KR101659820B1 - Filter material for deordorization and filter complex for deodorization and dustproofing using the same - Google Patents

Abstract

The present invention relates to a first thermally bonded carded web (TBCW) formed by thermally adhering a carded web; A balun layer formed by carding short fibers on the card TBCW and then needle punching; An activated carbon powder scattered on the vulcanized layer; And a second heat-sealable card web laminated on the honeycomb layer, and a filter for anti-deodorization and dustproofing using the same. The filter material for deodorization according to the present invention has excellent air permeability with an air permeability of 200 cm ³ / cm ² -sec or more as measured by the ISO 9237 method.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filter for deodorization and a deodorant-

The present invention relates to a filter material for deodorization and a deodorant and dustproof composite filter using the filter material. More particularly, the present invention relates to a thermally bonded carded web made by using a core-sheath type composite yarn as a support for supporting deodorization activated carbon particles, A deodorizing filter material having improved air permeability by forming a honeycomb layer on the honeycomb filter, and a deodorant-and-dustproof filter manufactured using the filter material.

A commonly used method for incorporating activated carbon into the air filter used for automobile air conditioning or for removal of hydrocarbons (e.g., styrene) is a method of inserting an activated carbon layer between two nonwoven fabrics.

However, in the case of forming the activated carbon layer according to this method, it is common to disperse the activated carbon layer together with an adhesive for fixing them, for example, hot-melt powder to prevent the activated carbon from falling off, It was inevitable to reduce the effective amount of activated carbon and reduce the permeability of the filter material. Also, in this method, in order to fix as much activated carbon as necessary, the structure of `activated carbon layer / adhesive layer` has to be repeated frequently, which causes the air permeability to deteriorate.

As a method for solving the above problem, various prior arts are known for air-conditioning filter materials formed in a multi-layer structure including a honeycomb layer.

For example, KR2009-0015347A discloses an air cleaner filter for automobiles in which a dense layer, an intermediate layer, a vulcanized layer containing Cisco sub-type low melting point polyethylene terephthalate fibers, and an activated carbon fiber laminated and thermally fused on the dense layer. In this document, the formation of the dense layer, the intermediate layer and the vulcanized layer is controlled by varying the fineness of the fibers constituting each layer.

As a method for forming a silicate layer by varying the fineness of the fibers, reference may be made to those disclosed in KR1998-072079A, KR2001-0089865A and KR2006-0016283A.

On the other hand, KR2007-0035344A discloses a method for preparing a web comprising short fibers mixed with a high melting point yarn and a low melting point yarn and then applying heat to form a bulkiness nonwoven fabric having a bottom surface which is bound to each other by melting low melting point yarns, Discloses a method for producing a composite filter by spraying a deodorant powder onto a bulky nonwoven fabric and then laminating a meltblown nonwoven fabric and a spunbond nonwoven fabric.

As a method similar to the above patent document, KR2006-0108418A discloses a method in which a fiber surface mixed with low melting point fibers is carded and molded according to a conventional nonwoven fabric manufacturing method, fed in a short fiber web state, and a meltblown non- Thereby forming a two-layer structure, and continuously piercing and needle-punching the same, thereby rendering a multilayer composite nonwoven fabric for a high-efficiency gas filter.

On the other hand, KR2008-0112560 discloses a nonwoven fabric produced by stretching a polyolefin resin and then using a fiber obtained by crimping.

However, even in the case of the above-described prior arts, the problem of reduction in the amount of airflow is still not solved.

An object of the present invention is to provide a deodorizing filter material having improved air permeability by forming a honeycomb layer on a support.

Another object of the present invention is to provide a deodorant-and-dustproof composite filter using the filter material.

The present invention relates to a first thermally bonded carded web (TBCW) formed by thermally adhering a carded web; A balun layer formed by carding short fibers on the card TBCW and then needle punching; An activated carbon powder scattered on the vulcanized layer; And a second thermal adhesive card web laminated on the vulcanized layer.

The fibrous materials of the first thermal adhesive card web, the vulcanizable layer and the second thermal adhesive card web are preferably core-sheath type PP / PE composite yarn or LM-PET.

The composite yarn preferably has a fineness of 2 to 20 denier.

The weight of the first thermal bond card web and the second thermal bond card web is independently from 20 to 150 g / m < ² > .

It is preferable that the weight of the balun layer is 20 to 90 g / m ² .

