JP2016203124A - Filter material for bag filter and method for producing the same - Google Patents
Filter material for bag filter and method for producing the same Download PDFInfo
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Abstract
Description
本発明は、バグフィルター用ろ過材及びその製造方法に関する。 The present invention relates to a filter material for a bag filter and a method for producing the same.
集塵機等に取り付けられるバグフィルターにおいて、ろ過材としてフェルトが用いられることがある。ろ過材に対しては、集塵率が高く、かつ圧力損失が低いことが望まれる。 In a bag filter attached to a dust collector or the like, felt may be used as a filter medium. For filter media, it is desired that the dust collection rate is high and the pressure loss is low.
フェルトをろ過材として用いる場合、表面に毛羽立ちがあると、毛羽立ちにダストが付着する。毛羽立ちに付着したダストは、フィルターを洗浄しても、ろ過材から離脱し難い。そのため、洗浄してもろ過材の圧力損失が十分に低くならず、ダストの捕集効率が下がる。 When felt is used as a filter medium, if there is fuzz on the surface, dust adheres to the fuzz. Dust adhering to the fluff is difficult to separate from the filter medium even if the filter is washed. Therefore, even if it is washed, the pressure loss of the filter medium is not sufficiently lowered, and the dust collection efficiency is lowered.
従来から、多くの毛羽立ち対策が提案されてきた。例えば特許文献１では、フェルトの表層を構成する繊維に熱可塑性樹脂からなる繊維を混合し、熱カレンダー処理を行うことによって、表層の表面を平滑化し毛羽立ちを抑えることが提案されている。 Conventionally, many fluffing countermeasures have been proposed. For example, Patent Document 1 proposes that a fiber made of a thermoplastic resin is mixed with a fiber constituting the surface layer of the felt, and the surface of the surface layer is smoothed by suppressing the fuzz by performing a thermal calendar process.
しかしながら、従来の熱カレンダー処理では溶融した低融点繊維が、フェルトの裏層側でも溶着するため、ろ過材の密度勾配が小さくなり、圧力損失が大きくなるという問題があった。 However, in the conventional heat calendering process, the melted low melting point fiber is also welded on the felt back layer side, so that there is a problem that the density gradient of the filter medium is reduced and the pressure loss is increased.
本発明は、毛羽立ちが抑えられ、圧力損失が低減されたバグフィルター用ろ過材を提供することを目的とする。 An object of this invention is to provide the filter material for bag filters by which fuzz was suppressed and the pressure loss was reduced.
本発明のある側面は、バグフィルター用ろ過材（２）であって、基布から形成される基布層（４）と、
前記基布層の一側に配置され、０．１〜１．５ｄｔｅｘの繊度を有する極細繊維、及び、０．９〜４．０ｄｔｅｘの繊度を有して、少なくとも外面の一部において前記極細繊維よりも融点が低い低融点素材を含む低融点繊維から形成された表層（６）と、前記基布層の他側に配置され、前記表層よりも密度が低く、かつ２〜３０ｄｔｅｘの繊度を有する太繊維から形成された裏層（８）とを備え、前記基布、前記極細繊維及び前記低融点繊維、並びに前記太繊維が互いに交絡された後に、前記表層側のロールのみが前記低融点繊維の融点よりも高くかつ前記極細繊維の融点よりも低い温度に加熱された片熱カレンダー加工が行われて形成されたことを特徴とする。
One aspect of the present invention is a filter medium for bag filter (2), a base fabric layer (4) formed from a base fabric,
An ultrafine fiber disposed on one side of the base fabric layer and having a fineness of 0.1 to 1.5 dtex, and a fineness of 0.9 to 4.0 dtex, and at least a part of the outer surface of the ultrafine fiber A surface layer (6) formed from a low-melting-point fiber containing a low-melting-point material having a lower melting point, and disposed on the other side of the base fabric layer, having a density lower than the surface layer and a fineness of 2 to 30 dtex A back layer (8) formed from thick fibers, and after the base fabric, the ultrafine fibers and the low melting point fibers, and the thick fibers are entangled with each other, only the roll on the surface layer side has the low melting point fibers. It is characterized by being formed by a one-sided calendering process that is heated to a temperature higher than the melting point of the microfiber and lower than the melting point of the ultrafine fiber.
この構成によれば、表層側においてのみ低融点素材が溶着してバインダー効果を発揮するため、表層表面の毛羽立ちを抑えることができるとともに、裏層側の密度が高くなることを防止できる。そのため、毛羽立ちによる圧力損失の増大を防ぎ、表層と裏層との間に密度勾配があるため、圧力損失を低減できる。 According to this configuration, since the low melting point material is welded only on the surface layer side and exhibits a binder effect, fuzz on the surface layer surface can be suppressed and the density on the back layer side can be prevented from increasing. Therefore, an increase in pressure loss due to fluffing is prevented, and a pressure gradient can be reduced because there is a density gradient between the surface layer and the back layer.
