WO2019188923A1 - フィルター用湿式不織布、フィルター用濾材、およびフィルター - Google Patents

フィルター用湿式不織布、フィルター用濾材、およびフィルター Download PDF

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Publication number
WO2019188923A1
WO2019188923A1 PCT/JP2019/012395 JP2019012395W WO2019188923A1 WO 2019188923 A1 WO2019188923 A1 WO 2019188923A1 JP 2019012395 W JP2019012395 W JP 2019012395W WO 2019188923 A1 WO2019188923 A1 WO 2019188923A1
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WO
WIPO (PCT)
Prior art keywords
filter
nonwoven fabric
wet nonwoven
average fiber
wet
Prior art date
Application number
PCT/JP2019/012395
Other languages
English (en)
French (fr)
Inventor
健人 高見
裕輔 日高
Original Assignee
東洋紡株式会社
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.)
Filing date
Publication date
Priority claimed from JP2018068385A external-priority patent/JP7200494B2/ja
Priority claimed from JP2018068398A external-priority patent/JP7200495B2/ja
Application filed by 東洋紡株式会社 filed Critical 東洋紡株式会社
Priority to CN201980023208.6A priority Critical patent/CN111971105A/zh
Priority to US17/040,655 priority patent/US20210016213A1/en
Priority to EP19777006.8A priority patent/EP3777991A4/en
Publication of WO2019188923A1 publication Critical patent/WO2019188923A1/ja

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Classifications

    • 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
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0027—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B01D46/0035—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions by wetting, e.g. using surfaces covered with oil
    • 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
    • B01D46/0027—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions
    • B01D46/0036—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours with additional separating or treating functions by adsorption or absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
    • 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
    • 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
    • D—TEXTILES; PAPER
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    • 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
    • D04H1/407—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 containing absorbing substances, e.g. activated carbon
    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4309—Polyvinyl alcohol
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • 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
    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • 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
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • 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
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/12—Organic non-cellulose fibres from macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/16—Polyalkenylalcohols; Polyalkenylethers; Polyalkenylesters
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/10—Organic non-cellulose fibres
    • D21H13/20—Organic non-cellulose fibres from macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H13/24—Polyesters
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/20—Macromolecular organic compounds
    • D21H17/33—Synthetic macromolecular compounds
    • D21H17/34—Synthetic macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H17/37—Polymers of unsaturated acids or derivatives thereof, e.g. polyacrylates
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/08—Filter paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0407—Additives and treatments of the filtering material comprising particulate additives, e.g. adsorbents
    • 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
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0457—Specific fire retardant or heat resistant properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0464—Impregnants
    • 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
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0471—Surface coating material
    • B01D2239/0478—Surface coating material on a layer of the filter
    • 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
    • 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
    • B01D2239/0627—Spun-bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0636—Two or more types of fibres present in the filter material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
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    • B01D2239/08—Special characteristics of binders
    • B01D2239/083—Binders between layers of the filter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B01D2239/12—Special parameters characterising the filtering material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/04—Filters

