WO2019230984A1 - フィルタ濾材とこれを備えるフィルタユニット - Google Patents
フィルタ濾材とこれを備えるフィルタユニット Download PDFInfo
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- WO2019230984A1 WO2019230984A1 PCT/JP2019/021892 JP2019021892W WO2019230984A1 WO 2019230984 A1 WO2019230984 A1 WO 2019230984A1 JP 2019021892 W JP2019021892 W JP 2019021892W WO 2019230984 A1 WO2019230984 A1 WO 2019230984A1
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- filter medium
- base material
- material layer
- modified surface
- modified
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
- B01D71/06—Organic material
- B01D71/30—Polyalkenyl halides
- B01D71/32—Polyalkenyl halides containing fluorine atoms
- B01D71/36—Polytetrafluoroethene
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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
- B01D39/08—Filter cloth, i.e. woven, knitted or interlaced material
- B01D39/083—Filter cloth, i.e. woven, knitted or interlaced material of organic material
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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
- B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
- B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
- B01D69/02—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor characterised by their properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
- B01D69/10—Supported membranes; Membrane supports
- B01D69/107—Organic support material
- B01D69/1071—Woven, non-woven or net mesh
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
- B01D69/12—Composite membranes; Ultra-thin membranes
- B01D69/1213—Laminated layers
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
- B01D71/06—Organic material
- B01D71/26—Polyalkenes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
- B01D71/06—Organic material
- B01D71/48—Polyesters
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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
- B01D2239/0216—Bicomponent or multicomponent fibres
- B01D2239/0233—Island-in-sea
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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
- B01D2239/04—Additives and treatments of the filtering material
- B01D2239/0414—Surface modifiers, e.g. comprising ion exchange groups
- B01D2239/0428—Rendering the filter material hydrophobic
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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
- B01D2239/0654—Support layers
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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
- B01D2239/12—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
- B01D2239/1258—Permeability
Definitions
- the present invention relates to a filter medium and a filter unit including the filter medium.
- An object of the present invention is to provide a novel filter medium that can suppress water permeation into the filter medium.
- the present invention Provided with a breathable base material layer, A filter medium in which the base material layer has a modified surface with fibrils of polytetrafluoroethylene (hereinafter referred to as “PTFE”); I will provide a.
- PTFE polytetrafluoroethylene
- the present invention provides: A filter unit comprising the filter medium of the present invention, I will provide a.
- the penetration of water into the filter medium can be suppressed by modification of PTFE fibrils (hereinafter referred to as “PTFE fibrils”) on the surface of the base material layer.
- PTFE fibrils PTFE fibrils
- FIG. 1 is a cross-sectional view schematically showing an example of the filter medium of the present invention.
- FIG. 2 is a plan view schematically showing an example of the modified surface of the base material layer in the filter medium of the present invention.
- FIG. 3 is a perspective view schematically showing an example of the filter unit of the present invention.
- FIG. 4 is a perspective view schematically showing an example of a filter pleat pack provided in the filter unit of the present invention.
- FIG. 5A is a diagram showing an image observed by a scanning electron microscope (hereinafter referred to as “SEM”) on the modified surface of the base material layer in the filter medium produced in Example 1.
- FIG. 5B is a diagram showing regions A, B, and C on the modified surface shown in FIG. 5A.
- 6 is a view showing an observation image by SEM with respect to the main surface of the filter medium produced in Comparative Example 1.
- FIG. 7 is a view showing an observation image by SEM on the main surface of the filter medium produced in Comparative Example 2.
- FIG. 1 shows an example of the filter medium of the present disclosure.
- a filter medium 1 shown in FIG. 1 includes a base material layer 2 having air permeability.
- the base material layer 2 has a modified surface 3 made of a large number of PTFE fibrils.
- the modified surface 3 of the base material layer 2 is exposed.
- the fibril that modifies the modification surface 3 is made of PTFE, which is a material having water repellency. Further, based on the modification with a large number of PTFE fibrils, a surface effect (an effect based on a large specific surface area) occurs on the modified surface 3. For this reason, the penetration of water into the filter medium 1 through the modified surface 3 is suppressed.
- the effect of suppressing the permeation of water in the filter medium 1 is the same as that of the base layer 2 except that the modified surface 3 is not provided, and the filter medium is provided with water repellency on the surface by water repellent treatment Compared to
- a plurality of PTFE fibrils 5 may extend so as to cross the ventilation region 4 of the base material layer 2 on the modification surface 3 when the modification surface 3 is viewed from a direction perpendicular to the modification surface 3. (See FIG. 2).
