JP2022539896A - Formaldehyde decomposition catalyst, formaldehyde decomposition felt and method for producing the same - Google Patents

Abstract

A formaldehyde decomposition catalyst, a formaldehyde decomposition felt, and a method for producing them are disclosed for the purpose of solving the technical problem of realizing efficient catalytic decomposition of formaldehyde. A formaldehyde decomposition catalyst is composed of submicron-micron size petal-like particles mainly formed by MnO2 of delta crystal structure. The formaldehyde-decomposing felt comprises a breathable support and a formaldehyde-decomposing catalyst attached to the breathable support. The above formaldehyde decomposition catalyst relates to MnO2 particles having a specific crystalline morphology, microscopic morphology, diameter size and diameter distribution, said MnO2 particles being obtained by a large-scale manufacturing process developed by the applicant, which process comprises , not only greatly improves the production efficiency of the formaldehyde decomposition catalyst, but also the obtained product, that is, the formaldehyde decomposition catalyst described above, has a formaldehyde removal effect more than expected, compared with the conventional formaldehyde decomposition catalyst, the formaldehyde The removal efficiency is ideal.

Description

Detailed description of the invention

〔Technical field〕
TECHNICAL FIELD The invention herein relates primarily to the technical field of filtration, and more particularly to the technical field of air filtration and purification.
[Background technology]
Pollutants in the air are mainly divided into solid pollutants and gaseous pollutants. Contamination of airborne solid pollutants (e.g. PM10, PM2.5) is usually removed by physical filtration (i.e., separating specific objects by physical methods), but airborne gaseous pollutants (e.g. VOC , ie, organic gaseous substances) are usually removed by chemical filtration (ie, by separating out specific targets according to the chemical properties of the substance).

Particulate matter (eg PM2.5) in solid pollutants poses a great threat to human health. When removing fine particles by physical filtration, fiber filtration materials with high filtration efficiency and good air permeability (for example, glass fiber, PP (polypropylene) fiber, PET (polyethylene terephthalate) fiber, expanded PTFE (fluorine) fiber, etc. ) is a particularly popular material. However, such materials tend to adhere bacteria to the fiber bundles during use and propagate, resulting in the risk of secondary contamination.

Among gas pollutants, formaldehyde is a substance that poses great harm to the human body. When formaldehyde is removed by chemical filtration, the use of manganese dioxide in metal oxides as a formaldehyde decomposition catalyst is believed to be feasible and has certain advantages in some embodiments. Currently, manganese dioxide as a formaldehyde decomposition catalyst is limited to nanoscale manganese dioxide, which can have a sufficient specific surface area so that the formaldehyde decomposition catalyst can reach an acceptable formaldehyde removal efficiency for use. .

Since air often contains different types of contaminants, in order to remove these contaminants, different filtration devices to be filtered are usually connected in series to form a filtration system. The filtration system may be composed of independent filtration devices, or may be composed of integrated filtration devices. When the filtration devices are integrated to form a filtration system, the filtration materials of the different filtration devices are individually mounted in the cover member or combined with each other as separate members.

The above filtration system has a relatively complicated structure, may require a large space, and is expensive to manufacture. may be restricted. In particular, it is difficult to attach such a filtering system directly to the parent device without changing the structure of the parent device or by slightly changing the structure of the parent device. In the case of forcible attachment, how to secure a sufficient filtration area for the filtration system is also an issue.
[Outline of the invention]
Based on the above background art, a novel air purification solution has been developed and the following inventions have been completed.

In one aspect, the present invention is a filtration material, a filtration assembly, a filter and a filtration method, which aims to solve the technical problem of improving the adhesion and growth of bacteria on the filtration material.

In one aspect, the present invention is a filtration structure, a filtration assembly and a method of manufacturing a filtration assembly, aimed at solving the technical problem of optimizing the composite structure of different functional layers of filtration material.

In one aspect, the present invention is a formaldehyde decomposition catalyst, a formaldehyde decomposition felt and a method for producing the same, which aims to solve the technical problem of efficient catalytic decomposition of formaldehyde.

SUMMARY OF THE INVENTION In one aspect, the present invention is a filtration assembly and aims to solve the technical problem of sealing a pleated filtration material to form a filtration assembly.

In order to solve the technical problem of improving the adhesion and breeding of bacteria on the filter material, the technical solutions of the filter material, filter assembly, filter and filter method are as follows. The filtration material includes different functional layers, all functional layers include a physical filtration layer, the physical filtration layers include a metal filtration layer and a fiber filtration layer, and the metal filtration layer and the fiber filtration layer are arranged back and forth in the filtration direction. overlaps with

Also, the metal filtration layer can be used as a conductive layer, and the fiber filtration layer can be used as an insulating layer for the conductive layer.

Also, the metal filtration layer is mainly made of a sintered powder metal porous material.

Also, the metal filtration layer is a bendable flexible metal membrane with a thickness of ≦200 μm.

The metal filtration layer also includes a meshwork and a powdered sintered metal porous material that fills the mesh pores of the framework.

In addition, the average pore size of the metal filtration layer≦200 μm, 190 μm, 180 μm, 170 μm, 160 μm, 150 μm, 140 μm, 130 μm, 120 μm, 110 μm or 100 μm, and the average pore size of the metal filtration layer≧5 μm, 10 μm, 20 μm, 30 μm, 40 μm , 50 μm, 60 μm, 70 μm, 80 μm, 90 μm or 100 μm.

Also, compared to the metal filtration layer, the fiber filtration layer has a higher filtration efficiency for solid particulate matter.

Also, the fiber filtration layer is mainly made of at least one fiber filtration material of glass fiber, PP fiber, PET fiber, expanded PTFE fiber, and/or the fiber filtration layer is mainly made of ultra-fine fiber filtration material. consists of

Also, the two adjacent surfaces of the metal filtration layer and the fiber filtration layer are in close contact, but not adhered.

In addition, all the functional layers include a chemical filtration layer, and the physical filtration layer and the chemical filtration layer overlap one another in the filtration direction.

Also, the chemical filtration layer includes at least one volatile organics filtration layer, and the at least one volatile organics filtration layer includes a corresponding volatile organics decomposition catalyst and/or adsorbent.

In addition, the at least one volatile organic matter filtration layer is a formaldehyde filtration layer, the decomposition catalyst is composed of micron-sized petal-like particles mainly formed of δ _- type crystal structure MnO2, and the submicron-micron Size The diameter of the petal-shaped particles is mainly distributed between 0.5 and 5 μm.

Also, the fiber filtration layer is an electrically insulating fiber filtration layer.

Also, two adjacent surfaces of the fibrous filtration layer and the at least one volatile organics filtration layer are in close contact but not adhered.

In addition, all the functional layers include a metal mesh support layer, and the physical filtration layer and the metal mesh support layer overlap back and forth in the filtration direction.

In addition, the physical filtration layer, the chemical filtration layer and the metal mesh support layer are stacked one on top of the other in the filtration direction.

Also, two adjacent surfaces of the at least one volatile organic filtering layer and the metal mesh support layer are in intimate contact, but not adhered.

Also, the filtering material has a pleated structure, and the blank of stacking all the functional layers of the filtering material is folded together to form a pleated structure.

Also, a local connection structure is provided between at least two adjacent functionalities in every functional layer, which can prevent translation between the at least two adjacent functional layers.

Also, said local connection structure comprises riveting which may be spaced along the edge of the filtering material, said riveting being respectively connected to at least two adjacent functional layers, or said local connection structure includes glue points that may be spaced along the edge of the filter material.

A filtering assembly comprising a filtering portion containing any one of the above filtering materials having a pleated structure, a positioning frame disposed around the filtering material to confine the filtering material therein and open both sides of the filtering material to the outside. and a sealing material disposed between the filtering material and the positioning part to prevent objects to be filtered from passing through the filtering material and penetrating the inner boundary region of the positioning frame. Includes sealing.

The locating portion is also provided with a conductive member for use in conductive connection with a metal filtration layer in the filtration material, the metal filtration layer being insulatively mounted in the filter assembly, and the conductive member being electrically conductive. becomes energized.

The sealant also includes a sealant adhered between the perimeter of the filtration material and the positioning frame.

Also, said seals are located at the edges of the filtering material, and are adhered by a sealant between the inner surface and the surface on which the corresponding edge of the filtering material resides, and the outer surface and the corresponding inner surface of the positioning frame. at least one sealing plate adhered by a sealant between the

Also, the filtering material is a pleated structure having a rectangular outer shape, a pair of opposing sides thereof being pleated wavy sides, another pair of opposing sides being straight sides, and the positioning frame is a rectangular positioning frame adapted to the filtering material, the surface of the filtering material on which the straight sides are present and the corresponding inner surface of the positioning frame are directly bonded by sealant, respectively, and the pleated wave-like sides and the inner surface of the corresponding positioning frame are respectively bonded by the at least one sealing plate.

Further, the positioning frame includes a side positioning frame provided with a sealing material between the filtering material, an upper positioning frame provided at the upper end of the side positioning frame and extending along the upper side of the side positioning frame, and a side face. a lower positioning frame provided at the lower end of the positioning frame and extending along the lower edge of the side positioning frame.

In addition, the upper positioning frame and the side positioning frame are separately connected, the bottom surface of the upper positioning frame has a stepped surface that matches the upper edge of the side positioning frame, and the sealant between the upper positioning frame and the side positioning frame is Basically it covers two parallel surfaces of said stepped surface.

In addition, the locating portion comprises a pleated shape retaining member provided on the side of the filter medium including a support material between a plurality of adjacent sets of spaced apart pleat waves provided on the filter medium.

Further, the support material comprises a positioning sealant that is respectively filled and hardened between the sets of adjacent pleat waves, the positioning sealant being filled only between the peaks of the respective adjacent pleat waves.

The filter is fitted with an air inlet, an air outlet, and any of the filtration assemblies described above with the windward side connected to the air inlet and the leeward side connected to the air outlet. and a duct.

Furthermore, an air conditioner with an air filter function can also be used as the filter.

The filtration method is to filter and purify the air through any of the above filter media, any of the above filter assemblies, or any of the above filter devices, in which the metal filtration layer is charged or non-charged.

The above filter material, filter assembly, filter and filtration method are based on the combination of the metal filtration layer and the fiber filtration layer in the same physical filtration layer in the filter material, and when used, the object to be filtered is the physical filtration layer When passing through, it is first filtered by the metal filtration layer and then secondary filtered by the fiber filtration layer, so the number of microorganisms such as bacteria that enter the fiber filtration layer is reduced, thereby reducing the number of microorganisms such as bacteria that enter the fiber filtration layer. While the adhesion and breeding of bacteria are reduced, the metal filtration layer has relatively good antibacterial properties, making it difficult for bacteria to grow.

Since the metal filtration layer and the fiber filtration layer that are stacked back and forth along the filtration direction can support each other, the stack formed by stacking the metal filtration layer and the fiber filtration layer back and forth along the filtration direction Since the support and/or positioning of itself is often achieved by the same members other than the metal filtration layer and the fiber filtration layer, the space occupied by the functional unit composed of the metal filtration layer and the fiber filtration layer is reduced. Helpful.

To solve the technical problem of optimizing the composite structure of different functional layers in the filter material, the technical solutions of the filtering structure, the filtering assembly and the manufacturing method of the filtering assembly are as follows.

The filtration structure comprises a filtration material comprising different functional layers and at least two adjacent functional layers of all functional layers are in intimate contact with each other but are not glued together. A blank that stacks all the functional layers of the filter medium is integrally processed and formed into a filter medium of a specific shape.

