KR102403900B1 - Manufacturing method of filter using materials with harmful gas removal and antibacterial and deodorizing functions - Google Patents

Abstract

The present invention provides a method for manufacturing a filter using a material having harmful gas removal and antibacterial and deodorizing functions, which increases deodorizing efficiency compared to an existing liquid antibacterial and deodorizing agent or a solid material such as activated carbon, a zeolite porous material and the like, has excellent durability, reduces manufacturing costs by more than 30% to be competitive in terms of price and quality, and has excellent deodorizing performance compared to an activated carbon filter which is widely used as a conventional deodorizing material to replace the activated carbon filter.

Description

Manufacturing method of filter using materials with harmful gas removal and antibacterial and deodorizing functions

The present invention relates to an inorganic composite shape and a method for manufacturing a filter using a material composed by applying ionization to the inorganic composite member. It is high in durability and has excellent manufacturing 　 cost 　 30% or more 　 can be reduced 　 price and 　 competitive in terms of quality and can replace the conventional activated carbon filter. it's about

In a situation where the problem of viruses and bacteria ranging from MERS to SARS and Corona is shaking the whole world, various technologies are emerging to combat it, and products using these technologies are coming out in various forms.

In particular, various gaseous pollutants such as odors and harmful gases exist in the air depending on living environment, work environment, industrial environment, etc., and there is interest in obtaining a comfortable environment by removing these gaseous pollutants .

For example, aldehyde-based gas is contained in various odors such as cigarette smoke, body odors (sweat odor, bad breath, etc.), pet odors, mold odors, paint odors, and printing odors. Since the influence has been pointed out, deodorizing filter media, deodorizing filters, etc. for purifying air containing aldehyde type gas have been proposed in recent years, indoors, inside cars, and the like.

Conventionally, as a deodorizing filter material for aldehyde type gas, what consists of a deodorant of a chemical adsorption type adhere|attaching to a nonwoven fabric, paper, etc. is known. In addition, in the following documents, the term "deodorizing filter (or deodorizing filter)" is used instead of a deodorizing filter medium.

In addition, conventional filters simply filter dust from the air, and most filters with antibacterial function use activated carbon, but their durability is low compared to the unit price, and there are limitations in the ability to remove ammonia or specific harmful gases and antibacterial properties. is showing

In addition, in recent years, problems with hydrogen sulfide, NOx, organic compounds, and methane-based harmful gases are increasing, and a technology capable of reducing these problems is required.

Domestic Patent Publication No. 2014-0015005

An object of the present invention is to use an ionizing material that is harmless to the human body by using a new inorganic material, and causes functional loss by breaking each intermolecular ring with respect to odors and harmful gases through an ionization mechanism, causing various odors and harmful gases To provide a filter manufacturing method using a material having harmful gas removal and antibacterial and deodorizing functions that can decompose and fundamentally prevent the propagation of bacteria, mold, and viruses, and directly decompose and remove the cause of odor.

In addition, an object of the present invention is to provide a filter manufacturing method using a material having a harmful gas removal and antibacterial and deodorizing function, which can easily adsorb ammonia and specific harmful gases, and can replace the conventional activated carbon filter.

One aspect of the present invention comprises the steps of preparing an adsorption decomposition material; preparing a material for forming a film by mixing and stirring the adsorption decomposition material and a binder; depositing or dipping the film-forming material on a nonwoven fabric to prepare a filter fabric having a film formed thereon; bending the filter fabric to be wrinkled; attaching a support to the edge of the pleated filter fabric; and installing a case around the filter fabric to which the support part is attached. Including, the step of preparing the adsorption decomposition material, distilled water and a total of 0.15 to 0.25 parts by weight based on 100 parts by weight of the distilled water, but stirring Ca ²⁺ and Si ⁴⁺ , Ca ²⁺ and Si ⁴⁺ 5 : 5 (Ca ²⁺ :Si ⁴⁺ ) preparing an ion catalyst; Distilled water (H ₂ O) at 22 to 25 ° C. in a mixer, 8 to 10 parts by weight of an ion catalyst based on 100 parts by weight of the distilled water, and 70 to 74 parts by weight of zinc chloride (ZnCl ₂ ) with respect to 100 parts by weight of the distilled water and stirring for 10 to 12 minutes in an atmosphere of 25° C. and 30 to 35% humidity to prepare a liquid raw material; Magnesium oxide (MgO), 135 to 165 parts by weight of alumina (Al ₂ O ₃ ) based on 100 parts by weight of the magnesium oxide, and 90 to 110 parts by weight of titanium dioxide (TiO ₂ ) or 90 to 110 parts by weight of zinc oxide (ZnO) ) to prepare a powder raw material by mixing one; Putting the liquid raw material and the powder raw material into a polymerization reactor in a ratio of 5:4 (liquid raw material: powder raw material), and performing a hydration reaction at 6 to 8° C. to prepare a hydration reaction product in an emulsion state; And a zeolite having an average size of 10mesh to the hydration reactant in an emulsion state is mixed in a ratio of 4:5 (hydration reactant:zeolite), and stirred in an atmosphere of 17 to 23° C. and 10 to 14% humidity to phase the pores and epidermis of the zeolite adsorption and deposition of a hydration reactant in an emulsion state; and drying the hydration reactant by natural heat for 30 to 40 minutes to remove by-products and external moisture contained in the hydration reactant; It provides a filter manufacturing method using a material having a harmful gas removal and antibacterial and deodorizing function, including the.