- the base material layer 2 is composed of fibers 6.
- the ventilation region 4 is a gap between adjacent fibers 6.
- a void portion exists between the PTFE fibrils 5 and the base material layer 2 (fiber 6) is exposed in the void portion.
- PTFE is a material with low bondability.
- the bondability of further layers and / or members to the modified surface 3 can be improved.
- FIG. 5A is an SEM observation image (magnification 500 times) of the modified surface 3 of the filter medium produced in Example 1, and the modified surface 3 has a diameter on the modified surface 3 as shown in FIG. 5B.
- regions A, B and C having a shape including a virtual circle of 5 ⁇ m. Regions A and B have a shape that includes a virtual circle having a diameter of 10 ⁇ m on the modification surface 3.
- the modification amount of PTFE fibrils on the modified surface 3 is, for example, less than 0.5 g / m 2 , 0.4 g / m 2 or less, 0.3 g / m 2 or less, and further 0.2 g / m 2 or less. Also good.
- the lower limit of the modification amount is, for example, 0.1 g / m 2 or more.
- the PTFE constituting the PTFE fibril may be a modified PTFE having a structural unit other than the structural unit derived from the tetrafluoroethylene monomer (TFE unit).
- TFE unit tetrafluoroethylene monomer
- the content of TFE units in the modified PTFE is preferably 50 mol% or more, more preferably 80 mol% or more, still more preferably 90 mol% or more, and particularly preferably 95 mol% or more.
- the base material layer 2 has air permeability in the thickness direction.
- the base material layer 2 is comprised with a fiber, for example.
- the fibers that can form the base material layer 2 may be any of long fibers, short fibers, and mixed fibers thereof.
- the base material layer 2 is a nonwoven fabric, a woven fabric, or a mesh, for example.
- the base material layer 2 is preferably a nonwoven fabric because it is excellent in air permeability, strength and flexibility. Examples of the nonwoven fabric include an airlaid nonwoven fabric, a meltblown nonwoven fabric, a spunbond nonwoven fabric, and a thermal bond nonwoven fabric. It may be a base material layer 2 (for example, a breathable support material described in JP-A-2014-30825) in which two or more different types of nonwoven fabrics are bonded. However, the base material layer 2 is not limited to these examples.
- the material constituting the base layer 2 is, for example, a polyolefin resin such as polyethylene (PE) or polypropylene (PP); a polyester resin such as polyethylene terephthalate (PET); a polyamide resin containing an aromatic polyamide; and a composite material thereof. is there.
- the material is preferably a polyolefin resin, and more preferably PE, since it has excellent bonding properties with PTFE fibrils and the surface of the base material layer 2 can be modified relatively easily with PTFE fibrils.
- An example of the composite material constituting the base material layer 2 is a composite fiber having a core-sheath structure including a core part and a sheath part covering the core part.
- the material which comprises each part differs in the core part and sheath part of a composite fiber. It is preferable that the melting point of the material constituting the sheath part is lower than the melting point of the material constituting the core part.
- the material which comprises a core part is polyester resins, such as PET, for example.
- the material which comprises a sheath part is polyolefin resin, such as PE, for example. When the material which comprises a sheath part is polyolefin resin, the polyolefin resin excellent in bondability with a PTFE fibril can be exposed to the surface of the base material layer 2 which is the modification surface 3.
- a more specific example of the base material layer 2 is a non-woven fabric including a composite fiber having a core-sheath structure including a core part made of a polyester resin and a sheath part made of a polyolefin resin and covering the core part. .
- the average fiber diameter of the fibers that can form the base material layer 2 is, for example, 1 to 50 ⁇ m, and may be 1 to 30 ⁇ m and 10 to 30 ⁇ m.
- the thickness of the base material layer 2 is, for example, 50 to 1000 ⁇ m, and may be 100 to 500 ⁇ m or 200 to 400 ⁇ m.
- the upper limit of the basis weight of the base material layer 2 is, for example, 1000 g / m 2 or less, and may be 500 g / m 2 or less, 200 g / m 2 or less, and further 100 g / m 2 or less.
- the lower limit of the basis weight of the base material layer 2 is, for example, 10 g / m 2 or more, and may be 50 g / m 2 or more.
- the base material layer 2 may be subjected to water repellent treatment and / or oil repellent treatment.
- the water-repellent treatment and the oil-repellent treatment on the substrate layer can be performed by a known method, for example, application and drying of a treatment liquid containing a water-repellent material and / or an oil-repellent material.
