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TWI568487B - Blended nonwovens, filter media and filter units - Google Patents

Blended nonwovens, filter media and filter units Download PDF

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Publication number
TWI568487B
TWI568487B TW102105817A TW102105817A TWI568487B TW I568487 B TWI568487 B TW I568487B TW 102105817 A TW102105817 A TW 102105817A TW 102105817 A TW102105817 A TW 102105817A TW I568487 B TWI568487 B TW I568487B
Authority
TW
Taiwan
Prior art keywords
fiber
core
sheath
filter medium
nonwoven fabric
Prior art date
Application number
TW102105817A
Other languages
English (en)
Other versions
TW201343234A (zh
Inventor
Shiho Uchiyama
Yuri Horie
Masahiro Arai
Masaaki Mori
Tetsuo Asano
Nobuhiro Matsunaga
Original Assignee
Nitto Denko Corp
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
Application filed by Nitto Denko Corp filed Critical Nitto Denko Corp
Publication of TW201343234A publication Critical patent/TW201343234A/zh
Application granted granted Critical
Publication of TWI568487B publication Critical patent/TWI568487B/zh

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Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/54—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
    • B01D46/543—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms using membranes
    • 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
    • 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
    • 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
    • B01D39/1692—Other shaped material, e.g. perforated or porous sheets
    • 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
    • B01D53/22—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 diffusion
