CN115916372A - 空气过滤器用过滤介质及其制造方法 - Google Patents

空气过滤器用过滤介质及其制造方法 Download PDF

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CN115916372A
CN115916372A CN202080101180.6A CN202080101180A CN115916372A CN 115916372 A CN115916372 A CN 115916372A CN 202080101180 A CN202080101180 A CN 202080101180A CN 115916372 A CN115916372 A CN 115916372A
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filter medium
fluororesin
cationic
filter
surfactant
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田代希
佐藤正
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Hokuetsu Kishu Paper Co Ltd
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Abstract

本发明的课题在于提供一种具有实用上充分的刚性及强度,同时具有高PF值及拨水性的空气过滤器用过滤介质,以及利用容易的制法来提供该过滤介质。本发明的空气过滤器用过滤介质是包含含有玻璃纤维的湿式无纺布者,其特征在于,该过滤介质包含阳离子性粘合剂树脂、氟树脂及阳离子性表面活性剂,所述氟树脂与所述表面活性剂的固形物成分质量比率处于30/70~80/20的范围内。

Description

空气过滤器用过滤介质及其制造方法
技术领域
本发明涉及一种设置于半导体、液晶、食品工业用无尘室、大厦空调或空气净化器等中的空气过滤器中使用的空气过滤器用过滤介质。
背景技术
为了捕获并去除空气中的次微米或微米单位的粒子,通常使用具备空气过滤器用过滤介质的空气过滤器。空气过滤器根据可捕获的粒径、捕获效率而分为粗尘用过滤器、中效过滤器、HEPA(High efficiency particulate air,高效微粒空气)过滤器、ULPA(UltraLow Penetration Air,超低穿透空气)过滤器,越往后性能越高。
压力损耗及捕获效率是表示空气过滤器用过滤介质的过滤性能的特性。压力损耗越高,通风所需的能量消耗量越多,并且过滤器的运转成本越高,因此,理想的是压力损耗较低且粒子捕获效率较高的过滤介质。作为基于这个观点所示的过滤性能的指标,包括由数1的式子定义的PF值。此外,透过率[%]=100-捕获效率[%],理想的是具有高PF值的过滤介质。
[数1]
Figure BDA0003954895290000011
作为空气过滤器用过滤介质所需的其它物性,可例举拨水性。如果拨水性较低,那么存在将过滤介质加工成空气过滤器单元时所使用的密封剂渗入的问题。另外,由于具有充分的拨水性,因此能够防止气温变化所导致的冷凝或湿度较高的空气通过时产生的水滴堵塞过滤介质的孔这种问题的发生。
进而,作为空气过滤器用过滤介质所需的物性,可例举刚性及强度。如果刚性较低,那么存在褶裥的峰因通风时的挠曲而彼此接触,而导致压力损耗上升的危险。另外,如果强度较低,那么将过滤介质褶裥加工成空气过滤器单元时或通风使用时,存在过滤介质发生破裂或开裂的危险。因此,需要对过滤介质赋予实用上充分的刚性及强度。然而,过滤介质中使用的玻璃纤维不具有自接着性,刚性及强度不充分,因此,通常使用粘合剂树脂、粘合剂纤维等粘合剂。其中,理想的是使用能够一并赋予刚性及强度的粘合剂树脂,但如果使粘合剂树脂附着于过滤介质,那么粘合剂的皮膜有可能会堵塞过滤介质的细孔而使得压力损耗上升,或者被覆具有大表面积的玻璃纤维的网状结构而阻碍粒子捕获,从而导致PF值降低。
