KR20010008271A - Engine intake air filtering and It's Manufacturing method - Google Patents

Abstract

PURPOSE: The title filter medium capable of maintaining a pore space of a dense layer at the side of an air outlet at the minimum, increasing the dust collecting efficiency and dust treating capacity of a dust collecting filter by combining a staple fiber nonwoven fabric filter medium comprising a single story or two or more stories fiber layer having a density gradient with one layer or more of an air permeable sheet is provided, which prolongs its service life and has an effect on increasing dust keeping capacity. CONSTITUTION: The filter medium for an air cleaner forms a density gradient to have two or more fiber layers to the air outlet side from the air inlet side, comprises a staple fiber obtained by mixing synthetic fiber such as polyester, polypropylene or the like having a melting temperature difference in which fibers on each layer have a diameter of 0.5 to 15 denier and a weight of 50 to 500g/m2 and two or more composite layers obtained by combining one or more of nonwoven fabrics comprising heat fusion weldable nonwoven fabric sheets of meshes with an air permeable sheet or staple fiber, spun bonded nonwoven fabric sheets, meltblown nonwoven fabrics, wet laid nonwoven fabrics and spunlaced nonwoven fabrics, an air permeable film and a weaving cloth and is made by heat fusing each layer.

Description

Filter media for air cleaners and its manufacturing method {Engine intake air filtering and It's Manufacturing method}

The present invention relates to a filter medium for an air cleaner and a method of manufacturing the same, which are used for automobile engines and air conditioning, and more particularly, it is possible to keep the dense layer air gap at the air outlet side to a minimum and maintain the uniformity of the air gap. The present invention relates to a filter medium for an air cleaner and a method of manufacturing the same, which improves the collection capacity of the filter medium to enable high efficiency collection.

In general, the filter medium for automobile engines and / or air conditioners for air conditioning filters dust and dust that are mixed in the air, thereby preventing deterioration of exo and clean efficiency due to dust and preventing premature damage to the equipment. It is well known to do.

In the conventional filter media of this kind, non-woven media and paper media are used. In the case of the paper media, it is composed of a single layer structure, and its thickness is composed of a thin and dense single layer of about 0.5 mm, so that the cleaning efficiency is high, but there is not enough space to collect dust, so the dust holding capacity is low. Short life of the, high ventilation resistance has a problem that takes a lot of media area.

In the case of non-woven media, a bulky layer having a large diameter is provided on the upstream side of the inlet air, and a dense layer having a fine diameter is provided on the outlet side of the air, and an intermediate layer having both medium-sized apertures is formed in the middle thereof. This multilayer fiber layer is bound together using a needle punch and a resin adhesive to form a density gradient nonwoven fabric. However, there is a problem in that the voids formed between the synthetic fibers are narrowed or blocked by the resin adhesive.

Conventional nonwoven filter media is composed of a multi-layered multi-layer structure having a density gradient is designed to maintain both efficient side and dust holding capacity together. Its manufacturing process involves loading webs composed of synthetic fibers only in two or more layers, forming a first binding with a needle punching machine, combining them with a resin adhesive, and selectively absorbing the resin adhesive due to the difference in synthetic fiber composition between the layers. After the drying process is prepared.

The filter media thus prepared is a filter media having a density gradient due to the difference in the composition and thickness of the synthetic fibers between the layers and the degree of absorption of the resin adhesive.

The conventional nonwoven filter media has a multi-layer structure having a density gradient, but the clean efficiency is dominated by the dense layer on the air outlet side. To increase the clean efficiency, the thickness of the dense layer is increased or the amount of the resin adhesive is increased. Promote republic.

And the layer that determines the dust holding capacity is dependent only on the intermediate layer and the bulky layer, the dense layer has a disadvantage that its role is negligible.

On the other hand, in the case of air cleaning for automobile engines, the distribution of the particle size of dust generated on the road is present from large to small.

In the case of dust of large particle size, dust is collected in the middle layer and the bulky layer, and the dust of small particle size is collected by the dense layer. In this case, if the amount of the resin adhesive is increased in the dense layer to increase the cleaning efficiency, the voids are small. As a result, clogging occurs and a problem of shortening the life of the filler occurs.

