CN114433244A - Filtering membrane for catalyzing and degrading formaldehyde, preparation method and air purification device - Google Patents
Filtering membrane for catalyzing and degrading formaldehyde, preparation method and air purification device Download PDFInfo
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- 230000000593 degrading effect Effects 0.000 title abstract description 39
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J31/00—Catalysts comprising hydrides, coordination complexes or organic compounds
- B01J31/26—Catalysts comprising hydrides, coordination complexes or organic compounds containing in addition, inorganic metal compounds not provided for in groups B01J31/02 - B01J31/24
- B01J31/32—Catalysts comprising hydrides, coordination complexes or organic compounds containing in addition, inorganic metal compounds not provided for in groups B01J31/02 - B01J31/24 of manganese, technetium or rhenium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
- B01D53/34—Chemical or biological purification of waste gases
- B01D53/74—General processes for purification of waste gases; Apparatus or devices specially adapted therefor
- B01D53/86—Catalytic processes
- B01D53/8668—Removing organic compounds not provided for in B01D53/8603 - B01D53/8665
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J35/00—Catalysts, in general, characterised by their form or physical properties
- B01J35/50—Catalysts, in general, characterised by their form or physical properties characterised by their shape or configuration
- B01J35/58—Fabrics or filaments
- B01J35/59—Membranes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J37/00—Processes, in general, for preparing catalysts; Processes, in general, for activation of catalysts
- B01J37/02—Impregnation, coating or precipitation
- B01J37/0215—Coating
- B01J37/0219—Coating the coating containing organic compounds
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2257/00—Components to be removed
- B01D2257/70—Organic compounds not provided for in groups B01D2257/00 - B01D2257/602
- B01D2257/704—Solvents not covered by groups B01D2257/702 - B01D2257/7027
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2259/00—Type of treatment
- B01D2259/45—Gas separation or purification devices adapted for specific applications
- B01D2259/4508—Gas separation or purification devices adapted for specific applications for cleaning air in buildings
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- Chemical Kinetics & Catalysis (AREA)
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- Organic Chemistry (AREA)
- Environmental & Geological Engineering (AREA)
- Inorganic Chemistry (AREA)
- Health & Medical Sciences (AREA)
- Biomedical Technology (AREA)
- Analytical Chemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Disinfection, Sterilisation Or Deodorisation Of Air (AREA)
- Catalysts (AREA)
- Exhaust Gas Treatment By Means Of Catalyst (AREA)
Abstract
The invention discloses a filtering membrane for catalyzing and degrading formaldehyde, a preparation method and an air purification device, comprising the following steps: the catalyst comprises a matrix and catalyst particles, wherein the matrix is provided with a net structure formed by fibers, the catalyst particles are attached to the fibers, and at least part of the catalyst particles are positioned in the net structure. Therefore, the formaldehyde is catalytically degraded by the catalyst loaded in the matrix, so that the effect of air purification is achieved.
Description
Technical Field
The invention relates to the field of filtration, in particular to a filtration membrane for catalyzing and degrading formaldehyde, a preparation method and an air purification device.
Background
In recent years, the demand for the quality of indoor air environment is higher and higher, and therefore, air purification materials are attracting much attention. Formaldehyde is a common indoor air pollutant, has the characteristics of long latent period, many release sources, slow release, persistent pollution and the like, has irritant toxicity, is a carcinogenic substance, and can affect human health through inhalation and skin contact. Common air purification materials in the market all adopt physical filtration and adsorption modes to remove pollutants in the air. But the limited adsorption capacity of the catalyst can not meet the purification requirement for a long time.
Therefore, a filtration membrane for catalytically degrading formaldehyde and a preparation method thereof, and an air cleaning apparatus are still to be improved.
Disclosure of Invention
In one aspect of the present application, the present invention provides a filtration membrane for catalytic degradation of formaldehyde, comprising: the catalyst comprises a matrix and catalyst particles, wherein the matrix is provided with a net structure formed by fibers, the catalyst particles are attached to the fibers, and at least part of the catalyst particles are positioned in the net structure. Therefore, the formaldehyde is catalytically degraded by the catalyst loaded in the matrix, so that the effect of air purification is achieved.
According to an embodiment of the invention, the mesh-like structure comprises a first region and a second region, the fiber aggregation density in the first region being greater than the fiber aggregation density in the second region, the total amount of mass of the catalyst particles distributed in the first region being greater than the total amount of mass of the catalyst particles distributed in the second region. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the invention, at least 95% of the catalyst particles are located inside the network. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the invention, said catalyst particles are located in the region between two of said fibers and in contact with one or both of said fibers, with or without the intersection of said fibers. Therefore, the performance of catalyzing and degrading formaldehyde by the filtering membrane can be further improved.
