KR101804827B1 - Air cleaning filter and air cleaner provided with same - Google Patents

Abstract

The surface area of the fiber of the fibrous aggregate is roughened to increase the surface area of the fiber per unit volume so that the contact area with the fine particles in the air can be increased and the fine particles such as PM2.5 are easily brought into contact with the surface of the fiber of the fibrous aggregate , It is possible to collect fine particles without missing them because of the strong force for adsorbing the fine particles, and it is possible to reliably hold the collected fine particles, and it is not only excellent in the efficiency and reliability of collecting the substance to be treated such as fine particles and fine particles , Excellent in shape stability and processability, excellent in corrosion resistance, durability and stability of quality, and can be removed by sucking the adsorbed substance to be treated or by a vacuum cleaner, thereby providing an air cleaning filter Provided. The present invention relates to a fiber aggregate comprising a fiber aggregate formed in the form of a nonwoven fabric made of aluminum or aluminum alloy fiber, a shape member having a plurality of holes and covering both planes of the fiber aggregate, and a recess formed by roughening at least the surface of the fiber on the upstream side of the fiber aggregate .

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to an air cleaning filter,

The present invention relates to an air purifying filter capable of purifying air by effectively collecting dust in the air by being installed in various devices having an air cleaning function and particularly suitable for particulate measures such as PM2.5, Lt; RTI ID = 0.0 > air purifier.

In recent years, there has been a tendency to increase the amount of formaldehyde and toluene generated from structural materials such as plywood, veneer, adhesive, paint and the like due to the progress of meat intensification of houses, offices, vehicles, and the extreme decrease in the number of natural ventilation of indoor air. Dust, fungus, house dust, mites, pet hair, smoke of a cigarette or the like, which are generated in a room or in a room, And may be brought into the room from the outdoors, thereby adversely affecting the human body and causing health damage. In order to remove these objects to be treated and obtain a comfortable living space, demand for various devices such as a deodorizer, an air conditioner, a humidifier, etc. having an air purifying function as well as an air purifier is increasing (hereinafter, A deodorizer having a clean function, an air conditioner, a humidifier, and the like are collectively referred to as an air purifier).

Various studies have been made on filters used in air purifiers.

For example, Japanese Unexamined Patent Publication (Kokai) No. 2002-344704 discloses a filter having a deodorizing function, a filter having a deodorizing function (first filter), a dust collecting filter (second filter), a photocatalytic filter (third filter), a metal phthalocyanine complex and a weakly alkaline metal salt And a honeycomb or colgate filter (fourth filter) supported on activated charcoal brine.

In addition, Patent Document 2 discloses an environmental pollutant removing filter formed by combining an environmental pollutant gas removing material and a high-performance dust removing material.

Patent Document 1: Japanese Patent Application Laid-Open No. 2007-260603 Patent Document 2: JP-A-11-165007

However, the conventional techniques described above have the following problems.

(1) In general, the trapping of fine particles in a filter can be prevented by blocking by fibers, collision with fibers due to inertia force, sedimentation of fine particles by gravity, contact with fibers by the Brownian motion of fine particles, and adsorption by electrostatic force However, fine particles passing through the gap of the filter as well as fine particles blown back from the fibers are also present.

Further, the fine particles collected on the fibers are retained by the intermolecular attraction or the electrostatic force, but there is a possibility that they pass through the filter due to the flow of air thereafter and are discharged to the outside. Particularly, the HEPA filter is suitably used also as a high-performance dust removing material of the dust-collecting pleat filter (second filter) of Patent Document 1 (Patent Document 2) or the high-performance dust removing material of Patent Document 2. However, the filter medium is mainly made of glass fiber, The electrostatic force for adsorbing the fine particles (such as PM2.5) charged in the positive atmosphere in the air is so weak that the stability and reliability of the trapping of the fine particles are lacking.

(2) The HEPA filter has a problem that the thickness is as thick as about 20 to 50 mm, the device is liable to be large in size, and space-saving is lacking.

(3) Further, since the HEPA filter can not basically be washed with water, it has to be replaced when clogging occurs, and the problem of maintenance and environmental protection is lacking.

The present invention solves the above-mentioned conventional problems, and it is an object of the present invention to provide a fiber aggregate which has a surface of a fiber roughened so that the surface area of the fiber per unit volume is large and the contact area with the fine particles in the air can be increased, PM2.5 are easily adhered to and adhere to each other, and the force for adsorbing the fine particles is strong, so that the fine particles can be collected without missing, and the captured fine particles can be reliably maintained. Even if the fine particles are thin, It is possible to remove the adsorbed substance to be treated by cleaning or by suction by a vacuum cleaner, and thus it is possible to remove the adsorbed substance, The present invention provides a filter for air purifying which is excellent in environmental protection, No two days to steal the processed material, such as fine particles to the outside Anna, reliability of the air purification, stability, reliability is excellent and, at the same time, miniaturization is easy, and another object the provision of an air cleaner is excellent in space savings.

Means for Solving the Problems In order to solve the above-described conventional problems, the air cleaning filter of the present invention and the air purifier equipped therewith have the following configuration.

The air cleaning filter according to Claim 1 of the present invention is a filter for air cleaning which is made of an aluminum or aluminum alloy fiber and which is formed in a nonwoven fabric form and made of aluminum or aluminum alloy and has a plurality of holes, And a surface layer of an alumite layer or a boehmite layer formed on an outer surface of the fiber aggregate and the shape memory member .