Furthermore, said at least two adjacent functional layers are present in any of the following or a combination of two or more forms. a) a physical filtration layer comprising two or more functional layers, b) a chemical filtration layer comprising two or more functional layers. c) a composite layer of a physical filtration layer containing one or more functional layers and a chemical filtration layer containing one or more functional layers, d) a physical filtration layer containing one or more functional layers and one or more functional layers e) a composite layer of a chemical filtration layer comprising one or more functional layers and a material support layer comprising one or more functional layers f) a physical filtration layer comprising one or more functional layers , a chemical filtration layer comprising one or more functional layers, and a material support layer comprising one or more functional layers.

Further, said physical filtration layer comprises a metal filtration layer and/or a fiber filtration layer, and/or said chemical filtration layer comprises at least one volatile organics decomposition catalyst and/or adsorbent containing corresponding volatile organic matter decomposition catalysts and/or adsorbents. and/or the material support layer comprises a metal mesh support layer.

Furthermore, a local connection structure is provided between the at least two adjacent functional layers that can prevent parallel displacement between the at least two adjacent functional layers.
Furthermore, said local connection structure comprises a riveting member respectively connected with said at least two adjacent functional layers and/or said local connection structure comprises an adhesive point.

Further, the local connection structures are spaced along the edges of the filter media.

Further, the riveting member is composed of a U-shaped metal nail with two legs bent inward, and the at least two adjacent functional layers are the connecting portion of the U-shaped metal nail head and the inner side of the leg. It is clamped between the bent part.

In addition, the blank, in which all the functional layers of the filter medium are stacked, is integrally processed and formed into a pleated filter medium.

The filtration assembly includes a filtration section having any of the above filtration structures in which the filtration material is integrally formed and formed into a pleated structure by a blank in which all the functional layers are stacked; A locating part having a locating frame provided around the filter material so that both sides are open to the outside, and an inner boundary area of the locating frame provided between the filter material and the locating part so that the object to be filtered does not pass through the filter material. a sealing portion having a sealing material to prevent intrusion into the

A method of manufacturing a filtration assembly includes sequentially superimposing individual blanks for forming each corresponding functional layer of filter media, forming blanks for all functional layers of the stacked filter media, and local connection structures. performing anti-lateral movement type connections at local connections of individual blanks for forming each corresponding functional layer of said filter media through a specific Integrating and molding the filter media into a shape and assembling the filter media with other parts of the filter assembly to form the filter assembly.

If at least two adjacent functional layers of all functional layers of the filter medium are tightly adhered to each other, basically the interface between the tightly adhered functional layers is sufficient to achieve such adhesion. Since it is inevitable to create a joint surface such as a viscous joint surface or a sintered joint surface that hinders the flow of fluid, the filtration resistance increases. Conversely, if at least two adjacent functional layers of all functional layers of the filter medium are in close contact with each other but are not adhered, the problem of increased filtration resistance does not occur. All the functional layer blanks of the stacked filter media are integrally processed and formed into a specific shape filter media, so that the filter media can be formed into the designed shape and structure, and the The shape and structure of the functional layers that are in close contact with each other can be made almost the same to achieve uniform fluid filtration and reduce filtration resistance, and these functional layers also contribute to the overall strength of the filter material. can also support each other to improve
When the blank, in which all the functional layers of the filter material are stacked, is integrally processed and formed into a filter material with a pleated structure, it not only increases the filtration area of the filter material, but also allows all the functional layers of the filter material to have a pleated structure. Therefore, relative displacement between functional layers that are in close contact but not adhered to each other is unlikely to occur.

In order to solve the technical problem of realizing efficient catalytic cracking of formaldehyde, the technical solutions of formaldehyde cracking catalyst, formaldehyde cracking felt and their production method are as follows.

The formaldehyde decomposition catalyst according to the present invention consists mainly of submicron-micron size petal-like particles formed by MnO ₂ with a δ crystal structure. Said submicron-micron size petal-like particles are a combination of sub-micron size petal-like particles having a diameter of 0.1-1 micron and micron-size petal-like particles having a diameter of 1-10 microns.

Typically, submicron-micron sized petaloid particles are ≧0.5 microns in diameter. That is, among these submicron-micron sized petal particles, the diameter of the largest diameter micron sized petal particle is at least 0.5 microns greater than the diameter of the smallest diameter submicron sized petal particle.

Furthermore, the diameter of the submicron-sized petal-shaped particles is mainly distributed in the range of 0.1 to 5 microns, more specifically in the range of 0.3 to 5 microns. . Furthermore, the diameter of said submicron-micron size petal-shaped particles is mainly distributed in the range of 0.5 to 5 microns. Moreover, the diameter of said submicron-micron size petal-shaped particles is mainly distributed in the range of 0.5 to 3 microns.

Further, the washing solution for the submicron-micron size petal-shaped particles is alkaline.

The formaldehyde-decomposing felt according to the present invention comprises an air-permeable support material, and any formaldehyde-decomposing catalyst described above attached to the air-permeable support material.

Furthermore, the formaldehyde decomposition catalyst is distributed outside the material forming the air-permeable support, and mainly fills the pores between the materials forming the air-permeable support.

Further, it comprises an adhesive distributed in said formaldehyde decomposition catalyst, which is preferably, but not limited to, an acrylic adhesive or a polyurethane adhesive.

Furthermore, the relative amount of formaldehyde decomposition catalyst attached to the air-permeable support material is 40 g/m ² or more when the weight of the formaldehyde decomposition catalyst is divided by the area of the windward surface of the air-permeable support material.

Furthermore, said breathable support material is a breathable fiber felt with an air permeability of ≧3000 m ³ /m ² ·h at a pressure difference of 100 Pa, preferably an air permeability of ≧5500 m at a pressure difference of 100 Pa. ³ /m ² ·hr of air-permeable fiber felt, and the relative adhesion amount is 40-120 g/m ² , preferably 50-70 g/m ² .

Further, said breathable support material is PP fiber felt or PET fiber felt.

Further, said breathable support material is a foamed porous support material or a support mesh, and when said breathable support material is a support mesh, said support mesh is either a woven mesh, a perforated mesh, or a tensioned mesh. is.

The volatile organics filtering material comprises a breathable support and a corresponding volatile organics decomposition catalyst or adsorbent attached to the breathable support, and
1) The volatile organic matter filtering material is formaldehyde decomposition felt, the formaldehyde decomposition felt is any of the formaldehyde decomposition felts described above, and the formaldehyde decomposition catalyst in the formaldehyde decomposition felt constitutes an air-permeable support material. The forcing and dispersing operation is performed in the coating step of applying the formaldehyde decomposition catalyst to the surface of the air-permeable support material and/or in the indenting step after the coating step, and ,
2) The volatile organic matter decomposition catalyst or adsorbent is forced into and dispersed in the pores between the materials constituting the air-permeable support material, and the forcing and dispersing operation causes the volatile organic matter decomposition catalyst or adsorbent to be aerated. In the application step of applying to the surface of the elastic support material and/or in the indentation step after the application step.

Further, the pressing and dispersing operation is performed by a pressing member capable of applying a pressing force perpendicular to the surface of the air-permeable support member to the formaldehyde decomposition catalyst/the volatile organic matter decomposition catalyst or adsorbent.

Furthermore, in the coating step and/or the pressing step, the formaldehyde decomposition catalyst/decomposition of the volatile organic matter adhering to the air-permeable support material is removed by a scraper that moves parallel along the surface of the air-permeable support material as a forcing member. It includes the step of forcing and dispersing the catalyst or adsorbent into the pores between the materials that make up the breathable support.

Furthermore, in the coating step and/or the pressing step, a formaldehyde decomposition catalyst adhering to the air-permeable support material/the decomposition of the volatile organic matter is removed by a press roller that rolls parallel along the surface of the air-permeable support material as a pressing member. It includes the step of forcing and dispersing the catalyst or adsorbent into the pores between the materials that make up the breathable support.

The above formaldehyde decomposition catalyst and formaldehyde decomposition felt using said formaldehyde catalyst decomposition relate to MnO ₂ particles with specific crystal morphology, microscopic morphology, diameter size and diameter distribution. The MnO ₂ particles are obtained by a large-scale manufacturing process developed by the applicant. This process not only greatly improves the production efficiency of the formaldehyde decomposition catalyst, but also the resulting product, that is, the above formaldehyde decomposition catalyst, has a formaldehyde removal effect that exceeds expectations, compared with conventional formaldehyde decomposition catalysts. Formaldehyde removal efficiency is then ideal.

For the above-mentioned formaldehyde decomposition felt, a technique in which it is difficult to uniformly disperse the formaldehyde decomposition catalyst in the air-permeable support material by pushing the formaldehyde decomposition catalyst into the pores between the materials that make up the air-permeable support material and dispersing it. It helps to solve the technical problem and further improve the formaldehyde removal effect of formaldehyde decomposition felt.

In addition, a protective function layer can be provided on the filtered side of the volatile organic matter filter material, and the protective function layer has a porous structure and a pore size smaller than the particle size of the decomposition catalyst or adsorbent. . Said protective functional layer is preferably PP fiber felt, PTE fiber felt or electrostatic cotton. The volatile organic filtering material and the protective function layer can be connected via a connecting layer, and the connecting layer may be an ultrasonic composite layer.

It has been confirmed that by providing the protective functional layer, the catalyst dropped from the chemical filtration layer can be filtered, the life of the catalyst can be extended, and the life of the chemical filtration layer can be extended by 30%. Also, the protective functional layer can support the functional layer of the filter media in front of the protective functional layer in a direction opposite to the filtration direction.

The method for producing a formaldehyde decomposition catalyst according to the present invention is a method of obtaining a formaldehyde decomposition catalyst by using potassium permanganate, manganese sulfate and water as raw materials for a mixing reaction, and specifically includes the following procedures.

A. Potassium permanganate is prepared into a 60-110 g/L potassium permanganate solution into the first titration tank, manganese sulfate is prepared into a 70-120 g/L manganese sulfate solution into the second titration tank, The ratio of the amount of potassium permanganate in the first titration tank and the amount of manganese sulfate in the second titration tank is 3:3-4:3, and the volume of potassium permanganate solution in the first titration tank or the volume of the potassium permanganate solution in the second titration tank is set as the reference volume, the reference volume shall not be less than 50L.

B. The potassium permanganate solution in the first titration tank and the manganese sulfate solution in the second titration tank are simultaneously added dropwise to at least twice the reference volume of water previously added to the mixing reactor, and the first titration tank The potassium permanganate solution and the manganese sulfate solution in the second titration tank are all added dropwise simultaneously within 10-45 minutes, and the mixture is thoroughly stirred at 70-90°C until the reaction is completed.

C. A formaldehyde decomposition catalyst is obtained by solid-liquid separation from the reacted mixture.

In the method for producing a formaldehyde decomposition catalyst according to the present invention, a target substance is washed with an alkali to obtain an alkali-washed formaldehyde decomposition catalyst. The target substance is 1) a formaldehyde decomposition catalyst obtained by a mixing reaction using potassium permanganate, manganese sulfate and water as raw materials, 2) a precipitate obtained in the procedure B of the above method for producing a formaldehyde decomposition catalyst, or 3). It is a formaldehyde decomposition catalyst obtained in Procedure C of the method for producing a formaldehyde decomposition catalyst described above.

The inventors found that a formaldehyde decomposition catalyst prepared from potassium permanganate, manganese sulfate and water as raw materials has an offensive odor that can be detected, and the offensive odor of the formaldehyde decomposition catalyst can be removed by washing with an alkali, and the formaldehyde decomposition catalyst The improvement of the can be improved.

A method for producing formaldehyde-decomposing felt according to the present invention includes providing a breathable support, providing a feed liquid containing a formaldehyde-decomposing catalyst, and forcing and dispersing the feed liquid into the breathable support. , wherein the formaldehyde decomposition catalyst is 1) any formaldehyde decomposition catalyst described above, 2) a formaldehyde decomposition catalyst obtained by the method for producing a formaldehyde decomposition catalyst described above, or 3) MnO mainly having a δ-type crystal structure It is a formaldehyde decomposition catalyst consisting of submicron-micron size petal-like particles formed by ₂ .

