CN114222781B - 驻极体及使用其的滤材 - Google Patents
驻极体及使用其的滤材 Download PDFInfo
- Publication number
- CN114222781B CN114222781B CN202080057987.4A CN202080057987A CN114222781B CN 114222781 B CN114222781 B CN 114222781B CN 202080057987 A CN202080057987 A CN 202080057987A CN 114222781 B CN114222781 B CN 114222781B
- Authority
- CN
- China
- Prior art keywords
- electret
- magnesium
- polyolefin resin
- nitrogen
- containing compound
- 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.)
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- -1 nitrogen-containing compound Chemical class 0.000 claims abstract description 40
- 239000002245 particle Substances 0.000 claims abstract description 40
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 claims abstract description 33
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 33
- 239000011777 magnesium Substances 0.000 claims abstract description 33
- 229920005672 polyolefin resin Polymers 0.000 claims abstract description 31
- 238000002834 transmittance Methods 0.000 claims abstract description 15
- 238000000034 method Methods 0.000 claims description 49
- 235000014113 dietary fatty acids Nutrition 0.000 claims description 12
- 239000000194 fatty acid Substances 0.000 claims description 12
- 229930195729 fatty acid Natural products 0.000 claims description 12
- 239000000155 melt Substances 0.000 claims description 9
- 238000007664 blowing Methods 0.000 claims description 7
- 150000001875 compounds Chemical class 0.000 claims description 7
- 150000001412 amines Chemical class 0.000 claims description 6
- 125000004432 carbon atom Chemical group C* 0.000 claims description 6
- 125000005313 fatty acid group Chemical group 0.000 claims description 5
- 230000008569 process Effects 0.000 claims description 3
- 239000000463 material Substances 0.000 abstract description 22
- 238000001914 filtration Methods 0.000 abstract description 12
- 239000000835 fiber Substances 0.000 description 43
- 239000007788 liquid Substances 0.000 description 18
- 239000002657 fibrous material Substances 0.000 description 14
- 238000009423 ventilation Methods 0.000 description 13
- 159000000003 magnesium salts Chemical class 0.000 description 10
- 239000004745 nonwoven fabric Substances 0.000 description 9
- HQKMJHAJHXVSDF-UHFFFAOYSA-L magnesium stearate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O HQKMJHAJHXVSDF-UHFFFAOYSA-L 0.000 description 8
- 230000000052 comparative effect Effects 0.000 description 7
- 150000002681 magnesium compounds Chemical class 0.000 description 7
- 229920005989 resin Polymers 0.000 description 7
- 239000011347 resin Substances 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 6
- 239000000428 dust Substances 0.000 description 6
