KR100264117B1 - Sintered-polymeric air filter stocks and method for manufacturing the same - Google Patents

Abstract

PURPOSE: A method for manufacturing air filter by coating macromolecular resin solution on a matrix obtained through sintering thermoplastic resin and adsorbent powder is provided to endow deodorant function to conventional filter. CONSTITUTION: The manufacturing method of the air filter comprises the processes of blending 1-10wt.% of adsorbent powder with 90-99wt.% of at least two kind of thermoplastic resin mixture selected from low density polyethylene, super high density polyethylene resin, polyacrylonitrile, polyvinylchloride, polyamide, and polyester; extrude-sintering the blend with a die in which the cylinder temperature of the die ranges from 50 to 200deg.C and the head temperature of the die ranges from 100 to 300deg.C so as to obtain a porous matrix; cooling the matrix to 30-50deg.C; coating it with 0.5-3.0wt.% of high molecular resin solution; and then drying it in the temperature range of 80 to 120deg.C.

Description

Sintered-Polymeric Air Filter Stocks and Method for Manufacturing the Same

The present invention relates to a filter material used for dust removal in a cyclone and a dust collector system and a method for manufacturing the same, which can be obtained by coating a matrix obtained by extrusion sintering thermoplastic resin powder and adsorbent powder with an aqueous solution of a polymer resin. The present invention relates to a sintered polymer air filter material having excellent filtration performance against impurities and a method of manufacturing the same.

Conventional dust removal air filters include bag filters and plate filters in which polymer synthetic fibers such as polypropylene, polyester, and polyacetal are processed into a woven or nonwoven fabric. The air filter is used to remove impurities contained in the atmosphere.

Since the air filter has a pore size of 20 to 30 μm, it is impossible to remove fine dust. Therefore, when using such a conventional air filter, not only dust is leaked out at the beginning of operation but also dust remains on the filter surface even after exhausting. The phenomenon occurs frequently. As a result, the filtration efficiency of the filter is lowered due to clogging due to dust leakage on the surface of the filter as well as the outflow of fine dust, thereby shortening the filter replacement cycle. In addition, when the filter system is installed, the installation area for filtration becomes large, which has a disadvantage in that a lot of installation and maintenance costs are required.

In order to solve the above problems, a filter material is developed to have two functions of deep filtration and surface filtration by adhering a porous polymer membrane to a filter material that complements the properties of the filter material, that is, a conventional woven and nonwoven type filter material. have.

In US Pat. Nos. 5,059,38A and 4,917,942A, a porous polypropylene membrane or a polyester membrane is adhered to a nonwoven fabric to achieve improved filtration performance such as removal of fine dust and smooth exhaustion. However, such a filter also could not solve the fundamental problems of the conventional filter material.

Therefore, the present inventors have conducted research to solve all the problems of the conventional filter material, the surface thin coating of the matrix of the extrusion resin sintered thermoplastic resin powder and the adsorbent powder with an aqueous solution of polymer resin, By providing adsorption functions in addition to the two functions, it has come to invent a filter material having excellent filtration performance by having a multi-functionality such as removal of fine dust, smooth exhaustion, prevention of clogging and removal of odors and heavy metals.

It is an object of the present invention to provide a sintered polymer air filter material having excellent filtration performance with multifunctionality and a method for producing the same.

Another object of the present invention is to provide an air filter made of the sintered polymer air filter material of the present invention.

1 is a manufacturing process chart of the sintered polymer air filter material of the present invention.

Figure 2 is a shape of the sintered polymer air filter material of the present invention.

In the sintered polymer air filter material of the present invention, a mixture of 90 to 99 wt% of thermoplastic resin powder and 1 to 10 wt% of adsorbent powder is extruded and sintered into a matrix, and 0.5 to 3.0 wt% of an aqueous polymer resin solution is cooled by cooling the extruded matrix. It is prepared by coating a thin film and drying.

The thermoplastic resin powder is 1 to 29 wt% low density polyethylene powder (LDPE, molecular weight: 500 to 8000, density: 0.94 g / cm ³ ) and 70 to 98 based on the total weight of the thermoplastic resin powder and the adsorbent powder. A mixture of wt% ultra high density polyethylene powder (UHMWPE, molecular weight: 4,000,000 to 6,000,000, density: 0.96 g / cm ³ ), 1 to 25 wt% polyacrylonitrile powder (PAN, molecular weight: 20,000 to 50,000) and 74 to A mixture of 98 wt% polyvinylchloride powder (molecular weight: 30,000-50,000), 1-20 wt% polyamide powder (molecular weight: 1,000-5,000) and 79-98 wt% polyester powder (molecular weight: 15,000-45,000 ) And a mixture of 1-27 wt% high density polyethylene powder (HDPE, molecular weight: 10,000-50,000) and 70-98 wt% polypropylene powder (alone polymer, molecular weight: 40,000-60,000). . Lower density polyethylene, polyacrylonitrile, polyamide and high density polyethylene powders in these mixtures have a particle size of 50-200 μm, and higher content of ultra high density polyethylene, polyvinylchloride, polyesters and polys in the mixture. Propylene powder has a particle size of 100-1000 μm.