Further, the supply liquid adheres to the breathable support during the application step, and the indentation dispersion step is included in the application step.

To solve the technical problem of packaging the pleated filter material into a filter assembly, the technical solution of the filter assembly is as follows.

The filtering assembly includes a filtering part having a filtering material with a pleated structure, a positioning part having a positioning frame provided around the filtering material so as to confine the filtering material inside and open both sides of the filtering material to the outside, A sealing portion provided between the filtering medium and the positioning portion and having a sealing material for preventing objects to be filtered from entering the inner boundary region of the positioning frame without passing through the filtering medium.

Additionally, the sealant comprises a sealant adhered between the perimeter of the filter media and the positioning frame.

Further, the sealing material adheres with a sealant the inner surface of the edge of the filter material and the surface where the corresponding edge of the filter material is located, and the outer surface and the corresponding inner surface of the positioning frame with a sealant. at least one sealing plate for

Further, the filter medium has a pleated structure with a rectangular outer shape, one set of opposite sides of the filter medium is a pleated wave-shaped side, another set of opposite sides is a straight side, and the positioning frame is a rectangular positioning frame that fits the filter material, and the inner surface of the positioning frame corresponding to the surface of the filter material where the straight side is located is directly bonded with a sealant, and the pleated wave-shaped side and the corresponding positioning The inner surface of the frame is glued with the at least one sealing plate.

Further, the positioning frame includes a side positioning frame provided with a sealing material between the filtering material, an upper positioning frame provided at the upper end of the side positioning frame and extending along the upper side of the side positioning frame, and a side face. a lower positioning frame provided at the lower end of the positioning frame and extending along the lower edge of the side positioning frame.

In addition, the upper positioning frame and the side positioning frame are separately connected, the bottom surface of the upper positioning frame has a stepped surface that matches the upper edge of the side positioning frame, and the sealant between the upper positioning frame and the side positioning frame is Basically it covers two parallel surfaces of said stepped surface.

In addition, the locating portion comprises a pleated shape retaining member provided on the side of the filter medium including a support material between a plurality of adjacent sets of spaced apart pleat waves provided on the filter medium.

Further, the support material comprises a positioning sealant that fills and hardens between each of the plurality of sets of adjacent pleat waves on the front side of the filter media, the positioning sealant only between the peaks of the adjacent pleat waves. be filled.

Further, the filter medium includes a metal filtration layer that is a collapsible flexible metal film with a thickness of ≦200 microns, composed at least primarily of a powdered sintered metal porous material.

Further, the filter medium comprises different functional layers, wherein at least two adjacent functional layers of all functional layers are in close contact with each other but not adhered, said different functional layers being metal made of metal mesh. The blank, which includes the material support layer, which is preferably a mesh support layer, and the stacking of all the functional layers of the filter medium, is integrally formed into a pleated filter medium.

The present application will now be further described with reference to the accompanying drawings and specific embodiments. Additional aspects and advantages of the present application will be set forth in part in the description that follows, and in part will be apparent from the description, or may be learned through the practice of the present application.

[Brief description of the drawing]
The accompanying drawings, which form part of this application, are used for the understanding of this application, and the content provided in the accompanying drawings and the descriptions related to them in this application are used to explain this application. but does not constitute an undue limitation of this application. Figures 1-7 show the manufacturing process of a filtration assembly according to the present invention.

1 is an exploded view of a blank stacking all functional layers of a filter medium; FIG.

FIG. 2 is a schematic illustration of a blank stacked with all functional layers of a filter medium;

FIG. 3 is a schematic view of the stacked blank of all the functional layers of the filter media after folding into the pleated structure of the filter media;

FIG. 4 is a schematic illustration of a positioning sealant each filling and curing between sets of adjacent pleat waves in a filter media;

FIG. 5 is a schematic diagram of attaching a sealing plate to a filter medium;

[Fig. 6] Fig. 6 is a schematic view of the filter material before it is put into the positioning frame.

FIG. 7 is a structural schematic diagram of the filtration assembly;

FIG. 8 is a structural schematic diagram of a filter according to the present invention;

FIG. 9 is a photograph of the structure shown in FIG. 4;

[Fig. 10] A scanning electron micrograph of a formaldehyde decomposition catalyst according to the present invention.
Figures (a) to (d) of Figure 10 are photographs of fields randomly selected on a glass slide during microscopic observation.

11 is an X-ray diffraction (XRD) diagram of the formaldehyde decomposition catalyst shown in FIG. 10. FIG.

FIG. 12 is a scanning electron micrograph of formaldehyde-decomposed felt according to the present invention.
Figures (a) to (d) of Figure 12 are photographs of fields randomly selected on a glass slide during microscopic observation.

13 is a scanning electron micrograph of the formaldehyde decomposition catalyst of Comparative Example 1. FIG.
Figures (a)-(b) of Figure 13 are photographs of fields randomly selected on a glass slide during microscopic observation.

FIG. 14 is a graph showing changes over time in formaldehyde concentration when a formaldehyde removal performance test was conducted using the formaldehyde decomposition catalyst of Example A1.

FIG. 15 is a graph showing changes over time in formaldehyde concentration when a formaldehyde removal performance test was conducted using the formaldehyde decomposition catalyst of Example A5.

[Fig. 16] A graph showing changes in formaldehyde concentration over time when a formaldehyde removal performance test was conducted using the formaldehyde decomposition catalyst of Comparative Example 1. [Fig.

FIG. 17 is a scanning electron micrograph of formaldehyde-decomposed felt according to the present invention.

[FIG. 18] A comprehensive performance test chart of the formaldehyde-decomposing felts of Examples B1 to B5.

FIG. 19 is a comparison diagram showing the uniformity of distribution of the formaldehyde decomposition catalyst in the formaldehyde decomposition felts of Examples B2 and B6.

[Description of symbols]
100 filter material 110 physical filtration layer 111 metal filtration layer 112 fiber filtration layer 120 chemical filtration layer 121 volatile organic matter filtration layer 121a breathable support material 121b decomposition catalyst 130 metal mesh support layer 101 pleated structure 101a pleated wave-shaped side 101b linear side 101c pleated wave 200 filtering assembly 210 filtering section 220 positioning section 221 positioning frame 221a side positioning frame 221b upper positioning frame 221b1 stepped surface 221c lower positioning frame 222 pleated shape retaining member 222a positioning sealant 223 conductive member 230 sealing section 231 Sealing plate 300 Filter 310 Intake port 320 Exhaust port 400 Pleated wave positioning tooling [Mode for carrying out the invention]
The present invention will now be described clearly and completely with reference to the accompanying drawings. Those skilled in the art can implement the present invention based on these descriptions.

Before describing the present application with reference to the accompanying drawings, the technical solutions and technical features provided in each part including the following description of the present application shall be regarded as It should be specifically pointed out that it is possible to combine the characteristic features.

Moreover, the embodiments and examples referred to in the following description are generally only some of the embodiments and examples of the present application, and not all of them. Therefore, all other embodiments and examples obtained without creative work by persons skilled in the art based on the embodiments and examples described in this application shall fall within the protection scope of this application. do.

The terms "include", "including", "having" and variations thereof in the specification and claims and related portions of this application are intended to cover non-exclusive inclusion. In addition, other related terms and units in this application can be reasonably explained based on the relevant content of this application.

Figures 1-7 and 9 show the manufacturing process of a filtration assembly according to the invention and can illustrate the relevant structure of the filtration assembly and its filter media.

As shown in FIGS. 1-7 and 9, the filter media 100 in the filter assembly includes different functional layers, all of which include a physical filtration layer 110, which consists of a metal filtration layer 111 and a fiber filtration layer. 112, and the metal filtration layer 111 and the fiber filtration layer 112 overlap back and forth along the filtration direction.

Among them, the metal filtering layer 111 is mainly made of metal (including alloy). The metal filtration layer 111 is preferably a metal filtration layer mainly composed of powder sintered metal porous material, more preferably a foldable flexible metal film with a thickness of ≦200 microns.

Since the flexible metal film has a thickness of ≦200 microns, it is easier to achieve higher breathability. Also, since the flexible metal film itself is foldable, it does not affect bending or folding of the filter medium 100 .

Said flexible metal film may be a porous film prepared by the method provided in Chinese patent document CN104874798A, or a flexible metal film prepared by other methods.

The present application recommends using the product with the trade name "Paper-type membrane" manufactured by the applicant of the present application based on the content of the above-mentioned patent document CN104874798A.

The paper type membrane is a flexible metal film comprising a mesh-like scaffold and a powdered sintered metallic porous material that fills the pores of the scaffold and is foldable with a thickness of ≤200 microns.

In the above physical filtration layer, the average pore size of the paper type membrane (or other metal filtration layer 111) is generally set in the range of 5-200 microns. The upper end of the range can optionally be set at 190 microns, 180 microns, 170 microns, 160 microns, 150 microns, 140 microns, 130 microns, 120 microns, 110 microns or 100 microns. The lower end of the range can optionally be set at 10 microns, 20 microns, 30 microns, 40 microns, 50 microns, 60 microns, 70 microns, 80 microns, 90 microns or 100 microns.

The term "average pore size" above is a commonly used parameter for characterizing porous materials and can be measured by the bubble method. The related art in the patent application document with publication number CN104266952A filed by the applicant of the present application can be used to measure the average pore size of the metal filtration layer 111 .

In order to achieve a good balance between air permeability and filtration efficiency of the metal filtration layer 111, the average pore size of the metal filtration layer 111 is typically 10-150 microns, further 10-120 microns, further 10-100 microns, furthermore 10-100 microns. It may be 80 microns.

The term "filtration efficiency" above refers to the ratio of the amount of solid particles filtered by the filter medium to the amount of solid particles contained in the gas to be filtered under test conditions.

The metal filtration layer 111 may contain a metal substance with a sterilizing function, such as copper, silver, or the like. In one/some embodiments of the filter media described above, the powder sintered metallic porous material of the metal filtration layer 111 consists primarily of a copper-nickel alloy formed by sintering the powder, and such metal filtration Layer 111 not only satisfies the requirement of "flexibility", but can also have some degree of sterilization function.

The fiber filtration layer 112 is mainly made of inorganic non-metallic fibers (such as glass fiber), organic fibers (such as PP fiber) or composites thereof. In general, the fiber filtration layer 112 consists mainly of at least one fiber filter material of glass fiber, PP fiber, PTE fiber and expanded PTFE fiber.

Generally speaking, the filtration efficiency for solid particles by the fiber filtration layer 112 is higher than that of the metal filtration layer 111 .

The fiber filter layer 112 is preferably a fiber filter layer mainly made of ultra-fine fiber filter material so that the fiber filter layer 112 can have better filtration efficiency and air permeability.

The above-mentioned "ultra-fine fiber filter medium" is a fiber filter medium having a diameter that forms a fiber filter layer that can remove 98% or more of dust with a particle size of ≧2.5 μm in the gas to be filtered. All of the above glass fibers, PP fibers, PET fibers and expanded PTFE fibers may be ultrafine fiber filter media.

Since the filter medium 100 is a combination of the metal filter layer 111 and the fiber filter layer 112, the object to be filtered is first filtered by the metal filter layer 111 and then secondarily filtered by the fiber filter layer 112, so that the fiber The number of bacteria invading the filtration layer 112 is reduced, thereby reducing the adhesion and propagation of bacteria on the fiber filtration layer, while the metal filtration layer 111 has relatively good antibacterial properties and is difficult for bacteria to grow. , the problem of bacteria breeding in the whole filter material 100, especially in the physical filtration layer 110, can be improved to some extent.