According to a preferred feature of the present invention, in the step of preparing the adsorption decomposition material, before the adsorption and deposition step, a zeolite having an average size of 10 mesh in a reaction mixer and concentrated to 60% or less is put into the reaction mixer and maintained at 21 to 23 ° C. The step of operating the reaction mixer is first performed, and the step of adsorption and deposition is to prepare a mixed material by putting a liquid raw material and a powder raw material in another reaction mixer and mixing, and then adding the mixed material to a reaction mixer with zeolite for 30 seconds. dividing by 20% at intervals; and maintaining the rotational state of the reaction mixer for 1 hour to prevent intergranular agglomeration of the zeolite; may include

According to a preferred feature of the present invention, in the step of preparing the adsorption decomposition material, after the step of removing by-products and external moisture contained in the hydration reactant, the temperature is raised to 80 to 90° C. and stirring is further performed for 30 minutes. so that the amount of moisture contained in the hydration reactant is 12 to 15%; and pulverizing the hydration reactant with controlled moisture content into powder; may further include.

According to a preferred feature of the present invention, the adsorption decomposition material is combined with the adsorption decomposition material, 225 to 275 parts by weight of activated carbon, 11.25 to 13.75 parts by weight of an ion catalyst, and 11.25 to 13.75 parts by weight based on 100 parts by weight of the adsorption decomposition material. preparing a mixed material by blending the polymer, heating and melting, and extruding; and cutting the mixed raw material in a die and cooling and extruding it in an extrusion air cooler to make activated carbon pellets; It can be prepared by further including.

According to a preferred feature of the present invention, the adsorption decomposition material, cutting the activated carbon pellets; It can be prepared by further including.

According to a preferred feature of the present invention, before bending the filter fabric to be wrinkled, the step of laminating a functional filter on one surface of the filter fabric can be performed.

According to an embodiment of the present invention, it is possible to manufacture an ion-bonded filter made of pure inorganic material that has excellent antibacterial, antifungal, and antiviral functions, and at the same time has harmful gas removal and deodorization functions.

In addition, the filter manufactured according to an embodiment uses a polymer binding material as a main material as an ionized catalyst, decomposes the cause of the mechanism to prevent self-growth of viruses, bacteria and fungi, and -OH as a response to bacteria By generating radicals, there is an effect of providing excellent antibacterial, antifungal and antiviral power.

In addition, since the filter manufactured according to one embodiment is a method of neutralizing and decomposing the cause of odor rather than capturing odor, it is semi-permanently excellent in antibacterial durability, harmful gas removal and deodorization durability, and acetaldehyde, four major odors (hydrogen sulfide, trimetalamine) , methylmethanecap, ammonia) and specific harmful gases are easily adsorbed and the deodorizing effect is semi-permanent, so it has the effect of replacing the conventional activated carbon filter.

1 is a flowchart illustrating a filter manufacturing method according to an embodiment of the present invention.
2 is a flowchart illustrating a method for manufacturing an adsorption decomposition material according to an embodiment applied to the present invention.
3 to 12 are test reports showing the deodorization effect test results of the adsorption decomposition material manufactured according to an embodiment of the present invention.
13 to 24 are test reports showing the antibacterial effect test results of the adsorption decomposition material prepared according to an embodiment of the present invention.
25 to 45 are test reports showing the results of the deodorization effect test of the filter manufactured according to an embodiment of the present invention.
46 to 69 are test reports showing the antibacterial effect test result of the filter manufactured according to an embodiment of the present invention.

The filter according to the present invention is made of an adsorption decomposition material, which is an ionic material based on an inorganic carrier harmless to the human body, as a main material, and the adsorption decomposition material has various kinds of inorganic oxide ion bonding methods, and has positive and negative charges in its composition. Elements use convection to act with oxygen and H ₂ O in the air to dissociate them and take away free electrons in molecules to break the bonds of bonds so that harmful substances are reduced to the air, thereby exhibiting antibacterial and deodorizing functions. It has non-toxic, odorless, and sterile properties, so it is harmless to the human body and has excellent antibacterial, antiviral and deodorizing functions.

Hereinafter, preferred embodiments of the present invention will be described. However, embodiments of the present invention may be modified in various other forms, and the scope of the present invention is not limited to the embodiments described below.

In addition, 'including' a certain component throughout the specification means that other components may be further included, rather than excluding other components, unless otherwise stated.

1 is a flowchart illustrating a filter manufacturing method according to an embodiment of the present invention.

Referring to FIG. 1 , the filter of the present invention may be manufactured through the following process.

First, an adsorption decomposition material is prepared (S1). The adsorption decomposition material used in the filter of the present invention will be described in more detail below.

Next, the material for film formation is prepared by mixing and stirring the adsorption decomposition material and the binder serving as an adhesive (S2).

Next, a filter fabric in which a film is formed on the surface of the nonwoven fabric is prepared by depositing a film forming material on the nonwoven fabric (deep-cotting) or dipping (dipping) (S3). In this case, the filter fabric may be formed in a rectangular shape, and the present invention is not limited thereto.

The nonwoven fabric may be made of spun-bonded favric, which is harmless to the human body, and is formed by spun polypropylene and polyester to have excellent air permeability, filtration and antibacterial properties, and then apply heat to bond them. In addition, the nonwoven fabric may be composed of an MB (melt blown) filter if necessary.

Next, in order to increase the specific surface area of the filter fabric, the filter fabric is wrinkled and made of a plurality of layers and is bent to provide a predetermined space between each layer (S4). At this time, the bending angle and bending amount are adjusted according to the purpose of the filter to be manufactured.

In addition, if necessary, before bending the filter fabric, the step (S7) of laminating the functional filter on one surface of the filter fabric may be performed first. In this case, the functional filter may be a HEPA filter or an MB (melt blown) filter.

Next, a support part serving as a reinforcing layer is attached to the edge of the pleated filter fabric so that the bent shape can be well maintained without being disturbed (S5).

Next, a case is installed around the filter fabric to which the support is attached (S6), thereby completing the filter. This case is for manufacturing the filter in a cartridge manner for the convenience of assembly and replacement.

