WO2022168982A1 - フィルター用濾材およびフィルター - Google Patents

フィルター用濾材およびフィルター Download PDF

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Publication number
WO2022168982A1
WO2022168982A1 PCT/JP2022/004761 JP2022004761W WO2022168982A1 WO 2022168982 A1 WO2022168982 A1 WO 2022168982A1 JP 2022004761 W JP2022004761 W JP 2022004761W WO 2022168982 A1 WO2022168982 A1 WO 2022168982A1
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WO
WIPO (PCT)
Prior art keywords
nonwoven fabric
filter
long
filter medium
layer
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/JP2022/004761
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English (en)
French (fr)
Japanese (ja)
Inventor
健人 高見
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toyobo Co Ltd
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Toyobo Co Ltd
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Filing date
Publication date
Application filed by Toyobo Co Ltd filed Critical Toyobo Co Ltd
Priority to JP2022579645A priority Critical patent/JPWO2022168982A1/ja
Publication of WO2022168982A1 publication Critical patent/WO2022168982A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L9/00—Disinfection, sterilisation or deodorisation of air
    • A61L9/16—Disinfection, sterilisation or deodorisation of air using physical phenomena
    • 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
    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B03—SEPARATION OF SOLID MATERIALS USING LIQUIDS OR USING PNEUMATIC TABLES OR JIGS; MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03C3/00—Separating dispersed particles from gases or vapour, e.g. air, by electrostatic effect
    • B03C3/28—Plant or installations without electricity supply, e.g. using electrets
    • 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