Since the metal filtration layer 111 and the fiber filtration layer 112 that are stacked back and forth along the filtration direction can support each other, by stacking the metal filtration layer 111 and the fiber filtration layer 112 back and forth along the filtration direction, Since the support and/or positioning of the formed laminate itself is often achieved by the same members other than the metal filtration layer 111 and the fiber filtration layer 112, the functional unit composed of the metal filtration layer 111 and the fiber filtration layer 112 helps reduce the space occupied by

When the fiber filtration layer 112 is a fiber filtration layer mainly composed of ultrafine fiber filter material, the average pore size of the metal filtration layer 111 is suitably 10 to 100 microns, more suitably 20 to 80 microns. is.

Experience has shown that the filtration accuracy of a porous filter medium is equal to about 1/10 of its average pore diameter. For example, when the average pore size of the metal filtration layer 111 is 80 microns, its filtration accuracy is about 8 microns. Also, during filtration, a filter cake is gradually formed on the metal filtration layer 111, which further improves the filtration accuracy, ie less than 8 microns. Therefore, if the metal filtration layer 111 has an average pore size of 80 microns, solid particles (dust) with a particle size of ≦8 microns can be filtered during filtration.

When the average pore size of the metal filtration layer 111 is 10 to 100 microns, the metal filtration layer 111 contains most of the larger solid particles such as PM10, mold spores (the particle size in the air is mainly 1 to 100 micron) and some bacteria (particle size in the air is mainly 0.5-10 microns). In this way, the adhesion and growth of fungi and bacteria on the fiber filtration layer 112 can be effectively inhibited.

However, if the average pore size of the metal filtration layer 111 is close to the lower limit of 10 to 100 microns, in addition to the metal filtration layer and the fiber filtration layer, other functional layers, especially functional layers with physical or chemical filtration functions may be included in the filtration. The material has low breathability.

Therefore, it is better to select relevant technical parameters such as the average pore size of the metal filtration layer 111 according to the overall filtration performance of the filter material 100 .

Due to the property that most metal filtration layers are conductive, the metal filtration layer 111 of the filter media 100 described above can also be used as a conductive layer, and when the metal filtration layer 111 is charged by an external power source, the metal The filtration layer 111 can repel and adsorb charged particles in the object to be filtered, thereby improving the filtration efficiency of the filter medium 100 .

On the other hand, since most fiber filtration layers have insulating properties, if the metal filtration layer 111 is also used as a conductive layer, the metal filtration layer 111 may be attached to the housing and/or other member to which the filter media 100 is attached. The fibrous filtration layer 112 can function as an insulating layer for the conductive layer, so as to insulatively connect to (such as other functional layers of filtration media).

The design of the metal filtering layer 111 as the conductive layer and the fiber filtering layer 112 as the insulating layer of the conductive layer further utilizes the material properties of the metal filtering layer 111 and the fiber filtering layer 112 to combine the metal filtering layer 111 and the fiber filtering layer 112 be better combined.

In addition to the metal filtration layer 111 and the fiber filtration layer 112, all functional layers of the filter media 100 also include a chemical filtration layer 120, and the physical filtration layer 110 and the chemical filtration layer 120 are arranged back and forth along the filtration direction. overlapping.

Preferably, chemical filtration layer 120 comprises at least one volatile organics filtration layer 121 containing a corresponding volatile organics decomposition catalyst 121b or adsorbent.

At least one volatile organics filtration layer 121 generally comprises a breathable support 121a having a decomposition catalyst 121b or adsorbent attached thereto.

Preferably, at least one volatile organics filtration layer 121 is a formaldehyde filtration layer. In this case, the volatile organic matter decomposition catalyst or adsorbent must be a formaldehyde decomposition catalyst or formaldehyde adsorbent.

Generally speaking, the formaldehyde filtration layer comprises a breathable support 121a and a formaldehyde decomposition catalyst or formaldehyde adsorbent attached to the breathable support 121a.

Preferably, the formaldehyde decomposition catalyst is the formaldehyde decomposition catalyst developed by the applicant of the present application, which consists mainly of submicron-micron size petal-like particles formed by MnO ₂ of δ crystal structure.

The main advantages of the above formaldehyde decomposition catalyst are its high formaldehyde removal effect and its ability to be mass-produced. Formaldehyde decomposition catalysts and formaldehyde filtration layers using the same are specifically described in subsequent portions of this specification.

The formaldehyde decomposition catalyst can also be replaced by other catalysts such as titanium dioxide catalyst (using photocatalytic technology). There are also various alternative formaldehyde adsorbents in the prior art, such as activated carbon, zeolites, porous clay ores, and the like, which can be used. When using a formaldehyde adsorbent in this application, it is preferred to use activated carbon.

If the metal filtration layer 111 is also used as a conductive layer and the fiber filtration layer 112 is used as an insulation layer for the conductive layer, the fiber filtration layer 112 acts as an insulator between the metal filtration layer 111 and the formaldehyde filtration layer. Therefore, it is possible to prevent the formaldehyde decomposition catalyst or formaldehyde adsorbent from being affected by the charging of the metal filtration layer 111. For example, the charging of the metal filtration layer 111 affects the electronic structure of the surface of the formaldehyde decomposition catalyst and reduces the catalytic activity. to prevent

Also, regardless of whether or not the metal filtration layer 111 is connected to an external power source, its surface may be charged. If the fiber filtration layer is set as a fiber filtration layer with electrical insulation properties, it can prevent the surface charge of the metal filtration layer 111 from affecting the decomposition catalyst 121b or adsorbent on the at least one volatile organics filtration layer 121. For example, the surface charge of the metal filtering layer 111 can prevent the electronic structure of the surface of the decomposition catalyst 121b from being affected and the catalytic activity being lowered.

In addition to the metal filtration layer 111 and the fiber filtration layer 112, all functional layers of the filter media 100 also include a metal mesh support layer 130, and the physical filtration layer 110 and the metal mesh support layer 130 are aligned along the filtration direction. They overlap front and back.

If possible, the metal mesh support layer 130 can be replaced with support layers of other materials. The meaning of so-called "equivalent" is consistent with the "equivalent doctrine" in determining patent infringement.

When all the functional layers of the filter material 100 include the chemical filtration layer 120, the physical filtration layer 110, the chemical filtration layer 120 and the metal mesh support layer 130 are sequentially stacked back and forth along the filtration direction.

The basic function of the metal mesh support layer 130 is to prevent the functional layer from deforming along the filtration direction, and the filter material 100 provided in front of the metal mesh support layer 130 along the direction opposite to the filtration direction. It supports the functional layers and prevents them from deforming along the filtration direction.

If the filter medium 100 includes the chemical filtration layer 120, considering that the chemical filtration layer 120 has some influence on the overall air permeability of the filter medium, even if the average pore size of the metal filtration layer 111 is appropriately increased, good.

In one/some embodiments of the filter media 100, the filter media consists of a metal filtration layer 111, a fiber filtration layer 112, a formaldehyde filtration layer and a metal mesh support layer 130, wherein the average The pore size is set in a range of 40 to 90 microns, such as about 42 microns, about 55 microns, 79 microns, 85 microns, etc., and the effect of using these metal filtering layers 111 is good.

Preferably, the filter medium 100 has a pleated structure 101 and the blank of all the stacked functional layers of the filter medium 100 is integrally folded and formed into the pleated structure 101 . Compared to filter media with smooth surfaces, the filter media 100 with the pleated structure 101 can greatly increase the filtering area of the filter media, thereby improving the filtration efficiency.

If all the functional layers of the filter medium 100 also include a metal mesh support layer 130, using the pleated structure 101, the metal mesh support layer 130 is placed in front of the metal mesh support layer 130 along the direction opposite to the filtration direction. In addition to supporting the functional layer of the filter material 100 provided, it has the function of positioning the pleat structure 101 with respect to the pleat wave 101c and retaining its shape. can prevent mismatching of gaps between

Additionally, as shown in FIGS. 1-7, the filter assembly 200 made of the filter media 100 includes:
a filtration unit 210 having a filter material 100 with a pleated structure 101;
a positioning portion 220 having a positioning frame 221 provided around the filter medium 100 so as to confine the filter medium 100 inside and open both sides of the filter medium 100 to the outside;
a sealing part 230 provided between the filter medium 100 and the positioning part 220 and having a sealing material for preventing the filtering object from entering the inner boundary area of the positioning frame 221 without passing through the filter medium 100; Prepare.

Filtration assembly 200, when using filter media 100 as described above, is a specific embodiment designed to make filter media 100 as a whole an independent module that can be removably installed in a parent device such as a filter. Yes, which facilitates separate manufacture, sale, installation and replacement of filtration assemblies.

It should be noted that filter assembly 200 is not limited to using filter material 100, and generally any filter material having a pleated structure can be used.

If the metal filtration layer 111 of the filter medium 100 is also used as a conductive layer, the positioning portion 220 of the filter assembly 200 is also provided with a conductive member 223 for conductively connecting with the metal filtration layer 111 of the filter medium 100. At the same time, metal filtration layer 111 is insulatively attached to filtration assembly 200 and can be charged by conduction of conductive member 223 .

Conductive members 223 are provided on the positioning portion 220 and preferably automatically contact electrical connection terminals on a parent device such as a filter after the filtration assembly 200 is attached to the parent device such as a filter. It can be any conductor installed in a way that allows

For example, the contact 223a (the contact may be provided on the side of the positioning frame 221, and if the filtration assembly 200 is attached to a parent device such as a filter, the side of the contact 223a may be on the parent device such as a filter). contacting the electrical connection terminal of the contact 223a and the metal filtering layer 111 through the copper terminal lug 223b.

In one embodiment of filtration assembly 200 , the only sealant in seal 230 is sealant adhered between the perimeter of filter media 100 and positioning frame 221 .

In another embodiment of the filtration assembly 200, the sealing material of the sealing portion 230 seals the inner surface of the edge of the filter media 100 and the corresponding surface on which the edge of the filter media 100 is located, and A sealing plate 231 is provided to bond the outer surface and the corresponding inner surface of the positioning frame 221 with a sealant.

Therefore, first, the sealing plate 231 and the filter medium 100 are adhered, and then the filter medium 100 to which the sealing plate 231 is adhered can be hermetically attached to the positioning frame 221, so that the sealing plate 231 The filter media 100 can be easily attached to the positioning frame 221 in a hermetically sealed state. However, providing the sealing plate 231 increases the manufacturing cost of the filtration assembly and takes up a certain amount of space.

In yet another embodiment of the filtration assembly 200, the filter media 100 is a pleated structure with a rectangular outer shape, one set of opposite sides of the filter media 100 being the pleated wave sides 101a and another set of opposite sides is the straight side 101b, and the positioning frame 221 is a rectangular positioning frame that fits the filter material 100. The inner surface of the positioning frame 221 corresponding to the surface of the filter medium 100 where the straight side 101b is located is directly The inner surface of the positioning frame 221 corresponding to the pleated wave-shaped side 101 a is adhered with a sealant, and at least one sealing plate 231 is adhered.

Therefore, the inner surface of the positioning frame 221 corresponding to the surface of the filter material 100 on which the straight side 101b is located is directly bonded with a sealant, and the inner surface of the positioning frame 221 corresponding to the pleated wave-shaped side 101a is bonded to at least one surface. They are bonded with a sealing plate 231 .

In this way, the filter media 100 can be easily and hermetically attached to the positioning frame 221 via the sealing plate 231, and not only can the purpose of effectively sealing the pleated wave-shaped side 101a be achieved, but also The number of stop plates 231 is also reduced, and the inner surface of the positioning frame 221 corresponding to the surface on the filter medium 100 on which the linear side 101b is located faces and is adhered to it, so that the sealing effect is good.

In order to better fix and seal the filter medium 100, the positioning frame 221 is provided with a side positioning frame 221a between which a sealing material is provided between the filter medium 100 and the upper end of the side positioning frame 221a, and An upper positioning frame 221b extending along the upper side of the side positioning frame 221a and a lower positioning frame 221c provided at the lower end of the side positioning frame 221a and extending along the lower side of the side positioning frame 221a are provided. The sealant between positioning frame 221 and filter media 100 may be a sealant.