作为提升空气过滤器用过滤介质的PF值的方法,提出了如下方法:对空气过滤器用过滤介质赋予作为季铵盐的阳离子性表面活性剂的方法(例如,参照专利文献1);除了粘合剂树脂及包含硫酸酯盐或磺酸盐中任一者或两者的表面活性剂以外还赋予氟系拨水剂的方法(例如,参照专利文献2);赋予粘合剂树脂、含有全氟烷基化合物的氟系表面活性剂及拨水剂的方法(例如,参照专利文献3)。
作为进一步提升PF值的方法,提出了一种赋予全熔型粘合剂纤维及芯鞘型粘合剂纤维的方法(例如,参照专利文献4)。
[背景技术文献]
[专利文献]
专利文献1:日本专利特开2010-94580号公报
专利文献2:日本专利特开2014-221456号公报
专利文献3:日本专利特开2017-42762号公报
专利文献4:日本专利特开2018-38983号公报
发明内容
[发明要解决的问题]
如上所述,作为提高空气过滤器用过滤介质的PF值的方法,提出了专利文献1~3的技术,但需要进一步提升PF值及拨水性。
另外,专利文献4中揭示的方法虽然能够获得充分的强度,但存在刚性不充分的问题。
如上所述,空气过滤器用过滤介质要求具有实用上充分的刚性、强度及拨水性,同时具有高PF值,但在以往的技术中,无法获得这些特性,尤其是充分的刚性、PF值及拨水性。因此,本发明的课题在于提供一种具有实用上充分的刚性及强度,同时具有高PF值及拨水性的空气过滤器用过滤介质,以及利用容易的制法来提供该过滤介质。
[解决问题的技术手段]
本发明的空气过滤器用过滤介质是包含含有玻璃纤维的湿式无纺布者,其特征在于,该过滤介质包含阳离子性粘合剂树脂、氟树脂及阳离子性表面活性剂,所述氟树脂与所述表面活性剂的固形物成分质量比率处于30/70~80/20的范围内。利用阳离子性粘合剂树脂使玻璃纤维粘结时,通过使玻璃纤维以所述比率一并吸附氟树脂及阳离子性表面活性剂,能够获得具有实用上充分的刚性及强度,同时具有高PF值及拨水性的空气过滤器用过滤介质。
在本发明的空气过滤器用过滤介质中,所述氟树脂优选为非离子性或阳离子性氟树脂。由于玻璃纤维具有负表面电荷,因此氟树脂更容易吸附于玻璃表面,拨水效果提升。
在本发明的空气过滤器用过滤介质中,所述过滤介质中所包含的所述粘合剂树脂、所述氟树脂及所述表面活性剂的合计固形物成分质量含有率相对于过滤介质整体优选为2~12%。过滤介质能够兼具充分的刚性及强度与高PF值。
在本发明的空气过滤器用过滤介质中,所述湿式无纺布优选包含纤维直径为1~10μm的玻璃棉纤维、纤维直径小于1μm的玻璃棉纤维及纤维直径为4~30μm的短切玻璃纤维作为所述玻璃纤维。容易获得高PF值及高强度。
在本发明的空气过滤器用过滤介质中,所述过滤介质还包含粘合剂纤维,所述过滤介质中所包含的所述粘合剂纤维、所述粘合剂树脂、所述氟树脂及所述表面活性剂的固形物成分质量含有率相对于过滤介质整体可为0%以上30%以下。能够在不大幅降低PF值的情况下进一步提高过滤介质的刚性及强度。
本发明的空气过滤器用过滤介质的制造方法的特征在于包括如下步骤:利用湿式抄纸法使含有玻璃纤维的浆料片材化,而形成湿润状态的片材的步骤;使所述湿润状态的片材含浸水性分散液的步骤,该水性分散液包含阳离子性粘合剂树脂、氟树脂及阳离子性表面活性剂,且所述氟树脂与所述表面活性剂的固形物成分质量比率处于30/70~80/20的范围内;以及使含浸有所述水性分散液的湿润状态的片材干燥,而获得干燥片材的步骤。由此,能够获得具有实用上充分的刚性及强度,同时具有高PF值及拨水性的空气过滤器用过滤介质。
[发明的效果]
通过本发明,能够提供一种具有实用上充分的刚性及强度,同时具有高PF值及拨水性的空气过滤器用过滤介质。
附图说明
图1是表示氟树脂/表面活性剂的固形物成分质量比率与0.10~0.15μm时的PF值的关系的曲线图。
图2是表示氟树脂/表面活性剂的固形物成分质量比率与拨水性的关系的曲线图。
具体实施方式
接下来,示出实施方式对本发明详细地进行说明,但本发明并非限定于这些记载来解释。实施方式可进行各种变化,只要取得本发明的效果即可。