In addition, the case may be manufactured by molding using a mold using a resin as a material. For example, when the filter fabric is made in a rectangular shape, the case may also be formed in a rectangular frame shape.

Hereinafter, a method for manufacturing the adsorption decomposition material applied to the filter of the present invention will be described in detail. The adsorption decomposition material may include activated carbon, and in this case, the content of activated carbon may be adjusted according to the purpose of the filter.

The adsorptive decomposition material according to the first embodiment is made of a chromatic type 2 material, prepares a composition consisting of an oxide and a hydroxyl material, binds the composition through ionization for functional enhancement, and then performs a hydration reaction It can be prepared through the process of composing an unstable material through a reaction formula and catalyzing it.

Referring to FIG. 2 , in order to prepare such an adsorption decomposition material, an ion catalyst is first prepared (S8). The ion catalyst is distilled water and a total of 0.15 to 0.25 parts by weight of Ca ²⁺ and Si ⁴⁺ based on 100 parts by weight of the distilled water, but Ca ²⁺ and Si ⁴⁺ are mixed with 5:5 (Ca ²⁺ :Si ⁴⁺ ) can be prepared as a ratio of

Then, in a mixer, distilled water (H ₂ O) at 22 to 25° C. and 8 to 10 parts by weight of an ion catalyst based on 100 parts by weight of distilled water, and mixed for 60 seconds.

At this time, when the temperature of the distilled water is less than 22 ℃, the problem of unsafe ionic bonding may occur, and when the temperature of the distilled water exceeds 25 ℃, there may be a problem that the curing process is incomplete due to the bonding instability.

In addition, when the ion catalyst is less than 8 parts by weight, a problem of weak ion distribution and diffusivity may occur, and when the ion catalyst exceeds 10 parts by weight, a problem of ion supersaturation may occur.

Here, the ion catalyst, which is a combination of Ca ²⁺ and Si ⁴⁺ , is an electrolytic material that promotes ionization to improve the ionization coefficient and electrical conductivity of the liquid raw material, thereby making the reaction better during the neutralization reaction to be described later. .

Then, 70 to 74 parts by weight of zinc chloride (ZnCl ₂ ) with respect to 100 parts by weight of distilled water is further added to the mixer, and stirred for 10 to 12 minutes in an atmosphere of a temperature of 25° C. and a humidity of 30 to 35%. to prepare (S10).

<Reaction formula 1> n(ZnCl ₂ + H ₂ O) + Si ⁴⁺ +Ca ²⁺ → [(Ca(OH) ₂ ,Si(OH) ₄ ] + nHCl + nZn ⁺

On the other hand, the liquid raw material may be more preferably prepared in a ratio of zinc chloride, distilled water, and an ionic catalyst of 40:55:5 (zinc chloride:distilled water:ion catalyst).

In the first embodiment, the most important part in competing for a composite material for making a hydroxyl radical (-OH) is that the ionized bonding material is the main causative component. For this purpose, through electrolysis based on zinc chloride (ZnCl ₂ ), a liquid raw material is obtained by dissociation by a direct solid-liquid-dislocation reaction.

At this time, when the amount of zinc chloride is less than 70 parts by weight, the molar amount of powder and the binding phase is insufficient, and incomplete bonding may occur.

Next, magnesium oxide (MgO), 135 to 165 parts by weight of alumina (Al ₂ O ₃ ) based on 100 parts by weight of the magnesium oxide, and 90 to 110 parts by weight of titanium dioxide (TiO ₂ ) Or 90 to 100 parts by weight of oxidation One of zinc (ZnO) is mixed to prepare a powder raw material (S20).

The powder raw material may include 150 parts by weight of alumina, 100 parts by weight of titanium dioxide, and 100 parts by weight of zinc oxide based on 100 parts by weight of magnesium oxide.

Here, magnesium oxide generates OH radicals through deoxidation, and is a material for obtaining divalent alkaline earth metal magnesium (Mg ²⁺ ) for an ionization catalyst. Alumina is a material for obtaining alumina (Al ³⁺ ) of 13 families for maintaining electrical conductivity and strength.

Titanium dioxide is to obtain titanium (Ti ^- ) of the 4th family for inducing the generation of hydroxide ions. Ti ⁴⁺ ionized from titanium dioxide attracts H ₂ O to create hydroxyl radicals, and plays a role in increasing the sterilizing power of the adsorbed material. will do

Titanium dioxide is used as a photocatalyst, but in one embodiment, the ions cause hole recombination more than the photocatalyst to cause reactants and hydroxyl groups attached to the surface. In this case, rather than using expensive single ionization, ionization is performed through an ion polymerization reaction that is relatively inexpensive, and a selective mechanism is possible without a separate catalyst.

When such titanium dioxide receives energy (300 to 400 nm) equal to or greater than its intrinsic bandgap energy (Eg), electrons in the valence band (VB) are excited and conduction band (CB) ), and holes are created in the valence band to move to the surface, and then oxygen radicals and peroxygen radicals are created. At this time, the generated -OH oxidizes and decomposes organic compounds or viruses.

Next, the liquid raw material and the powder raw material are put into a polymerization reactor in a ratio of 5:4 (liquid raw material: powder raw material) and mixed, and then hydrated according to Reaction Scheme 2 at 6 to 8° C. within 90 seconds to prepare a hydration reactant do (S30). At this time, preferably, the hydration reaction may be performed for 90 seconds.

At this time, functional metal salts Ti(OH) ₂ , Al ₂ (OH) ₃ , Mg(OH) may be generated. In addition, since Zn( ²⁺ ) and Mg( ²⁺ ) have similar ionicity and atomic radius, some Zn( ²⁺ ) atoms are replaced with Mg( ²⁺ ) atoms in the crystal, which may change the properties of the crystal lattice.