In the positioning frame 221, it is preferable that the upper positioning frame 221b and the side positioning frame 221a are separately connected in order to install the filter material 100 on the positioning frame 221 and then attach the upper positioning frame 221b to the side positioning frame 221a.

On top of this, the bottom surface of the upper positioning frame 221b is designed into a stepped surface 221b1 that fits the upper end of the side positioning frame 221a, and the sealant between the upper positioning frame 221b and the side positioning frame 221a is basically the stepped surface It is preferred to cover two parallel surfaces of . In this way, the mounting and positioning of the upper positioning frame 221b can be facilitated, and the sealing effect of the upper positioning frame 221b against the filter medium 100 can be ensured.

The upper positioning frame 221b and the lower positioning frame 221c can limit the filter media 100 and better confine it within the side positioning frame 221a.

In the filter assembly 200, compared to filter media with smooth surfaces, the filter media 100 with the pleated structure 101 can significantly increase the filtering area of the filter media, thereby improving filtering efficiency. However, the pleat waves 101c of the pleat structure 101 can deform during use, leading to mismatched gaps between the pleat waves 101c and uneven distribution of filtration flux in the filter media.

To address the above issues, the locating portion 220 of the filtration assembly 200 provides pleats on the sides of the filtration media 100 that include support material between sets of adjacent pleat waves 101c spaced apart on the filtration media 100. A shape retaining member 222 may be provided.

In the pleat shape retaining member 222, the deformation of the pleat waves 101c is prevented by supporting material between a plurality of sets of adjacent pleat waves 101c provided on the filter medium 100 at intervals. ensure the uniformity of the filtration flux.

Preferably, the support is composed of a positioning sealant 222a that is filled and solidified between sets of adjacent pleat waves 101c, respectively, and the support thus formed is low cost and easy to manufacture; Moreover, it can be adhered to the pleat wave 101c without falling off.

Additionally, the positioning sealant 222a may be filled only between the peaks of corresponding adjacent pleat waves 101c, thus reducing the coverage of the positioning sealant 222a on the filter media and mitigating the impact of the positioning sealant on filtration efficiency.

Preferably, the depth of the positioning sealant 222a filled in the gaps between the peaks of corresponding adjacent pleat waves 101c is 1.5 cm, 1.2 cm, 1 cm, 1 cm, 0.8 cm or 0.5 cm or less.

The depth of the positioning sealant 222a that fills the gaps between the peaks of corresponding adjacent pleat waves 101c is related to factors such as filter media properties. For example, if the filter material is relatively soft, it will be difficult for the positioning sealant 222a to effectively support the pleat waves 101c, so the positioning sealant 222a should only be filled between the peaks of corresponding adjacent pleat waves 101c. is not.

The metal filtration layer 111 of the filter media 100 in the filtration assembly 200 has relatively high resistance to deformation, and the metal filtration layer 111 is mainly powder sintered metal with ideal surface roughness. Since the metal filtration layer is preferably made of a porous material, the positioning sealant 222a is provided on the surface of the metal filtration layer so that the positioning sealant 222a is filled only between the peaks of the corresponding adjacent pleat waves 101c. effect can be realized.

The locating sealant 222 a may also form a continuous locating sealant line on the side of the filter media 100 . At this time, the pleated shape retaining member 222 may comprise at least two non-overlapping locating sealant lines provided on the sides of the filter media 100 .

1-7 and 9, the method of manufacturing an embodiment of the filtration assembly according to the present invention will be further described.

I. Obtaining a Blank Laminated with All Functional Layers of Filtration Media FIG. 1 is an exploded view of a blank laden with all functional layers of filtration media. FIG. 2 is a schematic diagram of a blank with all functional layers of filter media stacked.

As shown in FIGS. 1-2, the blanks stacking all the functional layers of the filter media are respectively the blank as the metal filtration layer 111, the blank as the fiber filtration layer 112, the blank as the chemical filtration layer 120, and the metal Including the blank as mesh support layer 130, they are separate members.

Therein, the blank of the metal filtering layer 111 is mainly made of copper-nickel alloy formed by powder sintering, which is a foldable flexible metal film with a thickness of ≦200 microns.

The blank of the metal filtration layer 111 comprises a reticulated framework and a powder sintered metal porous material (copper-nickel alloy) filled in the mesh pores of the framework, and the average pore size of the metal filtration layer 111 is set to 40-90 microns. It is

The blank of the fiber filter layer 112 adopts the ultra-fine fiber filter material purchased from the market, and according to its filtration accuracy, the fiber filter layer can remove 98% or more of the dust with a particle size of ≧2.5 μm in the gas to be filtered. .

The blank of the chemical filtration layer 120 consists of a volatile organics filtration layer 121, specifically a formaldehyde filtration layer comprising an air-permeable support and a formaldehyde decomposition catalyst attached to the air-permeable support, in which , the breathable support material is a commercially available PP (polypropylene) breathable film, and the formaldehyde decomposition catalyst is a formaldehyde decomposition catalyst developed by the applicant of the present application, which is mainly formed by _MnO2 with a δ-type crystal structure. and the diameter of the submicron-micron size petal-like particles is mainly distributed in the range of 0.3 to 5 microns.

The blank for the metal mesh support layer 130 is a commercially purchased stainless steel mesh.

The above blanks are stacked in order, with the metal filtration layer 111 blank on the top, the fiber filtration layer 112 blank on the bottom, the chemical filtration layer 120 blank on the bottom, and the metal mesh support layer 130 blank on the bottom. be.

In order to avoid dislocation of these stacked blanks in the subsequent molding process, local connection structures 140 are said to be provided between the blanks of the above four functional layers, which can prevent them from being displaced in parallel. Technical measures are also taken.

The local connection structure 140 specifically employs riveting members 141 spaced along the edges of the filter media, each riveting member 141 respectively blanking the above four functional layers. simultaneously connected to

The construction of the riveting member 141 is similar to that of commercial staples and consists of a U-shaped metal peg with inwardly bent legs. The above four functional layer blanks are clamped between the joints of the U-shaped metal nail heads and the inwardly bent portions of the legs, where for these four functional layer blanks, the adjacent The two blanks are in close contact with each other but are not glued together.

II. A blank of stacked filter media with all functional layers is integrally processed and formed into a filter media of a specific shape. Fig. 3 is a schematic view after being folded together; FIG. 4 is a schematic illustration of a positioning sealant filled and hardened between sets of adjacent pleat waves of filter media. FIG. 9 is a photograph of the structure shown in FIG.

As shown in FIG. 3 , all functional layer blanks of the stacked filter media are folded together (performed by existing folding equipment) and all functional layer blanks of the stacked filter media are folded into filter media 100 . are integrally folded into the pleated structure 101 of .

The blank with all the functional layers of the filter material stacked is provided with riveting members 141 in advance so that when folded together, the blank as the metal filtration layer 111, the blank as the fiber filtration layer 112 and the chemical filtration layer 120 Neither part of the blank as the metal mesh support layer 130 is displaced.

As shown in FIG. 3, a pleat wave positioning tool 400 is also used after the pleat structure 101 is formed to facilitate subsequent operations. The pleat wave positioning tool 400 is strip-shaped and has positioning grooves that correspond one-to-one with the pleat waves 101c of the pleat structure 101, and the pleat waves 101c of the pleat structure 101 are each snapped into the corresponding positioning groove. can be done.

The pleat structure 101 can be provided with different pleat wave positioning tools 400 at the same time. For example, two pleat wave positioning tools 400 are provided at the top and bottom of the pleat structure 101 respectively, and the two pleat wave positioning tools 400 at the top of the pleat structure 101 are respectively near the edges of the pleat structure 101 and the pleat structure 101 The two pleat wave positioning tools 400 at the bottom of the are each near the edge of the pleat structure 101 . Thus, the overall structure of the pleated structure 101 is stably maintained.

The pleated structure 101 held by the pleat wave positioning tool 400 is set in a specially designed adhesive applicator with the metal filtering layer 111 facing up. The conveyor belt of the adhesive applicator drives the pleat structure 101 held by the pleat wave positioning tool 400 to move parallel, and the direction of movement coincides with the length direction of the pleat wave positioning tool 400 .

An injector is mounted on the conveyor belt of the adhesive applicator, and as the pleat structure 101 held by the pleat wave positioning tool 400 passes under the injector, the injector injects the positioning sealant onto the top of the pleat structure 101. do. When injecting the positioning sealant, the injector moves relative to the filter medium 100 along the wave direction of the pleated waves 101c of the filter medium 100, so that the positioning sealant 222a injected onto the surface of the metal filtration layer 111 is finally continuous. form a locating sealant line.

By controlling the relative speed between the pleat structure 101 and the injector and the injection amount of the injector per unit time, the positioning sealant 222a injected into the gaps between the adjacent pleat waves 101c is controlled by the corresponding adjacent pleat waves. It can be ensured that it solidifies as soon as it is filled only between the peaks of 101c.

In this embodiment, the depth of positioning sealant 222a filled in the gaps between the peaks of corresponding adjacent pleat waves 101c is only about 0.5 cm (shown in FIG. 9).

After the pleat shape retaining member 222 is installed, the pleat wave positioning tool 400 is removed.

Since the adjacent functional layers of the metal filtration layer 111, the fiber filtration layer 112, the chemical filtration layer 120 and the metal mesh support layer 130 are in close contact with each other but not adhered to each other (as shown in FIG. different functional layers can be seen separately), which does not pose the problem of increased filtration resistance when the functional layers are adhered.

In addition, since the metal filtration layer 111, the fiber filtration layer 112, the chemical filtration layer 120, and the metal mesh support layer 130 have different materials and functions, they must be manufactured separately. Contribute to the improvement of production efficiency.

At the same time, all the functional layer blanks of the stacked filter media are integrally processed and formed into a specific shape of filter media, so that the shape and structure of the functional layers that are in close contact with each other in the filter media are basically are the same and can support each other.

When the blanks in which all the functional layers of the filter material are stacked are integrally processed and formed into a filter material with a pleated structure, the filter material not only has a larger filtering area, but also all the functional layers of the filter material have a pleated structure. Therefore, relative displacement between functional layers that are in close contact but not adhered to each other is unlikely to occur.

Since the filter medium 100 is positioned and supported on the windward side and the leeward side of the filter medium via the pleated shape retaining member 222 and the metal mesh support layer 130, a long service life of the filter medium can be ensured.

III. ASSEMBLED INTO FILTRATION ASSEMBLY Figure 5 is a schematic diagram of attaching the sealing plate to the filter media. FIG. 6 is a schematic view of the filtering material before it is put into the positioning frame. FIG. 7 is a structural schematic diagram of the filtration assembly.

As shown in FIGS. 2, 5 and 6, the filter medium 100 has a pleated structure with a rectangular outer shape. is a straight side 101b, and the positioning frame 221 is a rectangular positioning frame that fits the filter medium 100, and the filter medium 100 is placed on the positioning frame 221 to facilitate the packaging of the filter medium 100 into the positioning frame 221. A corresponding sealing plate 231 is attached to each pleated wave side 101a with a respective sealant before entering 221 .

In addition, since the corresponding sealing plates 231 are attached to the respective pleated wave sides 101a with a sealant, and the positioning sealant 222a is also provided on the filter medium 100, the straight sides 101b of the filter medium 100 are difficult to move. Then, it is difficult to directly bond the surfaces of the filter media 100 on which the linear sides 101b are located to the corresponding inner surfaces of the positioning frame 221 with a sealant. In order to solve this problem, since the filter medium 100 has a plurality of independent functional layers, the metal filter layer 111 on the filter medium 100 where the straight side 101b is located may be partially peeled off and sealed with a sealant. The stripped metal filtering layer 111 (see FIG. 5) is directly adhered to the inner surface of the corresponding positioning frame 221 .

