JP5747028B2 - 高いロフトのスパンボンドウェブ - Google Patents
高いロフトのスパンボンドウェブ Download PDFInfo
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- Chemical & Material Sciences (AREA)
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Description
本明細書では、用語「フィラメント」は、一組のオリフィスから押し出される熱可塑性材料の溶融流を指すために一般に用いられ、用語「繊維」は、それを含む固化したフィラメント及びウェブを指すために一般に用いられる。これらの指定は、単に説明の便宜上用いられる。本明細書に説明する処理で、部分的に固化したフィラメントと、わずかにべとつく及び/又は半溶融した表面を依然として含む繊維との間に明確な境界がない場合がある。
ソリディティ及びロフト
繊維ウェブの嵩密度の測定値をウェブの固体部分を構成する材料の密度で割ることで、ソリディティを求める。まずウェブの重量(例えば、10cm×10cmの断片)を測定することによって、ウェブの嵩密度を求めることができる。ウェブの重量の測定値をウェブの領域で割ることでウェブの坪量が得られ、g/m2で記録される。直径135mmの円盤状のウェブを採取(例えば、打抜きで)して、ウェブ上に直径100mmの230gのおもりを中央に置いてウェブの厚さを測定し、ウェブの厚さを測定することができる。ウェブの坪量をウェブの厚さで割ることで、ウェブの嵩密度が得られ、g/m3で記録される。
ウェブの有効繊維直径(EFD)を、Davies,C.N.,「The Separation of Airborne Dust and Particles,」Institution of Mechanical Engineers,London,Proceedings 1B,1952に記載される方法にしたがって評価する。別段の指定がない限り、試験は14cm/秒の面風速で行われる。
ウェブを500倍以上の倍率の走査型電子顕微鏡で撮影し、Olympus DP2−BSW画像解析プログラムを利用して、ウェブ内の繊維の実際の繊維直径(AFD)を評価する。少なくとも100の個別の直径測定をそれぞれのウェブ試料に対して行い、これらの測定値の平均値はそのウェブのAFDとして報告される。
ウェブ試料の浸透率、圧力低下、及び濾過品質係数(QF)を、DOP(フタル酸ジオクチル)の液滴を含むチャレンジエアゾールを(別段の指定がない限り)85リットル/分の流速で送液して求め、14cm/秒の面風速を供給して、TSI(商標)高速自動フィルター試験機(型番8130)(TSI Inc.より市販)を使用して評価した。DOP試験において、エアゾールは、約0.185μmの直径を有する粒子を含んでもよく、自動濾過試験機は、加熱機をオフにし、粒子中和器をオンにして操作してもよい。較正した光度計をフィルターの入口と出口とに使用し、フィルターを通る粒子濃度及び粒子の浸透率を測定することができる。フィルタを通して圧力低下(ΔP、mm H2O)を測定するために、MKS圧力変換器(MKS Instrumentsより市販)を用いてよい。式:
は、QFを算出するために用いてもよい。初期品質因子QF値は、通常、より高い初期QF値がより良い濾過性能を示し、より低い初期QF値が低い濾過性能を示す全体的な性能の確実な指標を提供する。QFの単位は逆圧力低下である(1/mm H20で報告される)。
フィルターの濾過特性を、ASHRAE Standard 52.2(「Method of Testing General Ventilation Air−Cleaning Devices for Removal Efficiency by Particle Size」)に説明される方法と同様の方法で試験することで求めることができる。試験は、ウェブをフィルター(例えば、ひだ付けしたフィルター及び/又は枠付けされたフィルター)として構成し、フィルターを試験ダクト内に取り付け、乾燥させ電荷を中和させた塩化カリウム粒子にさらして行う。1.5メートル/秒の試験面速度が使用されてもよい。光学式粒子数計測器が、一連の12の粒径範囲又はチャネルにわたる試験フィルターから上流側及び下流側の粒子濃度を測定するために使用されてもよい。式:
は、各チャネルの捕捉効率を求めるために使用することができる。初期効率測定の後に、フィルターの圧力が所定値に達するまで、連続する一連の塵の充填、及び効率測定値を行い、試験中の粒径チャネルのそれぞれの最低効率を求め、最低効率複合曲線を求める。フィルター全体の圧力低下を、初期、及び塵のそれぞれの充填後に測定し、塵の供給量及びフィルターの重量増加の双方を求める。最低効率複合曲線から、0.3〜1.0μmの4つの効率値を平均してE1に最低複合効率(MCE)を求めることができ、1.0〜3.0μmの4つの効率値を平均してE2 MCEを求めることができ、3.0〜10.0μmの4つの効率値を平均してE3 MCEを求めることができる。フィルターのMCE値から、標準の基準表を使用してフィルターの最低効率報告値(MERV)を求めることができる。
図1及び2に示される装置と同様の装置を使用して、単一成分単層ウェブを、Total Petrochemicalsより商品名3860で市販のメルトフローレート指数70を有するポリプロピレンから形成した。押出ヘッドには、36個のオリフィスが18列あり、それぞれは、ダイの中央で0.63インチ(16mm)の間隙により隔てられた9つの列の2つのブロックに分かれており、合計648個のオリフィスとなっている。0.25インチ(6.4mm)の間隔を有する千鳥状の模様でオリフィスを配列した。溶融高分子の流速は1つのオリフィス当たり毎分およそ0.71グラムであった。2つの対向した急冷空気流(図1の18bに示されるものと同様で、18aに示される種類の流れは使用しなかった)を、上流側として高さ16インチ(406mm)の急冷ボックスから0.3m/秒の概算面速度及び5℃の温度で、及び下側流として高さ7.75インチ(197mm)の急冷ボックスから0.1m/秒の概算面速度及び周囲室温で供給した。米国特許第6,607,624号及び同第6,916,752号に示されるものと同様の移動壁細径化器を、エアナイフの間隙0.030インチ(0.76mm)、エアナイフへ圧力14kPaでの空気供給、細径化器の上部の間隙幅6.1mm、細径化器の底部の間隙幅6.1mm、及び細径化チャンバの長さ6インチ(152mm)を用いて、使用した。押出ヘッドから細径化器までの距離は31インチ(79cm)で、細径化器から捕集ベルトまでの距離は27インチ(69cm)であった。捕集ベルトの下におよそ125Paの真空を作り出して、溶融紡糸繊維流を捕集ベルト上に約46cmの幅で堆積させた。捕集ベルトは、20メッシュステンレス鋼から作製され、表1に示される速度(「形成速度」)で動かした。