As the adsorbent powder, activated carbon, zeolite, and diatomaceous earth powder having a particle size of 50 to 200 μm are used.

The manufacturing process of the sintered polymer air filter material of this invention is demonstrated as follows by FIG. 1 as a continuous process.

First, as a raw material, the thermoplastic resin powder and the adsorbent powder are mixed at a predetermined ratio to obtain a mixture. The mixture is extruded and sintered in an extruder into a matrix, for example a matrix in the form of pleated channels. Subsequently, the extruded and sintered matrix is cooled, coated with 0.5 to 3.0 wt% of polytetrafluoroethylene or polyimide resin aqueous solution, and dried. After drying, it is cut into a predetermined size and manufactured into a filter unit meeting the specification of the desired filter system to obtain a sintered polymer air filter material. The example of the shape of the air filter raw material manufactured in this way is shown in FIG.

An example of an extruder that can be used in the present invention consists of a twin screw of 50 mm, a cylinder and a head, and extrusion sintering is performed with a screw rotational speed of 5 to 50 rpm, a cylinder temperature of 50 to 200 ° C and a head temperature of 100 to It performs under extrusion sintering conditions of 300 degreeC.

The sintered polymer air filter material of the present invention prepared through such a process has a pore of 1 to 10 μm, porosity of 50 to 90%.

The filter manufactured using the sintered polymer air filter material of the present invention exhibits improved filtration performance by removing fine dust, smoothing out dust and preventing clogging, compared to conventional woven and nonwoven filters, and using the filter semi-permanently. Due to several advantages, such as the installation area is reduced by 30-40% compared to the conventional filter, the installation cost and maintenance cost are low, and the manufacturing cost is low because the extrusion system can be performed in a continuous process. have. In addition, the sintered polymer air filter of the present invention can be widely used in a variety of applications, such as air conditioning systems of public facilities such as buildings and subways as well as dust collector systems.

Filtration performance test of air filter is carried out as follows according to the mass method of KSB 6141 standard. After passing through the filtration tester, flow meter and blower equipped with the filter to be tested at an air speed of 3.9 m / sec by adding 0.5 g / min of dust supplied from the dust supply to the air, that is, carbon black dust, in this order, This is performed by separating the collection filter provided at the outlet of the filtration test machine in which the dust passing through the test filter is collected and measuring the filtration rate. Filtration rate is calculated according to the following equation 1 by measuring the weight of the dust collected in the filter and the weight supplied to the air.

Filtration rate (%) = (1-(W ₂ / W ₁ )) x 100

Where W ₁ is the weight (g) of the total dust supplied and W ₂ is the weight (g) of dust collected in the collection filter through the test filter.

Thus, after performing a primary filtration test, the test filter used for the primary test was dedusted, and a secondary filtration test is performed by the same method as a primary filtration test. Similarly, after performing a secondary filtration test, the test filter used for the secondary test was exhausted and a tertiary filtration test is performed.

Hereinafter, the present invention will be described in detail with reference to some representative examples, but these examples are only for illustrating embodiments of the present invention and do not limit the scope of the present invention.

<Example 1>

20 wt% of 50 μm low density polyethylene powder, 75 wt% of 150 μm ultra high density polyethylene powder, and 5 wt% of 100 μm activated carbon powder were mixed. Subsequently, the mixture was cooled and sintered in an extruder under extrusion conditions of screw rotation speed 40 rpm, cylinder temperature 90 ° C. and head temperature 140 ° C., and a thin film having a thickness of 4 μm with 0.5 wt% aqueous polytetrafluoroethylene resin solution. After coating it was dried. After drying, a filtration test was carried out by fabricating a filter unit having a cross section of 0.1 m ² , and the test results compared to conventional filter products having the same cross section are shown in Table 1 below.

Filtration rate (%) 1st collection Secondary capture 3rd collection Example 92 96 97 Comparative example 79 82 71

<Example 2>

15 wt% of 100 μm polyacrylonitrile powder, 83 wt% of 200 μm polyvinylchloride powder, and 2 wt% of 100 μm zeolite powder were mixed. The mixture was then cooled in an extruder under extrusion sintering conditions of screw rotation speed of 20 rpm, cylinder temperature of 120 ° C. and head temperature of 200 ° C. to cool the matrix and thin film coated to a thickness of 6 μm with 1.0 wt% aqueous polyimide resin solution. And then dried. After drying, a filtration test was conducted by using a filter unit having a cross-sectional area of 0.1 m ² , and the test results compared with conventional filter products having the same cross-sectional area are shown in Table 2 below.