As shown in FIG. 6, the filter medium 100 is placed in the positioning frame 221, and the surface of the filter medium 100 where the linear side 101b is located (that is, the peeled metal filter layer 111) is treated with a sealant. The pleated wave-shaped sides 101a are respectively bonded to the inner surfaces of the corresponding positioning frames 221 via sealing plates 231. As shown in FIG.

For other aspects of assembling the filter assembly 200, reference can be made to the foregoing content of this specification, which will not be repeated here. In short, through the above steps, a finished filter assembly 200 is obtained.

FIG. 8 is a schematic structural diagram of a filter according to the present invention. As shown in FIG. 8, in one embodiment of a filter according to the present invention, a filter 300 includes an air inlet 310, an air outlet 320, and a windward side connected to the air inlet 310 and a leeward side connected to the air outlet 320. an air duct between the inlet and the outlet to which the filter assembly 200 described above is mounted.

An air conditioner with an air filter function can also be used as the filter 300 . Due to the special structure of the filter material 100, the thickness of the filter assembly 200 is relatively thin, and the filter assembly 200 can be directly installed in a conventional domestic air conditioner.

Also, the metal filtration layer 111 of the filtration assembly 200 can be selectively charged or uncharged when the filter 300 operates.

Hereinafter, details related to the formaldehyde decomposition catalyst according to the present invention will be specifically described. In the following description, examples of the formaldehyde decomposition catalyst are indicated by "Example A1", "Example A2", "Example A3", etc. (same below). Examples of formaldehyde-decomposing felt are indicated by "Example B1", "Example B2", "Example B3", etc. (same below).
Example A1
A formaldehyde decomposition catalyst was obtained by using potassium permanganate, manganese sulfate and water as raw materials for a mixed reaction. Specifically, potassium permanganate was prepared into a 95 g/L potassium permanganate solution and placed in the first titration tank, manganese sulfate was prepared into a 70 g/L manganese sulfate solution and placed in the second titration tank, and the The ratio of the amount of potassium permanganate in the first titration tank and the amount of manganese sulfate in the second titration tank is 4:3, and the volume of the potassium permanganate solution in the first titration tank is set as the reference volume, When set to 50L, the volume of manganese sulfate solution in the second titration tank is calculated based on the above conditions and the molecular weights of potassium permanganate and manganese sulfate, corresponding to about 50L. Next, the potassium permanganate solution in the first titration tank and the manganese sulfate solution in the second titration tank are simultaneously dropped into 100 L of water previously added to the mixing reactor, and the titration time is set to 10 minutes, The mixture was then stirred at 80° C. for 2 hours. Finally, after centrifugal dehydration was performed to obtain a formaldehyde decomposition catalyst from the reacted mixture, the obtained formaldehyde decomposition catalyst was washed, dried, and dispersed.

FIG. 10 is a scanning electron micrograph of the formaldehyde decomposition catalyst of Example A1, and FIGS. be. FIG. 11 is an X-ray diffraction (XRD) diagram of the formaldehyde decomposition catalyst shown in FIG.

As shown in FIG. 10, the formaldehyde decomposition catalyst of Example A1 consists mainly of submicron-micron size petal-like particles. Among them, the diameter of micron-sized petal-like particles (ie, particle size) is mainly distributed in the range of 1-3 microns, and the diameter of sub-micron-sized petal-like particles is mainly distributed in the range of 0.1-1 micron.

Upon further observation, these submicron-micron sized petal-like particles tended to agglomerate, with a heterogeneous distribution of particle sizes resulting in a large number of submicron-sized petal-like particles irregularly distributed around the micron-sized petal-like particles. It was found that the specific surface area of the distributed and agglomerated submicron-micron size petal-like particles was increased.

As shown in FIG. 11, the standard diffraction peaks of the (001), (002) and (111) crystal planes of manganese dioxide with a δ-type crystal structure (JCPDS 80-1089) and the reference “Manganese dioxide with different crystal structures can be controlled A study on suitable preparation conditions, Wang Ge et al., Inorganic Salt Industry, August 2017”, the submicron-micron size petal-like particles of the formaldehyde decomposition catalyst of Example A1 is _MnO2 with a δ-type crystal structure. .
Example A2
A formaldehyde decomposition catalyst was obtained by using potassium permanganate, manganese sulfate and water as raw materials for a mixed reaction. Specifically, potassium permanganate was prepared into a 60 g/L potassium permanganate solution and placed in the first titration tank, manganese sulfate was prepared into a 70 g/L manganese sulfate solution and placed in the second titration tank, and the The ratio of the amount of potassium permanganate in the first titration tank and the amount of manganese sulfate in the second titration tank is 1, and the volume of the potassium permanganate solution in the first titration tank is set as the reference volume, and the reference volume is 50L. The volume of manganese sulfate solution in the second titration tank, if set, was calculated based on the above conditions and the molecular weights of potassium permanganate and manganese sulfate. Next, the potassium permanganate solution in the first titration tank and the manganese sulfate solution in the second titration tank are simultaneously dropped into 100 L of water previously added to the mixing reactor, and the titration time is set to 10 minutes, The mixture was then stirred at 80° C. for 2 hours. Finally, after centrifugal dehydration was performed to obtain a formaldehyde decomposition catalyst from the reacted mixture, the obtained formaldehyde decomposition catalyst was washed, dried, and dispersed.

The formaldehyde decomposition catalyst of Example A2 was observed with a scanning electron microscope. The particle size distribution of the shaped particles is the same as that of the formaldehyde decomposition catalyst of Example A1.

X-ray diffraction tests performed on the formaldehyde decomposition catalyst of Example A2 confirmed that the submicron-micron size petal-like particles of the formaldehyde decomposition catalyst of Example A2 were MnO ₂ with a δ crystal structure.
Example A3
A formaldehyde decomposition catalyst was obtained by using potassium permanganate, manganese sulfate and water as raw materials for a mixed reaction. Specifically, potassium permanganate was prepared into a 110 g/L potassium permanganate solution and placed in the first titration tank, manganese sulfate was prepared into a 120 g/L manganese sulfate solution and placed in the second titration tank, and the The ratio of the amount of potassium permanganate in the first titration tank and the amount of manganese sulfate in the second titration tank is 1.1, the volume of the potassium permanganate solution in the first titration tank is set as the reference volume, and the reference volume is The volume of manganese sulfate solution in the second titration tank, when set at 50 L, was calculated based on the above conditions and the molecular weights of potassium permanganate and manganese sulfate. Next, the potassium permanganate solution in the first titration tank and the manganese sulfate solution in the second titration tank are simultaneously dropped into 100 L of water previously added to the mixing reactor, and the titration time is set to 10 minutes, The mixture was then stirred at 80° C. for 2 hours. Finally, after centrifugal dehydration was performed to obtain a formaldehyde decomposition catalyst from the reacted mixture, the obtained formaldehyde decomposition catalyst was washed, dried, and dispersed.

The formaldehyde decomposition catalyst of Example A3 was observed with a scanning electron microscope. The particle size distribution of the shaped particles is the same as that of the formaldehyde decomposition catalyst of Example A1.

X-ray diffraction tests performed on the formaldehyde decomposition catalyst of Example A3 confirmed that the submicron-micron size petal-like particles of the formaldehyde decomposition catalyst of Example A3 were MnO ₂ with a δ crystal structure.
Example A4
A formaldehyde decomposition catalyst was obtained by using potassium permanganate, manganese sulfate and water as raw materials for a mixed reaction. Specifically, potassium permanganate was prepared into a 95 g/L potassium permanganate solution and placed in the first titration tank, manganese sulfate was prepared into a 70 g/L manganese sulfate solution and placed in the second titration tank, and the The ratio of the amount of potassium permanganate in the first titration tank and the amount of manganese sulfate in the second titration tank is 4:3, and the volume of the potassium permanganate solution in the first titration tank is set as the reference volume, When set to 100L, the volume of manganese sulfate solution in the second titration tank is calculated based on the above conditions and the molecular weights of potassium permanganate and manganese sulfate, corresponding to about 100L. Next, the potassium permanganate solution in the first titration tank and the manganese sulfate solution in the second titration tank are simultaneously dropped into 200 L of water previously added to the mixing reactor, and the titration time is set to 18 minutes, The mixture was then stirred at 80° C. for 2 hours. Finally, after centrifugal dehydration was performed to obtain a formaldehyde decomposition catalyst from the reacted mixture, the obtained formaldehyde decomposition catalyst was washed, dried, and dispersed.

The formaldehyde decomposition catalyst of Example A4 was observed with a scanning electron microscope. The non-uniformity of the particle size distribution of the shaped particles is greater than that of the formaldehyde decomposition catalyst of Example A1.

X-ray diffraction tests performed on the formaldehyde decomposition catalyst of Example A4 confirmed that the submicron-micron size petal-like particles of the formaldehyde decomposition catalyst of Example A4 were MnO ₂ with a δ crystal structure.
Example A5
A formaldehyde decomposition catalyst was obtained by using potassium permanganate, manganese sulfate and water as raw materials for a mixed reaction. Specifically, potassium permanganate was prepared into a 95 g/L potassium permanganate solution and placed in the first titration tank, manganese sulfate was prepared into a 70 g/L manganese sulfate solution and placed in the second titration tank, and the The ratio of the amount of potassium permanganate in the first titration tank and the amount of manganese sulfate in the second titration tank is 4:3, and the volume of the potassium permanganate solution in the first titration tank is set as the reference volume, When set to 300L, the volume of manganese sulfate solution in the second titration tank is calculated based on the above conditions and the molecular weights of potassium permanganate and manganese sulfate, corresponding to about 300L. Next, the potassium permanganate solution in the first titration tank and the manganese sulfate solution in the second titration tank are simultaneously dropped into 600 L of water previously added to the mixing reactor, and the titration time is set to 35 minutes, The mixture was then stirred at 80° C. for 2 hours. Finally, after centrifugal dehydration was performed to obtain a formaldehyde decomposition catalyst from the reacted mixture, the obtained formaldehyde decomposition catalyst was washed, dried, and dispersed.

FIG. 12 is a scanning electron micrograph of the formaldehyde decomposition catalyst of Example A5, and FIGS. be. As shown in FIG. 12, the formaldehyde decomposition catalyst of Example A5 consists mainly of submicron-micron size petal-like particles. Among them, the diameter of micron-sized petal-like particles is mainly distributed between 1 and 4 microns, and the diameter of sub-micron-sized petal-like particles is mainly distributed between 0.3 and 1 micron.

Upon further observation, these submicron-micron sized petal-like particles tended to agglomerate, with a heterogeneous distribution of particle sizes resulting in a large number of submicron-sized petal-like particles irregularly distributed around the micron-sized petal-like particles. It was found that the specific surface area of the distributed (this phenomenon is more obvious than the formaldehyde decomposition catalyst of Example A1) and agglomerated submicron-micron size petal-like particles was increased. X-ray diffraction tests performed on the formaldehyde decomposition catalyst of Example A5 confirmed that the submicron-micron size petal-like particles of the formaldehyde decomposition catalyst of Example A5 were MnO ₂ with a δ crystal structure.

