JP2011178970A - Method of manufacturing polytetrafluoroethylene porous film and air-permeable member - Google Patents

Method of manufacturing polytetrafluoroethylene porous film and air-permeable member Download PDF

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JP2011178970A
JP2011178970A JP2010047328A JP2010047328A JP2011178970A JP 2011178970 A JP2011178970 A JP 2011178970A JP 2010047328 A JP2010047328 A JP 2010047328A JP 2010047328 A JP2010047328 A JP 2010047328A JP 2011178970 A JP2011178970 A JP 2011178970A
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ptfe
sheet
stretching
porous membrane
polytetrafluoroethylene
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Seiji Ayusawa
誠治 鮎澤
Shunichi Shimatani
俊一 島谷
Yoji Uchida
陽二 内田
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Nitto Denko Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a PTFE porous film for manufacturing the polytetrafluoroethylene (PTFE) porous film capable of satisfying both of air flow quantity and strength on high level. <P>SOLUTION: A non-calcinated PTFE sheet is extended in a predetermined direction at a temperature under a melting point of the PTFE, and the extended sheet is heat-treated at a temperature equal to or above the melting point, then the sheet after the heat treatment is further extended to a direction orthogonal to the predetermined direction. The PTFE porous film obtained by the method has a high air flow quantity and strength. The PTFE porous film is suitable for an application as an air-permeable member which is fixed at an opening part of the housing and assures the air permeability of the housing while preventing the inversion of a foreign substance to the inside of the housing. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

本発明は、ポリテトラフルオロエチレン多孔質膜の製造方法に関する。また、本発明は、当該製造方法により得たポリテトラフルオロエチレン多孔質膜を備える通気部材に関する。   The present invention relates to a method for producing a polytetrafluoroethylene porous membrane. Moreover, this invention relates to a ventilation member provided with the polytetrafluoroethylene porous membrane obtained by the said manufacturing method.

ランプ、圧力センサー、ECU(Electrical Control Unit)などの車両用電装部品ならびに携帯電話、カメラなどの電気製品の筐体に、筐体内外の通気を確保するとともに、筐体内部への水および塵芥などの異物の侵入を防ぐ通気部材が取り付けられている。このような通気部材は、気体を透過させるが異物を透過させない通気膜により実現される。通気膜には、ポリテトラフルオロエチレン(PTFE)多孔質膜が好適である。   Ensures ventilation inside and outside the housing of electrical components for vehicles such as lamps, pressure sensors, ECUs (Electrical Control Units), and electrical products such as mobile phones and cameras, as well as water and dust inside the housing. A ventilation member for preventing intrusion of foreign matter is attached. Such a ventilation member is realized by a gas permeable membrane that allows gas to pass therethrough but does not allow foreign matter to pass therethrough. As the gas permeable membrane, a polytetrafluoroethylene (PTFE) porous membrane is suitable.

PTFE多孔質膜の製造方法として、未焼成のPTFEシートを逐次二軸延伸する方法が広く採用されている。この方法により得られたPTFE多孔質膜は、延伸により生じた無数のPTFEフィブリルと当該フィブリル間の空隙とからなる多孔質構造を有する。   As a method for producing a PTFE porous membrane, a method of sequentially biaxially stretching an unfired PTFE sheet is widely adopted. The PTFE porous membrane obtained by this method has a porous structure composed of innumerable PTFE fibrils generated by stretching and voids between the fibrils.

逐次二軸延伸によりPTFE多孔質膜を得る具体的な方法として、特開平7-196831号公報には、未焼成のPTFEシートをPTFEの融点未満の温度にて逐次二軸延伸した後、PTFEの融点以上の温度で熱処理する方法が開示されている。特開2007-260547号公報には、未焼成のPTFEシートに対して、逐次二軸延伸の一段目の延伸をPTFEの融点以上の温度にて行い、次いで、二段目の延伸をPTFEの融点未満の温度にて、一段目の延伸とは異なる方向に行った後、PTFEの融点以上の温度で熱処理する方法(焼成延伸法)が開示されている。特表平11-515036号公報には、未焼成のPTFEシートに対して、逐次二軸延伸の一段目の延伸をPTFEの融点未満の温度にて行い、次いでPTFEの融点以上の温度で熱処理した後、二段目の延伸をPTFEの融点以上の温度にて行う方法が開示されている。   As a specific method for obtaining a PTFE porous membrane by sequential biaxial stretching, Japanese Patent Laid-Open No. 7-196831 discloses that after unsintered PTFE sheet is sequentially biaxially stretched at a temperature below the melting point of PTFE, A method of heat treatment at a temperature above the melting point is disclosed. In JP-A-2007-260547, the first step of sequential biaxial stretching is performed on an unfired PTFE sheet at a temperature equal to or higher than the melting point of PTFE, and then the second step of stretching is performed on the melting point of PTFE. A method (baking stretching method) is disclosed in which a heat treatment is performed at a temperature lower than the melting point of PTFE after performing in a direction different from the first-stage stretching at a temperature lower than that. In Japanese National Publication No. 11-515036, the unsintered PTFE sheet is subjected to successive biaxial stretching at the first stage at a temperature lower than the melting point of PTFE, and then heat-treated at a temperature higher than the melting point of PTFE. Thereafter, a method is disclosed in which the second-stage stretching is performed at a temperature equal to or higher than the melting point of PTFE.

特開平7-196831号公報Japanese Laid-Open Patent Publication No.7-196831 特開2007-260547号公報JP 2007-260547 特表平11-515036号公報Japanese National Patent Publication No. 11-515036

特開平7-196831号公報および特表平11-515036号公報に開示の方法では、逐次二軸延伸における各延伸の倍率を高く設定することで、通気量が大きいPTFE多孔質膜が得られる一方、得られたPTFE多孔質膜における強度が低下する。焼成延伸法では、高強度のPTFE多孔質膜が得られる一方で、通気量が大きいPTFE多孔質膜を得ることが難しい。   In the methods disclosed in Japanese Patent Application Laid-Open Nos. 7-196831 and 11-515036, a PTFE porous membrane having a large air permeability can be obtained by setting a high ratio of each stretching in sequential biaxial stretching. The strength of the obtained PTFE porous membrane is reduced. In the firing stretching method, a high-strength PTFE porous membrane can be obtained, but it is difficult to obtain a PTFE porous membrane having a large air flow rate.

