JP4342282B2 - Filter material - Google Patents
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- JP4342282B2 JP4342282B2 JP2003394145A JP2003394145A JP4342282B2 JP 4342282 B2 JP4342282 B2 JP 4342282B2 JP 2003394145 A JP2003394145 A JP 2003394145A JP 2003394145 A JP2003394145 A JP 2003394145A JP 4342282 B2 JP4342282 B2 JP 4342282B2
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- nonwoven fabric
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- 239000000463 material Substances 0.000 title claims description 30
- 239000004745 nonwoven fabric Substances 0.000 claims description 182
- 239000000835 fiber Substances 0.000 claims description 113
- 239000011148 porous material Substances 0.000 claims description 101
- 239000007788 liquid Substances 0.000 claims description 57
- 239000011800 void material Substances 0.000 claims description 21
- 239000000446 fuel Substances 0.000 claims description 16
- 238000009826 distribution Methods 0.000 claims description 10
- 229920002647 polyamide Polymers 0.000 claims description 4
- 239000002657 fibrous material Substances 0.000 claims description 3
- 229920005989 resin Polymers 0.000 claims description 2
- 239000011347 resin Substances 0.000 claims description 2
- 239000010410 layer Substances 0.000 description 197
- 239000002245 particle Substances 0.000 description 93
- 230000000052 comparative effect Effects 0.000 description 14
- 229920002292 Nylon 6 Polymers 0.000 description 12
- -1 copolyamide Substances 0.000 description 10
- 238000000034 method Methods 0.000 description 10
- 239000004744 fabric Substances 0.000 description 9
- 230000005484 gravity Effects 0.000 description 9
- 239000004750 melt-blown nonwoven Substances 0.000 description 9
- 229920002302 Nylon 6,6 Polymers 0.000 description 8
- 239000011241 protective layer Substances 0.000 description 7
- 238000001914 filtration Methods 0.000 description 6
- 239000012530 fluid Substances 0.000 description 6
- 239000012085 test solution Substances 0.000 description 5
- 239000004743 Polypropylene Substances 0.000 description 4
- 239000000428 dust Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000005259 measurement Methods 0.000 description 4
- 229920000728 polyester Polymers 0.000 description 4
- 229920001155 polypropylene Polymers 0.000 description 4
- 238000011144 upstream manufacturing Methods 0.000 description 4
- 239000002131 composite material Substances 0.000 description 3
- 238000011156 evaluation Methods 0.000 description 3
- 239000002828 fuel tank Substances 0.000 description 3
- 238000010030 laminating Methods 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 238000012935 Averaging Methods 0.000 description 2
- 229920003043 Cellulose fiber Polymers 0.000 description 2
- 229920001634 Copolyester Polymers 0.000 description 2
- 239000004952 Polyamide Substances 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 229920000297 Rayon Polymers 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 238000004049 embossing Methods 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 238000007654 immersion Methods 0.000 description 2
- 230000001788 irregular Effects 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 230000002035 prolonged effect Effects 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 229920003002 synthetic resin Polymers 0.000 description 2
- 239000000057 synthetic resin Substances 0.000 description 2
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- DHKHKXVYLBGOIT-UHFFFAOYSA-N acetaldehyde Diethyl Acetal Natural products CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 description 1
- 125000002777 acetyl group Chemical class [H]C([H])([H])C(*)=O 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 238000004364 calculation method Methods 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000007872 degassing Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000295 fuel oil Substances 0.000 description 1
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- NDLPOXTZKUMGOV-UHFFFAOYSA-N oxo(oxoferriooxy)iron hydrate Chemical compound O.O=[Fe]O[Fe]=O NDLPOXTZKUMGOV-UHFFFAOYSA-N 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 229920000139 polyethylene terephthalate Polymers 0.000 description 1
- 239000005020 polyethylene terephthalate Substances 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920000874 polytetramethylene terephthalate Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- BFKJFAAPBSQJPD-UHFFFAOYSA-N tetrafluoroethene Chemical group FC(F)=C(F)F BFKJFAAPBSQJPD-UHFFFAOYSA-N 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Landscapes
- Filtering Materials (AREA)
- Filtration Of Liquid (AREA)
- Laminated Bodies (AREA)
Description
本発明は、捕集性能がよく、高寿命なフィルター材、および燃料タンク内で使用する液体燃料用フィルターに関する。 The present invention relates to a filter material having good collection performance and a long life, and a filter for liquid fuel used in a fuel tank.
これまでに、不織布を用いた液体燃料用フィルターが知られている。例えば、小粒子を濾過する能力と耐摩耗性を有する燃料フィルターが開示されている（特許文献１参照）。また、自動車用燃料フィルター材および自動車用燃料フィルターが開示されている（特許文献２参照）。
しかしながら、文献１および２のフィルター材は、粒径が４０μｍ〜１００μｍといった粗い砂埃程度の粒子なら捕捉できたが、カーボン粒子等、粒径が数μｍ〜１０μｍ前後の粒子は通り抜ける。そのため、１個のフィルターを通過しただけで、エンジンルームに導入しても差し支えない程清浄な燃料を得ることはできない。そのため、燃料ラインには、さらに目の細かい別のフィルターを設置する必要があった。
So far, liquid fuel filters using non-woven fabrics are known. For example, a fuel filter having an ability to filter small particles and wear resistance is disclosed (see Patent Document 1). Moreover, the fuel filter material for motor vehicles and the fuel filter for motor vehicles are disclosed (refer patent document 2).
However, although the filter materials of Documents 1 and 2 were able to capture particles having a particle size of about 40 μm to 100 μm and about coarse dust particles, carbon particles and other particles having a particle size of about several μm to 10 μm pass through. Therefore, it is not possible to obtain fuel that is clean enough to pass through a single filter and can be introduced into the engine room. Therefore, it was necessary to install another finer filter in the fuel line.
特許文献１には、フィルターが目詰まりして通液抵抗が高くなり、使用できなくなるまでの時間、すなわち、寿命を長くする目的で、流体を、孔径の大きいシートを通してから小さいシートを通す、いわゆる多段濾過が開示されている。しかし、単純に開孔径の大きな層と小さな層を積層するだけでは、各々のフィルターに捕集される粒径は限定され、粒径の揃った粒子による緻密な堆積層が形成されるため、各々の層での通液抵抗が増加しやすい。したがって、フィルターの寿命をコントロールすることは難しく、高度な捕集性能と寿命を両立させるものではなかった。
本発明は、１０μｍ程度の粒子の捕集性能良好で、かつ、高寿命なフィルター材、および燃料タンク内で使用する新規な液体燃料用フィルターを提供することを目的とするものである。 An object of the present invention is to provide a filter material having a good collection performance of particles of about 10 μm and having a long life, and a novel filter for liquid fuel used in a fuel tank.
本発明者は、上記課題を解決するために鋭意研究を重ねた結果、流体が孔径の大きな層から小さな層へ順に通過する、いわゆる多段濾過と異なり、ほぼ同一の孔径の積層体でありながら、それぞれの繊維径及び空隙体積を特定の組み合わせにすることによって著しくフィルターの寿命を伸ばすことができることを見いだし、この知見に基づいて本発明を完成させるに至った。 As a result of intensive research in order to solve the above problems, the present inventor is a laminate having substantially the same pore diameter, unlike so-called multistage filtration, in which the fluid sequentially passes from a layer having a large pore diameter to a small layer. It has been found that the life of the filter can be remarkably extended by making each fiber diameter and void volume a specific combination, and the present invention has been completed based on this finding.
すなわち、本発明は、以下のとおりである。
（１） 繊維径が５μｍ以上２０μｍ以下の繊維からなる不織布Ａ層と、繊維径が８μｍ以下であり該不織布Ａ層を構成する繊維の繊維径に対して０．１５〜０．９５倍である繊維からなる不織布Ｂ層とを含有する積層体からなるフィルター材であって、該不織布Ａ層の開孔径の分布が、９０％開孔径が１μｍ以上１０μｍ以下であり、１０％開孔径が９０％開孔径より１０〜３０μｍ大きい数値で示される分布であり、該不織布Ｂ層の開孔径において、９０％開孔径が１μｍ以上１０μｍ以下であり、該不織布Ａ層の９０％開孔径に対して、５μｍ以上＋５μｍ以下の範囲内であることを特徴とする、少なくとも２層以上の繊維構造物積層体からなるフィルター材。
（２）不織布Ａ層の空隙体積が２００ｃｍ３／ｍ２以上２０００ｃｍ３／ｍ２以下である（１）に記載のフィルター材。
（３）繊維素材がポリアミド系樹脂である（１）または（２）に記載のフィルター材。
（４）液体燃料用フィルターであって、液体燃料がＡ層を通過した後、Ｂ層を通過するように配置された（１）〜（３）のいずれか１つに記載のフィルター材を用いた液体燃料用フィルター。
That is, the present invention is as follows.