It was speculated that the non-uniformity of the particle size distribution of MnO ₂ with δ crystal structure is related to the volume of the starting potassium permanganate or manganese sulfate solution and the corresponding titration time. Furthermore, it was speculated that large volumes of starting potassium permanganate or manganese sulfate solutions and correspondingly long titration times lead mainly to larger particles that nucleate first.
Example A6
A formaldehyde decomposition catalyst was obtained by using potassium permanganate, manganese sulfate and water as raw materials for a mixed reaction. Specifically, potassium permanganate was prepared into a 95 g/L potassium permanganate solution and placed in the first titration tank, manganese sulfate was prepared into a 70 g/L manganese sulfate solution and placed in the second titration tank, and the The ratio of the amount of potassium permanganate in the first titration tank and the amount of manganese sulfate in the second titration tank is 4:3, and the volume of the potassium permanganate solution in the first titration tank is set as the reference volume, When set to 50L, the volume of manganese sulfate solution in the second titration tank is calculated based on the above conditions and the molecular weights of potassium permanganate and manganese sulfate, corresponding to about 50L. Next, the potassium permanganate solution in the first titration tank and the manganese sulfate solution in the second titration tank are simultaneously dropped into 100 L of water previously added to the mixing reactor, and the titration time is set to 10 minutes, The mixture was then stirred at 80° C. for 2 hours. Finally, after centrifugal dehydration was performed to obtain a formaldehyde decomposition catalyst from the reacted mixed solution, the resulting formaldehyde decomposition catalyst was subjected to alkali washing, washing, drying and dispersion.

The alkali washing is to wash the formaldehyde decomposition catalyst with an alkaline solution. In this embodiment, the formaldehyde decomposition catalyst is added to deionized water, then a certain amount of alkaline solution is added, the pH value of the solution is adjusted to 9-11, and finally the formaldehyde decomposition catalyst is obtained by centrifugal dehydration. .
Comparative example 1
A formaldehyde decomposition catalyst was obtained by using potassium permanganate and absolute ethanol as raw materials for a mixed reaction. Specifically, potassium permanganate was prepared into a potassium permanganate solution with a concentration (mass percent) of 1.25%, and 4 L of the potassium permanganate solution and 1 L of absolute ethanol were mixed and stirred, and the mixture was stirred at room temperature for 10 minutes. After reacting for a period of time, a formaldehyde decomposition catalyst was obtained by centrifugal dehydration from the reacted mixed solution, and then the obtained formaldehyde decomposition catalyst was washed, dried and dispersed.

FIG. 13 is a scanning electron micrograph of the formaldehyde decomposition catalyst of Comparative Example 1, and FIGS. be. As shown in FIG. 13, the formaldehyde decomposition catalyst of Comparative Example 1 was mainly formed by agglomeration of nano-sized particles. An X-ray diffraction test performed on the formaldehyde decomposition catalyst of Comparative Example 1 confirmed that the formaldehyde decomposition catalyst of Comparative Example 1 was MnO ₂ with a δ-type crystal structure.

Using the formaldehyde decomposition catalysts of Example A1, Example A5, and Comparative Example 1, respectively, a formaldehyde removal performance test was carried out. For the principle and method of testing, create a closed experimental cabin, the size is 550mm × 415mm × 315mm, equipped with formaldehyde inlet and formaldehyde concentration test device, air outlet and air inlet on both sides of the experimental cabin, A pipe with a diameter of 200 mm connects the air outlet and the air inlet, and the pipe is fitted with a fan and also with a set of flanges for loading and unloading the formaldehyde decomposition catalyst for testing.

Before the test, a certain amount of formaldehyde decomposition catalyst was evenly applied to the PP breathable film, the coating amount was 0.04 g/ ^cm2 , and another PP breathable film covered the formaldehyde decomposition catalyst to remove the formaldehyde decomposition catalyst. Two PP breathable films sandwiched between were clamped between flanges to fix the formaldehyde decomposition catalyst in the pipe.

During the test, a formaldehyde solution with a certain volume and concentration was first heated and injected into the experimental cabin through the formaldehyde inlet, so that the initial concentration of formaldehyde in the experimental cabin was 1.4-2.0 mg/m ³ . When the formaldehyde concentration in the experimental cabin rose to the maximum value and stabilized for 1 minute, the fan was started and timed, and the formaldehyde concentration in the cabin was recorded every 5 minutes. The output is kept constant (wind speed about 3 m/s). After 15 minutes, the formaldehyde was reinjected as above and the 15 minute test was repeated. Each formaldehyde decomposition catalyst was tested in four replicates.

14, 15 and 16 show the formaldehyde concentration in the experimental cabin obtained by conducting the above formaldehyde removal performance test using the formaldehyde decomposition catalysts of Example A1, Example A5 and Comparative Example 1, respectively. It is a graph of change.

14, 15 and 16, it can be calculated as follows. When performing the above formaldehyde removal performance test using the formaldehyde decomposition catalyst of Example A1, the formaldehyde removal efficiency in the first 10 minutes is 76.2. When performing the above formaldehyde removal performance test using the formaldehyde decomposition catalyst of Example A5, the formaldehyde removal efficiency in the first 10 minutes is 81.2%. When performing the formaldehyde removal performance test using the formaldehyde decomposition catalyst of Comparative Example 1, the formaldehyde removal efficiency for the first 10 minutes is 64%.

The formaldehyde removal efficiency of the formaldehyde decomposition catalysts of Examples A1 and A5 is superior to that of the formaldehyde decomposition catalyst of Comparative Example 1. The reason for this is that although the formaldehyde decomposition catalyst of the comparative example consists of nano-sized particles, it tends to agglomerate. presumed to prevent full contact. Since the formaldehyde decomposition catalysts of the Examples have non-uniform particle size distribution, a large number of submicron-sized petal-shaped particles are irregularly distributed around the micron-sized petal-shaped particles. After flocculation, the petal-like particles became fully accessible to formaldehyde in the air.

In addition, an olfactory test by multiple testers (the test sample was placed 15 cm below the tester's nose) revealed that the formaldehyde decomposition catalyst of Example A6 was less odorous than the formaldehyde decomposition catalysts of Examples A1 to A5. decreased significantly.

The formaldehyde decomposition catalyst according to the present invention may be manufactured, sold, and used as a direct product, or may be used for formaldehyde decomposition felt and manufactured, sold, and used as formaldehyde decomposition felt. FIG. 17 is a scanning electron micrograph of formaldehyde-decomposed felt according to the present invention. As shown in FIG. 17, the formaldehyde decomposition felt according to the present invention comprises an air-permeable support material 121a and a formaldehyde decomposition catalyst (belonging to the decomposition catalyst 121b) attached to the air-permeable support material.

As shown in FIG. 17, the formaldehyde decomposition catalyst is distributed outside the material forming the air-permeable support 121a, and mainly fills the pores between the materials forming the air-permeable support.

In addition, the formaldehyde decomposition catalyst generally further comprises an adhesive in the formaldehyde decomposition catalyst so that it can be stably adhered to the air-permeable support 121a. The adhesive is preferably an acrylic adhesive or a polyurethane adhesive, and these two adhesives do not adversely affect the performance of the formaldehyde decomposition catalyst.

When the weight of the formaldehyde decomposition catalyst is divided by the area of the windward surface of the air-permeable support material 121a as the relative adhesion amount of the formaldehyde decomposition catalyst to the air-permeable support material 121a, the formaldehyde removal efficiency of the formaldehyde decomposition catalyst according to the present invention yields the above-mentioned relative amount. Since the coating weight is generally 40 g/m ² or more, the formaldehyde-decomposing felt basically has a commercially acceptable formaldehyde-removing effect.

In particular, when the relative adhesion amount is 40 g/m ² or more, when the formaldehyde decomposition catalyst is attached to the air-permeable support material 121a, the air permeability of the air-permeable support material 121a is significantly reduced. In order to have a removal effect and adequate air permeability, it is recommended that the air permeable support material 121a be a permeable fiber felt with an air permeability of ≧3000 m ³ /m ² ·hr at a pressure difference of 100 Pa.

Since the filter material according to the present invention has different functional layers, and the formaldehyde-decomposing felt is only one of the functional layers, the air-permeable support material 121a has a pressure difference of 100 Pa to ensure the air permeability of the entire filter material. It is preferably a breathable fiber felt with an air permeability at ≧5500 m ³ /m ² ·hr.

The above "air permeability at a pressure difference of 100 Pa" can be understood by its unit "m ³ /m ² ·hour". Specifically, "permeability of air at a pressure differential of 100 Pa" refers to the value of cubic meters of air passing through the formaldehyde decomposition felt per square meter per hour at a pressure differential of 100 Pa.

Breathable fiber felts meeting the above breathability requirements are available from the prior art such as PP fiber felts, PET fiber felts. PP fiber felt and PET fiber felt not only have good air permeability, but also suitable strength and other properties.

The formaldehyde-decomposing felt according to the present invention can not only be used as one of the functional layers of filter media, but also has other uses. In this case, the shape and performance of the formaldehyde-decomposed felt air-permeable support material 121a can also be changed significantly.

In places with high formaldehyde concentration (furniture factories, paint factories, etc.), in order to better remove formaldehyde, the foamed porous support can be used as the air-permeable support 121a of the formaldehyde-decomposing felt, so more formaldehyde-decomposing catalyst. is attached. The breathable support material 121a may be a support mesh, which may be a knitted mesh, a perforated mesh, a cable-tensioned mesh, etc., in order to independently install the formaldehyde-decomposing felt in a particular channel. .
Example B1
The formaldehyde decomposition catalyst of Example A1 was mixed with a dispersant and an adhesive to prepare a feed solution. In it, the adhesive is acrylic acid and the dispersant is water. The breathable support material 121a is PP fiber felt. The feed solution was applied to the PP fiber felt by a coating process. During application, a strip made of PP fiber felt was immersed in the liquid under the drive of a conveyor roller, lifted vertically from the surface of the liquid and passed through a channel formed between a pair of scrapers above the feed liquid. Each scraper moves parallel along the surface of the corresponding PP fiber felt, thus applying a squeezing force perpendicular to the surface of the PP fiber felt to the formaldehyde decomposition catalyst, thereby attaching it to the PP fiber felt. A formaldehyde-decomposing catalyst was forced into the pores between the materials constituting the air-permeable support material and dispersed therein. Finally, the formaldehyde-decomposing felt was dried to obtain a formaldehyde-decomposing felt. After drying, it was detected that the relative amount of formaldehyde decomposition catalyst on the PP fiber felt was about 40 g/m ² .
Example B2
Based on Example B1, the relative amount of formaldehyde decomposition catalyst attached to the PP fiber felt was increased. After drying, the relative amount of formaldehyde decomposition catalyst on the PP fiber felt was detected to be about 60 g/m ² .
Example B3
Based on Example B1, the relative amount of formaldehyde decomposition catalyst attached to the PP fiber felt was increased. After drying, the relative amount of formaldehyde decomposition catalyst on the PP fiber felt was detected to be about 80 g/m ² .
Example B4
Based on Example B1, the relative amount of formaldehyde decomposition catalyst attached to the PP fiber felt was increased. After drying, the relative amount of formaldehyde decomposition catalyst on the PP fiber felt was detected to be about 100 g/m ² .
Example B5
Based on Example B1, the relative amount of formaldehyde decomposition catalyst attached to the PP fiber felt was increased. After drying, the relative amount of formaldehyde decomposition catalyst on the PP fiber felt was found to be about 120 g/m ² .
Example B6
Based on Example B2, a pressing step was added between the coating step and the drying step. The pressing process includes a pair of press rollers, a channel is formed between the pair of press rollers, each press roller rolls in parallel along the surface of the corresponding formaldehyde decomposition felt, adheres to the PP fiber felt The formaldehyde decomposition catalyst present is forced into the pores between the materials that make up the air-permeable support and dispersed therein.

Using the formaldehyde-decomposing felts of Examples B1 to B5, a formaldehyde removal performance test was carried out. The principle and method of the test are almost the same as the formaldehyde removal performance test for formaldehyde decomposition catalyst, but the difference is that the formaldehyde decomposition felt is directly clamped between the flanges without using the PP breathable film.