- a treatment liquid containing a water-repellent material and / or an oil-repellent material for example, various compounds containing fluorine atoms are known.
- the upper limit of the contact angle of water on the modified surface 3 of the filter medium 1 may be, for example, 150 ° or less, 130 ° or less, and further 120 ° or less.
- the lower limit of the contact angle may be 50 ° or more, 70 ° or more, 90 ° or more, and further 100 ° or more.
- the contact angle of water on the modified surface 3 is a value evaluated by a sessile drop method defined in JIS R3257.
- JIS R3257 is a standard relating to a method for evaluating the contact angle of the substrate glass surface.
- the contact angle of water on the modified surface 3 can be evaluated according to the test conditions defined in the standard.
- the water content of the filter medium 1 by immersion in water for 2 hours is, for example, 150% or less.
- the water content of the filter medium 1 may be 100% or less, and further 70% or less.
- the lower limit of the moisture content of the filter medium 1 is, for example, 10% or more. The smaller the water content, the more the water permeation into the filter medium 1 can be suppressed.
- the filter medium 1 can be a filter medium capable of washing the modified surface 3 with water.
- “washable with water” means a circular filter medium 1 having a diameter of 47 mm, and 0.2 g of “11 types Kanto loam” which is a test powder described in JIS Z8901 is placed on the modification surface 3. This means that when the modified surface 3 is washed off with about 10 mL of water after suctioning from the opposite side at a linear velocity of 20 cm / sec for 60 seconds, there is substantially no reduction in the collection efficiency CE of the filter medium 1. To do.
- the fact that the reduction of the collection efficiency CE is not substantially observed means that the reduction of the collection efficiency CE is, for example, less than 30%, preferably 25% or less, more preferably 20% or less.
- the collection efficiency of the filter medium 1 can be increased by modifying the surface of the base material layer 2 with PTFE fibrils.
- the collection efficiency CE of the filter medium 1 is, for example, 65% or more when the linear velocity of the gas to be filtered is 5.3 cm / sec and the particle size of the particles to be collected is in the range of 0.3 to 0.5 ⁇ m. is there.
- the collection efficiency CE may be 70% or more, 75% or more, 80% or more, 85% or more, and further 90% or more.
- the collection efficiency CE is determined when the plurality of PTFE fibrils 5 extend across the ventilation region 4 of the base material layer 2 on the modified surface 3 when the modified surface 3 is viewed from a direction perpendicular to the modified surface 3. In particular, it can be increased.
- the collection efficiency CE can be evaluated as follows. A measuring holder composed of two plates having the same shape is prepared. Each plate has a through-hole (having a circular cross-sectional shape and an effective ventilation area of 100 cm 2 ). Next, the filter medium to be evaluated is sandwiched between both plates. The filter medium is clamped so that the through holes of both plates coincide with each other when viewed from the direction perpendicular to the main surface of the plate, and the filter medium covers the openings of the through holes of each plate. Further, the filter medium is sandwiched so that no gap is generated between each plate and the filter medium. In order not to generate a gap, a fixing member such as an O-ring or a double-sided adhesive tape may be used.
- a fixing member such as an O-ring or a double-sided adhesive tape may be used.
- a holder is set in a chamber to which a flow meter and a pressure gauge (manometer) are connected so that only air passes through the through hole and the filter medium located in the through hole.
- a pressure difference is generated between one surface of the holder and the other surface, and air starts to flow through the through hole and the filter medium.
- the pressure difference is adjusted so that the linear velocity of the air passing through the through hole and the filter medium is maintained at 5.3 cm / second as measured by the flow meter.
- the collection efficiency CE can be increased while suppressing an increase in pressure loss of the filter medium 1.
- the pressure loss PL of the filter medium 1 when air is permeated at a linear velocity of 5.3 cm / sec is, for example, less than 40 Pa.
- the pressure loss PL may be 35 Pa or less, 30 Pa or less, 25 Pa or less, and further 20 Pa or less.
- the pressure loss PL can be evaluated as follows.
- a measuring holder composed of two plates having the same shape is prepared. Each plate has a through-hole (having a circular cross-sectional shape and an effective ventilation area of 100 cm 2 ).
- the filter medium to be evaluated is sandwiched between both plates.
- the filter medium is clamped so that the through holes of both plates coincide with each other when viewed from the direction perpendicular to the main surface of the plate, and the filter medium covers the openings of the through holes of each plate.
- the filter medium is sandwiched so that no gap is generated between each plate and the filter medium.
