JP2769238B2 - Air purification filter - Google Patents

Description

[Detailed Description of the Invention] Field of industrial use There is a demand for deodorization such as dust collection in general households and removal of odors from pets and toilets.
It is getting stronger year by year in proportion to the spread of air conditioning equipment.

The present invention relates to an air purification filter used for an air purifier based on such a request.

2. Description of the Related Art As this type of filter, a method that has been used for a long time has been to simply fill a granular or zigzag filter case with a particulate adsorbent. This method has the drawbacks that the filling rate changes due to transportation, vibration, etc., fine powder is generated and becomes dirty, and the passage of the processing fluid changes, and the initial purification performance is not exhibited.

In addition, various filter processing methods have recently been proposed to compensate for these drawbacks. That is, as shown in FIG. 11, a particulate material of the adsorbent 32 is directly sprayed on the thermoplastic resin non-woven fabric 31 and thermocompression-bonded to form a filter.
As shown in the figure, an adhesive such as a rubber-based or vinyl-based adhesive is selected, and the non-woven fabric, the three-dimensional mesh-shaped elastic sheet 33 and the like are joined to the adsorbent 32.

Among them, the former has drawbacks such as a weak bonding force between the adsorbent 32 and the nonwoven fabric 31 and a change in the components attached to the adsorbent due to heat when heated. The pressure loss of air was also high. In the latter case, the use of an adhesive causes the solvent or solute to have a considerable effect on the adsorbing capacity of the adsorbent, resulting in a decrease in the adsorbing capacity, uneven distribution of the adsorbent, and an There were drawbacks such as an increase in pressure loss when the number was increased.

Therefore, the present inventors have previously proposed an air purification filter that solves the above-mentioned disadvantages (pending). Hereinafter, the configuration will be described with reference to FIGS. 13 to 15.

This air purifying filter is formed by curing a thin aluminum sheet or kraft paper with a phenolic resin or the like to form a honeycomb-shaped honeycomb base material 34.
An adsorbent 36 is placed in the cell 35, and a nonwoven fabric 38 is bonded on both sides with a web-like adhesive sheet 39. The air purifier uses the filter for air purification and the filter for dust collection in combination.

Problems to be Solved by the Invention However, in this air purification filter, since fine particles are usually contained as the adsorbent 36 inside the filter, it is necessary to increase the fiber basis weight of the nonwoven fabric 38, and the pressure loss increases. There were drawbacks. In addition, although the pressure loss is relatively low with respect to laminar air flow, there is a problem that the pressure loss increases due to the lateral flow and turbulent flow generated in actual use colliding with the honeycomb wall. .

SUMMARY OF THE INVENTION The present invention has been made to solve the above problems, and provides an air purification filter having a low pressure loss, a high dust collection function, and a high strength in realizing an air purifier having a low noise and a large air volume.

Means for Solving the Problems The present invention, in order to achieve the above object, put the granulated adsorbent in a core material consisting of a plurality of cells, bonded a net-like breathable sheet on both sides of the core material, Further, a wire mesh in contact with the air-permeable sheet on the windward side, and a dust-collecting nonwoven fabric further provided on the windward side, and an air purification filter integrally fixed with the mesh-shaped air-permeable sheet and the dust-collecting nonwoven fabric. Is what you do.

Effect The present invention has a low pressure loss by using a mesh-shaped air-permeable sheet, and even if a gas-permeable sheet is used by using a granulated adsorbent, the adsorbent can be prevented from wetting, and also integrated. The adsorbent in the cell does not jump out even if it is dropped or bent, and the wire mesh used as a reinforcing agent can be used as an electrode. it can.

Embodiment An embodiment of the present invention will be described below with reference to FIGS. The honeycomb-shaped core material 1 composed of a plurality of cells is formed by bending a thin aluminum plate, kraft paper, or the like.
After bonding with an adhesive, the resin is lightly cured with a phenolic resin or the like so as not to be largely changed in dimension, and then cut into length L and width W and thickness c required for the filter (FIG. 4). ). In this example, kraft paper was used. Generally, the dimension of the cell 5 is indicated by one dimension,
The dimension 1 and the dimension c greatly affect the filter performance. That is, the optimum size is set based on the size of the particles of the adsorbent 2 such as activated carbon to be used, and the amount and pressure loss to be used. Generally, it is easy to use one dimension of 2 mm to 15 mm (12 mm is used in the embodiment) and c dimension is 3 mm to 20 mm (7 mm is used in the embodiment).