本発明の他の側面は、上記構成において、前記表層の平均密度が、０．２〜０．８ｇ／ｃｍ３であり、前記裏層の平均密度が、前記表層の平均密度より小さく、かつ０．０５〜０．４ｇ／ｃｍ３であることを特徴とする。また、前記表層と前記裏層との平均密度比が、２：１〜１０：１であることを特徴とする。 According to another aspect of the present invention, in the above configuration, the average density of the surface layer is 0.2 to 0.8 g / cm 3 , the average density of the back layer is smaller than the average density of the surface layer, and 0 0.05 to 0.4 g / cm 3 . The average density ratio of the surface layer and the back layer is 2: 1 to 10: 1.
この構成によれば、表層と裏層との間の密度勾配が適切であるため、圧力損失を低減できる。 According to this configuration, the pressure gradient can be reduced because the density gradient between the surface layer and the back layer is appropriate.
本発明の他の側面は、上記構成において、前記極細繊維と前記低融点繊維との混合割合が、９７：３〜７０：３０であることを特徴とする。 Another aspect of the present invention is characterized in that, in the above configuration, a mixing ratio of the ultrafine fiber and the low melting point fiber is 97: 3 to 70:30.
この構成によれば、低融点素材の量が過大にならないため、溶着した低融点素材が表層表面を覆うことによるろ過面積の減少を抑えることができる。 According to this configuration, since the amount of the low melting point material does not become excessive, it is possible to suppress a decrease in the filtration area due to the welded low melting point material covering the surface of the surface layer.
本発明の他の側面は、上記構成において、前記極細繊維はポリエステル繊維からなり、前記低融点繊維は、ポリプロピレン繊維又は外層がポリプロピレンの芯鞘構造繊維からなることを特徴とする。 Another aspect of the present invention is characterized in that, in the above-described configuration, the ultrafine fibers are made of polyester fibers, and the low melting point fibers are made of polypropylene fibers or core-sheath structure fibers of polypropylene.
この構成によれば、極細繊維の耐熱温度及び融点と低融点素材の融点との関係が適切となり、低融点素材の融点はフィルターの耐熱温度に影響を与えない。 According to this configuration, the relationship between the heat resistance temperature and melting point of the ultrafine fiber and the melting point of the low melting point material is appropriate, and the melting point of the low melting point material does not affect the heat resistance temperature of the filter.
また、本発明のある側面は、基布層（４）、前記基布層の一側に配置された表層（６）、及び前記基布層の他側に配置されて前記表層より低密度な裏層（８）を備えたバグフィルター用ろ過材（２）を製造する方法であって、０．１〜１．５ｄｔｅｘの繊度を有する極細繊維、及び０．９〜４．０ｄｔｅｘの繊度を有して、少なくとも外面の一部において前記極細繊維よりも融点が低い低融点素材を含む低融点繊維から実質的になる第１不織布を基布の一側に重ね、２〜３０ｄｔｅｘの繊度を有する太繊維から実質的になる第２不織布を前記基布の他側に重ねるステップと、重ね合わされた前記第１不織布、前記基布及び前記第２不織布をニードルパンチにより互いに交絡させて積層体を形成するニードルパンチステップと、前記積層体をカレンダー加工して、互いに交絡した前記第１不織布、前記基布及び前記第２不織布をそれぞれ、前記表層、前記基布層及び前記裏層にするカレンダーステップとを含み、前記カレンダー加工は、前記第１不織布側のロールのみが前記低融点素材の融点よりも高く、かつ前記極細繊維の融点よりも低い温度に加熱された片熱カレンダー加工であることを特徴とする。 Moreover, the side surface with this invention is a base layer (4), the surface layer (6) arrange | positioned at the one side of the said base fabric layer, and it is arrange | positioned at the other side of the said base fabric layer, and is a lower density than the said surface layer. A method for producing a filter material (2) for a bag filter provided with a back layer (8), comprising ultrafine fibers having a fineness of 0.1 to 1.5 dtex, and a fineness of 0.9 to 4.0 dtex Then, a first non-woven fabric substantially made of a low-melting-point fiber including a low-melting-point material having a melting point lower than that of the ultrafine fiber is overlapped on one side of at least a part of the outer surface, and a thick having a fineness of 2 to 30 dtex. A step of superimposing a second non-woven fabric consisting essentially of fibers on the other side of the base fabric, and interlacing the superposed first non-woven fabric, the base fabric and the second non-woven fabric with a needle punch to form a laminate. Needle punch step and the laminate And calendering the first non-woven fabric, the base fabric, and the second non-woven fabric that are interlaced with each other to form the surface layer, the base fabric layer, and the back layer, respectively. Only the roll on one nonwoven fabric side is a one-sided calendering process in which the roll is heated to a temperature higher than the melting point of the low melting point material and lower than the melting point of the ultrafine fibers.