    • B01D53/228—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 diffusion characterised by specific membranes
    • 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
    • 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
    • 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
    • B01D71/261—Polyethylene
    • 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
    • B01D71/262—Polypropylene
    • 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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    • 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
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
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    • 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
    • B32B5/08—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 the fibres or filaments of a layer being of different substances, e.g. conjugate fibres, mixture of different fibres
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
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    • 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
    • D04H3/14—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 yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • 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
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    • 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
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    • B01D2239/0636—Two or more types of fibres present in the filter material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
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    • B32B2307/40—Properties of the layers or laminate having particular optical properties
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    • B32B2307/70—Other properties
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    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
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    • D10B2331/00—Fibres made from polymers obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. polycondensation products
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T442/641—Sheath-core multicomponent strand or fiber material

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • General Chemical & Material Sciences (AREA)
  • Analytical Chemistry (AREA)
  • Oil, Petroleum & Natural Gas (AREA)
  • Filtering Materials (AREA)
  • Separation Using Semi-Permeable Membranes (AREA)
  • Laminated Bodies (AREA)
  • Multicomponent Fibers (AREA)
  • Nonwoven Fabrics (AREA)

Description

混紡不織布、過濾器濾材及過濾器單元
本發明係關於一種積層有氟樹脂多孔質膜與透氣性支持材之過濾器濾材、用於該透氣性支持材之混紡不織布、及具備該過濾器濾材之過濾器單元。
為了從氣流過濾粒子等，會使用具有過濾器濾材之過濾器單元。於追求較高之捕集效率之用途中，過濾器濾材使用有：具備聚四氟乙烯(PTFE)多孔質膜等氟樹脂多孔質膜之濾材、對玻璃纖維添加黏合劑進行抄紙而成之濾材(玻璃濾材)、將熔噴(melt blown)不織布駐極體化而成之濾材(駐極體濾材)等。
其中，具備氟樹脂多孔質膜之濾材(氟樹脂多孔質膜型過濾器濾材)具有微小纖維之產生或自我發塵之問題較少、伴隨使用之壓力損失上升較少等特徵。又，作為氟樹脂之性質，亦具有摩擦係數較小滑動性良好、藉由對多孔質膜賦予衝擊而可容易地對捕集到之灰塵進行除塵等性質等。由於上述許多有利之特徵，故而期待具備氟樹脂多孔質膜(尤其是PTFE多孔質膜)之濾材今後使用量日益增加。
氟樹脂多孔質膜通常為富有柔軟性之材料。另一方面，尤其是於吸塵器用過濾器單元等透過較大風量之過濾器單元中，對過濾器濾材要求某種程度之剛性，以使過濾器濾材不因該風量而發生較大變形。因此，具備氟樹脂多孔質膜之過濾器濾材具有於作為透氣構件之氟樹脂多孔質膜上積層作為加強材料之透氣性支持材的構成。透氣性支持材使用有織布、 不織布、金屬製或樹脂製之篩子、金屬製或樹脂製之網、樹脂發泡體等，不織布由於價格低廉而多被使用。作為該不織布，通常使用如聚對酞酸乙二酯/聚乙烯芯鞘纖維之類，原材料之一部分使用聚乙烯等低熔點之熱塑性樹脂而具有熱接著性的不織布，且不織布係藉由熱層壓而與氟樹脂多孔質膜接著而積層(例如，參照專利文獻1)。
專利文獻1：日本特開2005-253711號公報
為了使利用過濾器濾材進行過濾時所需之力最小化，較佳為儘可能減小壓力損失，從而專利文獻1中記載之過濾器濾材於壓力損失方面有改善之餘地。
本發明之目的在於提供一種壓力損失較小之過濾器濾材、用於該過濾器濾材之透氣性支持材之不織布、及使用有該過濾器濾材之過濾器單元。
本發明為一種過濾器濾材，其具有：氟樹脂多孔質膜、及積層於該氟樹脂多孔質膜之至少一表面上之透氣性支持材； 該透氣性支持材為含有芯使用聚酯且鞘使用聚烯烴之芯鞘纖維(A)、聚酯纖維(B)、及芯使用聚酯且鞘使用共聚聚酯之芯鞘纖維(C)的混紡不織布。
於本發明之過濾器濾材中，較佳為，上述芯鞘纖維(A)為芯使用聚對酞酸乙二酯、鞘使用聚乙烯之芯鞘纖維，上述聚酯纖維(B)為聚對酞酸乙二酯纖維，上述芯鞘纖維(C)為芯使用聚對酞酸乙二酯、鞘使用共聚聚對酞酸乙二酯之芯鞘纖維。
