WO2018221063A1 - Filtre en tissu non tissé - Google Patents

Filtre en tissu non tissé Download PDF

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Publication number
WO2018221063A1
WO2018221063A1 PCT/JP2018/016211 JP2018016211W WO2018221063A1 WO 2018221063 A1 WO2018221063 A1 WO 2018221063A1 JP 2018016211 W JP2018016211 W JP 2018016211W WO 2018221063 A1 WO2018221063 A1 WO 2018221063A1
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WO
WIPO (PCT)
Prior art keywords
nonwoven fabric
resin
microfibers
fibers
fabric filter
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PCT/JP2018/016211
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English (en)
Japanese (ja)
Inventor
崇 西谷
直樹 柳岡
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日本バイリーン株式会社
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Priority to JP2019522020A priority Critical patent/JP7077515B2/ja
Publication of WO2018221063A1 publication Critical patent/WO2018221063A1/fr

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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
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs

Definitions

  • the present invention relates to a nonwoven fabric filter suitable for mounting on an air conditioner provided in a vehicle or a living environment, and particularly to a technique capable of maintaining a low pressure loss over a long period of time.
  • Nonwoven fabric filters with a large area and low pressure loss are known.
  • it is mesh
  • a non-woven member (B) composed of a plurality of bulges bulged in the opposite direction to the basal base, the mesh having an average pore diameter of 1 mm to 30 mm,
  • a nonwoven fabric filter composed of a composite fiber sheet having an average diameter of 0.01 mm to 10 mm is disclosed.
  • the non-woven fabric filter described in Patent Document 1 has a structure that collects dust at a bulging portion provided from one surface of the striate body toward the other surface to ensure a dust holding amount. .
  • a nonwoven fabric filter collects dust at a high density on the upstream surface as the collection proceeds, so that the pressure loss increases quickly and the time to reach a certain pressure loss is practical. Above, there was still a problem that it was short. Furthermore, when the pressure loss increases, there is a problem that the filter medium is compressed by the wind pressure and breaks through in a very short time.
  • an object of the present invention is to provide a non-woven fabric filter that is highly resistant to deformation in the thickness direction even when wind pressure is applied and suppresses an increase in pressure loss and increases dust retention, and has high shape maintainability. To do.
  • the present invention provides the following.
  • (1) 1st aspect of this invention is a nonwoven fabric filter provided with the microfiber which has a fiber diameter smaller than the average fiber diameter of a nonwoven fabric base-material constituent fiber in the thickness direction of a nonwoven fabric base material, Comprising: The said microfiber Is oriented with a depth of 10% or more and 100% or less with respect to the apparent thickness of the non-woven fabric substrate, and is formed by the fine fibers or a combination of the fine fibers and the non-woven fabric substrate constituting fibers. It is characterized by forming.
  • the “apparent thickness” referred to in the present invention refers to a dimension measured in a state where no external force is applied to the nonwoven fabric filter.
  • a second aspect of the present invention is the nonwoven fabric filter according to (1), wherein in a filtration performance test by a mass method using ASHRAE dust defined in ASHRAE 52.1-1992, the wind speed is 0.30 m.
  • the average mass method efficiency is 80% or more and 99% or less at the time of / sec, and the dust holding amount when the pressure loss rises to 100 Pa is 10.0 g / m 2 or more. To do.
  • a third aspect of the present invention is the nonwoven fabric filter according to (1) or (2), wherein the microfiber is a polyacrylonitrile resin, a polyethersulfone resin, a polyolefin resin, a polyester resin, or polyvinyl alcohol. It is formed by either resin or cellulose.
  • a fourth aspect of the present invention is the nonwoven fabric filter according to any one of (1) to (3), wherein the nonwoven fabric base-constituting fibers are made of a polyester resin and a modified polyester resin. It is characterized by comprising a composite fiber.
  • the nonwoven fabric filter of the present invention has a nonwoven fabric substrate and microfibers, and the microfibers are oriented with a depth of 10% or more and 100% or less with respect to the apparent thickness of the nonwoven fabric substrate, A mesh portion is formed by a combination of fine fibers and non-woven fabric base constituent fibers.