According to an embodiment of the invention, two of said fibers are connected by said catalyst particles. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the invention, the catalyst particles are located at the intersection points where a plurality of the fibers intersect. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the present invention, the total mass amount of the catalyst particles located between two or more of the fibers is larger than the total mass amount of the catalyst particles located on a single one of the fibers, and the total mass amount of the catalyst particles located between three or more of the fibers is larger than the total mass amount of the catalyst particles located between two of the fibers. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the invention more than 60% of said catalyst particles are located between three or more of said fibres. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the invention more than 60% to 80% of said catalyst particles are located between three or more of said fibres. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the invention, 2-5% of said catalyst particles are located between two of said fibres. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the invention, 0.01-2% of said catalyst particles are located on a single one of said fibers. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the present invention, the content of the catalyst particles located at a distance of 0.2mm or less between adjacent fibers is greater than the content of the catalyst particles located at a pitch of 0.2mm or more between adjacent fibers. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to the embodiment of the invention, the loading amount of the catalyst particles is 30-150g/m2. Therefore, the performance of catalyzing and degrading formaldehyde by the filtering membrane in unit area can be improved by larger catalyst loading capacity.
According to an embodiment of the present invention, the catalyst particles are manganese-based oxides. Therefore, the formaldehyde degradation performance of the filtering membrane can be improved by the advantages of high formaldehyde degradation efficiency through manganese oxide catalysis, no pollution, low price and the like.
According to an embodiment of the present invention, the median particle size of the catalyst particles is 100-500 nm. Thereby, the formaldehyde degradation performance of the filter membrane is further improved.
According to an embodiment of the invention, the fibers are formed from at least one of polypropylene, polyethylene terephthalate, polyamide, viscose, polyacrylonitrile, high density polyethylene and polyvinyl chloride. Therefore, the adhesive force of the fibers in the net structure to the catalyst particles can be improved, and the formaldehyde degradation performance of the filter membrane is further improved.
According to an embodiment of the invention, the grammage of the fibres is between 50 and 100g/m2. Therefore, the catalyst particle loading capacity of the fiber can be improved by regulating and controlling the gram weight of the fiber, and the formaldehyde degradation performance of the filtering membrane is further improved.
According to an embodiment of the invention, the diameter of the fibers is 5-30 microns. Therefore, the loading amount of the catalyst on the fiber can be improved by regulating and controlling the fiber diameter, and the formaldehyde degradation performance of the filtering membrane is further improved.
According to an embodiment of the present invention, further comprising a second filter layer on one side of the substrate, the second filter layer containing at least one of the following structures: a meltblown layer formed from a material comprising polypropylene; HEPA filter layer. Thereby, the formaldehyde degrading performance of the filter membrane can be further improved by the formation of the second filter layer.
According to the embodiment of the invention, the filtering membrane is provided with saw-tooth-shaped protrusions, and the included angle between two edges forming the saw-tooth-shaped protrusions is 5-30 degrees. From this, through the folding structure of filtration membrane further improve the formaldehyde degradation performance of filtration membrane.
In another aspect of the present invention, the present invention provides a method for preparing the aforementioned filter membrane for catalytic degradation of formaldehyde, comprising: forming a catalyst slurry; the catalyst slurry is supported on a substrate to fix the catalyst. Thus, the catalyst can be supported on the substrate by supporting the catalyst slurry, a filtration membrane containing catalyst particles therein is formed, and formaldehyde is catalytically degraded by the catalyst particles on the filtration membrane. The method has the advantages of simple preparation process, simple and convenient operation, low raw material cost and the like, and the prepared filter membrane has all the characteristics and advantages of the filter membrane for catalyzing and degrading formaldehyde and is not repeated herein.
According to an embodiment of the present invention, the catalyst paste includes a catalyst, a dispersion liquid, and a binder. Thereby, a stable and uniform catalyst slurry can be formed.
According to the embodiment of the invention, the viscosity of the catalyst slurry is 1200-1500 cP. Thus, the catalyst slurry can be uniformly applied to the surface of the fibers of the web structure by the high viscosity of the catalyst slurry.
According to an embodiment of the present invention, the catalyst in the catalyst slurry is 25 to 40% by weight. This can further increase the amount of the catalyst supported on the fiber surface of the network structure.
According to the embodiment of the invention, the weight part of the adhesive in the catalyst slurry is 10-20%. This can further increase the viscosity of the catalyst slurry.
According to an embodiment of the present invention, the catalyst is a manganese-based oxide. Thus, the manganese oxide can be used for catalyzing and degrading formaldehyde.
According to an embodiment of the present invention, the median particle size of the catalyst is 100-500 nm. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to an embodiment of the invention, the dispersion is water. This can further disperse the catalyst in the catalyst slurry.
According to an embodiment of the invention, the adhesive is a polyacrylic adhesive. Thereby, the viscosity of the catalyst paste can be increased by the binder.
According to an embodiment of the invention, the solid content of the polyacrylic acid adhesive is 45-50%. This can further increase the viscosity of the catalyst slurry.
According to an embodiment of the present invention, the loading of the catalyst ink on the substrate is achieved by at least one of roll coating, dip coating, and spray coating. Thus, the catalyst slurry can be uniformly applied to the surface of the substrate.
According to an embodiment of the present invention, after fixing the catalyst on the substrate, further comprises: a second filter layer is bonded to one side of the substrate. Therefore, the performance of catalyzing and degrading the formaldehyde by the filtering membrane can be improved by arranging the second filtering layer.
According to an embodiment of the invention, the second filter layer comprises at least one of a meltblown layer and a HEPA filter layer. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
In another aspect of the invention, the invention provides an air purification device, which is internally provided with the filter membrane for catalyzing and degrading formaldehyde. Therefore, the air purification device has all the characteristics and advantages of the filtering membrane for catalyzing and degrading formaldehyde, and the description is omitted.