較佳為，於上述混紡不織布中含有10~40重量%之上述芯鞘纖維(A)、20~80重量%之上述聚酯纖維(B)、10~40重量%之上述芯鞘纖維(C)。
較佳為，上述芯鞘纖維(A)之纖度為1~6 dtex，上述聚酯纖維(B)之纖度為6~25 dtex，上述芯鞘纖維(C)之纖度為1~6 dtex。
較佳為，上述混紡不織布之空隙率為65%以上，單位面積重量為60 g/m2以上。
上述氟樹脂多孔質膜較佳為聚四氟乙烯多孔質膜。
較佳為，藉由上述芯鞘纖維(A)之鞘之聚烯烴之至少一部分熔融，而使上述氟樹脂多孔質膜與上述混紡不織布積層。
較佳為，上述氟樹脂多孔質膜之平均孔徑為0.01~100 μm，使空氣以流速5.3 cm/秒透過時產生之壓力損失為10~300 Pa，將被過濾氣體之流速設為5.3 cm/秒、將捕集對象粒子之粒徑設為0.3~0.5 μm之範圍時的捕集效率為60%以上。
又，本發明為具備上述過濾器濾材之過濾器單元。本發明之過濾器單元可尤佳地用於吸塵器用途中。
又，本發明為一種混紡不織布，其係用作具有氟樹脂多孔質膜、與積層於該氟樹脂多孔質膜之至少一表面上之透氣性支持材的過濾器濾材中之透氣性支持材， 該混紡不織布含有芯使用聚酯且鞘使用聚烯烴之芯鞘纖維(A)、聚酯纖維(B)、及芯使用聚酯且鞘使用共聚聚酯之芯鞘纖維(C)。
於本發明之混紡不織布中，較佳為，上述芯鞘纖維(A)為芯使用聚對酞酸乙二酯、鞘使用聚乙烯之芯鞘纖維，上述聚酯纖維(B)為聚對酞酸乙二酯纖維，上述芯鞘纖維(C)為芯使用聚對酞酸乙二酯、鞘使用共聚聚對酞酸乙二酯之芯鞘纖維。
本發明之混紡不織布較佳為含有10~40重量%之上述芯鞘纖維(A)、20~80重量%之上述聚酯纖維(B)、10~40重量%之上述芯鞘纖維(C)。
於本發明之混紡不織布中，較佳為，上述芯鞘纖維(A)之纖度為1~6 dtex，上述聚酯纖維(B)之纖度為6~25 dtex，上述芯鞘纖維(C)之纖度為1~6 dtex。
於本發明之混紡不織布中，較佳為，空隙率為65%以上，單位面積重量為60 g/m2以上。
根據本發明，提供一種壓力損失較小之過濾器濾材及過濾器單元。
1‧‧‧過濾器濾材
2‧‧‧支持框
3‧‧‧過濾器單元
4‧‧‧氟樹脂多孔質膜
5‧‧‧混紡不織布
圖1係表示本發明之過濾器單元之一例的斜視圖。
圖2係本發明之過濾器濾材之一例的剖面圖。
如上所述，先前之具備氟樹脂多孔質膜與不織布之過濾器濾材係藉由利用熱層壓使氟樹脂多孔質膜與不織布熱接著而製造，於本發明人等之詳細研究中發現，於氟樹脂多孔質膜與不織布之界面上形成有接著之部分，流體之通過受到限制，此成為壓力損失之一個原因。於熱層壓中，會對氟樹脂多孔質膜與不織布之整個表面施加壓力與熱，故而於氟樹脂多孔質膜與不織布之界面上產生較多之形成有接著之部分。基於該見解，本發明人等認為，若可減少熱層壓後之氟樹脂多孔質膜與不織布之界面上之接著部分，則可構成壓力損失較小之過濾器濾材，並藉由如下過濾器濾材而將其實現，該過濾器濾材具有：氟樹脂多孔質膜、及積層於該氟樹脂多孔質膜之至少一表面上之透氣性支持材； 該透氣性支持材為含有芯使用聚酯且鞘使用聚烯烴之芯鞘纖維(A)、聚酯纖維(B)、及芯使用聚酯且鞘使用共聚聚酯之芯鞘纖維(C)的混紡不織布。
再者，於本發明中所謂壓力損失，係指流體通過過濾器濾材時產生之通過前後之壓力差。
作為構成本發明中所使用之氟樹脂多孔質膜之氟樹脂，可列舉：聚偏二氟乙烯、聚四氟乙烯(PTFE)、乙烯-四氟乙烯共聚物、四氟乙烯-六氟丙烯共聚物、四氟乙烯-全氟烷基乙烯基醚共聚物等，其中，就通用性之觀點而言最佳為PTFE。
作為氟樹脂多孔質膜，可較佳地使用平均孔徑為0.01~100 μm者，可更佳地使用0.01~50 μm者。
作為氟樹脂多孔質膜，可較佳地使用使空氣以流速5.3 cm/秒透過時產生之壓力損失為10~300 Pa者，可更佳地使用10~100 Pa者。
作為氟樹脂多孔質膜，可較佳地使用將被過濾氣體之流速設為5.3 cm/秒、將捕集對象粒子之粒徑設為0.3~0.5 μm之範圍時的捕集效率為60%以上者，可更佳地使用70~99.99%者。
具有上述壓力損失及捕集效率之氟樹脂多孔質膜可藉由適當設定氟樹脂多孔質膜之平均孔徑、空隙率、及厚度而獲得。