It is preferable that the activated carbon particles immobilized on the vulcanization layer have a weight of 200-400 g / m ² .

Wherein the first thermal adhesive card web and the second thermal adhesive card web have an air permeability of 600 cm < ³ > / cm < ² > The air permeability after formation of the vulcanized layer fixed on the first and the hot-pressed card web is 500 cm ³ / cm ² -sec or more; The air permeability after lamination of the second heat-bonding filter material is preferably 200 cm ³ / cm ² -sec or more.

Also, the present invention provides a deodorant-and-dustproof composite filter in which a meltblown nonwoven fabric is laminated on one surface of the deodorization filter material.

The air permeability of the composite filter measured by the ISO 9237 method is preferably 80 cm ³ / cm ² -sec or more.

The filter material for deodorization according to the present invention has excellent air permeability with an air permeability of 200 cm ³ / cm ² -sec measured by the ISO 9237 method by forming a vulcanization layer on the support and fixing the activated carbon to the formed vulcanization layer, A composite deodorant-dustproof composite filter having an air permeability of 80 cm ³ / cm ² -sec or more can be manufactured by laminating a dust-proofing meltblown nonwoven fabric on one surface of the deodorization filter material.

1 is a schematic cross-sectional view of an embodiment of a deodorizing filter material of the present invention.
2 is a schematic cross-sectional view of another embodiment of the deodorant-and-dustproof filter of the present invention.

Hereinafter, a deodorizing filter according to the present invention will be described with reference to the accompanying drawings.

1, a deodorizing filter material 10 according to an embodiment of the present invention includes a first thermally bonded carded web (TBCW) 11 formed by thermally adhering a carded web, ; A balun layer 12 formed by carding short fibers 14 on the card TBCW and then needle-punched; Activated carbon powder (15) contained in the vulcanized layer (12); And a second thermal bonding card web (13) laminated on the honeycomb layer (12).

1. A first thermal adhesive card web (11)

The first feature of the embodiment of the present invention is that the heat-adhesive card web 11, 13 is used as a support for supporting the vulcanized layer 12 including the activated carbon powder 15. [ The thermally adhesive card web can be produced by a method in which a fiber material is carded and then heat-bonded according to a conventional method. Preferably, a sheath-core type composite yarn is used to obtain a low-air-permeability thermal bond card web. As for the core-sheath type composite yarn used for this purpose, those disclosed in Korea Registered Patent No. 1296615 may be used. Preferably PP / PE composite yarn or LM-PET.

In the present invention, the fiber material used for producing the heat-sealable card web preferably has a denier of 2 to 20 denier. When a fiber material of less than 2 denier is used, the heat-bondable card web produced is less breathable. This is presumably because the density is too high or the space formed between the fibers is small. On the other hand, when a fiber material having a denier of more than 20 deniers is used, the activated carbon particles dispersed on the fiber material may fall off.

On the other hand, the weight of the thermally adhesive card web made of the above-described materials and fineness is preferably 20 to 150 g / m ² . If the weight of the web does not reach 20 g / m ² , it will not be suitable for use as a support due to the decrease in strength, and the activated carbon particles may be detached due to breakage occurring at the time of needle punching described later. On the other hand, when it exceeds 150 g / m ² , the decrease in air permeability becomes pronounced.

More preferably, the air permeability of the thermal adhesive card web itself used as a support in the deodorizing filter material composed of multiple layers should be not less than 600 cm ³ / cm ² sec.

In the prior art, a material generally used as the support is a spunbonded nonwoven fabric made of polypropylene or polyester. However, when the nonwoven fabric is used as a support, the filter media prepared from the nonwoven fabric due to its low air permeability also has a problem in that the differential pressure is large. According to the inventors' repeated experiments, a thermal adhesive carded web made using a polyethylene terephthalate (PET) spunbond nonwoven fabric of the same weight and a core-sheath type low melting point composite yarn made of polyethylene terephthalate (LM-PET) In comparison, it was confirmed that the ventilation amount could be about twice or more different.

2. The honeycomb layer (12)

In the filter material 10 for deodorization according to one embodiment of the present invention, the buffer layer 12 is a layer for fixing the activated carbon particles 15. The embossing layer 14 is formed by carding the short fibers 14 on the above-mentioned thermally adhesive card web 11 and then needle punching.