本实施方式的空气过滤器用过滤介质是包含含有玻璃纤维的湿式无纺布的空气过滤器用过滤介质,过滤介质包含阳离子性粘合剂树脂、氟树脂及阳离子性表面活性剂,氟树脂与表面活性剂的固形物成分质量比率处于30/70~80/20的范围内。另外,在过滤介质的制造步骤中,使含有玻璃纤维的浆料经湿式抄纸法片材化而成的湿润状态的片材含浸水性分散液,该水性分散液包含阳离子性粘合剂树脂、氟树脂及阳离子性表面活性剂,且氟树脂与表面活性剂的固形物成分质量比率处于30/70~80/20的范围内。通过含浸,氟树脂与表面活性剂一并吸附于玻璃纤维。继而,使已含浸的片材干燥。经过这种步骤的过滤介质中,玻璃纤维均匀地分散而防止了玻璃纤维彼此的凝聚,过滤介质的表面积增大。此外,利用表面活性剂使含浸液的表面张力降低,从而能够抑制过滤介质的表面或细孔被粘合剂树脂堵塞的问题,因此,能够获得与仅含浸粘合剂树脂的情况相比具有更高PF值的过滤介质。
本实施方式中的氟树脂与阳离子性表面活性剂在过滤介质中的固形物成分质量比率(氟树脂/表面活性剂)为30/70~80/20的比率,更优选为40/60~80/20的比率。通过设为该质量比率,能够获得兼具高PF值(例如,11以上)及高拨水性(例如,508mm水柱高以上)的空气过滤器用过滤介质。如果氟树脂的质量比率低于30且表面活性剂的质量比率高于70,那么氟树脂不会充分吸附于玻璃纤维,因此,PF值及拨水性降低,如果氟树脂的质量比率高于80且表面活性剂的质量比率低于20,那么表面活性剂不会充分吸附于玻璃纤维,因此,PF值降低。
本实施方式中使用的氟树脂是分子内含有氟烷基的树脂,通过由氟原子产生的反斥力而具有拨水性、拨油性、非粘着性等特性。优选使用作为拨水剂、拨油剂或防污剂市售的含有含全氟烷基树脂的水性乳液型或水性分散体型的氟树脂。氟树脂优选为非离子性或阳离子性,更优选为容易吸附于玻璃纤维的阳离子性氟树脂。由于玻璃纤维具有负表面电荷,因此,氟树脂更容易吸附于玻璃表面,拨水效果提升。此处所述的阳离子性是指氟树脂本身或乳化剂等为阳离子性,且分散于水中的氟树脂的胶体粒子具有正表面电荷。通过使用阳离子性氟树脂,容易吸附于在水中具有负表面电荷的玻璃纤维。
本实施方式中使用的表面活性剂从阳离子性表面活性剂中进行选择。作为阳离子性表面活性剂,例如可例举:伯胺~叔胺盐、季铵盐等。在本实施方式中,只要过滤介质包含阳离子性表面活性剂,那么在不影响本发明的效果的范围内,也可以还包含非离子性表面活性剂。
在本实施方式中,为了赋予空气过滤器用过滤介质所需的刚性及强度,使用粘合剂树脂,从阳离子性粘合剂树脂中进行选择。此处所述的阳离子性是指粘合剂树脂本身或乳化剂等为阳离子性,意指分散于水中的粘合剂树脂的胶体粒子具有正表面电荷。通过使用阳离子性粘合剂树脂,能够有效率地被覆玻璃纤维的表面,因此,能够兼顾刚性及强度的提升与拨水性的显现。另一方面,如果使用阴离子性粘合剂树脂,那么无法获得有效率地被覆玻璃纤维的表面所带来的效果,而且在与本实施方式中使用的阳离子性氟树脂及/或阳离子性表面活性剂混合时容易发生凝聚,难以使用。作为粘合剂树脂,例如为聚丙烯酸酯树脂、聚苯乙烯丁二烯树脂、聚乙酸乙烯酯树脂、聚氨基甲酸酯树脂,可使用包含它们的水性分散液。此外,如上所述,本实施方式中所使用的氟树脂因为氟原子会产生反斥力而使得赋予强度的效果较小,因此,不包括在此处所述的粘合剂树脂中。
过滤介质中的粘合剂树脂、氟树脂及表面活性剂的合计固形物成分质量含有率相对于过滤介质整体优选为2~12%,更优选为4~9%。如果这些成分的含有率低于2%,那么无法表现出充分的强度,如果含有率高于12%,那么PF值会降低。
本实施方式中的空气过滤器用过滤介质包含含有玻璃纤维的湿式无纺布。由于玻璃纤维具有较高的刚性,因此,在过滤介质内,能够充分维持空气通过所需的空隙,能够获得高PF值。作为玻璃纤维,可使用玻璃棉纤维及短切玻璃纤维。此处所述的玻璃棉纤维是通过火焰延伸法或旋转法进行延伸而制造的纤维直径具有一定程度分布宽度的不定形且不连续的棉状玻璃纤维。纤维直径的范围通常为约0.1~约10μm,由于具有一定程度分布宽度,因此,纤维直径的值通常用平均纤维直径来表示,本实施方式中使用的玻璃棉纤维的纤维直径也是平均纤维直径。