Definitions

  • the present invention relates to filter media for filters and filters.
  • the filter material for filters as described above has a problem that when it is used as a filter for air cleaning, vacuum cleaners, etc., if it is pleated, it is easy to break, especially at the crest point on the downstream side.
  • SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a filter material and a filter in which the crest points are not easily broken during pleating.
  • the present invention is as follows.
  • the base layer nonwoven fabric has a cross-sectional strength of 45 N or less, it is possible to suppress the influence of the force applied from the base layer nonwoven fabric to the long-fiber nonwoven fabric during pleating, and it tends to be difficult to tear.
  • the filter material of the present embodiment is a filter material in which a long-fiber nonwoven fabric and a base layer nonwoven fabric are laminated, and the cross-sectional strength of the base layer nonwoven fabric is 45 N or less.
  • the cross-sectional strength indicates the cross-sectional strength of the base layer nonwoven fabric alone as evaluated by a digital force gauge.
  • the base layer nonwoven fabric since the base layer nonwoven fabric has a cross-sectional strength of 45 N or less, it is possible to prevent the top points of the long-fiber nonwoven fabric laminated on the base layer nonwoven fabric from breaking during pleating.
  • polyolefin-based resins polyester-based resins, polyamide-based resins, polyurethane-based resins, and the like can be used as materials that constitute the long-fiber nonwoven fabric. Since the polyolefin resin has relatively high rigidity, the strength of the filter medium is increased and the pleating process is facilitated.
  • the fiber orientation of the long-fiber nonwoven fabric is not particularly limited, and may be, for example, random, cross, or parallel.
  • the basis weight of the long-fiber nonwoven fabric of the present embodiment is preferably 5 to 100 g/m 2 , more preferably 10 to 80 g/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 , not only does the pressure loss increase with an increase in the number of fibers, but also the dust holding space between fibers decreases, resulting in a reduced dust holding amount. decreases.
  • the average fiber diameter (diameter) of the constituent fibers of the long-fiber nonwoven fabric of this embodiment is preferably 1 to 100 ⁇ m, more preferably 1 to 50 ⁇ m.
  • the long-fiber nonwoven fabric is arranged as a downstream layer on the downstream side of the air flow during air cleaning. Therefore, since it is the inflow surface of the air to be treated, if the average fiber diameter of the constituent fibers is less than 1 ⁇ m, the gaps between the fibers become narrow, dust in the air accumulates on the nonwoven fabric, and the ventilation resistance rises sharply. If the average fiber diameter of the constituent fibers is more than 100 ⁇ m, the adsorbent, when sandwiched between the nonwoven fabric of the base material layer, pops out or falls off, particularly during pleating.
  • the long-fiber nonwoven fabric may be electret-processed.
  • Electret processing increases the effect of removing submicron particles such as cigarette smoke particles, carbon particles, and sea salt particles, thereby extending the filter life.
  • Electret processing is not particularly limited, and can be performed by a known method such as a corona discharge method or a water current charging method.
  • materials constituting the base layer nonwoven fabric include polyolefin-based resins, polyester-based resins, cellulose-based resins, polyamide-based resins, polyurethane-based resins, acrylic-based resins, polyvinyl alcohol-based resins, and polycarbonate-based resins. etc. can be used.
  • the fiber orientation of the base layer nonwoven fabric is not particularly limited, and may be, for example, random, cross, or parallel.
  • the average fiber diameter (diameter) of the constituent fibers of the base layer nonwoven fabric is preferably 1 to 100 ⁇ m, more preferably 5 to 50 ⁇ m. If the average fiber diameter of the constituent fibers is less than 1 ⁇ m, the gaps between the fibers become narrow, dust in the air accumulates, and the ventilation resistance rises sharply. If the average fiber diameter of the constituent fibers is larger than 100 ⁇ m, it becomes difficult to remove (capture) foreign matter.
  • the base layer nonwoven fabric preferably has a basis weight of 10 to 100 g/m 2 , more preferably 20 to 80 g/m 2 . If the basis weight is less than 10 g/m 2 , the texture is poor. When the basis weight exceeds 100 g/m 2 , the thickness of the filter medium increases, and the structural resistance increases when a pleated filter is formed.
  • the thickness of the filter medium of this embodiment is preferably 0.1 to 3.0 mm. If the thickness is less than 0.1 mm, the texture will be poor. If the thickness is more than 3.0 mm, the filter becomes too thick, and when the filter is pleated, the structural resistance increases, and as a result, the ventilation resistance of the entire filter becomes too high, which poses a practical problem.
  • an adsorbent may be sandwiched between the long-fiber nonwoven fabric and the base layer nonwoven fabric.
  • adsorbent of the filter material of this embodiment in addition to inorganic substances such as activated carbon, silica gel, zeolite, and sepaolite, organic porous bodies typified by styrene-divinylbenzene crosslinked bodies can be used.
  • activated carbon and silica gel are preferred because they have an extremely large specific surface area.
  • the shape and size of the adsorbent may be those known for use in filters.
  • activated carbon for example, coconut shell-based, wood-based, coal-based, and pitch-based activated carbons are suitable. It is preferable that the number of introduction holes to the inside, so-called macropores, seen by observing the surface be as large as possible. If the number of macropores is large, even if the binder coats the surface of the activated carbon when producing a mixed granule consisting of activated carbon and a granular binder, it can be adsorbed by gas desorption from the inside of the pores during hot press processing. Pores can be opened. In addition, when the surface of the activated carbon is rough to some extent, the flowability of the melted binder resin is deteriorated, and deterioration of adsorption performance can be suppressed.
  • the adsorbent may be chemically treated for the purpose of improving the adsorption performance of polar substances and aldehydes.
  • the target to be adsorbed is an aldehyde gas
  • a nitrogen compound such as NOx
  • a sulfur compound such as SOx
  • an acidic polar substance such as acetic acid
  • examples of chemicals used for chemical treatment include ethanolamine, polyethyleneimine, and aniline.
  • phosphoric acid, citric acid, malic acid, ascorbic acid, tartaric acid and the like are preferably used when the target to be adsorbed is a basic polar substance such as ammonia, methylamine, trimethylamine and pyridine.
  • a basic polar substance such as ammonia, methylamine, trimethylamine and pyridine.
  • the chemical treatment is performed, for example, by supporting or attaching the chemical to the adsorbent.
  • a chemical aqueous solution containing a thickening agent such as sodium alginate or polyethylene oxide, carry it, and attach it. This method is effective for supporting and attaching chemicals with low solubility in water, and also for suppressing drop-off of the chemicals.
  • a binder may be used to fix the adsorbent to the long-fiber nonwoven fabric and/or the base layer nonwoven fabric.
  • the binder is preferably made of a thermoplastic resin, and examples of thermoplastic resins include polyolefin-based resins, polyamide-based resins, polyester-based resins, ethylene-acrylic copolymer resins, and the like.
  • the component of the binder is not particularly limited, polyolefin-based resins and polyester-based resins are preferred. This is because the interface between the long-fiber nonwoven fabric and/or the base layer nonwoven fabric and the binder is firmly adhered to obtain high peel strength.
  • the thermoplastic resin used for the binder of the filter material of the present embodiment is preferably powdery (granular) with an average particle diameter of 100 to 400 ⁇ m.
  • the granular thermoplastic resin (particulate binder) is less than 100 ⁇ m, adhesive force due to Van der Waals force or electrostatic force acts between the adsorbent and the thermoplastic resin, and the thermoplastic resin is positively attached to the base layer. No contact is possible and sufficient peel strength is not obtained.
  • it exceeds 400 ⁇ m the thickness of the filter medium increases, and the structural resistance of the filter increases, which is not preferable for practical use.