Drawings
The above and/or additional aspects and advantages of the present invention will become apparent and readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
FIG. 1 shows a schematic structural diagram of a filtration membrane for catalytic degradation of formaldehyde according to one embodiment of the present invention;
FIG. 2 shows a schematic structural view of a filtration membrane for catalytic degradation of formaldehyde according to yet another embodiment of the present invention;
FIG. 3 shows a schematic structural diagram of a filtration membrane for catalytic degradation of formaldehyde according to another embodiment of the present invention;
FIG. 4 shows a schematic flow diagram of a process for preparing a filtration membrane for the catalytic degradation of formaldehyde according to one embodiment of the present invention;
fig. 5 shows a schematic flow diagram of a method for preparing a filtration membrane for catalytic degradation of formaldehyde according to yet another embodiment of the present invention.
Description of reference numerals:
100: catalyst particles; 200: a substrate; 300: an adhesive; 10: a filtration membrane; 20: a melt-blown layer; 30: a bonding layer; 40: HEPA filter layer.
Detailed Description
Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like or similar reference numerals refer to the same or similar elements or elements having the same or similar function throughout. The embodiments described below with reference to the accompanying drawings are illustrative only for the purpose of explaining the present invention, and are not to be construed as limiting the present invention.
The present application is made based on the findings of the inventors on the following problems:
the inventor finds that the active carbon can not play a role in air purification again along with the prolonging of the service time because the adsorption quantity of the active carbon is limited by taking the active carbon as an example for removing pollutants in the air by adopting a physical filtration and adsorption mode. The catalyst has the advantages of high efficiency, long sustainable time and the like, and can replace activated carbon to meet the requirement of air purification. The catalyst is loaded on the substrate of the filter membrane in a certain way, and when air flows through the surface of the substrate or penetrates through the substrate, formaldehyde in the air can contact with the catalyst so as to realize catalytic degradation of the formaldehyde.
The present application is directed to solving, to some extent, one of the technical problems in the related art.
In one aspect of the present application, with reference to fig. 1, the present invention proposes a filtration membrane for the catalytic degradation of formaldehyde, comprising: the catalyst comprises a substrate 200, wherein the substrate 200 has a net structure formed by fibers, and catalyst particles 100 are attached to the fibers, and at least part of the catalyst particles 100 are positioned in the net structure. Therefore, the formaldehyde is catalyzed and degraded by the catalyst particles loaded in the matrix, so that the air purification effect is achieved.
It should be noted that, in the present invention, the term "aggregation" is intended to mean that the distance between any two fibers is smaller than a predetermined threshold value, and it is determined that the fibers are aggregated here. In particular, the predetermined threshold value may be determined by the filament diameters of the two fibers. For example, according to one embodiment of the present invention, for a given two fibers, the diameter of the fibers can be measured, as well as the distance between the centers of the two fibers, which is the minimum of the diameters of the two fibers, i.e., the two fibers can be considered to be aggregated. The concentration density may be a ratio of the number of fibers collected per unit area to the total number of fibers in a certain section of the filter membrane. The aggregate density is also determined by the number of fibers per unit volume, with the greater the number of fibers per unit volume, the greater the aggregate density of the characterized fibers. It will be understood by those skilled in the art that the concentration density can be determined as a function of the actual conditions, i.e., if the filter membrane is the subject of interest, the concentration density can be determined as a function of the number of fibers per unit volume of filter membrane; when a certain cross section of the filtration membrane is the subject of investigation, the concentration density can be determined by the number of fibers per unit area of a certain cross section of the filtration membrane.
According to some embodiments of the invention, the mesh structure comprises a first region and a second region, the fiber aggregation density in the first region being greater than the fiber aggregation density in the second region, the total amount of mass of the catalyst particles distributed in the first region being greater than the total amount of mass of the catalyst particles distributed in the second region. For the area with higher fiber aggregation density, the slower the gas flowing speed among the fibers is, the more the total mass of the catalyst particles is distributed in the area, and the contact area and time between the air and the catalyst can be effectively improved, so that the catalytic efficiency is improved. If the number of catalyst particles attached to the region having a high fiber aggregation density is also large, the catalyst particles come into contact with each other, which contributes to improvement in the stability of attachment of the catalyst particles. For the area with low fiber aggregation density, the airflow speed in the area is high, and the number of the catalyst particles distributed in the area is small, so that the utilization rate of the catalyst particles in the area is high, and the adhesion stability of the catalyst can be improved. The first area and the second area act together, so that the overall catalytic purification efficiency of the filtering membrane is effectively improved, and the powder falling phenomenon can be remarkably reduced.
According to some embodiments of the present invention, the proportion of the catalyst particles located inside the mesh structure is not particularly limited, and for example, at least 95% of the catalyst particles may be located inside the mesh structure. Therefore, the loading capacity and the catalytic efficiency of the catalyst particles on the filter membrane can be effectively improved.