另一方面,短切玻璃纤维是将从具有特定直径的喷丝头纺丝而成的连续玻璃纤维切成特定纤维长度的定形且直线状的玻璃纤维,纤维直径的范围通常为约4~约30μm,纤维长度的范围通常为约1.5~约25mm。在本实施方式的过滤介质中,纤维直径较细且为不定形的玻璃棉纤维具有提高捕获效率并且保持过滤介质中的空隙的效果。纤维直径较粗且为直线状的短切玻璃纤维具有赋予过滤器单元加工时及使用时所需的强度及刚性的效果,但在过滤介质的制造过程中纤维容易沿水平方向堆积,因此,如果短切玻璃纤维的调配比率较高,那么过滤介质的密度趋于提高。在本实施方式中,在使用短切玻璃纤维作为玻璃纤维的情况下,短切玻璃纤维的调配率相对于过滤介质中的纤维的总纤维质量,优选为1~50质量%,更优选为3~30%质量%,进而优选为5~10质量%。
在本实施方式中,玻璃棉纤维的平均纤维直径并无特别限定,优选为0.1~10μm,更优选为0.2~7μm。另外,为了获得高PF值,优选为至少一部分的玻璃纤维的纤维直径小于1μm。
在本实施方式中,为了辅助粘合剂树脂的强度赋予效果,可使用粘合剂纤维。粘合剂纤维是被添加至含有玻璃纤维的浆料中,通过熔融接着、氢键合、物理交联等而赋予强度的纤维,其可在不损害本实施方式的效果的范围内自由选择。例如可为聚乙烯醇纤维、聚酯纤维、聚烯烃纤维等。在本实施方式中,这些纤维之中,优选使用熔融接着粘合剂纤维。作为熔融接着粘合剂纤维的形态,包括会熔融的部分与不会熔融的部分相邻地复合化而成的并列型粘合剂纤维、或具有不会熔融的芯部与会熔融的鞘部的芯鞘型粘合剂纤维、或整体熔融而有助于玻璃纤维等主体纤维彼此接着的全熔型粘合剂纤维等。粘合剂纤维的调配率相对于过滤介质中的纤维的总纤维质量,优选为0~30质量%,更优选为0~20质量%,进而优选为0~10质量%。熔融接着粘合剂纤维除了使空气过滤器用过滤介质包含并列型粘合剂纤维、芯鞘型粘合剂纤维及全熔型粘合剂纤维中任一种的形态以外,亦可使其包含2种或3种。作为包含2种的例子,包括并列型粘合剂纤维与芯鞘型粘合剂纤维的组合、并列型粘合剂纤维与全熔型粘合剂纤维的组合、或芯鞘型粘合剂纤维与全熔型粘合剂纤维的组合。
在本实施方式中,过滤介质还包含粘合剂纤维,过滤介质中所包含的粘合剂纤维、粘合剂树脂、氟树脂及表面活性剂的固形物成分质量含有率相对于过滤介质整体可为0%以上30%以下。在本实施方式中,由于过滤介质包含粘合剂树脂,因此,粘合剂纤维并非必需,但可作为助剂而包含在过滤介质中。但是,如果过滤介质中所包含的粘合剂纤维、粘合剂树脂、氟树脂及表面活性剂的固形物成分质量含有率超过30%,那么有可能会降低PF值,从而降低过滤介质的阻燃性。
在本实施方式的空气过滤器用过滤介质的制造步骤中,使原料纤维分散在水中而获得原料浆料,通过湿式抄纸法使其片材化,而获得湿润状态的片材。用于分散及抄纸的水优选为酸性,更优选为pH值2~4。通过在酸性下进行分散及抄纸,玻璃纤维容易分散,此外,能够提高湿纸强度,容易操作。
在本实施方式的过滤介质的制造步骤中,使利用所述方法所获得的湿润状态的片材含浸包含阳离子性粘合剂树脂、氟树脂、阳离子性表面活性剂的水性分散液,使片材干燥,从而获得空气过滤器用过滤介质。通过使干燥前的片材含浸粘合剂树脂、氟树脂及表面活性剂,能够提高本发明的效果。关于片材的干燥,优选使用抄纸机中的多筒式干燥机、扬克烘缸、热风干燥机,使用手抄装置中的旋转干燥机、循环干燥机等,在例如100~170℃,更优选为120~160℃的温度下使其干燥。
在本实施方式中,针对粘合剂树脂、氟树脂及表面活性剂水性分散液,可在不影响本发明的效果的范围内适当添加消泡剂等添加剂。
[实施例]
以下,示出具体实施例对本发明进行说明,但本发明并不限定于这些记载。此外,例子中的“份”表示原料浆料中的纤维的固形物成分质量比率、或含浸液中的成分的固形物成分质量比率,在原料浆料中,将全部纤维的合计量设为100份,在含浸液中,将粘合剂树脂设为100份。关于不含粘合剂树脂的含浸液,将合计量设为100份。另外,例子中的“%”表示含浸液中的成分的固形物成分质量浓度、或过滤介质中的成分的固形物成分质量含有率。
<实施例1>