With this configuration, the following actions are obtained.

(1) By having a fibrous aggregate formed in the form of a nonwoven fabric by a fiber made of aluminum or an aluminum alloy, it is easy to negatively charge the fiber and paper compared to glass fiber or paper, and attracts particulate such as PM2.5 which is positively charged in the air So that it is possible to collect the fine particles without missing them, and to keep the collected fine particles securely, which is excellent in the efficiency of capturing the fine particles and the reliability.

(2) Since the fibrous aggregate is formed into a nonwoven fabric so that the fibers are intricately entangled, fine particles are easily caught even if they are thin, and the substance to be treated such as ginseng and fine particles can be collected reliably and efficiently. It can be easily lightened, and resource saving and handleability are excellent.

(3) Since it has a plurality of hole portions and a shape member that is provided on both planes of the fiber aggregate, deformation or breakage of the fiber aggregate can be prevented and the shape stability and handling property are excellent. So that the design possibility is excellent.

(4) When the fibrous aggregate and the shape-retaining member are made of metal, it is possible to firmly fix the fibrous aggregate and the shape-retaining member by means of compression, welding, sintering or the like, so that the durability is excellent and it is necessary to provide a shape- It is possible to simplify the configuration and has excellent mass productivity.

(5) Since the surface area of the fiber of the fiber aggregate can be increased by having at least the recess formed by roughening the surface of the fiber on the upstream side (air inlet side) of the fiber aggregate, the contact area with the fine particles in the air can be increased So that the fine particles easily adhere to the surface of the fiber of the fibrous aggregate, and the efficiency and reliability of the trapping of fine particles are excellent.

(6) Since the fibrous aggregate is formed in the nonwoven fabric of fibers made of aluminum or aluminum alloy, the object to be treated adsorbed on the fibers can be cleaned or removed by suction by a vacuum cleaner, This is excellent.
(7) By having a skin layer formed on the outer surface of the fibrous aggregate and the shape-retaining member, the fibrous aggregate and the shape-retaining member can be protected, and the durability and longevity are excellent.
(8) The shape-forming member is made of aluminum or aluminum alloy. The surface layer is formed of an alumite layer or a boehmite layer. In particular, when it is a boehmite layer, its hardness is higher than pure aluminum and the like.
(9) Since the fibrous aggregate and the shape-retaining member are made of aluminum or aluminum alloy and have a higher boehmite layer than the pure aluminum or the like as the skin layer, the adhesiveness between the fibrous aggregate and the shape- Therefore, it is hard to cause peeling or cracking of the thermal sprayed coating, so that the product is excellent in durability, quality stability, and shape freedom property.
(10) Since the alumite layer and the boehmite layer are passive, it is possible to prevent the aggregation of the fibrous aggregates and the moldings due to moisture adhering to the surface of the filter for air cleaning, It is possible to improve the sterilization ability.

Here, as the fibers of the (a) fibrous aggregate, those having an average fiber diameter of 30 to 200 mu m are suitably used.

(b) As the average fiber diameter becomes smaller than 30 탆, the strength of the fiber becomes weak, the durability of the fiber aggregate lowers, and the fiber aggregate tends to be damaged when the concave portion is formed on the surface of the fiber, , The strength of the fiber becomes stronger as it becomes thicker than 200 탆, but the porosity or the surface area per unit volume is lowered, which makes it difficult for air to pass therethrough, and the adhesion performance of the fine particles tends to be lowered. .

(c) The roughening treatment method for forming the concave portion on the surface of the fiber can be suitably selected, and blast treatment, plasma discharge, or the like can be used. The concave portion may be formed at least on the surface of the fiber on the upstream side (air inflow side) of the fiber aggregate, but may be formed on the entire surface of the fiber. Further, in the case of forming the concave portion (performing the roughening treatment) while covering the both sides of the fiber aggregate with the protruding member and holding the fiber aggregate with the protruding member, concave portions may be formed on the surface of the protuberant member at the same time.

(d) The surface roughness of the fiber after the roughening treatment is preferably about Ra = 3 to 8 탆. As the surface roughness of the fiber after the roughening treatment becomes smoother than Ra = 3 占 퐉, the roughening effect is lowered and the surface area of the fiber tends to become insufficient, so that the fine particles tend to be hardly adhered. The unevenness of the surface of the fiber increases and the place where the fine particles can be adhered to is decreased to tend to lower the holding stability of the fine particles and the fiber tends to be lowered in strength and tends to be broken, It is not desirable.

As the (e) fibrous aggregate, those having a unit weight of 300 to 10,000 g / m 2 are suitably used.