  • the presence of the net-like portion oriented mainly in the thickness direction of the non-woven fabric base material serving as a base enables filtration utilizing the thickness, and clogging is less likely to occur.
  • the nonwoven fabric filter of the present invention suppresses an increase in pressure loss, increases the amount of dust, and is not easily crushed in the thickness direction even when wind pressure is applied, and has high shape maintainability.
  • FIG. 10 is an electron micrograph of a cross-section of a non-woven filter produced by a technique different from the microfiber formation technique shown in FIG. It is the electron micrograph which expanded the microfiber about Drawing 10A.
  • the nonwoven fabric filter of the present invention is a nonwoven fabric filter comprising fine fibers having a fiber diameter smaller than the average fiber diameter of the nonwoven fabric substrate constituting fibers in the thickness direction of the nonwoven fabric substrate, It is oriented with a depth of 10% or more and 100% or less with respect to the apparent thickness, and the mesh portion is formed by microfibers or a combination of microfibers and nonwoven fabric constituting fibers.
  • the filtration performance was evaluated by the mass method using ASHRAE dust according to the test method specified in ASHRAE 52.1-1992.
  • the average mass method efficiency was It is preferably 80% or more and 99% or less, and the dust holding amount at the time when the pressure loss rises to 100 Pa is preferably 10.0 g / m 2 or more.
  • the average mass method efficiency is 85% or more and 99% or less, the dust retention amount is more preferably 40.0 g / m 2 or more, and the average mass method efficiency is 90%. More preferably, the amount of dust is 99% or less, and the dust holding amount is 60.0 g / m 2 or more. Examples of suitable forms of each configuration are as follows.
  • the nonwoven fabric filter of the present invention has a nonwoven fabric substrate that retains the form of the nonwoven fabric filter and can support fine fibers.
  • the average fiber diameter of the nonwoven fabric base material constituting fiber is not particularly limited, but is preferably 7 ⁇ m or more, more preferably 10 ⁇ m or more, and further preferably 15 ⁇ m or more so as to be excellent in the above action. preferable.
  • the average fiber diameter is 15 ⁇ m or more, an increase in pressure loss is suppressed, the amount of dust retained is increased, and even if wind pressure is applied, the shape is not easily crushed and has high shape maintainability.
  • the upper limit of the average fiber diameter of a nonwoven fabric base constituent fiber is not specifically limited, It is preferable that it is 100 micrometers or less so that filtration efficiency may be excellent.
  • the “fiber diameter” in the present invention is a value obtained when a fiber existing on the surface of the substrate or inside the substrate is photographed and observed using a scanning electron microscope (SEM: Scanning Electron Microscope; hereinafter referred to as SEM) and visually read. Means fiber diameter.
  • SEM Scanning Electron Microscope
  • Nonwoven fabric base fibers include polyolefin resins (polyethylene, polypropylene, polymethylpentene, polyolefins having a structure in which a part of hydrocarbon is substituted with a cyano group or a halogen such as fluorine or chlorine), styrene resin, polyether resin (polyethylene).
  • polyolefin resins polyethylene, polypropylene, polymethylpentene, polyolefins having a structure in which a part of hydrocarbon is substituted with a cyano group or a halogen such as fluorine or chlorine
  • styrene resin polyether resin (polyethylene).
  • the organic polymer that becomes the nonwoven fabric base-constituting fiber either a linear polymer or a branched polymer may be used, and the organic polymer may be a block copolymer or a random copolymer. It does not matter whether the organic polymer has a three-dimensional structure or crystallinity.
  • the nonwoven fabric substrate constituting fiber one kind of resin component or a mixture of a plurality of resin components may be used. Also, it is possible to use a composite fiber in which a plurality of types of resin components are divided into different sections and combined non-uniformly.
  • the type of the composite fiber any of a core-sheath type, a sea-island type, a side-by-side type, and an orange type may be used. If so, durability can be imparted because the adhesive strength is high when the nonwoven fabric substrate is produced and when the nonwoven fabric filter is used, which is most preferable.