本発明は、高通気量および高強度を両立させたPTFE多孔質膜を製造できるPTFE多孔質膜の製造方法の提供を目的とする。   An object of this invention is to provide the manufacturing method of the PTFE porous membrane which can manufacture the PTFE porous membrane which made high air flow rate and high intensity | strength compatible.

本発明のPTFE多孔質膜の製造方法は、未焼成のPTFEシートを、PTFEの融点未満の温度において所定の方向へ延伸し(延伸A)、前記延伸したシートを、前記融点以上の温度で熱処理した後、前記熱処理後のシートを、前記融点未満の温度において、前記所定の方向に対して直交する方向にさらに延伸する(延伸B)方法である。   In the method for producing a porous PTFE membrane of the present invention, an unsintered PTFE sheet is stretched in a predetermined direction at a temperature lower than the melting point of PTFE (stretching A), and the stretched sheet is heat treated at a temperature equal to or higher than the melting point. Then, the sheet after the heat treatment is further stretched in a direction orthogonal to the predetermined direction at a temperature lower than the melting point (stretching B).

本発明の通気部材は、筐体の開口部に固定された状態で、前記開口部を通過する気体が透過する通気膜と、前記通気膜を支持する支持体と、を備える。前記通気膜は、本発明のPTFE多孔質膜の製造方法により得たPTFE多孔質膜を有する。   The ventilation member of the present invention includes a ventilation film that allows gas passing through the opening to pass through and a support that supports the ventilation film in a state of being fixed to the opening of the housing. The gas permeable membrane has a PTFE porous membrane obtained by the method for producing a PTFE porous membrane of the present invention.

本発明のPTFE多孔質膜の製造方法によれば、高通気量および高強度を両立させたPTFE多孔質膜が得られる。   According to the method for producing a porous PTFE membrane of the present invention, a porous PTFE membrane having both high air permeability and high strength can be obtained.

このような特性を有するPTFE多孔質膜は、通気部材の通気膜としての用途に好適である。当該PTFE多孔質膜を有する通気膜を備える本発明の通気部材は、筐体の開口部への取り付けによって、筐体内外の高い通気性を実現するとともに、筐体内部への水および塵芥などの異物の侵入をより確実に抑制する。   A PTFE porous membrane having such characteristics is suitable for use as a ventilation membrane of a ventilation member. The ventilation member of the present invention including the ventilation membrane having the porous PTFE membrane realizes high air permeability inside and outside the housing by attaching to the opening of the housing, and also provides water and dust to the inside of the housing. More reliably suppress the entry of foreign matter.

本発明の通気部材の一例を模式的に示す断面図である。It is sectional drawing which shows an example of the ventilation member of this invention typically. 実施例において実施した、PTFE多孔質膜の厚さ方向の強度を評価する方法を説明するための模式図である。It is a schematic diagram for demonstrating the method of evaluating the intensity | strength of the thickness direction of the PTFE porous membrane implemented in the Example.

[延伸A]
延伸Aでは、未焼成のPTFEシートを、PTFEの融点未満の温度において延伸する。未焼成のPTFEシートに対するこのような延伸が可能である限り、延伸Aの具体的な手法は特に限定されない。例えば、PTFEの融点未満の温度に保持した加熱炉を用いて、未焼成のPTFEシートを延伸すればよい(ゾーン延伸法)。ゾーン延伸法では、PTFEシートが加熱炉内に位置する時間を適切に設定することで、PTFEシートを上記融点未満の温度において延伸できる。延伸Aは、PTFEの融点未満の温度に加熱した加熱ロールを用いた熱ロール法により行ってもよい。
[Extension A]
In stretching A, an unsintered PTFE sheet is stretched at a temperature below the melting point of PTFE. As long as such stretching of the unfired PTFE sheet is possible, the specific method of stretching A is not particularly limited. For example, an unfired PTFE sheet may be stretched using a heating furnace maintained at a temperature lower than the melting point of PTFE (zone stretching method). In the zone stretching method, the PTFE sheet can be stretched at a temperature lower than the melting point by appropriately setting the time during which the PTFE sheet is positioned in the heating furnace. Stretching A may be performed by a hot roll method using a heated roll heated to a temperature lower than the melting point of PTFE.

延伸Aの延伸方向(上記所定の方向)は、PTFEシートの面内におけるいずれかの方向であり、具体的な方向は特に限定されないが、未焼成のPTFEシートが押出工程および/または圧延工程を経て得たシートである場合、例えば、当該各工程におけるMD方向(Machine Direction:押出方向、圧延方向)である。未焼成のPTFEシートが帯状である場合、例えば、その長手方向である。   The drawing direction of the drawing A (predetermined direction) is any direction in the plane of the PTFE sheet, and the specific direction is not particularly limited, but the unfired PTFE sheet is subjected to an extrusion process and / or a rolling process. In the case of the sheet obtained through the process, for example, it is the MD direction (Machine Direction: extrusion direction, rolling direction) in each step. When the unsintered PTFE sheet has a strip shape, for example, it is the longitudinal direction thereof.

延伸Aの延伸温度は、340℃未満であり、好ましくは327℃未満である。延伸温度の下限は、例えば150℃であり、これ以下ではPTFE多孔質膜自体を得ることが難しくなる。延伸Aの延伸温度がPTFEの融点以上になると、延伸B後に最終的に得られたPTFE多孔質膜の強度が低下する。延伸Aの延伸温度は、150℃以上327℃未満が好ましい。   The stretching temperature of stretching A is less than 340 ° C, preferably less than 327 ° C. The lower limit of the stretching temperature is, for example, 150 ° C., and below this, it becomes difficult to obtain the PTFE porous membrane itself. When the stretching temperature of the stretching A is equal to or higher than the melting point of PTFE, the strength of the PTFE porous membrane finally obtained after the stretching B is lowered. The stretching temperature of the stretching A is preferably 150 ° C. or higher and lower than 327 ° C.

延伸Aの延伸倍率の上限は、40倍以下が好ましく、20倍以下がより好ましい。延伸倍率の下限は、例えば1.2倍であり、2倍以上が好ましい。延伸Aの延伸倍率は、2〜40倍が好ましい。延伸Aの延伸倍率が過度に大きいと、延伸B後に最終的に得られたPTFE多孔質膜の強度が低下する。   The upper limit of the draw ratio of the stretch A is preferably 40 times or less, and more preferably 20 times or less. The lower limit of the draw ratio is, for example, 1.2 times, and preferably 2 times or more. The stretch ratio of the stretch A is preferably 2 to 40 times. When the stretch ratio of the stretch A is excessively large, the strength of the PTFE porous membrane finally obtained after the stretch B is lowered.

