CN111346448B

CN111346448B - Ultralow-resistance three-dimensional composite membrane filter element and protective mask made of same

Info

Publication number: CN111346448B
Application number: CN202010248042.2A
Authority: CN
Inventors: 吴汉阳; 王涛; 查昊燃; 程家太; 吴根洋; 倪小兰; 冯碧霄; 吴韬
Original assignee: Jiangxi Bocent Tec Co ltd
Current assignee: Jiangxi Boxin Environmental Protection Technology Co.,Ltd.
Priority date: 2020-04-01
Filing date: 2020-04-01
Publication date: 2021-09-14
Anticipated expiration: 2040-04-01
Also published as: CN111346448A

Abstract

The invention discloses an ultra-low resistance three-dimensional composite membrane filter core and a protective mask made of the same, wherein the composite membrane filter core is a three-dimensional honeycomb support body, honeycomb holes are formed in the honeycomb support body, the honeycomb holes are arranged in the honeycomb support body at intervals in the axial direction or in parallel, an inorganic membrane layer is arranged on the inner wall surface of each honeycomb hole, plugs are respectively arranged on the orifices at two ends of each honeycomb hole in a staggered manner, the honeycomb support body and the inorganic membrane layer on the inner wall surface of each honeycomb hole are subjected to hydrophobic modification integrally to form a hydrophobic three-dimensional composite membrane layer. Meanwhile, silver ions and the modifying solution are compounded into a modified three-dimensional composite film layer with a disinfection function.

Description

Ultralow-resistance three-dimensional composite membrane filter element and protective mask made of same

Technical Field

The invention belongs to a repeatedly regenerated composite membrane filter core and a protective mask made of the same in the technical field of sanitation.

Background

As is well known, masks and gas masks are common health care and safety articles for daily production and life of people, and are also a necessity for medical workers, fire fighters and workers in high dust-containing working environments.

At present, the following types of masks are mainly available on the market: the mask comprises a cotton cloth mask, a gauze mask, an activated carbon mask, a medical mask, an industrial dustproof mask, an anti-gas mask or a mask and the like, wherein the two-dimensional multilayer medium filter is adopted for any type of mask, the filtering area is very small, even if the porosity of a single-layer fiber cloth is more than 80%, the porosity of the mask formed by three or four layers of fiber cloth is 50% -60% at most, if the protection requirement is high, the resistance is very high, and for example, the filtering efficiency of particles below PM2.5 is required to be more than 95% or 99%; or require a filtration efficiency of greater than 95%, 99%, or 100% for ultrafine particles less than 0.3 microns; the breathing resistance of these masks is multiplied so that the dusty toxic gases pass directly through the gap where the mask and face are joined. Typically the size of the bacterial virus is in the range of substantially 0.1 to 1.0 um. Most masks have limited blocking effect on bacteria, aerosol, ultrafine particles and ultrafine particles below PM2.5, and a large amount of liquid drops and liquid mist are adhered to a fibrous net film after long use. The gaps between the fibers are closed, the resistance is rapidly increased, the breathing is difficult, the capability of blocking bacteria, viruses and ultrafine particles is very limited, the fibers cannot be repeatedly regenerated, the fibers are replaced every day, and the cost is very high.

Disclosure of Invention

Aiming at the problems of the mask in the prior art, the invention provides the protective mask made of the ultralow-resistance three-dimensional composite membrane filter element, which can achieve high-precision and high-efficiency filtration, can ensure that the respiratory resistance of a human body is small, the breathing is smooth and natural, no retardation is caused, and the mask can be regenerated repeatedly, so that the use cost is reduced.

