JP4627397B2 - Nonwoven fabric and extraction pack for filters - Google Patents
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- JP4627397B2 JP4627397B2 JP2003152548A JP2003152548A JP4627397B2 JP 4627397 B2 JP4627397 B2 JP 4627397B2 JP 2003152548 A JP2003152548 A JP 2003152548A JP 2003152548 A JP2003152548 A JP 2003152548A JP 4627397 B2 JP4627397 B2 JP 4627397B2
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Description
【０００１】
【発明の属する技術分野】
本発明はフィルター用不織布および抽出パックに関し、さらに詳しくはコーヒー粉末、紅茶、緑茶、烏龍茶等を袋に入れ、これを既存のコップに取り付けて熱湯を注ぐことにより、粉洩れがなく、簡便に成分の抽出をすることができるフイルター用不織布およびこれを用いた抽出パックに関する。
【０００２】
【従来の技術】
従来より、コーヒー粉末等をフィルターとしての袋状物に充填し、該袋状物を紙製などの簡易な固定具により既存のコップなどに固定し、熱湯を注ぎ、成分を抽出するドリップ方式による抽出方法が多く採用され、この袋状物には、紙や不織布等からなるフィルター材が用いられている。
しかし、紙製のフイルターでは、紙が緻密に構成されているため、コーヒー粉末の粉洩れが少なく、良好な抽出が行えるが、抽出成分中に紙成分が入りこみ、紙臭さが生じるという欠点があった。
一方、不織布製のフイルターでは、不織布の繊維間隙が比較的大きいため、粉洩れが生じ易いという欠点があった。そこで、近年では、繊維の細い極細繊維からなる不織布と繊維の太い合成繊維からなる不織布を積層し、熱エンボス加工により貼り合わせ加工を施した積層不織布が用いられている（例えば、特許文献１参照）。この積層不織布には、別々の工程で生産された不織布が用いられるため、極細繊維不織布や合成繊維不織布の繊度、目付、素材などを適宜選択ができる利点があるが、ハンドリング性などの点から使用する極細繊維不織布の目付けを１０ｇ／ｍ2 以上としなければならないため、積層不織布に占める極細繊維の割合が大きくなり、不織布に吸着される抽出成分が多くなり、抽出速度が遅く、かつコスト高になるなどの問題があった。また紅茶、緑茶、烏龍茶等の成分抽出を行う場合でも粉洩れが生じ易いなどの問題があった。
【０００３】
さらに、特許文献２には、スパンボンド繊維ウエブにメルトブロー法の極細繊維ウエブを積層した後、熱圧着する方法が記載されている。しかし、この方法は極細繊維ウエブがスパンボンド繊維ウエブの接着剤として働き、層間剥離の問題は生じないが、表面の毛羽立ち性や強力に劣るものであった。
【０００４】
【特許文献１】
特開２００２−１４２９９号公報
【特許文献２】
特公昭６０−１１１４８号公報
【０００５】
【発明が解決しようとする課題】
本発明の課題は、上記従来技術の問題点を解決し、極細繊維の構成比を小さく、かつ積層不織布の目付を低くした場合でも、耐水圧に優れ、粉漏れを防ぐことができ、さらに熱シール加工が可能なフィルター用不織布およびこれを用いた抽出パックを提供することにある。
【０００６】
【課題を解決するための手段】
本発明者らは、上記課題に鑑み、鋭意検討した結果、合成長繊維不織布と極細繊維不織布を同一ラインで積層させることにより、極細繊維の構成比率を小さくすることができ、かつ、積層する各不織布の繊維径を特定し、かつ積層不織布自体の部分熱圧着率、目付、平均みかけ密度および最大開口径を適切に選定することにより、粉洩れがなく、耐水圧などの特性を満足するフィルター用不織布が得られることを見出し、本発明に到達した。
すなわち、上記課題を達成するために本願で特許請求される発明は以下の通りである。
【０００７】
（１）平均繊維径が１〜６μｍであるポリオレフイン系極細繊維不織布（Ａ）と、該極細繊維不織布（Ａ）の上下に積層された、平均繊維径が１０〜３０μｍであるポリオレフイン系合成長繊維不織布（Ｂ）とを有し、かつ、前記極細繊維不織布（Ａ）と接する側の前記合成長繊維不織布（Ｂ）の少なくとも表面の繊維間隙を、該極細繊維不織布（Ａ）を構成する極細繊維が覆うように充填された積層不織布であって、該積層不織布は、前記（Ａ）と（Ｂ）の重量比（Ａ：Ｂ）が５：９５〜３０：７０であり、部分熱圧着率が３〜３５％、目付が１０〜５０ｇ／ｍ２ 、縦方向の引張強力が１５Ｎ／５ｃｍ以上であり、引張強力の縦／横比が１．０〜３．０、平均みかけ密度が０．０５〜０．４ｇ／ｃｍ３ 、およびＪＩＳ−Ｋ−３８３２によるバブルポイント法により測定される最大開口径が５０μｍ以下であることを特徴とするフイルター用不織布。
（２）前記極細繊維不織布（Ａ）が２層以上形成されていることを特徴とする（１）に記載のフイルター用不織布。