<Scheme 2> [[(Ca(OH) ₂ ,Si(OH) ₄ ]+nHCl+nZn ⁺ ] + 2(Al ₂ O ₃ ),MgO, TiO ₂ ,ZnO → ((Al ₂ (OH) ₃ + Ti(OH) ₄ +Mg(OH) ₂ +Zn(OH)) ₂ O ₁₆ ) + Si(OH) ₄ + Ca ²⁺ + nHCl

Next, granular zeolite having an average size of 10 mesh and concentrated to 60% or less is mixed with the hydration reaction product in an emulsion state in a ratio of 4:5 (hydration product: zeolite), 17 to 23 ° C, humidity 10 to 15% By stirring in the atmosphere of the zeolite for 13 to 17 minutes, immersion synthesis is performed so that adsorption and deposition of the hydration reactant in an emulsion state on the pores and epidermis of the zeolite are made (S40).

delete

Then, it is dried by natural heat (S50) for 30 to 40 minutes to remove by-products and external moisture contained in the hydration reactant, and harden the hydration reactant.

At this time, in the step of adsorption and deposition, the liquid raw material and the powder raw material prepared in the step prior to the other reaction mixer are added, mixed for 3 minutes to prepare the mixed material, and then the mixed material is adsorbed in a reaction mixer with zeolite at intervals of 30 seconds And it can be done by dividing by 20% while checking the state in which the deposition is made. If all the mixed materials are put into the reaction mixer at once, the dispersion may not be evenly distributed.

Thereafter, in order to prevent intergranular agglomeration of the zeolite in the course of the hydration reaction, a process of maintaining the rotational state of the reaction mixer for 1 hour when the hydration reaction is completed may be further performed.

On the other hand, when the temperature is raised to 80 to 90° C. and stirring is further performed for 30 minutes after the natural heat and natural drying process, external moisture contained in the hydration reactant is further removed while the humidity of the hydration reactant is further removed. can be lowered to a level of 12 to 15%.

Next, if necessary, the hydration reactant whose moisture content is adjusted is first coarsely pulverized using a cutter mill, etc., and then the coarsely pulverized hydration reactant is secondarily pulverized into powder with a particle diameter (D50) of 20 μm or less using ACM, etc. , followed by pulverizing into powders having a particle diameter (D50) of 4 μm or less using J-Mill (S60) to prepare an adsorbent material.

<Deodorization Effect Test>

3 to 12 are a deodorization test result report for the adsorption decomposition material according to the first embodiment. This test is to find out the removal ability of ammonia, toluene, acetic acid, benzene and formaldehyde gas of the adsorption decomposition material according to the first embodiment, and it is applied mutatis mutandis to the FITI test guideline FTM-5-2:2004, the gas detection tube method. was carried out

Specifically, a sample of 20 cm × 10 cm size is put into a 5L Tedler bag and heat-sealed, and a gas having an ammonia concentration of 100 ppm is injected into the Tedler bag containing the sample.

Then, the ammonia concentration at the time of 2 hours was measured with a gas meter and shown in FIGS. 3 to 12 .

And, for comparison, without injecting a sample, ammonia concentration was measured in the same manner as in the previous process (base test).

In addition, the concentration of each component was measured in the same manner as in the ammonia concentration test using toluene at a concentration of 20 ppm, acetic acid at a concentration of 50 ppm, benzene at a concentration of 50 ppm, and formaldehyde at a concentration of 15 ppm instead of ammonia. it was

gas type initial concentration Test result
(After 2 hours) ammonia 100ppm 95.0 toluene 20ppm greater than 97.5 acetic acid 50ppm greater than 99.9 benzene 20ppm greater than 97.5 formaldehyde 15ppm 96.4

Referring to Table 1 and FIGS. 3 and 4, in the case of ammonia, the deodorization rate of the adsorption decomposition material according to the first embodiment after 2 hours at an initial concentration of 100 ppm was 95.0%.

And, referring to Table 1 and FIGS. 5 and 6, in the case of toluene, the deodorization rate of the adsorption decomposition material according to the first embodiment after 2 hours at an initial concentration of 20 ppm exceeded 97.5%.

And, referring to Table 1 and FIGS. 7 and 8, in the case of acetic acid, the deodorization rate of the adsorption decomposition material according to the first embodiment after 2 hours at an initial concentration of 50 ppm exceeded 99.9%.

And, referring to Table 1 and FIGS. 9 and 10, in the case of benzene, the deodorization rate of the adsorption decomposition material according to the first embodiment after 2 hours at an initial concentration of 20 ppm exceeded 97.5%.

And, referring to Table 1 and FIGS. 11 and 12, in the case of formaldehyde, the deodorization rate of the adsorption decomposition material according to the first embodiment after 2 hours at an initial concentration of 15 ppm was 96.4%.

From these results, it can be seen that the adsorption decomposition material according to the first embodiment has an excellent deodorizing effect due to its excellent decomposition ability for odor-causing substances such as ammonia, toluene, acetic acid, benzene and formaldehyde.