- a fixing member such as an O-ring or a double-sided adhesive tape may be used.
- a holder is set in a chamber to which a flow meter and a pressure gauge (manometer) are connected so that only air passes through the through hole and the filter medium located in the through hole.
- a pressure difference is generated between one surface of the holder and the other surface, and air starts to flow through the through hole and the filter medium.
- the pressure difference (static pressure difference) is measured with a pressure gauge when the linear velocity of the air passing through the through hole and the filter medium becomes 5.3 cm / sec as measured by the flow meter.
- the pressure difference is measured eight times for one filter medium, and the average value is set as the pressure loss PL of the filter medium to be evaluated.
- the PF (Performance Factor) value indicating the balance between the collection efficiency and the pressure loss in the filter medium 1 is, for example, 30 or more, and may be 32 or more, 33 or more, or even 34 or more.
- the PF value of the filter medium 1 is obtained from the pressure loss PL and the collection efficiency CE of the filter medium 1 according to the following formula (2).
- Formula (2): PF value ⁇ l [g [(100 ⁇ CE) / 100] / (PL / 9.8) ⁇ ⁇ 100
- Each characteristic of the filter medium 1 can be controlled by, for example, the configuration of the base layer 2 and / or the state of modification of the modification surface 3 by PTFE fibrils.
- the modification state of the modification surface 3 can be controlled by, for example, the configuration of “PTFE modified body” described later.
- the filter medium 1 may include two or more base layers having air permeability. However, in this case, at least one of the two or more base material layers is the base material layer 2 having the modified surface 3. All of the two or more base material layers constituting the filter medium 1 may have the modified surface 3.
- the filter medium 1 is composed of, for example, two base material layers, and may have a modified surface 3 between the two base material layers. In the filter medium 1 having the modified surface 3 between the two base material layers, one base material layer and the other base material layer may be directly joined in the void portion between the PTFE fibrils on the modified surface 3. .
- one base layer located on the upstream side of the air flow when the filter medium 1 is used is a relatively large size particle contained in the air flow. It can also be used as a prefilter that collects.
- the base material layer that does not have the modified surface 3 can have the configuration described above in the description of the base material layer 2 except that the modified surface 3 is not provided.
- the basis weight of the filter medium 1 is, for example, 10 to 1000 g / m 2 , and may be 30 to 500 g / m 2 or 50 to 100 g / m 2 .
- the basis weight of the filter medium 1 can be obtained by dividing the weight of the filter medium 1 by the area of the main surface.
- the thickness of the filter medium 1 is, for example, 50 to 1000 ⁇ m, and may be 100 to 500 ⁇ m, 200 to 400 ⁇ m.
- the filter medium 1 may include any layer and / or member.
- the filter medium 1 can be formed, for example, by thermally laminating a base material layer that is a modified body and a modified body made of PTFE (hereinafter referred to as “PTFE modified body”).
- PTFE modified body a modified body made of PTFE
- the method of forming the filter medium 1 is not limited to the method of thermally laminating the original base material layer and the PTFE modified body.
- the bonding surface of the PTFE modified body in the raw base material layer becomes the modified surface 3.
- the modified surface 3 of the base material layer 2 formed by joining the PTFE modified body may be an exposed surface.
- the raw base material layer can have the configuration described above in the description of the base material layer 2 except that it does not have the modified surface 3.
- the PTFE modified body is typically composed of an infinite number of PTFE fibrils that are fine fibrous structures.
- the modified PTFE may have a PTFE node connected to a plurality of fibrils.
- a node may exist on the modification surface 3 of the formed filter medium 1.
- the node is typically observed as a nodule portion of PTFE having an area of 2 ⁇ m 2 or more in the enlarged image of the modified surface 3.
- the area may be 3 ⁇ m 2 or more, 5 ⁇ m 2 or more, 7 ⁇ m 2 or more, and further 10 ⁇ m 2 or more.
- the upper limit of the area is, for example, 450 ⁇ m 2 or less.
- the ratio of the length in the major axis direction to the length in the minor axis direction of the node is, for example, 10 or less, and may be 7 or less, 5 or less, 3 or less, or 2 or less.
- the magnified image can be obtained by a magnified observation technique such as SEM and an optical microscope.
- the PTFE-modified product is obtained by, for example, forming an admixture of unfired PTFE powder (fine powder) and a liquid lubricant into a film by a technique such as extrusion and / or rolling, and then liquid lubricant from the obtained unfired film. It can be formed by stretching after removing.