（３）前記積層不織布の耐水圧が１．０ｋＰａ以上であることを特徴とする（１）または（２）に記載のフイルター用不織布。
（４）（１）〜（３）のいずれかに記載のフイルター用不織布を袋状とし、該袋内に被抽出物を充填し、封入したことを特徴とする抽出パック。
（５）前記被抽出物が、コーヒー粉末、または紅茶、緑茶もしくは烏龍茶の葉であることを特徴とする（４）に記載の抽出パック。
【０００８】
【発明の実施の形態】
本発明のフィルター用不織布には、平均繊維径が１〜６μｍ、好ましくは２〜５μｍである極細繊維不織布（Ａ）と、該極細繊維不織布の上下に積層される２層の、平均繊維径が１０〜３０μｍ、好ましくは１２〜２５μｍである合成長繊維不織布（Ｂ）とを有する積層不織布が用いられる。
本発明に用いられる極細繊維不織布（Ａ）は、コーヒー粉末等の粉洩れをなくし、積層不織布の最大開口径および耐水圧を特定の範囲にする役割を有する。極細繊維の平均繊維径が１μｍ未満では粉洩れ性は良くなるが、繊維強度が低下し、極細繊維の生産性が低下する。一方、６μｍを超えると繊維強度は高くなり、生産性が良くなるが、極細繊維不織布（Ａ）の繊維間隙が大きくなり、粉洩れが生じ易くなる。
本発明に用いられる合成長繊維不織布（Ｂ）は、積層不織布の強度を確保する役割を有する。合成長繊維の平均繊維径が１０μｍ未満では、粉洩れ性は良くなるが、繊維強度が低下し、合成長繊維の生産性が低下する。一方、３０μｍを超えると、繊維強度は高くなり、生産性が良くなるが、繊維間隙が大きくなり、粉洩れ性が低下する。
【０００９】
本発明に用いられる積層不織布は、極細繊維不織布（Ａ）を構成する極細繊維と接する側の合成長維維不織布（Ｂ）の少なくとも表面の繊維開口部が、該極細繊維で被覆されていることが必要である。上記平均繊維径を有する２層の合成長繊維不織布（Ｂ）の間に上記平均繊維径を有する極細繊維不織布（Ａ）を介在させることにより、極細繊維と接する側の合成長繊維不織布（Ｂ）の繊維開口部（間隙）を極細繊維で覆い、充填させた状態とすることができる。このような構成とすることにより積層不織布の開口径分布を均一にすることができ、従って、最大開口径および耐水圧を特定の範囲にすることが容易となり、効率的にコーヒー粉末等の粉洩れをなくし、極細繊維不織布（Ａ）の使用量を少なくし、さらに目付を小さくすることが可能になる。また合成長繊維不織布（Ｂ）の繊維間隙部の極細繊維による充填度を調整することにより、フィルターの用途に応じた性能を容易に得ることが可能となる。
【００１０】
また積層不織布を構成する極細繊維不織布（Ａ）と合成長繊維不織布（Ｂ）の重量比（Ａ：Ｂ）は、５：９５〜３０：７０であることが必要であり、より好ましくは１０：９０〜２５：７５である。極細繊維不織布（Ａ）の割合が５％未満では、合成長繊維不織布（Ｂ）の繊維開口部を被覆するための繊維量が不足するため、積層不織布の最大開口径が大きくなり、粉洩れ生じ易くなり、耐水圧が不足する。極細繊維不織布（Ａ）の割合が３０重量％を超えると、抽出速度が遅くなり、コスト高となる。また合成長繊維の繊維間隙が大きすぎると極細繊維が繊維間隙に埋没し、または通過してしまうため、合成長繊維の平均繊維径および繊維量を上記の範囲とすることが重要である。
【００１１】
ポリオレフィン系極細繊維または合成長繊維としては、ポリエチレン、ポリプロピレン、共重合ポリプロピレンなど、また鞘がポリエチレン、ポリプロピレン、共重合ポリエステル、芯がポリプロピレン、ポリエステルなどの組み合わせからなる芯鞘構造等の複合繊維を用いることができる。
【００１２】
本発明における積層不織布は、公知のスパンボンド法およびメルトブロー法により一連の連続した工程で得ることができる。例えば、スパンボンド法による溶融紡糸方式で合成樹脂を溶融し、紡糸口金から紡糸、延伸してからコンベアネット上に開繊、捕集して合成長繊維ウエブを形成させ、その上にメルトブロー法により単層または２層以上からなる極細繊維ウエブを重ね、さらに上記スパンボンド法により合成繊長繊維ウエブを重ねて積層し、これらのウエブをエンボスロールと平滑ロール間を通させ、熱エンボス加工で部分熱圧着させることにより得られる。
【００１３】
上記工程において、合繊長繊維ウエブの上に極細繊維ウエブを複層形成させることが好ましい。例えば、１層目で極細繊維による合成長繊維ウエブの表面層のプレコートを行い、２層目以降で完全にコートする。この場合、１層目の目付と、２層目以降の目付をほぼ同程度にすることが好ましい。このような方法を採用することにより、低目付の極細繊維を均一に合成長繊維の繊維開口部に集中して効率的に薄く被覆状に極細繊維を充填させることができる。このように極細繊維と合成長繊維の積層構成を、太い繊維からなる合成長繊維の表面層を細い繊維の極細繊維で薄い膜状に被覆するように積層させることにより、広い範囲の開口径分布を、狭い範囲の小さい開口径分布とすることができる。積層不織布の開口径分布は、繊維量ではなく極細繊維径により決定される。
また得られる積層不織布の熱シール加工性を向上させるため、該積層不織布の融点と３０〜１５０℃程度の融点差を有する合成繊維不織布をさらに接合させてもよい。例えば、ポリオレフイン系繊維からなる積層不織布に、ポリエステル長繊維不織布を熱エンボス加工で接合した複合不織布としてもよい。