Filtration rate (%) 1st collection Secondary capture 3rd collection Example 88 94 93 Comparative example 79 82 71

<Example 3>

10 wt% of 80 μm polyamide powder, 89 wt% of 200 μm polyester powder, and 1 wt% of 60 μm activated carbon powder were mixed. Subsequently, the mixture was cooled in an extruder under extrusion sintering conditions of screw rotation speed of 30 rpm, cylinder temperature of 150 ° C. and head temperature of 250 ° C., and cooled to a thin film having a thickness of 4 μm with an aqueous 0.5 wt% polytetrafluoroethylene resin solution. After coating it was dried. After drying, a filter unit having a cross-sectional area of 0.1 m ² was fabricated and subjected to filtration tests, and the test results compared to conventional filter products having the same cross-sectional area are shown in Table 3 below.

Filtration rate (%) 1st collection Secondary capture 3rd collection Example 90 95 92 Comparative example 79 82 71

<Example 4>

25 wt% of 70 μm high density polyethylene powder, 68 wt% of 200 μm polypropylene powder, and 7 wt% of 150 μm diatomaceous earth powder were mixed. The mixture was then cooled in an extruder under extrusion sintering conditions of screw rotational speed of 50 rpm, cylinder temperature of 100 ° C. and head temperature of 150 ° C. to cool the matrix and thin film coated to a thickness of 5 μm with 0.5 wt% polyimide resin solution. Dried. After drying, a filtration test was carried out by fabricating a filter unit having a cross section of 0.1 m ² , and the test results compared to conventional filter products having the same cross section are shown in Table 4 below.

Filtration rate (%) 1st collection Secondary capture 3rd collection Example 89 94 90 Comparative example 79 82 71

The air filter manufactured from the sintered polymer air filter material of the present invention has a multifunction such as filtration and adsorption functions, and thus has excellent filtration performance and low installation, maintenance, and manufacturing costs, and therefore, not only a dust collector system but also an air conditioner It can also be used for systems.

Claims (7)

A mixture of two thermoplastic resins having different melting temperatures selected from the group consisting of a mixture of low density polyethylene powder and ultra high density polyethylene powder, a mixture of polyacrylonitrile powder and polyvinyl chloride powder, and a mixture of polyamide powder and polyester powder. The porous matrix obtained by extrusion-sintering a mixture composed of 90 to 99 wt% and adsorbent powder 1 to 10 wt% under a cylinder temperature of 50 to 200 캜 and a head die temperature of 100 to 300 캜 was cooled to 30 to 50 캜 to 0.5 to A method of manufacturing a sintered polymer air filter material, characterized in that the film is coated with a 3.0 wt% aqueous polymer resin solution and then dried at 80 to 120 ° C. The method according to claim 1, wherein the thermoplastic resin powder is a mixture of 1 to 29 wt% low density polyethylene powder and 70 to 98 wt% ultra high density polyethylene powder, based on the total weight of the thermoplastic resin powder and the adsorbent powder. Selected from the group consisting of a mixture of -25 wt% polyacrylonitrile powder and 74-98 wt% polyvinylchloride powder and a mixture of 1-20 wt% polyamide powder and 79-98 wt% polyester powder Method for producing a sintered polymer air filter material. The sintered polymer air according to claim 2, wherein the particle size of the low density polyethylene, polyacrylonitrile and polyamide powder is 50 to 200 m, and the particle size of the ultra high density polyethylene, polyvinyl chloride and polyester powder is 100 to 1000 m. Method of manufacturing filter material. The method for producing a sintered polymer air filter material according to claim 1, wherein the adsorbent powder is a powder of one selected from the group consisting of activated carbon, zeolite and diatomaceous earth having a particle size of 50 to 200 m. The method for producing a sintered polymer air filter material according to claim 1, wherein the aqueous polymer resin solution is a polytetrafluoroethylene or polyimide resin solution and has a thin film coating thickness of 1 to 10 µm. The method for producing a sintered polymer air filter material according to claim 1, wherein the pores are 1 to 10 m and the porosity is 50 to 90%. The method of claim 1, wherein the mixture of the low density polyethylene powder and the ultra high density polyethylene powder has a cylinder temperature of 70 to 100 ° C and a head die temperature of 120 to 150 ° C, and the mixture of the polyacrylonitrile powder and the polyvinylchloride powder has a cylinder temperature of 90 to 130 A method for producing a sintered polymer air filter material in which a mixture of a polyamide powder and a polyester powder is subjected to extrusion sintering under conditions of a cylinder temperature of 130 to 160 ° C and a head die temperature of 200 to 260 ° C.

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