In the binding method, needle punching and a resin adhesive are used together to produce a medium. Since the compacted layer of the media uses more curtains or rayon fibers than the intermediate layer or the bulky layer, the amount of the resin adhesive is relatively high in the dense layer when the resin adhesive is applied. The resin adhesive maintains the binding between the synthetic fibers and at the same time serves to maintain the clean efficiency by narrowing the voids between the synthetic fibers.

However, when higher cleaning efficiency is required, the amount of resin adhesive is increased to narrow the gaps a lot, or the voids are clogged, causing clogging of the dense layer to increase the airflow resistance and shorten the filtration life. There is.

The present invention has been made to solve such a conventional problem, the air leakage by laminating together a single-fiber nonwoven fabric consisting of two or more layers of fibers having a single layer or density gradient and a breathable sheet of one or more breathable sheets together Combined high efficiency to increase dust collection efficiency, ensure uniformity of filter media, increase dust holding capacity, and increase filter life by minimizing voids in the dense layer on the side and maintaining uniformity of voids Its purpose is to provide air purifier media.

In order to achieve the above object, the present invention forms a density gradient to have two or more fiber layers from the inflow side to the outflow side of the air, and each layer of the fiber has a diameter of 0.5 to 15 denier and a weight of 50 to 500 g / m 2. Short fiber layer composed of a mixture of synthetic fibers such as polyester and polypropylene having different melting temperatures, mesh nonwoven fabric sheet and long fiber nonwoven fabric sheet which can be heat-sealed with breathable sheet or short fiber ), At least two or more layers of laminated non-woven fabric consisting of meltblown non-woven fabric, wet-laid, spunlace nonwoven fabric, and breathable film and woven cloth. To achieve the above, there is provided a method of manufacturing a filter medium for an air cleaner, which is formed by thermally bonding each layer.

In addition, in order to achieve the object of the present invention, a short fiber nonwoven layer in which the dense layer, the intermediate layer, and the bulky layer are bonded to each other without using a resin adhesive is formed having a density gradient of at least one layer, and a breathable sheet on the surface of the dense layer. Provided is a filter medium for air cleaners, which is heat-sealed to have a multilayer structure.

1 is a manufacturing process chart showing the manufacturing process of the filter medium according to the present invention.

2 is a cross-sectional view of the filter medium according to the present invention,

(a) is a four-layer structure,

(b) is a five-layer structure of another embodiment.

3 is a thermal fusion process of the filter medium produced by the present invention,

(a) is a heat fusion process using a fuser oven,

(b) is a heat fusion process using a belt press,

(c) is a heat welding process by a calender.

<Description of the code | symbol about the principal part of drawing>

10: short fiber nonwoven fabric 12: dense layer

14: middle layer 16: bulky layer

18: breathable seat

Hereinafter, with reference to the accompanying drawings, the air filter filter media according to the present invention and the manufacturing method thereof are as follows.

A density gradient is formed to have two or more fiber layers from the inflow side to the outflow side of the air, and the fibers of each layer have a diameter of 0.5 to 15 deniers and a weight of 100 to 500 g / m 2 and have a difference in melting temperature. Short fiber nonwoven fabric layer 10 made of synthetic fiber mixture such as propylene, breathable sheet 18 or mesh, that is, nonwoven fabric sheet capable of heat fusion with short fibers, long fiber nonwoven fabric sheet (Spunbond), Combination of one, two or more of non-woven fabrics such as meltblown non-woven fabric, wet-laid, spunlace nonwoven fabric, breathable film, and woven cloth It has a structure of more than two layers, and can have three or more layers of composites, so that various types of products can be formed. It obtains the appointed filter media.

Here, the breathable sheet 18 before putting the breathable sheet 18 in the heat fusion process

It is further included to apply | coat a hot melt resin to (18) beforehand, and to laminate | stack in a thermofusion process.