以下に別段の指定がない限り、実施例1の一般的方法を使用して、Total Petrochemicalsより市販のメルトフローレート指数70を有する3860ポリプロピレンから単一成分単層ウェブを形成し、BASFより市販のUvinul 5050H、0.5重量%と混合させた。上流側の急冷流はおよそ0.4m/秒の面速度であった。34kPaの圧力で空気をエアナイフに送流した。溶融紡糸繊維流を捕集ベルト上に約46cmの幅で堆積させた。捕集ベルトの下の真空は約300Paであると見積もられた。出口スロットで、およそ5.7m/秒の速度で、空気を制御加熱接着装置を通して給送した。制御加熱装置のスロットを通過する空気の温度は、入口点でハウジング内に入る熱風を測定するとき、155℃であった。
以下に別段の指定がない限り、実施例1の一般的方法を使用して、Total Petrochemicalsより市販のメルトフローレート指数70を有する3860ポリプロピレンから単一成分単層ウェブを形成した。上流側の急冷流はおよそ0.6m/秒の面速度であった。溶融紡糸繊維流を捕集ベルト上に約46cmの幅で堆積させた。出口スロットで、およそ4.6m/秒の速度で、空気を制御加熱接着装置を通して給送した。
以下に別段の指定がない限り、実施例1の一般的方法を使用して、Total Petrochemicalsより市販のメルトフローレート指数70を有する3860ポリプロピレンから単一成分単層ウェブを形成した。上流側の急冷流はおよその0.7m/秒の面速度であった。下流側の急冷ボックスは使用しなかった。細径化器はエアナイフの間隙が0.020インチ(0.51mm)であった。83kPaの圧力で空気をエアナイフに送流した。押出ヘッドから細径化器までの距離は23インチ(58cm)で、細径化器から捕集ベルトまでの距離は21インチ(53cm)であった。溶融紡糸繊維流を捕集ベルト上に約51cmの幅で堆積させた。この場合、捕集ベルトはAlbany Internationalより市販の9 SS TCベルトであった。捕集ベルトの下の真空は約800Paであると見積もられた。出口スロットで、およそ11m/秒の速度で、空気を制御加熱接着装置を通して給送した。
米国特許第6,916,752号(Berriganら)の教示にしたがって単一成分ウェブを形成した。以下に別段の指定がない限り、実施例4(上記)の一般的方法を使用して、Total Petrochemicalsより市販のメルトフローレート指数70を有する3860ポリプロピレンからウェブを形成した。溶融高分子の流速は、(実施例4のオリフィス当たり毎分0.71グラムに対して)オリフィス当たり毎分およそ0.54グラムであった。捕集ベルトの下の真空は約2000Paであると見積もられた。
比較例1(C1)並びに試料1B、2B、3A及び4Aの実際の繊維直径、有効繊維直径、EFD/AFD比率、及びソリディティを表5に列記する。
Claims (2)
- 8.0%未満〜4.0%のソリディティを含み、少なくとも1.40の有効繊維直径の実際の繊維直径に対する比率を含むスパンボンドウェブであって、捲縮繊維、間隙が形成された繊維、及び二成分繊維が実質的に存在しない、スパンボンドウェブ。
- 複数の対向して面するひだを含む濾材と、前記濾材の縁部に沿って存在する周辺枠とを更に含む、自己支持型のひだ付けしたフィルターであって、前記濾材は、8.0%未満〜4.0%のソリディティを含み、少なくとも1.40の有効繊維直径の実際の繊維直径に対する比率を含むスパンボンドウェブを含み、前記スパンボンドウェブには捲縮繊維、間隙が形成された繊維、及び二成分繊維が実質的に存在しない、自己支持型のひだ付けしたフィルター。
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CA2767009C (en) | 2017-03-28 |
EP2449159A4 (en) | 2012-12-05 |
TWI580833B (zh) | 2017-05-01 |
WO2011002878A3 (en) | 2011-04-28 |
US8162153B2 (en) | 2012-04-24 |
US20110000845A1 (en) | 2011-01-06 |
CN102482819A (zh) | 2012-05-30 |
US8240484B2 (en) | 2012-08-14 |
TW201114966A (en) | 2011-05-01 |
JP2012532255A (ja) | 2012-12-13 |
KR20120092551A (ko) | 2012-08-21 |
CA2767009A1 (en) | 2011-01-06 |
BR112012000017A2 (pt) | 2016-03-15 |
KR101679899B1 (ko) | 2016-11-25 |
WO2011002878A2 (en) | 2011-01-06 |
EP2449159A2 (en) | 2012-05-09 |
EP2449159B1 (en) | 2013-11-06 |
CN102482819B (zh) | 2015-05-06 |
US20120171913A1 (en) | 2012-07-05 |
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