この構成によれば、表層側においてのみ低融点素材が溶着してバインダー効果を発揮するため、表層表面の毛羽立ちを抑えることができ、裏層側の密度が高くなることが防止される。すなわち、毛羽立ちによる圧力損失の増大を防ぎ、表層と裏層との間に密度勾配があるために圧力損失が低減されたバグフィルター用ろ過材を製造することができる。 According to this configuration, since the low melting point material is welded only on the surface layer side and exhibits a binder effect, fuzz on the surface layer surface can be suppressed, and the density on the back layer side is prevented from increasing. That is, an increase in pressure loss due to fluffing can be prevented, and a filter medium for a bag filter with reduced pressure loss can be produced because there is a density gradient between the surface layer and the back layer.
本発明によれば、毛羽立ちが抑えられ、圧力損失が低減されたバグフィルター用ろ過材を提供することができる。 According to the present invention, it is possible to provide a filter material for a bag filter with reduced fuzz and reduced pressure loss.
以下、図面を参照しつつ、本発明の実施形態を説明する。図１は、実施形態に係るろ過材２の縦断面図である。フェルトからなるろ過材２は、基布層４と、基布層４の図面上側に配置された表層６と、基布層４の図面下側に配置された裏層８とを備える。表層６は、極細繊維及び低融点繊維を主原料として形成される。表層６は、低融点繊維が溶着することにより、表面は、毛羽立ちが抑えられて平滑になっている。裏層８は、太繊維を主原料として形成される。なお、極細繊維及び低融点繊維と太繊維とは、ろ過材２の製造過程において交絡されるため、表層６には太繊維の一部が、裏層８には極細繊維の一部及び低融点繊維の一部が混ざっている。裏層８は、表層６よりも密度が小さい。以下、製造工程に沿って、詳細に説明する。 Hereinafter, embodiments of the present invention will be described with reference to the drawings. Drawing 1 is a longitudinal section of filter material 2 concerning an embodiment. The filter medium 2 made of felt includes a base fabric layer 4, a surface layer 6 disposed on the upper side of the base fabric layer 4 in the drawing, and a back layer 8 disposed on the lower side of the base fabric layer 4 in the drawing. The surface layer 6 is formed using ultrafine fibers and low melting point fibers as main raw materials. The surface layer 6 has a smooth surface with reduced fuzz due to the welding of low melting point fibers. The back layer 8 is formed using thick fibers as the main raw material. In addition, since the ultrafine fiber and the low melting point fiber and the thick fiber are entangled in the manufacturing process of the filter medium 2, a part of the thick fiber and a part of the ultrafine fiber and the low melting point are formed in the surface layer 6 and the back layer 8. Some of the fibers are mixed. The back layer 8 has a lower density than the surface layer 6. Hereinafter, it demonstrates in detail along a manufacturing process.
まず、基布層４を構成する基布を製織する。基布の材質、糸種及び組織は限定されるものではないが、例えば、基布として、複数の経糸１０と複数の緯糸１２とが互いに織り合わされて形成された平織の織布を使用することができる。経糸１０及び緯糸１２は、例えばポリエステルのマルチフィラメントを使用することができる。経糸１０及び緯糸１２には、ｍ−アラミド、ポリイミド等の他の素材の繊維やモノフィラメントを使用してもよい。また、基布として、平織以外の織布や、不織布を使用してもよい。 First, the base fabric constituting the base fabric layer 4 is woven. The material, thread type and structure of the base fabric are not limited. For example, a plain woven fabric formed by weaving a plurality of warps 10 and a plurality of wefts 12 is used as the base fabric. Can do. As the warp 10 and the weft 12, for example, a polyester multifilament can be used. For the warp 10 and the weft 12, fibers or monofilaments of other materials such as m-aramid and polyimide may be used. Moreover, you may use woven fabrics other than a plain weave, and a nonwoven fabric as a base fabric.
次に、基布の一側（図１の上側）に表層６となるべき第１不織布を、他側（図１の下側）に裏層８となるべき第２不織布を重ね合わせ、積層体を形成する。第１不織布は、短繊維の極細繊維と、短繊維の低融点繊維からなる。第２不織布は、短繊維の太繊維からなる。第１不織布及び第２不織布は、それぞれ複数枚重ね合わせられる。 Next, the first nonwoven fabric to be the surface layer 6 is laminated on one side of the base fabric (upper side in FIG. 1), and the second nonwoven fabric to be the back layer 8 is superimposed on the other side (lower side in FIG. 1), Form. The first non-woven fabric is composed of ultrafine fibers of short fibers and low melting point fibers of short fibers. A 2nd nonwoven fabric consists of a thick fiber of a short fiber. A plurality of first nonwoven fabrics and second nonwoven fabrics are superimposed on each other.