The filter media manufactured in this way is capable of maintaining a minimum void of the dense layer on the air outlet side and maintaining the uniformity of the pores compared to the conventional filter media, thereby improving the collection capacity of the filter media and producing a highly efficient filter media. To make it possible.

Here, it will be described with reference to Figure 2 (a) (b) in order to clarify the structure of the filter medium according to the present invention.

The dense layer 12 and the intermediate layer 14 and the bulky layer 16 are composed of a single fiber nonwoven fabric layer 10, which is bonded to each other without using a resin adhesive, having a density gradient of at least one layer or more, and the dense layer 12 The breathable sheet 18 is heat-sealed on the surface of the multilayer structure.

Here, the breathable sheet 18 is formed by laminating at least one or more layers of breathable sheets 18a and 18b together with the short fiber nonwoven fabric layer 10, and the breathable sheet 18 is not the same. The sheet is formed by laminating at least two layers with the short fiber nonwoven layer 10.

In addition, the breathable sheet 18 is made by sandwiching a hot melt sheet between the adhesive portion.

The short fiber nonwoven layer 10 may be manufactured in a single layer or a multilayer structure having a density gradient of two or more layers.

When used as an air purifier filter media, it is advantageous to have a multi-layer structure of two or more layers rather than a single layer to maintain a high dust holding capacity. When the product is manufactured in a single layer structure and manufactured, the weight of the laminated breathable sheet 18 (nonwoven fabric, film, fabric, etc.) of 50 g / m 2 or more is advantageous because it increases the efficiency of the filter medium.

And the short fiber nonwoven fabric layer 18 which forms the multilayer structure of two or more layers can raise the efficiency of a filter even if it uses the thing with relatively low weight of laminated meshes.

The short fiber nonwoven fabric layer 10 may be manufactured by mixing synthetic fibers such as polyester, polypropylene, rayon, and natural fibers such as cotton at a predetermined ratio or by using the same kind of fibers.

It is important here that the material of the breathable sheet 18 to be laminated with the short-fiber nonwoven fabric layer 10 is advantageous in that it uses a similar material as possible in the heat fusion process 106, which is advantageous when laminating.

If the material of the breathable sheet 18 is polypropylene-based, the material of the short fiber nonwoven fabric layer 10 should also increase the mixing ratio of polypropylene-based synthetic fibers.

The short fiber layer is advantageous in the multi-layer structure than the single layer also for the lamination process.

The single-fiber single-layer fiber layer uses 20 to 100% of the total weight of synthetic fibers, that is, thermoplastic fibers, which can be heat-sealed, and mixes less than 20% of the blending ratio of natural fibers such as fibers, rayon, and curtains without melting temperature. It is suitable, the weight of the short fiber layer is possible from 50 to 500g / ㎡, and determines the weight according to the filter use to form the raw material blending step (100).

For example, in the case of filter media for automobile engines, about 100 to 300 g / m 2 is an appropriate weight.

After passing through the raw material mixing step 100, the predetermined carding step 102 is completed.

In this case, the mixed raw fiber may be two cases of omitting the needle punching process in the case of the first binding by the needle punching 104. Both of these processes are possible, and the needle punching is handled during the manufacturing process. It is suitable for the process where the production process is not continuous and the short fiber fiber layer is made, and the lamination process is carried out step by step, and in the case of the production line where the continuous process is possible, the needle process is omitted and the heat fusion process is performed without first binding. It is possible to laminate at 106.

After completing the above process, the sheet is laminated with the breathable sheet in the heat fusion process 106.

In the lamination method, when the short fiber fiber layer 10 is introduced into the heat fusion process 106, the air permeable sheet 18 is added together to apply heat and pressure to composite the filter media.

As a method that can be used in the heat fusion process, a fusing oven method, a belt press method, a calender method, or the like may be used as shown in FIGS. 3 (a) to 3 (c).

The fusing oven method is a form in which the pressing roller 2 is attached to the front end of the dryer 1.

In the belt press method, the belts 4 and 5 are vertically placed in the dryer 1, and the pressing roller 2 presses the belts 4 and 5 at the front end of the belts 4 and 5. have.