<Antibacterial effect test>

In this test, Staphylococcus aureus ATCC 6538 (Staphylococcus aureus), Klebsiella pneumonia ATCC 4352 of the adsorption decomposition material according to the first embodiment (Bacillus pneumoniae), Salmonella typhimurium KCTC 1925, (Salmorella), Escherichia coli ATCC 25922 (E. coli) to investigate the antibacterial activity. This test is conducted according to ASTM E2149-20 test method.

strain Test result control test group Bacterial reduction rate Initial number of bacteria after 24 hours Initial number of bacteria after 24 hours Staphylococcus aureus 1.8 x 10 ⁵ 1.1 x 10 ⁵ 1.8 x 10 ⁵ < 30 99.9 pneumococcus 2.0 x 10 ⁵ 1.5 x 10 ⁵ 2.0 x 10 ⁵ < 30 99.9 Salmonella 1.8 x 10 ⁵ 1.5 x 10 ⁵ 1.8 x 10 ⁵ < 30 99.9 coli 1.8 x 10 ⁵ 1.5 x 10 ⁵ 1.8 x 10 ⁵ < 30 99.9

As a result of the test, in the case of Staphylococcus aureus, as shown in Table 2 and FIGS. 13 to 15, the initial number of bacteria in the control group was 1.8×10 ⁵ (number of bacteria/ml) and 1.1×10 ⁵ (number of bacteria/ml) after 24 hours. Although decreased, a large amount of bacteria was still identified. On the other hand, the initial number of bacteria in the test group was 1.8×10 ⁵ (number of bacteria/ml) and decreased to less than 30 (number of bacteria/ml) after 24 hours, showing a 99.9% reduction in bacteria.

And, in the case of bacillus pneumoniae, as shown in Table 2 and FIGS. 16 to 18, the initial number of bacteria in the control group was 2.0×10 ⁵ (number of bacteria/ml) and decreased to 1.5×10 ⁵ (number of bacteria/ml) after 24 hours. A large number of bacteria were still identified. On the other hand, the initial number of bacteria in the test group was 2.0×10 ⁵ (number of bacteria/ml) and decreased to less than 30 (number of bacteria/ml) after 24 hours, showing a bacterial reduction rate of 99.9%.

And, in the case of Salmorella, as shown in Table 2 and FIGS. 19 to 21, the initial number of bacteria in the control group is 1.8×10 ⁵ (number of bacteria/ml) and after 24 hours, it is reduced to 1.5×10 ⁵ (number of bacteria/ml). However, a large number of bacteria were still identified. On the other hand, the initial number of bacteria in the test group was 1.8×10 ⁵ (number of bacteria/ml) and decreased to less than 30 (number of bacteria/ml) after 24 hours, showing a 99.9% reduction in bacteria.

And, in the case of E. coli, as shown in Table 2 and FIGS. 22 to 24, the initial number of bacteria in the control group was 1.8×10 ⁵ (number of bacteria/ml), and after 24 hours it was reduced to 1.5×10 ⁵ (number of bacteria/ml), but it was still A large amount of bacteria was identified. On the other hand, the initial number of bacteria in the test group was 1.8×10 ⁵ (number of bacteria/ml) and decreased to less than 30 (number of bacteria/ml) after 24 hours, showing a 99.9% reduction in bacteria.

Therefore, it can be seen that the adsorption decomposition material according to the first embodiment has excellent antibacterial activity against Staphylococcus aureus, Bacillus pneumoniae, Salmorella and Escherichia coli.

Conventional filters remove bacteria and odors using physical adsorption, negative ions, or ozone, but this method has low efficiency, reliability and stability. The downside is that it needs to be replaced periodically.

The filter of one embodiment uses an eco-friendly solid inorganic compound containing an ionizing material as a material, and decomposes harmful bacteria and organic matter in a photochemical decomposition method, thereby having high efficiency, reliability and stability, harmless to the human body, secondary It has the advantage of being able to use semi-permanently because there is no contamination and the deodorization and antibacterial functions are continuously maintained.

Specifically, by making it possible to form a mechanism in an unstable state of the mineral according to ionization, positively charged metal ions interact electrostatically with negatively charged microbial components to penetrate hydrophobic chains into the cell wall, thereby protecting microbial cells, that is, harmful bacteria. destroys DNA

In the adsorption decomposition material of an embodiment, the metal cation binds to an electron-donating group such as sulfur, oxygen, and nitrogen to inhibit the metabolism of microorganisms. That is, the metal cation binds to the protein and cuts the covalent bond in the protein, and then the protein is precipitated, thereby inhibiting the production of enzymes and proteins that bind to DNA, thereby performing sterilization.

In addition, the adsorption decomposition material used in the filter of one embodiment reacts with moisture in the air through the oxidation-reduction reaction of metal cations initiated when in contact with molecules of harmful substances to dissociate them, and free electrons in the molecules through the decomposition mechanism of molecules Antibacterial and deodorizing functions can be exerted by removing the cause of bad odors by breaking the bond by taking them away.

Specifically, as TiO ₂ is irradiated with UV, electrons (e ⁻ ) and holes (h ⁺ ) are generated. And, O ₂ in the air reacts with electrons (e ^- ) to generate O ₂ ^- (superoxide ions), and H ₂ O and holes (h ⁺ ) in the air react to generate -OH (hydroxy radicals) do.

Hydroxyl radical (OH Radical/Hydroxyl Radical) is a powerful oxidizing material that exists in nature, and has excellent sterilization, disinfection, deodorization and decomposition capabilities, enabling sterilization, disinfection, chemical decomposition and removal of most contaminants. The oxidizing power of these hydroxyl groups is second only to fluorine and stronger than ozone/chlorine, and unlike fluorine, chlorine and ozone, hydroxyl groups are natural substances that are not toxic to the human body or harmful to the environment. Contaminants decomposed by ions by hydroxyl groups are It is reduced to water, oxygen, carbon dioxide, etc.

Accordingly, the filter of one embodiment is a strong sterilization (pneumococcus, aeruginosa, Escherichia coli, Salmonella, corona virus, etc.) and decomposition of organic matter by the reduction action of O ₂ ^- and the oxidation action of -OH. Carbon dioxide and water are generated by this redox action, and odor substances such as ammonia, hydrogen sulfide, methyl mercaptan, or trimetalamine are decomposed and destroyed into nitrate (NO ₃ ) and sulfate (SO ₄ ).

