CN111905461B - 一种pm2.5车载空气滤材及其制备方法 - Google Patents

一种pm2.5车载空气滤材及其制备方法 Download PDF

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CN111905461B
CN111905461B CN202010744811.8A CN202010744811A CN111905461B CN 111905461 B CN111905461 B CN 111905461B CN 202010744811 A CN202010744811 A CN 202010744811A CN 111905461 B CN111905461 B CN 111905461B
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CN111905461A (zh
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余振威
余青青
吕心钏
黄文俊
田忠强
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Gaobo Group Co ltd
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Abstract

一种PM2.5车载空气滤材及其制备方法，包括预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层，所述预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层之间层叠复合为一体，所述预过滤层、支撑保护层的内部均浸入有杀菌颗粒；S1、将支撑保护层、高效过滤层以及中效容灰层输送至热压机中；S2、将所述复合支撑层输送至冲制模具内；S3、将净化填充料填充至各个所述容纳槽内；S4、将预过滤层铺设在复合支撑层上；本发明通过多层复合滤材，能够提高0.3um颗粒物的效率，同时满足低的进气阻力，兼具抑菌杀菌、高效降解除异味、高容尘。

Description

一种PM2.5车载空气滤材及其制备方法
技术领域
本发明属于滤清器技术领域，特别涉及一种PM2.5车载空气滤材及其制备方法。
背景技术
汽车空调滤芯，作为净化进入汽车室内的新鲜空气，起着至关重要的作用。污浊的空气不仅影响乘客的感受，也威胁着乘客的身心健康。
经研究表明，PM2.5(粒径在2.5um以下的颗粒物)对人的呼吸道影响最为直接，此粒径下的颗粒物可以直接穿过人体呼吸道的保护层进入人体内部，对人体造成伤害。而病毒的粒径更是达到了0.08～0.12um之间，但是它们都是附着在载体上进行传播的，比如空气中的水气、气融胶、雾霾，飞沫等等，而这些载体一般粒径都大于0.3um，目前的滤材过滤能力有限，无法对PM2.5进行有效的滤除。
发明内容
本发明针对现有技术存在的不足，提供了一种PM2.5车载空气滤材，具体技术方案如下：
一种PM2.5车载空气滤材，包括预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层，所述预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层之间层叠复合为一体，所述预过滤层、支撑保护层的内部均浸入有杀菌颗粒。
进一步的，所述预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层由外至内依次设置，所述预过滤层为迎风面，所述支撑保护层为出风面。
进一步的，所述异味净化层为矩形阵列分布的净化填充料，所述净化填充料分布于预过滤层、中效容灰层之间，所述净化填充料之间留有网格间隙，所述网格间隙为预过滤层、中效容灰层的连接区域。
进一步的，所述预过滤层、中效容灰层的连接方式为压接和缝制中的一种或多种。
进一步的，所述中效容灰层、高效过滤层以及支撑保护层组成复合支撑层，所述复合支撑层的内部冲制有矩形阵列分布的容纳槽，所述容纳槽朝向支撑保护层下凹，每个所述容纳槽的内部均填充有净化填充料。
进一步的，所述预过滤层采用含杀菌物质的无纺布材料制得，所述中效容灰层采用热风棉制得，所述高效过滤层采用高效熔喷布制得，所述支撑保护层采用含杀菌物质的无纺布骨架制得，所述净化填充料采用椰壳活性炭和高分子颗粒物制得。
进一步的，所述支撑保护层、高效过滤层之间填充有香味散发层，所述香味散发层采用果香颗粒物制得。
一种PM2.5车载空气滤材的制备方法，所述制备方法包括以下步骤：
S1、将支撑保护层、高效过滤层以及中效容灰层输送至热压机中，支撑保护层、高效过滤层以及中效容灰层由下至上分布，使得支撑保护层、高效过滤层以及中效容灰层热压为复合支撑层；
S2、将所述复合支撑层输送至冲制模具内，冲制模具的上模板向下冲压复合支撑层，冲制模具的下模板从底部复合支撑层，上模板底面的分布有向下的凸头，上模板顶面分布有下凹的配合槽，凸头、配合槽共同在复合支撑层上冲制出矩形阵列分布的容纳槽，容纳槽之间留有网格间隙；
S3、将净化填充料填充至各个所述容纳槽内，并压实净化填充料，