【００１４】
本発明における積層不織布の目付は、１０〜５０ｇ／ｍ2 、好ましくは１２〜３０ｇ／ｍ2 である。目付が１０ｇ／ｍ2 未満では繊維間隙が大きく、粉洩れし易くなる。一方、５０ｇ／ｍ2 を超えると粉洩れが少なくなるが、耐水圧が大きくなり、通液性が低下し、抽出時間が長くなる。
また積層不織布の平均みかけ密度は、０．０５〜０．４０ｇ／ｃｍ3 、好ましくは０．０８〜０．３５ｇ／ｃｍ3 である。みかけ密度が０．０５ｇ／ｃｍ3 未満では繊維間隙が大きくなり、粉洩れが多くなる。一方、０．４０ｇ／ｃｍ3 超えると繊維間隙が小さくなり、粉洩れが良くなるが、耐水圧が大きくなり、通液性が低下し、抽出時間が長くなる。
【００１５】
また積層不織布の部分熱圧着率は、３〜３５％、好ましくは５〜３０％である。凹凸の表面構造を有するエンボスロールと表面が平滑なフラットロールからなる一対の加熱ロール間を通過させる部分熱圧着により、不織布全体に均等に分散した圧着部を形成させることができるため、不織布を構成する繊維間隙を小さくし、粉洩れをなくすことができる。部分熱圧着率が３％未満では、圧着部分が少なく、強度が低く、粉洩れし易い。一方、３５％を超えると粉洩れが少なくなるが、通液性が低下する。ここで部分熱圧着率は、不織布全体に対する圧着部分の面積の割合を示す。
【００１６】
さらに積層不織布の最大開口径は、５０μｍ以下である。最大開口径が５０μｍ超えると構成繊維の間隙が大きくなり、粉洩れ量が多くなる。本発明において、最大開口径とは、後述するようにＪＩＳ−Ｋ−３８３２のバブルポイント法に準じて測定された値をいう。
さらに本発明の積層不織布は、不織布の強度および取扱性等の点から、縦方向の引張強力が１５Ｎ／５ｃｍ以上、より好ましくは２０Ｎ／５ｃｍ以上であり、引張強力の縦／横比が１．０〜３．０、より好ましくは１．２〜２．５、耐水圧が１．０ｋＰａ以上、より好ましくは１．５ｋＰａ以上であることが好ましい。
【００１７】
本発明のフィルター用不織布は、上記特性を有する積層不織布で構成されるが、この不織布をコーヒー粉末等の抽出用不織布して使用する場合に、熱湯を注いだ際の不織布の浮き上がりを防止するために親水処理を施すことが好ましい。
親水処理は、例えば、不織布に、親水剤の０．０５〜５．０重量％、好ましくは０．１〜３重量％水溶液を部分的にまたは全面に塗布して行うことができる。親水剤には、食品用として用いられる界面活性剤、例えば、ソルビタン脂肪酸エステル、ポリグリセリン脂肪酸エステル、ショ糖脂肪酸エステルなどが用いられ、これらの成分は、水溶液、エチルアルコール溶液またはエチルアルコールと水の混合溶液としてグラビアロール方式、キスロール方式、浸漬方式、スプレー方式などにより塗布することができる。
【００１８】
本発明のフイルター用不織布は、例えば、これを袋状とし、該袋内に被抽出物を充填し、公知の方法により封入した抽出パックとして好適に使用することができる。被抽出物としては、コーヒー粉末、紅茶、緑茶または烏龍茶の葉などが用いられる。本発明のフイルター用不織布を抽出パックの袋材として用いることにより、出粉洩れが殆どなく、抽出液中に粉等が漏れ出ることがないため、また適切な抽出速度で抽出することができるため、コーヒー等の抽出を簡便に容易に行うことができ、さらに抽出パックを安価に提供することができる。
【００１９】
【実施例】
以下、本発明を実施例により具体的に説明するが、本発明はこれらに限定されるものではない。なお、例中の特性は、下記の方法で測定した。
１）目付（ｇ／ｍ2 ）：ＪＩＳ−Ｌ−１９０６に準じ、縦２０ｃｍ×横２５ｃｍの試料を３カ所切り取り、重量を測定し、その平均値を単位当たりの質量に換算して求める。
２）平均繊維径（μｍ）：顕微鏡で５００倍の拡大写真を取り、１０本の平均値で求める。
３）平均みかけ密度（ｇ／ｃｍ3 ）：目付と荷重１０ｋＰａの厚みから単位容積当たりの重量を求め３個所の平均で求める。
４）耐水圧：ＪＩＳ−Ｌ−１９０６、低水圧法に準じて測定する。
【００２０】
５）最大開口径：ＪＩＳ−Ｋ−３８３２、バブルポイント法に準じ、下記のようにして測定する。
試料（直径４０ｍｍ円形）を液体に満たし、毛細管現象を用いて試料の全孔に液体が入っている状態にする。この試料の下面から次第に空気圧をかけていき、気体圧力が毛細管内の液体表面張力に打ち勝った時、気泡がでてくる。この時に最初に気泡がでるのは最大孔径からであり、そのときの気体圧力を測定し、最大孔径を算出する。
６）粉洩れ性：コーヒー粉末を２ｇ入れた積層不織布に、２０ｃｃの熱湯を注ぎ、抽出液中の粉の溜まり状態で判定する。
○…粉の溜まりがほとんどない。
△…粉が少しあるが飲んでも違和感がほとんどない。
×…粉が多くあり、口の中に固形分が入り、飲みにくい。
【００２１】
７）超音波シール強度：試料の幅５ｃｍ×長さ３０ｃｍを縦、横各々６枚切り取り、出力４０ＫＨｚの超音波シール機（ブラザーミシン製品）の幅１ｍｍ丸刃形状のヘッドホーンを用い、各々３カ所をシールさせて超音波シールする。ついで、シール強度を、引張試験機で、つかみ間隔１０ｃｍ、引張速度１０ｃｍ／ｍｉｎ、上下方向に取り付け、最高強度を測定し、平均値で示す。