According to some embodiments of the present invention, the manner in which the catalyst particles are contacted with the fibers is not particularly limited. For example, the catalyst particles can be located in the region between two fibers and in contact with one or both of the two fibers, the two fibers can intersect or not, or the two fibers can be connected by catalyst particles, or catalyst particles can be located at the intersection of multiple fibers. When the catalyst particles and the fibers are contacted in the contact mode, the utilization rate of the catalyst particles attached to the fibers can be effectively improved, and the adhesive force between the catalyst particles and the fibers can be obviously enhanced.
According to some embodiments of the present invention, referring to fig. 2, the relationship between the distribution of the catalyst particles 100 and the number of fibers is not particularly limited, for example, the total mass of the catalyst particles 100 located between two or more fibers may be greater than the total mass of the catalyst particles 100 located on a single fiber, and the total mass of the catalyst particles 100 located between three or more fibers may be greater than the total mass of the catalyst particles 100 located between two fibers. The catalyst particles 100 and the matrix 200 having a network structure formed of fibers are bonded together by the adhesive 300, and when the contact area between the catalyst particles 100 and the matrix 200 is increased, the adhesive 300 enhances the bonding effect between the catalyst particles 100 and the matrix 200, and the adhesive force between the catalyst particles 100 and the matrix 200 is further increased. When the catalyst particles are positioned between two or more fibers, the catalyst particles are mainly positioned in the net-shaped structure formed by the fibers, the contact area between the catalyst particles and the net-shaped structure is larger, the adhesive force between the catalyst particles and the fibers is larger, the adhesive capacity of the catalyst particles on the surfaces of the fibers is effectively improved, and the stability of the catalyst particles on the filtering membrane is further improved.
According to some embodiments of the present invention, when gas flows through the filter membrane, the flow rate of the gas within the filter membrane is slowed due to the blocking effect of the filter membrane. When the catalyst particles can be positioned in the net structure, the contact time of the catalyst particles and the gas to be purified is longer than that of the catalyst particles positioned on the surface of the net structure, which is beneficial to further improving the performance of the catalyst for catalyzing and degrading formaldehyde. The proportion of the catalyst particles among the catalyst particles located between three or more fibers is not particularly limited, and specifically, more than 60% of the catalyst particles among the catalyst particles may be located between three or more fibers. According to some embodiments of the invention, there may be more than 60% to 80% of the catalyst particles located between three or more fibers. When more than 60% of catalyst particles are positioned among three or more fibers, the stability and the loading capacity of the loaded catalyst particles can be improved by increasing the contact area between the catalyst particles and the fibers, the reaction time between the catalyst particles and the gas to be purified can be prolonged, and the formaldehyde catalytic degradation performance of the filtering membrane is further improved. According to some embodiments of the present invention, the proportion of catalyst particles located between two fibers among the catalyst particles is not particularly limited, for example, there may be 2 to 5% of catalyst particles located between two fibers among the catalyst particles. According to some embodiments of the present invention, the proportion of catalyst particles among the catalyst particles that are located on individual fibers is not particularly limited, for example, the catalyst particles may have 0.01 to 2% of the catalyst particles located on individual fibers. Therefore, the performance of the filter membrane for catalyzing and degrading formaldehyde can be further improved.
According to some embodiments of the present invention, the distance between adjacent fibers is not particularly limited, for example, the distance between adjacent fibers may range from 0 to 0.2 mm. When the distance between adjacent fibers is greater than 0.2mm, the catalyst cannot be preferably supported between two or more fibers, which is disadvantageous for stably supporting the catalyst particles inside the network structure.
According to some embodiments of the present invention, the relationship between the content of catalyst particles located on a distance of 0.2mm or less between adjacent fibers and the content of catalyst particles located on a distance of more than 0.2mm between adjacent fibers is not particularly limited, for example, the content of catalyst particles located on a distance of 0.2mm or less between adjacent fibers may be larger than the content of catalyst particles located on a distance of more than 0.2mm between adjacent fibers. When the content of the catalyst particles positioned on the distance between the adjacent fibers is larger than 0.2mm and is larger than the content of the catalyst particles positioned on the distance between the adjacent fibers is smaller than or equal to 0.2mm, most of the catalyst particles on the filtering membrane are only contacted with a single fiber, the adhesive force between the catalyst particles and the fibers is small, and the powder removal phenomenon of the catalyst particles is easy to occur in the actual use process.
It will be appreciated by those skilled in the art that for two non-parallel aligned fibers, the distance between the two fibers at different locations will be different. It should be noted that the distance between adjacent fibers is a distance between adjacent fibers around a catalyst particle and a catalyst. Specifically, for two adjacent fibers a and b and catalyst particles c, the distance is the shortest distance of a straight line passing through the catalyst c between the fiber a and the fiber b. Specifically, a line segment passing through the catalyst particles c can be made between the fibers a and b, one end point of the line segment is positioned on the fibers a, the other end point of the line segment is positioned on the fibers b, when two ends of the line segment move on the fibers a and b, the value of the line segment changes, and the minimum value of the line segment is the distance between adjacent fibers. The value may be 0. I.e. when two fibers a and b are present, the distance between adjacent fibers at the intersection is 0.