(1) The nonwoven fabric A layer composed of fibers having a fiber diameter of 5 μm or more and 20 μm or less, and the fiber diameter is 8 μm or less, which is 0.15 to 0.95 times the fiber diameter of the fibers constituting the nonwoven fabric A layer. A filter material comprising a laminate comprising a non-woven fabric B layer comprising fibers, wherein the non-woven fabric A layer has a pore size distribution of 90% pore size of 1 μm to 10 μm, and 10% pore size of 90%. a distribution indicated by 10~30μm a number greater than the opening diameter, the pore size of the nonwoven fabric layer B, 90% pore diameter is at 1μm or more 10μm or less, with respect to 90% pore size of the nonwoven fabric layer a, 5 [mu] m or + to 5 [mu] m, wherein the der Turkey within the following range, the filter material consists of at least two layers of fiber structure laminate.
(2) The filter material according to (1), wherein the non-woven fabric A layer has a void volume of 200 cm 3 / m 2 or more and 2000 cm 3 / m 2 or less.
(3) The filter material according to (1) or (2), wherein the fiber material is a polyamide-based resin.
(4) A liquid fuel filter using the filter material according to any one of (1) to (3), which is disposed so that the liquid fuel passes through the A layer and then passes through the B layer. Liquid fuel filter.
本発明によれば、不織布Ａ層にて１０μｍ以上の種々の粒径を有する粒子を大量に捕捉し、不織布Ｂ層にて粒径１０μｍ以上の粒子の９０％を阻止することが可能である。
本発明のフィルター材に１０μｍ程度の粒子を含む種々の粒径が混合された粒子を含む流体を通過させると、層別に均一な粒子層が形成されるいわゆる多段濾過と異なり、不織布Ａ層において１０μｍ以上の種々の粒径を有する粒子による層が形成されるため、緻密な層が形成され難く、そのため、通液抵抗が上昇し難くなり、フィルター寿命が長くなる。
また、不織布Ａ層により捕捉された粒子は、粒子のみの層ではなく、繊維径５μｍ以上２０μｍ以下であるＡ層の内部に粒子を取り込んだ形態、すなわち、繊維と多種の粒径の粒子による層を形成しながら粒子の捕集が行われるため、粗い層が形成されている。また、１０μｍ程度の粒子の幾分かは不織布Ａ層を透過するので、９０％開孔径が不織布Ａ層の９０％開孔径と同程度、具体的には１〜１０μｍであり、かつ、不織布Ａ層の９０％開孔径に対して−５μｍ以上＋５μｍ以下の範囲内である不織布Ｂ層にて１０μｍ以上の粒子の９０％を確実に阻止する。
According to the present invention, a large amount of particles having various particle diameters of 10 μm or more can be captured in the nonwoven fabric A layer, and 90% of particles having a particle diameter of 10 μm or more can be blocked in the nonwoven fabric B layer.
Unlike the so-called multi-stage filtration in which a uniform particle layer is formed for each layer when a fluid containing particles mixed with various particle sizes including particles of about 10 μm is passed through the filter material of the present invention, the nonwoven fabric A layer has a thickness of 10 μm. Since a layer of particles having various particle diameters as described above is formed, it is difficult to form a dense layer. For this reason, it is difficult to increase the liquid flow resistance and the filter life is prolonged.
In addition, the particles captured by the nonwoven fabric A layer are not a layer of particles alone, but a form in which the particles are incorporated into the layer A having a fiber diameter of 5 μm or more and 20 μm or less, that is, a layer composed of fibers and particles of various particle sizes. Since the particles are collected while forming, a coarse layer is formed. Further, since some of the particles of about 10 μm permeate the nonwoven fabric A layer, the 90% pore diameter is the same as the 90% pore diameter of the nonwoven fabric A layer, specifically 1 to 10 μm, and the nonwoven fabric A The nonwoven fabric B layer within the range of −5 μm or more and +5 μm or less with respect to the 90% pore diameter of the layer surely prevents 90% of particles of 10 μm or more.
不織布Ｂ層が、不織布Ａ層と同程度の９０％開孔径であるにもかかわらず、Ａ層を透過してしまった粒子を捕捉できる理由は、Ｂ層において粒子と繊維との接触頻度が高いためである。すなわち、不織布Ｂ層の繊維径が不織布Ａ層の繊維径より小さく、単位体積あたりの繊維表面積が大きいことに起因すると考えられる。具体的には、不織布Ｂ層の繊維径を、不織布Ａ層の繊維径の０．１５倍から０．９５倍とすることにより、開孔径が同程度で通液抵抗を低く抑えながら、不織布層内での単位空間内における表面積はＡ層よりＢ層が増えた形となり、粒子の衝突の頻度が増えるのでＡ層を透過してしまった粒子を捕捉できる。 The reason why the non-woven fabric B layer can capture the particles that have passed through the A layer even though the non-woven fabric A layer has the same 90% pore size as the non-woven fabric A layer is because the contact frequency between the particles and the fibers is high in the B layer. Because. That is, it is considered that the fiber diameter of the nonwoven fabric B layer is smaller than the fiber diameter of the nonwoven fabric A layer and the fiber surface area per unit volume is large. Specifically, by setting the fiber diameter of the non-woven fabric B layer to 0.15 to 0.95 times the fiber diameter of the non-woven fabric A layer, the non-woven fabric layer has the same pore diameter and low liquid flow resistance. The surface area in the unit space is such that the B layer increases from the A layer, and the frequency of particle collision increases, so that the particles that have passed through the A layer can be captured.
本発明のフィルター材を用いることによって、１０μｍ程度の粒子の捕集性能が良好で、かつ、寿命の長い、今までのフィルター材に無い捕集性能と寿命性能の両立ができる。 By using the filter material of the present invention, it is possible to achieve both a collection performance and a life performance that are not present in conventional filter materials, which have a good collection performance of particles of about 10 μm and a long life.
以下、本発明を詳細に説明する。
本発明に用いられる不織布Ａ層は、９０％開孔径が１μｍ以上１０μｍ以下、かつ、１０％開孔径が９０％開孔径より１０〜３０μｍ大きい不織布である。９０％開孔径は、好ましくは２μｍ以上８μｍ以下、より好ましくは２μｍ以上６μｍ以下である。１０％開孔径は、好ましくは９０％開孔径より１２〜２５μｍ大きく、より好ましくは９０％開孔径より１５〜２５μｍ大きい。
Hereinafter, the present invention will be described in detail.
The nonwoven fabric A layer used in the present invention is a nonwoven fabric having a 90% pore diameter of 1 μm or more and 10 μm or less, and a 10% pore diameter larger by 10 to 30 μm than the 90% pore diameter. The 90% pore diameter is preferably 2 μm or more and 8 μm or less, more preferably 2 μm or more and 6 μm or less. The 10% pore diameter is preferably 12-25 μm larger than the 90% pore diameter, more preferably 15-25 μm larger than the 90% pore diameter.
本発明における開孔径とは、木村尚史 酒井清孝 白田利勝 鵜飼哲雄 編著「膜分離技術マニュアル」株式会社アイピーシー出版、１９９０年８月１０日、ｐ１４７に記載されているエアフロー法で求めることができる。すなわち、フィルターをあらかじめ表面張力が既知の液体に浸し、フィルターの全ての細孔を液体の膜で覆った状態からフィルターに圧をかけ、液膜の破壊される圧力と液の表面張力から計算された細孔の孔径を言う。計算には下記の数式（１）を用いる。
ｄ＝Ｃ・ｒ／Ｐ （１）
式中、ｄはフィルターの孔径、ｒは液の表面張力、Ｐはその孔径の液膜が破壊される圧力、Ｃは定数である。
The aperture diameter in the present invention can be determined by the airflow method described in Naoki Kimura, Kiyotaka Sakai, Toshikatsu Shirata, and Tetsuo Sukai, “Membrane Separation Technology Manual”, IP Publishing Co., Ltd., August 10, 1990, p147. That is, the filter is soaked in a liquid with a known surface tension in advance, and pressure is applied to the filter from a state in which all pores of the filter are covered with a liquid film. The pore diameter of the fine pores. The following formula (1) is used for the calculation.
d = C · r / P (1)
In the formula, d is the pore diameter of the filter, r is the surface tension of the liquid, P is the pressure at which the liquid film having the pore diameter is broken, and C is a constant.