  • the binder used in the filter material of this embodiment is preferably used in an amount of 10 to 80% by weight, more preferably 20 to 60% by weight, relative to the adsorbent. This is because within such a range, a filter medium having excellent adhesion to the substrate layer, pressure loss, and deodorizing performance can be obtained.
  • the filter medium of this embodiment may be configured to contain components having incidental functions such as antibacterial agents, antifungal agents, antiviral agents, and flame retardants. These components may be kneaded into the fibers or nonwoven fabric forming the base material layer, or may be attached and supported in post-processing. For example, by configuring the filter medium including a flame retardant, FMVSS. It is possible to manufacture filter media that meet the retarded flame standards specified 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 pleated or attached to a frame, for example.
  • the filter of this embodiment may be formed by combining the filter medium of this embodiment with other materials.
  • the filter medium was installed in the duct, air was passed through so that the air filtration speed was 50 cm/sec, and the static pressure difference between the upstream and downstream sides of the filter medium was read with a differential pressure gauge to measure the pressure loss (Pa).
  • the bending resistance in the MD direction was measured according to JIS L-1096 A method (Gurley method).
  • Cross-sectional strength The cross-sectional strength was evaluated using a digital force gauge.
  • a sample of 2 cm (MD direction) ⁇ 30 cm (TD direction) is wrapped around a tube with an outer diameter of 7 mm ⁇ , taped to the end, and the tube is removed.
  • a digital force gauge is used to read the maximum value from the time the sample is set up until it is pressed down and buckled.
  • Ton of melt blown nonwoven fabric when pleating When processed with a pleating machine under the condition of a crest height of 38 mm, a pleat block of 5 cm width ⁇ 10 crests is visually observed, and the number of tears in the nonwoven fabric is counted. If there are 5 or more visible tears, it is evaluated as x (not acceptable), and if it is 4 or less, it is evaluated as ⁇ (acceptable).
  • Example 1 An electretized melt blown nonwoven fabric made of white polypropylene fibers having an average fiber diameter of 2 ⁇ m and a basis weight of 18 g/m 2 was used as the downstream layer (long fiber nonwoven fabric).
  • coconut husk granular activated carbon having an average particle size of 250 ⁇ m and a BET specific surface area of 950 m2/g as an adsorbent, EVA resin (average particle size of 250 ⁇ m, MI of 20 g/10 min, melting point of 110°C) as a thermoplastic powder resin, and silica gel containing dihydrazide adipic acid.
  • a spunbond nonwoven fabric having a cross-sectional strength of 30N (average fiber diameter of 30 ⁇ m, basis weight of 40 g/m 2 ) is superimposed as an upstream layer (base material layer nonwoven fabric) on the intermediate layer, and the Teflon (registered trademark) / glass belt
  • the belt gap was set to 0.5 mm, the pressure was set to 100 kPa, and hot pressing was performed at 110° C. for 15 seconds. After that, it was cooled to obtain the desired filter medium for air cleaning. After that, pleat processing was performed.
  • An electret-treated meltblown nonwoven fabric composed of white polypropylene fibers having an average fiber diameter of 2 ⁇ m and a basis weight of 18 g/m 2 was used as the downstream layer.
  • coconut husk granular activated carbon having an average particle size of 250 ⁇ m and a BET specific surface area of 950 m2/g as an adsorbent, EVA resin (average particle size of 250 ⁇ m, MI of 20 g/10 min, melting point of 110°C) as a thermoplastic powder resin, and silica gel containing dihydrazide adipic acid. They were weighed so that the ratio was 50:50:50, and after stirring and mixing for 15 minutes with a hoop shaker (manufactured by Kyomachi Sangyo Sharyo Co., Ltd.), this mixed powder was added to the downstream layer so that the total amount was 150 g / m 2 . It was evenly dispersed in the middle layer.
  • a thermal bonded nonwoven fabric having a cross-sectional strength of 30 N (average fiber diameter 40 ⁇ m, basis weight 65 g / m 2 ) is superimposed as an upstream layer on the intermediate layer, sandwiched between Teflon (registered trademark) / glass belts, and this belt spacing was set to 0.5 mm and the pressure was set to 100 kPa, and hot pressing was performed at 110° C. for 15 seconds. After that, it was cooled to obtain the desired filter medium for air cleaning. After that, pleat processing was performed.
  • An electretized spunbond nonwoven fabric made of white polypropylene fibers having an average fiber diameter of 20 ⁇ m and a basis weight of 80 g/m 2 was used as the downstream layer.
  • coconut husk granular activated carbon having an average particle size of 250 ⁇ m and a BET specific surface area of 950 m2/g as an adsorbent, EVA resin (average particle size of 250 ⁇ m, MI of 20 g/10 min, melting point of 110°C) as a thermoplastic powder resin, and silica gel containing dihydrazide adipic acid. They were weighed so that the ratio was 50:50:50, and after stirring and mixing for 15 minutes with a hoop shaker (manufactured by Kyomachi Sangyo Sharyo Co., Ltd.), this mixed powder was added to the downstream layer so that the total amount was 150 g / m 2 . was dispersed evenly over the surface to form an intermediate layer.
  • a thermal bonded nonwoven fabric having a cross-sectional strength of 30 N (average fiber diameter 40 ⁇ m, basis weight 65 g / m 2 ) is superimposed as an upstream layer on the intermediate layer, sandwiched between Teflon (registered trademark) / glass belts, and this belt spacing was set to 0.5 mm and the pressure was set to 100 kPa, and hot pressing was performed at 110° C. for 15 seconds. After that, it was cooled to obtain the desired filter medium for air cleaning. After that, pleat processing was performed.
  • An electret-treated meltblown nonwoven fabric composed of white polypropylene fibers having an average fiber diameter of 2 ⁇ m and a basis weight of 18 g/m 2 was used as the downstream layer.
  • coconut husk granular activated carbon having an average particle size of 250 ⁇ m and a BET specific surface area of 950 m2/g as an adsorbent, EVA resin (average particle size of 250 ⁇ m, MI of 20 g/10 min, melting point of 110°C) as a thermoplastic powder resin, and silica gel containing dihydrazide adipic acid. They were weighed so that the ratio was 50:50:50, and after stirring and mixing for 15 minutes with a hoop shaker (manufactured by Kyomachi Sangyo Sharyo Co., Ltd.), this mixed powder was added to the downstream layer so that the total amount was 150 g / m 2 . was dispersed evenly over the surface to form an intermediate layer.
  • a spunbond nonwoven fabric having a cross-sectional strength of 50 N (average fiber diameter 40 ⁇ m, basis weight 65 g / m 2 ) is superimposed as an upstream layer on the intermediate layer, sandwiched between Teflon (registered trademark) / glass belts, and this belt spacing was set to 0.5 mm and the pressure was set to 100 kPa, and hot pressing was performed at 110° C. for 15 seconds. After that, it was cooled to obtain the desired filter medium for air cleaning. After that, pleat processing was performed.
  • An electret-treated meltblown nonwoven fabric made of white polypropylene fibers having an average fiber diameter of 2 ⁇ m and a basis weight of 18 g/m 2 was used as the downstream layer.
  • coconut husk-based granular activated carbon having an average particle size of 250 ⁇ m and a BET specific surface area of 950 m2/g as an adsorbent, EVA resin (average particle size of 250 ⁇ m, MI of 20 g/10 min, melting point of 110°C) as a thermoplastic powder resin, and silica gel containing dihydrazide adipic acid. They were weighed at 50:50:50, stirred and mixed for 15 minutes with a hoop shaker (manufactured by Kyomachi Sangyo Sharyo Co., Ltd.), and then the mixed powder was added to the downstream layer so that the total amount was 150 g / m 2 . was dispersed evenly over the surface to form an intermediate layer.
  • a thermal bonded nonwoven fabric having a cross-sectional strength of 50 N (average particle size 40 ⁇ m, basis weight 65 g/m 2 ) is superimposed as an upstream layer on the intermediate layer, and sandwiched between Teflon (registered trademark) / glass belts. was set to 0.5 mm and the pressure was set to 100 kPa, and hot pressing was performed at 110° C. for 15 seconds. After that, it was cooled to obtain the desired filter medium for air cleaning. After that, pleat processing was performed.
  • the filter medium for filters of the present invention is highly resistant to breakage during pleating and is highly industrially useful. For example, it can be used in a wide range of fields such as automobiles, air purifiers, air conditioners, copiers, printers, multifunctional OA equipment, and toilet deodorizers, and can greatly contribute to the industrial world.