According to some embodiments of the present invention, the loading amount of the catalyst particles on the filtration membrane is not particularly limited, for example, the loading amount of the catalyst particles may range from 30 to 150g/m2. When the loading amount of the catalyst particles on the filter membrane is less than 30g/m2When the amount of catalyst particles on the filtering membrane is too small, the substrate cannot be covered by the catalyst comprehensively, and the integral catalytic performance of the filtering membrane is not enough to meet the daily air purification requirement; when the loading amount of the catalyst particles on the filter membrane is more than 150g/m2The process is difficult, andand because the catalyst quantity on the unit area is more, the cavity of base member is blockked up by the catalyst, and the resistance that receives when treating the air current of purifying through the filter membrane is great, and the flow rate is slower, and filter membrane catalytic degradation formaldehyde is efficient less, is not enough to satisfy daily air purification demand. And the filter membrane with large loading capacity is easy to generate the phenomenon of catalyst particle shedding in the actual use process, and when the catalyst particles are blown away into indoor air by gas, the catalyst particles can be inhaled into the body by people, so that the risk of health hazard exists.
According to some embodiments of the present invention, the kind of the catalyst particles is not particularly limited as long as it has good performance of catalytically degrading formaldehyde, and the formaldehyde degradation product has no pollution to the environment and is low in cost. For example, the catalyst particles may be manganese-based oxides.
According to some embodiments of the present invention, the median particle diameter of the catalyst particles is not particularly limited, for example, the median particle diameter of the catalyst particles may range from 100 to 500 nm. When the median diameter is less than 100nm, the catalyst particles loaded on the surface of the substrate are easy to fall off, and the performance of the catalyst particles for catalyzing and degrading formaldehyde is unstable. When the median diameter is larger than 500nm, the particles of the catalyst powder are larger, the amount of the catalyst particles which can be loaded on a unit area is less, and the formaldehyde catalytic degradation performance of the filtering membrane is related to the number of the catalyst particles, so that the catalytic degradation performance of the filtering membrane is not improved. In addition, when the median diameter of the catalyst particles is too large, in practical application, the catalyst particles on the filtering membrane may be separated from the filtering membrane due to insufficient adhesive force, and further the performance of the filtering membrane for catalyzing and degrading formaldehyde is deteriorated, and the requirement of long-duration use cannot be met.
According to some embodiments of the present invention, the kind of the fiber forming the mesh structure is not particularly limited as long as the fiber can form a non-woven fabric. For example, the fibers forming the network structure may be at least one of propylene, polyethylene terephthalate, polyamide, viscose, polyacrylonitrile, high density polyethylene, and polyvinyl chloride.
According to some embodiments of the invention, the grammage of the fibers is not particularly limited, e.g., the grammage of the fibers may range from50-100g/m2. According to some embodiments of the invention, the diameter of the fibers is not particularly limited, for example the diameter of the fibers may range from 5 to 30 microns. When the diameter of the fiber is less than 5 microns or the gram weight of the fiber is less than 50g/m2In the process of loading the catalyst, the fiber is easy to break, the loading capacity is low, the performance requirement of catalyzing and degrading formaldehyde cannot be met, and the strength of the filtering membrane is low, so that the filtering membrane is easy to deform; when the diameter of the fiber is more than 30 microns or the gram weight of the fiber is more than 100g/m2During the process, the wind resistance of the net structure formed by the fibers is large, the air penetration resistance is large after the catalyst is loaded, and the filtering efficiency of the filtering membrane cannot meet the requirement of catalytic degradation of formaldehyde.
According to some embodiments of the present invention, referring to fig. 3, a second filter layer may be further formed at one layer of the filter membrane 10, the second filter layer being located at one side of the substrate. The composition of the second filter layer is not particularly limited, for example, the second filter layer may be a meltblown layer 20 or a meltblown layer 20 and a HEPA filter layer 40, wherein the meltblown layer 20 and the high efficiency filter layer 40 are connected by a bonding layer 30. Through the formation of the second filter layer, the gas flow speed and the fluid direction of the gas to be purified can be adjusted, the contact time of catalyst particles in the filter membrane and the gas to be purified is further prolonged, and the performance of the filter membrane for degrading and degrading formaldehyde is improved. According to some embodiments of the present invention, the material forming the meltblown layer is not particularly limited, for example, the material forming the meltblown layer may be polypropylene.
According to some embodiments of the present invention, referring to fig. 3, since the base material of the filtering membrane is a non-woven fabric, the filtering membrane is bendable, and the internal structure is not affected after being folded at a certain angle. The shape of the filtering membrane is not particularly limited, for example, the filtering membrane may have saw-tooth shaped protrusions, and the angle between both sides of the saw-tooth shaped protrusions is not particularly limited, for example, the angle α between both sides of the saw-tooth shaped protrusions may range from 5 to 30 degrees. It should be noted that the included angle is an acute angle between the included angles of the two sides of the saw-tooth protrusion. Therefore, the contact area of the filtering membrane and the air can be increased through the sawtooth-shaped convex structures, the wind resistance of the net-shaped structure formed by the fibers can be reduced, and the purification amount of the air in unit time is improved
According to some embodiments of the present invention, the structure of the filtering membrane is not particularly limited, and the filtering membrane has flexibility because the base material of the filtering membrane is a non-woven fabric, and the internal structure is not affected after bending at a certain angle. For example, the filtering membrane can be in a circular arc or cylindrical structure, so that the air purifying device can be suitable for air purifying devices with different shapes and structures.