利用台式解离机,使用pH值3.0的酸性水对平均纤维直径0.65μm的玻璃棉(B-06-F,Unifrax Co.制造)60份、平均纤维直径2.44μm的玻璃棉(B-26-R,Unifrax Co.制造)30份、平均纤维直径6μm且切断长度6mm的短切玻璃纤维(EC-6-6-SP,Unifrax Co.制造)10份进行解离,从而获得原料浆料。继而,将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)1.5份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)3.5份及水混合并将固形物成分浓度调节为1.8%,由此获得含浸液,对湿纸赋予该含浸液并使其含浸该含浸液,使用130℃的旋转干燥机使其干燥,从而获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.2%。
<实施例2>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)2份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)3份及水混合并将固形物成分浓度调节为1.8%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.2%。
<实施例3>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)3份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)2份及水混合并将固形物成分浓度调节为1.5%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.2%。
<实施例4>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)4份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)1份及水混合并将固形物成分浓度调节为1.2%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.2%。
<实施例5>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、非离子性氟树脂(AsahiGuard AG-E550D,AGC(股)制造)2份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)3份及水混合并将固形物成分浓度调节为1.8%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为4.0%。
<实施例6>
利用台式解离机,使用pH值3.0的酸性水对平均纤维直径0.65μm的玻璃棉(B-06-F,Unifrax Co.制造)60份、平均纤维直径2.44μm的玻璃棉(B-26-R,Unifrax Co.制造)12份、平均纤维直径6μm且切断长度6mm的短切玻璃纤维(EC-6-6-SP,Unifrax Co.制造)10份、切断长度5mm的芯/鞘为聚酯/聚酯的芯鞘粘合剂纤维(Melty 4080,Unitika(股)制造)18份进行解离,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.1%。
<实施例7>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)2份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)3份及水混合并将固形物成分浓度调节为4.8%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为11.8%。
<比较例1>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)及水混合并将固形物成分浓度调节为0.40%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.5%。