作為氟樹脂多孔質膜之厚度，較佳為1~300 μm，更佳為2~100 μm。
氟樹脂多孔質膜可以市售品之形式獲取，又，可根據公知方法進行製造。作為一例，PTFE多孔質膜可藉由將由擠出以PTFE細粉作為原料之漿料所獲得之PTFE片材延伸而製造。於延伸時，PTFE片材之面積延伸倍率(單軸方向之延伸倍率與垂直於其之方向之延伸倍率的累計)設為50~900倍左右即可。
繼而對用作本發明之過濾器濾材之透氣性支持材的混紡不織布(亦為本發明之混紡不織布)進行說明。
芯鞘纖維(A)對不織布賦予接著性。芯鞘纖維(A)中鞘 使用聚烯烴。於將氟樹脂多孔質膜與不織布進行熱層壓時，藉由該聚烯烴之一部分熔融而於氟樹脂多孔質膜與不織布之界面上形成接著部分。
作為構成芯鞘纖維(A)之芯之聚酯，可列舉：聚對酞酸乙二酯(PET)、聚對酞酸丙二酯、聚對酞酸丁二酯、聚萘二甲酸乙二酯、聚萘二甲酸丁二酯等，較佳為PET。
作為構成芯鞘纖維(A)之鞘之聚烯烴，可列舉：聚乙烯(PE)、聚丙烯(PP)、聚丁烯、聚甲基戊烯、乙烯/丙烯共聚物等，其中，較佳為聚乙烯。
作為芯鞘纖維(A)之纖度，較佳為1~10 dtex，更佳為1~6 dtex。若纖度未達1 dtex，則有不織布之壓力損失變得過大之虞，若纖度超過10 dtex，則有與氟樹脂多孔質膜之接著強度變小並且捕集效率降低之虞。作為芯鞘纖維(A)之纖維長，較佳為5~100 mm，更佳為20~80 mm。於使用纖維長較短者之情形時，對過濾器濾材進行褶襉加工時之摺疊性提高。
聚酯纖維(B)其本身之剛性較大，對不織布賦予剛性。作為聚酯纖維(B)，可使用PET纖維、聚對酞酸丙二酯纖維、聚對酞酸丁二酯纖維、聚萘二甲酸乙二酯纖維、聚萘二甲酸丁二酯纖維等，其中，可較佳地使用PET纖維。
作為聚酯纖維(B)之纖度，較佳為1~50 dtex，更佳為6~25 dtex。若纖度未達1 dtex，則有壓力損失變得過大之虞，若纖度超過50 dtex，則有捕集效率降低之虞。作為聚酯纖維(B)之纖維長，較佳為5~100 mm，更佳為20~80 mm。於使用纖維長較短者之情形時，對過濾器濾材進行褶襉加工時之摺疊性提高。
芯鞘纖維(C)係藉由發生與聚酯纖維(B)之接著及芯鞘纖維(C)彼此間之接著而對不織布賦予更高之剛性。
作為構成芯鞘纖維(C)之芯之聚酯，可列舉：PET、聚對酞酸丙二酯、聚對酞酸丁二酯、聚萘二甲酸乙二酯、聚萘二甲酸丁二酯等，其中，較佳為PET。
作為構成芯鞘纖維(C)之鞘之共聚聚酯，可列舉使選自由鄰苯二甲酸、間苯二甲酸、間苯二甲酸-5-磺酸鈉、己二酸、癸二酸、1,4-丁二醇、二乙二醇、聚乙二醇、ε-己內酯、乳酸等所組成之群中之至少1種與PET、聚對酞酸丙二酯、聚對酞酸丁二酯、聚萘二甲酸乙二酯、聚萘二甲酸丁二酯等聚酯共聚合而成者。共聚聚酯較佳為共聚PET，就物性及獲取之容易性之觀點而言，尤佳為使間苯二甲酸與PET共聚合而成者、使1,4-丁二醇與PET共聚合而成者、以及使ε-己內酯及1,4-丁二醇與PET共聚合而成者。再者，該共聚聚酯係選擇較構成芯鞘纖維(C)之芯之聚酯熔點低者。
作為芯鞘纖維(C)之纖度，較佳為1~10 dtex，更佳為1~6 dtex。若纖度未達1 dtex，則有不織布之壓力損失變得過大之虞，若纖度超過10 dtex，則有纖維間之接著強度變小而不織布之剛性不充分並且捕集效率降低之虞。作為芯鞘纖維(C)之纖維長，較佳為5~100 mm，更佳為20~80 mm。於使用纖維長較短者之情形時，對過濾器濾材進行褶襉加工時之摺疊性提高。
以往，使用僅由相當於芯鞘纖維(A)之纖維所構成之不織布，然而如上所述，本發明之不織布係藉由與芯鞘纖維(A)以外之纖維混紡而減少芯鞘纖維(A)之含量，減少熱層壓後之氟樹脂多孔質膜與不織布之界面上之接著部分。於由單一種類之纖維所構成之不織布中，即便增大纖度(=不織布之眼變粗)亦可減少接著部分，但於該情形時，熱層壓時不織布與氟樹脂多孔質膜之接觸點較少，故而對各接著部分(接觸點)施加之壓力變大而對氟樹脂多孔質膜造成損傷，捕集效率降低。然而，於如 本發明般藉由混紡不織布而減少接著部分之情形時，熱層壓溫度下不熔融之聚酯纖維(B)以夾雜之方式存在，故而於熱層壓時氟樹脂多孔質膜與不織布之接觸點不怎麼減少，壓力因聚酯纖維(B)而分散。因此推測，不降低捕集效率便可減少壓力損失之上升。而且，因接著部分之減少而過濾器濾材之剛性減少，但該情況藉由與聚酯纖維(B)及芯鞘纖維(C)混紡而彌補。