(f) As the unit weight is less than 300 g / m 2, the amount of fibers per unit volume is reduced, and the substances to be treated such as fine particles in the air, bacteria, viruses, odorous substances, etc. are easily passed, , And as the number of fibers increases from 10000 g / m < 2 >, the amount of fibers per unit area increases, clogging tends to occur, and the service life tends to be shortened.
(g) The porosity of the fibrous aggregate is preferably 50 to 90%. As the porosity is less than 50%, the amount of air that can pass through is reduced, and clogging tends to occur. When the porosity is larger than 90%, the eyes become clogged and the particulates can not be collected. It tends to be easily deteriorated, and neither is preferable.
(h) The thickness of the filter for air cleaning is preferably 1 to 4 mm. As the thickness of the filter for air cleaning becomes thinner than 1 mm, the proportion of the fibrous aggregate becomes smaller, the substance to be treated in the air tends to pass and the particulate matter can not be collected, and the collecting performance tends to decrease. As the thickness becomes thicker than 4 mm, the amount of the fibrous aggregate increases, and the amount of air that can pass through the fibrous aggregate tends to be small, so that clogging tends to occur easily. Since the thickness of the air cleaning filter is as thin as 1 to 4 mm, bending processing and the like can be performed, and the processability is excellent and the degree of freedom of design is high. Do.
(i) It is preferable that a layer (coating film) of boehmite (aluminum hydrate) is formed on the surface of the fiber aggregate as well as the shape-forming member made of aluminum or aluminum alloy.
(j) Boehmite is passivation that is formed by reacting hot water or contact surface of water vapor with aluminum by exposing aluminum to hot water (or water vapor) of about 90 ° C or more. Therefore, by forming the boehmite layer on the surfaces of the fibrous aggregate and the shape-retaining member, even when the sterilizing metal is mixed with the sprayed coating, the aluminum and the dissimilar metal are not in contact with each other, The galvanic corrosion of the protruding member can be prevented.
The thickness of the (k) boehmite layer is preferably 0.2 to 2 占 퐉. As the thickness of the boehmite layer becomes thinner than 0.2 탆, it is difficult to form the boehmite layer, and the strength of the skin layer is hardly improved, the adhesion with the thermal sprayed coating is lowered, and the corrosion resistance and durability are likely to be lowered And when it is thicker than 2 탆, the formation of the boehmite layer takes time, and productivity tends to be lowered.
(l) The skin layer formed on the outer surface of the fibrous aggregate and the shape-retaining member may be any material as long as it can protect the fibrous aggregate and the shape-retaining member. Preferably, however, it is hard and excellent in corrosion resistance and abrasion resistance.
(m) When a thermal sprayed coating is formed on the outer surface of the skin layer, the skin layer is not particularly limited as long as it can improve the adhesion of the sprayed material, has excellent corrosion resistance, and has a high melting point.
Examples of the skin layer in the case where the fiber aggregate and the shape-retaining member are made of aluminum or an aluminum alloy include alumite and boehmite. Among them, in the case of boehmite, it is preferable because the skin layer can be formed on the entire surface irrespective of the shape of the air cleaning filter.

(n) The shape-retaining member may be any material as long as it has a plurality of holes and can maintain the shape of the fiber aggregate. The material is not particularly limited, and may be a metal or a synthetic resin. When the shape member is made of metal, it is not particularly limited as long as it is a net or a porous metal plate, but expanded metal, punching metal, metal net and the like are suitably used. Among them, expanded metal has no deformation of the mesh, and the joint portion is unified, so that it is excellent in fastness, and the flow of air is hardly blocked, and the stability of the shape is also excellent.

When the shape member is made of metal, the material is not particularly limited, and iron, copper, silver, gold, aluminum, nickel, stainless steel, tungsten, molybdenum and the like can be used.

(o) The opening ratio of the shape member is preferably 50 to 90%. The coverage of the fibrous aggregate becomes smaller and the amount of the air that can pass through the fibrous aggregate per unit time becomes smaller to tend to cause clogging and become larger than 90% The structural strength of the shape-forming member is weakened due to the external force or the like, and it tends to be easily damaged.

(p) The opening area of one hole portion of the complementary member is suitably used in the range of 0.5 to 500 mm < 2 >. As the opening area of the hole portion becomes smaller than 0.5 mm 2, the eyes become denser and the air becomes less likely to pass and the clogging tends to occur. As the opening area becomes larger than 500 mm 2, the eyes become clogged and the particulates can not be collected , The collection performance tends to be lowered, and any of them is not preferable.

(q) The thickness of the complementary member is suitably 0.3 to 1 mm. As the thickness of the shape-retaining member becomes thinner than 0.3 mm, the bending strength tends to be insufficient and it tends to be easily broken at the time of manufacturing. As the thickness becomes larger than 1 mm, the ratio of the fiber aggregate to the thickness of the entire air- And the function of separating the substance to be treated at the time of air passage tends to be insufficient, which is undesirable.

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According to a second aspect of the present invention, there is provided an air cleaning filter as set forth in the first aspect, which has a constitution including a thermal sprayed coating formed on the outer surface of the skin layer and containing a metal compound having a photocatalytic function.

With this configuration, in addition to the function of claim 1, the following actions are obtained.
(1) Since a thermal spray coating containing a metal compound having a photocatalytic function is formed on the outer surface of the skin layer of the fiber aggregate and the shape memory member, the adhesion of the metal compound due to thermal spraying is high and peeling of the thermal sprayed coating is hardly caused, Excellent in quality stability.
(2) Since the skin layer and the thermal sprayed film do not come into direct contact with each other by the skin layer, if the skin layer is passivated, there is no occurrence of galvanic corrosion of the fibrous aggregate or the protruding member due to moisture attached to the surface of the air cleaning filter, The sterilization ability can be improved by mixing the sprayed coating with a sterilizing metal such as silver or copper.
(3) Since the surface of the fiber on which the skin layer is formed is roughened and the irregularities are formed on the outer surface of the skin layer, the sprayed material is easily permeable to the concave portion of the skin layer by the anchor effect, Do.

