—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms using nano- or microfibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—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 structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
- B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
- B01D2239/0604—Arrangement of the fibres in the filtering material
- B01D2239/0618—Non-woven
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
- B01D2239/065—More than one layer present in the filtering material
- B01D2239/0668—The layers being joined by heat or melt-bonding
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- 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
- B01D2239/0681—The layers being joined by gluing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/12—Special parameters characterising the filtering material
- B01D2239/1233—Fibre diameter
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/12—Special parameters characterising the filtering material
- B01D2239/1291—Other parameters
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
- B01D2275/10—Multiple layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
Definitions
- the present invention relates to an air filter material used for filtering a gas such as air, and particularly relates to a medium to high performance air filter material.
- melt blown nonwoven fabric is used. Since melt-blown nonwoven fabrics are ultrafine fibers, they have low tensile strength and tear strength and are inferior in handleability. Therefore, it is used by being laminated with a nonwoven fabric composed of high-definition constituent fibers, for example, a spunbond nonwoven fabric or a short fiber nonwoven fabric obtained by the card method (Patent Document 1).
- thermocompression bonding is employed to laminate and integrate a melt blown nonwoven fabric and a spunbond nonwoven fabric.
- a constituent fiber of a spunbond nonwoven fabric a core-sheath type composite long fiber using a high melting point polyester component as a core component and a low melting point polyester component as a sheath component is used. Is then pressed and heated between a pair of hot embossing rolls to melt and solidify the low-melting polyester component and use this as an adhesive component to laminate and integrate the melt-blown nonwoven fabric and the spunbond nonwoven fabric. ing.
- the voids of the spunbond nonwoven fabric are filled with the melted low-melting polyester, and the air filter obtained has a reduced air permeability.
- melt blown nonwoven and the spunbond nonwoven are bonded and integrated with another adhesive. It is done.
- an emulsion type adhesive or a hot melt adhesive as another adhesive.
- An object of the present invention is to provide an air filter material in which a spunbond nonwoven fabric and a melt blown nonwoven fabric are laminated and integrated without reducing air permeability.
- the present invention is an air filter material in which an ultrafine fiber nonwoven fabric composed of ultrafine fibers and a polyester nonwoven fabric composed of polyester long fibers are laminated and integrated. , Connected to the top, bottom, left and right at the bottom of the approximate Y-shape The polyester long fibers are bonded to each other by heat-sealing, and the ultrafine fiber nonwoven fabric and the polyester nonwoven fabric are composed of ultrafine fibers and polyester long fibers.
- the present invention relates to an air filter material characterized by being bonded with a powdery or web-like hot melt adhesive having a melting point lower than the melting point.
- the polyester nonwoven fabric constituting the air filter material of the present invention has polyester long fibers as constituent fibers and is characterized by the cross-sectional shape of the long fibers.
- This cross-sectional shape has four substantially Y-characters as shown in FIG. And it is connected to the upper and lower sides and the right and left at the lower end 1 of a substantially Y shape, and has a substantially Y4 shape as shown in FIG.
- the substantially Y4 shape has four concave portions 2, eight convex portions 3, and four small concave portions 4. In particular, due to the presence of the four recesses 2, relatively large voids are formed between the polyester long fibers.
- the polyester long fiber is preferably composed of a low-melting polyester component and a high-melting polyester component. That is, it is preferable that the substantially V-shaped portion 6 having a cross-sectional shape is formed of a low-melting polyester component, and the substantially + -shaped portion 5 is a composite polyester long fiber formed of a high-melting polyester component.
- the polyester nonwoven fabric used in the present invention has a low melting point between the polyester long fibers by accumulating the composite polyester long fibers melt-spun from the composite spinning holes, and then softening or melting the low melting point polyester component and then solidifying it. It is obtained by fusing with a polyester component. Since the long fibers are bonded to each other by fusion of the low melting point polyester component, the mechanical properties such as tensile strength and tear strength are excellent, and the handling property is excellent.
- the fusion of the low-melting-point polyester component is obtained by performing a heat treatment, and this heat treatment is performed by hot embossing or hot air treatment.
- hot embossing the intersections of the polyester filaments are fused in the partially provided thermocompression bonding part.
- the intersection of polyester long fibers is fuse
- hot embossing and hot air treatment may be used in combination.
- heat embossing is preferred in which thermocompression bonding is performed by partially applying heat and pressure.