一般に、フィルターの開孔径は分布を持つ。開孔径分布は、連続的に圧力を変化させ、各圧力でフィルターを通過する流量の変化から、その圧力で破壊された液膜の量を計算することにより求めることができる。測定装置には、例えば、ＡＳＴＭ Ｅ １２９４−８９に基づく装置である、ＰＭＩ社のパームポロメーターが用いられる。
数式（１）より、液に浸したフィルターにかける圧力Ｐを低圧から高圧に連続的に変化させた場合、初期の圧力は最も大きな細孔の液膜でも破壊されないので、流量は０である。圧力を上げていくと、最も大きな細孔の液膜が破壊され、流量が発生する（バブルポイント）。さらに圧力を上げていくと、最も小さな細孔の液膜が破壊され、液に浸していない場合の流量（Ｄｒｙ流量）と一致する。
In general, the pore size of the filter has a distribution. The pore diameter distribution can be obtained by continuously changing the pressure and calculating the amount of the liquid film destroyed by the pressure from the change in the flow rate passing through the filter at each pressure. As the measuring device, for example, a palm porometer manufactured by PMI, which is a device based on ASTM E 1294-89, is used.
From Equation (1), when the pressure P applied to the filter immersed in the liquid is continuously changed from the low pressure to the high pressure, the initial pressure is not broken even by the liquid film having the largest pores, and the flow rate is zero. As the pressure is increased, the liquid film with the largest pores is destroyed and a flow rate is generated (bubble point). When the pressure is further increased, the liquid film with the smallest pores is destroyed, and the flow rate (Dry flow rate) when not immersed in the liquid is matched.
１０％開孔径とは、フィルターを液に浸した場合の流量（Ｗｅｔ流量）が、浸していない場合の流量（Ｄｒｙ流量）の１０％となる圧力で破壊される液膜の孔径である。
９０％開孔径とは、フィルターを液に浸した場合の流量（Ｗｅｔ流量）が、浸していない場合の流量（Ｄｒｙ流量）の９０％となる圧力で破壊される液膜の孔径である。
１０％開孔径および９０％開孔径は、後に述べる方法により求められる。
数式（１）より、あるフィルターの１０％開孔径は、９０％開孔径より大きい。１０％開孔径と９０％開孔径の差が大きい程、そのフィルターの持つ細孔の大きさの分布は広いと言える。
The 10% pore diameter is the pore diameter of the liquid film that is broken at a pressure at which the flow rate when the filter is immersed in the liquid (Wet flow rate) is 10% of the flow rate when the filter is not immersed (Dry flow rate).
The 90% pore diameter is the pore diameter of the liquid film that is broken at a pressure at which the flow rate when the filter is immersed in the liquid (Wet flow rate) is 90% of the flow rate when the filter is not immersed (Dry flow rate).
The 10% aperture diameter and the 90% aperture diameter are determined by the method described later.
From Equation (1), the 10% aperture diameter of a certain filter is larger than the 90% aperture diameter. It can be said that the larger the difference between the 10% opening diameter and the 90% opening diameter, the wider the pore size distribution of the filter.
不織布Ａ層の９０％開孔径が１μｍ未満の場合、繊維間隔が狭すぎてＡ層がすぐに目詰まりし、通液抵抗が高くなる。不織布Ａ層の９０％開孔径が１０μｍを越える場合、繊維間隔が広すぎてＡ層を通過する粒子が増え、不織布Ｂ層が目詰まりして通液抵抗が高くなり、フィルターの寿命が短くなる。
不織布Ａ層の１０％開孔径が（９０％開孔径＋１０μｍ）未満の場合、９０％開孔径との差が小さく、均一な孔径分布となり、均一な粒子による緻密な堆積層がＡ層上に形成され、通液抵抗が早く高くなる。不織布Ａ層の１０％開孔径が（９０％開孔径＋３０μｍ）を越える場合、部分的に通液抵抗の低い大きな孔部分から集中して粒子が流出し、不織布Ｂ層を目詰まりさせる。
When the 90% opening diameter of the nonwoven fabric A layer is less than 1 μm, the fiber spacing is too narrow and the A layer is clogged immediately, and the liquid flow resistance becomes high. When the 90% pore size of the nonwoven fabric A layer exceeds 10 μm, the fiber spacing is too wide and the number of particles passing through the A layer increases, the nonwoven fabric B layer becomes clogged, the liquid flow resistance increases, and the filter life is shortened. .
When the 10% pore size of the nonwoven fabric A layer is less than (90% pore size + 10 μm), the difference from the 90% pore size is small and the pore size distribution is uniform, and a dense deposited layer of uniform particles is formed on the A layer. As a result, the liquid flow resistance increases quickly. When the 10% opening diameter of the nonwoven fabric A layer exceeds (90% opening diameter + 30 μm), the particles are partially concentrated from a large hole portion having a low liquid flow resistance, and the nonwoven fabric B layer is clogged.
本発明に用いられる不織布Ａ層の繊維径は５μｍ以上２０μｍ以下である必要があり、好ましくは５μｍ以上１７μｍ以下、より好ましくは５μｍ以上１５μｍ以下である。繊維径は、電子顕微鏡で５０本の繊維を撮影し、平均して求めることができる。不織布Ａ層の繊維径が５μｍ未満の場合、繊維表面積が著しく大きくなり、粒子が通過する際の衝突の頻度が増える。そのため、衝突によりエネルギーを失う小粒径の粒子が繊維表面上に堆積して、緻密層が形成され易くなり、通液抵抗が高くなり易い。不織布Ａ層の繊維径が２０μｍを越える場合、繊維表面積が少ないため、粒子の衝突頻度が低くなる。そのため、不織布Ａ層を通過する粒子が増え、不織布Ｂ層が目詰まりして通液抵抗が増加する。 The fiber diameter of the nonwoven fabric A layer used in the present invention needs to be 5 μm or more and 20 μm or less, preferably 5 μm or more and 17 μm or less, more preferably 5 μm or more and 15 μm or less. The fiber diameter can be determined by photographing 50 fibers with an electron microscope and averaging them. When the fiber diameter of the nonwoven fabric A layer is less than 5 μm, the fiber surface area is remarkably increased, and the frequency of collision when particles pass is increased. Therefore, particles with a small particle size that lose energy due to collision accumulate on the fiber surface, and a dense layer tends to be formed, and the liquid flow resistance tends to increase. When the fiber diameter of the nonwoven fabric A layer exceeds 20 μm, the fiber surface area is small, so that the frequency of particle collision is low. Therefore, the particles passing through the nonwoven fabric A layer increase, the nonwoven fabric B layer is clogged, and the liquid flow resistance increases.
本発明で用いる不織布Ａ層または不織布Ｂ層の繊維の断面形状は、円形でも、円形以外の異型でもよい。異型断面の場合の繊維径は、繊維断面の周長が同じとなる円断面の直径とみなす。分割繊維等で繊維の断面形状が複雑で直接測定できない場合は、その不織布の表面積と不織布を構成する物質が占める体積から計算される、みかけ上の繊維径で代替できる。
本発明に用いられる不織布Ａ層の空隙体積は２００ｃｍ３／ｍ２以上２０００ｃｍ３／ｍ２以下であることが好ましく、より好ましくは２００ｃｍ３／ｍ２以上１０００ｃｍ３／ｍ２以下である。
The cross-sectional shape of the fibers of the nonwoven fabric A layer or the nonwoven fabric B layer used in the present invention may be circular or an irregular shape other than circular. The fiber diameter in the case of an irregular cross section is regarded as the diameter of a circular cross section in which the circumference of the fiber cross section is the same. When the cross-sectional shape of the fiber is complicated and cannot be directly measured with a split fiber or the like, it can be replaced with the apparent fiber diameter calculated from the surface area of the nonwoven fabric and the volume occupied by the material constituting the nonwoven fabric.
The void volume of the nonwoven fabric A layer used in the present invention is preferably 200 cm 3 / m 2 or more and 2000 cm 3 / m 2 or less, more preferably 200 cm 3 / m 2 or more and 1000 cm 3 / m 2 or less.