８）引張強度：引張試験機を用い、幅５ｃｍ×長さ３０ｃｍ試料を切り取り、つかみ間隔１０ｃｍ、引張速度１０ｃｍ／ｍｉｎで測定し、５％中間応力、破断時の強度、破断時の伸度を縦、横方向、各々３点測定し、平均値で示す。
【００２２】
〔実施例１〜５および比較例１〜２〕（ポリプロピレン系積層不織布）
公知のスパンボンド法でポリプロピレン樹脂（ＭＦＲ３９）を用い、エクストルーダー、ギヤポンプ、紡糸口金を通じ、溶融紡糸、延伸、開繊、捕集工程で、繊維径、目付を変えて表１に示すそれぞれの合成長繊維ウエブを得た。
この合成長繊維ウエブ上に、メルトブロー方式でポリプロピレン樹脂（ＭＦＲ９０) を用いて表１に示す繊維径および目付を有する１層または２層の極細繊維ウエブを積層させた。この際には、合成長繊維の太い繊維間隙の表面層を、細い繊維の薄い膜状の極細繊維ウエブで被覆するようにし、細い繊維の薄い膜状の極細繊維が、破れず、かつ太い繊維間隙の裏面層に極細繊維がでないように圧力、吸引力などの積層条件を調節した。実施例１、２では極細繊維ウエブを２層目に、実施例３、４、５では極細繊維ウエブを２層目および３層目に形成した。また、比較例１、２では極細繊維ウエブは積層しなかった。
さらに極細繊維ウエブ上に上記と同様にして合成長繊維ウエブを積層した。次いでエンボスロールと平滑ロール間で、加熱（温度１５５℃）、加圧（５００Ｎ／ｃｍ）で熱圧着し、部分熱圧着加工して積層不織布を得た。得られた不織布または積層不織布の特性を調べ、その結果を表１に示した。
【００２３】
【表１】
表１から、本発明の積層不織布は、目付が小さいにもかからわず、最大開口径が小さく、耐粉漏れ性、耐水圧性に優れ、また不織布強度および超音波シール性に優れ、フィルター用不織布として好適であることわかった。これに対し、比較例１、２では最大開口径が大きく、粉漏れのし易いフィルター不織布であった。
【００２５】
〔実施例６〕（抽出パック）
実施例１で得られた積層不織布を袋状とし、コーヒー粉末を充填し、開口部を超音波シールして抽出パックを製造した。この抽出パックをカップに取り付けて熱湯を注ぎコーヒーの抽出を行ったが、抽出パックが湯圧で浮き上がるこもなく、粉漏れもなく、コーヒーの抽出を速やかにに行うことができた。
【００３２】
【発明の効果】
本願の請求項１〜５に記載のフイルター用不織布によれば、極細繊維の構成比が小さく、かつ積層不織布自体の目付が低いにもかかわらず、最大開口径を小さくして粉漏れを防ぐことができ、また優れた耐水圧を得ることができる。従って、このフイルター用不織布は、コーヒー粉末、紅茶、緑茶、烏龍茶などの葉を粉砕した粒子形状の被抽出物を入れる包装材として好適に使用することができる。また、被抽出物を充填した抽出パックに熱湯を注いでも、該パックの浮き上がりを防止して成分抽出を速やかに行うことができる。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a non-woven fabric for a filter and an extraction pack. More specifically, coffee powder, black tea, green tea, oolong tea, etc. are put in a bag, and this is attached to an existing cup and poured with hot water, so that there is no powder leakage and the ingredients It is related with the nonwoven fabric for filters which can perform extraction, and an extraction pack using the same.
[0002]
[Prior art]
Conventionally, coffee powder etc. are filled into a bag as a filter, the bag is fixed to an existing cup etc. with a simple fixture such as paper, hot water is poured, and the components are extracted Many extraction methods are employed, and a filter material made of paper, nonwoven fabric or the like is used for the bag-like material.
However, in paper filters, the paper is densely configured, so coffee powder is less leaked and good extraction can be performed, but the paper component gets into the extracted components and the paper odor is generated. there were.