延伸Aでは、未焼成のPTFEシートにおいて、その延伸の方向に伸びるフィブリルが形成されるとともに、PTFEが部分的に凝集したノードが形成されると考えられる。   In the stretching A, it is considered that in the unfired PTFE sheet, fibrils extending in the stretching direction are formed and nodes in which PTFE is partially aggregated are formed.

[熱処理]
本発明の製造方法では、延伸A後のPTFEシートを、PTFEの融点以上の温度に加熱して熱処理する。熱処理の具体的な手法は特に限定されず、例えば、PTFEの融点以上の温度に保持した加熱炉に、延伸A後のPTFEシートを収容すればよい。当該PTFEシートが加熱炉に収容される時間を適切に設定することにより(通常5秒以上、好ましくは10秒以上200秒以下)、当該PTFEシートをPTFEの融点以上の温度で熱処理できる。PTFEの融点以上の温度に加熱した加熱ロールを用いて、熱処理を行ってもよい。
[Heat treatment]
In the production method of the present invention, the PTFE sheet after stretching A is heated to a temperature equal to or higher than the melting point of PTFE. The specific method of the heat treatment is not particularly limited, and for example, the PTFE sheet after stretching A may be accommodated in a heating furnace maintained at a temperature equal to or higher than the melting point of PTFE. By appropriately setting the time during which the PTFE sheet is accommodated in the heating furnace (usually 5 seconds or more, preferably 10 seconds or more and 200 seconds or less), the PTFE sheet can be heat-treated at a temperature equal to or higher than the melting point of PTFE. You may heat-process using the heating roll heated to the temperature more than melting | fusing point of PTFE.

熱処理温度は、340℃以上であり、350℃以上400℃以下が好ましい。   The heat treatment temperature is 340 ° C. or higher, and preferably 350 ° C. or higher and 400 ° C. or lower.

熱処理は、延伸Aに続いて連続的に行ってもよい。   The heat treatment may be performed continuously following the stretching A.

熱処理では、PTFEシートにおけるフィブリルの統合が進行すると考えられる。これにより、延伸Aにより形成されたPTFEフィブリルの径が太くなって、最終的に高強度のPTFE多孔質膜が得られることになる。   In the heat treatment, it is considered that the integration of fibrils in the PTFE sheet proceeds. Thereby, the diameter of the PTFE fibril formed by the stretching A is increased, and a high-strength porous PTFE membrane is finally obtained.

なお、必要に応じて、延伸A後のPTFEシートを熱処理しながら、延伸Aと同一の方向(上記所定の方向)にさらに延伸してもよい。この熱処理に伴う延伸の延伸倍率は、最大でも2倍以下とする。   If necessary, the PTFE sheet after stretching A may be further stretched in the same direction as the stretching A (predetermined direction) while heat-treating. The draw ratio of the draw accompanying this heat treatment is at most 2 times.

[延伸B]
本発明の製造方法では、熱処理後のPTFEシートを、PTFEの融点未満の温度において、延伸Aの方向に対して直交する方向にさらに延伸する。熱処理後のPTFEシートに対するこのような延伸が可能である限り、延伸Bの具体的な手法は特に限定されず、例えば、延伸Aにおいて説明したゾーン延伸法を適用できる。
[Stretching B]
In the production method of the present invention, the PTFE sheet after heat treatment is further stretched in a direction orthogonal to the direction of stretch A at a temperature lower than the melting point of PTFE. As long as such stretching of the PTFE sheet after heat treatment is possible, the specific method of stretching B is not particularly limited. For example, the zone stretching method described in stretching A can be applied.

延伸Bの延伸方向は、PTFEシートの面内方向であって、延伸Aの方向と直交する方向である限り特に限定されない。延伸Aを行う前の未焼成のPTFEシートが押出工程および/または圧延工程を経て得たシートである場合、例えば、当該各工程におけるTD方向(Transverse Direction)である。延伸A前の未焼成のPTFEシートが帯状である場合、例えば、その幅方向である。帯状のシートをその幅方向に延伸するためには、例えば、テンター法を用いればよい。シートが矩形状である場合、二軸延伸機を使用することもできる。   The stretching direction of stretching B is not particularly limited as long as it is an in-plane direction of the PTFE sheet and is a direction orthogonal to the direction of stretching A. When the unsintered PTFE sheet before the stretching A is a sheet obtained through an extrusion process and / or a rolling process, for example, it is a TD direction (Transverse Direction) in each process. When the unsintered PTFE sheet before stretching A has a strip shape, for example, the width direction. In order to stretch the belt-like sheet in the width direction, for example, a tenter method may be used. If the sheet is rectangular, a biaxial stretching machine can be used.

本発明の製造方法では、延伸Aを行う前の未焼成のPTFEシートが帯状であり、延伸Aの方向(所定の方向)が当該帯状のシートの長手方向であり、延伸Bの方向(所定の方向に直交する方向)が当該帯状のシートの幅方向であってもよい。   In the production method of the present invention, the unsintered PTFE sheet before stretching A is in a strip shape, the direction of stretching A (predetermined direction) is the longitudinal direction of the strip-shaped sheet, and the direction of stretching B (predetermined The direction perpendicular to the direction) may be the width direction of the belt-like sheet.

延伸Bの延伸温度は、340℃未満であり、好ましくは327℃未満である。延伸温度の下限は、例えば50℃であり、これ以下では、熱処理により統合したフィブリル間の間隔を増大させて高通気量のPTFE多孔質膜を得ることが難しくなる。延伸Bの延伸温度がPTFEの融点以上になると、得られたPTFE多孔質膜の強度が低下する。延伸Bの延伸温度は、50℃以上327℃未満が好ましい。   The stretching temperature of stretching B is less than 340 ° C, preferably less than 327 ° C. The lower limit of the stretching temperature is, for example, 50 ° C. Below this, it is difficult to obtain a PTFE porous membrane having a high air flow rate by increasing the interval between the integrated fibrils by heat treatment. When the stretching temperature of the stretching B is equal to or higher than the melting point of PTFE, the strength of the obtained PTFE porous membrane is lowered. The stretching temperature of stretching B is preferably 50 ° C. or higher and lower than 327 ° C.