  • thermoplastic resin a thermoplastic resin
  • general-purpose regular fiber having a single component
  • latent crimpable property having a plurality of resins having different thermal shrinkage rates.
  • a composite fiber may be used.
  • nonwoven fabric base fiber is preferably composed of at least one kind of composite fiber made of a polyester resin and a modified polyester resin because the base material after heat bonding has high rigidity and is relatively inexpensive.
  • the basis weight of the nonwoven fabric base material is not particularly limited, but is preferably 50 g / m 2 or more and 450 g / m 2 or less so as to suppress an increase in pressure loss and increase the dust holding amount. It is more preferably 70 g / m 2 or more and 300 g / m 2 or less, and further preferably 100 g / m 2 or more and 200 g / m 2 or less. If the basis weight is lower than the lower limit of this preferable numerical range, the shape of the mesh portion becomes non-uniform, and it may be difficult to improve the dust holding amount. Moreover, when the said fabric weight is set higher than the said range, an early rise of pressure loss will be caused and the lifetime of a nonwoven fabric filter may become remarkably short.
  • the nonwoven fabric filter of the present invention is a nonwoven fabric filter comprising fine fibers having a fiber diameter smaller than the average fiber diameter of the nonwoven fabric substrate constituting fibers in the thickness direction of the nonwoven fabric substrate, Oriented with a depth of 10% or more and 100% or less with respect to the apparent thickness, and the net-like portion is formed by the microfiber or the combination of the microfiber and the non-woven fabric substrate constituent fiber.
  • This is a non-woven fabric filter with high shape-maintainability that prevents clogging, prevents pressure clogging, suppresses increase in pressure loss, increases dust retention, and does not collapse in the thickness direction even when wind pressure is applied. is there.
  • the “thickness maintaining ratio” when subjected to the above-mentioned filtration performance test is preferably 95% or more, more preferably 97% or more, and still more preferably 98% or more.
  • the above-mentioned “thickness direction” means a direction substantially perpendicular to the main surface of the nonwoven fabric filter.
  • the fine fibers may be present at any position on the nonwoven fabric substrate. For example, it can exist from at least one surface of the nonwoven fabric substrate to the inside, or can be present only within the nonwoven fabric substrate. In particular, if a form existing from at least one surface to the inside of the nonwoven fabric substrate is taken, a density gradient in which the upstream side becomes rough can be realized in the filter medium when the surface is used as the filtration downstream side. Furthermore, if the fiber diameter of the microfibers is smaller than the average fiber diameter of the nonwoven fabric base constituent fibers, dust that cannot be collected by the nonwoven fabric base material can be collected by the net-like portion.
  • the fiber diameter of the microfibers is not particularly limited as long as it is smaller than the average fiber diameter of the nonwoven fabric base constituent fibers. That is, when the average fiber diameter of the nonwoven fabric base constituent fiber is 7 ⁇ m or more, the fiber diameter of the microfiber is preferably 1 nm or more and less than 7 ⁇ m, and when the average fiber diameter of the nonwoven fabric base constituent fiber is 10 ⁇ m or more, The fiber diameter of the microfiber is preferably 1 nm or more and less than 10 ⁇ m. When the average fiber diameter of the nonwoven fabric base constituent fiber is 15 ⁇ m or more, the fiber diameter of the microfiber is preferably 1 nm or more and less than 15 ⁇ m, and preferably 1 nm or more.
  • the electron micrograph of FIG. 6 shows the fiber diameter of the microfiber.
  • Such microfibers are oriented with a depth of 10% or more and 100% or less with respect to the apparent thickness of the nonwoven fabric substrate, and form a net-like portion containing the microfibers, so that much dust is trapped. I can gather. The deeper the depth, the wider the range of the net-like portion containing the microfibers and the better the dust collecting ability. Therefore, the depth is 30% or more and 100% or less with respect to the apparent thickness of the nonwoven fabric substrate.
  • orientation with a depth more preferably with a depth of 40% or more and 100% or less, and even more preferably with a depth of 50% or more and 100% or less.
  • “orientation with a depth of 10% or more and 100% or less with respect to the apparent thickness” means 10% or more and 100% or less of the value of the thickness with respect to the apparent thickness of the substrate. The state where the “net-like part” has reached the depth.