(4) Since a spray coating containing a metal compound having a photocatalytic function is formed on the outer surface of the skin layer of the fibrous assembly and the shape-retaining member, it is excellent in bactericidal action against viruses and bacteria contacting the surface of the air cleaning filter.

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Here, the thermal spraying material for forming the thermal spray coating is not particularly limited as long as it is a metal compound having at least a photocatalytic function, and may be titanium dioxide, zinc oxide, tungsten oxide, cadmium oxide, indium oxide, silver oxide, manganese oxide, Metal oxide semiconductors such as tin oxide, vanadium oxide, niobium oxide and zirconium oxide, metal sulfide semiconductors such as cadmium sulfide, zinc sulfide, indium sulfide, lead sulfide, copper sulfide, molybdenum sulfide, tungsten sulfide, antimony sulfide and bismuth sulfide, Strontium, cadmium selenide, potassium tantalate, and mixtures thereof. Among them, titanium dioxide is preferable because it is inexpensive, has excellent chemical stability, and has high catalytic activity.

The titanium dioxide has an anatase type or a rutile type depending on the difference in crystal structure, but the crystal structure is not particularly limited, and either one of them may be used, or a mixture thereof may be used. It is preferable to use anatase type titanium dioxide when the photocatalytic function is important, and rutile type titanium dioxide is preferable when cost is important.

In addition, by doping sulfur, carbon, nitrogen or the like into the crystal lattice of titanium dioxide or by mixing or supporting at least one compound selected from metal complexes such as iron, copper, chromium and nickel, or metal salts, A visible-light responsive thermal spray coating may be used.

In addition to the metal compound having a photocatalytic function, the spraying material for forming the thermal spray coating may carry a sterilizing metal having a sterilizing function. As the sterilizing metal, silver, copper, zinc, nickel, cobalt, aluminum, iron or a compound thereof can be used. When these sterilizing metals are added to increase the bactericidal resistance, it is preferable to include 0.1 to 10 mass% of the total amount of the spray coating.

As the amount of the sterilizing metal in the sprayed coating is less than 0.1 mass%, the improvement of the sterilizing property tends not to be improved. When the amount of the metal compound having the photocatalytic function is reduced as the amount exceeds 10 mass%, the sterilizing property The amount of the treating substance in the air passing through the filter for air cleaning is in contact with the metal compound having a photocatalytic function in the thermal sprayed coating per unit time is lowered and the treating amount by the photocatalytic function tends to be lowered It is not desirable either.

The method of forming the thermal sprayed coating is not particularly limited as long as it is thermal spraying, and methods such as frame spraying, high speed frame spraying, gas spraying, arc spraying, plasma spraying, electric spraying such as spraying spraying, cold spraying and the like can be used. In particular, in the high-speed frame spraying, since the sprayed material is sprayed in a semi-molten state, the sprayed material is hardly influenced by heat, and the sprayed material is injected at a speed several times as high as the sonic speed, so that the sprayed material tends to penetrate into the fiber composite, , And a sprayed coating having high denseness and high adhesion can be formed.

The dissolved amount of the thermal sprayed coating is preferably 5 to 40 g / m 2, and more preferably 10 to 30 g / m 2. As the sprayed amount is less than 10 g / m 2, the sprayed coating on the surface of the filter for air cleaning becomes thin, so that the sprayed coating is likely to peel off due to external force, and the stability and durability of the quality tend to deteriorate. These tendencies become remarkable, which is undesirable. Further, since the thermal spraying film becomes thicker as it is larger than 30 g / m 2, cracks tend to be generated on the surface when the air cleaning filter is bent, and accordingly, the thermal spraying film tends to peel off, As the amount is larger than 40 g / m 2, these tendencies become remarkable, which is not preferable.

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The air purifier according to claim 3 of the present invention has the configuration including the air purifying filter according to claim 1 or 2.

With this configuration, the following actions are obtained.

(1) The particulate such as PM2.5 which is positively charged in the air can be strongly attracted and collected by the air cleaning filter which is easily negatively charged, and besides, the target substance such as collected particulate matter or particulate matter It is possible to maintain the reliability of the air purification, stability, and reliability because there is no need to keep the airflow out to the outside.

(2) Even though the fibers are thin, fine particles are easily caught in the fibers, and the filter has an air cleaning filter which has a large surface area of the fibers and is easy to adhere to the fine particles, thereby being excellent in the efficiency of capturing fine particles, It is excellent in economy.

(3) Providing an air purifying filter capable of removing a substance to be treated such as collected particulate matter by suction or cleaning is excellent in maintenance, environmental protection, and stability of the air cleaning function.

Here, the air purifier refers to a generic term for a so-called general air purifier, various devices such as a deodorizer, an air conditioner, and a humidifier having an air purifying function.

In the air purifier, only the air purifying filter may be used alone, or may be used in combination with other filters having a photocatalytic function or sterilizing and deodorizing function.

In addition, when an ionizer or the like for generating negative ions is incorporated in the air cleaner, the negative ions can be brought into contact with the fiber aggregate of the air purifying filter to positively negatively charge, and the fine particles charged in the air can be attracted So that it is possible to reliably collect and hold the fine particles, thereby improving the efficiency and reliability of collecting the fine particles.