Definitions

  • the present invention relates to a wet nonwoven fabric for a filter, a filter medium for a filter, and a filter that are excellent in removing adhered foreign substances.
  • Patent Document 4 As a further enhancement of functionality, there is an increasing demand for filters that can easily remove adhering foreign substances. However, since foreign substances cannot be easily removed, it is difficult to reuse the filter. Regarding the reuse of the filter, for example, there is a dust removal method using a suction nozzle (Patent Document 4).
  • the present invention has been made in view of the above problems, and an object thereof is to provide a reusable wet nonwoven fabric for a filter, a filter medium for a filter, and a filter that can easily remove adhering foreign matters.
  • the present invention is as follows.
  • SMD surface roughness
  • MIU average friction coefficient
  • the wet nonwoven fabric for a filter according to any one of (1) to (3) comprising a fiber having a fiber length of 30 mm or less.
  • the wet nonwoven fabric for a filter according to any one of (1) to (4) which contains 0.001 to 0.1% by weight of a polyacrylic acid ester.
  • a filter using the filter wet nonwoven fabric according to any one of (1) to (5) A filter medium for a filter having a laminate structure in which a long fiber nonwoven fabric and the wet nonwoven fabric according to any one of (1) to (5) are laminated.
  • the filter medium according to (7) or (8), wherein an adsorbent is sandwiched between the long fiber nonwoven fabric and the wet nonwoven fabric.
  • the wet nonwoven fabric for filter according to the present invention has a flat surface disposed on the upstream side of ventilation, and therefore can easily remove foreign substances. Therefore, the filter medium and the filter can be easily cleaned using the wet nonwoven fabric for filter of the present invention.
  • the wet nonwoven fabric of this embodiment is composed of vinylon, polyester, and polyvinyl alcohol, contains 10 to 20% by weight of the polyvinyl alcohol, and has a surface roughness (SMD) of a surface disposed on the upstream side of ventilation. It is 2.7 ⁇ m or less, and is used for filter media and filters.
  • SMD surface roughness
  • the surface roughness is a value of SMD indicating an average deviation of surface roughness data in an evaluation by a Kato Tech friction tester (KES-SE). As the value of SMD increases, the surface is rough and has unevenness.
  • the wet nonwoven fabric of the present embodiment has a surface roughness (SMD) of a surface disposed on the upstream side of ventilation of 2.7 ⁇ m or less. When it is larger than 2.7 ⁇ m, the adhered foreign matter is difficult to remove due to the unevenness of the surface.
  • SMD surface roughness
  • the average friction coefficient is a value of an average friction coefficient (MIU) of the degree of slippage of the surface measured in an evaluation by a Kato Tech friction tester (KES-SE). As the MIU value decreases, the surface tends to slip.
  • MIU average friction coefficient
  • the wet nonwoven fabric of this embodiment has an MIU of 0.15 indicating the average friction coefficient of the surface disposed on the upstream side of ventilation. If it is larger than 0.15, the adhered foreign matter is difficult to remove due to surface friction.
  • the average fiber diameter of the fibers constituting the wet nonwoven fabric of this embodiment is preferably 1 to 100 ⁇ m, and more preferably 5 to 50 ⁇ m.
  • the average fiber diameter of the constituent fibers is smaller than 1 ⁇ m, the gap between the fibers becomes narrow, dust in the air accumulates on the cover layer, and the airflow resistance increases rapidly.
  • the average fiber diameter of the constituent fibers is larger than 100 ⁇ m, it is difficult to remove foreign matters.
  • the fiber length of the fibers constituting the wet nonwoven fabric of this embodiment is preferably 30 mm or less. When the fiber length is longer than 30 mm, the fibers are easily oriented in the thickness direction, and the surface roughness is increased.
  • the wet nonwoven fabric of this embodiment preferably has a thickness of 0.1 to 3.0 mm. If the thickness is smaller than 0.1 mm, a problem of formation occurs. When the thickness is larger than 3.0 mm, the thickness of the entire filter is too large, and when the filter is pleated, the structural resistance increases. As a result, the ventilation resistance of the entire filter becomes too high, which causes a practical problem.
  • Wet-laid nonwoven fabric of the present embodiment is preferably basis weight is 10 ⁇ 100g / m 2, more preferably 20 ⁇ 80g / m 2. If the basis weight is less than 10 g / m 2 , the texture becomes poor. If the basis weight exceeds 100 g / m 2 , the thickness increases, and the structural resistance during pleating increases when used in a filter.
  • the material of the fiber structure constituting the wet nonwoven fabric of this embodiment is composed of vinylon, polyester, and polyvinyl alcohol.
  • it is less than 10% the wet strength of the wet nonwoven fabric is weak, and furthermore, it is difficult to obtain surface smoothness.
  • it is more than 20% by weight the ventilation resistance is increased.
  • the wet nonwoven fabric of this embodiment preferably contains 0.001 to 0.1% by weight of polyacrylate. If it is less than 0.001%, the surface smoothness and the surface slipperiness will not be improved, and if it exceeds 0.1% by weight, the ventilation resistance will increase.
  • the wet nonwoven fabric of this embodiment can be manufactured by a known paper machine by a known wet paper making method.
  • the filter medium of the present embodiment is a filter medium having a laminate structure in which a long fiber nonwoven fabric and the wet nonwoven fabric described above are stacked, and the long fiber nonwoven fabric is disposed downstream of the wet nonwoven fabric.
  • the long fiber nonwoven fabric of the present embodiment is a sheet-like material made of polyolefin fiber, polyester fiber, polyamide fiber, polyurethane fiber, or the like, and polyester fiber is preferable. Since the polyester fiber is relatively high in rigidity, the strength of the filter medium is increased and pleating is facilitated.
  • the method for producing the long fiber nonwoven fabric is preferably a spunbond method.
  • Basis weight of the long fiber nonwoven fabric of the present embodiment is preferably 5 ⁇ 100g / m 2, more preferably 10 ⁇ 80g / m 2. If the basis weight is less than 5 g / m 2 , the rigidity becomes weak. On the other hand, if it exceeds 100 g / m 2 , the pressure loss increases as the number of fibers increases, and the dust holding space between the fibers decreases, and the dust holding amount Decreases.
  • the fiber diameter of the fibers constituting the long fiber nonwoven fabric of this embodiment is preferably 3 to 100 ⁇ m, more preferably 5 to 80 ⁇ m, and even more preferably 10 to 60 ⁇ m. Within such a range, an increase in pressure loss can be prevented and sufficient rigidity can be obtained.
  • the fiber orientation of the long-fiber nonwoven fabric of the present embodiment is not particularly limited.
  • the nonwoven fabric may be in a random shape, a cloth shape, or a parallel shape.
  • the filter medium of the present embodiment preferably has a thickness of 0.1 to 3.0 mm. If the thickness is smaller than 0.1 mm, the texture becomes worse. When the thickness is larger than 3.0 mm, the thickness of the entire filter medium is too large, and the structural resistance becomes large when a pleated filter is used. As a result, the ventilation resistance of the entire filter becomes too high, which causes a practical problem.
  • the filter medium of the present embodiment may sandwich a granular adsorbent and an adhesive (binder) between a long fiber nonwoven fabric and a wet nonwoven fabric.
  • the binder to be gripped is preferably made of a thermoplastic resin, and examples of the thermoplastic resin include polyolefin resins, polyamide resins, polyester resins, and ethylene-acrylic copolymer resins.
  • the component of a binder is not specifically limited, A polyester-type resin is preferable.
  • the polyester fiber is preferable as the material for the long fiber nonwoven fabric.
  • the polyester resin having the same components as these is composed of a base material layer (long fiber nonwoven fabric or wet nonwoven fabric) and a binder. This is because the interface is firmly bonded and high peel strength is obtained.
  • the thermoplastic resin used for the binder of the filter medium of this embodiment is preferably in the form of powder (granular) and the average particle size is 100 to 300 ⁇ m.
  • the granular thermoplastic resin (granular binder) is less than 100 ⁇ m, the adhesion force due to van der Waals force or electrostatic force acts between the granular adsorbent and the thermoplastic resin, and the thermoplastic resin is positively associated with the base material layer. Cannot be contacted with the film, and sufficient peel strength cannot be obtained.
  • the thickness exceeds 300 ⁇ m, the thickness of the filter medium increases, and the structural resistance in the case of a filter increases, which is not preferable for practical use.
  • the granular binder used in the filter medium of the present embodiment is preferably used in an amount of 10 to 80% by weight, more preferably 20 to 60% by weight, based on the granular adsorbent. This is because, within such a range, a filter medium excellent in adhesive strength with the base material layer, pressure loss, and deodorizing performance can be obtained.
  • an organic porous body typified by a crosslinked styrene-divinylbenzene can be used in addition to inorganic substances such as activated carbon, silica gel, zeolite, and sepalite.
  • activated carbon is preferable because it has a very large specific surface area.
  • activated carbon When activated carbon is used as the granular adsorbent, activated carbon such as coconut shell, wood, coal, and pitch is suitable. It is better that the number of so-called macropores introduced into the interior as seen by surface observation is large. When the number of macropores is large, when producing mixed powders composed of activated carbon and granular binder, even if the binder covers the activated carbon surface, it can be adsorbed by gas desorption from the inside of the pores during hot pressing. The hole can be opened. Moreover, when the surface of the activated carbon is rough to some extent, the fluidity of the melted binder resin is deteriorated, and the decrease in adsorption performance can be suppressed.