On the other hand, a nonwoven fabric filter has a drawback that powder leakage is likely to occur because the fiber gap of the nonwoven fabric is relatively large. Therefore, in recent years, a laminated nonwoven fabric obtained by laminating a nonwoven fabric made of ultrafine fibers with fine fibers and a nonwoven fabric made of synthetic fibers with thick fibers and performing a bonding process by hot embossing is used (for example, see Patent Document 1). ). Because this laminated nonwoven fabric uses nonwoven fabrics produced in separate steps, there is an advantage that the fineness, basis weight, material, etc. of the ultrafine fiber nonwoven fabric or synthetic fiber nonwoven fabric can be selected as appropriate, but it is used from the viewpoint of handling properties, etc. Since the basis weight of the ultrafine fiber nonwoven fabric must be 10 g / m 2 or more, the proportion of the ultrafine fibers in the laminated nonwoven fabric increases, the extraction components adsorbed on the nonwoven fabric increase, the extraction speed is slow, and the cost is high. There were problems such as becoming. In addition, there is a problem that powder leakage is likely to occur even when extracting components such as black tea, green tea, and oolong tea.
[0003]
Further, Patent Document 2 describes a method in which a melt-blown ultrafine fiber web is laminated on a spunbond fiber web and then thermocompression bonded. However, in this method, the ultrafine fiber web acts as an adhesive for the spunbond fiber web, and the problem of delamination does not occur, but the surface fluffiness and strength are poor.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 2002-14299 [Patent Document 2]
Japanese Patent Publication No. 60-11148 [0005]
[Problems to be solved by the invention]
The object of the present invention is to solve the above-mentioned problems of the prior art, and even when the composition ratio of the ultrafine fibers is small and the basis weight of the laminated nonwoven fabric is low, it is excellent in water pressure resistance, can prevent powder leakage, and further It is providing the nonwoven fabric for filters which can be sealed, and an extraction pack using the same.
[0006]
[Means for Solving the Problems]
As a result of intensive studies in view of the above problems, the present inventors can reduce the component ratio of ultrafine fibers by laminating a synthetic long fiber nonwoven fabric and an ultrafine fiber nonwoven fabric in the same line, and each layer to be laminated. By specifying the fiber diameter of the nonwoven fabric and appropriately selecting the partial thermocompression bonding rate, basis weight, average apparent density, and maximum opening diameter of the laminated nonwoven fabric, there is no powder leakage and the filter satisfies the characteristics such as water pressure resistance. The present inventors have found that a non-woven fabric can be obtained and have reached the present invention.
That is, the invention claimed in the present application in order to achieve the above-described problems is as follows.
[0007]
(1) A polyolefin-based ultrafine fiber nonwoven fabric (A) having an average fiber diameter of 1 to 6 μm, and a polyolefin-based synthetic long fiber having an average fiber diameter of 10 to 30 μm, which are laminated above and below the ultrafine fiber nonwoven fabric (A) The ultrafine fiber that comprises the ultrafine fiber nonwoven fabric (A) with a fiber gap on at least the surface of the synthetic long fiber nonwoven fabric (B) on the side in contact with the ultrafine fiber nonwoven fabric (A) The laminated nonwoven fabric is filled so that the weight ratio (A: B) of (A) and (B) is 5:95 to 30:70, and the partial thermocompression bonding rate is 3 to 35%, basis weight is 10 to 50 g / m 2 , longitudinal tensile strength is 15 N / 5 cm or more, tensile strength aspect ratio is 1.0 to 3.0, average apparent density is 0.05 ~0.4g / cm 3, and to the JIS-K-3832 Filter nonwoven fabric for the maximum aperture diameter measured by bubble point method is characterized in that it is 50μm or less.
( 2 ) The nonwoven fabric for filters according to ( 1 ), wherein the ultrafine fiber nonwoven fabric (A) is formed in two or more layers.
(3) the resistance pressure of the laminated nonwoven fabric is characterized in that at least 1.0 kPa (1) or (2) filter for nonwoven fabric according to.
( 4 ) An extraction pack characterized in that the nonwoven fabric for filter according to any one of (1) to ( 3 ) is formed into a bag shape, and an extraction target is filled and enclosed in the bag.
( 5 ) The extraction pack according to ( 4 ), wherein the extract is a coffee powder, or a leaf of black tea, green tea, or oolong tea.
[0008]
DETAILED DESCRIPTION OF THE INVENTION
The nonwoven fabric for filters of the present invention has an average fiber diameter of 1 to 6 μm, preferably 2 to 5 μm, and an average fiber diameter of two layers laminated above and below the ultrafine fiber nonwoven fabric. A laminated nonwoven fabric having a synthetic long-fiber nonwoven fabric (B) of 10 to 30 μm, preferably 12 to 25 μm is used.
The ultrafine fiber nonwoven fabric (A) used in the present invention has a role of eliminating leakage of coffee powder or the like and setting the maximum opening diameter and water pressure resistance of the laminated nonwoven fabric to a specific range. When the average fiber diameter of the ultrafine fibers is less than 1 μm, the powder leakage is improved, but the fiber strength is lowered and the productivity of the ultrafine fibers is lowered. On the other hand, if it exceeds 6 μm, the fiber strength increases and the productivity is improved, but the fiber gap of the ultrafine fiber nonwoven fabric (A) becomes large, and powder leakage tends to occur.
The synthetic long fiber nonwoven fabric (B) used for this invention has a role which ensures the intensity | strength of a laminated nonwoven fabric. When the average fiber diameter of the combined fibers is less than 10 μm, the powder leakage is improved, but the fiber strength is lowered and the productivity of the synthetic long fiber is lowered. On the other hand, if it exceeds 30 μm, the fiber strength is increased and the productivity is improved, but the fiber gap is increased and the powder leakage is reduced.