(Effects of the Invention)

According to the invention described in claim 1, the following effects can be obtained.

(1) Compared to glass fiber or paper, it is easy to charge negatively, and particulate such as PM2.5 which is positively charged in the air can be attracted strongly and can be collected without missing, and also, It is possible to provide an air cleaning filter excellent in the efficiency of capturing particulates and reliable.
(2) It is possible to provide an air cleaning filter excellent in durability and long life reputation that can protect the fibrous assembly and the prosthetic member in the skin layer.

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According to the invention described in claim 2, in addition to the effect described in claim 1, the following effects can be obtained.

(1) It is possible to provide an air cleaning filter excellent in durability and quality stability of a product in which the adhesion of the metal compound by spraying is high and the spray coating is hardly peeled off.
(2) It is possible to provide an air cleaning filter which is excellent in denseness and adhesion of the sprayed coating and excellent in bactericidal action against viruses and bacteria that come into contact with the surface.
(3) It is possible to improve the adhesion between the fibrous aggregate and the casting member and the sprayed coating through the boehmite layer, and to provide a product having excellent durability, quality stability, and shape freedom property Filter can be provided.

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According to the invention described in claim 3, the following effects can be obtained.

(1) The particulate such as PM2.5, which is positively charged in the air, can be strongly attracted and collected by the air purifying filter which is easily negatively charged, and at the same time, the target substance such as collected particulate matter and particulate matter The air cleaning filter can be provided with excellent reliability, stability, and reliability of air purification that does not leak out to the outside.

1 is a exploded schematic perspective view of an air cleaning filter according to Embodiment 1,
Fig. 2 is a schematic perspective view and partial schematic enlarged view of the air cleaning filter of Embodiment 1,
Fig. 3 is an enlarged view of the BB line sectional view of Fig. 2,
Fig. 4 is a schematic side view of the fibers forming the fiber aggregate of the air cleaning filter in the first embodiment, Fig.
Fig. 5 (a) is a schematic cross-sectional view showing an initial state of the fibers forming the fiber aggregate of the air cleaning filter of the first embodiment, Fig. 5 (b) (C) is a schematic sectional view showing a state after the skin layer forming step of the fiber forming the fiber aggregate of the air cleaning filter of Embodiment 1, and (d) is a schematic cross- (E) is a schematic cross-sectional view showing a second state after the spraying process of the fiber forming the fiber aggregate of the air cleaning filter according to the first embodiment, Fig.
Fig. 6 is a side elevational view showing the configuration of an air purifier provided with an air purifying filter according to Embodiment 1. Fig.
7 is a graph showing the relationship between the 2 mu m particle removal time and the removal rate in the air cleaning filter of Example 1. Fig.

DESCRIPTION OF THE PREFERRED EMBODIMENTS An air purifying filter and an air purifier equipped with the same will be described below with reference to the drawings. The present invention is not limited to the embodiments described below.

(Embodiment 1)

2 is a schematic perspective view and a partial schematic enlarged view of an air cleaning filter according to a first embodiment. Fig. 3 is an enlarged view And Fig. 4 is a schematic side view of the fibers forming the fiber aggregate of the air cleaning filter of Embodiment 1. Fig.

1 and 2, reference numeral 1 denotes an air cleaning filter according to Embodiment 1 of the present invention, 2 denotes a fiber aggregate formed into a nonwoven fabric by fibers made of aluminum or aluminum alloy, 3 denotes a fibrous aggregate (2) And a compressed portion 4 in which the fibrous assembly 2 and the protuberant member 3 are pressed together.

3, reference numeral 5 denotes a skin layer formed on the surfaces of the fibrous aggregate 2 and the prosthetic member 3, and 6 denotes a thermal sprayed film composed of a metal compound having a photocatalytic function formed on the surface of the skin layer 5 and the like.

4, numeral 7 is a fiber forming the fiber aggregate 2, and 8 is a recess formed on the surface of the fiber 7 by roughening treatment such as blast or plasma discharge.

The fibers 7 forming the fibrous aggregate 2 have an average fiber diameter of 30 to 200 mu m. The strength of the fiber 7 becomes weak as the average fiber diameter becomes smaller than 30 탆 and the durability of the fiber aggregate 2 is lowered to form the concave portion 8 on the surface of the fiber 7, 2 tend to be broken and the yield tends to decrease. The strength of the fiber 7 becomes stronger as it becomes thicker than 200 탆, but the porosity or the surface area per unit volume is lowered, It tends to be liable to lower the adhesion performance of the resin.

The unit weight of the fibrous aggregate (2) was set to 300 to 10,000 g / m 2. As the unit weight is less than 300 g / m 2, the amount of fibers per unit volume is reduced, and the substances to be treated such as fine particles in the air, bacteria, viruses, odor substances, etc. are easily passed, And the amount of the fibers 7 per unit area increases as the number of fibers becomes larger than 10,000 g / m < 2 > and clogging tends to occur, so that the life span tends to be shortened.

As the material of the mold-forming member 3, metals such as iron, copper, silver, gold, nickel, stainless steel, tungsten, molybdenum, and synthetic resins may be used in addition to aluminum or an aluminum alloy.