- 239000010410 layer Substances 0.000 description 6
- 238000002844 melting Methods 0.000 description 6
- 230000008018 melting Effects 0.000 description 6
- 238000002156 mixing Methods 0.000 description 6
- 239000002253 acid Substances 0.000 description 4
- 150000004665 fatty acids Chemical class 0.000 description 4
- 235000019359 magnesium stearate Nutrition 0.000 description 4
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 4
- JYEUMXHLPRZUAT-UHFFFAOYSA-N 1,2,3-triazine Chemical group C1=CN=NN=C1 JYEUMXHLPRZUAT-UHFFFAOYSA-N 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 3
- 239000000654 additive Substances 0.000 description 3
- 230000000996 additive effect Effects 0.000 description 3
- 238000004378 air conditioning Methods 0.000 description 3
- 238000001523 electrospinning Methods 0.000 description 3
- 230000007246 mechanism Effects 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 229920000098 polyolefin Polymers 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 239000002994 raw material Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 238000009987 spinning Methods 0.000 description 3
- 238000005979 thermal decomposition reaction Methods 0.000 description 3
- RYPKRALMXUUNKS-UHFFFAOYSA-N 2-Hexene Natural products CCCC=CC RYPKRALMXUUNKS-UHFFFAOYSA-N 0.000 description 2
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 2
- RRHGJUQNOFWUDK-UHFFFAOYSA-N Isoprene Chemical compound CC(=C)C=C RRHGJUQNOFWUDK-UHFFFAOYSA-N 0.000 description 2
- 241000784303 Ochrosia compta Species 0.000 description 2
- 229910052783 alkali metal Inorganic materials 0.000 description 2
- 150000001340 alkali metals Chemical class 0.000 description 2
- 150000001336 alkenes Chemical class 0.000 description 2
- 238000000149 argon plasma sintering Methods 0.000 description 2
- 238000004380 ashing Methods 0.000 description 2
- 239000002585 base Substances 0.000 description 2
- HQABUPZFAYXKJW-UHFFFAOYSA-N butan-1-amine Chemical compound CCCCN HQABUPZFAYXKJW-UHFFFAOYSA-N 0.000 description 2
- 229920001577 copolymer Polymers 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 125000001841 imino group Chemical group [H]N=* 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229910052697 platinum Inorganic materials 0.000 description 2
- 238000011045 prefiltration Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000003014 reinforcing effect Effects 0.000 description 2
- 229910052723 transition metal Inorganic materials 0.000 description 2
- LIKMAJRDDDTEIG-UHFFFAOYSA-N 1-hexene Chemical compound CCCCC=C LIKMAJRDDDTEIG-UHFFFAOYSA-N 0.000 description 1
- KWKAKUADMBZCLK-UHFFFAOYSA-N 1-octene Chemical compound CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 1