The filter unit A is provided with such a honeycomb base material 1.
The adsorbent 2 is put in the cell 5, and the air-permeable air-permeable sheet 3 is joined on both sides with the web-like adhesive sheet 4, and the upper frame 6 and the lower frame 7 are integrated. As the adsorbent 2, normal activated carbon granulated, activated carbon impregnated with an effective chemical to odor components,
Use something like zeolite, silica or alumina. The particle size of the adhesive 2 is determined based on the adsorptive capacity. Generally, a cylindrical extruded product having a diameter of 2 mm to 4 mm and a length of 2 mm to 7 mm, or a spherical extruded product having a diameter of 2 mm to 5 mm is used. . In the examples, granulated coal having a diameter of 2 mm and a length of 2 mm to 5 mm was used. The type of the adsorbent 2 may be selected from one type or two or more types. In the embodiment, four types are selected for aldehyde, ammonia, sulfur, and hydrocarbon.

Next, the mesh-shaped air-permeable sheet 3 is a woven fabric made of a thermoplastic resin such as polyester, acrylic, PP, PE, etc., having a thickness of one twisted thread of about 0.5 mm and a pitch between the twisted threads of about 1.5 mm. Use Here, in order to also serve as an electrode at the time of electrostatic dust collection, an acrylic fiber which has been subjected to a conductive treatment in advance is used as the gas permeable sheet 3. The conductivity only needs to be at least one of the air-permeable sheets 3, and the conductivity is 1 KΩ / cm or less.

A nonwoven fabric having a high opening ratio, that is, a nonwoven fabric having a high opening ratio, that is, a non-solvent type heat-welding resin (nylon-based, polyester-based, etc.) is used as an adhesive sheet 4 for joining the core material 1 and the air-permeable sheet 3 An adhesive sheet is used. The upper frame 6 and the lower frame 7 are made of hard polypropylene or AB so that the filter unit A does not bend due to dropping or the like.
It is made of S resin and forms a rigid frame.

Regarding the processing procedure, first, the core material 1 and the air permeable sheet 3 are joined together on one side only by hot pressing or the like with a web-like adhesive sheet 4, and then the adsorbent 2 is evenly sprayed from above. Next, vibration is applied by brush or the like, and a spider web-like adhesive sheet 4 is placed on the top, and the air permeable sheet 3 is further placed on the adhesive sheet 4 and heated by a hot press or the like to complete the deodorizing filter B. The condition of the hot pressing is 130 ° C. × 2 to 3 seconds here. Finally, upper frame 6 and lower frame 7
Is fitted around the frame around the deodorizing filter B, and the filter unit A is integrated so as not to be bent.

The filter unit A for air purification obtained in this way has a size of 460 mm x 308 mm x thickness 13 mm (excluding the frame is 454 mm x 3
02mm x thickness about 7.5mm), the amount of adsorbent is about 300g,
Used in actual air purifiers as shown in Figs.

5 and 6, reference numeral 10 denotes an air inlet, 11 denotes an air outlet, and 12 denotes a control unit. The filter A for air purification is set by the jig 13 as shown in FIG. 14 is a pre-filter for removing large dust in the air, 15 is a filter for electrostatic dust collection, 16 is a motor, 17 is a fan unit, and 18 is a flow path of air. Reference numeral 19 denotes a discharge electrode of a positive electrode for generating a high voltage for electric dust collection, and a conductive portion on at least one surface of the filter unit A functions as a counter electrode. 20 is the body of the air purifier.