  • activated carbon such as coconut shell, wood, coal, and pitch is suitable. It is better that the number of so-called macropores introduced into the interior as seen by surface observation is large. When the number of macropores is large, when producing mixed powders composed of activated carbon and granular binder, even if the binder covers
  • the granular adsorbent may be subjected to chemical treatment for the purpose of improving the adsorption performance of polar substances and aldehydes.
  • chemicals used for chemical treatment include adsorption of aldehyde gas, nitrogen compounds such as NOx, sulfur compounds such as SOx, and acidic polar substances such as acetic acid such as ethanolamine, polyethyleneimine, and aniline.
  • Amine amines such as P-anisidine, sulfanilic acid, tetrahydro-1.4-oxazine, hydrazide compounds. Tetrahydro-1.4-oxazine is preferred as the amine drug. Since it is relatively easy to obtain and easily soluble in water, it is easy to apply.
  • the adsorption target is a basic polar substance such as ammonia, methylamine, trimethylamine, or pyridine
  • phosphoric acid, citric acid, malic acid, ascorbic acid, tartaric acid, and the like are preferably used.
  • Adsorbents treated with these chemicals may be used alone or mixed with adsorbents not treated with chemicals.
  • the chemical treatment is performed, for example, by carrying or attaching a chemical to the adsorbent.
  • a chemical aqueous solution mixed with a thickener such as sodium alginate or polyethylene oxide, and carry and attach it. This method is effective in supporting and attaching a chemical having low solubility in water and further suppressing the chemical from falling off.
  • the filter medium of this embodiment may be configured to include components having ancillary functions such as antibacterial agents, antifungal agents, antiviral agents, and flame retardants. These components may be kneaded into the fibers or the nonwoven fabric constituting the base material layer, or may be added and supported by post-processing. For example, by configuring the filter medium including a flame retardant, FMVSS. It is possible to produce a filter medium that meets the standards for retarding flame retardancy defined in 302 and UL flame retardant standards.
  • the filter of the present embodiment using the filter medium of the present embodiment is also within the scope of the present invention.
  • the filter of the present embodiment may be subjected to, for example, pleating or attaching to a frame.
  • the filter of this embodiment may be formed by combining other materials with the filter medium of this embodiment.
  • the filter medium is installed in the duct, the atmosphere is vented so that the air filtration rate is 50 cm / sec, the difference in static pressure upstream and downstream of the sample is read with a differential pressure gauge, and the pressure loss (Pa) is measured.
  • Example 1 Vinylon fiber (17 dtex, average fiber length 12 mm, average fiber diameter 40 ⁇ m), vinylon fiber (7 dtex, average fiber length 10 mm, average fiber diameter 25 ⁇ m), vinylon fiber (2.2 dtex, average fiber length 6 mm, average fiber diameter 15 ⁇ m) polyester Fiber (0.6 dtex, average fiber length 5 mm, average fiber diameter 8 ⁇ m), polyester fiber (2.2 dtex, average fiber length 5 mm, average fiber diameter 15 ⁇ m), PVA fiber (1.1 dtex, average fiber length 3 mm, average fiber diameter) 10 ⁇ m) was mixed at a weight ratio of 26: 31.25: 5.25: 11.25: 11.25: 15 and dispersed in water with a pulper to prepare a wet papermaking stock solution.
  • This wet papermaking stock solution is made by a short net-type paper making method to make a wet web, and then lightly drawn by a press roller and dried by a rotary drying drum at 140 ° C., with a basis weight of 40 g / m 2 and a thickness of 0.3 mm.
  • the wet nonwoven fabric of Example 1 was obtained.
  • mixing is performed in which the weight ratio of coconut shell activated carbon having an average particle diameter of 200 ⁇ m and polyester-based thermoplastic resin having an average particle diameter of 200 ⁇ m is 1: 0.5.
  • the powder was spread so as to have a basis weight of 90 g / m 2 .
  • a polyester-based long fiber nonwoven fabric having a basis weight of 20 g / m 2 was superposed on it and formed into a sheet by a heat treatment at 140 ° C., thereby producing a filter medium for Example 1.
  • This wet papermaking stock solution is made by a short net-type papermaking method to form a wet web, and then lightly drawn by a press roller and dried by a rotary drying drum at 140 ° C., with a basis weight of 30 g / m 2 and a thickness of 0.2 mm.
  • the wet nonwoven fabric of Example 2 was obtained.
  • a filter medium for a filter of Example 2 was produced in the same manner as in Example 1 except that the wet nonwoven fabric of Example 2 was used instead of the wet nonwoven fabric of Example 1.
  • Example 3 Vinylon fiber (7 dtex, average fiber length 10 mm, average fiber diameter 25 ⁇ m), vinylon fiber (2.2 dtex, average fiber length 6 mm, average fiber diameter 15 ⁇ m) polyester fiber (0.6 dtex, average fiber length 5 mm, average fiber diameter 8 ⁇ m) Polyester fiber (2.2 dtex, average fiber length 5 mm, average fiber diameter 15 ⁇ m), PVA fiber (1.1 dtex, average fiber length 3 mm, average fiber diameter 10 ⁇ m), 45: 7.6: 16.2: 16. The mixture was mixed at a weight ratio of 2:15, and measured to be 0.05% with respect to the weight of the fiber charged with polyacrylate, and dispersed in water with a pulper to prepare a wet papermaking stock solution.
  • This wet papermaking stock solution is made by a short net-type papermaking method to form a wet web, and then lightly drawn by a press roller and dried by a rotary drying drum at 140 ° C., with a basis weight of 30 g / m 2 and a thickness of 0.2 mm.
  • the wet nonwoven fabric of Example 3 was obtained.
  • a filter medium for a filter of Example 3 was produced in the same manner as in Example 1 except that the wet nonwoven fabric of Example 3 was used instead of the wet nonwoven fabric of Example 1.
  • Example 4 Vinylon fiber (7 dtex, average fiber length 10 mm, average fiber diameter 25 ⁇ m), vinylon fiber (2.2 dtex, average fiber length 6 mm, average fiber diameter 15 ⁇ m) polyester fiber (0.6 dtex, average fiber length 5 mm, average fiber diameter 8 ⁇ m) Polyester fiber (2.2 dtex, average fiber length 5 mm, average fiber diameter 15 ⁇ m), PVA fiber (1.1 dtex, average fiber length 3 mm, average fiber diameter 10 ⁇ m), 39: 7.6: 16.2: 16. The mixture was mixed at a weight ratio of 2:21 and dispersed in water with a pulper to prepare a wet papermaking stock solution.
  • This paper stock solution is made by a short net-type paper making method to form a wet web, and then lightly drawn by a press roller and dried by a rotary drying drum at 140 ° C., and has a basis weight of 30 g / m 2 and a thickness of 0.2 mm. 4 wet nonwoven fabrics were obtained.
  • a filter medium for a filter of Example 4 was produced in the same manner as in Example 1 except that the wet nonwoven fabric of Example 4 was used instead of the wet nonwoven fabric of Example 1.
  • Example 5 Vinylon fiber (7 dtex, average fiber length 10 mm, average fiber diameter 25 ⁇ m), vinylon fiber (2.2 dtex, average fiber length 6 mm, average fiber diameter 15 ⁇ m) polyester fiber (0.6 dtex, average fiber length 5 mm, average fiber diameter 8 ⁇ m) Polyester fiber (2.2 dtex, average fiber length 5 mm, average fiber diameter 15 ⁇ m), PVA fiber (1.1 dtex, average fiber length 3 mm, average fiber diameter 10 ⁇ m), 45: 7.6: 16.2: 16. The mixture was mixed at a weight ratio of 2:15, and further measured to 0.15% with respect to the weight of the fiber charged with polyacrylate, and dispersed in water with a pulper to prepare a wet papermaking stock solution.
  • This wet papermaking stock solution is made by a short net-type papermaking method to form a wet web, and then lightly drawn by a press roller and dried by a rotary drying drum at 140 ° C., with a basis weight of 30 g / m 2 and a thickness of 0.2 mm.
  • the wet nonwoven fabric of Example 5 was obtained.
  • the filter medium for Example 5 was produced in the same manner as Example 1 except that the wet nonwoven fabric of Example 5 was used instead of the wet nonwoven fabric of Example 1.
  • This wet papermaking stock solution is made by a short net-type paper making method to make a wet web, and then lightly drawn by a press roller and dried by a rotary drying drum at 140 ° C., with a basis weight of 30 g / m 2 and a thickness of 0.2 mm.
  • the wet nonwoven fabric of Example 2 was obtained.
  • a filter medium for a filter of Comparative Example 2 was produced in the same manner as in Example 1 except that the wet nonwoven fabric of Comparative Example 2 was used instead of the wet nonwoven fabric of Example 1.
  • This wet papermaking stock solution is made by a short net-type paper making method to make a wet web, and then lightly drawn by a press roller and dried by a rotary drying drum at 140 ° C., with a basis weight of 30 g / m 2 and a thickness of 0.2 mm.
  • the wet nonwoven fabric of Example 3 was obtained.
  • a filter medium for a filter of Comparative Example 3 was produced in the same manner as in Example 1 except that the wet nonwoven fabric of Comparative Example 3 was used instead of the wet nonwoven fabric of Example 1.
  • Table 1 shows the evaluation of wet nonwoven fabrics and thermal bond nonwoven fabrics of Examples and Comparative Examples.
  • Table 2 shows the evaluation of filter media prepared in Examples and Comparative Examples.
  • the filter media of Examples 1 to 5 and the filter media of Comparative Examples 2 and 3 were measured with the wet nonwoven fabric side upstream of the ventilation and the long fiber nonwoven fabric side downstream of the ventilation.
  • the non-woven fabric for filter, filter filter medium, and filter of the present invention are excellent for removing foreign matters when cleaning, for example, automobiles, air purifiers, air conditioners, photocopiers, printers, multi-function OA devices, and toilet deodorizers. It can be used effectively for all filters used in machines.