In the calendering method, the pressing roller 2 is formed of two or more heating rollers vertically or horizontally to give temperature and pressure when the product passes between them.

The temperature setting of the heat fusion process is configured differently according to the input raw materials. The mixing of low melting point raw material fibers and release raw material fibers can be carried out by keeping the temperature lower in the heat fusion process than when using general raw material fibers. Do.

In general, in the case of using a low melting point raw material fiber or a raw material fiber of a release component in addition to the general fiber, the temperature can be operated at less than 160 ℃, it is advantageous to increase the productivity because it can work at a lower temperature than using only ordinary fibers.

In addition, another method of easily performing the lamination process by thermal fusion may include a method of hot melt treatment before introducing the breathable sheet 18 to be laminated into the thermal fusion process.

There are two methods of spraying pouches of hot melt resin on the breathable sheet 18 or coating liquid hot melt.

When the hot-melt resin is treated in advance in this way, the lamination can be easily performed at a lower temperature of less than 160 ° C when laminating in the heat fusion process, even when the components of the short fiber nonwoven fabric layer 10 and the breathable sheet 18 are completely different. There is an advantage of easy lamination. In a similar process, a hot melt sheet may be added together between the breathable sheets 18a and 18b arranged in two layers of the breathable sheet 18 to be laminated, thereby laminating in a heat fusion process.

The method for forming the short fiber nonwoven fabric layer 10 in multiple layers is determined by the difference in melting temperature of the raw fiber and the thickness of the fiber.

The inflow side of the air, that is, the bulky layer 16 uses a thick fiber (for example, a mixture of three or more deniers), and the intermediate layer 14 is thinner than the bulky layer 16 as a whole. Example: Mix more than 2 denier) and air outlet side use 3 denier (for example, mix less than 2 denier) to differentiate the thickness of the fiber and parallel the difference of melting temperature. Melt temperature of polyethylene: 120 ℃, polypropylene: 160 ℃, polyester: 260 ℃, nylon: 220 ℃, rayon, curtain: no melting.

In the case of modified raw fiber, the melting temperature may be modified to have a low melting temperature, unlike the general melting temperature.

For example, in the case of a low melting polyester, the melting temperature is formed about 110-200 degreeC.

In addition, there are many raw fibers in which the release component is present in the raw fibers such as polypropylene and polyester, polyethylene and polypropylene, polyethylene and polyester. The fiber layer of a multilayer structure can be comprised.

The filter media prepared by the above method has a uniform micropore due to the complex on the air outlet side, the size of the micropore is smaller than the conventional filter media has a high collection efficiency, even in the formation of a multi-layer structure 4 layers or The multi-layered structure of five or more layers is formed, and the dust holding capacity is also high.

Example 1

The short fiber non-woven fabric layer has a three-layer structure, and the air-permeable sheet is an air purifier filter material in which a heat-sealed short fiber nonwoven fabric composed of a release component (polyethylene + polypropylene) is laminated.

Composition and Weight of Raw Fiber in Short Fiber Nonwoven Layer

Air inflow layer (bulky layer) Mezzanine Air outlet layer Raw Material Composition and Mixing Ratio PET 7d 80% LM PET 4d 20% PET 7d 40% PET 3d 20% LM PET 4d 20% PE-PP 3d 20% PE-PP 1.5d 50% LM PET 2d 50% Weight (g / ㎡) 80 60 60 Breathable sheet: PE-PP heat-sealed short fiber nonwoven fabric (weight: 30g / ㎡) -PET: General polyester (melting temperature: 260 ℃)-LM PET: Low melting point polyester (melting temperature: 110 ℃) -PE-PP: Release component fiber (polyethylene-polypropylene, melting temperature: 110 ℃ ~ 160 ℃

Among the raw material fibers, the release component fiber of PE-PP is used to maintain the bonding strength by improving the affinity when laminating because the breathable sheet to be laminated is made of PE-PP material.

[Manufacture process]

After mixing enough to evenly mix the above raw material fibers to each carding machine to perform the carding.