  • This microfiber depth measurement method uses 10 electron micrographs of a non-woven fabric filter cross section, and in each photo, select 10 points that are equal in the plane direction of the non-woven fabric filter, and stretch the mesh portion in the thickness direction. Is measured with three significant figures on the photograph. The 10-point average is calculated 10 times, and the average is defined as “depth” (2 significant digits). “Depth” as used herein does not necessarily match the length of the microfiber, and is defined as the deepest distance of the fiber from the surface closer to the microfiber existing portion at the location selected as the observation site of the cross-sectional photograph. To do. For example, when different microfibers are continuously observed from one surface to the other surface in the base material, the deepest portion is defined as “depth”. In addition, with respect to the “apparent thickness” of the nonwoven fabric substrate, the nonwoven fabric substrate is averaged using the same method as the average thickness of the nonwoven fabric substrate extending in the thickness direction. The apparent thickness of the substrate (2 significant digits) was used.
  • the net part in the present invention may be a case where the net part is composed of fine fibers and non-woven fabric base constituent fibers. More specifically, as the form of the “net-like part”, (A) A state in which microfibers having branches are connected mainly in the thickness direction across the nonwoven fabric base constituent fibers as shown in FIGS. 10A and 10B described later, for example. (B) Microfibers having relatively few branches However, as shown in FIG. 9 to be described later, for example, a state (columnar shape) connected across the thickness direction of the nonwoven fabric substrate (C) The state in which the branched microfibers are connected in the form of pockets within the nonwoven fabric substrate as shown in FIG. It is possible to improve the shape maintaining property of the nonwoven fabric filter in any state.
  • the microfibers can be bonded and connected, or can be simply contacted and connected without bonding.
  • positioning position in the thickness direction of this mesh part may be any of the deeper positions than the surface part of the nonwoven fabric filter.
  • the density gradient can be provided in the nonwoven fabric filter by variously selecting the arrangement position in the thickness direction of the mesh portion.
  • the life of the filter can be improved by using this for the inflow surface.
  • the average hole diameter read with the photograph by SEM in the surface (filtration surface) used for the inflow surface of a nonwoven fabric filter is 5 micrometers or more, and it is preferable that it is 10 micrometers or more.
  • the “average hole diameter” as used herein refers to, for example, arbitrarily selecting 10 openings in an electron micrograph of the filtration surface taken at a predetermined magnification as shown in FIG. 1B, and configuring each opening.
  • the diameter of a perfect circle inscribed in the fibers to be treated is regarded as “open hole diameter”, and the average value at 10 locations is defined as “average open hole diameter”.
  • the perfect circle for reading the aperture diameter is to be read on a generally two-dimensional plane (front side in the electron micrograph), and the perfect circle for the aperture observed on the back side in the electron micrograph is from the object to be measured. Shall be excluded.
  • the constituent resin of the microfiber is not particularly limited, for example, polyvinylidene fluoride (PVDF) resin, polyvinylidene fluoride-hexafluoropropylene copolymer resin, polyacrylonitrile (PAN) resin, polyacrylonitrile-methacrylate copolymer Resin, polymethacrylic acid resin, polymethyl methacrylate resin, polyvinyl chloride resin, polyvinylidene chloride-acrylate copolymer resin, polycarbonate resin, polystyrene resin, polyethylene resin, polyethersulfone resin, polyolefin resin, polyester resin, polypropylene resin Nylon resin such as nylon 12, nylon-4, 6, etc., aramid resin, polyimide resin, polybenzimidazole resin, carbon nanotube, cellulose, cellulose acetate resin, acetic acid Rulose butyrate resin, polyvinylpyrrolidone-vinyl acetate resin, poly (bis- (2- (2-methoxy-eth
  • the pitch-based resin can be given.
  • the resin is composed of any one selected from a polyacrylonitrile resin, a polyethersulfone resin, a polyolefin resin, a polyester resin, a polyvinyl alcohol resin, and a cellulose having good fiber-forming properties.
  • the basis weight of the microfiber is not particularly limited, but is preferably 0.1 g / m 2 or more and 50 g / m 2 or less so as to suppress an increase in pressure loss and to increase the dust holding amount.