- LEVFXWNQQSSNAC-UHFFFAOYSA-N 2-(4,6-diphenyl-1,3,5-triazin-2-yl)-5-hexoxyphenol Chemical compound OC1=CC(OCCCCCC)=CC=C1C1=NC(C=2C=CC=CC=2)=NC(C=2C=CC=CC=2)=N1 LEVFXWNQQSSNAC-UHFFFAOYSA-N 0.000 description 1
- 125000000954 2-hydroxyethyl group Chemical group [H]C([*])([H])C([H])([H])O[H] 0.000 description 1
- BHPQYMZQTOCNFJ-UHFFFAOYSA-N Calcium cation Chemical compound [Ca+2] BHPQYMZQTOCNFJ-UHFFFAOYSA-N 0.000 description 1
- PXGOKWXKJXAPGV-UHFFFAOYSA-N Fluorine Chemical compound FF PXGOKWXKJXAPGV-UHFFFAOYSA-N 0.000 description 1
- JLVVSXFLKOJNIY-UHFFFAOYSA-N Magnesium ion Chemical compound [Mg+2] JLVVSXFLKOJNIY-UHFFFAOYSA-N 0.000 description 1
- 125000002723 alicyclic group Chemical group 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 230000000844 anti-bacterial effect Effects 0.000 description 1
- 230000003373 anti-fouling effect Effects 0.000 description 1
- 230000000840 anti-viral effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 229910001424 calcium ion Inorganic materials 0.000 description 1
- 238000011088 calibration curve Methods 0.000 description 1
- 150000003857 carboxamides Chemical class 0.000 description 1
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 1
- 238000009960 carding Methods 0.000 description 1
- 239000002738 chelating agent Substances 0.000 description 1
- YACLQRRMGMJLJV-UHFFFAOYSA-N chloroprene Chemical compound ClC(=C)C=C YACLQRRMGMJLJV-UHFFFAOYSA-N 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- ZBCBWPMODOFKDW-UHFFFAOYSA-N diethanolamine Chemical compound OCCNCCO ZBCBWPMODOFKDW-UHFFFAOYSA-N 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000005684 electric field Effects 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- 208000016253 exhaustion Diseases 0.000 description 1
- 229910052731 fluorine Inorganic materials 0.000 description 1
- 239000011737 fluorine Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229920001519 homopolymer Polymers 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 230000010354 integration Effects 0.000 description 1
- 229920000554 ionomer Polymers 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910001425 magnesium ion Inorganic materials 0.000 description 1
- 229940105112 magnesium myristate Drugs 0.000 description 1
- 229940063002 magnesium palmitate Drugs 0.000 description 1
- 229940057948 magnesium stearate Drugs 0.000 description 1
- OBQVOBQZMOXRAL-UHFFFAOYSA-L magnesium;docosanoate Chemical compound [Mg+2].CCCCCCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCCCCCC([O-])=O OBQVOBQZMOXRAL-UHFFFAOYSA-L 0.000 description 1
- BJZBHTNKDCBDNQ-UHFFFAOYSA-L magnesium;dodecanoate Chemical compound [Mg+2].CCCCCCCCCCCC([O-])=O.CCCCCCCCCCCC([O-])=O BJZBHTNKDCBDNQ-UHFFFAOYSA-L 0.000 description 1