[0009]
In the laminated nonwoven fabric used in the present invention, at least the surface fiber openings of the synthetic long-fiber nonwoven fabric (B) on the side in contact with the ultrafine fibers constituting the ultrafine fiber nonwoven fabric (A) are coated with the ultrafine fibers. is required. By interposing the ultrafine fiber nonwoven fabric (A) having the average fiber diameter between two layers of the synthetic long fiber nonwoven fabric (B) having the average fiber diameter, the synthetic long fiber nonwoven fabric (B) on the side in contact with the ultrafine fibers is interposed. These fiber openings (gap) can be covered and filled with ultrafine fibers. By adopting such a configuration, the opening diameter distribution of the laminated nonwoven fabric can be made uniform. Therefore, the maximum opening diameter and the water pressure resistance can be easily set within a specific range, and the coffee powder or the like can be efficiently leaked. This makes it possible to reduce the amount of the ultrafine fiber nonwoven fabric (A) used and further reduce the basis weight. Moreover, it becomes possible to easily obtain the performance according to the use of the filter by adjusting the filling degree of the fiber gap portion of the synthetic long-fiber nonwoven fabric (B) with the ultrafine fibers.
[0010]
The weight ratio (A: B) of the ultrafine fiber nonwoven fabric (A) and the synthetic long fiber nonwoven fabric (B) constituting the laminated nonwoven fabric needs to be 5:95 to 30:70, more preferably 10: 90-25: 75. If the proportion of the ultrafine fiber nonwoven fabric (A) is less than 5%, the amount of fibers for covering the fiber opening of the synthetic long fiber nonwoven fabric (B) is insufficient, so that the maximum opening diameter of the laminated nonwoven fabric increases and powder leakage occurs. It becomes easy and water pressure resistance is insufficient. When the proportion of the ultrafine fiber nonwoven fabric (A) exceeds 30% by weight, the extraction speed becomes slow and the cost increases. Further, if the fiber gap of the synthetic long fiber is too large, the ultrafine fibers are buried or passed through the fiber gap, so it is important that the average fiber diameter and the fiber amount of the synthetic long fiber are within the above ranges.
[0011]
As polyolefin-based ultrafine fibers or synthetic long fibers , polyethylene, polypropylene, copolymer polypropylene , etc., and composite fibers having a sheath-core structure in which the sheath is made of a combination of polyethylene, polypropylene, copolymerized polyester, the core is polypropylene, polyester, etc. are used. be able to.
[0012]
The laminated nonwoven fabric in the present invention can be obtained in a series of continuous steps by a known spunbond method and melt blow method. For example, a synthetic resin is melted by a melt spinning method by a spunbond method, spun from a spinneret, stretched, then opened on a conveyor net, collected to form a synthetic long fiber web, and then melt blown on it. Superfine fiber webs consisting of a single layer or two or more layers are stacked, and the synthetic filament fiber webs are stacked by the spunbond method, and these webs are passed between an embossing roll and a smooth roll. Obtained by thermocompression bonding.
[0013]
In the above step, it is preferable to form a multi-layered ultrafine fiber web on the synthetic long fiber web. For example, the surface layer of the synthetic long fiber web with ultrafine fibers is pre-coated in the first layer, and completely coated in the second and subsequent layers. In this case, it is preferable that the basis weight of the first layer is substantially the same as the basis weight of the second and subsequent layers. By adopting such a method, it is possible to concentrate the fine fibers with a low basis weight uniformly on the fiber openings of the synthetic long fibers and efficiently fill the fine fibers in a thin coating. In this way, the laminated structure of ultrafine fibers and synthetic long fibers is laminated so that the surface layer of synthetic long fibers made of thick fibers is covered with a thin film with ultrafine fibers of thin fibers, thereby providing a wide range of aperture diameter distributions. Can be a small aperture diameter distribution in a narrow range. The opening diameter distribution of the laminated nonwoven fabric is determined not by the fiber amount but by the ultrafine fiber diameter.
Moreover, in order to improve the heat seal processability of the laminated nonwoven fabric obtained, a synthetic fiber nonwoven fabric having a melting point difference of about 30 to 150 ° C. may be further joined to the melting point of the laminated nonwoven fabric. For example, it is good also as a composite nonwoven fabric which joined the polyester nonwoven fabric nonwoven fabric by hot embossing to the lamination nonwoven fabric which consists of polyolefin fiber.
[0014]
The basis weight of the laminated nonwoven fabric in the present invention is 10 to 50 g / m 2 , preferably 12 to 30 g / m 2 . If the basis weight is less than 10 g / m 2 , the fiber gap is large, and powder leakage tends to occur. On the other hand, if it exceeds 50 g / m 2 , powder leakage decreases, but the water pressure resistance increases, the liquid permeability decreases, and the extraction time increases.
The average apparent density of the laminated nonwoven fabric is 0.05 to 0.40 g / cm 3 , preferably 0.08 to 0.35 g / cm 3 . When the apparent density is less than 0.05 g / cm 3 , the fiber gap increases and powder leakage increases. On the other hand, when it exceeds 0.40 g / cm 3 , the fiber gap is reduced and powder leakage is improved, but the water pressure resistance is increased, the liquid permeability is lowered, and the extraction time is extended.