極細繊維は、０．１〜１．５ｄｔｅｘの繊度を有する。低融点繊維は、０．５〜１１．２ｄｔｅｘ、好ましくは０．９〜４．０ｄｔｅｘの繊度を有し、少なくとも外面の一部において極細繊維よりも融点が低い低融点素材を含む。低融点繊維は、繊維全体が低融点素材からなる繊維でもよく、融点の高い繊維の回りを低融点素材で覆った芯鞘構造の繊維でもよい。熱処理時に極細繊維が融解することを防ぐために、低融点素材の融点と極細繊維の融点との温度差は、３０℃以上あることが好ましく、６０℃以上あることがさらに好ましい。フィルターの耐熱温度を下げないように、低融点素材の融点は、極細繊維の耐熱温度より高いことが望ましい。極細繊維と低融点繊維との混合割合は、９７：３〜７０：３０である。 The ultrafine fiber has a fineness of 0.1 to 1.5 dtex. The low melting point fiber includes a low melting point material having a fineness of 0.5 to 11.2 dtex, preferably 0.9 to 4.0 dtex, and having a melting point lower than that of the ultrafine fiber at least at a part of the outer surface. The low melting point fiber may be a fiber made of a low melting point material as a whole, or may be a core-sheath fiber in which a fiber having a high melting point is covered with a low melting point material. In order to prevent the ultrafine fibers from melting during the heat treatment, the temperature difference between the melting point of the low melting point material and the melting point of the ultrafine fibers is preferably 30 ° C. or higher, and more preferably 60 ° C. or higher. In order not to lower the heat resistant temperature of the filter, the melting point of the low melting point material is desirably higher than the heat resistant temperature of the ultrafine fiber. The mixing ratio of the ultrafine fiber and the low melting point fiber is 97: 3 to 70:30.
太繊維は、極細繊維よりも太い、２〜３０ｄｔｅｘの繊度を有する。太繊維の耐熱温度と融点との間に、低融点素材の融点があることが望ましい。第２不織布の密度は、第１不織布の密度よりも低い。 The thick fibers are thicker than the ultrafine fibers and have a fineness of 2 to 30 dtex. It is desirable that the low melting point material has a melting point between the heat resistance temperature and the melting point of the thick fiber. The density of the second nonwoven fabric is lower than the density of the first nonwoven fabric.
例えば、極細繊維及び太繊維にポリエステル繊維を使用し、低融点繊維にポリプロピレン繊維、又はポリエステルとポリプロピレンの芯鞘構造繊維を使用することができる。表層６となる第１不織布の繊維の平均繊度と、裏層８となる第２不織布の平均繊維の繊度との比は、１：２〜１：２０である。なお、極細繊維−低融点繊維のその他の組み合わせとして、ポリエステル−低融点ポリエステル、ポリエステル−６ナイロン、ｍ-アラミド−ＰＰＳ、ポリイミド−ＰＰＳ等が使用できる。 For example, polyester fibers can be used for ultrafine fibers and thick fibers, and polypropylene fibers or polyester / polypropylene core-sheath structure fibers can be used for the low melting point fibers. The ratio of the average fineness of the fibers of the first nonwoven fabric that becomes the surface layer 6 and the average fineness of the fibers of the second nonwoven fabric that becomes the back layer 8 is 1: 2 to 1:20. As other combinations of ultrafine fibers and low melting point fibers, polyester-low melting point polyester, polyester-6 nylon, m-aramid-PPS, polyimide-PPS, etc. can be used.
次に、ニードルパンチを行い、基布、第１不織布及び第２不織布を互いに交絡させ、積層体をフェルト状にする。洗浄時のダスト払い落とし性を重視する場合、表突き上がりニードルが行われる。すなわち、第２不織布側からニードルパンチが行われた後、第１不織布側から仕上げのニードルパンチが行われる。第２不織布側からのニードルパンチでは、針が積層体を貫通しないように行われてもよい。表突き上がりニードルの場合、第１不織布側の表面の毛羽立ちが抑えられるため、熱処理後の表層６が平滑となり、ダスト払い落とし性が高くなる。また、集塵率を重視する場合、裏突き上がりニードルが行われる。すなわち、第１不織布側からニードルパンチが行われた後、第２不織布側から仕上げのニードルパンチが行われる。第２不織布側からのニードルパンチでは、針が積層体を貫通するように行われてもよい。裏突き上がりニードルの場合、第１不織布の表面に毛羽立ち生じ、後述の熱処理によって大きな毛羽立ちは抑えられるが、細かい毛羽立ちが残り易い。この細かい毛羽立ちにダストが吸着して、プレコート層が形成され、フィルターはより細かいダストを吸着し、集塵率が向上する。 Next, needle punching is performed, and the base fabric, the first nonwoven fabric, and the second nonwoven fabric are entangled with each other to make the laminate into a felt shape. When importance is attached to dust removal during cleaning, a needle is pushed up. That is, after needle punching is performed from the second nonwoven fabric side, finishing needle punching is performed from the first nonwoven fabric side. The needle punch from the second nonwoven fabric side may be performed so that the needle does not penetrate the laminate. In the case of a needle that rises up, the surface of the first nonwoven fabric side can be prevented from fuzzing, so that the surface layer 6 after the heat treatment becomes smooth and the dust removal property is improved. Further, when importance is attached to the dust collection rate, a back-up needle is performed. That is, after needle punching is performed from the first nonwoven fabric side, finishing needle punching is performed from the second nonwoven fabric side. The needle punch from the second nonwoven fabric side may be performed so that the needle penetrates the laminate. In the case of a back-up needle, fuzz occurs on the surface of the first nonwoven fabric, and large fuzz is suppressed by heat treatment described later, but fine fuzz tends to remain. The fine fluff adsorbs dust to form a precoat layer, and the filter adsorbs finer dust and improves the dust collection rate.