- ABSWXCXMXIZDSN-UHFFFAOYSA-L magnesium;hexadecanoate Chemical compound [Mg+2].CCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCC([O-])=O ABSWXCXMXIZDSN-UHFFFAOYSA-L 0.000 description 1
- DMRBHZWQMKSQGR-UHFFFAOYSA-L magnesium;tetradecanoate Chemical compound [Mg+2].CCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCC([O-])=O DMRBHZWQMKSQGR-UHFFFAOYSA-L 0.000 description 1
- AXLHVTKGDPVANO-UHFFFAOYSA-N methyl 2-amino-3-[(2-methylpropan-2-yl)oxycarbonylamino]propanoate Chemical compound COC(=O)C(N)CNC(=O)OC(C)(C)C AXLHVTKGDPVANO-UHFFFAOYSA-N 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- HRYSOBDFNHXNTM-UHFFFAOYSA-N n-butylbutan-1-amine;1,3,5-triazine Chemical compound C1=NC=NC=N1.CCCCNCCCC HRYSOBDFNHXNTM-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 230000035699 permeability Effects 0.000 description 1
- 230000010287 polarization Effects 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920000306 polymethylpentene Polymers 0.000 description 1
- 239000011116 polymethylpentene Substances 0.000 description 1
- 229920005629 polypropylene homopolymer Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 125000002924 primary amino group Chemical group [H]N([H])* 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 238000004445 quantitative analysis Methods 0.000 description 1
- 230000009257 reactivity Effects 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 239000013557 residual solvent Substances 0.000 description 1
- 150000004671 saturated fatty acids Chemical class 0.000 description 1
- 235000003441 saturated fatty acids Nutrition 0.000 description 1
- 125000000467 secondary amino group Chemical group [H]N([*:1])[*:2] 0.000 description 1
- 238000006884 silylation reaction Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000012086 standard solution Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 125000000999 tert-butyl group Chemical group [H]C([H])([H])C(*)(C([H])([H])[H])C([H])([H])[H] 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 239000012085 test solution Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 150000004670 unsaturated fatty acids Chemical class 0.000 description 1
- 235000021122 unsaturated fatty acids Nutrition 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Classifications
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- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
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- B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
- B01J20/26—Synthetic macromolecular compounds
- B01J20/261—Synthetic macromolecular compounds obtained by reactions only involving carbon to carbon unsaturated bonds
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- 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