- the pressure-bonding area ratio of the embossing roll to be used (area ratio of the convex part of the embossing roll) is preferably 10 to 20%. If the crimping area ratio is too small, mechanical properties such as tensile strength tend to decrease. On the other hand, when the crimping area ratio is too large, voids between the polyester long fibers are reduced, and the air permeability tends to decrease.
- mass ratio of the low melting point polyester component decreases, the mechanical properties such as the tensile strength of the polyester nonwoven fabric tend to decrease.
- mass ratio of the low-melting polyester component increases, the low-melting polyester component flows into the gaps between the polyester long fibers during the heat treatment, and the air permeability tends to decrease.
- the polyester nonwoven fabric can be obtained by a conventionally known method, for example, a spunbond method, except that the nozzle hole used for melt spinning is changed. That is, in the method for producing a spunbonded nonwoven fabric by accumulating composite-type long fibers obtained by composite melt spinning of low-melting polyester and high-melting polyester, the shape of the nozzle hole used for melt spinning is Y-shaped. Connected to the top, bottom, left and right at the lower end, and adjacent Y-shaped / s and ⁇ s are parallel A shape (hereinafter referred to as “Y4 shape”) may be used.
- Y4 shape A shape
- This nozzle hole has four Y-shapes shown in FIG. And it connects with the upper and lower sides and right and left by the lower end 7 of Y character, and becomes Y4 form shown in FIG.
- Y4 form adjacent Y-shaped / 8s and 8s are parallel to each other, and ⁇ 9,9s are parallel to each other.
- polyester long fibers having a substantially Y4 cross section can be obtained.
- polyester long fibers having four concave portions 2 can be obtained by making adjacent Y-shaped / 8,8 and ⁇ 9,9 parallel to each other.
- tip can be obtained.
- the low melting point polyester is supplied to the Y4 type V-shaped portion 10 and the high melting point polyester is supplied to the Y4 type + shaped portion 11.
- a composite type polyester continuous fiber in which the approximately V-shaped portion 6 is formed of a low-melting polyester component and the approximately + -shaped portion 5 is formed of a high-melting polyester component is obtained.
- a polyester nonwoven fabric is obtained by fusing. You may give a small amount of binders to the obtained polyester nonwoven fabric as needed.
- the fineness of the polyester long fiber is preferably 10 dtex or more, more preferably 15 dtex or more. If the fineness is less than 10 decitex, the air permeability and mechanical properties tend to decrease.
- the upper limit of the fineness is not particularly limited, but is preferably about 30 dtex. When the fineness exceeds 30 dtex, when melt spinning, the cooling property of the long fibers is lowered, and the productivity is lowered.
- the basis weight of the polyester nonwoven fabric is preferably about 30 to 130 g / m 2 .
- the basis weight is less than 30 g / m 2 , the mechanical properties tend to decrease.
- a fabric weight exceeds 130 g / m ⁇ 2 >, a polyester nonwoven fabric will become heavy and it will be inferior to handleability.
- a conventionally well-known thing is used as an ultrafine fiber nonwoven fabric. Specifically, a melt blown nonwoven fabric is used.
- the material for the ultrafine fiber polyolefin such as polyethylene or polypropylene, polyester, or the like is used.
- the thickness of the ultrafine fiber the fiber diameter (diameter in terms of a circle) is about 1 to 5 ⁇ m. When the fiber diameter exceeds 5 ⁇ m, it becomes difficult to obtain a medium / high performance air filter material. If the fiber diameter is less than 1 ⁇ m, the productivity tends to decrease.
- the basis weight of the ultrafine fiber nonwoven fabric is preferably about 10 to 30 g / m 2 .
- the basis weight is less than 10 g / m 2 , the fiber density is low, and it becomes difficult to obtain a medium to high performance air filter material. If the basis weight exceeds 30 g / m 2 , the quality becomes excessive and unreasonable.
- the ultrafine fiber non-woven fabric and the polyester non-woven fabric are bonded with a powdered or web-like hot melt adhesive.
- the hot-melt adhesive has a melting point lower than that of the ultrafine fibers and the long polyester fibers.
- the melting point of the polypropylene ultrafine fibers is lower.
- the specific melting point of the hot melt adhesive is about 50 to 120 ° C.
- the hot melt adhesive is in the form of a powder or a web. This is to secure an area where no hot melt adhesive is present and to prevent a decrease in air permeability. For example, when an ultrafine fiber nonwoven fabric and a polyester nonwoven fabric are bonded with a film-like hot melt adhesive, the hot melt adhesive is present on the entire surface, and the air permeability of the obtained air filter material is extremely lowered.