S4、将预过滤层铺设在复合支撑层上，预过滤层覆盖住各个容纳槽，然后对预过滤层相对网格间隙的区域进行固定操作，使得预过滤层固定在复合支撑层上。
进一步的，在S4中，所述固定操作所采用的方式为压接和缝制中的一种或多种。
进一步的，所述预过滤层采用含杀菌物质的无纺布材料制得，所述中效容灰层采用热风棉制得，所述高效过滤层采用高效熔喷布制得，所述支撑保护层采用含杀菌物质的无纺布骨架制得，所述净化填充料采用椰壳活性炭和高分子颗粒物制得。
本发明的有益效果是：通过多层复合滤材，能够提高0.3um颗粒物的效率，同时满足低的进气阻力，兼具抑菌杀菌、高效降解除异味、高容尘。
附图说明
图1示出了本发明的PM2.5车载空气滤材的结构示意图；
图2示出了本发明的滤材俯视截面结构示意图；
图3示出了本发明的冲制模具动作结构示意图。
具体实施方式
为了使本发明的目的、技术方案及优点更加清楚明白，以下结合实施例，对本发明进行进一步详细说明。应当理解，此处所描述的具体实施例仅仅用以解释本发明，并不用于限定本发明。
如图1所示，一种PM2.5车载空气滤材，包括预过滤层1、异味净化层6、中效容灰层2、高效过滤层3以及支撑保护层4，所述预过滤层1、异味净化层6、中效容灰层2、高效过滤层3以及支撑保护层4之间层叠复合为一体，所述预过滤层1、支撑保护层4的内部均浸入有杀菌颗粒；预过滤层可以拦截大颗粒灰尘、杂质，并对细菌、真菌、病毒进行灭杀，防止霉变；异味净化层能够有效的吸附异味、有害气体，降解COX、SOX、NOX、SHX等；中效容灰层可针对10微米及以上颗粒物，能够有效吸附、阻挡其通过；针对0.3微米及以上微笑颗粒、细菌、病毒等，能够有效吸附、阻挡其通过；支撑保护层起支撑保护作用，增加材料的整体强度、同时对预过滤层未杀灭的细菌进行二次杀灭。
作为上述技术方案的改进，所述预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层由外至内依次设置，所述预过滤层为迎风面，所述支撑保护层为出风面；通过多层材料复合在一起，使得滤材能够充分过滤空气中的杂质，使得车内空气更为洁净。
如图2所示，所述异味净化层6为矩形阵列分布的净化填充料，所述净化填充料分布于预过滤层1、中效容灰层3之间，所述净化填充料之间留有网格间隙61，所述网格间隙为预过滤层、中效容灰层的连接区域；将净化填充料设计为网格状分布，可预留出网格间隙作为连接区域，避免填充料在预过滤层、中效容灰层受损，保证填充料内部空隙正常，提高过滤效果；网格间隙的设置可极大的降低预过滤层、中效容灰层的连接面，预过滤层、异味净化层、中效容灰层三者之间只需将预过滤层与中效容灰层固定连接即可，无需再将异味净化层与预过滤层连接、异味净化层与中效容灰层连接，减少了作业工序的同时，也减少了作业面，使得滤材的生产更为简便、高效。
作为上述技术方案的改进，所述预过滤层、中效容灰层的连接方式为压接和缝制中的一种或多种；利用上述三种方式能够完成预过滤层、中效容灰层的有效固定，提高连接强度。
作为上述技术方案的改进，所述中效容灰层2、高效过滤层3以及支撑保护层4组成复合支撑层5，所述复合支撑层5的内部冲制有矩形阵列分布的容纳槽51，所述容纳槽朝向支撑保护层下凹，每个所述容纳槽的内部均填充有净化填充料；向出风面凸起的容纳槽可增大整个滤材的覆盖面，从而弥补网格间隙而缺失的接触面，保证异化净化层的过滤能力；容纳槽可以填充料进行预固定，使得净化填充料的填充更为简便。
作为上述技术方案的改进，所述预过滤层采用含杀菌物质的无纺布材料制得，所述中效容灰层采用热风棉制得，所述高效过滤层采用高效熔喷布制得，所述支撑保护层采用含杀菌物质的无纺布骨架制得，所述净化填充料采用椰壳活性炭和高分子颗粒物制得。
作为上述技术方案的改进，所述支撑保护层、高效过滤层之间填充有香味散发层，所述香味散发层采用果香颗粒物制得；香味散发层可散发香味，改善汽车室内气味。
一种PM2.5车载空气滤材的制备方法，所述制备方法包括以下步骤：
S1、将支撑保护层、高效过滤层以及中效容灰层输送至热压机中，支撑保护层、高效过滤层以及中效容灰层由下至上分布，使得支撑保护层、高效过滤层以及中效容灰层热压为复合支撑层；
S2、将所述复合支撑层输送至冲制模具内，冲制模具的上模板7向下冲压复合支撑层，冲制模具的下模板8从底部复合支撑层，上模板底面的分布有向下的凸头，上模板顶面分布有下凹的配合槽，凸头、配合槽共同在复合支撑层5上冲制出矩形阵列分布的容纳槽51，容纳槽51之间留有网格间隙61；
S3、将净化填充料填充至各个所述容纳槽内，并压实净化填充料，
S4、将预过滤层铺设在复合支撑层上，预过滤层覆盖住各个容纳槽，然后对预过滤层相对网格间隙的区域进行固定操作，使得预过滤层固定在复合支撑层上。
所述固定操作所采用的方式为压接和缝制中的一种或多种；可单独热压固定，单独缝制固定，也可在压接完毕后再缝制操作，保证预过滤层对各个净化填充料的覆盖效果，避免净化填充料流出。
所述预过滤层采用含杀菌物质的无纺布材料制得，所述中效容灰层采用热风棉制得，所述高效过滤层采用高效熔喷布制得，所述支撑保护层采用含杀菌物质的无纺布骨架制得。
以上所述仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明的保护范围之内。