關於該等纖維(A)~(C)，就與氟樹脂多孔質膜之接著性、不織布之剛性、及所獲得之過濾器濾材之壓力損失之觀點而言，不織布中，芯鞘纖維(A)較佳為含有1~80重量%，更佳為含有10~40重量%。聚酯纖維(B)較佳為含有10~90重量%，更佳為含有20~80重量%。芯鞘纖維(C)較佳為含有1~80重量%，更佳為含有10~40重量%。
作為不織布之單位面積重量，就來自不織布之加強效果或成型加工性之觀點而言，較佳為10 g/m2以上，更佳為60 g/m2以上。另一方面，就成本或成型加工性之觀點而言，較佳為1000 g/m2以下，更佳為400 g/m2以下。
作為不織布之空隙率，就壓力損失之觀點而言，較佳為65%以上，更佳為70%以上。另一方面，就捕集效率及不織布之剛性之觀點而言，較佳為90%以下，更佳為85%以下。再者，不織布之空隙率係將不織布中所使用之纖維本身之密度設為a、將不織布之單位面積重量設為b、將不織布之厚度設為c，而可藉由下述式求出。
空隙率(%)=[1-(b/a×c)]×100
不織布之厚度並無特別限制，就不織布之剛性及壓力損失之觀點而言，較佳為200~2000 μm，更佳為250~1000 μm。
不織布可根據公知方法進行製造。例如，可藉由如下方式而獲得：對纖維(A)~(C)賦予捲縮，切割為特定之長度後，以根據用途 或其要求特性所決定之比率進行混棉，於以梳棉機或Air Layer等形成網狀物之後，通過熱處理裝置使纖維之黏合劑成分熔融而使纖維發生點接合。於該情形時，亦可於熱處理之前進行針刺加工(needling working)。作為熱處理裝置，使用熱風循環乾燥機、熱風貫流乾燥機、抽吸式轉筒乾燥機、揚克(Yankee)轉筒乾燥機等，選定配合黏合劑成分之熔點之處理溫度與處理時間進行處理即可。進而為了獲得所欲厚度之不織布，亦可於接壓受控制之加熱輥間進行熱壓接處理。
本發明之過濾器濾材亦可經撥液處理(撥水處理及/或撥油處理)。於該情形時，成為具有撥液性能之過濾器濾材。此種過濾器濾材容易將過濾器濾材捕集之物質藉由洗淨而去除或機械性地抖落。
本發明之過濾器濾材亦可經抗菌處理，於該情形時，成為具有抗菌性能之過濾器濾材。此種過濾器濾材例如於吸塵器用途中，可抑制吸塵器內之細菌之增生。
本發明之過濾器濾材亦可經除臭處理，於該情形時，成為具有除臭性能之過濾器濾材。此種過濾器濾材例如於吸塵器用途中，可減少吸塵器內之臭味。
本發明之過濾器濾材於不妨礙本發明之目的之範圍內，視需要亦可積層氟樹脂多孔質膜及混紡不織布以外者。
於本發明之過濾器濾材中，亦可使用複數片氟樹脂多孔質膜，同樣地，亦可使用複數片混紡不織布。此時，氟樹脂多孔質膜與混紡不織布之任一者位於最表面皆可。
本發明之過濾器濾材視需要亦可經褶襉加工，對褶襉之形狀並無特別限制。褶襉加工可將平板狀之過濾器濾材不斷送出進行連續加工，亦可將切為適當尺寸之過濾器濾材(單板)加工成褶襉狀。於平板狀之過濾器濾材之褶襉加工中，可使用公知之褶襉加工機(旋轉式褶襉機、 往復式褶襉機、壓折褶襉機等)。就抑制褶襉加工時對過濾器濾材之損傷之觀點而言，較佳為使用往復式褶襉機。
於本發明之過濾器濾材中，氟樹脂多孔質膜或不織布亦可經著色。著色可藉由於氟樹脂多孔質膜或不織布之原料中混練顏料、對不織布進行染色、藉由後處理而使顏料等附著於不織布之表面等公知方法進行。
本發明之過濾器濾材可依照公知方法，藉由積層氟樹脂多孔質膜及上述混紡不織布而製造，較佳為藉由對氟樹脂多孔質膜及上述混紡不織布進行熱層壓而製造。藉由熱層壓，芯鞘纖維(A)之鞘之聚烯烴之至少一部分熔融，使氟樹脂多孔質膜與混紡不織布接著而積層。熱層壓可對使氟樹脂多孔質膜及混紡不織布重合而成之長條卷連續進行，亦可對使氟樹脂多孔質膜及混紡不織布重合而成之短條片材個別進行。作為熱層壓之方法，具體而言，使氟樹脂多孔質膜及混紡不織布重合並通過一對熱輥間施加熱與壓力即可。再者，作為積層方法，使用接著劑或熱熔劑之方法亦可，但於使用該等之情形時，有因製程之增加所致之產率降低、或於加熱時由接著劑產生逸氣之不利情形。
本發明之過濾器濾材具有壓力損失較小之優點。又，本發明之過濾器濾材具有充分之剛性，且具有氟樹脂多孔質膜具有之優點。本發明之過濾器濾材可用於各種用途，例如，可用於無塵室用途、口罩用途、家電製品用途等。