- the amount of hot melt adhesive applied is preferably about 1 to 30 g / m 2 .
- the application amount of the hot melt adhesive is less than 1 g / m 2 , the fine fiber nonwoven fabric and the polyester nonwoven fabric tend to be easily peeled off.
- the application amount of the hot melt adhesive exceeds 30 g / m 2 , the area where the adhesive does not exist decreases, and the air permeability tends to decrease.
- the air filter material according to the present invention is used as an air filter by a conventionally known method.
- the air filter material according to the present invention is cut into an appropriate size and attached to a filter frame to be used as an air filter for a clean room or the like.
- the air filter material according to the present invention is pleated and fixed to a filter frame, and used as an air filter for a dust collector, an automobile or the like.
- the air filter material according to the present invention is a polyester nonwoven fabric having a specific cross-sectional shape, which is laminated and integrated with an ultrafine fiber nonwoven fabric using a specific hot melt adhesive, so that the air permeability is unlikely to decrease. There is an effect.
- Low-melting polyester (relative viscosity [ ⁇ rel] 1.44, which is a copolymer of 92 mol% terephthalic acid (TPA) and 8 mol% isophthalic acid (IPA) as the dicarboxylic acid component and 100 mol% ethylene glycol (EG) as the diol component.
- TPA terephthalic acid
- IPA isophthalic acid
- EG ethylene glycol
- a melting point of 230 ° C. was prepared, and 4% by mass of titanium oxide as a crystal nucleating agent was added to the low melting point polyester as a low melting point polyester component.
- polyethylene terephthalate obtained by cocondensation polymerization of a monomer composed of 100 mol% of terephthalic acid (TPA) as a dicarboxylic acid component and 100 mol% of ethylene glycol (EG) as a diol component is converted into a high melting point polyester component (relative viscosity [ ⁇ rel] 1.38, melting point 260 ° C.).
- a low melting point polyester component is supplied to the V-shaped portion, and a high melting point polyester component is supplied to the + -shaped portion, and the spinning temperature is 285 ° C., the single-hole discharge rate is 8.33 g / Melt spun in minutes.
- the mass ratio of the supply amount of the low melting point polyester component and the supply amount of the high melting point polyester component was 1/2.
- the long fiber group discharged from the nozzle hole was introduced into the air soccer entrance 2 m below and pulled so that the fineness of the polyester long fiber was 17 dtex.
- the composite polyester long fiber group having the cross section shown in FIG. 2 discharged from the air soccer exit was opened using a fiber opening device and then accumulated on a moving net conveyor to obtain a long fiber web.
- This long fiber web was introduced into a hot embossing device consisting of an embossing roll (the area of each embossing convex part is 0.7 mm 2 and the area ratio of the embossing convex part to the total area of the roll is 15%) and a flat roll, Thermal embossing was performed under conditions of a surface temperature of 213 ° C. and a linear pressure of 300 N / cm to obtain a polyester nonwoven fabric A having a basis weight of 40 g / m 2 .
- a polyester nonwoven fabric B was obtained in the same manner as in Production Example A except that the basis weight was changed to 70 g / m 2 .
- Ultrafine fiber nonwoven fabric Polypropylene having a melting point of 162 ° C. is introduced into a melt-blowing die, heated air is blown from the die to form ultrafine fibers, accumulated on a moving conveyor, and made of ultrafine fibers having a fiber diameter of about 3 ⁇ m. An ultrafine fiber nonwoven fabric of m 2 was obtained.
- Example 1 A powdered hot melt adhesive (powder made of low-density polyethylene having a melting point of about 100 ° C.) is sprayed on the ultrafine fiber nonwoven fabric so as to be 5 g / m 2, and a polyester nonwoven fabric A is laminated thereon. A laminate was obtained.
- the laminated body was subjected to heat treatment while being carried on a lower conveyor of a heat treatment apparatus in which a conveyor whose surface was covered with a Teflon film was arranged in two stages.
- the temperature of the gap between the upper and lower conveyors was controlled at 100 ° C., and this gap was gradually narrowed from the inlet toward the outlet, and the gap at the outlet was 1 mm.
- the laminated body which came out of the heat processing apparatus was cooled, and the air filter material which the ultrafine fiber nonwoven fabric and the polyester nonwoven fabric A integrated was obtained.