延伸Bの延伸倍率の上限は、40倍以下が好ましく、10倍以下がより好ましい。延伸倍率の下限は、例えば1.2倍であり、2倍以上が好ましい。延伸Bの延伸倍率は、2〜40倍が好ましく、2〜10倍がより好ましく、2〜6倍がさらに好ましい。延伸Bの延伸倍率が過度に大きいと、膜が破断することがある。延伸Bの延伸倍率が過度に小さいと、最終的に得られたPTFE多孔質膜の強度が低下する。   The upper limit of the draw ratio of the stretch B is preferably 40 times or less, and more preferably 10 times or less. The lower limit of the draw ratio is, for example, 1.2 times, and preferably 2 times or more. The draw ratio of the stretch B is preferably 2 to 40 times, more preferably 2 to 10 times, and even more preferably 2 to 6 times. If the stretch ratio of stretch B is excessively large, the film may break. If the stretch ratio of stretch B is excessively small, the strength of the finally obtained PTFE porous membrane is lowered.

即ち、本発明の製造方法では、延伸Aの(所定の方向への)延伸倍率が2倍以上40倍以下であり、延伸Bの(所定の方向とは直交する方向への)延伸倍率が2倍以上40倍以下であることが好ましい。   That is, in the production method of the present invention, the stretch ratio of the stretch A (in a predetermined direction) is 2 to 40 times, and the stretch ratio of the stretch B (in a direction orthogonal to the predetermined direction) is 2. It is preferable that they are 2 times or more and 40 times or less.

延伸Bは、熱処理に続いて連続的に行ってもよい。   Stretching B may be performed continuously following the heat treatment.

延伸Bでは、熱処理後のPTFEシートにおいて、熱処理により統合したフィブリル間の間隔が増大して、シートの強度が確保されたまま、その通気性が向上する。   In the stretch B, in the PTFE sheet after the heat treatment, the interval between the fibrils integrated by the heat treatment is increased, and the air permeability is improved while the strength of the sheet is ensured.

[未焼成のPTFEシート]
本発明の製造方法に用いる未焼成のPTFEシートの形成方法は特に限定されない。例えば、PTFE微粉末(ファインパウダー)と液状潤滑剤との混合物を、押出および圧延から選ばれる少なくとも1つの方法によりシートに成形すればよい。
[Unfired PTFE sheet]
The method for forming the unfired PTFE sheet used in the production method of the present invention is not particularly limited. For example, a mixture of PTFE fine powder (fine powder) and a liquid lubricant may be formed into a sheet by at least one method selected from extrusion and rolling.

PTFE微粉末の種類は特に限定されず、市販の製品を用いることができる。市販のPTFE微粉末は、例えば、ポリフロンF−104(ダイキン工業製)、フルオンCD−123(旭・ICIフロロポリマーズ社製)、テフロン6J(三井・デュポンフロロケミカル社製)である。   The kind of PTFE fine powder is not particularly limited, and a commercially available product can be used. Commercially available PTFE fine powders are, for example, Polyflon F-104 (manufactured by Daikin Industries), Fullon CD-123 (manufactured by Asahi ICI Fluoropolymers), and Teflon 6J (manufactured by Mitsui / DuPont Fluorochemicals).

液状潤滑剤の種類は、PTFE微粉末の表面を濡らすことが可能であり、上記混合物をシートに成形した後に、蒸発や抽出などの手段によって除去可能な物質である限り、特に限定されない。液状潤滑剤は、例えば、流動パラフィン、ナフサ、ホワイトオイル、トルエン、キシレンなどの炭化水素油であり、各種のアルコール類、ケトン類、エステル類などを用いることもできる。   The type of the liquid lubricant is not particularly limited as long as it can wet the surface of the PTFE fine powder and can be removed by means such as evaporation or extraction after the mixture is formed into a sheet. The liquid lubricant is, for example, a hydrocarbon oil such as liquid paraffin, naphtha, white oil, toluene, xylene, and various alcohols, ketones, esters, and the like can also be used.

PTFE微粉末と液状潤滑剤との混合比は、PTFE微粉末および液状潤滑剤の種類あるいはPTFEシートの形成方法に応じて適宜調整でき、通常、PTFE微粉末100重量部に対して、液状潤滑剤が5〜50重量部程度である。   The mixing ratio of the PTFE fine powder and the liquid lubricant can be appropriately adjusted according to the type of the PTFE fine powder and the liquid lubricant or the method of forming the PTFE sheet. Usually, the liquid lubricant is 100 parts by weight of the PTFE fine powder. Is about 5 to 50 parts by weight.

押出および/または圧延の具体的な方法は特に限定されない。例えば、上記混合物をロッド状に押出成形した後、得られたロッド状の成形体を一対のロールにより圧延してシートに成形してもよい。あるいは、上記混合物をそのままシートに押出成形してもよいし、シートに押出成形した後に、さらに圧延を加えてもよい。   The specific method of extrusion and / or rolling is not particularly limited. For example, after the mixture is extruded into a rod shape, the obtained rod-shaped formed body may be rolled with a pair of rolls to be formed into a sheet. Alternatively, the mixture may be extruded into a sheet as it is, or may be further rolled after being extruded into a sheet.

未焼成のPTFEシートの厚さは、得たいPTFE多孔質膜の厚さに応じて適宜調整すればよく、通常、0.05〜0.5mm程度である。   What is necessary is just to adjust the thickness of a non-baking PTFE sheet | seat suitably according to the thickness of the PTFE porous membrane to obtain, and it is about 0.05-0.5 mm normally.

液状潤滑剤は、延伸Aを行う前に、加熱あるいは抽出などの手法によりPTFEシートから除去することが好ましい。   The liquid lubricant is preferably removed from the PTFE sheet by a technique such as heating or extraction before the stretching A is performed.

本発明の製造方法では、延伸A、延伸Bおよび熱処理の温度、延伸AおよびBの延伸倍率、ならびに未焼成のPTFEシートの厚さなどを調整することにより、以下に示す特性を有するPTFE多孔質膜が得られる。   In the production method of the present invention, the PTFE porous material having the following characteristics is adjusted by adjusting the temperature of stretch A, stretch B and heat treatment, the stretch ratio of stretch A and B, the thickness of the unfired PTFE sheet, and the like. A membrane is obtained.