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- B01D46/0001—Making filtering elements
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- B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
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- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28002—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their physical properties
- B01J20/28011—Other properties, e.g. density, crush strength
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- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
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- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/3007—Moulding, shaping or extruding
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- C08K5/098—Metal salts of carboxylic acids
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- C08K5/34—Heterocyclic compounds having nitrogen in the ring
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- C08K5/3435—Piperidines
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- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
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- C08K5/3492—Triazines
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- D—TEXTILES; PAPER
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- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
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- D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
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- D01F6/46—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from mixtures of polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds as major constituent with other polymers or low-molecular-weight compounds of polyolefins
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Abstract
本发明提供即使在包含聚烯烃树脂及镁元素的情况下,过滤性能也优异的驻极体及使用其的滤材。本发明为包含聚烯烃树脂及含氮化合物的驻极体,其特征在于,相对于上述聚烯烃树脂100质量份,上述含氮化合物的含量为0.1~5质量份,上述驻极体中的镁元素的含有比例为5~100ppm,将粒径为0.3~0.5μm的粒子作为捕集对象时,下述式表示的QF值为1.00mmAq‑1以上。QF[mmAq‑1]=‑[ln(粒子透过率(%)/100)]/[通气阻力(mmAq)]。
Description
技术领域
本发明涉及驻极体及使用其的滤材。
背景技术
以往,在防尘罩、各种空调用元件、空气净化器、舱室过滤器的各种装置中,使用以集尘、保护、通气等为目的的多孔滤材。
多孔滤材中,由纤维状物形成的滤材具有高空隙率、长寿命、低通气阻力这样的优点,因此被广泛使用。对于上述由纤维状物形成的滤材,粒子通过接触附着、扩散、惯性碰撞等机械捕集机理捕捉到纤维上。虽然会依据粒子的物性、滤材的纤维直径、粒子的透过风速等变更这些机理,但已知在实际应用的使用环境中,要捕捉的粒子的空气动力学当量直径为0.1~1.0μm左右时,滤材的粒子捕集效率变得最低。
为了提高针对空气动力学当量直径为0.1~1.0μm左右的粒子的滤材粒子捕集效率,已知有并用电吸引力的方法。例如,已知有对成为捕集对象的粒子赋予电荷的方法,对滤材赋予电荷的方法,将滤材设置于电场中的方法等,也已知将上述方法多种组合的方法。作为对滤材赋予电荷的方法,已知有:在电极间配置滤材、并在通风时进行介电极化的方法;对绝缘材料赋予准永久静电电荷的方法,特别是在后者的方法的情况下,由于不需要外部电源等能量,因此包含这样的绝缘材料的滤材被广泛用作驻极体滤材。
为了提高驻极体滤材的捕集效率,已知优选通过使液体接触或碰撞纤维状物的方法(液体接触带电法)来对纤维状物赋予静电电荷以制成驻极体。例如,作为兼具成本和性能的驻极体,已知有通过使水等液体接触由在以聚烯烃树脂为主成分的树脂中添加了受阻胺系化合物等含氮化合物的混合物形成的纤维状物,从而赋予静电电荷的驻极体。