次に、カレンダー加工による熱処理によって、低融点繊維を溶着させる。この熱処理は、片熱カレンダー加工、すなわち、第１不織布側のロールを低融点素材の融点よりも高く、かつ前記極細繊維の融点よりも低い温度に設定し、第２不織布側のロールを低融点素材の融点よりも低い温度、例えば常温に設定したカレンダー加工によってなされる。 Next, the low melting point fiber is welded by heat treatment by calendering. This heat treatment is one-sided calendering, that is, the roll on the first nonwoven fabric side is set to a temperature higher than the melting point of the low melting point material and lower than the melting point of the ultrafine fiber, and the roll on the second nonwoven fabric side is set to the low melting point. This is done by calendering set to a temperature lower than the melting point of the material, for example, room temperature.
毛焼き加工を行うと低融点素材の溶融玉が発生しやすいが、カレンダー加工は、低融点素材の溶融玉の発生を防止できる。極細繊維と低融点繊維との混合割合が９７：３〜７０：３０であること、低融点繊維の繊度が極細繊維と同等以下であること、及び片熱カレンダー加工であることによって、低融点繊維のバインダー効果を発揮させて毛羽を抑えることができるとともに、図２に示すように、低融点素材が表層６の表面に過剰に溶着してろ過面積が減少することを防ぐことができる。また、低融点素材の溶着によって、表層側の平均密度が高くなる。一方、裏層８側は加熱されていないため、ニードルパンチによる繊維の交絡によって裏層８側に侵入した低融点繊維は融着せず、裏層側の密度が高くなることは防止される。もともとの第１不織布及び第２不織布間の密度差と、片熱カレンダー加工とによって、表層６及び裏層８間の密度勾配が形成され、圧力損失の増加を防ぐ。 When the hair baking process is performed, molten balls of a low melting point material are likely to be generated, but the calendar process can prevent the generation of molten balls of a low melting point material. Low melting point fiber by mixing ratio of ultrafine fiber and low melting point fiber is 97: 3 to 70:30, fineness of low melting point fiber is equal to or less than ultrafine fiber, and single heat calendering As shown in FIG. 2, it is possible to prevent the low melting point material from being excessively welded to the surface of the surface layer 6 and reducing the filtration area. Further, the average density on the surface layer side is increased by the welding of the low melting point material. On the other hand, since the back layer 8 side is not heated, the low-melting-point fibers that have entered the back layer 8 side due to fiber entanglement by needle punching are not fused, and the density on the back layer side is prevented from increasing. The density difference between the surface layer 6 and the back layer 8 is formed by the density difference between the original first nonwoven fabric and the second nonwoven fabric and the one-side calendering process, thereby preventing an increase in pressure loss.
完成したろ過材２において、表層６の平均密度は、０．２〜０．８ｇ／ｃｍ３であり、裏層８の平均密度は、表層６よりも低く、かつ０．０５〜０．４ｇ／ｃｍ３であり、好ましくは０．０５〜０．２５ｇ／ｃｍ３である。表層６と裏層８との平均密度比は、２：１〜１０：１である。表層６が小繊度かつ高密度であるため、集塵率を高くすることができる。また、表層６が繊度の小さい繊維から高密度に形成され、裏層８が繊度の大きな繊維から低密度に形成されているため、圧力損失を抑えることができる。 In the completed filter medium 2, the average density of the surface layer 6 is 0.2 to 0.8 g / cm 3 , the average density of the back layer 8 is lower than the surface layer 6, and 0.05 to 0.4 g / cm 3. cm 3 , preferably 0.05 to 0.25 g / cm 3 . The average density ratio between the surface layer 6 and the back layer 8 is 2: 1 to 10: 1. Since the surface layer 6 has a small fineness and a high density, the dust collection rate can be increased. Moreover, since the surface layer 6 is formed with a high density from fibers having a small fineness and the back layer 8 is formed with a low density from fibers having a high fineness, pressure loss can be suppressed.