FIG. 18 is a comprehensive performance test diagram of the formaldehyde decomposition felts of Examples B1-B5. As shown in FIG. 18, the abscissa is the relative amount of formaldehyde decomposition catalyst on the PP fiber felt, in which "40" means that the amount of adhesion is about 40 g/ ^m2 ; Corresponds to the formaldehyde-decomposed felt of Example B1, the rest is analogized therewith. The ordinate on the left side of FIG. 18 is airflow, in units of m ³ /m ² ·h, which means the value in cubic meters of air passing through the formaldehyde-decomposing felt per square meter per hour. The higher the value, the better the air permeability of the formaldehyde-decomposed felt, and the worse. The left ordinate of FIG. 18 is the formaldehyde removal rate, which can be calculated from the same data presented in FIGS. 14-16.

As shown in FIG. 18, when performing the above formaldehyde removal performance test using the formaldehyde decomposition felts of Examples B1 to B5, the formaldehyde removal efficiency in the first 10 minutes increased from about 66% to 72%, There is some increase, but the range is not large.

Breathability tests were carried out using the formaldehyde-decomposed felts of Examples B1-B5, respectively, i.e. air passing through the formaldehyde-decomposed felt per square meter per hour at a certain pressure difference (which is specifically 10 Pa) was measured in cubic meters. Due to limitations in the scale of the flow meter, when conducting the air permeability test using the formaldehyde-decomposed felts of Examples B1-B5, the test was performed by stacking six sheets of the same formaldehyde-decomposed felt, which reduces the flow rate. , met the limits of the flow meter scale.

As shown in FIG. 18, the air permeability of the formaldehyde-decomposed felts of Examples B1 to B5 decreased sequentially. The air permeability of the formaldehyde-decomposing felt and the efficiency of formaldehyde removal are most well balanced when the relative coating amount is about 70 g/m ² (60 g/m ² to 70 g/m ² ).

As shown in FIG. 18, when the relative adhesion amount is 120 g/m ² , the air permeability of the formaldehyde-decomposed felt is 0, but this phenomenon does not mean that the formaldehyde-decomposed felt is airtight. This is because each formaldehyde-decomposed felt is actually breathable to some extent, whereas six identical formaldehyde-decomposed felts were stacked during the test.

FIG. 19 is a comparison diagram of the distribution uniformity of the formaldehyde decomposition catalyst in the formaldehyde decomposition felts of Examples B2 and B6. This comparison is made by exposing the two types of formaldehyde-decomposing felts to light, and clearly shows that the distribution of the formaldehyde-decomposing catalyst in the formaldehyde-decomposing felt of Example B6 is significantly more uniform and finer.

The content of the present application has been described above. A person skilled in the art will be able to implement the present application based on these descriptions. In addition, all other preferred embodiments and examples obtained by persons skilled in the art without creative work based on the above content of this application shall fall within the protection scope of this application.

FIG. 3 is an exploded view of a blank with all functional layers of filter media stacked. FIG. 2 is a schematic diagram of a blank stacked with all functional layers of filter media; FIG. 4 is a schematic view of the stacked blank of all the functional layers of the filter media after folding into the pleated structure of the filter media; FIG. 4 is a schematic diagram of a positioning sealant that is each filled and cured between sets of adjacent pleat waves in a filter media; It is the schematic which attaches a sealing plate to a filter medium. FIG. 4 is a schematic view of the filtering material before it is put into the positioning frame; FIG. 4 is a structural schematic diagram of a filtration assembly; 1 is a structural schematic diagram of a filter according to the present invention; FIG. 5 is a photograph of the structure shown in FIG. 4; 1 is a scanning electron micrograph of a formaldehyde decomposition catalyst according to the present invention. Figures (a) to (d) of Figure 10 are photographs of fields randomly selected on a glass slide during microscopic observation. FIG. 11 is an X-ray diffraction (XRD) diagram of the formaldehyde decomposition catalyst shown in FIG. 10; 1 is a scanning electron micrograph of formaldehyde-decomposed felt according to the present invention. Figures (a) to (d) of Figure 12 are photographs of fields randomly selected on a glass slide during microscopic observation. 1 is a scanning electron micrograph of a formaldehyde decomposition catalyst of Comparative Example 1. FIG. Figures (a)-(b) of Figure 13 are photographs of fields randomly selected on a glass slide during microscopic observation. FIG. 10 is a time-dependent change graph of formaldehyde concentration when a formaldehyde removal performance test was conducted using the formaldehyde decomposition catalyst of Example A1. FIG. FIG. 10 is a graph of changes in formaldehyde concentration over time when a formaldehyde removal performance test was conducted using the formaldehyde decomposition catalyst of Example A5. FIG. 4 is a graph of changes in formaldehyde concentration over time when a formaldehyde removal performance test was conducted using the formaldehyde decomposition catalyst of Comparative Example 1. FIG. 1 is a scanning electron micrograph of formaldehyde-decomposed felt according to the present invention. FIG. 2 is a comprehensive performance test diagram of formaldehyde decomposition felts of Examples B1-B5. FIG. 4 is a comparative diagram showing the uniformity of distribution of formaldehyde decomposition catalysts in formaldehyde decomposition felts of Examples B2 and B6.

Claims (21)

Mainly composed of submicron-micron size petal-like particles formed by MnO ₂ of δ crystal structure, said submicron-micron size petal-like particles having a diameter of 0.1 to 1 micron. A formaldehyde decomposition catalyst characterized by being a combination of micron-shaped particles and micron-sized petal-shaped particles having a diameter of 1 to 10 microns. The diameter of the submicron size petal-shaped particles is mainly distributed in the range of 0.1 to 5 microns, more specifically, mainly in the range of 0.3 to 5 microns. The formaldehyde decomposition catalyst according to claim 1. The formaldehyde decomposition catalyst according to claim 2, wherein the diameter of said submicron-micron size petal-like particles is mainly distributed in the range of 0.5 to 5 microns. The formaldehyde decomposition catalyst according to claim 3, wherein the diameter of said submicron-micron size petal-like particles is mainly distributed in the range of 0.5 to 3 microns. 5. The formaldehyde decomposition catalyst according to any one of claims 1 to 4, wherein the submicron-micron size petal-shaped particles are washed with an alkaline solution. A formaldehyde-decomposing felt comprising an air-permeable support and the formaldehyde-decomposing catalyst according to any one of claims 1 to 5 attached to the air-permeable support. 7. The method according to claim 6, wherein the formaldehyde decomposition catalyst is distributed outside the material forming the air-permeable support, and is mainly filled in the pores between the materials forming the air-permeable support. Formaldehyde decomposition felt as described. 7. The formaldehyde-decomposing felt of claim 6, comprising an adhesive, preferably but not limited to an acrylic or polyurethane-based adhesive, distributed in the formaldehyde-decomposing catalyst. The relative adhesion amount of the formaldehyde decomposition catalyst to the air-permeable support material is 40 g/m ² or more when the weight of the formaldehyde decomposition catalyst is divided by the area of the windward surface of the air-permeable support material. Formaldehyde decomposition felt according to claim 6. Said breathable support material is a breathable fiber felt with an air permeability of ≧3000 m ³ /m ² ·h at a pressure difference of 100 Pa, preferably an air permeability of ≧5500 m ³ /h at a pressure difference of 100 Pa. Formaldehyde decomposition according to claim 9, characterized in that it is a permeable fiber felt of ^40-120 g/m ² , preferably 50-70 g/m ² . felt. The formaldehyde-decomposing felt according to claim 10, wherein the breathable support material is PP fiber felt or PET fiber felt. The breathable support material is a foamed porous support material or a support mesh, and when the breathable support material is a support mesh, the support mesh is either a knitted mesh, a perforated mesh, or a cable-tensioned mesh. The formaldehyde decomposition felt according to claim 6, characterized by: comprising a breathable support and a corresponding volatile organic decomposition catalyst or adsorbent attached to the breathable support;
1) The volatile organic matter filtering material is formaldehyde decomposition felt, the formaldehyde decomposition felt is the formaldehyde decomposition felt according to any one of claims 6 to 12, and the formaldehyde decomposition catalyst in the formaldehyde decomposition felt is It is dispersed by being pushed into the pores between the materials constituting the air-permeable support. carried out in the process, and
2) The volatile organic matter decomposition catalyst or adsorbent is forced into and dispersed in the pores between the materials constituting the air-permeable support material, and the forcing and dispersing operation causes the volatile organic matter decomposition catalyst or adsorbent to be aerated. volatile organic matter filter material, characterized in that it is applied in a coating step of coating on the surface of a volatile support material and/or in a pressing step after the coating step. The pressing and dispersing operation is performed by a pressing member capable of applying a pressing force perpendicular to the surface of the air-permeable support member to the formaldehyde decomposition catalyst/the volatile organic matter decomposition catalyst or adsorbent. Item 14. The volatile organic filter medium according to item 13. In the coating step and/or the pressing step, the formaldehyde decomposition catalyst adhering to the air-permeable support material/the volatile organic substance decomposition catalyst or 15. The volatile organic matter filtering material according to claim 14, further comprising a step of forcing and dispersing the adsorbent into pores between materials constituting the air-permeable support material. In the coating step and/or the pressing step, the formaldehyde decomposition catalyst adhering to the air-permeable support material/the volatile organic substance decomposition catalyst or 15. The volatile organic matter filtering material according to claim 14, further comprising a step of forcing and dispersing the adsorbent into pores between materials constituting the air-permeable support material. A protective function layer is provided on the filtered side of the volatile organic matter filter medium, and the protective function layer has a porous structure and a pore size smaller than the particle size of the decomposition catalyst or adsorbent. Potassium permanganate, manganese sulfate and water are used as raw materials for a mixed reaction to obtain a formaldehyde decomposition catalyst. Specifically,
A. Potassium permanganate is prepared into a 60-110 g/L potassium permanganate solution into the first titration tank, manganese sulfate is prepared into a 70-120 g/L manganese sulfate solution into the second titration tank, The ratio of the amount of potassium permanganate in the first titration tank and the amount of manganese sulfate in the second titration tank is 3:3-4:3, and the volume of potassium permanganate solution in the first titration tank or the volume of the potassium permanganate solution in the second titration tank When the volume of the manganese sulfate solution is set as the reference volume, the reference volume is not less than 50 L,
B. The potassium permanganate solution in the first titration tank and the manganese sulfate solution in the second titration tank are simultaneously added dropwise to at least twice the reference volume of water previously added to the mixing reactor, and the first titration tank The potassium permanganate solution and the manganese sulfate solution in the second titration tank are all added dropwise simultaneously within 10-45 minutes, and the mixture is thoroughly stirred at 70-90°C until the reaction is completed;
C. A method for producing a formaldehyde decomposition catalyst, which comprises obtaining a formaldehyde decomposition catalyst by solid-liquid separation from a reacted mixture. A target substance is washed with alkali to obtain an alkali-washed formaldehyde decomposition catalyst, and the target substance is
1) A formaldehyde decomposition catalyst obtained by a mixing reaction using potassium permanganate, manganese sulfate and water as raw materials,
2) the precipitate obtained in the procedure B of the method for producing a formaldehyde decomposition catalyst; or 3) the formaldehyde decomposition catalyst obtained in the procedure C of the method for producing a formaldehyde decomposition catalyst. Production method. providing a breathable support;
providing a feed solution containing a formaldehyde decomposition catalyst;
and forcing and dispersing the feed liquid into a breathable support;
Among them, the formaldehyde decomposition catalyst is
1) The formaldehyde decomposition catalyst according to any one of claims 1 to 5,
2) A method for producing formaldehyde-decomposing felt, characterized in that the formaldehyde-decomposing catalyst is obtained by the method for producing a formaldehyde-decomposing catalyst according to any one of claims 18 to 19. 21. The method for producing formaldehyde-decomposed felt according to claim 20, wherein the supply liquid adheres to the air-permeable support material in a coating step, and the pressing and dispersing step is included in the coating step.

Images