- the liquid lubricant is, for example, a hydrocarbon oil such as naphtha, white oil, dodecane, or liquid paraffin.
- the liquid lubricant is not limited as long as it can wet the surface of the PTFE powder and can be removed later by a technique such as drying.
- Stretching is, for example, a stretching ratio of 5 to 100 times in the MD direction (longitudinal direction) of the film, a longitudinal stretching at a stretching temperature of 100 to 380 ° C., and a stretching ratio of 10 to 300 times in the TD direction (width direction) of the film.
- Biaxial stretching combined with transverse stretching at a temperature of 100 to 380 ° C.
- the lower limit of the stretching ratio of the longitudinal stretching may be more than 5 times, or 20 times or more.
- the lower limit of the stretching ratio of the transverse stretching may be more than 10 times, or 30 times or more. Any of the longitudinal stretching and the lateral stretching may be performed first. Further, the stretching conditions (stretching ratio and stretching temperature) may be opposite to those described above between the longitudinal stretching and the lateral stretching.
- the total draw ratio which is the product of the draw ratio of the longitudinal draw and the draw ratio of the transverse draw, is, for example, 10,000 times or more, and may be 12,000 times or more, 13000 times or more, 14000 times or more, and even 15000 times or more. .
- firing may be performed at any timing to heat the film to a temperature equal to or higher than the melting point of PTFE.
- the thickness of the modified PTFE is, for example, less than 3.0 ⁇ m, and may be 2.5 ⁇ m or less, 2.0 ⁇ m or less, or even 1.8 ⁇ m or less.
- the lower limit of the thickness of the modified PTFE is, for example, 0.1 ⁇ m or more.
- the basis weight of the modified PTFE is, for example, less than 0.5 g / m 2 , and may be 0.4 g / m 2 or less, 0.3 g / m 2 or less, and further 0.2 g / m 2 or less.
- the lower limit of the basis weight of the modified PTFE is, for example, 0.1 g / m 2 or more.
- the amount of modification of PTFE fibrils on the modified surface 3 can be controlled by the basis weight of the modified PTFE.
- the filter medium 1 can be used, for example, for removing a foreign substance such as dust contained in the gas by allowing a gas such as air to pass therethrough.
- the filter medium 1 is typically an air filter medium that allows air to pass therethrough.
- the filter medium 1 in which the modified surface 3 of the base material layer 2 is exposed may be used so that the modified surface 3 is located on the most upstream side of the airflow.
- the filter medium 1 can be used for various products such as an air cleaner, an air conditioner and a vacuum cleaner.
- Air conditioners and air purifiers include large products such as building air conditioning systems and products provided in transportation equipment such as automobiles and railway vehicles, in addition to small products mainly intended for indoor use. .
- the use of the filter medium 1 is not limited to these examples.
- the filter medium 1 may be used as a filter unit shown below.
- FIG. 3 shows an example of the filter unit of the present disclosure.
- the filter unit 11 shown in FIG. 3 includes a filter pleat pack 12 obtained by pleating the filter medium 1 and a frame 13 that supports the pleat pack 12.
- the frame 13 supports the circumferential end of the filter pleat pack 12 over the entire circumference.
- the configuration of the filter unit of the present disclosure is not limited to the example illustrated in FIG.
- the filter pleat pack 12 has a structure in which a sheet-like filter medium 1 is folded into a pleat shape.
- the filter pleat pack 12 has a bead 14.
- the bead 14 is a string-like body made of resin, and is a kind of spacer that maintains the pleated shape of the filter medium 1.
- the bead 14 is disposed on the surface of the folded filter medium 1 so as to draw a continuous line or an intermittent line that runs along a direction intersecting the pleat line 15 (fold line) of the filter medium 1.
- the beads 14 may be disposed on one surface of the filter medium 1 or on both surfaces.
- a bead 14 may be disposed on the modified surface 3.
- the bead 14 can be formed by, for example, applying a molten resin in a string shape to the surface of the filter medium 1.
- the resin constituting the bead 14 is not limited, and examples thereof include polyamide, polyolefin, and ethylene-vinyl acetate copolymer.
- the filter media 1 can be pleated using, for example, a reciprocating or rotary pleating machine.
- the frame 13 is made of, for example, metal, resin, or a composite material thereof.
- the filter pleat pack 12 can be fixed to the frame body 13 simultaneously with the molding of the frame body 13.
- the configuration of the frame 13 may be the same as the configuration of the frame included in the conventional filter unit.
- the filter unit 11 may include an arbitrary member other than the members described above.