Abstract

本発明のフィルター用湿式不織布は、ビニロン、ポリエステル、及びポリビニルアルコールから構成され、前記ポリビニルアルコールを１０～２０重量％含有しており、通気の上流側に配置される面の表面粗さ（ＳＭＤ）が２．７μｍ以下である。

Description

フィルター用湿式不織布、フィルター用濾材、およびフィルター
　本発明は、付着した異物の除去に優れたフィルター用湿式不織布、フィルター用濾材、およびフィルターに関するものである。
　近年、空調用、エアコン用、自動車用等のフィルターにおいて、濾材の高性能化、低コストの要求が高まってきており、除塵性能と脱臭性能を両立するフィルター用濾材の検討が多くなされている（例えば、特許文献１～３参照）。更なる高機能化として付着した異物を簡易に除去できるフィルターの要求も高まってきている。しかし、異物は容易には除去できないため、フィルターの再利用は難しい状況にある。フィルターの再利用に関しては、例えば吸引ノズルを用いた粉塵除去方法がある（特許文献４）。
特開平１１－５０５８号公報 特開平３－９８６４２号公報 特開２００１－２１８８２４号公報 特開２０１４－１３６４７５号公報
　しかしながら、吸引ノズルを使用して異物を除去すると、フィルターが変形し、性能が十分に回復しないといった問題がある。
　そこで本発明は、上記課題に鑑みなされ、その目的は、付着した異物を容易に除去でき、再利用可能なフィルター用湿式不織布、フィルター用濾材、およびフィルターを提供することにある。
　本発明者らは鋭意検討した結果、以下に示す手段により、上記課題を解決できることを見出し、本発明に到達した。すなわち本発明は以下の通りである。
（１）ビニロン、ポリエステル、及びポリビニルアルコールから構成され、通気の上流側に配置される面の表面粗さ（ＳＭＤ）が２．７μｍ以下であるフィルター用湿式不織布。
（２）通気の上流側に配置される面の平均摩擦係数（ＭＩＵ）が０．１５以下である（１）に記載のフィルター用湿式不織布。
（３）前記ポリビニルアルコールを１０～２０重量％含有している（１）または（２）に記載のフィルター用湿式不織布。
（４）繊維長３０ｍｍ以下の繊維から成ることを特徴とする（１）～（３）のいずれか１つに記載のフィルター用湿式不織布。
（５）ポリアクリル酸エステルを０．００１～０．１重量％含有している（１）～（４）のいずれか１つに記載のフィルター用湿式不織布。
（６）（１）～（５）のいずれか１つに記載のフィルター用湿式不織布を用いたフィルター。
（７）長繊維不織布と（１）～（５）のいずれか１つに記載の湿式不織布とが積層された積層体構造を有するフィルター用濾材。
（８）前記長繊維不織布はスパンボンド不織布であることを特徴とする（７）に記載のフィルター用濾材。
（９）前記長繊維不織布と前記湿式不織布との間に吸着剤を挟み込んでいることを特徴とする（７）または（８）に記載のフィルター用濾材。
（１０）（７）～（９）のいずれか１つに記載のフィルター用濾材を用いたフィルター。
　本発明のフィルター用湿式不織布は、通気の上流側に配置される面が平坦であるため、簡易に異物を除去できる。そのため、本発明のフィルター用湿式不織布を用いたフィルター用濾材およびフィルターの清掃を容易にすることができる。
　以下、本発明の実施形態について詳細に説明する。
　本実施形態の湿式不織布は、ビニロン、ポリエステル、及びポリビニルアルコールから構成され、前記ポリビニルアルコールを１０～２０重量％含有しており、通気の上流側に配置される面の表面粗さ（ＳＭＤ）が２．７μｍ以下であり、フィルター用濾材やフィルターに用いられる。
　本明細書において表面粗さとは、カトーテック製摩擦感テスター（ＫＥＳ－ＳＥ）による評価において、表面の凹凸データの平均偏差を示すＳＭＤの値である。ＳＭＤの値が大きくなるに従い、表面が粗く、凹凸性を有していることを示す。
　本実施形態の湿式不織布は、通気の上流側に配置される面の表面粗さ（ＳＭＤ）が２．７μｍ以下である。２．７μｍよりも大きいと、付着した異物が表面の凹凸性により除去し難い。
　本明細書において平均摩擦係数とは、カトーテック製摩擦感テスター（ＫＥＳ－ＳＥ）による評価において測定される表面の滑り度合いの平均摩擦係数（ＭＩＵ）の値である。ＭＩＵの値が小さくなるに従い、表面が滑り易いことを示す。
　本実施形態の湿式不織布は、通気の上流側に配置される面の平均摩擦係数を示すＭＩＵが０．１５である。０．１５よりも大きいと、付着した異物が表面の摩擦により除去し難い。
　本実施形態の湿式不織布を構成する繊維の平均繊維径は、１～１００μｍが好ましく、５～５０μｍがより好ましい。構成繊維の平均繊維径が１μｍよりも小さいと、繊維間の空隙も狭くなり、空気中の塵埃がカバー層上に堆積し、通気抵抗が急上昇する。構成繊維の平均繊維径が１００μｍよりも大きいと、異物を除去し難くなる。
　本実施形態の湿式不織布を構成する繊維の繊維長は３０ｍｍ以下が好ましい。繊維長が３０ｍｍよりも大きいと、繊維が厚み方向に配向しやすくなり、表面粗さが大きくなる。
　本実施形態の湿式不織布は、厚みが０．１～３．０ｍｍであることが好ましい。厚みが０．１ｍｍよりも小さいと地合いの問題が生じる。厚みが３．０ｍｍよりも大きいとフィルター全体の厚みが大き過ぎ、フィルターをプリーツ状にした場合に構造抵抗が大きくなり、結果としてフィルター全体での通気抵抗が高くなり過ぎ、実用上問題がある。
　本実施形態の湿式不織布は、目付量が１０～１００ｇ／ｍ２であることが好ましく、２０～８０ｇ／ｍ２がより好ましい。目付が１０ｇ／ｍ２未満であれば地合いが悪くなる。目付が１００ｇ／ｍ２を越えると、厚みが大きくなり、フィルターに用いる際にプリーツ加工時の構造抵抗が大きくなる。
　本実施形態の湿式不織布を構成する繊維構造体の素材は、ビニロン、ポリエステル、及びポリビニルアルコールから構成されている。ここで、ポリビニルアルコールを１０～２０重量％含有しているのが好ましい。１０％未満であると、湿式不織布の腰強度が弱く、更には表面平滑性が得られにくい。２０重量％よりも多いと、通気抵抗が上がってしまう。