On the other hand, the weight of the buffer layer 12 is preferably 20 to 90 g / m ² . If the weight of the honeycomb layer does not reach 20 g / m ² , the activated carbon particles to be described later are not sufficiently fixed, so that when a large amount of activated carbon particles are to be fixed, the particles fall off. On the other hand, if it exceeds 90 g / m ² , it may cause a decrease in air permeability.

In the present invention, there is no particular limitation as to the needle density of the needle punching for fixing the vulcanized layer 12 and the first thermal bonding card web 11, and for example, ordinary pre-punching and punching density 500 to 4000 pieces / m ² can be carried out.

When the activated carbon particles are sprayed on the vulcanized layer 12, the activated carbon particles 15 are positioned in the space formed between the short fibers 14 of the vulcanized layer 12. Partially, the activated carbon particles 15 may be distributed to the first heat-sealable card web through the bulky layer 12. On the other hand, when spraying, the filling density of deodorizing powders can be increased by performing suction under the first thermal adhesive card web 11 on the lower surface.

The activated carbon may be used without limitation as long as it has a function of removing hydrocarbon gas or other odor. For this purpose, those having an average particle diameter of usually 100 to 1,500 mu m are used.

Another advantage of the deodorizing filter material according to the present invention is that a large amount of activated carbon particles can be fixed without a separate adhesive such as hot melt powder. Specifically, it was confirmed that, according to experiments by the inventors of the weight of 30g / m ² and a particle application amount of activated carbon in the case of forming the bee kicheung 200g / m ² or more is possible, can be applied even 400g / m ^2.

As a method of fixing the activated carbon between the nonwoven fabrics in the conventional method, a method of fixing the activated carbon / activated carbon particles or the activated carbon / nonwoven fabric layer using hot melt powder was used. However, when the above hot melt adhesive is used, not only the air permeability is lowered in the present invention, but in the case of fixing a large amount of activated carbon, there is a problem that the `activated carbon / hot melt powder` must be laminated in order. In the present invention, the above-described problems are solved by fixing the activated carbon particles 15 in the space formed between the staple fibers forming the honeycomb layer 12, so that the deodorizing filter material Can be produced.

In the embodiment of the present invention, it is preferable to use the same material as that of the above-mentioned first thermal bonding card web in consideration of the case of additionally requiring a thermal bonding process. On the other hand, there is no particular limitation on the fineness of the staple fibers.

On the other hand, it is preferable to use a short fiber having a length of 30 to 100 mm. If the length of the short fibers is less than 30 mm, inter-fiber interlinkage is not sufficient. If the length exceeds 100 mm, there is a greater possibility of problems such as drying of the fibers in the roll during the carding process.

On the other hand, in the preferred embodiment of the present invention, the honeycomb layer 12 is laminated on the first thermal bonding card web 11, and the air permeability in the state of being fixed by needle punching is adjusted to 500 cm ³ / cm ² -sec or more .

3. Second Thermal Adhesive Card Web (13)

The filter media 10 according to the present invention is formed by fixing and then fixing a second thermal bonding card web 13 on the balun layer 12 fixed by needle punching.

The fixing may be performed by a method of dissolving and compressing only the low melting point sheath portion of the core-sheath type composite yarn without performing the needle punching or interposing the adhesive.

The material and manufacturing method of the second thermal bonding card web 13 are the same as those of the first thermal bonding card web 13.

On the other hand, in the filter material for deodorization according to the present invention, the weight of the first and second thermal adhesive card webs 11, 13 may be the same or different. For example, when the manufactured deodorizing filter material is used alone, the weight of the first and second thermal adhesive card webs 11 and 13 may be designed to be the same. As another example, when another material is laminated on the upper surface of the second thermal adhesive carded web, the weight of the second thermal adhesive carded web can be reduced to minimize the loss of air permeability, as described below.

In a preferred embodiment of the present invention, the first and second thermal bonded carded web (11, 13) may be the same or different design, which when the filter media (10) and the deodorization weight of the air permeability is 200cm ³ / cm < ² > -sec or more.

4. Deodorant - Dustproof composite filter

2 is a schematic cross-sectional view illustrating a layer structure of a deodorant and dustproof composite filter according to the present invention. As shown in Fig. 2, the deodorizing filter material 10 may be made of a composite filter 20 having a deodorizing and dust-proofing function combined or laminated with the filter material 21 for dustproofing.