作为通过液体接触带电法使以聚烯烃树脂为主成分的纤维状物带电的驻极体网,公开了以下专利文献1~3。专利文献1公开了包含由热塑性高分子材料制造的纤维的无纺驻极体网,上述热塑性高分子材料包含聚合物、第1添加剂(a)和第2添加剂(b),上述第1添加剂(a)对通过极性液体处理在上述纤维生成的电荷进行捕捉,上述第2添加剂(b)包含衍生自具有29-50个碳原子的羧酸,以及具有1个或2个伯氨基和/或仲氨基的同时在脂肪族基团中具有1-6个碳原子的脂肪族胺的有机酰胺。专利文献2公开了在赋予静电电荷且承载氟的载体上层叠增强材料而成的驻极体材料。另外,专利文献3公开了包含热塑性树脂和特定的电荷加强添加剂的驻极体网。
现有技术文献
专利文献
专利文献1:日本专利第6346640号公报
专利文献2:日本特开2018-202369号公报
专利文献3:日本特表2018-523761号公报
发明内容
发明要解决的课题
上述专利文献中,对于驻极体、驻极体滤材中包含聚烯烃树脂及镁元素的情况下的过滤性能,存在改善空间。
用于解决课题的手段
本发明人等进行了深入研究,结果发现,通过使镁元素的含有比例为少量,可以获得过滤性能优异的驻极体及使用其的滤材,从而完成了本发明。
即,本发明包含以下发明。
[1]一种驻极体,其为包含聚烯烃树脂及含氮化合物的驻极体,其特征在于,相对于上述聚烯烃树脂100质量份,上述含氮化合物的含量为0.1~5质量份;上述驻极体中的镁元素的含有比例为5~100ppm;将粒径为0.3~0.5μm的粒子作为捕集对象时,下述式表示的QF值为1.00mmAq-1以上。
QF[mmAq-1]=-[ln(粒子透过率(%)/100)]/[通气阻力(mmAq)]
[2]根据上述[1]所述的驻极体,其中,包含脂肪酸镁盐。
[3]根据上述[1]或[2]所述的驻极体,其中,上述含氮化合物包含受阻胺系化合物。
[4]根据上述[1]~[3]中任一项所述的驻极体,其为纤维集合体。
[5]根据上述[1]~[4]中任一项所述的驻极体,其由熔喷法制作。
[6]一种滤材,其使用上述[1]~[5]中任一项所述的驻极体。
发明的效果
本发明的驻极体及使用其的滤材的QF值优异。
具体实施方式
本发明的驻极体包含聚烯烃树脂及含氮化合物,相对于上述聚烯烃树脂100质量份,上述含氮化合物的含量为0.1~5质量份,上述驻极体中的镁元素的含有比例为5~100ppm,上述驻极体的QF值为1.00mmAq-1以上。
<聚烯烃树脂>
从形状的自由度及驻极体的电荷稳定性的观点考虑,本发明的驻极体使用疏水性且电阻高的聚烯烃树脂。作为聚烯烃树脂,例如可举出乙烯、丙烯、丁烯、己烯、辛烯、丁二烯、异戊二烯、氯丁二烯、甲基-1-戊烯、环状烯烃等烯烃的均聚物或由2种以上的上述烯烃构成的共聚物。聚烯烃树脂可以选择1种上述聚合物或共聚物单独使用,也可以选择2种以上组合使用。聚烯烃树脂优选包含选自聚丙烯及聚甲基戊烯中的至少1种,更优选包含聚丙烯。100质量份驻极体中的聚烯烃树脂的含有比例为80质量份以上,更优选为85质量份以上,进一步优选为90质量份以上,特别优选为95质量份以上,最优选为97质量份以上。聚烯烃树脂的含有比例的上限没有特别限定,例如为99.5质量份以下,优选为99质量份以下。另外,当改变芯鞘纤维、并列纤维等纤维的左右、芯鞘中所含的树脂时,仅将包含聚烯烃树脂的部分作为本发明的驻极体。
<含氮化合物>
相对于聚烯烃树脂100质量份中而言的含氮化合物的含有比例为0.1~5质量份,优选为0.5~3质量份,更优选为0.75~1.5质量份。另外,当驻极体中混合2种以上的纤维或者在一个纤维中混合2种以上的树脂时,是指聚烯烃树脂中所含的含氮化合物的比例。即使是在驻极体中包含聚烯烃以外的树脂时,聚烯烃以外的树脂也会溶解于溶剂、酸碱或者染色性不同,因而可以判别,也可以通过DSC、NMR等定量法来判别聚烯烃树脂。含氮化合物的含有比例低于0.1质量份时,电荷量变低,因此导致过滤特性降低;高于5质量份时,由于吸湿性的增大而失去了作为驻极体的稳定性。
驻极体100质量份中的含氮化合物的含有比例优选为0.1~5质量份,更优选为0.5~3质量份,进一步优选为0.75~1.5质量份。通过在上述范围内,可以提高过滤特性,并且可以抑制吸湿性从而提高作为驻极体的稳定性。
含氮化合物只要可以获得上述所期望的特性则没有特别限制,优选包含2,2,6,6-四甲基哌啶结构及三嗪结构中的至少一种的受阻胺系化合物,更优选受阻胺系化合物包含2,2,6,6-四甲基哌啶结构及三嗪结构。
作为受阻胺系化合物,没有特别限定,例如可举出聚[{6-(1,1,3,3-四甲基丁基)氨基-1,3,5-三嗪-2,4-二基}{(2,2,6,6-四甲基-4-哌啶基))亚氨基}六亚甲基{(2,2,6,6-四甲基-4-哌啶基)亚氨基}](Chimassrob(注册商标)944LD,BASF Japan公司制造)、琥珀酸二甲基-1-(2-羟乙基)-4-羟基-2,2,6,6-四甲基-4-哌啶缩聚物(Tinuvin(注册商标)622LD,BASF Japan公司制造)、2-[[3,5-双(1,1-二甲基乙基)-4-羟苯基]甲基]-2-丁基丙二酸双[1,2,2,6,6-五甲基-4-哌啶基]酯(Tinuvin(注册商标)144,BASF Japan公司制造)、二丁基胺1,3,5-三嗪/N,N-双(2,2,6,6-四甲基-4-哌啶基)-1,6-六亚甲基二胺/N-(2,2,6,6)-四甲基-4-哌啶基)丁基胺的缩聚物(Chimassrob(注册商标)2020FDL,BASF Japan公司制造)、2-(4,6-二苯基-1,3,5-三嗪-2-基)-5-(己氧基)-苯酚(Tinuvin(注册商标)1577FF,BASF Japan公司制造)等。其中,优选包含2,2,6,6-四甲基哌啶结构及三嗪结构,更优选Chimassrob(注册商标)944LD或Chimassrob(注册商标)2020FD。作为受阻胺系化合物,可以单独使用上述化合物中的1种,也可以并用2种以上。
<镁元素>
驻极体中的镁元素的含有比例为5ppm以上100ppm以下,优选为10ppm以上70ppm以下,更优选为15ppm以上且小于40ppm,进一步优选为15ppm以上35ppm以下。在镁元素的含有率过低或过高时,驻极体中的电荷量小,因此通气阻力小,过滤性能也不充分。