Claims (7)

1.一种PM2.5车载空气滤材，其特征在于：包括预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层，所述预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层之间层叠复合为一体，所述预过滤层、支撑保护层的内部均浸入有杀菌颗粒；
所述预过滤层、异味净化层、中效容灰层、高效过滤层以及支撑保护层由外至内依次设置，所述预过滤层为迎风面，所述支撑保护层为出风面；
所述异味净化层为矩形阵列分布的净化填充料，所述净化填充料分布于预过滤层、中效容灰层之间，所述净化填充料之间留有网格间隙，所述网格间隙为预过滤层、中效容灰层的连接区域；
所述中效容灰层、高效过滤层以及支撑保护层组成复合支撑层，所述复合支撑层的内部冲制有矩形阵列分布的容纳槽，所述容纳槽朝向支撑保护层下凹，每个所述容纳槽的内部均填充有净化填充料；
PM2.5车载空气滤材的制备方法，所述制备方法包括以下步骤：
S1、将支撑保护层、高效过滤层以及中效容灰层输送至热压机中，支撑保护层、高效过滤层以及中效容灰层由下至上分布，使得支撑保护层、高效过滤层以及中效容灰层热压为复合支撑层；
S2、将所述复合支撑层输送至冲制模具内，冲制模具的上模板向下冲压复合支撑层，冲制模具的下模板从底部复合支撑层，上模板底面的分布有向下的凸头，上模板顶面分布有下凹的配合槽，凸头、配合槽共同在复合支撑层上冲制出矩形阵列分布的容纳槽，容纳槽之间留有网格间隙；
S3、将净化填充料填充至各个所述容纳槽内，并压实净化填充料，
S4、将预过滤层铺设在复合支撑层上，预过滤层覆盖住各个容纳槽，然后对预过滤层相对网格间隙的区域进行固定操作，使得预过滤层固定在复合支撑层上。
2.根据权利要求1所述的一种PM2.5车载空气滤材，其特征在于：所述预过滤层、中效容灰层的连接方式为压接和缝制中的一种或多种。
3.根据权利要求1所述的一种PM2.5车载空气滤材，其特征在于：所述预过滤层采用含杀菌物质的无纺布材料制得，所述中效容灰层采用热风棉制得，所述高效过滤层采用高效熔喷布制得，所述支撑保护层采用含杀菌物质的无纺布骨架制得，所述净化填充料采用椰壳活性炭和高分子颗粒物制得。
4.根据权利要求1所述的一种PM2.5车载空气滤材，其特征在于：所述支撑保护层、高效过滤层之间填充有香味散发层，所述香味散发层采用果香颗粒物制得。
5.一种PM2.5车载空气滤材的制备方法，其特征在于：所述制备方法包括以下步骤：
S1、将支撑保护层、高效过滤层以及中效容灰层输送至热压机中，支撑保护层、高效过滤层以及中效容灰层由下至上分布，使得支撑保护层、高效过滤层以及中效容灰层热压为复合支撑层；
S2、将所述复合支撑层输送至冲制模具内，冲制模具的上模板向下冲压复合支撑层，冲制模具的下模板从底部复合支撑层，上模板底面的分布有向下的凸头，上模板顶面分布有下凹的配合槽，凸头、配合槽共同在复合支撑层上冲制出矩形阵列分布的容纳槽，容纳槽之间留有网格间隙；
S3、将净化填充料填充至各个所述容纳槽内，并压实净化填充料，
S4、将预过滤层铺设在复合支撑层上，预过滤层覆盖住各个容纳槽，然后对预过滤层相对网格间隙的区域进行固定操作，使得预过滤层固定在复合支撑层上。
6.根据权利要求5所述的一种PM2.5车载空气滤材的制备方法，其特征在于：在S4中，所述固定操作所采用的方式为压接和缝制中的一种或多种。
7.根据权利要求5所述的一种PM2.5车载空气滤材的制备方法，其特征在于：所述预过滤层采用含杀菌物质的无纺布材料制得，所述中效容灰层采用热风棉制得，所述高效过滤层采用高效熔喷布制得，所述支撑保护层采用含杀菌物质的无纺布骨架制得，所述净化填充料采用椰壳活性炭和高分子颗粒物制得。
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