又，本發明為具備上述過濾器濾材之過濾器單元。
作為過濾器單元之形態，可列舉：濾袋、濾管、濾板單元、濾匣等。
作為過濾器單元之典型構成，過濾器單元具有上述過濾器濾材與支持框。過濾器單元可根據公知方法而製造，例如，藉由使用過濾器濾材及構成支持框之樹脂進行嵌入成形而製造。
圖1表示本發明之過濾器單元之構成例。經褶襉加工之過濾器濾材1之周圍由支持框2支持而構成過濾器單元3。過濾器濾材1亦可使用未經褶襉加工者。
過濾器濾材1係如圖2所示，具有積層有氟樹脂多孔質膜4與混紡不織布5之構造。
支持框2之材料使用樹脂，作為樹脂，可使用丙烯腈-丁二烯-苯乙烯共聚物(ABS)、聚碳酸酯、聚丙烯、各種彈性體等，通常使用聚丙烯、ABS，但就容易確保尺寸精度且可抑制使用時之變形而言，較佳為ABS。又，樹脂亦可含有玻璃纖維等填料，此時，支持框2之尺寸精度進一步提高。
若使用過濾器單元3，則可於過濾器濾材1之褶襉形狀之凹部集塵，且藉由自過濾器單元之下游側對該凹部給予衝擊而亦容易進行除塵。
本發明之過濾器單元壓力損失較小，可用於各種用途。例如，可用作無塵室用空氣過濾器單元、家電製品用過濾器單元等，尤佳之用途為吸塵器用過濾器單元。
[實施例]
以下，列舉實施例及比較例詳細說明本發明，但本發明並不限定於該等實施例。
實施例1
首先，對PTFE細粉(商品名「Polyflon F-104」，Daikin工業公司製造)100重量份均勻混合作為液狀潤滑劑之烴油(商品名「Isopar M」，Esso石油公司製造)25重量份。繼而，於壓力20 MPa下將所獲得之混合物進行壓縮預成形，此後將預成形物擠出成形為桿狀，進而使該桿狀之擠出成形物通過一對金屬輥進行壓延，獲得厚度0.2 mm、寬度150 mm之帶狀之PTFE片 材。
繼而，將所獲得之片材加熱至220℃去除該片材中所含有之液狀潤滑劑，此後於未燒成之狀態下以倍率20倍於MD方向(機械方向)上延伸，繼而以倍率30倍於TD方向(橫斷方向)上延伸，進而，於固定尺寸之狀態下以PTFE之熔點以上之溫度進行燒成，獲得帶狀之PTFE多孔質膜。該PTFE多孔質膜之平均孔徑為10 μm，使空氣以流速5.3 cm/秒透過時產生之壓力損失為40 Pa，將被過濾氣體之流速設為5.3 cm/秒、將捕集對象粒子之粒徑設為0.3~0.5 μm之範圍時的捕集效率為80%。
作為透氣性支持材，準備厚度300 μm之3成分短纖維混紡不織布。該不織布以PET/PE芯鞘纖維(25重量%，纖度4.4 dtex，纖維長51 mm)、PET纖維(40重量%，纖度17 dtex，纖維長51 mm)、及PET/間苯二甲酸共聚PET芯鞘纖維(35重量%，纖度4.4 dtex，纖維長51 mm，共聚成分軟化點110℃)作為成分。又，單位面積重量設為100 g/m2，空隙率設為75%。
以2片不織布夾持上述中製作而成之PTFE多孔質膜之兩側，於溫度200℃、壓力約0.1~0.5 kPa下進行熱層壓，獲得3層構造之過濾器濾材。
實施例2
將實施例1中使用之3成分短纖維混紡不織布之厚度變更為750 μm，將單位面積重量變更為200 g/m2，且將空隙率變更為80%，除此以外，以與實施例1相同之方式獲得過濾器濾材。
比較例1
將3成分混紡不織布變更為厚度350 μm之3成分積層不織布，除此以外，以與實施例1相同之方式製造過濾器濾材。3成分積層不織布具有PET/PE芯鞘纖維層(25重量%，纖度2.2 dtex，纖維長51 mm)、PET纖維層 (50重量%，纖度17 dtex，纖維長51 mm)、PET/間苯二甲酸共聚PET芯鞘纖維層(25重量%，纖度2.2 dtex，纖維長51 mm)，且於積層有PET/PE芯鞘纖維層之面上與PTFE多孔質膜進行熱層壓。3成分積層不織布之單位面積重量設為100 g/m2，空隙率設為79%。
壓力損失之測定
將實施例及比較例之過濾器濾材設置於有效面積100 cm2之圓柱狀固持器上，使過濾器濾材之兩面產生壓力差並使空氣透過該過濾器濾材。以壓力計測定將透過之空氣之流速以流量計調整為5.3 cm/sec(流量31.8 m3/min)時之壓力損失。該測定亦可對使用之不織布進行。又，對實施例及比較例之僅使氟樹脂多孔質膜與不織布重合而成之試樣進行同樣之實驗。將對該試樣之測定結果設為層壓前之壓力損失，使用過濾器濾材之壓力損失之值除以層壓前之壓力損失之值所得的值，求出層壓時之壓力損失上升率。將結果示於表1。