According to some embodiments of the present invention, the filtering membrane may be bent into a circular arc shape or a cylindrical shape as a whole while having the saw-tooth shaped protrusions. Therefore, on one hand, the contact area with air can be increased and the wind resistance can be reduced by utilizing the zigzag protrusions, and on the other hand, the novel air purifier is also suitable for different air purification devices. For example, the cylindrical filtering membrane can make air flow from the outer surface of the cylindrical shape to the side of the inner surface of the cylindrical shape, thereby realizing the filtering of the air and the catalytic removal of formaldehyde.
It should be noted that, because the filtering membrane has better flexibility, the filtering membrane can be directly bent into a shape and a structure suitable for actual conditions, and the shape and the structure can be adjusted after the filtering membrane is attached to the attached functional layer. For example, when the functional layer is the second filter layer, the filter membrane and the second filter layer may be respectively folded to form the saw-toothed protrusions and then attached, or the filter membrane and the second filter layer may be attached first, and then the attached composite membrane layer is folded to obtain the saw-toothed protrusions. The skilled person can choose when to perform the folding and bending operations of the filter membrane according to the actual situation.
In another aspect of the present invention, the present invention provides a method for preparing the foregoing filtration membrane for catalytically degrading formaldehyde, the method comprising: forming a catalyst slurry; the catalyst slurry is supported on a substrate to fix the catalyst. Thus, the catalyst can be supported on the substrate by supporting the catalyst slurry, a filtration membrane containing catalyst particles therein is formed, and formaldehyde is catalytically degraded by the catalyst particles on the filtration membrane. The method has the advantages of simple preparation process, simple and convenient operation, low raw material cost and the like, and the prepared filter membrane has all the characteristics and advantages of the filter membrane for catalyzing and degrading formaldehyde, and is not repeated herein.
Specifically, referring to fig. 4, the method may include the steps of:
s100: forming a catalyst slurry
According to some embodiments of the invention, a catalyst slurry is formed at this step. The slurry of the catalyst should have a viscosity to form a uniform and stable coating on the surface of the fiber, and thus the catalyst slurry should include a binder for adjusting the viscosity of the catalyst slurry and a dispersion for dispersing catalyst particles in a solution, in addition to the catalyst.
According to some embodiments of the present invention, the catalyst ink should form a uniform and stable coating of the catalyst ink on the fiber surface, thereby improving the dispersion of the catalyst particles on the fiber surface. The viscosity of the catalyst slurry is not particularly limited, and for example, the viscosity of the catalyst slurry may range from 1200-1500 cP. When the viscosity of the catalyst slurry is less than 1200cP, the retention time of the catalyst slurry on the fiber surface is short, and a uniform and stable catalyst slurry coating cannot be formed; when the viscosity of the catalyst slurry is greater than 1500cP, the flowing speed of the catalyst slurry is too low, the time for forming a uniform and stable catalyst slurry coating on the fiber surface is too long, and the subsequent drying operation is not facilitated due to the large content of the adhesive in the catalyst slurry.
According to some embodiments of the present invention, the weight part of the catalyst in the catalyst slurry is not particularly limited, for example, the weight part of the catalyst in the catalyst slurry may range from 25 to 40%. When the weight part of the catalyst in the catalyst slurry is less than 25%, the concentration of the catalyst in the catalyst slurry is low, and the loading amount of the catalyst on the filter membrane cannot meet the requirement. If the requirement of the loading capacity needs to be met, multiple times of processing are needed, the process flow is complex, and the industrial production is not facilitated; when the weight part of the catalyst in the catalyst slurry is more than 40%, the viscosity of the catalyst slurry is high, a pipeline is blocked when the catalyst slurry is loaded on a substrate, the uniformity of the loading amount of the catalyst on a filtering membrane is difficult to control, and the performance index of the product is unqualified.
According to some embodiments of the present invention, the weight part of the binder in the catalyst paste is not particularly limited, for example, the weight part of the binder in the catalyst paste may range from 10 to 20%. When the weight part of the adhesive in the catalyst slurry is less than 10%, the viscosity of the catalyst slurry is low, which is not favorable for forming a uniform coating on the fiber surface. When the weight part of the adhesive in the catalyst slurry is higher than 20%, the viscosity of the catalyst slurry is too high, the catalyst slurry flows slowly, the process consumes long time, and the mass production is not facilitated.
According to some embodiments of the present invention, the kind of the catalyst is not particularly limited, and for example, the catalyst may be a manganese-based oxide. According to some embodiments of the present invention, the median particle size of the catalyst is not particularly limited, for example, the median particle size of the catalyst may range from 100 to 500 nm. When the median particle size of the catalyst is less than 100nm, the powder surface energy of the catalyst is large, agglomeration is easy to occur, the catalyst is difficult to be uniformly dispersed in an aqueous solution in the loading process, the catalyst is easy to fall off from fibers after being loaded, and the performance is unstable. When the median particle size of the catalyst is larger than 500nm, the particles of the catalyst powder are larger, the specific surface area which can be provided is greatly reduced, and the catalytic efficiency of the catalyst is poorer.
According to some embodiments of the present invention, the kind of the dispersion liquid is not particularly limited as long as the catalyst particles are well dissolved. For example, the dispersion may be water.