  • 0.2 g / more preferably m is 2 or more 40 g / m 2 or less, further preferably 1.0 g / m 2 or more 30 g / m 2 or less, 2.0 g / m 2 or more 15 g / m 2
  • any means may be adopted as long as it is a well-known manufacturing method capable of realizing a nonwoven fabric as a base of a mesh portion containing microfibers.
  • nonwoven fabric substrate production methods include dry spinning, wet spinning, direct spinning (melt blow, spunbond, flash span), wet, or dry (eg card, airlay) )
  • After forming the fiber web for example, a method in which the fibers constituting the fiber web are fused under pressure or no pressure, a method of bonding with a binder, a method of intertwining with a water stream or a needle, etc.
  • a known method such as the above can be used.
  • the method of bonding fibers together can form a relatively bulky nonwoven fabric substrate and form a fine fiber network within the nonwoven fabric substrate. It is suitable because it is easy to do.
  • nonwoven fabric substrate made of fibers having an average fiber diameter of 7 ⁇ m or more, more preferably a nonwoven fabric substrate made of fibers having an average fiber diameter of 10 ⁇ m or more, and an average fiber diameter of It is most preferable to prepare a nonwoven fabric substrate composed of fibers of 15 ⁇ m or more.
  • the non-woven fabric filter of the present invention is formed by orienting the net-like portion containing microfibers with respect to the non-woven fabric substrate with a depth of 10% or more and 100% or less with respect to the apparent thickness of the non-woven fabric substrate. be able to.
  • Examples of a method for forming a mesh-like portion containing microfibers include, for example, (a) a technique in which pulp-like microfibers are placed inside a substrate by a wet method and then fused and fixed (b) a solvent such as water or an organic solvent (C) A technique for discharging and spinning a synthetic resin dissolved in a base material by high-speed air and fixing it inside the base material (c) Dispersing fine fibers such as cellulose fibers having a nano-order fiber diameter in a solvent such as water, A technique of freeze-drying in a state in which at least a portion of the prepared nonwoven fabric base material is soaked (d) A resin material that is a raw material of microfibers is dissolved in a solvent, applied to at least a portion of the nonwoven fabric substrate, and freeze-dried Technology (e) A solution in which a resin material of microfibers is dissolved in a nonwoven fabric base material is applied, and an air flow is applied in the thickness direction of the base material to generate a
  • Technology Rukoto can. In selecting these technologies, by adopting a manufacturing method in which microfibers are easily oriented in the thickness direction of the base material, the shape maintenance property of the nonwoven fabric filter is increased, and the densification of the filter medium due to wind pressure is reduced.
  • a manufacturing technique capable of preventing the decrease can be employed.
  • the structure of the above-described microfibers is formed by a die used for melt spinning or flash spinning, which is disposed at a distance of 100 mm or less from one surface of the nonwoven fabric substrate. While spraying the resin, suction may be performed from the other surface of the nonwoven fabric substrate.
  • the constituent resin of the microfibers discharged from the base must be carried out in a state where the fluidity remains without solidifying until reaching the nonwoven fabric base constituent fibers, and the formation depth of the microfibers Therefore, the distance between the surface of the nonwoven fabric substrate and the die is more preferably 50 mm or less.
  • Example 6 90% by mass of a commercially available core-sheath composite fiber (fineness 2.2 dtex, fiber length 51 mm) made of a polyester resin and a modified polyester resin, and a commercially available core-sheath composite fiber (fineness of 6.
  • a non-woven fabric substrate (average fiber diameter of 15 ⁇ m) obtained by the same method as above using 6 dtex, fiber length 51 mm) and 10 mass% was used in Example 6.
  • Example 7 It consists of 50% by mass of a commercially available core-sheath type composite fiber (fineness 17.0 dtex, fiber length 51 mm) made of polyester resin and modified polyester resin, and 50% by mass of a commercially available polyester fiber (fineness 33 dtex, fiber length 76 mm).
  • a nonwoven fabric substrate (average fiber diameter of 54 ⁇ m) was prepared by the same method as described above and used in Example 7.