根據表1，實施例之過濾器濾材之壓力損失與比較例之壓力損失相比小6.5~11.4 Pa。又，若比較層壓時之壓力損失上升率，則實施例因層壓所致之壓力損失較小為10~28%。
可認為其原因在於：由於使不織布為添加有PET/PE芯鞘纖維以外之成分之混紡系，故而存在於不織布表面之PE之量變少。可認為其原因在於：藉此，於熱層壓後，PTFE多孔質膜與不織布之接著點變少， 由PE所堵塞之PTFE多孔質膜之孔之數量減少。
[產業上之可利用性]
本發明之混紡不織布係用於氟樹脂多孔質膜型過濾器濾材之透氣性支持材。本發明之過濾器濾材可用於無塵室用途、口罩用途、家電製品用途。本發明之過濾器單元可用作無塵室用空氣過濾器單元、家電製品用過濾器單元等，尤其可較佳地用於吸塵器用過濾器單元。
1‧‧‧過濾器濾材
4‧‧‧氟樹脂多孔質膜
5‧‧‧混紡不織布

Claims (15)

  1. 一種過濾器濾材，其具有：氟樹脂多孔質膜、及積層於該氟樹脂多孔質膜之至少一表面上之透氣性支持材；該透氣性支持材為含有芯使用聚酯且鞘使用聚烯烴之芯鞘纖維(A)、聚酯纖維(B)、及芯使用聚酯且鞘使用共聚聚酯之芯鞘纖維(C)的混紡不織布。
  2. 如申請專利範圍第1項之過濾器濾材，其中，該芯鞘纖維(A)為芯使用聚對酞酸乙二酯、鞘使用聚乙烯之芯鞘纖維，該聚酯纖維(B)為聚對酞酸乙二酯纖維，該芯鞘纖維(C)為芯使用聚對酞酸乙二酯、鞘使用共聚聚對酞酸乙二酯之芯鞘纖維。
  3. 如申請專利範圍第1項之過濾器濾材，其中，於該混紡不織布含有10~40重量%之該芯鞘纖維(A)、20~80重量%之該聚酯纖維(B)、10~40重量%之該芯鞘纖維(C)。
  4. 如申請專利範圍第1項之過濾器濾材，其中，該芯鞘纖維(A)之纖度為1~6 dtex，該聚酯纖維(B)之纖度為6~25 dtex，該芯鞘纖維(C)之纖度為1~6 dtex。
  5. 如申請專利範圍第1項之過濾器濾材，其中，該混紡不織布之空隙率為65%以上，單位面積重量為60 g/m2以上。
  6. 如申請專利範圍第1項之過濾器濾材，其中，該氟樹脂多孔質膜為聚四氟乙烯多孔質膜。
  7. 如申請專利範圍第1項之過濾器濾材，其藉由該芯鞘纖維(A)之鞘之聚烯烴之至少一部分熔融而使該氟樹脂多孔質膜與該混紡不織布積層。
  8. 如申請專利範圍第1項之過濾器濾材，其中，該氟樹脂多孔質膜之平均孔徑為0.01~100 μm，使空氣以流速5.3 cm/秒透過時產生之壓力損 失為10~300 Pa，將被過濾氣體之流速設為5.3 cm/秒、將捕集對象粒子之粒徑設為0.3~0.5 μm之範圍時的捕集效率為60%以上。
  9. 一種過濾器單元，其具備有申請專利範圍第1項之過濾器濾材。
  10. 如申請專利範圍第9項之過濾器單元，其用於吸塵器。
  11. 一種混紡不織布，被使用作為過濾器濾材中之透氣性支持材，該過濾器濾材具有氟樹脂多孔質膜、與積層於該氟樹脂多孔質膜之至少一表面上的透氣性支持材，該混紡不織布含有芯使用聚酯且鞘使用聚烯烴之芯鞘纖維(A)、聚酯纖維(B)、及芯使用聚酯且鞘使用共聚聚酯之芯鞘纖維(C)。
  12. 如申請專利範圍第11項之混紡不織布，其中，該芯鞘纖維(A)為芯使用聚對酞酸乙二酯、鞘使用聚乙烯之芯鞘纖維，該聚酯纖維(B)為聚對酞酸乙二酯纖維，該芯鞘纖維(C)為芯使用聚對酞酸乙二酯、鞘使用共聚聚對酞酸乙二酯之芯鞘纖維。
  13. 如申請專利範圍第11項之混紡不織布，其含有10~40重量%之該芯鞘纖維(A)、20~80重量%之該聚酯纖維(B)、10~40重量%之該芯鞘纖維(C)。
  14. 如申請專利範圍第11項之混紡不織布，其中，該芯鞘纖維(A)之纖度為1~6 dtex，該聚酯纖維(B)之纖度為6~25 dtex，該芯鞘纖維(C)之纖度為1~6 dtex。
  15. 如申請專利範圍第11項之混紡不織布，其空隙率為65%以上，單位面積重量為60 g/m2以上。
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