本発明における空隙体積とは、１ｍ２の不織布中に占める空隙量を言う。不織布の目付と厚みから計算される、１ｍ２の不織布の体積をＷｏ、１ｍ２の不織布中で不織布を構成する物質が占める体積をＷｍ、空隙体積をＷｅとすると、空隙体積は下記の数式（２）で示される。
Ｗｅ＝Ｗｏ−Ｗｍ （２）
不織布の目付は、ＪＩＳＬ−１０９６で求めることができる。不織布の厚みは、フィルターが使用される場合にかかる圧力から測定することが好ましい。本発明では０．４９ｋＰａで測定した。
The void volume in the present invention refers to the amount of voids occupied in a 1 m 2 nonwoven fabric. The volume of the nonwoven fabric of 1 m 2 calculated from the basis weight and thickness of the nonwoven fabric is Wo, the volume occupied by the material constituting the nonwoven fabric in the nonwoven fabric of 1 m 2 is Wm, and the void volume is We. 2).
We = Wo-Wm (2)
The basis weight of the nonwoven fabric can be determined according to JISL-1096. The thickness of the nonwoven fabric is preferably measured from the pressure applied when a filter is used. In this invention, it measured at 0.49 kPa.
不織布Ａ層の空隙体積が２００ｃｍ３／ｍ２未満の場合、捕捉できる総量が少なくなり、不織布Ｂ層上にケーキ層として堆積する粒子が増加する傾向がある。そのため、通液抵抗が上昇し易く、フィルターの寿命が短くなることがある。不織布Ａ層の空隙体積が２０００ｃｍ３／ｍ２を越える場合、厚みが大きく、また空気層を多く含むため熱融着による接着精度が低く、ろ過中にリークを起こす場合がある。 When the void volume of the nonwoven fabric A layer is less than 200 cm 3 / m 2 , the total amount that can be captured tends to decrease, and the particles deposited as a cake layer on the nonwoven fabric B layer tend to increase. For this reason, the liquid flow resistance is likely to increase, and the filter life may be shortened. When the void volume of the nonwoven fabric A layer exceeds 2000 cm 3 / m 2 , the thickness is large and the air layer contains many air layers, so the adhesion accuracy by heat fusion is low, and leakage may occur during filtration.
本発明に用いられる不織布Ａ層または不織布Ｂ層を構成する素材は、開孔径および繊維径が上記の範囲内であれば限定されない。合成樹脂系繊維でもセルロース系繊維でもよい。合成樹脂繊維としては、ナイロン６、ナイロン６６，共重合ポリアミド等のポリアミドからなる繊維、ポリエチレン、ポリプロピレン、共重合ポリプロピレン等のポリオレフィンからなる繊維、ポリエチレンテレフタレート、ポリテトラメチレンテレフタレート、共重合ポリエステル等のポリエステルからなる繊維、アクリル系繊維、アセタール系繊維、４フッ化エチレン系繊維等が挙げられる。セルロース系繊維としてはビスコースレーヨン、キュプラレーヨン、パルプ等が挙げられる。これらは単独で用いても２種以上混合して用いてもよい。 The material which comprises the nonwoven fabric A layer or the nonwoven fabric B layer used for this invention will not be limited if an aperture diameter and a fiber diameter are in said range. Synthetic resin fibers or cellulose fibers may be used. Synthetic resin fibers include nylon 6, nylon 66, fibers made of polyamide such as copolyamide, fibers made of polyolefin such as polyethylene, polypropylene, copolypropylene, polyesters such as polyethylene terephthalate, polytetramethylene terephthalate, and copolyester. Fiber, acrylic fiber, acetal fiber, and tetrafluoroethylene fiber. Cellulose fibers include viscose rayon, cupra rayon, pulp and the like. These may be used alone or in combination of two or more.
また鞘部分がポリエチレン、ポリプロピレン、共重合ポリエステル等からなり、芯部分がポリプロピレン、ポリエステル等からなる複合繊維等であってもよい。その中でもポリアミド系繊維が耐燃料油性、耐摩耗性および強度の点から好ましい。
本発明で用いる不織布Ａ層の製造方法は限定されないが、空隙体積の量が減らないことが好ましいので、スパンレース法やニードルパンチ法を用いた不織布が好適に使用される。
本発明の不織布Ａ層の表面形状は、平滑でも、エンボス加工等により凹凸が施されていてもよい。その中でも、フィルターとして用いる場合、上流面に凹凸があると、粒子の運動エネルギーの大きな、初期に衝突する繊維表面積が増え、Ａ層を通過してしまう粒子が少なくなり、Ｂ層が目詰まりするのが遅れて寿命が長くなるので好ましい。
Moreover, the sheath part may be made of polyethylene, polypropylene, copolyester or the like, and the core part may be a composite fiber made of polypropylene, polyester or the like. Of these, polyamide fibers are preferred from the viewpoint of fuel oil resistance, wear resistance and strength.
Although the manufacturing method of the nonwoven fabric A layer used by this invention is not limited, Since it is preferable that the quantity of void | hole volume does not reduce, the nonwoven fabric using a spunlace method or a needle punch method is used suitably.
The surface shape of the nonwoven fabric A layer of the present invention may be smooth, or may be uneven by embossing or the like. Among them, when used as a filter, if there are irregularities on the upstream surface, the surface area of the fiber that collides with the initial stage, the particle kinetic energy increases, the number of particles that pass through the A layer decreases, and the B layer becomes clogged. This is preferable since the service life is prolonged with a delay.
本発明に用いる不織布Ｂ層は、９０％開孔径が１μｍ以上１０μｍ以下であり、かつ、不織布Ａ層の９０％開孔径に対して−５μｍ以上＋５μｍ以下の範囲内である必要があり、好ましくは不織布Ａ層の９０％開孔径に対して−３μｍ以上＋３μｍ以下の範囲内である。
不織布Ａ層の９０％開孔径から不織布Ｂ層の９０％開孔径を引いた差が５μｍを越える場合、不織布Ａ層を通過した粒子を捕捉しすぎるため、通液抵抗が早く高くなる。また、不織布Ｂ層の９０％開孔径が１μｍ未満になると、エンジンの耐久性に寄与しないような、小さすぎる粒子まで捕捉するため、通液抵抗が短時間で高くなる。不織布Ｂ層の９０％開孔径から不織布Ａ層の９０％開孔径を引いた差が５μｍを越える場合、不織布Ａ層を通過した粒子は不織布Ｂ層も通過する。また不織布Ｂ層の９０％開孔径が１０μｍを越えると、目的である１０μｍの粒子を９０％捕集することができない。
The nonwoven fabric B layer used in the present invention must have a 90% pore diameter of 1 μm or more and 10 μm or less, and must be within a range of −5 μm or more and +5 μm or less with respect to the 90% pore diameter of the nonwoven fabric A layer. It is in the range of -3 μm or more and +3 μm or less with respect to the 90% pore diameter of the nonwoven fabric A layer.
When the difference obtained by subtracting the 90% aperture diameter of the nonwoven fabric B layer from the 90% aperture diameter of the nonwoven fabric A layer exceeds 5 μm, particles passing through the nonwoven fabric A layer are trapped too much, so that the liquid flow resistance increases quickly. In addition, when the 90% pore size of the nonwoven fabric B layer is less than 1 μm, too small particles that do not contribute to the durability of the engine are captured, so that the liquid flow resistance increases in a short time. When the difference obtained by subtracting the 90% aperture diameter of the nonwoven fabric A layer from the 90% aperture diameter of the nonwoven fabric B layer exceeds 5 μm, the particles that have passed through the nonwoven fabric A layer also pass through the nonwoven fabric B layer. If the 90% pore diameter of the nonwoven fabric B layer exceeds 10 μm, 90% of the target 10 μm particles cannot be collected.