- the air filter material had an air permeability of 26.5 cc / m 2 / sec.
- the ultrafine fiber nonwoven fabric and the polyester nonwoven fabric A were firmly integrated, and the ultrafine fiber nonwoven fabric was damaged when it was peeled off.
- Example 2 An air filter material was obtained by the same method as in Example 1 except that the polyester nonwoven fabric B was used in place of the polyester nonwoven fabric A.
- the air filter material had an air permeability of 25.7 cc / m 2 / sec. Moreover, the ultrafine fiber nonwoven fabric and the polyester nonwoven fabric B were firmly integrated.
- Example 3 An air filter material was obtained by the same method as in Example 1 except that the amount of powdered hot melt adhesive (powder made of low density polyethylene having a melting point of about 100 ° C.) was changed to 10 g / m 2 . .
- the air filter material had an air permeability of 25.3 cc / m 2 / sec.
- the ultrafine fiber nonwoven fabric and the polyester nonwoven fabric A were firmly integrated.
- Example 4 An air filter material was obtained in the same manner as in Example 2 except that the amount of powdered hot melt adhesive (powder made of low density polyethylene having a melting point of about 100 ° C.) was changed to 10 g / m 2 . .
- the air filter material had an air permeability of 25.0 cc / m 2 / sec.
- the ultrafine fiber nonwoven fabric and the polyester nonwoven fabric B were firmly integrated.
- Example 5 Instead of powdered hot melt adhesive (powder made of low-density polyethylene with a melting point of about 100 ° C.), a web-like hot melt adhesive (manufactured by Kureha Tech Co., Ltd., product number “LNS0020”) is made of copolymer polyamide. The melting point is 115 ° C., and the weight per unit area is 20 g / m 2 . The air filter material had an air permeability of 23.7 cc / m 2 / sec. Moreover, the ultrafine fiber nonwoven fabric and the polyester nonwoven fabric A were firmly integrated.
- a web-like hot melt adhesive manufactured by Kureha Tech Co., Ltd., product number “LNS0020”
- the melting point is 115 ° C.
- the weight per unit area is 20 g / m 2 .
- the air filter material had an air permeability of 23.7 cc / m 2 / sec.
- Example 6 Instead of powdered hot-melt adhesive (powder made of low-density polyethylene with a melting point of about 100 ° C.), a web-shaped hot-melt adhesive (manufactured by Kureha Tech Co., Ltd., product number “LNS0020”) is made of copolymer polyamide. Yes, the melting point is 115 ° C., and the basis weight is 20 g / m 2 . The air filter material had an air permeability of 23.9 cc / m 2 / sec. Moreover, the ultrafine fiber nonwoven fabric and the polyester nonwoven fabric B were firmly integrated.
- SYMBOLS 1 One substantially Y-shaped lower end of the substantially Y shape which is the cross-sectional shape of a long fiber 2