  • Comparative Example 2 As a base material other than the non-woven fabric, a commercially available polyester resin mesh disclosed in Patent Document 1 described above (a pore diameter of 3 mm and a wire diameter of 0.8 mm defined by the mesh) is prepared. Using.
  • a net-like portion containing microfibers that is, a net-like portion where fibers constituting the microfibers are bonded to each other is confirmed. it can.
  • Example 1D shown in FIG. 4 or FIG. 5 in which the main part of FIG. 5 is enlarged a number of substantially bag-like nets are formed as pocket-shaped components on one surface side of the nonwoven fabric filter.
  • FIG. 7 in the nonwoven fabric filter according to Comparative Example 1A it is understood that the mesh portion is hardly formed, and the microfibers formed by ejection are laminated and deposited on the surface of the nonwoven fabric substrate. it can.
  • the nonwoven fabric filter according to Comparative Example 2 the above-mentioned commercially available polyester resin mesh is used as a base material, and a net-like part containing microfibers in the thickness direction of the base material, that is, a microscopic part.
  • a net-like portion in which fibers are bonded to each other is not formed, and is formed so that a convex protrusion rises on the back side of the base material on which fine fibers are discharged and deposited.
  • the viscosity of the polymer solution for forming microfibers hereinafter abbreviated as “viscosity”) was lower than that in each Example, or because the absolute resin concentration was low, the droplets were coated on the substrate. It was not possible to form a net-like part.
  • the nonwoven fabric filter comprised only with the nonwoven fabric base material without having a microfiber was used for the comparative example 4 as a blank.
  • the main one is a thickness when a compression load of 20 g / cm 2 specified in JIS L 1096 is applied by a commercially available Maeda type compression elasticity measuring instrument, and a thickness without any load.
  • the ratio with (apparent thickness) was obtained as a percentage and recorded as the thickness retention rate.
  • Table 1 shows the configuration of the nonwoven fabric substrate described above, the discharge formation conditions and configuration of the mesh portion formed thereon, and the thickness maintenance ratio.
  • Example 1A the basis weight of the mesh portion is 5 g / m 2 , the depth of the mesh portion is 2.8 mm, the thickness maintenance rate is as high as 99.3%, and it is good without almost being crushed. Was in good condition.
  • Example 1D configured with the same basis weight as that of Example 1A has a thickness maintenance ratio of 97.0% even when the depth of the mesh part is relatively shallow, 0.8 mm. Like 1A, it was not crushed by the wind pressure and maintained a good state. As shown in FIG. 1B, such a small pressure loss means that a relatively large opening of 5 ⁇ m or more is formed and the pressure loss is low as seen from the filtration surface side.
  • Comparative Example 1B (mesh portion depth 0.26 mm) in which microfibers are provided only on the surface of the base material, the thickness of the mesh portion is small even if the basis weight of the microfibers is increased. The retention rate was as low as 93.5%. Furthermore, in Comparative Example 2 prepared by imitating the technique of Patent Document 1 described above, since there is no base material skeleton for maintaining the thickness of the entire microfiber, the thickness maintenance ratio is 37.5%, It was judged that good filtration performance could not be exhibited.
  • the initial pressure loss (Pa) was a value measured without supplying dust at the above wind speed.
  • Table 2 shows measurement results of average mass efficiency, initial pressure loss, and dust retention.
  • any of ⁇ , ⁇ , ⁇ is described according to the following criteria, and since Comparative Example 4 does not include microfibers, “-” is described in the evaluation column. is doing.
  • Double-circle Average mass method efficiency was 85% or more, and the dust holding amount was 40 g / m ⁇ 2 > or more.
  • A The average mass method efficiency was 80% or more, and the dust retention amount was 10 g / m 2 or more and less than 40 g / m 2 .
  • X The average mass method efficiency was less than 80%, or the dust retention amount was less than 10 g / m 2 .
  • the dust holding amount was extremely small.
  • Comparative Example 3 since the viscosity prepared as described above is low or the absolute resin concentration is low, the microfibers cannot be ejected, and as a result, there is no network part. Equally low value.