[0015]
The partial thermocompression bonding rate of the laminated nonwoven fabric is 3 to 35%, preferably 5 to 30%. A non-woven fabric can be formed by forming a pressure-bonded portion evenly distributed throughout the non-woven fabric by partial thermo-compression passing between a pair of heating rolls consisting of an embossing roll having an uneven surface structure and a flat roll having a smooth surface. The gap between the fibers can be reduced, and powder leakage can be eliminated. When the partial thermocompression bonding rate is less than 3%, there are few crimped portions, the strength is low, and powder leakage is likely. On the other hand, if it exceeds 35%, powder leakage decreases, but the liquid permeability decreases. Here, the partial thermocompression bonding rate indicates the ratio of the area of the crimping portion to the entire nonwoven fabric.
[0016]
Furthermore, the maximum opening diameter of the laminated nonwoven fabric is 50 μm or less. When the maximum opening diameter exceeds 50 μm, the gap between the constituent fibers increases and the amount of powder leakage increases. In the present invention, the maximum opening diameter means a value measured according to the bubble point method of JIS-K-3832, as will be described later.
Furthermore, the laminated nonwoven fabric of the present invention has a tensile strength in the longitudinal direction of 15 N / 5 cm or more, more preferably 20 N / 5 cm or more, and a tensile strength aspect ratio of 1. The pressure is preferably 0 to 3.0, more preferably 1.2 to 2.5, and the water pressure resistance is 1.0 kPa or more, and more preferably 1.5 kPa or more.
[0017]
The non-woven fabric for filter of the present invention is composed of a laminated non-woven fabric having the above-mentioned characteristics, but when this non-woven fabric is used as a non-woven fabric for extraction such as coffee powder, in order to prevent the non-woven fabric from floating when hot water is poured. It is preferable to apply a hydrophilic treatment to.
The hydrophilic treatment can be performed by, for example, applying a 0.05 to 5.0% by weight, preferably 0.1 to 3% by weight, aqueous solution of a hydrophilic agent partially or entirely to a nonwoven fabric. As the hydrophilic agent, surfactants used for foods, for example, sorbitan fatty acid ester, polyglycerin fatty acid ester, sucrose fatty acid ester and the like are used. These components can be used as an aqueous solution, an ethyl alcohol solution, or ethyl alcohol and water. The mixed solution can be applied by a gravure roll method, a kiss roll method, a dipping method, a spray method, or the like.
[0018]
The nonwoven fabric for filters of the present invention can be suitably used as an extraction pack, for example, in the form of a bag, filled with an extractable substance in the bag, and sealed by a known method. As the extract, coffee powder, black tea, green tea or oolong tea leaves are used. By using the nonwoven fabric for a filter of the present invention as a bag material for an extraction pack, there is almost no powder leakage and powder or the like does not leak into the extract, and the extraction can be performed at an appropriate extraction rate. In addition, coffee and the like can be extracted easily and easily, and an extraction pack can be provided at a low cost.
[0019]
【Example】
Hereinafter, the present invention will be specifically described by way of examples, but the present invention is not limited thereto. The characteristics in the examples were measured by the following methods.
1) Weight per unit area (g / m 2 ): According to JIS-L-1906, three samples of 20 cm long × 25 cm wide are cut out, weighed, and the average value is calculated by converting to mass per unit.
2) Average fiber diameter (μm): Take a 500 times magnified photograph with a microscope, and obtain the average value of 10 fibers.
3) Average apparent density (g / cm 3 ): The weight per unit volume is obtained from the basis weight and the thickness of the load of 10 kPa, and the average is obtained at three locations.
4) Water pressure resistance: Measured according to JIS-L-1906, low water pressure method.
[0020]
5) Maximum opening diameter: Measured as follows according to JIS-K-3832, bubble point method.
Fill the sample (circular with a diameter of 40 mm) with a liquid, and use capillary action to bring the liquid into all the holes of the sample. Air pressure is gradually applied from the lower surface of the sample, and bubbles appear when the gas pressure overcomes the liquid surface tension in the capillary tube. At this time, bubbles are first generated from the maximum pore diameter, and the gas pressure at that time is measured to calculate the maximum pore diameter.
6) Powder leakage: 20 cc of hot water is poured into a laminated nonwoven fabric containing 2 g of coffee powder, and the state is determined by the state of the powder in the extract.
○… There is almost no accumulation of powder.
Δ: There is a little powder, but there is almost no sense of incongruity when drinking.
×… There are a lot of powders, solids in the mouth, and difficult to drink.
[0021]
7) Ultrasonic seal strength: 6 cm each of 5 cm wide x 30 cm long samples were cut out vertically and horizontally, and 3 mm each using a 1 mm wide round blade shaped headphone of an ultrasonic sealing machine (brother sewing machine product) with an output of 40 KHz. Seal the place and ultrasonically seal. Next, the seal strength is measured with a tensile tester at a grip interval of 10 cm, a tensile speed of 10 cm / min, in the vertical direction, the maximum strength is measured, and the average value is shown.
8) Tensile strength: Using a tensile tester, cut a sample 5 cm wide x 30 cm long, measure it with a grip interval of 10 cm and a tensile speed of 10 cm / min, and determine the 5% intermediate stress, strength at break, and elongation at break. Three points are measured in the vertical and horizontal directions, and the average value is shown.