- the filter unit 11 can be used, for example, to remove a foreign substance such as dust contained in the gas by allowing a gas such as air to pass therethrough.
- the filter unit 11 is typically an air filter unit that allows air to pass therethrough.
- the filter unit 11 can be used for various products such as an air cleaner, an air conditioner, and a vacuum cleaner.
- Air conditioners and air purifiers include large products such as building air conditioning systems and products provided in transportation equipment such as automobiles and railway vehicles, in addition to small products mainly intended for indoor use. .
- the use of the filter unit 11 is not limited to these examples.
- the evaluation method of the filter medium produced in this example is shown below.
- the thickness of the base material layer and the filter medium was evaluated with a digital dial gauge. Moreover, the thickness of the PTFE modified body was evaluated as follows. First, the PTFE modified body to be evaluated was embedded in an epoxy resin, and then the cross section including the PTFE modified body was exposed, polished and leveled, and further subjected to ion polishing. Next, image analysis of the magnified observation image (magnification of about 500 times) of the cross section obtained using a field emission SEM (FE-SEM; JSM-7500F manufactured by JEOL Ltd., acceleration voltage 5 kV, reflected electron image) is performed. The thickness of the modified PTFE was determined.
- FE-SEM field emission SEM
- the thickness at at least 10 measurement points was evaluated while changing the location, and the average value was taken as the thickness of the PTFE modified product.
- the above-described method using FE-SEM can also be applied to the evaluation of the thickness of the base material layer and the PTFE modified body contained in the filter medium.
- the basis weight of the modified PTFE was determined by dividing the weight of the modified PTFE by the area of the main surface.
- the contact angle with water on the main surface (Comparative Examples 1 and 2) on the modification surface (Example 1) or upstream side (upstream side when evaluating the collection efficiency) of the filter medium is JIS R3257 (the surface of the substrate glass According to the wettability test method and the sessile drop method), the contact angle was measured using a contact angle measuring device (Contact Angle System OCA 30, manufactured by DataPhysics Instruments GmbH).
- the water washability of the filter media was evaluated as follows. First, a filter medium to be evaluated was cut into a circle having a diameter of 47 mm to obtain a test piece. Next, 0.2 g of “11 kinds of Kanto loam” as test powders described in JIS Z8901 are uniformly applied to the modified surface (Example 1) or the upstream main surface (Comparative Examples 1 and 2) of the test piece. The sample was placed and sucked from the opposite side of the test piece at a linear velocity of 20 cm / second for 60 seconds. Next, the powder placement surface was held vertically, and about 10 mL of water was poured over the placement surface using a washing bottle to wash away the powder. Next, the collection efficiency CE of the filter medium is evaluated, and when the difference from the collection efficiency CE before placing the powder is less than 30%, “washability / good ( ⁇ )”, 30% or more In the case of “Washing ability / impossible ( ⁇ )”.
- Example 1 100 parts by weight of PTFE fine powder (F-104, manufactured by Daikin Industries, Ltd.) and 19 parts by weight of dodecane which is a liquid lubricant were uniformly mixed, and the resulting mixture was preformed. Next, the preform was paste-extruded into a sheet shape, and the obtained molded body was roll-rolled to obtain a strip-shaped sheet having a thickness of 200 ⁇ m. Next, after removing the liquid lubricant from the obtained sheet by drying, the sheet is stretched in the MD direction at a stretching temperature of 280 ° C. and a stretching ratio of 85 times, and subsequently in the TD direction at a stretching temperature of 150 ° C. and a stretching ratio of 200 times. Drawing was carried out by a tenter method to obtain a modified product A composed of PTFE fibrils. The obtained modified product A had a thickness of 1.5 ⁇ m and a basis weight of 0.2 g / m 2 .
- an airlaid nonwoven fabric / PET nonwoven fabric assembly (thickness 320 ⁇ m, basis weight 100 g / m 2 , an airlaid nonwoven fabric is composed of a composite fiber having a core-sheath structure of a PET core and a PE sheath) Manufactured by the method described in paragraphs 0071 to 0073 of Kokai No. 2014-30825) and modified body A, and the laminated body is heat-laminated to form a base material layer having a modified surface by modified body A Filter medium A was obtained. The thermal lamination was performed so that the airlaid nonwoven fabric and the modified product A were in contact with each other.
- the obtained filter medium A had a pressure loss PL of 20 Pa and a collection efficiency CE of 80%. Further, the modification amount by the modified product A was 0.2 g / m 2 .
- An observation image (magnification 500 times) by SEM with respect to the modified surface of the filter medium A is shown in FIG. 5A.