<比较例2>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)5份及水混合并将固形物成分浓度调节为2.0%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.2%。
<比较例3>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)1份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)4份及水混合并将固形物成分浓度调节为2.0%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.2%。
<比较例4>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)4.5份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)0.5份及水混合并将固形物成分浓度调节为1.1%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.2%。
<比较例5>
使用如下含浸液,该含浸液是通过将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuardAG-E060,AGC(股)制造)5份及水混合并将固形物成分浓度调节为1.1%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为5.5%。
<比较例6>
使用如下含浸液,该含浸液是通过将阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)60份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)40份及水混合并将固形物成分浓度调节为0.10%而获得,除此以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。此外,过滤介质中的含浸成分的含有率为0.23%。
<比较例7>
除了含浸步骤以外,以与实施例1相同的方式获得基重70g/m2的空气过滤器用过滤介质。
<比较例8>
将阳离子性粘合剂树脂(Boncoat SFC-54,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)3份、阴离子性表面活性剂(Hytenol 330T,第一工业制药(股)制造)2份及水以固形物成分浓度成为1.5%的方式进行混合,结果产生了凝聚物。因此,无法制作使用该含浸液的空气过滤器用过滤介质。
<比较例9>
将阴离子性粘合剂树脂(Boncoat AN-1190S,DIC(股)制造)100份、阳离子性氟树脂(AsahiGuard AG-E060,AGC(股)制造)3份、阳离子性表面活性剂(CATIOGEN TMP,第一工业制药(股)制造)2份及水以固形物成分浓度成为1.5%的方式进行混合,结果产生了凝聚物。因此,无法制作使用该含浸液的空气过滤器用过滤介质。
关于实施例及比较例中所获得的空气过滤器用过滤介质的评价,使用下文所示的方法来进行。
<压力损耗>
关于压力损耗,使用测压计(Manostar Gauge WO81,山本电机制作所(股)制造)测定以面风速5.3cm/秒对有效面积100cm2的空气过滤器用过滤介质进行通风时的差压作为压力损耗。
<透过率>
关于透过率,使用激光粒子计数器(KC-18,RION(股)制造)测定由拉斯金喷嘴产生的包含多分散聚α烯烃(PAO)粒子的空气以面风速5.3cm/秒通过有效面积100cm2的空气过滤器用过滤介质时的上游及下游的PAO粒子的个数,根据上游与下游的粒子数的比来求出。对象粒径设为0.10~0.15μm。
<PF值>
关于PF值,根据压力损耗及粒子透过率的值,使用数1所示的式子进行计算。对象粒径设为0.10~0.15μm。