- the recessed part formed in the substantially Y4 shape 3 The convex part formed in the substantially Y4 shape 4
- the small recessed part formed in the substantially Y4 shape 5 Approximate cross section in the approximate Y4 shape 6
- One Y-shaped lower end of the Y4 shape that is the shape of the nozzle hole at the time of melt spinning 8 9 Y-shaped ⁇ 10 Y4 V-shaped part 11 Y4 cross
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Nanotechnology (AREA)
- Nonwoven Fabrics (AREA)
- Filtering Materials (AREA)
- Laminated Bodies (AREA)
Abstract
Description
形状(以下、「略Y4形状」という。)であって、該ポリエステル長繊維相互間は熱融着によって結合されており、前記極細繊維不織布と前記ポリエステル不織布とは、極細繊維及びポリエステル長繊維の融点よりも低い融点を持つ粉末状又はくもの巣状ホットメルト接着剤によって貼合されていることを特徴とするエアフィルター材に関するものである。
形状(以下、「Y4形」という。)のものを用いればよい。
(1)融点(℃):
パーキンエルマー社製DSC-7型の示差走査型熱量計を用いて、昇温速度20℃/分で測定した融解吸熱ピークの最大値を与える温度を融点とした。
(2)相対粘度[ηrel]:
フェノールと四塩化エタンとの等質量比の混合溶媒100mlに試料0. 5gを溶解し、温度20℃の条件で常法により測定した。
(3)通気度(cc/m2/sec):
フラジール型通気度試験機を用い、JIS L 1096-1979の「一般織物試験方法」に準拠し、傾斜型気圧計は1.27cmに固定して測定した。
ジカルボン酸成分としてテレフタル酸(TPA)92mol%とイソフタール酸(IPA)8mol%、ジオール成分としてエチレングリコール(EG)100mol%との共重合体である低融点ポリエステル(相対粘度〔ηrel〕1.44、融点230℃)を準備し、この低融点ポリエステルに、結晶核剤として4質量%の酸化チタンを添加したものを低融点ポリエステル成分として用いた。
目付を70g/m2に変更する他は、上記製造例Aと同一の方法で、ポリエステル不織布Bを得た。
融点162℃のポリプロピレンをメルトブローダイに導入し、ダイ中から加熱空気を吹き付けて極細繊維を形成し、移動するコンベア上に集積して、繊維径が概ね3μm程度の極細繊維よりなる、目付20g/m2の極細繊維不織布を得た。
極細繊維不織布の上に、粉末状ホットメルト接着剤(融点が約100℃の低密度ポリエチレンよりなるパウダー)を5g/m2となるように散布し、さらにその上にポリエステル不織布Aを積層して積層体を得た。この積層体を、表面がテフロン膜で覆われたコンベアが上下二段に配置された加熱処理装置の下段のコンベアに載せて搬送しながら、加熱処理を行った。上段と下段のコンベアの隙間の温度は100℃に制御され、この隙間は入口から出口に向けて徐々に狭くし、出口での隙間を1mmとした。
ポリエステル不織布Aに代えて、ポリエステル不織布Bを用いる他は、実施例1と同一の方法により、エアフィルター材を得た。このエアフィルター材の通気度は、25.7cc/m2/secであった。また、極細繊維不織布とポリエステル不織布Bとは強固に一体化していた。
粉末状ホットメルト接着剤(融点が約100℃の低密度ポリエチレンよりなるパウダー)の散布量を、10g/m2に変更する他は、実施例1と同一の方法により、エアフィルター材を得た。このエアフィルター材の通気度は、25.3cc/m2/secであった。また、極細繊維不織布とポリエステル不織布Aとは強固に一体化していた。
粉末状ホットメルト接着剤(融点が約100℃の低密度ポリエチレンよりなるパウダー)の散布量を、10g/m2に変更する他は、実施例2と同一の方法により、エアフィルター材を得た。このエアフィルター材の通気度は、25.0cc/m2/secであった。また、極細繊維不織布とポリエステル不織布Bとは強固に一体化していた。
粉末状ホットメルト接着剤(融点が約100℃の低密度ポリエチレンよりなるパウダー)に代えて、くもの巣状ホットメルト接着剤(呉羽テック株式会社製、品番「LNS0020」、素材は共重合ポリアミドであり、融点は115℃であり、目付は20g/m2である。)を用いる他は、実施例1と同一の方法でエアフィルター材を得た。このエアフィルター材の通気度は、23.7cc/m2/secであった。また、極細繊維不織布とポリエステル不織布Aとは強固に一体化していた。
粉末状ホットメルト接着剤(融点が約100℃の低密度ポリエチレンよりなるパウダー)に代えて、くもの巣状ホットメルト接着剤(呉羽テック株式会社製、品番「LNS0020」、素材は共重合ポリアミドであり、融点は115℃であり、目付は20g/m2である。)を用いる他は、実施例2と同一の方法でエアフィルター材を得た。このエアフィルター材の通気度は、23.9cc/m2/secであった。また、極細繊維不織布とポリエステル不織布Bとは強固に一体化していた。
2 略Y4形状で形成された凹部
3 略Y4形状で形成された凸部
4 略Y4形状で形成された小凹部
5 略Y4形状中の略十字部
6 略Y4形状中の略V字部
7 溶融紡糸する際のノズル孔の形状であるY4形状の一つのY字の下端
8 Y字の/
9 Y字の\
10 Y4形のV字部
11 Y4形の十字部
Claims (3)
- 略Y4形状の各々の略V字部が低融点ポリエステルよりなり、その他の略+字部が高融点ポリエステルよりなる複合型ポリエステル長繊維よりなる請求項1記載のエアフィルター材。
- 低融点ポリエステルの熱融着によって、ポリエステル長繊維相互間が結合されている請求項2記載のエアフィルター材。
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JP2018199876A (ja) * | 2017-05-26 | 2018-12-20 | ユニチカ株式会社 | 熱成型不織布の製造方法 |
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