JP2000185088A - Deodorizing filter material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a deodorizing filter material having little pressure loss, obtained by dispersing activated charcoal and/or other deodorant powder into an aqueous binder, then impregnating a synthetic resin net with the dispersion, and drying the net, with the deodorant resisting drop from the net material and with the binder used causing a relatively small decrease in deodorizing performance. SOLUTION: This deodorizing filter material is obtained by uniformly dispersing activated charcoal with 150 or more meshes and/or other water-insoluble deodorant powder into an aqueous binder to obtain a dispersion in which the solid ratio of the activated charcoal and/or the other deodorant to a binder is 1/2 to 5/1, with total solids being 35% to 55%, then immersing a synthetic resin net in the dispersion, and drying it.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a deodorizing filter material obtained by dispersing activated carbon and / or other deodorizing agent powder in an aqueous binder, impregnating the same with a synthetic resin net, and then drying. The present invention relates to a filter material having a low pressure drop, in which a deodorant hardly falls off from a net material, and a decrease in deodorizing performance due to a binder used is relatively small.

[0002]

2. Description of the Related Art As a conventional deodorizing filter material, activated carbon and other deodorizing agents are dispersed in a binder, impregnated into a base material such as a polyurethane foam, a nonwoven fabric, a synthetic resin net, and adhered to the polyurethane foam. There are those obtained by impregnating and adhering an adhesive and adhering activated carbon powder thereto, and those obtained by wrapping granular activated carbon with a nonwoven fabric or polyurethane foam.

[0003] However, in the conventional deodorizing filter material, the deodorizing performance is deteriorated due to the work process of attaching the deodorizing filter material to the base material, the deodorizing material layer is dropped off during handling or use, and in addition to these reasons, other factors are involved. For example, it is difficult to combine such a filter with a dust filter material or the like, and in this regard, there has been a demand for a filter material which is easy to handle and has an excellent deodorizing effect.

[0004] Of these, a deodorizing filter in which activated carbon powder is dispersed in a binder and attached to a synthetic resin net is also known, but the solid content of activated carbon and / or other deodorizing agents / binders is too small, resulting in deodorizing performance. There have been problems such as being low and the deodorant layer easily falling off the strands of the synthetic resin net. In recent years, a deodorizing filter is often used in combination with a charging filter (dust removing) for air cleaning.

[0005] In particular, when low pressure loss is required, a deodorizing filter in which activated carbon and / or other deodorizing agents are adhered to a synthetic resin net is used as a deodorizing filter, and a thin charged nonwoven fabric is used as a charging filter. It has been considered to use a combination of a so-called pleated-type charging filter or the like that has been folded.

[0006]

SUMMARY OF THE INVENTION The present invention provides a deodorizing filter based on a synthetic resin net which has a high deodorizing effect and is easy to handle. Another object of the present invention is to provide a synthetic resin net-based deodorizing filter in which a synthetic resin net-based deodorizing filter can be bonded and combined by thermocompression bonding so as to facilitate the above. Such compounding is very advantageous for continuous production of products and directly leads to an increase in production efficiency.

[0007]

SUMMARY OF THE INVENTION The present invention has been made to overcome such problems of the prior art.
The gist of the invention is as follows. That is, activated carbon and / or other water-insoluble deodorant powder of 150 mesh or more, particularly preferably 200 mesh or more, are uniformly dispersed in an aqueous binder, and the activated carbon and / or other deodorant / binder solid content ratio is 2%. / 1 to 5/1, total solids 35
% Is a net-like deodorizing filter material obtained by immersing a synthetic resin net in a dispersion liquid having a concentration of from 55% to 55%, followed by drying, wherein the strand interval of the synthetic resin net is preferably 1.5 to 7 m / m, It is more preferably 2 to 5 m / m, and is preferably immersed in an aqueous binder using the synthetic resin net or a binder having good adhesiveness with the binder and dried to prevent falling off.
A binder film is previously formed on the strand of the synthetic resin net. Preferably synthetic resin net 1
Activated carbon and / or other deodorant per 15 m ²
It is a deodorizing filter material adhered to 60 gr.