　本実施形態の湿式不織布は、ポリアクリル酸エステルは０．００１～０．１重量％含有していることが好ましい。０．００１％未満であると、表面平滑性及び表面滑り性が向上せず、０．１重量%よりも多くなると、通気抵抗が上がってしまう。
　本実施形態の湿式不織布は、公知の湿式抄紙法により公知の抄紙機で製造することが可能である。
　本実施形態の濾材は、長繊維不織布と上述した湿式不織布とが積層された積層体構造を有するフィルター用濾材であって、長繊維不織布は、湿式不織布よりも通気の下流に配置される。
　本実施形態の長繊維不織布は、ポリオレフィン系繊維、ポリエステル系繊維、ポリアミド系繊維、ポリウレタン系繊維等の繊維から成るシート状物であり、ポリエステル系繊維が好ましい。ポリエステル系繊維であると、剛性が比較的高いため、濾材の強度が高まり、プリーツ加工が容易となる。長繊維不織布の製造方法はスパンボンド法が好ましい。
　本実施形態の長繊維不織布の目付は、５～１００ｇ／ｍ２が好ましく、１０～８０ｇ／ｍ２がより好ましい。目付が５ｇ／ｍ２未満では剛性が弱くなり、他方、１００ｇ／ｍ２を超えると、繊維本数の増加に伴い圧力損失が高くなるばかりか、繊維間の粉塵保持空間が減少し、粉塵保持量が低下する。
　本実施形態の長繊維不織布を構成する繊維の繊維径は、３～１００μｍが好ましく、５～８０μｍがより好ましく、１０～６０μｍがさらに好ましい。かかる範囲であれば、圧力損失の増加を防ぎ、かつ、十分な剛性を得ることができる。
　本実施形態の長繊維不織布の繊維配向は、特に限定はなく、例えば不織布状であればランダム状、クロス状、パラレル状いずれでも構わない。
　本実施形態の濾材は、厚みが０．１～３．０ｍｍであることが好ましい。厚みが０．１ｍｍよりも小さいと地合いが悪くなる。厚みが３．０ｍｍよりも大きいと濾材全体の厚みが大き過ぎ、プリーツ状のフィルターとした場合に構造抵抗が大きくなり、結果としてフィルター全体での通気抵抗が高くなり過ぎ、実用上問題がある。
　本実施形態の濾材は、長繊維不織布と湿式不織布との間に、粒状吸着材と接着材（バインダー）とを挟持してもよい。
　把持されるバインダーは、熱可塑性樹脂から成ることが好ましく、この熱可塑性樹脂として、ポリオレフィン系樹脂、ポリアミド系樹脂、ポリエステル系樹脂、エチレン－アクリル共重合体樹脂等が挙げられる。バインダーの成分は特に限定されるものではないが、ポリエステル系樹脂が好ましい。長繊維不織布の材質としてポリエステル系繊維が好ましいのは先に述べた通りであるが、これらと同一の成分となるポリエステル系樹脂の方が、基材層（長繊維不織布または湿式不織布）とバインダーとの界面が強固に接着され、高い剥離強度が得られるためである。
　本実施形態の濾材のバインダーに使用する熱可塑性樹脂は、粉末状（粒状）で、その大きさが平均粒子径で１００～３００μｍであるものが好ましい。粒状の熱可塑性樹脂（粒状バインダー）が１００μｍ未満であると、粒状吸着材と熱可塑性樹脂との間にファンデルワールス力や静電気力による付着力が働き、熱可塑性樹脂が基材層と積極的に接触することができず、十分な剥離強度が得られない。他方、３００μｍを超えると、濾材の厚みが大きくなり、フィルターとした場合の構造抵抗が増加し、実用上好ましくない。
　本実施形態の濾材に用いられる粒状バインダーは、粒状吸着材に対して１０～８０重量％使用するのが好ましく、２０～６０重量％使用するのがより好ましい。かかる範囲内であれば、基材層との接着力、圧力損失、脱臭性能に優れる濾材が得られるからである。
　本実施形態の濾材の粒状吸着材としては、活性炭、シリカゲル、ゼオライト、セパオライト等の無機物の他、スチレン－ジビニルベンゼン架橋体に代表される有機系の多孔質体が使用可能である。特に、極めて大きな比表面積を持っているため、活性炭が好ましい。
　粒状吸着材として活性炭を用いる場合、例えば、ヤシガラ系、木質系、石炭系、ピッチ系等の活性炭が好適である。表面観察によって見られる内部への導入孔いわゆるマクロ孔数は多い方がよい。マクロ孔数が多いと、活性炭と粒状バインダーとから成る混合粉粒体を製造する際に、バインダーが活性炭表面を被覆しても、熱プレス加工時に細孔内部からのガス脱着により、吸着可能な孔を開放することができる。また、活性炭表面はある程度粗い方が溶融したバインダー樹脂の流動性も悪くなり、吸着性能低下を抑えることができる。
　本実施形態の濾材では、粒状吸着材に、極性物質やアルデヒド類の吸着性能を向上することを目的として、薬品処理を施して用いてもよい。薬品処理に用いられる薬品としては、吸着対象が、アルデヒド系ガスやＮＯｘ等の窒素化合物、ＳＯｘ等の硫黄化合物、酢酸等の酸性の極性物質である場合には、例えばエタノールアミン、ポリエチレンイミン、アニリン、Ｐ－アニシジン、スルファニル酸、テトラヒドロ－１．４－オキサジン、ヒドラジド化合物等のアミン系薬剤が挙げられる。アミン系薬剤としてはテトラヒドロ－１．４－オキサジンが好ましい。比較的容易に入手でき、また水に溶けやすいため、添着加工が容易である。またそれ以外には、水酸化ナトリウム、水酸化カリウム、炭酸グアニジン、リン酸グアニジン、アミノグアニジン硫酸塩、５．５－ジメチルヒダントイン、ベンゾグアナミン、２．２－イミノジエタノール、２．２．２－ニトロトリエタノール、エタノールアミン塩酸塩、２－アミノエタノール、２．２－イミノジエタノール塩酸塩、Ｐ－アミノ安息香酸、スルファニル酸ナトリウム、Ｌ－アルギニン、メチルアミン塩酸塩、セミカルバジド塩酸塩、ヒドラジン、ヒドロキノン、硫酸ヒドロキシルアミン、過マンガン酸塩、炭酸カリウム、炭酸水素カリウム等が好適に用いられる。吸着対象が、アンモニア、メチルアミン、トリメチルアミン、ピリジン等の塩基性の極性物質である場合には、例えば、リン酸、クエン酸、リンゴ酸、アスコルビン酸、酒石酸等が好適に用いられる。これらの薬品にて処理した吸着材は、単独あるいは薬品処理していない吸着材と混合して用いてもよい。