本発明で用いる不織布Ｂ層の繊維径は、不織布Ａ層の０．１５倍から０．９５倍の範囲内、かつ、８μｍ以下である必要があり、好ましくは０．１５倍以上０．８倍以下、より好ましくは０．１５倍以上０．５倍以下である。不織布Ｂ層の繊維径が、不織布Ａ層の０．１５倍未満の場合、繊維表面積が大きくなり、粒子が通過する際の衝突の頻度が増える。そのため、９０％開孔径が不織布Ａ層の９０％開孔径と−５μｍ以上＋５μｍ以下の範囲内の場合でも、エンジンの耐久性に寄与しないような、小さすぎる粒子まで捕捉する。そのため、極めて緻密な層が形成され易く、通液抵抗が短時間で高くなる。不織布Ｂ層の繊維径が不織布Ａ層の０．９５倍を越える場合、繊維表面積が少ないため、粒子の衝突頻度が低くＢ層を通過する粒子が増加し、１０μｍの粒子を９０％捕集することができない。 The fiber diameter of the nonwoven fabric B layer used in the present invention needs to be in the range of 0.15 to 0.95 times that of the nonwoven fabric A layer and 8 μm or less, preferably 0.15 times to 0.8 times. Hereinafter, it is more preferably 0.15 times or more and 0.5 times or less. When the fiber diameter of the nonwoven fabric B layer is less than 0.15 times that of the nonwoven fabric A layer, the fiber surface area increases and the frequency of collision when particles pass through increases. Therefore, even when the 90% pore diameter is within the range of −5 μm to +5 μm with respect to the 90% pore diameter of the nonwoven fabric A layer, particles that are too small to contribute to engine durability are captured. Therefore, an extremely dense layer is easily formed, and the liquid flow resistance is increased in a short time. When the fiber diameter of the nonwoven fabric B layer exceeds 0.95 times that of the nonwoven fabric A layer, since the fiber surface area is small, the collision frequency of the particles is low and the number of particles passing through the B layer is increased, and 90% of 10 μm particles are collected. I can't.
本発明に用いられる不織布Ｂ層の製造方法は、開孔径と繊維径を満足する限りは限定されない。開孔径と繊維径を満足する好ましい製造方法としては、例えば、メルトブロー法、スパンレース法，フラッシュスパン法等が挙げられる。
本発明のフィルター材をフィルターとして用いる場合には、流体が不織布Ａ層を通過した後、不織布Ｂ層を通過するように配置する必要がある。すなわち、先に流体が通過するＡ層で流体中に含まれる粒子のうち、主に１０μｍを越える粒子を不織布の表層と不織布層内部の空隙に捕集する。次にＢ層の、主に表層で１０μｍの粒子を９０％確実に捕集する。
The manufacturing method of the nonwoven fabric B layer used in the present invention is not limited as long as the pore diameter and the fiber diameter are satisfied. Preferable production methods satisfying the aperture diameter and fiber diameter include, for example, a melt blow method, a spun lace method, a flash span method, and the like.
When the filter material of the present invention is used as a filter, it is necessary to dispose the fluid so as to pass through the nonwoven fabric B layer after passing through the nonwoven fabric A layer. That is, among the particles contained in the fluid in the A layer through which the fluid passes first, the particles mainly exceeding 10 μm are collected in the surface layer of the nonwoven fabric and the voids inside the nonwoven fabric layer. Next, 90% of 10 μm particles of the B layer are mainly collected on the surface layer.
本発明のフィルター材を液体燃料用フィルターとして用いる場合、必要に応じて、本発明のフィルター材の前後に保護層を設けることができる。保護層は、例えば、フィルターの生産やモジュールへの装着時、実際の使用時等において、振動や摩擦からフィルターを保護する目的で用いられる。保護層には、例えば、モノフィラメント織物、スパンボンド等が用いられる。
不織布Ａ層の上流に設置する保護層の９０％開孔径は、通液抵抗を阻害しないためにＡ層の９０％開孔径より大きいことが好ましい。不織布Ｂ層の下流に設置する保護層の９０％開孔径は、通液抵抗を阻害しないためにＢ層の９０％開孔径より大きいことが好ましい。
When the filter material of the present invention is used as a liquid fuel filter, protective layers can be provided before and after the filter material of the present invention, if necessary. The protective layer is used for the purpose of protecting the filter from vibration and friction, for example, during production of the filter, mounting on a module, and actual use. For the protective layer, for example, monofilament woven fabric, spunbond or the like is used.
The 90% pore diameter of the protective layer placed upstream of the nonwoven fabric A layer is preferably larger than the 90% pore diameter of the A layer so as not to impede liquid flow resistance. The 90% pore diameter of the protective layer placed downstream of the nonwoven fabric B layer is preferably larger than the 90% pore diameter of the B layer so as not to impede liquid flow resistance.
本発明のフィルター材をフィルターとして用いる場合、不織布Ａ層の上流にフィルター層を設置してもよい。このフィルター層の９０％開孔径は、通液抵抗を阻害しないために不織布Ａ層の９０％開孔径より大きいことが好ましい。Ａ層とＢ層の間に別のフィルター層を設置してもよい。このフィルター層の９０％開孔径は、通液抵抗を阻害しないために不織布Ｂ層の９０％開孔径より大きいことが好ましい。不織布Ｂ層の下流に不織布Ｂ層の９０％開孔径より小さなフィルター層を加えると通液抵抗を阻害する。
本発明の少なくとも２層以上のフィルター材を一体化する方法は限定されないが、フィルター材の空隙量と表面積をできる限り潰さない方法が好ましい。例えば、部分的に熱融着を行うエンボス接合、粉黛や繊維状の熱可塑性樹脂によるサーマルボンド等が用いられる。
When the filter material of the present invention is used as a filter, a filter layer may be installed upstream of the nonwoven fabric A layer. The 90% pore diameter of the filter layer is preferably larger than the 90% pore diameter of the nonwoven fabric A layer so as not to impede liquid flow resistance. Another filter layer may be provided between the A layer and the B layer. The 90% pore size of the filter layer is preferably larger than the 90% pore size of the nonwoven fabric B layer so as not to impede liquid flow resistance. When a filter layer smaller than the 90% pore size of the nonwoven fabric B layer is added downstream of the nonwoven fabric B layer, the liquid flow resistance is inhibited.
The method for integrating at least two layers of the filter material of the present invention is not limited, but a method that does not collapse the void amount and surface area of the filter material as much as possible is preferable. For example, emboss bonding in which heat fusion is partially performed, thermal bonding using powder cake or a fibrous thermoplastic resin, or the like is used.
本発明の不織布Ａ層がＡ層ではないフィルター層ないし保護層と一体化されていて、測定のために剥離した際に明らかに剥離によって生じた部分的な孔が有る場合は、開孔径は孔を避けて測定するか、接着剤等で剥離によって生じた孔を埋めてから測定する。
本発明の不織布Ｂ層がＢ層ではないフィルター層ないし保護層と一体化され、Ｂ層単独の開孔径が測定できない場合は、Ｂ層の９０％開孔径は、一体化された状態で測定したシートの９０％開孔径で代用することができる。
When the nonwoven fabric A layer of the present invention is integrated with a filter layer or a protective layer that is not the A layer, and there is a partial hole that is clearly caused by peeling when peeling for measurement, the opening diameter is the hole The measurement is performed by avoiding or by filling a hole formed by peeling with an adhesive or the like.
When the nonwoven fabric B layer of the present invention is integrated with a filter layer or protective layer that is not the B layer, and the pore diameter of the B layer alone cannot be measured, the 90% pore diameter of the B layer was measured in an integrated state. A 90% aperture diameter of the sheet can be substituted.
繊維径は、一体化された状態のシートの断面からＢ層部分の繊維径を測定して求めることができる。例えばＢ層がスパンボンドの紡孔とメルトブローの紡孔が隣り合っていて、積層直後に一体化した、いわゆるＳＭ（スパンボンド／メルトブロー） ＳＭＳ（スパンボンド／メルトブロー／スパンボンド） ＳＭＭＳ（スパンボンド／メルトブロー／メルトブロー／スパンボンド）等のメルトブロー層の場合、９０％開孔径は、複合不織布全体で測定した値を用いることができる。繊維径は、複合不織布の断面からメルトブロー層部分の繊維径を測定して用いる。 A fiber diameter can be calculated | required by measuring the fiber diameter of a B layer part from the cross section of the sheet | seat of the integrated state. For example, layer B is spunbonded with spunbond and meltblown spun, and so-called SM (spunbond / meltblown) SMS (spunbond / meltblown / spunbond) SMMS (spunbond / In the case of a melt blow layer such as (melt blow / melt blow / spun bond), a value measured for the entire composite nonwoven fabric can be used as the 90% pore diameter. The fiber diameter is used by measuring the fiber diameter of the meltblown layer portion from the cross section of the composite nonwoven fabric.