According to some embodiments of the present invention, the kind of the adhesive is not particularly limited as long as the catalyst can be bonded to the surface of the fiber. For example, the adhesive may be a polyacrylic adhesive. According to some embodiments of the present invention, the solid content of the polyacrylic acid adhesive is not particularly limited, and the solid content of the polyacrylic acid adhesive may range from 45 to 50%.
S200: loading catalyst slurry onto a substrate
According to some embodiments of the invention, the catalyst slurry is loaded onto the substrate at this step, and the catalyst is immobilized.
According to some embodiments of the invention, the process of supporting the catalyst slurry on the substrate is not particularly limited as long as the catalyst slurry can be uniformly coated on the fibers in the network structure forming the substrate. For example, the process of supporting the catalyst slurry on the substrate may be at least one of roll coating, dip coating, and spray coating.
According to some embodiments of the present invention, the catalyst may be immobilized after the catalyst slurry is loaded on the substrate. The method of fixing the catalyst is not particularly limited, and for example, the substrate on which the catalyst slurry is supported may be subjected to a drying operation to fix the catalyst. The method of fixing the catalyst after loading the catalyst slurry on the substrate can be selected by those skilled in the art according to the actual circumstances.
In order to further improve the performance of the filter membrane for catalyzing and degrading formaldehyde, the method can further bond a second filter layer on one side of the substrate after the catalyst is fixed on the substrate, and the specific steps are as follows with reference to fig. 5:
s300: bonding a second filter layer to one side of the substrate
According to some embodiments of the invention, the second filter layer is formed at this step. The second filter layer can further adjust the gas flow speed and the fluid trend of the gas to be purified, and the performance of the filter membrane for catalyzing and degrading formaldehyde is further improved. According to some embodiments of the present invention, the composition of the second filter layer is not particularly limited, for example, the second filter layer may include at least one of a meltblown layer and a HEPA filter layer.
In another aspect of the invention, the invention provides an air purification device, and the air purification device is internally provided with the filter membrane for catalyzing and degrading formaldehyde. Therefore, the air purification device has all the characteristics and advantages of the filtering membrane for catalyzing and degrading formaldehyde, and the description is omitted.
The following embodiments are provided to illustrate the present application, and should not be construed as limiting the scope of the present application. The examples, where specific techniques or conditions are not indicated, are to be construed according to the techniques or conditions described in the literature in the art or according to the product specifications. The reagents or instruments used are not indicated by the manufacturer, and are all conventional products commercially available.
Example 1:
1. dispersing a manganese dioxide catalyst with a median particle size of 200nm in purified water, wherein the weight part of the catalyst is 30 parts, stirring the mixture for 5 minutes at 1500 revolutions per minute by using a high-speed stirrer, adding 45 parts by weight of polyacrylic acid adhesive with solid content of 50% into the manganese dioxide aqueous solution, and uniformly dispersing and mixing the mixture at a high speed to form catalyst slurry with viscosity of 1300 cP.
2. Uniformly loading the catalyst slurry to the fiber with the gram weight of 45g/m in a spraying manner2Drying the polyethylene terephthalate fiber non-woven fabric substrate at 110 ℃ for 30min, wherein the loading capacity of the catalyst is 80g/m2And obtaining the filtering membrane, wherein 80% of catalyst particles are positioned in the net-shaped structure and positioned among three or more fibers, and the distance between every two adjacent fibers at most of the catalyst is less than 0.2 mm.
3. The filtering membrane is folded into a structure with zigzag protrusions, and the included angle between two edges of the zigzag protrusions is 15 degrees. And (4) carrying out formaldehyde removal performance test on the filtering membrane with the structure with the saw-toothed protrusions.
The results show that: the removal rate of formaldehyde from the filtration membrane was 95%.
Example 2:
the filtration membrane preparation and formaldehyde removal performance test of this example were consistent with those of example 1, except that the grammage of the polyethylene terephthalate fiber was 60g/m2The loading of the catalyst is 100g/m2The included angle between two sides of the zigzag projection is 20 degrees.
The results show that: the formaldehyde removal rate of the filtration membrane was 98%.
Comparative example 1:
the filtration membrane preparation and formaldehyde removal performance test of this example were consistent with those of example 1, except that the grammage of the polyethylene terephthalate fiber was 30g/m2The included angle between two sides of the zigzag projection is 20 degrees.
The results show that: the removal rate of formaldehyde from the filtration membrane was 31%.
Comparative example 2:
the filter membrane preparation and formaldehyde removal performance test of this example were consistent with those of example 1, except that the median particle diameter of the manganese dioxide particles was 50nm and the gram weight of the polyethylene terephthalate fiber was 60g/m2The included angle between two sides of the zigzag projection is 20 degrees.
The results show that: the removal rate of formaldehyde by the filtration membrane was 23%.
Comparative example 3:
the filtration membrane preparation and formaldehyde removal performance test of this example were consistent with those of example 1, except that the grammage of the polyethylene terephthalate fiber was 60g/m2The loading of the catalyst is 20g/m2The included angle between two sides of the zigzag projection is 20 degrees.
The results show that: the removal rate of formaldehyde from the filtration membrane was 15%.