A typical example of the dustproof filter material 21 used for the above purpose is a meltblown nonwoven fabric. The meltblown nonwoven fabric exhibits excellent properties as a medium-high-performance filter. Medium and high performance filters refer to filters corresponding to the MERV levels 7 to 16 of the American Air Filter Standard ANSI / ASHRAE 52.2 (1999), and dustproof filters conforming to this standard are not limited to the dustproof melt blown nonwoven fabric .

On the other hand, when the vibration damping filter material 21 is a meltblown nonwoven fabric, it is possible to simultaneously perform the function of supporting or fixing the activated carbon particles. In this case, the heat-bonding card nonwoven fabric contacting with the meltblown nonwoven fabric is omitted, The filter may be manufactured in the form of a first thermal adhesive carded web, a vulcanized layer in which activated carbon is fixed, and a meltblown nonwoven fabric layered and bonded in order.

The deodorizing filter material 10 and the dustproofing filter material 21 may be formed by various known methods such as needle punching, thermal bonding such as calendering, adhesion using a pressure sensitive adhesive, a hot melt adhesive such as powder or nonwoven fabric, Or by means of an adhesive.

On the other hand, the deodorant / dustproof composite filter 20 of the present invention comprising the deodorization filter material 10 and the dustproof filter material 21 may be provided with additional layers having various purposes. For example, a spunbonded nonwoven fabric may be laminated on the dustproof filter material, or to protect the filter material between the deodorizing filter material and the dustproof filter material, or to give the composite filter shape stability. Further, the deodorization-and-dustproofing filter may be further subjected to electrostatic treatment according to a known method after lamination. A commonly used electrostatic treatment method is to treat by wire type corona charging method at room temperature, but not limited thereto.

Hereinafter, the present invention will be described in detail with reference to examples. The following examples illustrate the present invention, but the scope of the present invention is not limited to the following examples.

Example 1

First, the second component is co-PET, and centripetal minutes PET in core-sheath type composite yarn (LM-PET, 10 denier) the carding one and then heat bonding ^{(130 ℃, 1ton / cm 2} ) a first thermal bonding of 30g / m ² The card web was prepared. The air permeability of the first thermal adhesive card web was 700 cm ³ / cm ² -sec.

Next, 10-denier LM-PET was carded on the first thermal adhesive card web, and needle punched at intervals of 15 to 30 mm to form a bulky layer. The air permeability of the two layers constituted by the first heat-sealable card web / vulcanization layer prepared above was 550 cm ³ / cm ² -sec.

The prepared needle punching nonwoven fabric was used as a lower support, and 20 to 40 mesh sized activated carbon particles were uniformly dispersed in an amount of 200 g / m ² thereon.

A 20 g / m ² polypropylene meltblown nonwoven fabric (1 to 10 denier) with a spunbond nonwoven fabric laminated thereon was covered on the coated activated carbon and heat-bonded at a temperature of 200 캜 using a laminate to prepare a deodorization-dustproof filter.

Example 2

A deodorant-dustproof filter was prepared in the same manner as in Example 1, except that the amount of the activated carbon particles dispersed was increased to 300 g / m ² .

Example 3

Activated carbon particles having a size of 20 to 40 mesh size were dispersed in an amount of 200 g / m ² in a first thermal adhesive card web / balckey layer prepared in the same manner as in Example 1, and then core-sheath type composite yarns (LMPET 10 denier) (Same weight as that of the first heat-sealable card web), and then heat-bonded at a temperature of 200 ° C using a laminate to prepare a filter material for deodorization.

A meltblown nonwoven fabric was laminated on the fabricated filter material for deodorization on a second thermal adhesive card web, and heat-bonded at a temperature of 200 캜 using a laminate to prepare a filter for deodorizing-dustproofing.

Comparative Example 1

A filter for deodorant-and-dustproofing was produced in the same manner as in Example 1 except that a PET spunbonded nonwoven fabric of 30 g / m ² was used as a support instead of the first thermal adhesive card web.

Comparative Example 2

A filter for deodorizing-dustproofing was manufactured in the same manner as in Comparative Example 1, except that the amount of dispersed activated carbon particles was increased to 300 g / m ² .

Comparative Example 3

The deodorant-and-dustproof filter was prepared by dispersing the activated carbon particles directly on the first heat-adhesive carded web at a weight of 300 g / m ² without forming a honeycomb layer, laminating the meltblown nonwoven fabrics and then thermally adhering them .