　なお、薬品処理は、例えば、吸着材に薬品を担持させたり、添着したりすることにより行う。また、吸着材に直接薬品を処理する以外に、濾材表面付近に通常のコーティング法等で添着加工する方法や濾材全体に含浸添着することも可能である。この際、アルギン酸ソーダやポリエチレンオキサイド等の増粘剤を混入した薬品水溶液を作り、これを担持、添着を実施する方法も可能である。この方法では水への溶解度が低い薬品を担持、添着し、さらに薬品の脱落を抑制するのにも有効である。
　本実施形態の濾材は、抗菌剤、抗かび剤、抗ウイルス剤、難燃剤等の付随的機能を有する成分等を含めて構成してもよい。これらの成分は基材層を成す繊維類や不織布中に練り込んでも、後加工で添着、及び担持して付与してもよい。例えば、濾材を難燃剤を含めて構成することにより、ＦＭＶＳＳ．３０２で規定されている遅燃性の基準やＵＬ難燃規格に合致した濾材を製造することが可能である。
　本実施形態の濾材を用いた本実施形態のフィルターも本発明の範疇である。本実施の形態のフィルターには、例えば、プリーツ加工や、枠などへの取付加工が施されていてもよい。また、本実施形態のフィルターは、本実施形態の濾材に他の材料を組み合わせて形成されてもよい。
　以下に実施例を示し、本発明をより具体的に説明するが、本発明は実施例に記載されたものに限定されない。まず、実施例および比較例で用いた湿式不織布およびフィルター用濾材の物性の測定方法について説明する。
［表面凹凸性］
　評価はカトーテック製、摩擦感テスター（ＫＥＳ－ＳＥ）にて評価を行う。テーブルに固定した試料（不織布）を１ｍｍ／ｓの速度で、１０ｇｆの荷重をかけながら、接触子を掃引させ、検出された表面凹凸データの平均偏差を表面粗さ（ＳＭＤ）の値とする。
［平均摩擦係数］
　評価はカトーテック製、摩擦感テスター（ＫＥＳ－ＳＥ）にて評価を行う。テーブルに固定した試料を１ｍｍ／ｓの速度で、２５ｇｆの荷重をかけながら、接触子を掃引させ、検出された平均摩擦係数（ＭＩＵ）を算出する。
［異物除去性］
　１５ｃｍ角のサイズに試料を切り取り、ＪＩＳ１５種粉塵を５ｍ３／ｍｉｎにて負荷させ、通気抵抗がベースよりも５０Ｐａアップした時点で負荷を止める。試料に捕集された粉塵量を重量にて評価する。そして１５ｃｍ角の試料を机上に対して垂直に治具に設置し、高さ１０ｃｍのところから１０回落とす。最後に試料の重量を測り、試料から落ちた重量を確認する。試料から落ちた重量が付着量の７割であれば、異物除去性能は良好である（○）との判定とする。
［圧力損失］
　濾材をダクト内に設置し、空気濾過速度が５０ｃｍ／秒になるよう大気を通気させ、試料の上流および下流の静圧差を差圧計にて読み取り、圧力損失（Ｐａ）を測定する。
［剥離強度］
　長繊維不織布と湿式不織布との間の平均剥離強度を測定する。試験片のサイズは巾５０ｍｍ、長さ２００ｍｍとして、引張強度１００ｍｍ／分で実施する。
［剛性］
　ＪＩＳ　Ｌ－１０９６　Ａ法（ガーレ法）に準拠し、ＭＤ方向の剛軟度を測定する。
〔実施例１〕
　ビニロン繊維（１７ｄｔｅｘ、平均繊維長１２ｍｍ、平均繊維径４０μｍ）、ビニロン繊維（７ｄｔｅｘ、平均繊維長１０ｍｍ、平均繊維径２５μｍ）、ビニロン繊維（２．２ｄｔｅｘ、平均繊維長６ｍｍ、平均繊維径１５μｍ）ポリエステル繊維（０．６ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径８μｍ）、ポリエステル繊維（２．２ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径１５μｍ）、ＰＶＡ繊維（１．１ｄｔｅｘ、平均繊維長３ｍｍ、平均繊維径１０μｍ）を、２６：３１．２５：５．２５：１１．２５：１１．２５：１５の重量比で混繊し、パルパーで水中に分散させ、湿式抄紙用原液を調整した。
　この湿式抄紙用原液を短網式抄紙法にて抄紙して湿潤ウェッブをつくり、その後プレスローラーで軽く絞り１４０℃で回転乾燥ドラムにて乾燥し、目付４０ｇ／ｍ２、厚み０．３ｍｍの実施例１の湿式不織布を得た。
　次に、得られた実施例１の湿式不織布の下流となる側に、平均粒径２００μｍのヤシ殻活性炭および平均粒径２００μｍのポリエステル系熱可塑性樹脂の重量比が１：０．５である混合粉末を、目付９０ｇ／ｍ２になるように散布した。さらに、その上から目付２０ｇ／ｍ２のポリエステル系長繊維不織布を重ね合わせ、１４０℃の加熱処理にてシート化を行ない、実施例１のフィルター用濾材を作製した。
〔実施例２〕
　ビニロン繊維（７ｄｔｅｘ、平均繊維長１０ｍｍ、平均繊維径２５μｍ）、ビニロン繊維（２．２ｄｔｅｘ、平均繊維長６ｍｍ、平均繊維径１５μｍ）、ポリエステル繊維（０．６ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径８μｍ）、ポリエステル繊維（２．２ｄｔ
ｅｘ、平均繊維長５ｍｍ、平均繊維径１５μｍ）、ＰＶＡ繊維（１．１ｄｔｅｘ、平均繊維長３ｍｍ、平均繊維径１０μｍ）を、５１：７．６：１６．２：１６．２：９の重量比で混繊し、更にポリアクリル酸エステルを投入した繊維重量に対して０．０５％となるように測り、パルパーで水中に分散させ、湿式抄紙用原液を調整した。
　この湿式抄紙用原液を短網式抄紙法にて抄紙して湿潤ウェッブをつくり、その後プレスローラーで軽く絞り１４０℃で回転乾燥ドラムにて乾燥し、目付３０ｇ／ｍ２、厚み０．２ｍｍの実施例２の湿式不織布を得た。
　次に、実施例１の湿式不織布の代わりに実施例２の湿式不織布を用いた以外は実施例１と同様に、実施例２のフィルター用濾材を作製した。
〔実施例３〕