[通気量]
本発明の製造方法では、JIS P8117に準拠して測定したガーレー通気度にして、3秒/100mL以下、好ましくは2秒/100mL以下のPTFE多孔質膜を形成できる。
[Air flow rate]
In the production method of the present invention, a PTFE porous membrane having a Gurley permeability measured in accordance with JIS P8117 can be formed at 3 seconds / 100 mL or less, preferably 2 seconds / 100 mL or less.

[強度]
本発明の製造方法では、実施例に記載の方法により測定した面内強度にして、20MPa以上、好ましくは24MPa以上のPTFE多孔質膜を形成できる。また、実施例に記載の方法により測定した厚さ方向の強度にして、10N/25mm以上、好ましくは11N/25mm以上のPTFE多孔質膜を形成できる。
[Strength]
In the production method of the present invention, a PTFE porous membrane having an in-plane strength measured by the method described in the Examples can be formed at 20 MPa or more, preferably 24 MPa or more. Also, a PTFE porous membrane having a strength in the thickness direction measured by the method described in the Examples and having a thickness of 10 N / 25 mm or more, preferably 11 N / 25 mm or more can be formed.

[通気部材]
本発明の通気部材は、上述した本発明の製造方法により得たPTFE多孔質膜を有する通気膜を備える。本発明の製造方法により得たPTFE多孔質膜は、高通気性および高強度である。このようなPTFE多孔質膜を有する当該通気膜は、高い通気性を有するとともに、水および塵芥などの異物の透過をより確実に防ぐ、即ち、例えば、高い耐水性を示す。本発明の通気部材は、当該部材が備えるPTFE多孔質膜および通気膜のこのような特性に基づき、筐体の開口部への取り付けによって、筐体内外の高い通気性を実現するとともに、筐体内部への異物の侵入をより確実に抑制する。
[Ventilation member]
The ventilation member of the present invention includes a ventilation film having a PTFE porous film obtained by the production method of the present invention described above. The PTFE porous membrane obtained by the production method of the present invention has high air permeability and high strength. The gas permeable membrane having such a porous PTFE membrane has high air permeability and more reliably prevents the passage of foreign matters such as water and dust, that is, exhibits high water resistance, for example. The ventilation member of the present invention realizes high air permeability inside and outside the casing by attaching to the opening of the casing based on such characteristics of the PTFE porous membrane and the ventilation membrane included in the member. Prevent foreign objects from entering inside more reliably.

本発明の通気部材が備える通気膜は、本発明の製造方法により得たPTFE多孔質膜以外の層を有していてもよい。当該層は、例えば、PTFE多孔質膜を支持する通気性支持材である。この場合、通気膜の強度が向上し、当該通気膜を備える通気部材の寿命が長くなる。   The gas permeable membrane provided in the gas permeable member of the present invention may have a layer other than the PTFE porous membrane obtained by the production method of the present invention. The layer is, for example, a breathable support material that supports the PTFE porous membrane. In this case, the strength of the gas permeable membrane is improved, and the life of the gas permeable member including the gas permeable membrane is extended.

PTFE多孔質膜および通気性支持材を有する通気膜は、両者を重ね合わせて、あるいは接着ラミネート、熱ラミネートなどの手法により一体化して製造できる。   The PTFE porous membrane and the gas permeable membrane having the gas permeable support material can be manufactured by superimposing the two or by integrating them with a technique such as adhesive lamination or heat lamination.

通気性支持材の材料、構造は、本発明の製造方法により得たPTFE多孔質膜よりも通気性に優れる限り、特に限定されない。   The material and structure of the breathable support material are not particularly limited as long as the breathable support material is more breathable than the PTFE porous membrane obtained by the production method of the present invention.

通気性支持材の構造は、例えば、フェルト、不織布、織布、メッシュ(網目状シート)である。強度、柔軟性および製造工程における作業性に優れることから、不織布からなる通気性支持材が好ましく、この場合、不織布を構成する少なくとも一部の繊維が、いわゆる芯鞘構造を有する複合繊維であることが好ましい。芯成分の融点が鞘成分の融点よりも高い芯鞘構造を有する場合、通気膜を製造する際における通気性支持材とPTFE多孔質膜との加熱圧着が容易となる。   The structure of the breathable support material is, for example, felt, non-woven fabric, woven fabric, or mesh (mesh-like sheet). From the viewpoint of strength, flexibility, and workability in the manufacturing process, a breathable support material made of a nonwoven fabric is preferable. In this case, at least some of the fibers constituting the nonwoven fabric are composite fibers having a so-called core-sheath structure. Is preferred. When the core component has a core-sheath structure in which the melting point of the core component is higher than the melting point of the sheath component, thermocompression bonding between the breathable support material and the PTFE porous membrane in manufacturing the breathable membrane is facilitated.

通気性支持材の材料は、ポリエチレン、ポリプロピレンなどのポリオレフィン;ポリエステル;ナイロンなどのポリアミド、芳香族ポリアミド;ならびにこれらの複合材である。通気性支持材として、フッ素系樹脂、例えば、PFA(テトラフルオロエチレン/パーフルオロアルキルビニルエーテル共重合体)、FEP(テトラフルオロエチレン/ヘキサフルオロプロピレン共重合体)の多孔質膜を用いてもよい。   The material of the breathable support material is polyolefin such as polyethylene and polypropylene; polyester; polyamide such as nylon; aromatic polyamide; and a composite material thereof. As the breathable support material, a porous film of a fluorine resin, for example, PFA (tetrafluoroethylene / perfluoroalkyl vinyl ether copolymer) or FEP (tetrafluoroethylene / hexafluoropropylene copolymer) may be used.