[0008] In particular, for the purpose of complexing, the total solid content of the deodorant powder and the binder is set to 100 parts by weight in the dispersion, and the hot melt adhesive powder is added in an amount of 100 to 180 parts by weight.
It is preferable to add parts by weight.Furthermore, the water-based binder used or a water-based binder having good adhesiveness with the deodorant and the binder layer obtained by drying, which is attached to the synthetic resin net and dried, is used. It consists of coating. In the aqueous binder for such coating, the total solid content of the deodorant powder and the binder was 100 parts by weight,
The hot melt adhesive powder may be added in an amount of 200 to 500 parts by weight, and the softening temperature of the used hot melt adhesive powder is 60 to 120 ° C, more preferably 60 to 8 ° C.
0 ° C.

As a synthetic resin net as a base material, various synthetic resin nets such as polyethylene, polypropylene, polyester, polyamide and polyvinyl chloride are used. Among them, heat resistance is required in drying after impregnation. From the viewpoint of properties, polyester, polyamide and the like are preferable, but from the viewpoint of cost, polypropylene is preferable because of its moderate heat resistance. Specific examples of the net to be used include a synthetic resin extruded into a strand, a stretched film into which fine cracks are formed into split fibers, which are continuously laminated vertically and horizontally, and heat-welded nonwoven fabric, and A material obtained by knitting a plurality of fine fibers in a net shape is used.

In the case of activated carbon and other powder adhering to the above-mentioned synthetic resin net, when the particle size of the powder is larger than a standard, a uniform product which is easy to settle in the dispersion is obtained. Not only that, when a frictional force is applied to the filter, the particles easily fall and the product is unsightly in appearance.

On the other hand, the ratio of the solid content of the deodorant / binder is desirably in the above-mentioned range because if the ratio is too large, the deodorant tends to fall off. Is the choice.

It is desirable to increase the amount of the deodorizing agent per unit area of the synthetic resin net, which leads to an improvement in the performance as a deodorizing agent. Can be raised. However, if the distance between the strands of the net is too small, the net cannot be sufficiently removed even if the net is impregnated with the dispersion and then the air is blown with air or the like to remove the excess dispersion having a film between the strands. In other words, a product in a so-called clogged state is obtained, the appearance is unsightly, and the pressure loss is increased, and the commercial value is lost. Therefore, there is also a condition for optimization as a filter here.

The deodorizing filter of the present invention is a filter obtained by impregnating a synthetic resin net with a dispersion and drying the net. The deodorizing filter has a form in which a binder layer in which a deodorant is dispersed is attached around strands of the net. If the adhesiveness between the resin of the net and the binder layer is poor, the deodorant / binder layer may fall off due to external force such as friction or vibration.
Therefore, in order to prevent this, the net can be prevented by dipping the net in a binder in advance and forming a continuous film on the resin strand of the net. This treatment can be particularly effective when the synthetic resin net is made of a material such as polyethylene, polypropylene, polyester or the like having poor adhesion to binders.

Although it is possible to prevent the deodorant / binder layer from falling off from the net strand as described above, the deodorant powder dispersed and partially embedded in the binder layer may be removed by friction, vibration, impact, or the like. May fall off layers.

When this is used as a deodorizing filter or the like of an air conditioner, the inside of the room becomes dirty, which is a serious problem. In order to prevent this, a great effect can be obtained by further applying a binder from above the binder layer. This coating is performed by spraying, a roll coater, impregnation, or the like, but a spray treatment is preferable for controlling the coating amount to a small and constant amount. If the coating amount is too small, the effect is small, and if the coating amount is too large, the deodorizing performance is greatly reduced.

On the other hand, when bonding with another base material, for example, when combining with a charged nonwoven fabric or a pleated charged nonwoven fabric, a thermocompression bonding method is preferable. For this reason, it is a preferable embodiment to disperse the powder of the hot melt adhesive in the binder in order to give the adhesive strength. If the amount of the hot melt adhesive powder is too small, the adhesive force by thermocompression bonding is not sufficient. If the amount is too large, the inherent adhesive force of the binder becomes insufficient, and the amount of the deodorant added is undesirably reduced. If the softening temperature of such a hot melt adhesive is too low, for example, when used as a deodorizing filter for an air conditioner, it is not preferable because it is softened by warm air, while if it is too high, it is necessary to raise the temperature by thermocompression bonding. In any case, there is a preferable range for softening the net itself.