The operation of the air purifier in the above configuration will be described. The rotation of the fan unit 17 causes the air suction ports on both sides to rotate.
First, large dust is removed from the air sucked from 10 by the pre-filter 14. Subsequently, fine dust and smoke are positively charged by corona discharge of the discharge electrode 19, and the electrostatic dust filter 15
Caught in Thereafter, gas components such as odors are adsorbed by the adsorbent 2 of the filter unit A, and the purified air flows out of the air outlet 11.

Instead of the web-like adhesive sheet 4 of the above embodiment, a hot melt resin is directly applied to the core material 1 by spraying or the like, or an adhesive is applied within a range that does not affect the adsorbent 2. Then, the breathable sheet 3 may be joined.

Hereinafter, a second embodiment of the present invention will be described with reference to FIGS. 7 to 9.

The three-dimensional knitting 21 consisting of a plurality of polygonal mesh-like cells,
It is a core material, a polygonal mesh on both sides woven with twisted yarn
22 and 23 are connected in parallel by a connecting thread 24, and have a gas permeable partition wall 25. Here, the front and back polygonal nets 22 and 23 are made of polyester twisted yarn, and the connecting yarn 24 is made of a single nylon yarn. The size of the cell is generally indicated by the 1 'dimension as shown in FIG. 9, and the 1' and c 'dimensions greatly affect the performance of the filter. That is, the optimum size is set based on the size of the particles of the adsorbent 2 such as activated carbon to be used, and the amount and pressure loss to be used. Generally, it is easy to use the 1 'dimension of 2 mm to 15 mm (12 mm is used in the embodiment) and the c' dimension of 3 mm to 20 mm (7 mm is used in the embodiment).

In the filter unit A ', the adsorbent 2 is put in the cell 26 of such a three-dimensional knit 21 and the air permeable sheet 3 is joined to both sides with the spider web-like adhesive sheet 4, and the upper frame 27 and the lower frame 28 are integrated. I have to. As the adsorbent 2, as in Example 1,
Four types of granulated coal having a diameter of 2 mm and a length of 2 mm to 5 mm for aldehyde, ammonia, sulfur, and hydrocarbon were used.

The same air-permeable sheet 3 and adhesive sheet 4 as in Example 1 were used. The upper frame 27 and the lower frame 28 are also made of hard polypropylene, ABS resin, or the like so that the upper frame 27 and the lower frame 28 do not bend due to dropping or the like and the adhesive is not separated.

As a processing procedure, first, the three-dimensional knitted fabric 21 and the air permeable sheet 3 are joined only on one side by a hot press or the like with a web-like adhesive sheet 4, and then the adsorbent 2 is uniformly sprayed thereon. Next, vibration is applied by brush or the like, and a spider web-like adhesive sheet 4 is placed thereon, and a breathable sheet 3 is further placed therefrom and heated by a hot press or the like to complete the deodorizing filter B '. The conditions of the hot pressing are 135 ° C. × 4 to 5 cm here. Finally, the upper frame 27 and the lower frame 28 are fitted together around the frame with the filter B 'interposed therebetween, and integrated so that the filter unit A' is not bent.

The air purification filter unit A 'thus obtained has the same 460 mm × 308 mm × 13 mm thickness (454 mm × 302 mm × about 7.5 mm thickness except for the frame) as in the first embodiment. Is about 300 g and is used in an actual air purifier as shown in FIGS.

Next, a third embodiment of the present invention will be described with reference to FIG.

Here, first, the deodorizing filter C was manufactured using the same material and the same method as the deodorizing filter B of the first embodiment. Next, a 14 mesh SUS430 wire mesh 29 is sandwiched between the deodorizing filter C and the electrostatic dust collecting filter 30 made of polypropylene.
The outer peripheral portion 30a of the electrostatic precipitating filter 30 and the outer peripheral portion of the deodorizing filter C were heated and fused at 130 ° C. to 150 ° C. for 3 seconds to 7 seconds to obtain an integrated filter unit D. In this case, the wire mesh 20 serves to supplement the strength of the deodorizing filter C, but since it also functions as a counter electrode of the electric dust collection, the air permeable sheet 3 may not have conductivity.