図1に、本発明の通気部材の一例を示す。図1に示す通気部材1は、上述した本発明の製造方法により得たPTFE多孔質膜を有する通気膜2と、通気膜2を支持する支持体3とを備える。通気膜2は、筒状の支持体3の一方の開口を覆うように、支持体3に接合されている。支持体3の他方の開口に筐体11の開口部12が挿入されることによって、通気部材1は、筐体11の開口部12に固定されている。通気部材1が開口部12に固定されている状態で、気体は、通気膜2、支持体3の内部および開口部12を通って、筐体11の内部から外部へ、あるいは外部から内部へと流れる。気体の経路に通気膜2が存在するために、水および塵芥などの異物の筐体11内部への侵入が抑制される。   FIG. 1 shows an example of the ventilation member of the present invention. A ventilation member 1 shown in FIG. 1 includes a ventilation membrane 2 having a PTFE porous membrane obtained by the above-described production method of the present invention, and a support 3 that supports the ventilation membrane 2. The gas permeable membrane 2 is joined to the support 3 so as to cover one opening of the cylindrical support 3. The ventilation member 1 is fixed to the opening 12 of the housing 11 by inserting the opening 12 of the housing 11 into the other opening of the support 3. In a state where the ventilation member 1 is fixed to the opening 12, the gas passes from the inside of the housing 11 to the outside or from the outside to the inside through the ventilation film 2, the support 3 and the opening 12. Flowing. Since the gas permeable membrane 2 exists in the gas path, entry of foreign matter such as water and dust into the housing 11 is suppressed.

図1に示す通気部材1は、保護カバー4をさらに備える。保護カバー4は、筐体11外部と通気膜2との間で気体の経路が確保されるように、支持体3に固定されている。保護カバー4は、比較的大きな異物が通気膜2に衝突して、通気膜2が破損することを防ぐ。   The ventilation member 1 shown in FIG. 1 further includes a protective cover 4. The protective cover 4 is fixed to the support 3 so that a gas path is secured between the outside of the housing 11 and the gas permeable membrane 2. The protective cover 4 prevents a relatively large foreign object from colliding with the gas permeable membrane 2 and damaging the gas permeable membrane 2.

支持体3および保護カバー4は、典型的には、樹脂により構成される。支持体3は、常温において可撓性を有する樹脂またはエラストマーにより構成されることが好ましく、この場合、筐体11の開口部12への固定が容易かつ確実となる。   The support 3 and the protective cover 4 are typically made of resin. The support 3 is preferably made of a resin or elastomer having flexibility at room temperature. In this case, the housing 11 can be easily and reliably fixed to the opening 12.

本発明の通気部材の構成は、図1に示す例に限定されない。本発明の効果が得られる限り、本発明の通気部材は、任意の構成を有することができる。   The configuration of the ventilation member of the present invention is not limited to the example shown in FIG. As long as the effect of the present invention is obtained, the ventilation member of the present invention can have any configuration.

以下、実施例により、本発明をさらに詳細に説明する。本発明は、以下の実施例に限定されない。   Hereinafter, the present invention will be described in more detail with reference to examples. The present invention is not limited to the following examples.

本実施例では、製造方法を変化させることで4種類のPTFE多孔質膜を作製し(実施例1種類、比較例3種類)、作製したPTFE多孔質膜の通気量および強度を評価した。   In this example, four types of PTFE porous membranes were produced by changing the production method (one type of Example and three types of Comparative Examples), and the air permeability and strength of the produced PTFE porous membranes were evaluated.

PTFE多孔質膜における特性の評価方法を示す。   The evaluation method of the characteristic in a PTFE porous membrane is shown.

[通気量]
通気量としてPTFE多孔質膜のガーレー通気度(秒/100mL)を、JIS P8117に準拠し、自動ガーレー式デンソメーターを用いて評価した。
[Air flow rate]
The Gurley air permeability (second / 100 mL) of the PTFE porous membrane was evaluated using an automatic Gurley type densometer in accordance with JIS P8117.

[強度]
PTFE多孔質膜の強度として、その面内方向および厚さ方向のそれぞれの強度を、以下のように評価した。なお、強度を評価した面内方向は、圧延により得た延伸前のPTFEシートにおける圧延方向(MD方向)である。また、面内方向の強度は引張強度、厚さ方向の強度は引き剥がし強度である。
[Strength]
As the strength of the PTFE porous membrane, the strengths in the in-plane direction and the thickness direction were evaluated as follows. In addition, the in-plane direction which evaluated the intensity | strength is a rolling direction (MD direction) in the PTFE sheet before extending | stretching obtained by rolling. Further, the strength in the in-plane direction is tensile strength, and the strength in the thickness direction is peeling strength.

・面内方向(MD方向)の強度
面内方向の強度(MPa)は、PTFE多孔質膜に対してテンシロン(オリエンテック製、UTM-III-100)を用いた引張試験を行うことで評価した。引張試験の条件は、以下のとおりである:サンプル形状は幅10mmの短冊、チャック間距離は20mm、引張速度は200mm/分、測定温度は25℃。
-In-plane direction (MD direction) strength In-plane direction strength (MPa) was evaluated by conducting a tensile test using Tensilon (Orientec, UTM-III-100) on a PTFE porous membrane. . The conditions of the tensile test are as follows: the sample shape is a strip having a width of 10 mm, the distance between chucks is 20 mm, the tensile speed is 200 mm / min, and the measurement temperature is 25 ° C.

・厚さ方向の強度
厚さ方向の強度(N/25mm)は、次のように求めた。最初に、評価対象であるPTFE多孔質膜を、TD方向が幅方向となるように、幅25mmの短冊状に加工した。これとは別に、幅25mmの短冊状に加工した接着フィルム(東セロ製、アドマーQE-060)およびアルミシートを準備し、PTFE多孔質膜を、当該接着フィルムを介して一対の当該アルミシートにより挟持した。このとき、PTFE多孔質膜、接着フィルムおよびアルミシートの幅方向および長手方向を揃えた。また、アルミシートの長さをPTFE多孔質膜の長さよりも長くすることで、各アルミシートに、接着フィルムを介してPTFE多孔質膜に接しない部分を設けた。次に、各層を、200℃、2秒の加熱により熱溶着させ、アルミシート103/接着フィルム102/PTFE多孔質膜101/接着フィルム102/アルミシート103の積層体(幅25mmの短冊状、図2(a)参照)を形成した。
-Strength in the thickness direction The strength in the thickness direction (N / 25 mm) was determined as follows. First, the PTFE porous membrane to be evaluated was processed into a strip shape having a width of 25 mm so that the TD direction was the width direction. Separately, a 25 mm wide strip-shaped adhesive film (manufactured by Tosero, Admer QE-060) and an aluminum sheet are prepared, and the PTFE porous membrane is sandwiched between the pair of the aluminum sheets via the adhesive film. did. At this time, the width direction and the longitudinal direction of the PTFE porous film, the adhesive film, and the aluminum sheet were aligned. In addition, by making the length of the aluminum sheet longer than the length of the PTFE porous membrane, each aluminum sheet was provided with a portion that did not contact the PTFE porous membrane via an adhesive film. Next, each layer was thermally welded by heating at 200 ° C. for 2 seconds, and a laminate of aluminum sheet 103 / adhesive film 102 / PTFE porous film 101 / adhesive film 102 / aluminum sheet 103 (a strip shape having a width of 25 mm, FIG. 2 (a)).