次に、実施例および比較例によって本発明を具体的に説明する。
本発明に用いられる測定法は以下のとおりである。
（１）９０％開孔径（μｍ）
ＰＭＩ社製パームポロメーター 型式ＣＦＰ−１２００ＡＥＸを用いて測定する。浸液には表面張力２０．１ｄｙｎｅｓ／ｃｍのＰＭＩ社製Ｓｉｌｗｉｃｋを用いる。浸液に浸したサンプルは、−８０ｋＰａに脱気してサンプル内に泡が残らないように前処理する。測定径はφ２０ｍｍとする。乾燥空気をフィルターに通し、段階的に気体圧力を増加させて、その時の気体流量を観測する。フィルターを液に浸した場合の流量（Ｗｅｔ流量）が、浸していない場合の流量（Ｄｒｙ流量）の９０％となる圧力Ｐ９０（ＰＳＩ）を求め、数式（３）より９０％開孔径を求める。
ｄ９０＝Ｃ・ｒ／Ｐ９０ （３）
ここで、ｄ９０は９０％開孔径（μｍ）、ｒは液の表面張力で２０．１（ｄｙｎｅｓ／ｃｍ）、定数Ｃは０．４５１（μｍ・ｃｍ・ＰＳＩ／ｄｙｎｅｓ）である。３回測定しその平均値を求める。
Next, the present invention will be specifically described with reference to examples and comparative examples.
The measuring method used in the present invention is as follows.
(1) 90% pore size (μm)
Measurement is performed using a palm porometer model CFP-1200AEX manufactured by PMI. A PMI Silwick having a surface tension of 20.1 dynes / cm is used for the immersion liquid. The sample immersed in the immersion liquid is pre-treated so that bubbles do not remain in the sample by degassing to -80 kPa. The measurement diameter is 20 mm. Pass the dry air through the filter, increase the gas pressure step by step, and observe the gas flow at that time. The pressure P 90 (PSI) at which the flow rate when the filter is immersed in the liquid (Wet flow rate) is 90% of the flow rate when the filter is not immersed (Dry flow rate) is obtained, and the 90% pore diameter is obtained from Equation (3). .
d 90 = C · r / P 90 (3)
Here, d 90 90% pore diameter (μm), r is 20.1 in the surface tension of the liquid (dynes / cm), the constant C is 0.451 (μm · cm · PSI / dynes). Measure three times and find the average value.
（２）１０％開孔径（μｍ）
フィルターを液に浸した場合の流量（Ｗｅｔ流量）が、浸していない場合の流量（Ｄｒｙ流量）の１０％となる圧力Ｐ１０（ＰＳＩ）について、（１）と同様に数式（４）より求める。３回測定しその平均値を求める。
ｄ１０＝Ｃ・ｒ／Ｐ１０ （４）
(2) 10% pore size (μm)
The pressure P 10 (PSI) at which the flow rate when the filter is immersed in the liquid (Wet flow rate) is 10% of the flow rate when the filter is not immersed (Dry flow rate) is obtained from Equation (4) in the same manner as (1). . Measure three times and find the average value.
d 10 = C · r / P 10 (4)
（３）繊維径（μｍ）
電子顕微鏡で５０本の繊維を撮影し、平均して求める。
（４）空隙体積（ｃｍ３／ｍ２）
目付（ｇ／ｍ２）の測定は、ＪＩＳＬ−１０９６にしたがう。厚み（ｍｍ）は、０．４９ｋＰａの荷重をかけた１０秒後に測定する。これより１ｍ２の不織布の体積Ｗｏ（ｃｍ３／ｍ２）を計算し、次に、目付（ｇ／ｍ２）と繊維を構成する物質の比重（ｇ／ｃｍ３）より、１ｍ２の不織布中で不織布を構成する物質が占める体積Ｗｍ（ｃｍ３／ｍ２）を計算する。次に、数式（２）より、空隙体積Ｗｅ（ｃｍ３／ｍ２）を計算する。
Ｗｅ＝Ｗｏ−Ｗｍ （２）
(3) Fiber diameter (μm)
50 fibers are photographed with an electron microscope and obtained by averaging.
(4) Void volume (cm 3 / m 2 )
The basis weight (g / m 2 ) is measured according to JISL-1096. The thickness (mm) is measured 10 seconds after applying a load of 0.49 kPa. From this calculate the 1 m 2 of the nonwoven fabric volume Wo (cm 3 / m 2) , then, from the basis weight (g / m 2) and forming the fiber material specific gravity (g / cm 3), of 1 m 2 nonwoven The volume Wm (cm 3 / m 2 ) occupied by the material constituting the nonwoven fabric is calculated. Next, the void volume We (cm 3 / m 2 ) is calculated from Equation (2).
We = Wo-Wm (2)
（５）９０％捕集粒径
試料を、濾過面積１２．６ｃｍ２のフィルターホルダーにセットする。試験液は、ＦｉｓｈｅｒＣｈｅｍｉｃａｌ社製のＦｅｒｒｉｃＯｘｉｄｅと、ＪＩＳＺ−８９０１の試験用ダスト７種を１：２の割合で混合したものを純水に２ｍｇ／ｌで分散させて用いる。試験液を流量５４ｍｌ／ｍｉｎでフィルターホルダーに通し、フィルター透過前後の試験液の粒度分布をハイアックロイコ社の粒度分布計で測定し、各粒子径での捕集効率を数式（５）より計算する。
ｐ（％）＝ｓａ／ｓｂ×１００ （５）
ここで、ｐ（％）は捕集効率、ｓｂはフィルター透過前の粒子量（ｍｇ／ｌ）、ｓａはフィルター透過後の粒子量（ｍｇ／ｌ）である。
捕集効率ｐ（％）が９０％となる粒子径を、９０％捕集粒径（μｍ）とする。
(5) 90% collection particle diameter The sample is set in a filter holder having a filtration area of 12.6 cm 2 . The test solution is a mixture of Ferric Oxide manufactured by Fisher Chemical and 7 types of test dust of JISZ-8901 in a ratio of 1: 2, dispersed in pure water at 2 mg / l. Pass the test solution through the filter holder at a flow rate of 54 ml / min, measure the particle size distribution of the test solution before and after permeation of the filter with a particle size distribution meter of Hiac Royco, and calculate the collection efficiency at each particle size from Equation (5). To do.
p (%) = s a / s b × 100 (5)
Here, p (%) is the collection efficiency, s b is the amount of particles before filter permeation (mg / l), and s a is the amount of particles after permeation of the filter (mg / l).
The particle diameter at which the collection efficiency p (%) is 90% is defined as 90% collection particle diameter (μm).
（６）寿命
サンプルを、濾過面積１２．６ｃｍ２のフィルターホルダーにセットする。試験液は、ＪＩＳＺ−８９０１の試験用ダスト７種を２．５ｇ、ＪＩＳＺ−８９０１の試験用ダスト８種を１．２５ｇ、ＰＴＩ社のＳＯＦＴＥＣ−２Ａを４．８３ｇ、軽油を９．５リットル混合し均一に分散させて用いる。試験液を流量３５．２ｍｌ／ｍｉｎでフィルターホルダーに通し、差圧が９．８ｋＰａとなるまでの時間を測定する。
(6) Life A sample is set in a filter holder having a filtration area of 12.6 cm 2 . The test solution is 2.5 g of 7 kinds of JISZ-8901 test dust, 1.25 g of 8 kinds of JISZ-8901 test dust, 4.83 g of PTI's SOFTTEC-2A, and 9.5 liters of light oil. And uniformly dispersed. The test solution is passed through the filter holder at a flow rate of 35.2 ml / min, and the time until the differential pressure reaches 9.8 kPa is measured.
実施例と比較例に用いた不織布は、表１および２に示すように調整して作成した。また実施例と比較例の評価結果を表１および２に示した。
[実施例１]
不織布Ａ層として、ナイロン６６繊維を水流交絡させた不織布を用いた。この不織布の目付、厚み、比重、繊維径、９０％開孔径、１０％開孔径および空隙体積は表１のとおりである。不織布Ｂ層として、ナイロン６繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。
不織布Ａ層と不織布Ｂ層を積層して、Ａ層からＢ層に液が流れるようにして、９０％捕集粒径と寿命を測定した。結果は表１に示したとおり、９０％捕集粒径も寿命も良好であった。
Nonwoven fabrics used in Examples and Comparative Examples were prepared by adjusting as shown in Tables 1 and 2. The evaluation results of Examples and Comparative Examples are shown in Tables 1 and 2.
[Example 1]
As the nonwoven fabric A layer, a nonwoven fabric in which nylon 66 fibers were hydroentangled was used. Table 1 shows the basis weight, thickness, specific gravity, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. As the nonwoven fabric B layer, a melt blown nonwoven fabric made of nylon 6 fibers was used. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric.