[0017]

The present invention will be described below with reference to specific examples. Example 1 and Comparative Examples 1 to 5 The first example is a deodorizing filter material according to claim 2 of the present invention.
00 mesh-Y-300 manufactured by Hokuetsu Carbon Industry Co., Ltd.
C) and a synthetic deodorant (average particle size: about 200 mesh; KD-211 manufactured by Lhasa Industry Co., Ltd.). The activated carbon and the synthetic deodorant were blended in a ratio of 100: 60. As a reason for combining these two types of deodorants,
Activated carbon mainly has an adsorbing action for tobacco odor and the like, and a synthetic deodorant has an adsorbing function for ammonia and the like.

The net used was a polypropylene net, and the strand spacing was 3 mm in both length and width using TSX-350P manufactured by Mitsui Oil & Plastics Co., Ltd. An acrylic emulsion (solid content: 52.5%) was used as a binder.
AE-932 manufactured by Japan Synthetic Rubber Co., Ltd.).

In preparing the sample of the first embodiment,
After adjusting the solid content ratio of the deodorizer to the binder to 3.5: 1 and adjusting the total solid content of the blended liquid to 45%, the net surface is impregnated with the slurry, and the clogging of the space between the net strands is blown off by air. And dried at 70 ° C. for 3 minutes. Structurally, it has a structure in which a deodorant is attached with a binder in a net shape.

The total solid content is selected within a certain range. If the total solid content is too low, the slurry of the deodorant and the binder cannot be sufficiently adhered to the net surface, and a satisfactory deodorant can be obtained. When the total solid content is too high, on the other hand, if the total solid content is too high, the compounded liquid becomes muddy and cannot be impregnated and adhered to the net surface. Table 1 shows the evaluation of the deodorizer and the evaluation of the deodorization adsorption.

[0021]

[Table 1]

The evaluation method is as follows. Measurement of deodorizing performance The removal rate was calculated by the following formula. Removal rate = ｛(source gas concentration-
(Processing gas concentration) / original gas concentration｝ × 100 (%). For generation of benzene odor, a standard gas of 30 ppm is obtained by using a standard gas generator manufactured by Gastech Co., Ltd.

On the other hand, the generation of the ammonia odor was carried out by diluting a 28% concentration ammonia reagent to 1/500 with water,
The cc was weighed into a gas cleaning bottle and bubbled with air at 1 l / min to generate 100 ppm ammonia gas.

A gas was generated under such conditions, four samples were stacked, and the measurement was performed with a gas contact diameter of 40 mm, and the removal rate after 5 minutes of measurement was determined.

Measurement of pressure loss The measurement of the pressure loss is carried out in accordance with the second performance test method specified by the Japan Air Cleaning Association, and is a value at a wind speed of 1 m / sec.

Evaluation of powder dropping property Evaluation was a sensory evaluation and was based on the following criteria. ◎: The net was lightly beaten with a hand, and no impact was observed even when an impact was given. ：: Under the same conditions, only a small amount of powder was removed on the palm. △: Under the same conditions, some powder was eliminated on the palm. ×: Under the same conditions as above, a considerable amount of powder dropping was confirmed on the palm, and the resin strand was visible.

Evaluation of Settling Test of Liquid The evaluation was a sensory evaluation and was based on the following criteria. ：: No sedimentation was observed after standing for 24 hours. Δ: Some sedimentation was observed after standing for 24 hours. ×: Approximately 30% or more sedimented after standing for 24 hours. Cannot be redispersed into

Example 2 / Comparative Examples 6 to 7 Example 2 is based on claim 2 of the present invention, in which the deodorant and the binder are adjusted in the same manner as in Example 1, and the distance between the strands of the resin net is reduced. It was changed and evaluated. The average particle size of the deodorant used in the comparative example was 300 mesh. Table 2 shows the evaluation results. As a result, it is understood that a material having a specific mesh interval is preferable.

[0029]

[Table 2]

Embodiment 3 Embodiment 3 shows an embodiment based on claim 3 of the present invention, and features thereof will be described in comparison with the above-described embodiment 1. In this example, in the deodorizing filter material of Example 1, a binder was previously impregnated and adhered to the surface of the strand of the synthetic resin net, and was dried to form a binder film. Thereafter, it was produced in the same manner as in Example 1. Filter material. The binder used was an acrylic emulsion (E-1016D) manufactured by Soken Chemical Co., Ltd., having a solid content of 46%, and was adhered in a dry state at 23 g / m ² . Structurally, the binder is attached to the net, and the deodorant is attached to the binder with the second binder. Table 3 shows the deodorizing performance and the releasability of the deodorant from the strand.