次に、図2(b)に示すように、アルミシート103におけるPTFE多孔質膜101に接しない部分103aを持ち手として、各アルミシート103を、互いに逆の方向に引っ張った。引っ張る力を強くしていくと、ある時点で、図2(c)に示すようにPTFE多孔質膜101が裂け始めるが、この時点においてアルミシート103に加えた力を、PTFE多孔質膜の厚さ方向の強度(N/25mm)とした。   Next, as shown in FIG. 2B, the aluminum sheets 103 were pulled in directions opposite to each other using the portion 103 a of the aluminum sheet 103 not contacting the PTFE porous membrane 101 as a handle. When the pulling force is increased, the PTFE porous membrane 101 starts to tear at a certain point as shown in FIG. 2C. At this point, the force applied to the aluminum sheet 103 is applied to the thickness of the PTFE porous membrane. The strength in the vertical direction (N / 25 mm) was used.

(実施例1)
PTFEファインパウダー(ダイキン工業製、ポリフロンF104)100重量部と、液状潤滑剤としてドデカン19重量部とを均一に混合し、PTFEファインパウダーと液状潤滑剤との混合物であるPTFEペーストを形成した。次に、形成したPTFEペーストを、2MPa(20kg/cm2)の圧力でロッド状に押出成形し、さらに1対の金属ロールにより圧延して、帯状のPTFEシートを形成した。次に、形成したPTFEシートから、120℃、3分の熱乾燥によって液状潤滑剤を除去した。
Example 1
100 parts by weight of PTFE fine powder (manufactured by Daikin Industries, Polyflon F104) and 19 parts by weight of dodecane as a liquid lubricant were uniformly mixed to form a PTFE paste which is a mixture of PTFE fine powder and liquid lubricant. Next, the formed PTFE paste was extruded into a rod shape at a pressure of 2 MPa (20 kg / cm 2 ) and further rolled with a pair of metal rolls to form a strip-shaped PTFE sheet. Next, the liquid lubricant was removed from the formed PTFE sheet by heat drying at 120 ° C. for 3 minutes.

このようにして得た未焼成かつ未延伸のPTFEシートを、ゾーン延伸法により、そのMD方向(長手方向)に、延伸温度300℃、延伸倍率4倍で延伸した後に、380℃で30秒間、熱処理した。次に、熱処理後のPTFEシートを、ゾーン延伸法により、そのTD方向(幅方向)に、延伸温度100℃、延伸倍率5倍で延伸して、PTFE多孔質膜を得た。なお、MD方向の延伸には、回転速度が異なる一対のロールを用いた。この場合、延伸倍率は、実質的に双方のロールの回転速度の比により示される。TD方向の延伸は、テンター法により行った。延伸方法は、以降の比較例においても同様である。   The unsintered and unstretched PTFE sheet thus obtained was stretched in the MD direction (longitudinal direction) by a zone stretching method at a stretching temperature of 300 ° C. and a stretching ratio of 4 times, and then at 380 ° C. for 30 seconds. Heat treated. Next, the PTFE sheet after the heat treatment was stretched in the TD direction (width direction) by a zone stretching method at a stretching temperature of 100 ° C. and a stretching ratio of 5 times to obtain a PTFE porous membrane. In addition, a pair of rolls having different rotation speeds were used for stretching in the MD direction. In this case, the draw ratio is substantially indicated by the ratio of the rotational speeds of both rolls. Stretching in the TD direction was performed by a tenter method. The stretching method is the same in the following comparative examples.

(比較例1)
実施例1と同様にして得た未焼成かつ未延伸のPTFEシートを、ゾーン延伸法により、そのMD方向(長手方向)に、延伸温度300℃、延伸倍率4倍で延伸した後に、引き続きそのTD方向(幅方向)に、延伸温度200℃、延伸倍率5倍で延伸した。次に、延伸後のPTFEシートを、380℃で60秒間、熱処理して、特開平7-196831号公報に開示の方法に基づくPTFE多孔質膜を得た。
(Comparative Example 1)
An unsintered and unstretched PTFE sheet obtained in the same manner as in Example 1 is stretched in the MD direction (longitudinal direction) by a zone stretching method at a stretching temperature of 300 ° C. and a stretching ratio of 4 times, and subsequently the TD. The film was stretched in the direction (width direction) at a stretching temperature of 200 ° C. and a stretching ratio of 5 times. Next, the PTFE sheet after stretching was heat-treated at 380 ° C. for 60 seconds to obtain a PTFE porous membrane based on the method disclosed in JP-A-7-96831.

(比較例2)
実施例1と同様にして得た未焼成かつ未延伸のPTFEシートを、ゾーン延伸法により、そのMD方向(長手方向)に、延伸温度380℃、延伸倍率4倍で延伸した。次に、延伸後のPTFEシートを、380℃で60秒間、熱処理した。次に、熱処理後のPTFEシートを、そのTD方向(幅方向)に、延伸温度300℃、延伸倍率5倍で延伸して、特開2007-260547号公報に開示の方法(焼成延伸法)に基づくPTFE多孔質膜を得た。
(Comparative Example 2)
An unfired and unstretched PTFE sheet obtained in the same manner as in Example 1 was stretched in the MD direction (longitudinal direction) at a stretching temperature of 380 ° C. and a stretching ratio of 4 times by a zone stretching method. Next, the stretched PTFE sheet was heat-treated at 380 ° C. for 60 seconds. Next, the heat-treated PTFE sheet is stretched in the TD direction (width direction) at a stretching temperature of 300 ° C. and a stretching ratio of 5 times, and the method disclosed in JP 2007-260547 A (firing stretching method) A PTFE porous membrane based was obtained.