The filter C of the filter unit D for air purification obtained in this way has a thickness of 186 mm × 123 mm and a thickness of about 7.5 mm, and the amount of the adsorbent 6 is about 50 g, as shown in FIGS. 5 and 6. Used in actual air purifiers. In this example,
The filter unit D is set on the jig 13 and used.

Next, the filters of the first to third examples (Examples 1, 2, and 3) and the unreinforced deodorizing filters B (Comparative Example 1), B '(Comparative Example 2), and C (Comparative Example 3) , And FIG. 10 ~
A filter (comparative example 4) using a honeycomb core using crushed coal and kraft paper shown in FIG. 12 was compared with the pressure loss and the filter strength. In the filter of Comparative Example 4, the dimensions of the kraft paper cell were the same as those in Examples 1 and 3, 12 mm and 7 mm in thickness, and the adsorbent 36 was 6 mesh to 12 mesh (about 4 mm to 2 mm) for aldehyde, ammonia, 4 for sulfur compounds and hydrocarbons
300 g of crushed charcoal was used. The nonwoven fabric 38 is a fibrous nonwoven fabric made of a thermoplastic resin such as polyester, acrylic, PP, or PE, and has a basis weight of 30 g / m ² . The spider web-like adhesive sheet 39 used was the same as in each embodiment, and the dimensions of the filter were 454 mm × 302 mm.

The evaluation of pressure loss was performed by measuring the filter alone with a layer amount at a flow rate of 1 m / sec. In addition, the filter strength indicates the number of broken or broken filters out of 10 when the filter is dropped onto a floor three times from a height of 70 cm with the corners and sides of the filter down.
Table 1 shows the results.

As is evident from the results in Table 1, the filters of the examples of the present invention have extremely lower pressure loss than the conventional filter of Comparative Example 4 and have excellent filter strength.

It is to be noted that the bacteria, bacteria, fungi and the like can be prevented from multiplying by subjecting each breathable sheet to a fungicide / fungal treatment.

Effects of the Invention As is clear from the above examples, according to the present invention, the use of a granulated adsorbent and a mesh-shaped air-permeable sheet has extremely low pressure loss, and the filter is reinforced with a frame, and Since the dust-collecting nonwoven fabric and the deodorizing filter are integrated with the wire mesh interposed therebetween, it is possible to provide an air purification filter with extremely low pressure loss and sufficient strength for practical use. Further, by the air purification filter according to the present invention,
An air purifier with a low noise and a large air volume can be used.

[Brief description of the drawings]

FIG. 1 is a longitudinal sectional view of a filter according to an embodiment of the present invention, and FIG.
FIG. 3 is a plan view thereof, FIG. 3 is a partially enlarged cross-sectional view of FIG. 1, FIG. 4 is a perspective view of a core material, and FIGS. 5 and 6 show air used in the air purification filter of the present invention. FIG. 7 is a longitudinal sectional view of an air purification filter according to another embodiment of the present invention, FIG. 8 is a partially enlarged sectional view thereof, and FIG. 9 is a perspective view of a three-dimensional knitted fabric. FIG. 10 is a longitudinal sectional view of an air purification filter according to still another embodiment of the present invention, and FIG.
FIG. 12 is a cross-sectional view showing the structure of a conventional filter. FIG. 13 is a cross-sectional view of the filter proposed so far.
FIG. 14 is an enlarged sectional view of a portion E in FIG. 13, and FIG.
It is a perspective view of the core material in a figure. 2 ... adsorbent, 3 ... breathable sheet, 6 ... upper frame, 7 ...
… Lower frame, 29… Wire mesh, 30… Electrostatic dust filter.

Continuation of the front page (58) Field surveyed (Int. Cl. ⁶ , DB name) B01D 39/00-39/20 B01D 53/02-53/12

Claims (1)

(57) [Claims] 1. A granulated adsorbent is put into a core material composed of a plurality of cells, and a net-like air-permeable sheet is bonded to both sides of the core material. Further, a nonwoven fabric for dust collection is provided on the windward side, and the net-shaped air-permeable sheet and the nonwoven fabric for dust collection are fixed to each other to form an air filter.