相对于聚烯烃树脂100质量份中而言的镁元素的含有比例优选为5ppm以上100ppm以下,更优选为10ppm以上70ppm以下,进一步优选15ppm以上且小于40ppm,特别优选为15ppm以上35ppm以下。另外,当在驻极体中混合2种以上的纤维或者在一个纤维中混合2种以上的树脂时,是指聚烯烃树脂中混合的镁元素的比例。镁元素的含有率在上述范围内时,可以形成通气阻力大、具有高过滤性能的驻极体。
向聚烯烃树脂添加镁元素的方法只要可以获得所期望的特性则没有特别限制,但优选通过熔融混合、溶解混合、离子碰撞、蒸发粘附、超临界、竭染处理等而使驻极体的表面的至少一部分存在镁元素。聚烯烃树脂对有机溶剂、酸碱水溶液稳定,因此进行混合等时,优选进行粉碎混合、分散混合,或者对镁化合物赋予熔融混合性优异的特性。另外,在聚烯烃树脂的聚合时预先添加镁化合物也是优选的方法。
作为向均质性、加工性优异的聚烯烃树脂添加镁元素的方法,例如,可使用镁盐、离聚物、各种螯合物等镁化合物,其中,优选使作为与有机物的复合体的脂肪酸镁盐溶解于熔融的聚烯烃树脂中。
从与聚烯烃的混合性、热稳定性优异的观点考虑,本发明的驻极体优选包含镁盐,更优选选自由脂肪酸镁盐、脂环酸镁盐及芳香族镁盐组成的组中的至少1种,进一步优选包含脂肪酸镁盐。镁盐的熔点优选为80℃以上,更优选为100℃以上,热分解温度优选为200℃以上。热分解温度、熔点低时,加工时、使用时可能发生分解物的释放、发粘。镁盐的热分解温度或熔点的上限没有特别限定,例如为300℃以下。
作为脂肪酸镁盐,没有特别限定,但优选具有碳原子数为10~50的脂肪酸基团的脂肪酸镁盐,更优选具有碳原子数为12~30的脂肪酸基团的脂肪酸镁盐,进一步优选具有碳原子数为16~22的脂肪酸基团的脂肪酸镁盐。另外,作为脂肪酸镁盐,优选具有直链状脂肪酸基团的脂肪酸镁盐,另外,与镁键合的脂肪酸链可以为1条或2条,但优选2条。作为脂肪酸镁盐,具体而言,可举出月桂酸镁、肉豆蔻酸镁、棕榈酸镁、硬脂酸镁、山萮酸镁等直链状饱和脂肪酸的镁盐;油酸镁、芥子酸镁等直链状不饱和脂肪酸的镁盐,从熔点、反应性的观点考虑,优选直链状饱和脂肪酸的镁盐,更优选硬脂酸镁。
另外,本发明中,通过使用预先使镁化合物和含氮化合物一体化的成分,能够使上述特性在一种成分中表现。镁化合物的准备方法或制作方法没有特别限定,可以使用市售的镁化合物;可以在一体化前用镁制作镁化合物;也可以分别添加具有螯合性的化合物和镁,并在驻极体加工前通过熔融等的方法使其反应。
镁元素以外的金属元素会对作为聚烯烃树脂的高分子的稳定性及电荷稳定性、电荷产生进行阻碍,因此优选包含极少量或完全不存在。驻极体中镁元素以外的金属元素的含量优选各金属元素分别为500ppm以下,更优选为250ppm,进一步优选为100ppm以下,最优选为50ppm以下。特别是优选不包含碱金属及有色的过渡金属元素,具体而言,优选驻极体中的碱金属及有色的过渡金属元素的含量合计为100ppm以下,更优选为50ppm以下,进一步优选为25ppm以下,最优选为10ppm以下。
<驻极体的物性>
本发明的驻极体的QF值为1.00mmAq-1以上,优选为1.20mmAq-1以上,更优选为1.45mmAq-1以上。QF值的上限没有特别限定,例如为6.00mmAq-1以下,优选为4.00mmAq-1以下,更优选为2.00mmAq-1以下。若QF值小于1.00mmAq-1,则驻极体无法充分地捕捉粒子,过滤性能不充分。另外,QF值为通过下述式算出的值,关于粒子透过率及通气阻力的测定方法,在下文说明。另外,在本说明书中,“粒子透过率”是指将粒径为0.3~0.5μm的粒子作为捕集对象时的粒子透过率。
QF[mmAq-1]=-[ln(粒子透过率(%)/100)]/[通气阻力(mmAq)]
本发明的驻极体中的粒子透过率优选为15%以下,更优选为5%以下,进一步优选为2%以下,特别优选为0.5%以下。上述粒子透过率的下限没有特别限定,考虑到与通气性的平衡,例如为0.00001%以上。
本发明的驻极体中的通气阻力优选为1.0mmAq以上,更优选为2.0mmAq以上,进一步优选为3.0mmAq以上。通过使通气阻力为1.0mmAq以上,可以降低粒子透过率,即可以增大QF值。通气阻力的上限没有特别限定,为10mmAq以下,优选为8.0mmAq以下。通过使用通气阻力在上述范围内的驻极体,可以实现高初始效率,适合于空气净化器、空调滤材用途。
本发明的驻极体中的纤度(fineness)优选为0.5~15μm,更优选为0.7~10μm,进一步优选为0.9~7μm,最优选为1.0~3.5μm。上述纤度使用扫描型电子显微镜,以在同一视野中纤维没有重叠的方式测量50根纤维的直径,算出几何平均。纤维过细时,容易发生堵塞、断丝;纤维过粗时,由于厚度变大而难以提高效率、难以形成褶皱形状。
<驻极体的形状>
本发明的驻极体的形状没有特别限定,例如可以为纤维状物、注塑成型体、薄膜状、粉末状物、粒子状物等任意形状,但在出于净化气体等的目的而用作滤材时,优选纤维状物。作为本发明的驻极体,可以根据用途而使用成型为适当形状及厚度的驻极体。
上述纤维状物优选纤维集合体,作为纤维集合体,例如可举出由长纤维或短纤维形成的机织针织物、非织造布、棉状物等纤维状物或由拉伸薄膜获得的纤维状物等。所谓纤维集合体,是指用扫描型电子显微镜、光学显微镜等装置对驻极体进行表面观察时确认为纤维状的形态,且构成纤维集合体的纤维彼此的至少一部分为熔融一体化的状态。
在将驻极体用作滤材用途的情况下,纤维集合体优选非织造布。作为获得非织造布的方法,可以使用:通过梳理、气流成网、湿式抄纸法等将单成分纤维、芯鞘纤维、并列纤维这样的复合纤维、分割纤维等短纤维制成片材的方法;通过形成连续纤维的纺粘法、熔喷法、静电纺丝法、强力纺丝法等获得的方法;等现有公知的方法。其中,从有效地利用机械性捕集机理的观点考虑,优选由容易获得致密且细纤度的熔喷法、静电纺丝法或强力纺丝法获得的非织造布,从不需要处理残留溶剂的观点考虑,更优选通过熔喷法、熔融静电纺丝法或熔融强力纺丝法获得的非织造布,特别优选通过熔喷法获得的非织造布。
上述纤维状物中使用的纤维的平均纤维直径优选为0.001~100μm,更优选为0.1~20μm,进一步优选为0.2~10μm,特别优选为0.5~5μm,最优选为1~3μm。纤维的平均纤维直径比100μm粗时,难以获得实用的捕集效率,电荷衰减时的效率降低大。纤维的平均纤维直径比0.001μm细时,难以制作赋予了电荷的驻极体。
上述纤维状物可以是由单独的制法、原材料形成的均一物,也可以是使用制法、原材料及纤维直径不同的2种以上的原材料而成的混合物。
<驻极体化法>