　ビニロン繊維（７ｄｔｅｘ、平均繊維長１０ｍｍ、平均繊維径２５μｍ）、ビニロン繊維（２．２ｄｔｅｘ、平均繊維長６ｍｍ、平均繊維径１５μｍ）ポリエステル繊維（０．６ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径８μｍ）、ポリエステル繊維（２．２ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径１５μｍ）、ＰＶＡ繊維（１．１ｄｔｅｘ、平均繊維長３ｍｍ、平均繊維径１０μｍ）を、４５：７．６：１６．２：１６．２：１５の重量比で混繊し、更にポリアクリル酸エステルを投入した繊維重量に対して０．０５％となるように測り、パルパーで水中に分散させ、湿式抄紙用原液を調整した。
　この湿式抄紙用原液を短網式抄紙法にて抄紙して湿潤ウェッブをつくり、その後プレスローラーで軽く絞り１４０℃で回転乾燥ドラムにて乾燥し、目付３０ｇ／ｍ２、厚み０．２ｍｍの実施例３の湿式不織布を得た。
　次に、実施例１の湿式不織布の代わりに実施例３の湿式不織布を用いた以外は実施例１と同様に、実施例３のフィルター用濾材を作製した。
〔実施例４〕
　ビニロン繊維（７ｄｔｅｘ、平均繊維長１０ｍｍ、平均繊維径２５μｍ）、ビニロン繊維（２．２ｄｔｅｘ、平均繊維長６ｍｍ、平均繊維径１５μｍ）ポリエステル繊維（０．６ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径８μｍ）、ポリエステル繊維（２．２ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径１５μｍ）、ＰＶＡ繊維（１．１ｄｔｅｘ、平均繊維長３ｍｍ、平均繊維径１０μｍ）を、３９：７．６：１６．２：１６．２：２１の重量比で混繊し、パルパーで水中に分散させ、湿式抄紙用原液を調整した。
　この抄紙用原液を短網式抄紙法にて抄紙して湿潤ウェッブをつくり、その後プレスローラーで軽く絞り１４０℃で回転乾燥ドラムにて乾燥し、目付３０ｇ／ｍ２、厚み０．２ｍｍの実施例４の湿式不織布を得た。
　次に、実施例１の湿式不織布の代わりに実施例４の湿式不織布を用いた以外は実施例１と同様に、実施例４のフィルター用濾材を作製した。
〔実施例５〕
　ビニロン繊維（７ｄｔｅｘ、平均繊維長１０ｍｍ、平均繊維径２５μｍ）、ビニロン繊維（２．２ｄｔｅｘ、平均繊維長６ｍｍ、平均繊維径１５μｍ）ポリエステル繊維（０．６ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径８μｍ）、ポリエステル繊維（２．２ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径１５μｍ）、ＰＶＡ繊維（１．１ｄｔｅｘ、平均繊維長３ｍｍ、平均繊維径１０μｍ）を、４５：７．６：１６．２：１６．２：１５の重量比で混繊し、更にポリアクリル酸エステルを投入した繊維重量に対して０．１５％となるように測り、パルパーで水中に分散させ、湿式抄紙用原液を調整した。
　この湿式抄紙用原液を短網式抄紙法にて抄紙して湿潤ウェッブをつくり、その後プレスローラーで軽く絞り１４０℃で回転乾燥ドラムにて乾燥し、目付３０ｇ／ｍ２、厚み０．２ｍｍの実施例５の湿式不織布を得た。
　次に、実施例１の湿式不織布の代わりに実施例５の湿式不織布を用いた以外は実施例１と同様に、実施例５のフィルター用濾材を作製した。
〔比較例１〕
　低融点ポリエステル繊維（２２ｄｔｅｘ、平均繊維長６４ｍｍ、平均繊維径４５μｍ）、低融点ポリエステル繊維（４．４ｄｔｅｘ、平均繊維長５１ｍｍ、平均繊維径２０μｍ）、レギュラーポリエステル繊維（１７ｄｔｅｘ、平均繊維長５１ｍｍ、平均繊維径４０μｍ）を、重量比５：３：２で混繊し、サーマルボンド法により、厚み０．２ｍｍ、目付６５ｇ／ｍ２、の比較例１のサーマルボンド不織布を得た。
　次に、実施例１の湿式不織布の代わりに比較例１のサーマルボンド不織布を用いた以外は実施例１と同様に、比較例１のフィルター用濾材を作製した。
〔比較例２〕
　ビニロン繊維（７ｄｔｅｘ、平均繊維長１０ｍｍ、平均繊維径２５μｍ）、ビニロン繊維（２．２ｄｔｅｘ、平均繊維長６ｍｍ、平均繊維径１５μｍ）ポリエステル繊維（０．６ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径８μｍ）、ポリエステル繊維（２．２ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径１５μｍ）、ＰＶＡ繊維（１．１ｄｔｅｘ、平均繊維長３ｍｍ、平均繊維径１０μｍ）を、５１：７．６：１６．２：１６．２：９の重量比で混繊し、パルパーで水中に分散させ、湿式抄紙用原液を調整した。
　この湿式抄紙用原液を短網式抄紙法にて抄紙して湿潤ウェッブをつくり、その後プレスローラーで軽く絞り１４０℃で回転乾燥ドラムにて乾燥し、目付３０ｇ／ｍ２、厚み０．２ｍｍの比較例２の湿式不織布を得た。
　次に、実施例１の湿式不織布の代わりに比較例２の湿式不織布を用いた以外は実施例１と同様に、比較例２のフィルター用濾材を作製した。
〔比較例３〕
　ビニロン繊維（７ｄｔｅｘ、平均繊維長１０ｍｍ、平均繊維径２５μｍ）、ビニロン繊維（２．２ｄｔｅｘ、平均繊維長６ｍｍ、平均繊維径１５μｍ）ポリエステル繊維（０．６ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径８μｍ）、ポリエステル繊維（２．２ｄｔｅｘ、平均繊維長５ｍｍ、平均繊維径１５μｍ）、ＰＶＡ繊維（１．１ｄｔｅｘ、平均繊維長３ｍｍ、平均繊維径１０μｍ）を、４５：７．６：１６．２：１６．２：１５の重量比で混繊し、更にポリアクリル酸エステルを投入した繊維重量に対して０．０００９％となるように測り、パルパーで水中に分散させ、湿式抄紙用原液を調整した。
　この湿式抄紙用原液を短網式抄紙法にて抄紙して湿潤ウェッブをつくり、その後プレスローラーで軽く絞り１４０℃で回転乾燥ドラムにて乾燥し、目付３０ｇ／ｍ２、厚み０．２ｍｍの比較例３の湿式不織布を得た。
　次に、実施例１の湿式不織布の代わりに比較例３の湿式不織布を用いた以外は実施例１と同様に、比較例３のフィルター用濾材を作製した。
　表１に実施例及び比較例の湿式不織布、サーマルボンド不織布の評価を示す。
Figure JPOXMLDOC01-appb-T000001
  