Comparative example 4:
the filtration membrane preparation and formaldehyde removal performance test of this example were consistent with those of example 1, except that the grammage of the polyethylene terephthalate fiber was 60g/m2And the included angle between two edges of the zigzag protrusions is 1 degree.
The results show that: the formaldehyde removal rate of the filtration membrane was 5%.
In the description herein, references to the description of "one embodiment," "another embodiment," etc., mean that a particular feature, structure, material, or characteristic described in connection with the embodiment is included in at least one embodiment of the invention. In this specification, the schematic representations of the terms used above are not necessarily intended to refer to the same embodiment or example. Furthermore, the particular features, structures, materials, or characteristics described may be combined in any suitable manner in any one or more embodiments or examples. Furthermore, various embodiments or examples and features of different embodiments or examples described in this specification can be combined and combined by one skilled in the art without contradiction.
Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention, and that variations, modifications, substitutions and alterations can be made to the above embodiments by those of ordinary skill in the art within the scope of the present invention.
Claims (20)
1. A filtration membrane for the catalytic degradation of formaldehyde, comprising:
a matrix having a network structure of fibers,
catalyst particles attached to the fibers, at least a portion of the catalyst particles being located within the network.
2. The filtration membrane according to claim 1, wherein said mesh-like structure comprises a first zone and a second zone, the fiber packing density in said first zone being greater than the fiber packing density in said second zone, the mass sum of the distribution of said catalyst particles in said first zone being greater than the mass sum of the distribution of said catalyst particles in said second zone;
optionally, at least 95% of the catalyst particles are located inside the network.
3. The filtration membrane of claim 2, wherein said catalyst particles are located in a region between two of said fibers and in contact with one or both of said fibers, with or without the intersection of said fibers;
optionally, two of said fibres are connected by said catalyst particles.
4. The filtration membrane of claim 2, wherein the catalyst particles are located at an intersection point where a plurality of the fibers intersect.
5. The filtration membrane according to claim 2, wherein the total mass amount of the catalyst particles located between two or more of the fibers is larger than the total mass amount of the catalyst particles located on a single one of the fibers, and the total mass amount of the catalyst particles located between three or more of the fibers is larger than the total mass amount of the catalyst particles located between two of the fibers.
6. The filtration membrane of claim 5, wherein more than 60% of said catalyst particles are located between three or more of said fibers;
preferably, more than 60% to 80% of said catalyst particles are located between three or more of said fibres.
7. The filtration membrane according to claim 5, characterized in that between 2 and 5% of said catalyst particles are located between two of said fibers.
8. The filtration membrane according to claim 5, characterized in that 0.01-2% of said catalyst particles are located on a single one of said fibers.
9. The filtration membrane according to claim 1, wherein the content of said catalyst particles located at a distance of 0.2mm or less between adjacent said fibers is greater than the content of said catalyst particles located at a pitch of 0.2mm or more between adjacent said fibers.
10. A filtration membrane according to any one of claims 1 to 9, characterized in that the loading of said catalyst particles is in the range of 30 to 150g/m2；
Optionally, the catalyst particles are manganese-based oxides;
optionally, the catalyst particles have a median particle size of 100-500 nm.
11. A filter membrane according to any of claims 1-9, c h a r a c t e r i z e d in that the fibers are formed from at least one of polypropylene, polyethylene terephthalate, polyamide, viscose, polyacrylonitrile, high density polyethylene and polyvinyl chloride;
optionally, the fibers have a grammage of 50 to 100g/m2；
Optionally, the fibers have a diameter of 5 to 30 microns.
12. The filtration membrane of claim 1, further comprising a second filtration layer on one side of the substrate, the second filtration layer comprising at least one of the following structures:
a meltblown layer formed from a material comprising polypropylene;
HEPA filter layer.
13. A filter membrane according to claim 12, c h a r a c t e r i z e d in that said filter membrane has saw-tooth like protrusions, the angle between the two edges constituting said saw-tooth like protrusions being 5-30 degrees.
14. A method for preparing a filtration membrane for the catalytic degradation of formaldehyde according to any one of claims 1 to 13, comprising:
forming a catalyst slurry;
the catalyst slurry is supported on a substrate to fix the catalyst.
15. The method of claim 14, wherein the catalyst slurry comprises a catalyst, a dispersion, and a binder;
optionally, the viscosity of the catalyst slurry is 1200-1500 cP;
optionally, the weight part of the catalyst in the catalyst slurry is 25-40%;
optionally, the weight part of the adhesive in the catalyst slurry is 10-20%.
16. The method of claim 15, wherein the catalyst is a manganese-based oxide;
optionally, the catalyst has a median particle size of 100-500 nm;
optionally, the dispersion is water;
optionally, the adhesive is a polyacrylic adhesive;
optionally, the polyacrylic acid adhesive has a solids content of 45-50%.
17. The method of claim 14, wherein supporting the catalyst slurry on the substrate is achieved by at least one of roll coating, dip coating, and spray coating.
18. The method of claim 14, further comprising, after immobilizing the catalyst on the substrate:
a second filter layer is bonded to one side of the substrate.
19. The method of claim 18, wherein the second filter layer comprises at least one of a meltblown layer and a HEPA filter layer.
20. An air cleaning device having therein the filter membrane according to any one of claims 1 to 13.
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