サンプルＡは、本発明の実施例である。基布は、経糸及び緯糸にポリエステルマルチフィラメントを使用した平織組織から形成された。表層は、極細繊維９０％（ポリエステル繊維、平均繊度０.７ｄｔｅｘ）と低融点繊維１０％（ポリプロピレン繊維、平均繊度２.２ｄｔｅｘ）とから形成され、その平均密度は０．４８ｇ／ｍ３であった。裏層は、太繊維１００％（ポリエステル繊維、平均繊度７．７ｄｔｅｘ）から形成され、その平均密度は０．０９ｇ／ｍ３であった。表層と裏層との平均密度比は、５．３：１であった。なお、平均密度は、基布目付分を表層及び裏層に均等に割り振って算出した。全体として、目付が４０１ｇ／ｍ２、厚さが２．７ｍｍであった。 Sample A is an example of the present invention. The base fabric was formed from a plain weave structure using polyester multifilaments for warp and weft. The surface layer is formed of 90% extra fine fibers (polyester fiber, average fineness 0.7 dtex) and 10% low melting point fiber (polypropylene fiber, average fineness 2.2 dtex), and the average density is 0.48 g / m 3. It was. The backing layer was formed from 100% thick fibers (polyester fibers, average fineness 7.7 dtex), and the average density was 0.09 g / m 3 . The average density ratio of the surface layer and the back layer was 5.3: 1. The average density was calculated by equally allocating the basis weight of the base fabric to the surface layer and the back layer. As a whole, the basis weight was 401 g / m 2 and the thickness was 2.7 mm.
サンプルＢは、比較対照であり、表層の表面側に細繊維、表層の裏面側に極細繊維、裏層に繊度が細繊維と太繊維の中間の通常繊維を用いたものである。基布は、経糸及び緯糸にポリエステルマルチフィラメントを使用した平織組織から形成された。表層は、表面側に細繊維（ポリエステル繊維、平均繊度２．２ｄｔｅｘ）、裏面側に極細繊維（ポリエステル繊維、平均繊度０．８ｄｔｅｘ）を用いて形成され、その平均密度は０．２７ｇ／ｍ３であった。裏層は、通常繊維１００％（ポリエステル繊維、平均繊度３．３ｄｔｅｘ）から形成され、その平均密度は０．２３ｇ／ｍ３であった。表層と裏層との平均密度比は、１．２：１であった。全体として、目付が５００ｇ／ｍ２、厚さが２．０ｍｍであった。また、表層の表面には鏡面加工がなされた。 Sample B is a comparative control, using fine fibers on the surface side of the surface layer, ultrafine fibers on the back surface side of the surface layer, and normal fibers having fineness between fine fibers and thick fibers on the back layer. The base fabric was formed from a plain weave structure using polyester multifilaments for warp and weft. The surface layer is formed by using fine fibers (polyester fiber, average fineness 2.2 dtex) on the front side and ultrafine fibers (polyester fiber, average fineness 0.8 dtex) on the back side, and the average density is 0.27 g / m 3. Met. The backing layer was usually formed from 100% fiber (polyester fiber, average fineness 3.3 dtex), and the average density was 0.23 g / m 3 . The average density ratio of the surface layer and the back layer was 1.2: 1. As a whole, the basis weight was 500 g / m 2 and the thickness was 2.0 mm. The surface of the surface layer was mirror-finished.
サンプルＣは、別の比較対照であり、表層の表面側に極細繊維、表層の裏面側に通常繊維、裏層に通常繊維を用いたものである。基布は、経糸及び緯糸にポリエステルマルチフィラメントを使用した平織組織から形成された。表層は、表面側に極細繊維（ポリエステル繊維、平均繊度０．９ｄｔｅｘ）、裏面側に通常繊維（ポリエステル繊維、平均繊度４．４ｄｔｅｘ）を用いて形成され、その平均密度は０．３５ｇ／ｍ３であった。裏層は、通常繊維１００％（ポリエステル繊維、平均繊度４．４ｄｔｅｘ）から形成され、その平均密度は０．３３ｇ／ｍ３であった。表層と裏層との平均密度比は、１．１：１であった。全体として、目付が５４６ｇ／ｍ２、厚さが１．４ｍｍであった。また、表層の表面には鏡面加工がなされた。 Sample C is another comparative control, which uses ultrafine fibers on the surface side of the surface layer, normal fibers on the back surface side of the surface layer, and normal fibers on the back layer. The base fabric was formed from a plain weave structure using polyester multifilaments for warp and weft. The surface layer is formed using ultrafine fibers (polyester fiber, average fineness 0.9 dtex) on the front side and normal fibers (polyester fiber, average fineness 4.4 dtex) on the back side, and the average density is 0.35 g / m 3. Met. The backing layer was usually formed from 100% fiber (polyester fiber, average fineness 4.4 dtex), and the average density was 0.33 g / m 3 . The average density ratio of the surface layer and the back layer was 1.1: 1. As a whole, the basis weight was 546 g / m 2 and the thickness was 1.4 mm. The surface of the surface layer was mirror-finished.