　表１から、通気の上流に配置される面の表面粗さ（ＳＭＤ）が２．７μｍ以下である湿式不織布を用いることで、異物の除去性能に優れることが分かる。つまり、本発明のフィルター用湿式不織布を用いたフィルターの清掃を容易にすることができる。
　次に、実施例および比較例で作製した濾材の評価について表２に示す。なお、実施例１～５の濾材および比較例２，３の濾材については、それぞれ、湿式不織布側を通気の上流にし、長繊維不織布側を通気の下流にして測定を行った。また、比較例１の濾材については、サーマルボンド不織布側を通気の上流にし、長繊維不織布側を通気の下流にして測定を行った。
Figure JPOXMLDOC01-appb-T000002
  
　表２から、通気の最上流に配置される面の表面粗さ（ＳＭＤ）が２．７μｍ以下である湿式不織布を用いることで、濾材の異物の除去に優れることが分かる。
　なお、上記開示した実施の形態および各実施例はすべて例示であり制限的なものではない。また、実施の形態および各実施例で開示した構成を適宜組み合わせた実施の形態や実施例も本発明に含まれる。つまり、本発明の技術的範囲は、特許請求の範囲によって有効であり、特許請求の範囲の記載と均等の意味および範囲内のすべての変更・修正・置き換え等を含むものである。
　本発明のフィルター用不織布、フィルターよう濾材、およびフィルターは、清掃する際の異物除去に対して優れており、例えば、自動車、空気清浄機やエアコン、コピー機、プリンター、多機能ＯＡ機器やトイレ脱臭機などで用いられるフィルター全般に有効に利用できる。
 

Claims (10)

  1. 　ビニロン、ポリエステル、及びポリビニルアルコールから構成され、
    　通気の上流側に配置される面の表面粗さ（ＳＭＤ）が２．７μｍ以下であることを特徴とするフィルター用湿式不織布。
  2. 　通気の上流側に配置される面の平均摩擦係数（ＭＩＵ）が０．１５以下であることを特徴とする請求項１に記載のフィルター用湿式不織布。
  3. 　前記ポリビニルアルコールを１０～２０重量％含有していることを特徴とする請求項１または２に記載のフィルター用湿式不織布。
  4. 　前記ポリアクリル酸エステルを０．００１～０．１重量％含有していることを特徴とする請求項１～３のいずれか１項に記載のフィルター用湿式不織布。
  5. 　繊維長３０ｍｍ以下の繊維から成ることを特徴とする１～５のいずれか１項に記載のフィルター用湿式不織布。
  6. 　請求項１～５のいずれか１項に記載のフィルター用湿式不織布を用いたフィルター。
  7. 　長繊維不織布と請求項１～５のいずれか１項に記載のフィルター用湿式不織布とが積層された積層体構造を有するフィルター用濾材。
  8. 　前記長繊維不織布はスパンボンド不織布であることを特徴とする請求項７に記載のフィルター用濾材。
  9. 　前記長繊維不織布と前記湿式不織布との間に吸着剤を挟み込んでいることを特徴とする請求項８まはた９に記載のフィルター用濾材。
  10. 　請求項７～９のいずれか１項に記載のフィルター用濾材を用いたフィルター。
     
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