The opening ratio of the shape memory member 3 was set to 50 to 90%. As the percent open area ratio of the complementary mold member 3 becomes smaller than 50%, the exposure of the fibrous aggregate 2 becomes small, and the amount of air that can pass through the fibrous aggregate 2 per unit time becomes small, And the structural strength of the shape-forming member 3 is weakened as it is larger than 90%, so that it tends to be easily damaged by an external force or the like.

The opening area of one hole portion of the protuberance member 3 was 0.5 to 500 mm < 2 >. As the opening area of the hole portion becomes smaller than 0.5 mm 2, the eyes become denser and the air becomes less likely to pass and the clogging tends to occur. As the opening area becomes larger than 500 mm 2, the eyes become clogged and the particulates can not be collected , And the trapping performance tends to be lowered. In this embodiment, as shown in Fig. 1, the tubular member 3 is provided on both sides of the fiber aggregate 2 such that the openings of the tubular member 3 are oriented in the same direction from the front and rear sides of the air purifying filter 1, But it is also possible to improve the strength by rotating one of the plurality of prosthetic members 3 by 90 degrees so that the directions of the openings of the prosthetic members 3 are perpendicular to each other.

The thickness of the prosthesis member 3 is 0.3 to 1 mm. As the thickness of the protuberance member 3 becomes thinner than 0.3 mm, the bending strength becomes insufficient and tends to be broken at the time of manufacture. As the thickness of the protuberance member 3 becomes thicker than 1 mm, It was found that the ratio of the fibrous aggregates 2 was small and the function of separating the substance to be treated at the time of passing of air tended to be insufficient.

The metal compound forming the thermal spray coating 6 is not particularly limited as long as it has a photocatalytic function, but titanium dioxide is preferable because it is inexpensive in the photocatalyst and has no toxicity to the human body.

Copper, zinc, aluminum, nickel, cobalt, iron, or the like, which is a sterilizing metal, may be supported on the thermal spray coating 6 in addition to the metal oxide.

When the sterilizing metal is carried, it is preferable that the sterilization metal is carried in an amount of 0.1 to 10% by mass based on the total amount of the thermal spray coating (6). As the amount of the sterilizing metal in the thermal spray coating 6 is less than 0.1 mass%, the improvement in bactericidal property tends not to be improved. When the amount is larger than 10 mass%, the amount of the metal compound having a photocatalytic function is reduced, And the amount of the substance to be treated in the air passing through the air purifying filter 1 can be brought into contact with the metal compound having the photocatalytic function in the thermal sprayed film 6 per unit time is lowered so that the photocatalytic function It is likely that the throughput due to the heat treatment tends to decrease.

The concave portion 8 was formed so that the surface roughness of the fiber 7 was about Ra = 3 to 8 탆. As the surface roughness of the fiber 7 after the roughening treatment becomes smoother than Ra = 3 탆, the roughening effect is lowered and the surface area of the fiber 7 tends to become insufficient, The roughness of the surface of the fiber 7 is increased and the place where the fine particles can be adhered is decreased and the holding stability of the fine particles is easily lowered and the strength of the fiber 7 is lowered And that it tends to be easier to break down.

The concave portion 8 may be formed at least on the surface of the fiber 7 on the upstream side of the fiber aggregate 2 but may also be formed on the surface of the fiber 7 on the downstream side of the fiber aggregate 2, By making both sides of the aggregate 2 roughened, the front and back of the air cleaning filter 1 can be used without worrying, and handling is excellent. It is also possible to coat the both sides of the fibrous assembly 2 with the mold members 3 and form the recesses 8 in the state of holding the fibrous assembly 2 with the mold members 3 , The concave portion 8 may be formed on the surface of the mold member 3 at the same time.

A method of manufacturing an air cleaning filter according to the first embodiment of the present invention constructed as described above will be described.

Fig. 5 (a) is a schematic sectional view showing an initial state of the fibers forming the fiber aggregate of the air cleaning filter of the first embodiment, and Fig. 5 (b) 5 (c) is a schematic cross-sectional view showing the state after the skin layer forming step of the fiber forming the fiber aggregate of the air cleaning filter of Embodiment 1, and Fig. 5 5D is a schematic cross-sectional view showing a first state after the spraying process of fibers forming the fiber aggregate of the air cleaning filter of Embodiment 1, and Fig. 5E is a schematic cross- Fig. 3 is a schematic cross-sectional view showing a second state of the fiber after the spraying process.

First, as the fiber aggregate embossing step, the fiber aggregate 2 obtained by collectively compressing the fibers is sandwiched by the embossing member 3 such as an expanded metal or punch metal as shown in Fig. 1, The shape of the fiber aggregate 2 and the shape retaining member 3 is maintained by forming the pressed portion 4 by spot welding the elements of the fiber aggregate 2 and the shape retaining member 3 as shown in Fig. And the adhesiveness between the fibrous assembly 2 and the shape memory member 3 is enhanced. At this time, the fiber aggregate 2 and the prosthetic member 3 are regularly exposed on the surface of the air cleaning filter 1 (see A in FIG. 2).