- FIG. 5A shows a state in which the fibers of the base material layer exposed in the gaps between the PTFE fibrils are deformed into a flat plate shape by the pressure during thermal lamination.
- Comparative Example 1 The nonwoven fabric joined body prepared in Example 1 was used as the filter medium B of Comparative Example 1. As the filter medium B, an air laid nonwoven fabric was disposed on the upstream side. The evaluation results of the filter medium B are shown in Table 1 below, and the observation image by SEM on the upstream main surface is shown in FIG.
- Comparative Example 2 The nonwoven fabric joined body prepared in Example 1 was used as the filter medium C of Comparative Example 2.
- the filter medium C a PET nonwoven fabric was disposed on the upstream side.
- Table 1 The evaluation results of the filter medium C are shown in Table 1 below, and the observation image by SEM on the upstream main surface is shown in FIG. As shown in FIG. 7, the water repellent was adhered to the surface of the fibers constituting the PET nonwoven fabric.
- the water content of the filter medium of the example was greatly reduced as compared with the filter medium of the comparative example.
- a significant increase in the collection efficiency was confirmed.
- the filter medium of the present invention can be used for applications where a conventional filter medium is used.
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Filtering Materials (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Description
通気性を有する基材層を備え、
前記基材層が、ポリテトラフルオロエチレン(以下、「PTFE」と記載する)のフィブリルによる修飾面を有するフィルタ濾材、
を提供する。
上記本発明のフィルタ濾材を備えるフィルタユニット、
を提供する。
式(1):捕集効率CE=[1-(下流側の粒子濃度)/(上流側の粒子濃度)]×100(%)
式(2):PF値={-lоg[(100-CE)/100]/(PL/9.8)}×100
図3に、本開示のフィルタユニットの一例を示す。図3に示すフィルタユニット11は、フィルタ濾材1がプリーツ加工されてなるフィルタプリーツパック12と、プリーツパック12を支持する枠体13と、を備える。枠体13は、フィルタプリーツパック12の周端部を全周にわたって支持している。ただし、本開示のフィルタユニットの構成は、図3に示す例に限定されない。
基材層及びフィルタ濾材の厚さは、デジタルダイヤルゲージにより評価した。また、PTFE修飾体の厚さは、以下のように評価した。最初に、評価対象物であるPTFE修飾体をエポキシ樹脂に包埋した後、PTFE修飾体を含む断面を露出させて研磨及び整面し、更にイオンポリッシング加工した。次に、電解放出型SEM(FE-SEM;日本電子製JSM-7500F、加速電圧5kV、反射電子像)を用いて得た当該断面の拡大観察像(倍率500倍程度)を画像解析することで、PTFE修飾体の厚さを求めた。ただし、画像解析の際には、場所を変えながら少なくとも10の測定ポイントにおける厚さを評価し、その平均値をPTFE修飾体の厚さとした。なお、FE-SEMを用いた上記方法は、フィルタ濾材に含まれる基材層及びPTFE修飾体の厚さの評価にも適用できる。
PTFE修飾体の目付は、PTFE修飾体の重量を主面の面積で除して求めた。
フィルタ濾材の圧力損失PL及び捕集効率CEは、上述の方法により評価した。
フィルタ濾材の修飾面(実施例1)又は上流側(捕集効率を評価する際の上流側)の主面(比較例1,2)における水との接触角は、JIS R3257(基板ガラス表面のぬれ性試験方法、静滴法)に従い、接触角測定装置(Contact Angle System OCA 30、DataPhysics Instruments GmbH製)を用いて測定した。