本发明中的驻极体化法只要可以获得使用驻极体时所期望的特性,则没有特别限制,但优选使液体接触或碰撞上述纤维状物的方法(液体接触带电法),通过液体接触带电法可以获得具有高过滤特性的驻极体。更具体而言,优选通过抽吸、加压、喷射等方法使液体接触或碰撞纤维集合体的方法。
液体接触带电法中,进行接触或碰撞的液体只要是可以获得所期望的特性的液体,则没有特别限制,但从操作性和性能面考虑,优选水。水的导电率及pH根据钙离子、镁离子的含量等而变化。也可以使用水中添加了辅助成分(水以外的成分)的液体来代替水,该液体的导电率及pH可以通过添加的辅助成分的种类、添加量等来调整。
液体接触带电法中,进行接触或碰撞的液体优选pH为1~11,更优选pH为3~9,进一步优选pH为5~7。另外,液体接触带电法中,进行接触或碰撞的液体优选导电率为100μS/cm以下,更优选为10μS/cm以下,进一步优选为3μS/cm以下。
<其他>
本发明的驻极体可以根据需要而与其他构成部件组合使用。即,本发明的驻极体可以与预过滤层、纤维保护层、增强部件、功能性纤维层等组合使用。
作为预过滤层及纤维保护层,例如为纺粘非织造布、热粘合非织造布、发泡聚氨酯等,作为增强部件,例如可示例热粘合非织造布、各种网。另外,作为功能性纤维层,例如可示例抗菌、抗病毒以及以识别、外观设计为目的的着色纤维层等。
本发明的驻极体和使用其的滤材通过由本发明获得的集尘、保护、通气、防污、防水等功能而可被广泛使用,尤其是可适合用作防尘罩、各种空调用元件、空气净化器、舱室过滤器、以保护各种装置为目的的滤材。
本申请主张基于在2019年8月21日提交的日本专利申请第2019-151213号的优先权权益。将2019年8月21日提交的日本专利申请第2019-151213号的说明书的全部内容援用于本申请用于参考。
实施例
以下,对本发明的实施方式进行说明。试验方法如下所示。
(1)试样中的镁的浓度
将0.5g试样称取至铂制坩埚,在加热板上直至400℃进行预碳化。然后,使用Yamato科学公司制电炉FO610型,于550℃实施8小时灰化处理。灰化后,添加3mL的6.0N的盐酸,在加热板上于100℃进行酸分解,并进行加热处理直至盐酸完全挥发。酸分解结束后,添加20mL的1.2N的盐酸,将其作为检测液,使用日立Hightech Science公司制ICP发光分析装置SPECTROBLUE型,通过以目标元素的标准溶液制成的校准曲线,实施检测液中的镁量的定量,通过下述式求出试样中的镁浓度。
试样中的镁浓度:A(ppm(=mg/kg))
上述检测液中的镁浓度:B(mg/L)
除了不使用试样(不将试样称取至铂制坩埚)以外,通过与上述同样的方法测定的镁浓度:C(mg/L)
A=(B-C)×(20÷1000)(L)/(0.5÷1000)(kg)
(2)通气阻力
将冲孔的样品安装于有效通气直径为/>的适配器,在上下连结连接有微差压计的内径为50mm的配管,以10cm/s进行通风,测量无扭曲状态下的通气阻力(压力损失)。
(3)粒子透过率
将冲孔的样品安装于有效通气直径为/>的适配器,使用光散射式粒子计数装置Rion公司制KC-01E,通过以下方法,实施滤材的粒子透过率。
评价粒子:大气尘
风速:10cm/s
效率计算:通过光散射计数法测定粒径为0.3~0.5μm的粒子个数。
粒子透过率(%)=(透过驻极体的粒径为0.3~0.5μm的粒子个数÷透过驻极体前的粒径为0.3~0.5μm的粒子个数)
(4)滤材品质系数(QF)
使用上述(2)测定的通气阻力及上述(3)测定的粒子透过率的值,由下式求出QF值。
QF[mmAq-1]=-[ln(粒子透过率(%)/100)]/[通气阻力(mmAq)]
<实施例1>
在熔体流动速率(MFR)为1200g/10分钟、镁浓度为0.1ppm以下的聚丙烯均聚物100质量份中,添加0.00025质量份的硬脂酸镁(熔点:88℃)、1质量份的作为受阻胺系化合物的BASF公司制Chimassrob(注册商标)944,将所得物使用熔喷装置,在树脂温度260℃、空气温度260℃的条件下进行纺丝,得到单位面积重量为20g/m2的纤维片材。对得到的纤维片材,通过与电导率为0.7μS/cm、pH为6.8的水碰撞而带电后,于100℃放置30分钟进行干燥,得到驻极体滤材。通气阻力为3.60mmAq,QF值为1.13mmAq-1、镁浓度为7.8ppm。
<实施例2~实施例8、比较例1~4>
除了使添加的硬脂酸镁的量为表1记载的量以外,与实施例1同样地制作驻极体滤材。
<比较例5>
除了不添加受阻胺系化合物以外,与实施例5同样地制作驻极体滤材。
<比较例6>
除了通过电晕放电法使得到的纤维片材带电以外,与实施例5同样地制作驻极体滤材。
实施例、比较例的结果整理在以下表1中。
由实施例1~8可知,镁元素及含氮化合物的含有比例在特定范围内且与水碰撞而带电的驻极体滤材的QF值大,表现出高过滤特性。另外,对于实施例1~8的驻极体,使用扫描型电子显微镜,以在同一视野中纤维没有重叠的方式测量50根纤维的直径,以几何平均算出纤度,结果为驻极体的纤度均在2~2.5μm的范围内。
另一方面,关于比较例1~4,由于镁元素的含有比例在特定范围外,因此QF值小,过滤特性不充分。另外,关于不添加受阻胺系化合物的比较例5、通过电晕放电法而带电的比较例6,QF值均较小,过滤特性不充分。
工业上的可利用性
本发明的驻极体由于过滤性能优异而可以在防尘罩、空气净化器等各种用途中用作滤材。
Claims (5)
1.一种驻极体,其为包含聚烯烃树脂及含氮化合物的驻极体,其特征在于,
相对于所述聚烯烃树脂100质量份,所述含氮化合物的含量为0.1~5质量份,
所述含氮化合物包含受阻胺系化合物,
所述驻极体中的镁元素的含有比例为5~100ppm,
所述镁元素,来源于具有碳原子数为16~22的脂肪酸基团的脂肪酸镁盐,
将粒径为0.3~0.5μm的粒子作为捕集对象时,下述式表示的QF值为1.00mmAq-1以上,
QF[mmAq-1]=-[ln(粒子透过率(%)/100)]/[通气阻力(mmAq)]。
2.根据权利要求1所述的驻极体,其中,所述含氮化合物为受阻胺系化合物。
3.根据权利要求1或2所述的驻极体,其为纤维集合体。
4.根据权利要求1或2所述的驻极体,其由熔喷法制作。
5.一种滤材,其使用权利要求1~4中任一项所述的驻极体。
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