Then, the air cleaning filter 1 is subjected to a roughening treatment process using a blast, a plasma discharge, or the like. As shown in Fig. 5 (b), the fiber 7 in the initial state is formed in a substantially cylindrical shape as shown in Fig. 5 (a), but at least the fiber 7 on the upstream side of the fiber aggregate 2 A plurality of concave portions 8 can be formed on the surface of the fiber 7. [ When the surface of the fiber 7 is roughened by blasting, an alumina grid is suitably used as the blast material. The particle size of the blast material varies depending on the average fiber diameter of the fibers 7 and the target surface roughness, but is preferably about 150 to 180 mu m. The blast pressure of the blast material and the blast treatment time can be appropriately selected depending on the average fiber diameter of the fiber 7, the target surface roughness, the area of the fiber aggregate, and the like.

Subsequently, the air cleaning filter 1, which is roughened on the surface of the fiber aggregate 2 in the roughening treatment process, is cleaned with pure water, and the air cleaning filter 1 is formed as a skin layer forming process (boilite treatment process) (Boehmite layer) having a thickness of 0.2 to 2 占 퐉 is formed as shown in Fig. 5 (c) by immersing in hot water of 90 占 폚 or more for 30 minutes or more, or by contacting with water vapor of 90 占 폚 or more for 30 minutes or longer . After the formation of the skin layer 5, the skin layer 5 can be stabilized by drying in a drying oven at about 100 to 200 DEG C for several hours.

The sprayed coating 6 is sprayed on the surfaces of the fiber aggregate 2 and the mold 3 by spraying a metal compound having a photocatalytic function onto the air cleaning filter 1 by a high speed frame spraying method or the like, And the air cleaning filter 1 according to the first embodiment of the present invention is manufactured. 5 (d), the thermal spray coating 6 may be formed only on the surface on the upstream side of the fiber 7, or may be formed on the entire surface of the fiber 7 as shown in Fig. 5 (e).

The air cleaning filter 1 can be cut or deformed to a predetermined size when it is used.

Either or both of the skin layer forming step (boehmite treatment step) and the spraying step may be omitted.

Next, the air purifier provided with the air purifying filter according to the first embodiment configured as described above will be described.

Fig. 6 is a side view showing the configuration of an air cleaner provided with an air cleaning filter according to the first embodiment; Fig.

6, reference numeral 10 denotes an air purifier having an air cleaning filter 1 according to Embodiment 1, 11 denotes a photocatalytic filter provided downstream of the air purifying filter 1, 12 denotes a photocatalytic filter And is a fan installed on the downstream side to suck air into the air cleaner 10.

6, when the air cleaner 10 is operated, the fan 12 rotates, and a substance to be treated such as dust or fine particles included in the air together with air in the room is sucked into the air cleaner 10.

At this time, since the air purifying filter 1 is provided on the most upstream side (air inlet side) of the air purifier 10, the substance to be treated is trapped and held in the air purifying filter 1. The air having passed through the air cleaning filter 1 is deodorized and sterilized by the downstream side photocatalytic filter 11 and the purified air is discharged from the air outlet of the air cleaner 10.

The configuration of the air cleaner 10 is not limited to the present embodiment, and the photocatalytic filter 11 may be omitted or one or a plurality of filters having other functions may be used in combination. An ionizer or the like for negatively charging the air cleaning filter 1 may also be incorporated.

Although the air purifier 10 is described in the present embodiment, the air purifying filter 1 can be used as a filter for various devices such as a deodorizer having an air purifying function, an air conditioner, a humidifier, and the like.

The air cleaning filter in the first embodiment configured as described above has the following actions.

(1) By having a fibrous aggregate formed in the form of a non-woven fabric of a fiber made of aluminum or an aluminum alloy, it is easier to negatively charge the fiber than the glass fiber or paper, and particulate such as PM2.5 which is positively charged in the air is strongly attracted Therefore, the fine particles can be collected without missing the fine particles, and the captured fine particles can be reliably maintained, which makes the efficiency and reliability of the fine particle collection excellent.

(2) Since the fibrous aggregate is formed into a nonwoven fabric so that the fibers are intricately entangled, it is possible to surely and efficiently collect the substance to be treated such as an anatomic particles and the like, which are liable to be entrapped with fine particles, It is possible to achieve weight saving, and it is excellent in resource saving and handling.

(3) Since it has a plurality of hole portions and a shape-forming member provided on both planes of the fiber aggregate, it is possible to prevent deformation or breakage of the fiber aggregate, and is excellent in shape stability and handling property, So that the design freedom is excellent.

(4) When the fibrous aggregate and the shape-retaining member are made of metal, it is possible to firmly fix the fibrous aggregate and the shape-retaining member by means of compression, welding, sintering or the like, so that the durability is excellent and it is necessary to provide a shape- It is possible to simplify the configuration and has excellent mass productivity.

(5) Since the surface area of the fiber of the fiber aggregate can be increased by having at least the recess formed by roughening the surface of the fiber on the upstream side (air inlet side) of the fiber aggregate, the contact area with the fine particles in the air can be increased And the fine particles easily adhere to the surface of the fiber of the fibrous aggregate, and the efficiency and the reliability of the fine particles are excellent.

(6) Since the fibrous aggregate is formed in a nonwoven fabric of fibers made of aluminum or aluminum alloy, it is possible to remove the object to be treated adsorbed on the fiber or to remove it by a vacuum cleaner, outstanding

(7) Since a spray coating containing a metal compound having a photocatalytic function is formed on the outer surface of the fibrous aggregate and the shape-retaining member, the sterilizing property against viruses and bacteria in contact with the surface of the air purifying filter is excellent.