The technical scheme adopted by the technical content to be solved by the invention is as follows: the utility model provides an ultralow resistance three-dimensional composite film filter core, the composite film filter core is the honeycomb supporter of three-dimensional solid form, has the honeycomb hole in the honeycomb supporter, honeycomb hole is crisscross or parallel arrangement along honeycomb supporter axial interval, be provided with three-dimensional composite film layer on the honeycomb hole inner wall surface, crisscross end cap that is provided with respectively on the drill way of honeycomb hole both ends, three-dimensional composite film carries out whole hydrophobic modification by the inorganic rete that sets up in advance on honeycomb supporter and its honeycomb hole inner wall surface and makes, the membrane pore aperture of three-dimensional composite film layer is 0.05 ~ 0.5um, and three-dimensional composite film layer thickness is 10~ 30um, and the intraformational capillary pore of three-dimensional composite film is greater than 90 with the contact angle or the moist angle of water, all faces that can contact with the air of three-dimensional composite film layer are all covered by the modified material.

The utility model provides a protective facial mask who makes with complex film filter core, it includes the cover body, the frenulum that links to each other with the cover body and the complex film filter core of assembly on the cover body, the cover body includes plastic support and filter core box.

The cross section of the composite membrane filter core is in a shape of a polygon such as a circle, an ellipse, a racetrack circle, a square, a pentagon, a hexagon and the like, a heart or other shapes.

The honeycomb holes are one of square holes, triangular holes, hexagonal holes, round holes and rectangular holes or a combination of the square holes, the triangular holes, the hexagonal holes and the rectangular holes.

The composite membrane filter element has a cell size of greater than 100, preferably greater than 400, cells per square inch.

The composite membrane filter element is formed by a honeycomb support body and a three-dimensional composite membrane layer, wherein the honeycomb support body is formed by one or at least two of cordierite, alumina, mullite, silicon carbide, silicon nitride, corundum, quartz, fused quartz and glass powder, proper amount of water is added into the cordierite, the alumina, the mullite, the silicon carbide, the silicon nitride, the corundum, the quartz, the fused quartz and the glass powder to be uniformly mixed to prepare a mud material, then the mud material is extruded and formed and fired at high temperature, honeycomb holes are formed in the honeycomb support body, an inorganic membrane layer is coated on the inner wall surface of each honeycomb hole, then the inorganic membrane layer is dried and fired, the two end holes of the honeycomb are alternately plugged (the plugging hole material is an organic material), then the organic membrane layer is dried, cured, integrally coated with organic modified liquid, dried and thermally treated to prepare an organic three-dimensional composite membrane layer, a hydrophobic breathable composite membrane filter element is obtained, and then the hydrophobic breathable composite membrane filter element is connected with a plastic support to prepare the protective mask.

The invention relates to a protective mask made of an ultralow-resistance three-dimensional composite membrane filter element, which is characterized in that the aim of the protective mask is realized by the following technical measures:

A. the filtering material is changed from two-dimensional plane cotton, gauze or active carbon mask filtering in the prior art into three-dimensional structure ceramic honeycomb hole filtering, thereby greatly increasing the filtering area, and the ratio of the filtering areas of two-dimensional and three-dimensional solid films with different thicknesses on the same section is shown in a table I:

B. increasing the mesh number (i.e., the number of cells per square inch) of the three-dimensional structured honeycomb as much as possible;

C. the inner wall of the three-dimensional composite membrane is as thin and uniform as possible, and has no pores or cracks;

D. the two surfaces of the inner wall of the honeycomb hole are simultaneously coated with films, the film thickness is required to be uniform, the film thickness is 10-20 microns, if ultrafine particles enter and penetrate through the inner wall of the honeycomb hole by utilizing the defects of a film on one side, the difficulty of the ultrafine particles passing through the film on the other side is quite large, and thus the double-sided film can ensure the filtering precision;

E. the hydrophilic inorganic material capillary channel is easy to absorb water vapor into the capillary channel and condense in the capillary channel, so that the channel is blocked, and the breathing is difficult; the invention carries out hydrophobic modification without dead angles on inorganic membranes on the inner walls of the honeycomb holes and all pore passages in the support body, so that the contact angle or wetting angle between the inorganic membranes and water is more than 90 degrees, preferably more than 140 degrees, and the honeycomb holes can be kept to have good air permeability; the specific method is to modify the hydrophilic inorganic membrane layer by using a fluorocarbon coupling agent, a fluorine-silicon system, an organic silicon system and other modifying agents simultaneously having hydrophobic and hydrophilic groups, so that the hydrophilic groups of the coupling agent and the inorganic material matrix are chemically bonded, the bonding force is firm, the hydrophobic groups are consistent and outwards form a hydrophobic surface and basically form a monomolecular layer, and the organic hydrophobic modified membrane layer does not change the pore size and distribution of the inorganic porous body, but the surface property is completely changed. The membrane structure is changed into an asymmetric three-layer (sandwich) inorganic-organic three-dimensional composite membrane layer with good hydrophobic and air permeability.