The nonwoven fabric A layer and the nonwoven fabric B layer were laminated, and 90% collection particle size and life were measured so that the liquid flowed from the A layer to the B layer. As shown in Table 1, the 90% collection particle size and the lifetime were good.
［実施例２〜３および比較例１］
実施例２および３では、不織布Ａ層として、ナイロン６６繊維を水流交絡させた不織布を用いた。この不織布の目付、厚み、比重、繊維径、９０％開孔径、１０％開孔径、および空隙体積は表１のとおりである。不織布Ｂ層として、ナイロン６繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。
不織布Ａ層と不織布Ｂ層を積層してＡ層からＢ層に液が流れるように、９０％捕集粒径と寿命を測定した。結果は表１に示したとおり、９０％捕集粒径も寿命も良好であった。
[Examples 2-3 and Comparative Example 1]
In Examples 2 and 3, a nonwoven fabric in which nylon 66 fibers were hydroentangled was used as the nonwoven fabric A layer. Table 1 shows the basis weight, thickness, specific gravity, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. As the nonwoven fabric B layer, a melt blown nonwoven fabric made of nylon 6 fibers was used. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric.
The nonwoven fabric A layer and the nonwoven fabric B layer were laminated, and 90% collected particle size and life were measured so that the liquid flowed from the A layer to the B layer. As shown in Table 1, the 90% collection particle size and the lifetime were good.
一方、比較例１では、不織布Ａ層として、ナイロン６繊維からなるスパンボンドを用いた。不織布Ｂ層には実施例３と同様のものを用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。９０％捕集粒径と寿命を測定したところ、表１のとおり、寿命が短かった。これは不織布Ａ層の９０％開孔径が大きすぎ、粒子がＡ層をとおり抜けてしまい、不織布Ｂ層上に粒子が増えて通液抵抗が上昇し、寿命となったためであった。 On the other hand, in Comparative Example 1, a spunbond made of nylon 6 fiber was used as the nonwoven fabric A layer. The same thing as Example 3 was used for the nonwoven fabric B layer. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric. When 90% collection particle diameter and lifetime were measured, as shown in Table 1, the lifetime was short. This was because the 90% pore size of the nonwoven fabric A layer was too large, and the particles passed through the A layer, the particles increased on the nonwoven fabric B layer, the liquid flow resistance increased, and the life was reached.
［実施例４、５および比較例２］
実施例４および５では、不織布Ａ層として、ナイロン６６繊維を水流交絡させた不織布を用いた。この不織布の目付、厚み、比重、繊維径、９０％開孔径、１０％開孔径、および空隙体積は表１のとおりである。不織布Ｂ層として、ナイロン６繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。
[Examples 4 and 5 and Comparative Example 2]
In Examples 4 and 5, a nonwoven fabric in which nylon 66 fibers were hydroentangled was used as the nonwoven fabric A layer. Table 1 shows the basis weight, thickness, specific gravity, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. As the nonwoven fabric B layer, a melt blown nonwoven fabric made of nylon 6 fibers was used. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric.
不織布Ａ層と不織布Ｂ層を積層してＡ層からＢ層に液が流れるように、９０％捕集粒径と寿命を測定した。結果は表１に示したとおり、９０％捕集粒径も寿命も良好であった。
一方、比較例２では、不織布Ａ層として、実施例３で用いた不織布に針で穴あけ加工を行った。不織布Ｂ層には実施例３と同様のものを用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。９０％捕集粒径と寿命を測定したところ、表１のとおり、寿命が短かった。これは不織布Ａ層の１０％開孔径が大きすぎ、部分的に通液抵抗の低い大きな孔部分から集中して粒子が流出し、不織布Ｂ層を目詰まりさせてしまい、Ｂ層上に粒子が増えて通液抵抗が上昇し、寿命となったためであった。
The nonwoven fabric A layer and the nonwoven fabric B layer were laminated, and 90% collected particle size and life were measured so that the liquid flowed from the A layer to the B layer. As shown in Table 1, the 90% collection particle size and the lifetime were good.
On the other hand, in Comparative Example 2, the nonwoven fabric used in Example 3 was punched with a needle as the nonwoven fabric A layer. The same thing as Example 3 was used for the nonwoven fabric B layer. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric. When 90% collection particle diameter and lifetime were measured, as shown in Table 1, the lifetime was short. This is because the non-woven fabric A layer has a 10% pore diameter that is too large, and the particles flow out from the large pores where the flow resistance is partially low, causing the non-woven fabric B layer to be clogged. This was because the liquid flow resistance increased and the life was reached.
［実施例６、７および比較例３］
実施例６、７では、不織布Ａ層として、ナイロン６６繊維を水流交絡させた不織布を用いた。この不織布の目付、厚み、比重、繊維径、９０％開孔径、１０％開孔径、および空隙体積は表１のとおりである。不織布Ｂ層として、ナイロン６繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。
不織布Ａ層と不織布Ｂ層を積層してＡ層からＢ層に液が流れるように、９０％捕集粒径と寿命を測定した。結果は表１に示したとおり、９０％捕集粒径も寿命も良好であった。
[Examples 6 and 7 and Comparative Example 3]
In Examples 6 and 7, a nonwoven fabric in which nylon 66 fibers were hydroentangled was used as the nonwoven fabric A layer. Table 1 shows the basis weight, thickness, specific gravity, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. As the nonwoven fabric B layer, a melt blown nonwoven fabric made of nylon 6 fibers was used. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric.
The nonwoven fabric A layer and the nonwoven fabric B layer were laminated, and 90% collected particle size and life were measured so that the liquid flowed from the A layer to the B layer. As shown in Table 1, the 90% collection particle size and the lifetime were good.
一方、比較例３では、不織布Ａ層として、ナイロン６繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、９０％開孔径、１０％開孔径、および空隙体積は表１のとおりである。不織布Ｂ層には実施例１と同じものを使用した。結果は表１に示したとおり、寿命が短かった。これは不織布Ａ層の繊維径が小さく、繊維表面積が著しく大きくなり、粒子が通過する際の衝突の頻度が増え、衝突によりエネルギーを失う小粒径の粒子が繊維表面上で堆積し、緻密層を形成してしまい、通液抵抗が高くなってしまったためであった。 On the other hand, in Comparative Example 3, a melt blown nonwoven fabric made of nylon 6 fibers was used as the nonwoven fabric A layer. Table 1 shows the basis weight, thickness, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. The same thing as Example 1 was used for the nonwoven fabric B layer. As a result, as shown in Table 1, the lifetime was short. This is because the nonwoven fabric A layer has a small fiber diameter, the fiber surface area is remarkably increased, the frequency of collision when particles pass through, and particles with small particle diameters that lose energy due to collision accumulate on the fiber surface. This is because the liquid flow resistance became high.
［実施例８〜１１および比較例４］
実施例８〜１１では、不織布Ａ層として、ナイロン６６繊維を水流交絡させた不織布を用いた。この不織布の目付、厚み、比重、繊維径、９０％開孔径、１０％開孔径、および空隙体積は表１のとおりである。不織布Ｂ層として、ナイロン６繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。
[Examples 8 to 11 and Comparative Example 4]
In Examples 8 to 11, a nonwoven fabric in which nylon 66 fibers were hydroentangled was used as the nonwoven fabric A layer. Table 1 shows the basis weight, thickness, specific gravity, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. As the nonwoven fabric B layer, a melt blown nonwoven fabric made of nylon 6 fibers was used. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric.
不織布Ａ層と不織布Ｂ層を積層してＡ層からＢ層に液が流れるように、９０％捕集粒径と寿命を測定した。結果は表１に示したとおり、９０％捕集粒径も寿命も良好であった。
一、方比較例４では、不織布Ａ層として、実施例１と同じものを用いた。不織布Ｂ層にはナイロン６６繊維を水流交絡させた不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりだった。結果は表１に示したとおり、９０％捕集孔径が大きかった。これは不織布Ｂ層の繊維径が小さいことにより、繊維表面積が少ないため、粒子の衝突頻度が低くＢ層を通過する粒子が増加したためであった。
The nonwoven fabric A layer and the nonwoven fabric B layer were laminated, and 90% collected particle size and life were measured so that the liquid flowed from the A layer to the B layer. As shown in Table 1, the 90% collection particle size and the lifetime were good.
In one and comparative example 4, the same nonwoven fabric A layer as in Example 1 was used. The nonwoven fabric B layer was a nonwoven fabric in which nylon 66 fibers were hydroentangled. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric. As a result, as shown in Table 1, the 90% collection hole diameter was large. This is because the fiber surface area is small due to the small fiber diameter of the nonwoven fabric B layer, and therefore, the collision frequency of the particles is low and the number of particles passing through the B layer is increased.