That is, the adsorption decomposition material of the first embodiment not only collects odor-causing particles, but also reacts with viruses, harmful substances (benzene, toluene, xylene, formaldehyde, etc.) and odor particles in a state harmless to the human body. Viruses, odors, and harmful substances can be removed by converting them back into the air.

Therefore, the filter using the adsorption decomposition material of the first embodiment is effective in removing trimetalamine, methylmethanecap and hydrogen sulfide, and as a result of the harmful gas removal test, the deodorization rate after 2 hours is 95.0% in ammonia and 97.5% in toluene , more than 99.9% in acetic acid, more than 97.5% in benzene, and 96.4% in formaldehyde, it can be seen that there is an excellent deodorizing effect. In addition, the filter using the adsorption decomposition material of the first embodiment is effective in removing other harmful gases such as xylene and TVOC, NOx, and various molds.

This showed superior results compared to copper, silver nano, and zeolite, which are materials with an antibacterial function, and the OH radical generation catalyst developed in the form of an inorganic solid generated through a hydration reaction rather than a physical/electrical OH radical provides excellent antibacterial properties. Because.

On the other hand, according to the second embodiment of the present invention, the following step may be further performed so that activated carbon is included when manufacturing the adsorption decomposition material.

First, 225 to 275 parts by weight of activated carbon, 11.25 to 13.75 parts by weight of an ion catalyst based on 100 parts by weight of the first powder (adsorption decomposition material) prepared through the manufacturing process of the first embodiment, and the first powder (adsorption decomposition material) And 11.25 to 13.75 parts by weight of the binding polymer is blended and stirred, and then heated and melted and extruded to prepare a mixed raw material.

In this case, the content of the activated carbon may be adjusted in consideration of the use of the filter and the like. The mixed raw material may include 250 parts by weight of activated carbon, 12.5 parts by weight of an ion catalyst, and 12.5 parts by weight of a binding polymer based on 100 parts by weight of the fine powder (adsorption decomposition material).

The binding polymer is preferably a water-soluble polymer such as polyacrylamide or polyvinyl alcohol, and serves as an adhesive so that the first powder is adhered to the epidermis and pores of the activated carbon, so that the first powder is easily formed by external impact, etc. The effect of preventing separation can be expected. In addition, the activated carbon may have an average size of 50 mesh.

The mixed raw material is prepared by mixing and stirring each material, then moving it to the main feeder, setting the input amount per hour, and injecting the mixture into the extruder. have.

Next, the mixed raw material is cut in a die in the form of pellets. Then, the mixed raw material discharged to the outlet of the die is moved to an extrusion air cooler, and then cooled and extruded by air in the extrusion air cooler to produce activated carbon pellets (S70).

At this time, the process of re-extrusion after crushing the activated carbon pellets may be performed two more times so that the stirred binder and the functional material can be evenly distributed throughout the activated carbon pellets. And, after the final extrusion, the dust that is not bound to the activated carbon pellets is removed through a brush.

According to a third embodiment of the present invention, when manufacturing an adsorption decomposition material, the step of cutting the activated carbon pellets to a predetermined size (S80) is further performed to use as a material for a filter for removing harmful gases or, if necessary, into fine pellets. can make In this case, strand cutting may be used in the cutting process, and the present invention is not limited thereto.

As described above, the filter manufactured by the present invention can be utilized as an indoor antibacterial filter, an indoor air conditioning filter, an indoor purification filter, an indoor/outdoor industrial filter, and the like. For example, it may be used as a filter for automobiles, an air conditioner filter, an air purifier filter, a filter for a vacuum cleaner, and the like.

<Deodorization Effect Test>

25 to 45 are a deodorization test result report for the filter according to an embodiment. This test is to find out the removal ability of methyl mercaptan, hydrogen sulfide, trimetalamine, formaldehyde, toluene, acetaldehyde and ammonia gas of the filter according to an embodiment, SPS-KCL12218-6218, gas detection tube method It was applied mutatis mutandis.

Specifically, a 10cm×20cm size sample is put into a 5L reactor and heat-sealed, and a gas having a methylmercaptan concentration of 50ppm is injected into the reactor containing the sample.

Then, the concentration of methyl mercaptan at the time of 2 hours was measured with a gas meter and shown in FIGS. 25 to 27 .

And, for comparison, without injecting a sample, ammonia concentration was measured in the same manner as in the previous process (base test).

In addition, instead of methyl mercaptan, hydrogen sulfide at a concentration of 50 ppm, trimethylamine at a concentration of 50 ppm, formaldehyde at a concentration of 20 ppm, toluene at a concentration of 50 ppm, acetaldehyde at a concentration of 50 ppm, and ammonia at a concentration of 50 ppm were used respectively to test the methyl mercaptan concentration and The concentration of each component was measured in the same way, and it is shown in FIGS. 28 to 45 .

gas type Test result Control (ppm) Test group (ppm) Decrease rate (%) initial concentration after 120 minutes initial concentration after 120 minutes methyl mercaptan 50 48 50 < 0.05 99.9 hydrogen sulfide 50 48 50 < 0.1 99.8 trimetalamine 50 40 50 < 0.1 99.8 formaldehyde 20 17 20 < 0.5 97.1 toluene 50 42 50 < 0.5 98.8 acetaldehyde 50 47 50 < 0.25 99.5 ammonia 50 38 50 < 0.2 99.5

Referring to Table 3 and FIGS. 25 and 27, in the case of methyl mercaptan, the filter according to an embodiment showed a deodorization rate of 99.9% after 2 hours at an initial concentration of 50 ppm.

And, referring to Table 3 and FIGS. 28 and 30, in the case of hydrogen sulfide, the filter according to an embodiment showed a deodorization rate of 99.8% at an initial concentration of 50 ppm after 2 hours.