The technical points of the invention are as follows: firstly, a high-pore-density honeycomb ceramic body is used as a three-dimensional filtering support body, so that the filtering area is greatly increased, and high-efficiency and high-precision air filtration is realized; and secondly, firstly, hydrophilic inorganic film layers are coated on the two surfaces of the inner wall of the three-dimensional honeycomb hole, the honeycomb hole is dried, sintered and blocked in a staggered mode, then the support body and the inorganic film layers are modified by using a modifying liquid, or the inorganic film layers and the support body are directly modified into a hydrophobic body at the same time after the hydrophilic inorganic film layers are coated on the support body, and then the honeycomb holes at the two ends of the honeycomb are blocked in a staggered mode after modification, so that the inorganic and organic three-dimensional composite film layer with good air permeability is obtained.

The mask is made of the modified hydrophobic inorganic-organic composite membrane filter element, and the composite membrane filter element can be disinfected, cleaned and repeatedly regenerated and reused, so that the service life of the mask is prolonged, and the use cost is reduced.

Compared with the prior art, the invention has the advantages of large filtering area and high filtering efficiency, and can ensure that water vapor naturally flows in the capillary channel and is naturally discharged during breathing and exhausting, so that the human body can breathe smoothly without any blocking feeling. Meanwhile, the composite membrane filter element can be disinfected and cleaned, can be repeatedly regenerated and reused, the service life of the mask is prolonged, and the use cost is reduced.

The three-dimensional composite membrane filter element with good air permeability can be used for gas masks and protective clothing, and the gas masks and the protective clothing have the breathing function, namely, the natural exchange process of gas entering and exiting the gas masks and the protective clothing is realized, the muggy and high-humidity environment of the body is eliminated, and the body and the mind are in a natural state. Compounding silver ions and the modified liquid into a modified three-dimensional composite film layer with a disinfection function.

Drawings

Figure 1 is a schematic perspective view of the mask of the present invention,

figure 2 is an enlarged X-X schematic view of the structure of figure 1,

figure 3 is a schematic view of the structure in direction a of figure 1,

FIG. 4 is a schematic view of the Y-Y structure of FIG. 2.

In the figure, the device comprises a lacing 1, a lacing 2, a cover body 3, a honeycomb support body 4, honeycomb holes 5, honeycomb hole inner walls 6, plugs 7, capillary channels 8 and a three-dimensional composite film layer.

Detailed Description

In the figure, the protective mask comprises a mask body 2, a lacing 1 connected with the mask body and a composite membrane filter element assembled on the mask body (consisting of a filter core box and a plastic support), wherein the composite membrane filter element is a three-dimensional honeycomb support body 3, honeycomb holes 4 are formed in the honeycomb support body, a three-dimensional composite membrane layer 8 is formed on the surface of the inner wall 5 of each honeycomb hole through coating, the honeycomb holes are arranged in an axially staggered or parallel mode along the honeycomb support body, plugs 6 are respectively arranged on two ports of each honeycomb hole in a staggered mode, the pore diameter of a membrane hole of the three-dimensional composite membrane layer 8 dip-coated on the surface of the inner wall 5 of each honeycomb hole is 0.05-0.5 um, the thickness of the three-dimensional composite membrane layer is 10-30 um, and the three-dimensional composite membrane layer is manufactured through the following method: after the honeycomb supporter is made, firstly coating inorganic film layer on the inner wall surface of honeycomb hole and honeycomb supporter, drying and sintering the inorganic film layer, cross-plugging holes at two ends of honeycomb hole by plugs (organic material for plugs or inorganic material of honeycomb supporter body, such as epoxy resin, fluororesin and organic silicon resin, drying and solidifying, then coating the whole honeycomb supporter in modifying liquid, drying and heat-treating to make the inorganic film layer become inorganic and organic stereo composite film, thus obtaining hydrophobic and air permeable composite film filter core, and then making the composite film filter core into protective mask Titanate, phosphate, zirconate, borate, aluminate, fluorosilane, fluorocarbon, fatty acid coupling agent or activator, or a composite of at least two of the two as main raw materials) and a solvent; the solvent is one of alcohols, ketones, lipids, alkane and cyclane or the combination of at least two of the alcohols, the ketones, the lipids, the alkane and the cyclane, and the proportioning of the solute in the solvent is 0.1wt percent to 5.0wt percent.