サンプルＡ、Ｂ及びＣの通気度は、それぞれ、１３．５ｃｍ３／秒／ｃｍ２、７．９ｃｍ３／秒／ｃｍ２及び６．２ｃｍ３／秒／ｃｍ２であった。 The air permeability of Samples A, B, and C were 13.5 cm 3 / sec / cm 2 , 7.9 cm 3 / sec / cm 2, and 6.2 cm 3 / sec / cm 2 , respectively.
サンプルＡ、Ｂ及びＣの集塵率は、新品時で、それぞれ、９９．９９５％、９９．９９６％及び９９．９９５％であり、エージング後では全て１００％となり、集塵率では有意な差は見られなかった。一方、圧力損失では、図３に示すように有意な差が見られた。集塵試験は、JIS Z 8909-1：2005 「集じん用ろ布の試験方法」に基づいて行われ、一定濃度（５ｇ／ｍ３）のダストを流してフィルターにダストを付着させ、決まった圧損（１０００Ｐａ）になるとパルスを打ってダストを払い落とした。図３に示す試験時間は、これを３０サイクル行うのにかかった時間である。例えば、圧損上昇速度が速い、または、目詰まりが進んで圧損の下がりが悪い、などの現象が見られると、短時間で1000Paになり試験時間は短くなる。前者後者ともパルスを頻繁に打つこととなるが、後者はそれに加えて圧損が常に高い状態で使用されることになる。いずれの場合もエネルギーコストは増大する。したがって、試験時間の長いものほどが、エネルギーコストを抑えることができる。サンプルＡ、Ｂ及びＣの試験時間は、それぞれ、７９２．４５分、３６７．４３分及び９２．２分であり、サンプルＡが最も優れていた。 The dust collection rates of Samples A, B, and C are 99.995%, 99.996%, and 99.995%, respectively, when new, and are all 100% after aging. Was not seen. On the other hand, in the pressure loss, a significant difference was seen as shown in FIG. The dust collection test was conducted based on JIS Z 8909-1: 2005 “Dust collection filter cloth test method”, and a fixed concentration (5 g / m 3 ) of dust was applied to the filter to determine the dust. When pressure loss (1000 Pa) was reached, a pulse was applied to remove dust. The test time shown in FIG. 3 is the time taken to perform this 30 cycles. For example, when a phenomenon such as a high pressure loss increase rate or a phenomenon in which clogging progresses and the pressure loss decreases is low, the test time is shortened to 1000 Pa in a short time. In the former and the latter, pulses are frequently applied. In addition, the latter is used in a state where pressure loss is always high. In either case, energy costs increase. Therefore, the longer the test time, the lower the energy cost. Samples A, B and C had test times of 792.45 minutes, 367.43 minutes and 92.2 minutes, respectively, with sample A being the best.
以上で具体的実施形態の説明を終えるが、本発明は上記実施形態に限定されることなく幅広く変形実施することができる。 Although the description of the specific embodiment is finished as described above, the present invention is not limited to the above embodiment and can be widely modified.
２...ろ過材、４...基布層、６...表層、８...裏層、１０...経糸、１２...緯糸 2 ... filter material, 4 ... base fabric layer, 6 ... surface layer, 8 ... back layer, 10 ... warp, 12 ... weft
Claims (6)
基布から形成される基布層と、
前記基布層の一側に配置され、０．１〜１．５ｄｔｅｘの繊度を有する極細繊維、及び、０．９〜４．０ｄｔｅｘの繊度を有して、少なくとも外面の一部において前記極細繊維よりも融点が低い低融点素材を含む低融点繊維から形成された表層と、
前記基布層の他側に配置され、前記表層よりも密度が低く、かつ２〜３０ｄｔｅｘの繊度を有する太繊維から形成された裏層とを備え、
前記基布、前記極細繊維及び前記低融点繊維、並びに前記太繊維が互いに交絡された後に、前記表層側のロールのみが前記低融点繊維の融点よりも高くかつ前記極細繊維の融点よりも低い温度に加熱された片熱カレンダー加工が行われて形成されたことを特徴とするバグフィルター用ろ過材。 A filter material for a bag filter,
A base fabric layer formed from the base fabric;
An ultrafine fiber disposed on one side of the base fabric layer and having a fineness of 0.1 to 1.5 dtex, and a fineness of 0.9 to 4.0 dtex, and at least a part of the outer surface of the ultrafine fiber A surface layer formed from a low melting point fiber including a low melting point material having a lower melting point,
A back layer formed from a thick fiber disposed on the other side of the base fabric layer, having a density lower than that of the surface layer and having a fineness of 2 to 30 dtex,
After the base fabric, the ultrafine fiber and the low melting point fiber, and the thick fiber are entangled with each other, only the surface side roll has a temperature higher than the melting point of the low melting point fiber and lower than the melting point of the ultrafine fiber. A filter material for a bag filter, which is formed by performing a one-sided calendering process that is heated on a bag.