<格利刚性>
关于格利刚性,使用格利刚性测试机(熊谷理机工业(股)制造),在试验宽度1inch、试验长度2inch的条件下进行测定。
<拉伸强度>
关于拉伸强度,使用自动立体测图仪AGX-S(岛津制作所(股)制造),在试验宽度1inch、试验长度100mm、拉伸速度15mm/min的条件下进行测定。
<拨水性>
拨水性是依据MIL-STD-282进行测定的。
将利用所述方法进行的空气过滤器用过滤介质的评价结果示于表1及表2中。另外,使用实施例1~4及比较例2~5的结果,将表示氟树脂/表面活性剂的固形物成分质量比率与0.10~0.15μm时的PF值、拨水性的关系的曲线图各自示于图1及图2中。
Figure BDA0003954895290000121
Figure BDA0003954895290000131
根据实施例1~4,在包含阳离子性粘合剂树脂且以30/70~80/20的范围的比率包含阳离子性氟树脂及阳离子性表面活性剂的情况下,能够获得具有实用上充分的强度及刚性与高PF值(11以上)及拨水性(508mm水柱高以上)的过滤介质。根据实施例5,在包含非离子性氟树脂的情况下,虽然拨水性比实施例2低一些,但是能够获得具有相同特征的过滤介质。即,可知更优选为使用阳离子性氟树脂的实施例2。根据实施例6,在使用粘合剂纤维的情况下,虽然PF值比实施例2低一些,但是能够获得具有高强度及刚性的过滤介质。根据实施例7,在将含浸成分的附着量提高到约12%的情况下,虽然PF值比实施例2低一些,但是能够获得具有高强度、刚性及拨水性的过滤介质。
根据比较例1,在不含氟树脂及表面活性剂的情况下,PF值较低。根据比较例2,在不含氟树脂的情况下,PF值及拨水性较低。根据比较例3,在氟树脂的调配比率较低的情况下,PF值及拨水性较低。根据比较例4,在表面活性剂的调配比率较低的情况下,PF值较低。根据比较例5,在不含表面活性剂的情况下,PF值较低。根据比较例6,在不含粘合剂树脂的情况下,刚性及强度较低。根据比较例7,在完全不含有含浸成分的情况下,刚性及强度较低,完全无法获得拨水性。根据比较例8,在使表面活性剂为阴离子性的情况下,因化学品彼此的相容性而发生了凝聚,因此无法制作过滤介质。根据比较例9,在使粘合剂树脂为阴离子性的情况下,因化学品彼此的相容性而发生了凝聚,因此无法制作过滤介质。

Claims (6)

1.一种空气过滤器用过滤介质,其是包含含有玻璃纤维的湿式无纺布者,其特征在于,
该过滤介质包含阳离子性粘合剂树脂、氟树脂及阳离子性表面活性剂,
所述氟树脂与所述表面活性剂的固形物成分质量比率处于30/70~80/20的范围内。
2.根据权利要求1所述的空气过滤器用过滤介质,其特征在于,所述氟树脂为非离子性或阳离子性氟树脂。
3.根据权利要求1或2所述的空气过滤器用过滤介质,其特征在于,所述过滤介质中所包含的所述粘合剂树脂、所述氟树脂及所述表面活性剂的合计固形物成分质量含有率相对于过滤介质整体为2~12%。
4.根据权利要求1至3中任一项所述的空气过滤器用过滤介质,其特征在于,所述湿式无纺布包含纤维直径为1~10μm的玻璃棉纤维、纤维直径小于1μm的玻璃棉纤维及纤维直径为4~30μm的短切玻璃纤维作为所述玻璃纤维。
5.根据权利要求1至4中任一项所述的空气过滤器用过滤介质,其特征在于,所述过滤介质还包含粘合剂纤维,所述过滤介质中所包含的所述粘合剂纤维、所述粘合剂树脂、所述氟树脂及所述表面活性剂的固形物成分质量含有率相对于过滤介质整体为0%以上30%以下。
6.一种空气过滤器用过滤介质的制造方法,其特征在于包括如下步骤:
利用湿式抄纸法使含有玻璃纤维的浆料片材化,而形成湿润状态的片材的步骤;
使所述湿润状态的片材含浸水性分散液的步骤,该水性分散液包含阳离子性粘合剂树脂、氟树脂及阳离子性表面活性剂,且所述氟树脂与所述表面活性剂的固形物成分质量比率处于30/70~80/20的范围内;以及
使含浸有所述水性分散液的湿润状态的片材干燥,而获得干燥片材的步骤。
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