  • FIG. 9 shows a case in which a solution of polyvinyl alcohol resin using water as a solvent is applied to the surface of a nonwoven fabric substrate made of a core-sheath type composite fiber used in the above-described embodiment, and high-speed air is applied by a commercially available blower. It is the photograph which image
  • the nonwoven fabric filter shown as FIG. 10A and FIG. 10B is prepared by impregnating a commercially available nanocellulose fiber dispersion into the same nonwoven fabric substrate and then removing the water of the dispersion medium with a freeze vacuum dryer. .
  • a net-like net-like portion was confirmed in a region surrounded by a one-dot chain line. From this, it can be expected that the present structure improves a high thickness maintenance rate and collection performance, and the same excellent filtration performance can be exhibited by the above-described measurement test.
  • the form of the microfiber defined in the present invention can be obtained by arbitrarily selecting the viscosity of the solution in which the resin is dispersed and the technology for fiberizing, so that the columnar shape (see FIG. 9) and the mesh shape (see FIG. 1A, FIG. 1B, FIG. 1C, FIG. 2, FIG. 3, FIG. 10A, FIG. 10B, etc.) or a bag shape (see FIG. 5). Even if the thickness maintenance ratio is improved and the aperture diameter of the nonwoven fabric base material is increased, it is possible to collect fine dust by providing a net-like part, and to achieve excellent filtration performance. did it.

Abstract

L'objectif de la présente invention est de fournir un filtre en tissu non tissé ayant des propriétés de rétention de forme élevées de telle sorte qu'un écrasement dans la direction d'épaisseur ne soit pas facile, même si une pression de vent est appliquée, en supprimant les augmentations de perte de pression et en augmentant la capacité de retenue de saleté. L'invention concerne un filtre en tissu non tissé pourvu de microfibres ayant un diamètre de fibre plus petit que le diamètre de fibre moyen de fibres constituant un matériau de base de tissu non tissé dans la direction de l'épaisseur de matériau de base de tissu non tissé, les microfibres étant orientées avec une profondeur de 10 à 100 % par rapport à l'épaisseur apparente du matériau de base de tissu non tissé, et une partie de type filet étant formée par les microfibres ou une combinaison des microfibres et des fibres constituant le matériau de base de tissu non tissé.
PCT/JP2018/016211 2017-05-31 2018-04-19 Filtre en tissu non tissé WO2018221063A1 (fr)

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JP2020001010A (ja) * 2018-06-29 2020-01-09 日本バイリーン株式会社 不織布フィルタ
WO2021039981A1 (fr) 2019-08-30 2021-03-04 ダイキン工業株式会社 Matériau de filtration pour filtre à air, et produit de filtre à air
WO2021234946A1 (fr) * 2020-05-22 2021-11-25 北越コーポレーション株式会社 Procédé de production de milieu de filtre à air et procédé de production de filtre à air
WO2022239430A1 (fr) 2021-05-14 2022-11-17 北越コーポレーション株式会社 Matériau filtrant pour filtre à air et son procédé de production

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JP2020001010A (ja) * 2018-06-29 2020-01-09 日本バイリーン株式会社 不織布フィルタ
JP7103871B2 (ja) 2018-06-29 2022-07-20 日本バイリーン株式会社 不織布フィルタ
WO2021039981A1 (fr) 2019-08-30 2021-03-04 ダイキン工業株式会社 Matériau de filtration pour filtre à air, et produit de filtre à air
WO2021234946A1 (fr) * 2020-05-22 2021-11-25 北越コーポレーション株式会社 Procédé de production de milieu de filtre à air et procédé de production de filtre à air
JP7453363B2 (ja) 2020-05-22 2024-03-19 北越コーポレーション株式会社 エアフィルタ用濾材の製造方法及びエアフィルタの製造方法
WO2022239430A1 (fr) 2021-05-14 2022-11-17 北越コーポレーション株式会社 Matériau filtrant pour filtre à air et son procédé de production
KR20230145116A (ko) 2021-05-14 2023-10-17 호쿠에츠 코포레이션 가부시키가이샤 에어 필터용 여과재 및 그 제조 방법

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