[0022]
[Examples 1 to 5 and Comparative Examples 1 and 2] (polypropylene-based laminated nonwoven fabric)
Using a polypropylene resin (MFR39) by a known spunbond method, the fiber diameter and basis weight are changed in the melt spinning, drawing, fiber opening, and collection steps through an extruder, gear pump, and spinneret. A grown fiber web was obtained.
On this synthetic long fiber web, a one-layer or two-layer ultrafine fiber web having the fiber diameter and basis weight shown in Table 1 was laminated using a polypropylene resin (MFR90) by a melt blow method. In this case, the surface layer of the thick fiber gap of the synthetic long fiber is covered with a thin membrane-like ultrafine fiber web of thin fibers, and the thin membrane-like ultrafine fibers of the thin fibers are not broken and are thick fibers. Lamination conditions such as pressure and suction force were adjusted so that there were no ultrafine fibers on the back layer of the gap. In Examples 1 and 2, the ultrafine fiber web was formed in the second layer, and in Examples 3, 4 and 5, the ultrafine fiber web was formed in the second and third layers. In Comparative Examples 1 and 2, the ultrafine fiber web was not laminated.
Further, a synthetic long fiber web was laminated on the ultrafine fiber web in the same manner as described above. Subsequently, between the embossing roll and the smooth roll, thermocompression bonding was performed by heating (temperature 155 ° C.) and pressure (500 N / cm), and partial thermocompression processing was performed to obtain a laminated nonwoven fabric. The properties of the obtained nonwoven fabric or laminated nonwoven fabric were examined, and the results are shown in Table 1.
[0023]
[Table 1]
From Table 1, the laminated nonwoven fabric of the present invention has a small maximum opening diameter, a small maximum opening diameter, excellent powder leakage resistance and water pressure resistance, excellent nonwoven fabric strength and ultrasonic sealability, and for filters. It turned out that it is suitable as a nonwoven fabric. On the other hand, Comparative Examples 1 and 2 were filter nonwoven fabrics having a large maximum opening diameter and easily leaking powder.
[0025]
[Example 6] (Extraction pack)
The laminated nonwoven fabric obtained in Example 1 was made into a bag shape, filled with coffee powder, and the opening was ultrasonically sealed to produce an extraction pack. The extraction pack was attached to a cup and hot water was poured to extract coffee. However, the extraction pack did not float due to the hot water pressure, and there was no powder leakage, and the coffee could be extracted quickly.
[0032]
【The invention's effect】
According to the nonwoven fabric for a filter according to claims 1 to 5 of the present application, the maximum opening diameter is reduced to prevent powder leakage even though the composition ratio of the ultrafine fibers is small and the basis weight of the laminated nonwoven fabric itself is low. In addition, excellent water pressure resistance can be obtained. Therefore, this nonwoven fabric for filters can be suitably used as a packaging material for containing an extract in the form of particles obtained by pulverizing leaves such as coffee powder, black tea, green tea, and oolong tea. Moreover, even if hot water is poured into an extraction pack filled with an extractable substance, the pack can be prevented from lifting and component extraction can be performed quickly.
Claims (5)
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| JP5741493B2 (en) * | 2011-03-10 | 2015-07-01 | 三菱レイヨン株式会社 | Filter material for purifying acrylonitrile-based polymer solution, method for producing acrylonitrile-based polymer solution using the filter material, etc. |
| JP2014084548A (en) * | 2012-10-26 | 2014-05-12 | Teijin Ltd | Nonwoven fabric and method for producing the same |
| JP6114022B2 (en) * | 2012-12-13 | 2017-04-12 | ユニチカ株式会社 | Laminated nonwoven fabric |
| JP7147329B2 (en) * | 2018-02-28 | 2022-10-05 | 東レ株式会社 | Laminated nonwoven fabric and filter material |
| JP7395949B2 (en) * | 2019-10-21 | 2023-12-12 | 東洋紡エムシー株式会社 | Laminated filter media |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2616851B2 (en) * | 1991-06-09 | 1997-06-04 | 株式会社ユニカフェ | Coffee bags and coffee filters |
| JPH08150079A (en) * | 1994-11-30 | 1996-06-11 | Asahi Chem Ind Co Ltd | Bag filter |
| JPH11107153A (en) * | 1997-09-30 | 1999-04-20 | Unitika Ltd | Packaging material comprising conjugate filament nonwoven fabric |
| JP3674486B2 (en) * | 2000-09-27 | 2005-07-20 | 大紀商事株式会社 | Coffee filter for drip |
| JP4081974B2 (en) * | 2000-11-16 | 2008-04-30 | 大紀商事株式会社 | Beverage extraction filter for microwave oven |
| JP4368066B2 (en) * | 2001-02-21 | 2009-11-18 | 旭化成せんい株式会社 | Extraction filter with steaming function |
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2003
- 2003-05-29 JP JP2003152548A patent/JP4627397B2/en not_active Expired - Fee Related
Cited By (2)
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|---|---|---|---|---|
| CN103946435A (en) * | 2011-11-28 | 2014-07-23 | 东丽株式会社 | Mixed fiber non-woven fabric and filter element using same |
| CN103946435B (en) * | 2011-11-28 | 2016-11-09 | 东丽株式会社 | Mixed fine non-weaving cloth and its filter material of use |
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| JP2004154760A (en) | 2004-06-03 |
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