Comparative Example 4

A deodorant-and-dustproof filter was prepared in the same manner as in Comparative Example 3, except that the activated carbon particles were directly sprayed on the first thermal adhesive carded web at a weight of 200 g / m ² .

evaluation

1. Thickness and basis weight

The thickness of the sample was measured by MITUTOYO thickness gauge according to KS K ISO 9073-1 and the basis weight was calculated in g / m ^{2 according} to KS K 0514.

2. Air permeability

The air permeability of the prepared activated carbon composite filter media was measured using a fretier type air permeability tester (AP-360) according to ISO 9237, and samples were taken from the left, Respectively. The air pressure used for the measurement was 125 Pa.

3. Gas removal efficiency

A unit was prepared from the filter media of the prepared sample to measure the harmful gas removal efficiency. The flow rate was set to 150 m ³ / h using a harmful gas removal efficiency evaluation device (PAF 113, TOPAS GMBH), the toluene gas concentration as a noxious gas was set to 80 ppm, the concentration of the initial inflow gas was measured, And the adsorption efficiency was measured by measuring the inlet gas concentration after 5 minutes.

4. Release state of activated carbon

When the activated carbon was dropped to less than 50ea / m ² between the filter media in the bending process (pleating) for producing the deodorant-proof filter medium as a unit, it was recorded as `good`.

The results of the physical properties evaluation of the examples and comparative examples are summarized in the following table.

Air permeability
cm ³ / cm ² -sec Active carbon release state Gas Removal Efficiency (%) Example 1 157 Good 50 Example 2 120 Good 73 Example 3 166 Good 50 Comparative Example 1 85 Good 49 Comparative Example 2 49 Good 65 Comparative Example 3 159 Breakaway 40 Comparative Example 4 124 Breakaway 58

The deodorant-and-dustproof filter manufactured in the embodiments of the present invention is good in the detached state of activated carbon, has high gas removal efficiency, and has a high air permeability, which is preferable for use as a filter media.

On the other hand, the air permeability of Comparative Example 3 was the highest among the manufactured filter media, but the activated carbon was detached due to a lack of a binder for fixing the activated carbon, which was not preferable for use as a filter media. In addition, the prototypes prepared in Comparative Examples 1 and 2 were good in the state of leaving the activated carbon, but it is expected that the pressure difference will be large when the filter is used because the air permeability is very low.

The composite filter of the present invention can be used as a cabin air filter for an automobile, a filter for air conditioning or an air purifying filter.

10 .. filter material for deodorization 11 .. first thermal adhesive card web
12. BULK KEY layer 13 .. Second thermal bond card web
14 .. Short fiber 15 .. Activated carbon particles
20 .. deodorant - dustproof composite filter 21 .. dustproof filter material

Claims (8)

A first thermally bonded carded web (TBCW) formed by thermally adhering a carded web and having an air permeability of 600 cm ³ / cm ² -sec or greater measured by the ISO 9237 method;
A vulcanizable layer having a weight of 20 to 90 g / m < ² > formed by carding short fibers having a length of 30 to 100 mm on the first heat-sealable card web and then needle punching; And
A second thermal adhesive card web laminated on the vulcanizable layer and formed by thermally adhering a carded web and having an air permeability of 600 cm ³ / cm ² -sec or more measured by an ISO 9237 method,
Wherein 200 to 400 g / m < ² > of activated carbon particles are fixed in a space formed between the staple fibers of the vulcanized layer. The deodorization filter material according to claim 1, wherein the fiber material of the first thermal bonding card web, the honeycomb layer and the second thermal bonding card web is a core-sheath type PP / PE composite yarn or LM-PET. The composite yarn according to claim 2, wherein the composite yarn has a fineness of 2 to 20 denier; The weight of the first thermal bond card web and the second thermal bond card web is independently from 20 to 150 g / m < ² > Wherein the filter is a filter. delete delete The method according to claim 1,
An air permeability of 500 cm ³ / cm ² -sec or more after the formation of the vulcanized layer fixed on the first thermal adhesive card web;
And air permeability after lamination of the second thermal adhesive carded web is 200 cm ³ / cm ² -s or more. A deodorant-and-dustproof composite filter in which a meltblown nonwoven fabric is laminated on one surface of a deodorizing filter material according to claim 1. The deodorant-and-dustproof composite filter according to claim 7, wherein the air permeability measured by the ISO 9237 method is 80 cm ³ / cm ² -sec or more.

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