The inorganic membrane layer is made into a hydrophobic inorganic and organic three-dimensional composite membrane through hydrophobic modification, the contact angle or wetting angle of a capillary channel 7 in the three-dimensional composite membrane layer and water is more than 90 degrees, and the honeycomb support body must meet the following requirements: the honeycomb support body has regular shape, the size specification meets the design requirement, and the honeycomb support body has no broken ribs, and has no defects of holes, cracks and the like on the filter wall.

The number of honeycomb holes per square inch of the honeycomb support body is required to be more than 100, preferably more than 400, and the thickness of the inner wall of each honeycomb hole is 0.06-0.6 (mm), preferably less than 0.3 mm;

the longitudinal compressive strength (A axis) of the honeycomb support body is more than 2.0MPa, and the transverse compressive strength (B axis) of the honeycomb support body is more than 0.4 MPa;

the water absorption rate of the honeycomb support body is more than 30 percent, the apparent porosity is more than 45 percent, preferably more than 55 percent, and generally between 50 and 70 percent (%); the aperture (d 50) can be adjustable at 0.5 ~ 10.0 (um) as required, and the aperture distribution is narrow, and the dispersion is less than 1.5.

The aperture (d 50) of the composite membrane is between 0.05 and 0.5 (um), the thickness of the membrane is between 10 and 30 (um), all bacteria, viruses and ultrafine particles are guaranteed to be intercepted, the particle filtration efficiency of less than PM2.5 is more than 99.95 percent, and the respiratory resistance is less than 80 Pa.

The composite membrane hole filter element is a three-dimensional membrane core and belongs to a three-dimensional structure, and the filter materials of other masks are two-dimensional plane materials; under the condition of the same unit cross section (unit area square inch), the filtering area is 5-80 times of the filtering area of the common mask, and even higher.

The organic modified main material can also be various hydrophobic thermoplastic resin materials, thermosetting resin and curing agents. The raw materials for the honeycomb support body are one or at least two of cordierite, alumina, mullite, silicon carbide, silicon nitride, corundum, quartz, fused quartz and glass, which are compounded (ball-milled and mixed) and mixed with a proper amount of water and a bonding agent to prepare pug, and the pug is prepared by ageing, extrusion molding, drying and shaping and high-temperature firing (the compound mixing proportion and the manufacturing process of the raw materials are the prior art of honeycomb ceramics); the inorganic material coated on the inner wall surface of the honeycomb hole can be the raw material or TiO₂、SiO₂And ZnO or at least two of them are compounded (ball-milled and mixed) and added with proper amount of water and additives (such as wood dust, carbon powder and other pore-forming agents) and mixed and stirred to prepare the composite material, and the compounding and mixing proportion is the prior art. Porosity, water absorption, strength, pore size and component of inner wall of honeycomb support bodyWhen the cloth meets the filtering requirement, the hydrophobic membrane can be directly modified after cross hole plugging to obtain the three-dimensional composite membrane, or the support carrier meeting the filtering requirement can be directly modified for hydrophobic property, and then cross hole plugging is carried out to obtain the three-dimensional composite membrane with good air permeability. The protective mask consists of a mask body, a lacing and a composite membrane filter element assembled on the mask body, wherein the composite membrane filter element is fixed in a filter element box, a filter core box, a plastic bracket and three to six layers of fibers are welded on the whole mask through ultrasonic welding, and the fiber mask and the mask edge are a whole. The filter core box consists of a box body, an upper sealing ring, a lower sealing ring, a box cover and the like, wherein the box cover and the box bottom all belong to porous barrier ventilation structures. The number of the three-dimensional composite membrane filter elements arranged on the mask body can be one or more. The filter core box and the plastic bracket can be integrated or separated. Of course, the mask is preferably provided with a nose clip (not shown) for securing the mask.