０．１〜１．５ｄｔｅｘの繊度を有する極細繊維、及び０．９〜４．０ｄｔｅｘの繊度を有して、少なくとも外面の一部において前記極細繊維よりも融点が低い低融点素材を含む低融点繊維のみから実質的になる第１不織布を基布の一側に重ね、前記極細繊維よりも太く、かつ２〜３０ｄｔｅｘの繊度を有する太繊維のみから実質的になる第２不織布を前記基布の他側に重ねるステップと、
重ね合わされた前記第１不織布、前記基布及び前記第２不織布をニードルパンチにより互いに交絡させて積層体を形成するニードルパンチステップと、
前記積層体をカレンダー加工して、互いに交絡した前記第１不織布、前記基布及び前記第２不織布をそれぞれ、前記表層、前記基布層及び前記裏層にするカレンダーステップとを含み、
前記カレンダー加工は、前記第１不織布側のロールのみが前記低融点素材の融点よりも高く、かつ前記極細繊維の融点よりも低い温度に加熱された片熱カレンダー加工であることを特徴とする製造方法。 A method for producing a filter material for a bag filter having a base fabric layer, a surface layer disposed on one side of the base fabric layer, and a back layer disposed on the other side of the base fabric layer and having a lower density than the surface layer. There,
Low melting point containing ultrafine fibers having a fineness of 0.1 to 1.5 dtex, and a low melting point material having a fineness of 0.9 to 4.0 dtex and having a melting point lower than that of the ultrafine fibers in at least a part of the outer surface A first non-woven fabric consisting essentially of fibers is superimposed on one side of the base fabric, and a second non-woven fabric consisting essentially of thick fibers thicker than the ultrafine fibers and having a fineness of 2 to 30 dtex is formed on the base fabric. A step to overlap the other side;
A needle punch step of forming a laminate by interlacing the first nonwoven fabric, the base fabric and the second nonwoven fabric, which are overlapped, with a needle punch;
Calendering the laminate, and calendering the first non-woven fabric, the base fabric and the second non-woven fabric entangled with each other into the surface layer, the base fabric layer and the back layer, respectively.
The calendering is a one-sided calendering process in which only the roll on the first nonwoven fabric side is heated to a temperature higher than the melting point of the low melting point material and lower than the melting point of the ultrafine fibers. Method.
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| WO2017169687A1 (en) * | 2016-03-29 | 2017-10-05 | 東レ株式会社 | Laminated polyarylene sulfide heat-resistant filter |
| CN112076538A (en) * | 2020-09-11 | 2020-12-15 | 厦门格锐特环保科技有限公司 | Pure PTFE (polytetrafluoroethylene) filtering material and preparation method thereof |
| CN120001124A (en) * | 2024-12-27 | 2025-05-16 | 中材科技膜材料（山东）有限公司 | A polyester film-coated filter material for pleated filter cartridge and a preparation method thereof |
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| JPH0571055A (en) * | 1991-09-06 | 1993-03-23 | Ichikawa Woolen Textile Co Ltd | Heat resistant filter cloth |
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Cited By (5)
| Publication number | Priority date | Publication date | Assignee | Title |
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| WO2017169687A1 (en) * | 2016-03-29 | 2017-10-05 | 東レ株式会社 | Laminated polyarylene sulfide heat-resistant filter |
| JPWO2017169687A1 (en) * | 2016-03-29 | 2019-02-14 | 東レ株式会社 | Multilayer polyarylene sulfide heat resistant filter |
| US10688753B2 (en) | 2016-03-29 | 2020-06-23 | Toray Industries, Inc. | Laminated polyarylene sulfide heat-resistant filter |
| CN112076538A (en) * | 2020-09-11 | 2020-12-15 | 厦门格锐特环保科技有限公司 | Pure PTFE (polytetrafluoroethylene) filtering material and preparation method thereof |
| CN120001124A (en) * | 2024-12-27 | 2025-05-16 | 中材科技膜材料（山东）有限公司 | A polyester film-coated filter material for pleated filter cartridge and a preparation method thereof |
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| Publication number | Publication date |
|---|---|
| JP6453152B2 (en) | 2019-01-16 |
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