[0031]

[Table 3]

The evaluation of the releasability of the deodorant from the strand is as follows. First, the net is lightly rubbed three times by hand to give a peeling force to the deodorant film and the strand surface. ：: Most of the deodorant adheres to the surface of the strand even after the above operation. ：: A considerable amount of the deodorant peels off, but most of the deodorant remains adhered to the surface of the strand. Almost all deodorants flake off from the strand surface

From the above results, it can be seen that the deodorizing performance of this embodiment is almost the same as that of the first embodiment, but the deodorizing agent has a remarkably improved peeling performance.

Fourth Embodiment A fourth embodiment shows a fourth embodiment according to the sixth aspect of the present invention, which will be described in comparison with the first embodiment. In this example, a coating of EVA hot melt powder (Tokyo Ink Co., Ltd. 5020C (60P)) was formed on the surface of the deodorizing filter of Example 1.

The above-mentioned EVA hot melt powder is prepared in advance by using water and a surfactant (Meanwhile, Inc.
3), EVA using an acrylic emulsion (AE-932 manufactured by Nippon Synthetic Rubber Co., Ltd.) as a binder
Make a hot melt slurry. Each compounding ratio is EVA hot melt powder / water / surfactant / binder, and when the weight of EVA hot melt powder is 100 parts, it is 100 / 203.5 / 1.0 / 47.6 parts by weight. Thereafter, for viscosity adjustment, 15 parts of A-201 manufactured by Toa Gosei Co., Ltd. is added as a thickener into the above-mentioned compounding liquid.
This hot melt slurry was impregnated onto a sample prepared in the same manner as in Example 3 so that 350 parts by weight of the hot melt adhesive powder was added as a total solid content of 100 parts by weight of the deodorant powder and the binder and dried. did.

From a structural point of view, a deodorant is attached as a first layer on a net with a binder, and a hot melt powder is attached as a second layer with a binder.
The polypropylene nonwoven fabric (PK-103, manufactured by Mitsui Petrochemical Industries, Ltd.) and the deodorizing filter materials of Examples 4 and 3 were pressure-bonded with a 130 ° C. iron for 5 seconds to evaluate the adhesion.

Evaluation method of heat weldability ：: Deodorized filter material and polypropylene nonwoven fabric are bonded by heat welding, and are not easily peeled off even if pulled lightly by hand. X: State of easy peeling without adhesion at all. It is shown in Table 4.

[0038]

[Table 4]

[0039]

As described above, the present invention has a remarkable feature as compared with the conventional deodorizing filter material. The deodorizing material has not only its performance, but also its adhesion is certain, and its handling is very careful. It is not necessary and has extremely high practical value.

Claims (8)

[Claims] An activated carbon and / or other water-insoluble deodorant powder of 150 mesh or more is uniformly dispersed in an aqueous binder, and the activated carbon and / or other deodorant / binder has a solid content ratio of 2/1 to 1. 5/1, total solid content 35% -5
A net-like deodorizing filter material obtained by immersing a synthetic resin net in a 5% dispersion and drying it. 2. The deodorizing filter material according to claim 1, wherein a strand interval of the synthetic resin net is 1.5 to 7 m / m. 3. The synthetic resin net is immersed in a water-based binder to be used or a binder having good adhesiveness to the binder, and then dried to form a binder film on the strand of the synthetic resin net in advance. The deodorizing filter material according to claim 1. 4. The deodorizing filter material according to claim 1, wherein 100 to 180 parts by weight of a hot-melt adhesive powder is added to the dispersion with the total solid content of the deodorizing agent powder and the binder being 100 parts by weight. 5. A water-based binder used or a water-based binder having good adhesion with the deodorant and a binder layer obtained by drying and attaching to a synthetic resin net. The deodorizing filter material according to 1. 6. The deodorizing filter material according to claim 5, wherein 200 to 500 parts by weight of a hot-melt adhesive powder is added to the aqueous binder with the total solid content of the deodorizing agent powder and the binder being 100 parts by weight. . 7. The softening temperature of the hot melt adhesive powder is 6
The deodorizing filter material according to claim 4, wherein the temperature is 0 to 120 ° C. 8. 8. Synthetic resin net 1 m ² per activated carbon and / or other deodorant deodorizing filter material of claims 1 to 7, wherein adhering 15～60Gr.