And, referring to Table 3 and FIGS. 31 and 33, in the case of trimetalamine, the filter according to an embodiment showed a deodorization rate of 99.8% at an initial concentration of 50 ppm after 2 hours.

And, referring to Table 3 and FIGS. 34 and 36, in the case of formaldehyde, the filter according to an embodiment showed a deodorization rate of 97.1% after 2 hours at an initial concentration of 20 ppm.

And, referring to Table 3 and FIGS. 37 and 39, in the case of toluene, the deodorization rate of the filter according to an embodiment after 2 hours at an initial concentration of 50 ppm was 98.8%.

And, referring to Table 3 and FIGS. 40 and 42, in the case of acetaldehyde, the filter according to an embodiment showed a deodorization rate of 99.5% at an initial concentration of 50 ppm after 2 hours.

And, referring to Table 3 and FIGS. 43 and 45, in the case of ammonia, the filter according to an embodiment showed a deodorization rate of 99.5% at an initial concentration of 50 ppm after 2 hours.

From these results, it can be seen that the filter according to an embodiment has an excellent deodorizing effect against odor-causing substances such as methyl mercaptan, hydrogen sulfide, trimetalamine, formaldehyde, toluene, acetaldehyde, and ammonia.

<Antibacterial effect test>

Pseudomonas aeruginosa ATCC 15442 (Pseudomonas aeruginosa), Bacillus cereus ATCC 11778 (Bacillus), MRSA ( Staphylococcus aureus subsp. aureus ) ATCC 33591 (superbacteria), Saphylococcus aureus ATCC 6538P (Staphylococcus aureus ATCC 6538P) ), Klebsiella pneumonia ATCC 4352 (Pneumococcus), Escherichia coli ATCC 25922 (E. coli) to find out the antibacterial activity. This test is conducted according to the KCL-FIR-1003:2018 test method.

strain Test result control test group Decrease rate (%) Initial number of bacteria after 24 hours Initial number of bacteria after 24 hours Pseudomonas aeruginosa 2.7 × 10 ⁵ 8.2 × 10 ⁶ 2.7 × 10 ⁵ 3.7 × 10 ⁴ 99.5 bacillus 1.6 × 10 ⁵ 4.3 × 10 ⁶ 1.6 × 10 ⁵ 7.4 × 10 ⁵ 82.7 super bacteria 1.3 × 10 ⁵ 6.8 × 10 ⁶ 1.3 × 10 ⁵ 3.5 × 10 ⁵ 94.8 Staphylococcus aureus 2.1 × 10 ⁵ 7.0 × 10 ⁶ 2.1 × 10 ⁵ 2.1 × 10 ⁵ 97.0 pneumococcus 1.8 × 10 ⁵ 7.4 × 10 ⁶ 1.8 × 10 ⁵ 5.5 × 10 ⁴ 99.2 coli 3.3 × 10 ⁵ 8.5 × 10 ⁶ 3.3 × 10 ⁵ 5.7 × 10 ⁴ 99.3

As a result of the test, in the case of Pseudomonas aeruginosa, as shown in Table 4 and FIGS. 46 to 49 , the initial number of bacteria in the control group was 2.7×10 ⁵ (number of bacteria/ml) and 8.2×10 ⁶ (number of bacteria/ml) after 24 hours. On the other hand, the initial number of bacteria in the test group was 2.7×10 ⁵ (number of bacteria/ml), and after 24 hours, 3.7×10 ⁴ (number of bacteria/ml) showed a 99.5% reduction in bacteria.

And, in the case of Bacillus bacteria, as shown in Table 4 and FIGS. 50 to 53, the initial number of bacteria in the control group was 1.6×10 ⁵ (bacterial number/ml) and 4.3×10 ⁶ (bacterial number/ml) after 24 hours. On the other hand, the initial number of bacteria in the test group was 1.6×10 ⁵ (number of bacteria/ml), and after 24 hours, it was 7.4×10 ⁵ (number of bacteria/ml), showing a bacterial reduction rate of 82.7%.

And, in the case of super bacteria, as shown in Table 4 and FIGS. 54 to 57, the initial number of bacteria in the control group was 1.3×10 ⁵ (bacterial number/ml) and after 24 hours, 6.8×10 ⁶ (bacterial number/ml). On the other hand, the initial number of bacteria in the test group was 1.3×10 ⁵ (number of bacteria/ml), and after 24 hours, it was 3.5×10 ⁵ (number of bacteria/ml), showing a 94.8% reduction in bacteria.

And, in the case of Staphylococcus aureus, as shown in Table 4 and FIGS. 58 to 61, the initial number of bacteria in the control group is 2.1×10 ⁵ (number of bacteria/ml) and 7.0×10 ⁶ (number of bacteria/ml) after 24 hours. . On the other hand, the initial number of bacteria in the test group was 2.1×10 ⁵ (number of bacteria/ml) and 2.1×10 ⁵ (number of bacteria/ml) after 24 hours, showing a 97.0% reduction rate of bacteria.

And, in the case of pneumococcus, as shown in Table 4 and FIGS. 62 to 65, the initial number of bacteria in the control group was 1.8×10 ⁵ (number of bacteria/ml) and 7.4×10 ⁶ (number of bacteria/ml) after 24 hours. On the other hand, the initial number of bacteria in the test group was 1.8×10 ⁵ (number of bacteria/ml), and after 24 hours, it was 5.5×10 ⁴ (number of bacteria/ml), showing a bacterial reduction rate of 99.2%.

And, in the case of Escherichia coli, as shown in Table 4 and FIGS. 66 to 69, the initial number of bacteria in the control group was 3.3×10 ⁵ (number of bacteria/ml) and 8.5×10 ⁶ (number of bacteria/ml) after 24 hours. On the other hand, the initial number of bacteria in the test group was 3.3×10 ⁵ (number of bacteria/ml), and after 24 hours, it was 5.7×10 ⁴ (number of bacteria/ml), showing a bacterial reduction rate of 99.3%.