［実施例１２および１３］
実施例１２および１３では、不織布Ａ層として、ナイロン６６繊維を水流交絡させた不織布を用いた。この不織布の目付、厚み、比重、繊維径、９０％開孔径、１０％開孔径、および空隙体積は表１のとおりである。不織布Ｂ層として、ナイロン６繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。不織布Ａ層と不織布Ｂ層を積層してＡ層からＢ層に液が流れるように、９０％捕集粒径と寿命を測定した。結果は表１に示したとおり、９０％捕集粒径も寿命も良好であった。
[Examples 12 and 13]
In Examples 12 and 13, a nonwoven fabric in which nylon 66 fibers were hydroentangled was used as the nonwoven fabric A layer. Table 1 shows the basis weight, thickness, specific gravity, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. As the nonwoven fabric B layer, a melt blown nonwoven fabric made of nylon 6 fibers was used. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric. The nonwoven fabric A layer and the nonwoven fabric B layer were laminated, and 90% collected particle size and life were measured so that the liquid flowed from the A layer to the B layer. As shown in Table 1, the 90% collection particle size and the lifetime were good.
［実施例１４］
不織布Ａ層にはポリエステル繊維を水流交絡させた不織布を用いた。この不織布の目付、厚み、比重、繊維径、９０％開孔径、１０％開孔径、および空隙体積は表２のとおりである。不織布Ｂ層として、ポリエステル繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表２のとおりである。結果は表２に示したとおり、９０％捕集粒径も寿命も良好であった。
[Example 14]
The nonwoven fabric A layer was a nonwoven fabric in which polyester fibers were hydroentangled. Table 2 shows the basis weight, thickness, specific gravity, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. As the nonwoven fabric B layer, a melt blown nonwoven fabric made of polyester fibers was used. Table 2 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric. As shown in Table 2, the 90% collection particle size and the lifetime were good.
［実施例１５］
不織布Ａ層には実施例１と同じものを使用した。不織布Ｂ層として、ポリプロピレン繊維からなるスパンボンド，メルトブロー，スパンボンドを積層後、エンボス加工により結合させた不織布を用いた。この不織布のメルトブロー部分の目付、厚み、および繊維径は表２のとおりである。９０％開孔径は、スパンボンド−メルトブロー−スパンボンド全体で測定した値を表２に記載した。結果は表２に示したとおり、９０％捕集粒径も寿命も良好であった。
[Example 15]
The same thing as Example 1 was used for the nonwoven fabric A layer. As the nonwoven fabric B layer, a nonwoven fabric obtained by laminating spunbond, meltblown, and spunbond made of polypropylene fibers and then bonding them by embossing was used. Table 2 shows the basis weight, thickness, and fiber diameter of the meltblown part of the nonwoven fabric. The 90% pore diameter is shown in Table 2 as measured by spunbond-meltblown-spunbond as a whole. As shown in Table 2, the 90% collection particle size and the lifetime were good.
［比較例５］
実施例１に記載の不織布Ｂ層のみで評価を行った。結果は表２に示したとおり、短時間で通液抵抗が増加した。
[Comparative Example 5]
Evaluation was carried out only with the nonwoven fabric B layer described in Example 1. As a result, as shown in Table 2, the flow resistance increased in a short time.
［比較例６］
実施例１に記載の不織布Ａ層のみで評価を行った。結果は表２に示したとおり、９０％捕集粒径が大きく、１０μｍ９０％捕集を達成できなかった。
[Comparative Example 6]
Evaluation was carried out only with the nonwoven fabric A layer described in Example 1. As shown in Table 2, the 90% collection particle size was large and 10 μm 90% collection could not be achieved.
［比較例７］
不織布Ａ層として、ナイロン６繊維からなるスパンボンドを用いた。この不織布の目付、厚み、比重、繊維径、９０％開孔径、１０％開孔径、および空隙体積は表２のとおりである。不織布Ｂ層として、ナイロン６繊維からなるメルトブロー不織布を用いた。この不織布の目付、厚み、繊維径、および９０％開孔径は表１のとおりである。不織布Ａ層の上流にナイロン製の押出メッシュ、不織布Ｂ層の下流に繊維径２４μｍのナイロン６繊維からなるスパンボンドを積層し、ポイントを熱圧着したフィルター材を作成した。結果は表２に示したとおり、１０μｍ９０％捕集が達成できなかった。これは不織布Ｂ層の繊維径が大きく、繊維表面積が少ないため、粒子の衝突頻度が低くＢ層を通過する粒子が増加したためであった。
[Comparative Example 7]
As the nonwoven fabric A layer, spunbond made of nylon 6 fiber was used. Table 2 shows the basis weight, thickness, specific gravity, fiber diameter, 90% pore diameter, 10% pore diameter, and void volume of this nonwoven fabric. As the nonwoven fabric B layer, a melt blown nonwoven fabric made of nylon 6 fibers was used. Table 1 shows the basis weight, thickness, fiber diameter, and 90% pore diameter of this nonwoven fabric. A filter material was prepared by laminating an extruded mesh made of nylon upstream of the nonwoven fabric A layer and a spunbond composed of nylon 6 fibers having a fiber diameter of 24 μm downstream of the nonwoven fabric B layer, and thermocompression bonding the points. As a result, as shown in Table 2, 10 μm 90% collection could not be achieved. This is because the nonwoven fabric B layer has a large fiber diameter and a small fiber surface area, and therefore, the collision frequency of the particles is low and the number of particles passing through the B layer is increased.
本発明のフィルター材を用いることによって、１０μｍ程度の粒子の捕集性能が良好で、かつ高寿命なフィルターを得ることができ、特に燃料タンク内で使用する液体燃料用フィルターとして好適に使用できる。 By using the filter material of the present invention, it is possible to obtain a filter having good collection performance of particles of about 10 μm and having a long life, and can be suitably used particularly as a liquid fuel filter used in a fuel tank.
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| US20080105626A1 (en) * | 2006-11-02 | 2008-05-08 | David Charles Jones | Fuel filter |
| JP2008274806A (en) * | 2007-04-26 | 2008-11-13 | Nifco Inc | Fuel filter device |
| JPWO2008153071A1 (en) * | 2007-06-15 | 2010-08-26 | 旭化成せんい株式会社 | Loop heat pipe type heat transfer device |
| JP5093069B2 (en) * | 2008-11-19 | 2012-12-05 | 株式会社デンソー | Fuel filter |
| JP5126321B2 (en) * | 2010-01-19 | 2013-01-23 | 株式会社デンソー | Fuel filter device |
| EP3689436A1 (en) | 2010-02-12 | 2020-08-05 | Donaldson Company, Inc. | Liquid filtration media |
| WO2013025445A2 (en) | 2011-08-12 | 2013-02-21 | Donaldson Company, Inc. | Liquid filtration media containing melt-blown fibers |
| JP6013302B2 (en) | 2013-10-04 | 2016-10-25 | 東京エレクトロン株式会社 | Bubble removal method, bubble removal apparatus, deaeration apparatus, and computer-readable recording medium |
| JP6832089B2 (en) * | 2016-07-27 | 2021-02-24 | 旭化成株式会社 | Filter material for automobile fuel |
| JP7047038B2 (en) * | 2020-09-30 | 2022-04-04 | 旭化成株式会社 | Filter material for automobile fuel |
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| JPS55163136U (en) * | 1979-05-11 | 1980-11-22 | ||
| JP3373877B2 (en) * | 1993-01-22 | 2003-02-04 | 日本バイリーン株式会社 | Nonwoven fabric having pore diameter gradient and method for producing the same |
| JP3578229B2 (en) * | 1995-01-11 | 2004-10-20 | 東洋紡績株式会社 | Fine particle filter media |
| JPH11216316A (en) * | 1998-01-30 | 1999-08-10 | Nippon Glass Fiber Co Ltd | Filter medium for liquid filter |
| JP2000218113A (en) * | 1999-01-29 | 2000-08-08 | Toyobo Co Ltd | Laminated nonwoven fabric for filter and filtration method using the same |
| JP2001321620A (en) * | 2000-05-17 | 2001-11-20 | Japan Vilene Co Ltd | Cylindrical filter |
| JP4152642B2 (en) * | 2002-02-19 | 2008-09-17 | 旭化成せんい株式会社 | Automotive fuel filter material and automotive fuel filter |
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