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  • Health & Medical Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Epidemiology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Animal Behavior & Ethology (AREA)
  • General Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Veterinary Medicine (AREA)
  • Filtering Materials (AREA)
PCT/JP2022/004761 2021-02-08 2022-02-07 フィルター用濾材およびフィルター Ceased WO2022168982A1 (ja)

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JP2021-018218 2021-02-08

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11290623A (ja) * 1998-04-08 1999-10-26 Toray Ind Inc フィルター材
JP2001137630A (ja) * 1999-11-18 2001-05-22 Tonen Tapyrus Co Ltd 空気清浄用フィルター
JP2015044183A (ja) * 2013-07-31 2015-03-12 東洋紡株式会社 脱臭フィルター用濾材
JP2017113670A (ja) * 2015-12-22 2017-06-29 東レ株式会社 エアフィルター用濾材およびエアフィルター

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH11290623A (ja) * 1998-04-08 1999-10-26 Toray Ind Inc フィルター材
JP2001137630A (ja) * 1999-11-18 2001-05-22 Tonen Tapyrus Co Ltd 空気清浄用フィルター
JP2015044183A (ja) * 2013-07-31 2015-03-12 東洋紡株式会社 脱臭フィルター用濾材
JP2017113670A (ja) * 2015-12-22 2017-06-29 東レ株式会社 エアフィルター用濾材およびエアフィルター

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