Claims

1. The utility model provides an ultra-low resistance three-dimensional composite membrane filter core which characterized by: the composite membrane filter element is a three-dimensional honeycomb support body (3), honeycomb holes (4) are formed in the honeycomb support body, the honeycomb holes are arranged in a staggered mode or in a parallel mode along the axial direction of the honeycomb support body at intervals, a three-dimensional composite membrane layer (8) is arranged on the surface of the inner wall (5) of each honeycomb hole, plugs (6) are respectively arranged on the openings at two ends of each honeycomb hole in a staggered mode, the three-dimensional composite membrane layer is prepared by carrying out integral hydrophobic modification on the honeycomb support body and an inorganic membrane layer which is arranged on the surface of the inner wall of each honeycomb hole in advance and is used for modifying water, the pore diameter of each membrane hole of the three-dimensional composite membrane layer is 0.05-0.5 mu m, the thickness of each three-dimensional composite membrane layer is 10-30 mu m, the contact angle or wetting angle between a capillary pore (7) in each three-dimensional composite membrane layer and water is larger than 90 degrees, and all surfaces, which can be in contact with air, of the three-dimensional composite membrane layers are covered by modified substances; the inorganic film layer is made of one of cordierite, alumina, mullite, silicon carbide, silicon nitride, corundum, quartz, fused quartz and glass or the mixture of the cordierite, the alumina, the mullite, the silicon carbide, the silicon nitride, the corundum, the quartz, the fused quartz and the glass which are mutually compounded and mixed uniformly with a proper amount of water, or TiO₂、SiO₂One of ZnO and the mixture are mutually compounded and added with proper amount of water to be evenly mixed to prepare the ZnO-based composite material; the modifying solution is prepared from organic modifying solutes: silaneOne or a compound of titanate, phosphate, zirconate, borate, aluminate, fluorosilane, fluorocarbon and fatty acid is mixed with a solvent to prepare the composite material; the solvent is one or the combination of alcohols, ketones, lipids, alkane and naphthenic solvents, and the ratio of the solute in the solvent is 0.1 wt% -5.0 wt%.

2. The ultra-low resistance three-dimensional composite membrane filter element of claim 1, which is characterized in that: the plug process is used for positioning product holes or manually positioning the product holes by a computer vision technology, dispensing and plugging the holes by an automatic needle type dispenser, and the other plug process is used for positioning the product holes or manually positioning the product holes by the computer vision technology, laminating, punching, scraping and removing the laminated film on a support body.

3. The ultra-low resistance three-dimensional composite membrane cartridge of claim 1, wherein: the cross section of the composite membrane filter core is circular, oval, runway circle, square, pentagonal or hexagonal.

4. The ultra-low resistance three-dimensional composite membrane cartridge of claim 1, wherein: the honeycomb holes (4) are square holes, triangular holes, hexagonal holes, round holes or rectangular holes, and the number of the honeycomb holes per square inch on the composite membrane filter element is more than 100.

5. The ultra-low resistance three-dimensional composite membrane cartridge of claim 1, wherein: the longitudinal compressive strength (A axis) of the honeycomb support body is greater than 2.0MPa, and the transverse compressive strength (B axis) of the honeycomb support body is greater than 0.4 MPa.

6. The ultra-low resistance three-dimensional composite membrane cartridge of claim 1, wherein: the water absorption rate of the honeycomb support body is more than 30%, the apparent porosity is 50-70%, the pore size distribution is narrow, and the dispersion is less than 1.5.

7. A protective mask made of the ultra-low resistance three-dimensional composite membrane filter element of claim 1, which is characterized in that: it comprises a cover body (2), a tying belt (1) and a composite membrane filter element assembled on the cover body.