Therefore, it can be seen that the filter according to an embodiment has excellent antibacterial activity against Pseudomonas aeruginosa, Bacillus, superbacteria, Staphylococcus aureus, pneumococcus and Escherichia coli.

The present invention is not limited by the above-described embodiment. Therefore, various types of substitution, modification and change will be possible by those skilled in the art within the scope not departing from the technical spirit of the present invention described in the claims, and it is also said that it falls within the scope of the present invention. something to do.

S1: adsorption decomposition material preparation step;
S2: Preparing material for film formation
S3: Filter fabric preparation stage
S4: Bending the filter fabric
S5: Step of attaching the support to the filter fabric
S6: Step of installing the case around the filter fabric
S7: Laminating functional filter
S8: Ion catalyst preparation step
S10: Liquid raw material preparation step
S20: powder raw material preparation step
S30: Hydration reactant preparation step
S40: curing step
S50: firing stage
S60: first crushing step
S70: secondary grinding step
S80: Mixed raw material preparation stage
S90: Activated Carbon Pellets Manufacturing Step
S100: activated carbon pellet cutting step

Claims (6)

preparing an adsorption decomposition material;
preparing a material for forming a film by mixing and stirring the adsorption decomposition material and a binder;
depositing or dipping the film-forming material on a nonwoven fabric to prepare a filter fabric having a film formed thereon;
bending the filter fabric to be wrinkled;
attaching a support to the edge of the pleated filter fabric; and
installing a case around the filter fabric to which the support part is attached; including,
The step of preparing the adsorption decomposition material,
Distilled water and a total of 0.15 to 0.25 parts by weight of Ca ²⁺ and Si ⁴⁺ based on 100 parts by weight of the distilled water are stirred, but Ca ²⁺ and Si ⁴⁺ are mixed in a ratio of 5:5 (Ca ²⁺ :Si ⁴⁺ ) to prepare an ion catalyst;
Distilled water (H ₂ O) at 22 to 25 ° C. in a mixer, 8 to 10 parts by weight of an ion catalyst based on 100 parts by weight of the distilled water, and 70 to 74 parts by weight of zinc chloride (ZnCl ₂ ) with respect to 100 parts by weight of the distilled water and stirring for 10 to 12 minutes in an atmosphere of 25° C. and 30 to 35% humidity to prepare a liquid raw material;
Magnesium oxide (MgO), 135 to 165 parts by weight of alumina (Al ₂ O ₃ ) based on 100 parts by weight of the magnesium oxide, and 90 to 110 parts by weight of titanium dioxide (TiO ₂ ) or 90 to 110 parts by weight of zinc oxide (ZnO) ) to prepare a powder raw material by mixing one;
Putting the liquid raw material and the powder raw material into a polymerization reactor in a ratio of 5:4 (liquid raw material: powder raw material), and performing a hydration reaction at 6 to 8° C. to prepare a hydration reaction product in an emulsion state; and
A zeolite having an average size of 10 mesh is mixed with a hydration reaction product in an emulsion state in a ratio of 4:5 (hydration product: zeolite), and stirred in an atmosphere of 17 to 23° C. and a humidity of 10 to 14% on the pores and epidermis of the zeolite. adsorption and deposition of a hydration reactant in an emulsion state; and
drying the hydration reactant by natural heat for 30 to 40 minutes to remove by-products and external moisture contained in the hydration reactant; A filter manufacturing method using a material having a harmful gas removal and antibacterial and deodorizing function, including. According to claim 1, wherein the step of preparing the adsorption decomposition material,
Before the adsorption and deposition step, put the zeolite having an average size of 10 mesh and concentrated to 60% or less in the reaction mixer and operating the reaction mixer while maintaining 21 to 23 ° C.
The step of adsorption and deposition is to put a liquid raw material and a powder raw material in another reaction mixer to prepare a mixed material, and then divide the mixed material into a reaction mixer with zeolite by 20% at intervals of 30 seconds; and
maintaining the rotational state of the reaction mixer for 1 hour to prevent intergranular agglomeration of the zeolite; Filter manufacturing method using a material having a harmful gas removal and antibacterial and deodorizing function, characterized in that it comprises a. According to claim 1, wherein the step of preparing the adsorption decomposition material,
After removing the by-products and external moisture contained in the hydration reactant, raising the temperature to 80 to 90° C. and further stirring for 30 minutes so that the amount of moisture contained in the hydration reactant becomes 12 to 15%; and
pulverizing the hydration reactant whose moisture content is controlled into powder; Filter manufacturing method using a material having a harmful gas removal and antibacterial and deodorizing function, characterized in that it further comprises. The method according to any one of claims 1 to 3, wherein the preparing the adsorption decomposition material comprises:
preparing a mixed raw material by mixing 225 to 275 parts by weight of activated carbon, 11.25 to 13.75 parts by weight of an ion catalyst, and 11.25 to 13.75 parts by weight of a binding polymer with respect to 100 parts by weight of the adsorption decomposition material, heating and melting and extruding; and
cutting the mixed raw material in a die and cooling and extruding it in an extrusion air cooler to make activated carbon pellets; Filter manufacturing method using a material having a harmful gas removal and antibacterial and deodorizing function, characterized in that it further comprises. According to claim 4, wherein the step of preparing the adsorption decomposition material,
Filter manufacturing method using a material having a harmful gas removal and antibacterial and deodorizing function, characterized in that it further comprises the step of cutting the activated carbon pellets. According to claim 1,
A method of manufacturing a filter using a material having a harmful gas removal and antibacterial deodorization function, characterized in that the step of laminating a functional filter on one surface of the filter fabric is performed first before bending the filter fabric to be wrinkled.

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