(比較例3)
実施例1と同様にして得た未焼成かつ未延伸のPTFEシートを、ゾーン延伸法により、そのMD方向(長手方向)に、延伸温度300℃、延伸倍率4倍で延伸した後に、380℃で30秒間、熱処理した。次に、熱処理後のPTFEシートを、ゾーン延伸法により、そのTD方向(幅方向)に、延伸温度380℃、延伸倍率5倍で延伸して、特表平11-515036号公報に開示の方法に基づくPTFE多孔質膜を得た。
(Comparative Example 3)
An unfired and unstretched PTFE sheet obtained in the same manner as in Example 1 was stretched in the MD direction (longitudinal direction) at a stretching temperature of 300 ° C. and a stretching ratio of 4 times by a zone stretching method at 380 ° C. Heat treatment was performed for 30 seconds. Next, the heat-treated PTFE sheet is stretched in the TD direction (width direction) by a zone stretching method at a stretching temperature of 380 ° C. and a stretching ratio of 5 times, and the method disclosed in Japanese Patent Publication No. 11-515036 A PTFE porous membrane based on was obtained.

実施例および比較例で作製した各PTFE多孔質膜について、その通気量および強度の評価結果を以下の表1に示す。また、実施例および比較例3について、MD方向への延伸および熱処理を行った後、TD方向への延伸を行う前の時点におけるPTFEシートの通気量および面内強度の評価結果を、中間物における通気量および面内強度として、併せて表1に示す。さらに比較例2について、PTFEの融点以上の温度におけるMD方向への延伸を行った後、TD方向への延伸を行う前の時点におけるPTFEシートの通気量および面内強度の評価結果を、中間物における通気量および面内強度として、併せて表1に示す。   Table 1 below shows the evaluation results of the air flow rate and strength of each PTFE porous membrane produced in Examples and Comparative Examples. Moreover, about the Example and the comparative example 3, after extending | stretching to MD direction and heat processing, the evaluation result of the air flow rate and in-plane intensity | strength of the PTFE sheet in the time before extending | stretching to TD direction is shown in an intermediate. Table 1 shows the air flow rate and the in-plane strength. Further, with respect to Comparative Example 2, the evaluation results of the air permeability and in-plane strength of the PTFE sheet at the time point after the stretching in the MD direction at a temperature equal to or higher than the melting point of PTFE and before the stretching in the TD direction are shown as intermediates Table 1 also shows the air flow rate and the in-plane strength.

Figure 2011178970
Figure 2011178970

表1に示すように、比較例に比べて実施例では、高通気量かつ高強度のPTFE多孔質膜が得られた。   As shown in Table 1, a PTFE porous membrane having a higher air flow rate and higher strength was obtained in the examples than in the comparative examples.

本発明のPTFE多孔質膜の製造方法によれば、通気量と強度とを高いレベルで両立させたPTFE多孔質膜が得られ、このようなPTFE多孔質膜は、通気部材の通気膜としての用途に好適である。   According to the method for producing a PTFE porous membrane of the present invention, a PTFE porous membrane having both high air flow rate and strength can be obtained. Such a PTFE porous membrane can be used as a gas permeable membrane for a ventilation member. Suitable for use.

1 通気部材
2 通気膜
3 支持体
4 保護カバー
11 筐体
12 開口部
101 PTFE多孔質膜
102 接着フィルム
103 アルミシート
103a 持ち手
DESCRIPTION OF SYMBOLS 1 Ventilation member 2 Ventilation film 3 Support body 4 Protective cover 11 Case 12 Opening part 101 PTFE porous film 102 Adhesive film 103 Aluminum sheet 103a Handle

Claims (5)

未焼成のポリテトラフルオロエチレンシートを、ポリテトラフルオロエチレンの融点未満の温度において所定の方向へ延伸し、
前記延伸したシートを、前記融点以上の温度で熱処理した後、
前記熱処理後のシートを、前記融点未満の温度において、前記所定の方向に対して直交する方向にさらに延伸する、ポリテトラフルオロエチレン多孔質膜の製造方法。
An unsintered polytetrafluoroethylene sheet is stretched in a predetermined direction at a temperature below the melting point of polytetrafluoroethylene,
After heat treating the stretched sheet at a temperature equal to or higher than the melting point,
The method for producing a polytetrafluoroethylene porous membrane, wherein the heat-treated sheet is further stretched in a direction orthogonal to the predetermined direction at a temperature lower than the melting point.
前記未焼成のポリテトラフルオロエチレンシートが帯状であり、
前記所定の方向が、当該シートの長手方向であり、
前記直交する方向が、当該シートの幅方向である請求項1に記載のポリテトラフルオロエチレン多孔質膜の製造方法。
The unsintered polytetrafluoroethylene sheet is strip-shaped,
The predetermined direction is a longitudinal direction of the sheet;
The method for producing a polytetrafluoroethylene porous membrane according to claim 1, wherein the orthogonal direction is a width direction of the sheet.
前記所定の方向への延伸倍率が、2〜40倍であり、
前記直交する方向への延伸倍率が、2〜40倍である請求項1に記載のポリテトラフルオロエチレン多孔質膜の製造方法。
The draw ratio in the predetermined direction is 2 to 40 times,
The method for producing a polytetrafluoroethylene porous membrane according to claim 1, wherein a draw ratio in the orthogonal direction is 2 to 40 times.
ポリテトラフルオロエチレン微粉末と液状潤滑剤との混合物を、押出および圧延から選ばれる少なくとも1つの方法によりシートに成形して、前記未焼成のポリテトラフルオロエチレンシートを得る、請求項1に記載のポリテトラフルオロエチレン多孔質膜の製造方法。   The mixture of the polytetrafluoroethylene fine powder and the liquid lubricant is formed into a sheet by at least one method selected from extrusion and rolling to obtain the unfired polytetrafluoroethylene sheet. A method for producing a polytetrafluoroethylene porous membrane. 筐体の開口部に固定された状態で、前記開口部を通過する気体が透過する通気膜と、
前記通気膜を支持する支持体と、を備える通気部材であって、
前記通気膜が、請求項1〜4のいずれかに記載の製造方法により得たポリテトラフルオロエチレン多孔質膜を有する通気部材。
A gas permeable membrane that allows gas passing through the opening to pass through while being fixed to the opening of the housing;
A ventilation member that supports the gas permeable membrane,
The ventilation member in which the said ventilation film has the polytetrafluoroethylene porous film obtained by the manufacturing method in any one of Claims 1-4.
JP2010047328A 2010-03-04 2010-03-04 Method of manufacturing polytetrafluoroethylene porous film and air-permeable member Pending JP2011178970A (en)

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