フィルタ濾材の含水率は、以下のように評価した。最初に、評価対象のフィルタ濾材を150mm×125mmの長方形に切り出して試験片を得た。次に、25℃及び65%RHの雰囲気に少なくとも12時間、試験片を放置した後、試験片の重量(乾燥時重量W1)を測定した。次に、試験片の全体を水中に浸漬して2時間放置した。次に、水中から試験片を取り出して表面に付着している水滴をふき取った後、その重量(湿潤時重量W2)を測定した。測定した重量W1及びW2から、以下の式により、フィルタ濾材の含水率を求めた。
式:含水率=(W2-W1)/W1×100(%)
フィルタ濾材の水洗い性は、以下のように評価した。最初に、評価対象のフィルタ濾材を直径47mmの円形に切り出して試験片を得た。次に、試験片の修飾面(実施例1)又は上流側の主面(比較例1,2)に、JIS Z8901に記載の試験用粉体である「11種 関東ローム」0.2gを満遍なく載せ、試験片の反対側から線速度20cm/秒で60秒吸引した。次に、粉体の戴置面を垂直に保持し、約10mLの水を洗瓶を用いて戴置面の全体に流しかけることで、粉体を洗い流した。次に、フィルタ濾材の捕集効率CEを評価し、粉体を戴置する前の捕集効率CEとの差が30%未満である場合を「水洗い性/良(○)」、30%以上である場合を「水洗い性/不可(×)」とした。
(実施例1)
PTFEファインパウダー(ダイキン工業製、F-104)100重量部と、液状潤滑剤であるドデカン19重量部とを均一に混合し、得られた混合物を予備成形した。次に、予備成形物をシート状にペースト押出成形し、得られた成形体をロール圧延して、厚さ200μmの帯状のシートを得た。次に、得られたシートから液状潤滑剤を乾燥除去した後、シートのMD方向に延伸温度280℃、延伸倍率85倍で延伸し、続いてTD方向に延伸温度150℃、延伸倍率200倍でテンター法により延伸して、PTFEのフィブリルから構成される修飾体Aを得た。得られた修飾体Aの厚さは1.5μm、目付は0.2g/m2であった。
実施例1で準備した不織布接合体を比較例1のフィルタ濾材Bとした。フィルタ濾材Bは、エアレイド不織布を上流側に配置して用いた。フィルタ濾材Bの評価結果を以下の表1に、上流側の主面に対するSEMによる観察像を図6に示す。
実施例1で準備した不織布接合体を比較例2のフィルタ濾材Cとした。フィルタ濾材Cは、PET不織布を上流側に配置して用いた。フィルタ濾材Cの評価結果を以下の表1に、上流側の主面に対するSEMによる観察像を図7に示す。図7に示すように、PET不織布を構成する繊維の表面には撥水剤が付着していた。
Claims (10)
- 通気性を有する基材層を備え、
前記基材層が、ポリテトラフルオロエチレンのフィブリルによる修飾面を有するフィルタ濾材。 - 前記基材層の前記修飾面が露出している、請求項1に記載のフィルタ濾材。
- 前記修飾面に垂直な方向から前記修飾面を見たときに、前記修飾面における前記基材層の通気領域を横断するように複数の前記フィブリルが延びている、請求項1又は2に記載のフィルタ濾材。
- 前記修飾面に垂直な方向から倍率500倍で前記修飾面を見たときに、
前記基材層を構成する材料が露出した前記フィブリル間の空隙部分が存在し、
前記空隙部分において露出した前記材料の領域が、前記修飾面上の直径5μmの仮想の円を内包する形状を有する、請求項1~3のいずれかに記載のフィルタ濾材。 - 前記修飾面における前記フィブリルの修飾量が0.5g/m2未満である、請求項1~4のいずれかに記載のフィルタ濾材。
- 前記基材層が繊維により構成される、請求項1~5のいずれかに記載のフィルタ濾材。
- 前記基材層が不織布である、請求項6に記載のフィルタ濾材。
- 前記不織布が、ポリエステル樹脂から構成される芯部と、ポリオレフィン樹脂から構成され、前記芯部を被覆する鞘部との芯鞘構造を有する複合繊維を含む、請求項7に記載のフィルタ濾材。
- 請求項1~8のいずれかに記載のフィルタ濾材を備えるフィルタユニット。
- 前記フィルタ濾材がプリーツ加工されている請求項9に記載のフィルタユニット。
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EP19810027.3A EP3812026A4 (en) | 2018-06-01 | 2019-05-31 | FILTERING MEDIUM AND FILTER UNIT EQUIPPED THEREOF |
JP2020522648A JP7356972B2 (ja) | 2018-06-01 | 2019-05-31 | フィルタ濾材とこれを備えるフィルタユニット |
US17/059,309 US20210162354A1 (en) | 2018-06-01 | 2019-05-31 | Filter medium and filter unit including same |
CN201980036922.9A CN112218696B (zh) | 2018-06-01 | 2019-05-31 | 过滤器滤材和具备该过滤器滤材的过滤器单元 |
KR1020207037118A KR20210014137A (ko) | 2018-06-01 | 2019-05-31 | 필터 여과재와, 이를 구비하는 필터 유닛 |
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US20210162354A1 (en) | 2021-06-03 |
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JP7356972B2 (ja) | 2023-10-05 |
KR20210014137A (ko) | 2021-02-08 |
EP3812026A4 (en) | 2022-03-16 |
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