(8) By having a skin layer formed on the outer surface of the fiber aggregate and the shape memory member, the fiber aggregate and the shape memory member can be protected, and durability and longevity are excellent.

(9) Since a thermal spray coating containing a metal compound having a photocatalytic function is formed on the outer surface of the skin layer formed on the outer surface of the fiber aggregate and the shape memory member, the adhesion of the metal compound by spraying is high, The product is excellent in durability and quality stability.

(10) Since the surface of the fiber on which the skin layer is formed is roughened and the irregularities are formed on the outer surface of the skin layer, the spray material is easily permeable to the concave portion of the skin layer due to the anchor effect, Do.

(11) Since the shape member is made of aluminum or an aluminum alloy, and the surface layer is a boehmite layer, the hardness is higher than pure aluminum and the like, and therefore the durability and longevity are excellent.

(12) Since the fibrous aggregate and the shape-retaining member are made of aluminum or aluminum alloy and have a higher boehmite layer than the pure aluminum or the like as the skin layer, the adhesiveness between the fibrous aggregate and the shape- And is excellent in durability, quality stability, and shape freedom property of a product because it is hard to cause peeling or cracking of a thermal spray film.

(13) Since the boehmite is passive, it is possible to mix the sterilization metal such as silver and copper to the sprayed coating without causing the aggregation of the fibrous aggregate or the protruding member (galvanic corrosion) caused by the moisture attached to the surface of the filter for air- And the sterilization ability can be improved.

The air purifier equipped with the air purifying filter according to the first embodiment configured as described above has the following actions.

(1) It is possible to strongly attract and collect particulate matter such as PM2.5 which is positively charged in the air by an air cleaning filter which is easily negatively charged, and at the same time, So that there is no need to keep it out and leak out to the outside, so that the reliability of air purification, reliability, and reliability are excellent.

(2) Even if it is thin, it is easy to attach fine particles to fibers that are intricately entangled with each other, and the surface area of fibers is so large that the fine particles adhere easily to the air cleaning filter so that the efficiency of capturing fine particles and the reliability are excellent, It is excellent in space saving.

(3) Providing an air purifying filter capable of removing a substance to be treated such as collected particulate matter by suction or cleaning is excellent in maintenance, environmental protection, and air cleaning function stability.

(Example)

Hereinafter, the present invention will be described in detail with reference to examples. The present invention is not limited to these embodiments.

(Example 1)

On the both surfaces of a fibrous aggregate formed into a nonwoven fabric having a porosity of 65% and a unit weight of 850 g / m 2 on an aluminum fiber having an average fiber diameter of 100 탆, an aluminum sheet having a thickness of 0.8 mm, an aperture ratio of 65% And the elements were spot-welded by compression so that the total thickness was 2 mm.

Thereafter, roughening treatment was carried out so that the surface roughness of the fiber on the upstream side of the fibrous aggregate was about Ra = 3 to 8 占 퐉.

The air purifying filter of Example 1 obtained as described above was attached to an air purifier and operated at a rated air flow rate to measure the removal time and the removal rate of 2 mu m particles.

7 is a graph showing the relationship between the 2 mu m particle removal time and the removal rate in the air cleaning filter of Example 1. Fig.

From Fig. 7, it can be seen from Fig. 7 that the air cleaning filter of Example 1 can capture 99.5% of the fine particles having a particle diameter of 2 占 퐉 in 30 minutes from the start of operation and collect almost 100% in 1 hour and 30 minutes Could know.

From these results, it can be said that the air cleaning filter of Example 1 has a very high trapping ability with respect to the fine particles, and can be used suitably for the particulate measure typified by PM 2.5 in each home.

(Industrial availability)

The surface of the fiber of the fiber aggregate is roughened so that the surface area of the fiber per unit volume is large so that the contact area with the fine particles in the air can be increased and fine particles such as PM2.5 are brought into contact with the surface of the fiber of the fiber aggregate The fine particles can be trapped without missing and the particulate collected can be reliably held. Even if it is thin, the efficiency and reliability of the trapping of the substance to be treated such as particles and fine particles are excellent In addition, it has excellent shape stability and processability, is also excellent in corrosion resistance, durability and quality stability, and can be removed by sucking the adsorbed substance to be treated or by suction in a vacuum cleaner, The provision of a cleaning filter, and the use of a substance to be treated such as particulate or particulate matter captured by the filter It is possible to provide an air purifier excellent in reliability of air purification, stability and reliability, and also capable of providing an air cleaner which is easy to downsize and is excellent in space saving. In addition, You can contribute.

1: air purifying filter 2: fiber aggregate
3: bolt portion 4:
5: Skin layer 6: Spray coating
7: fiber 8: concave
10: air cleaner 11: photocatalyst filter
12: Fans

Claims (6)

A fiber aggregate formed of a fiber made of aluminum or an aluminum alloy in the form of a nonwoven fabric, a mold made of aluminum or aluminum alloy and having a plurality of holes and covering both planes of the fiber aggregate, A concave portion formed by roughening the surface of the fiber, and a skin layer of an alumite layer or boehmite layer formed on the outer surface of the fiber aggregate and the shape memory member. The method according to claim 1,
And a sprayed coating formed on the outer surface of the skin layer and containing a metal compound having a photocatalytic function. An air purifier comprising the air purifying filter according to claim 1 or 2. delete delete delete

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