The role of the carding machine is a machine that performs the function of finely weaving the raw fiber, and the carding is good so that the uniformity of the product is excellent.

The raw fiber exiting the carding machine is called a webbra.

The web that exits the carding machine is first bound in the needle puncher.

The needling operation can be omitted, but the first binding was performed to proceed with the process.

After the needling, the web is put into a heat fusion process. The heat fusion process uses a fusing oven method among the three methods mentioned above.

At this time, the PE-PP breathable sheet (100%, weight: 30g / m2, heat-sealed non-woven fabric) is put together under the web under the fuser oven to form a composite of the product by laminating.

At this time, if the temperature of the fuser oven is 160 ℃, the hot air is 1000RPM, the raw material fiber having a melting temperature of 160 ℃ below the melting is caused by the hot air gradually, and apply a temperature of about 160 ℃ to the pressing roller and pressing roller When the raw materials are squeezed, the raw material fibers that are melted are bound together and the raw material fibers having a melting temperature of 160 ° C or higher are passed through the fuser oven without melting and cooling is performed. Is completed with an air purifier.

Example 2

The short-fiber nonwoven fabric layer has a three-layer structure, and the breathable sheet is used as an air purifier filter material in which two layers of a heat-sealed nonwoven fabric of a release component (polyethylene + polypropylene) and a polypropylene meltblown nonwoven fabric are laminated.

Composition and Weight of Raw Fiber in Short Fiber Nonwoven Layer

Air inflow layer (bulky layer) Mezzanine Air outlet layer Raw Material Composition and Mixing Ratio PET 7d 80% LM PET 4d 20% PET 7d 40% PET 3d 20% LM PET 4d 20% PE-PP 3d 20% PE-PP 1.5d 50% LM PET 2d 50% Weight (g / ㎡) 80 60 60 Breathable sheet 1) Polypropylene melt blown nonwoven fabric (weight: 15g / m2) 2) PE-PP heat-sealed short fiber nonwoven fabric (weight: 30g / m2) -PET: General polyester (melting temperature: 260 ℃)-LM PET: Low melting point polyester (melting temperature: 110 ℃) PE-PP: Release component fiber (polyethylene-polypropylene, melting temperature: 110 ℃ -160 ℃)

[Manufacture process]

The manufacturing process is the same as in Example 1 and before the heat fusion process. The heat fusion process is also the same, but at the same time, the breathable sheet is meltblown non-woven fabric and PE-PP heat fusion non-woven fabric at the same time. The short fiber nonwoven fabric layer + meltblown nonwoven fabric layer + PE-PP heat-sealed nonwoven fabric layer can produce a total of five layers of air cleaner media.

The melt blown nonwoven layer makes use of the melt blown micro voids, which enables a high level of capture performance differently from conventional products.

[Performance evaluation results]

Type of filter Structure Weight (g / ㎡) Thickness (mm) Initial Clean Efficiency (%) Life Cleaning Efficiency (%) Dust Dust Capacity (g / 530㎠) Example 1 4-layer structure 230 3.0 99.1 99.5 68.9 Example 2 5-layer structure 245 3.2 99.7 99.9 65.3 Comparative Example 1 3-layer structure 230 2.7 98.3 99.0 55.7 Comparative Example 2 1 story 150 0.65 98.5 99.1 18.0

The above measurement results were measured until the air flow resistance increased by 300mmAq. Example 1 is a conventional nonwoven fabric filter medium using a resin adhesive, and Example 2 is a conventional paper filter medium.

From the above measurement results, it can be seen that the products produced by the present invention, which achieved the air outlet side, that is, the uniformity of the dense layer and the densification of the fine pores, maintain high efficiency. It was proved to be advantageous in terms of dosage.

As described above, the filter medium for air purifiers and the method of manufacturing the same of the present invention have a complex formation on the air outlet side uniformly, and the size of the fine pores is smaller than that of the conventional filter medium, and thus has a high collection efficiency. In forming, since four or five layers or more structures are formed, there is an effect of increasing the dust holding capacity.

Claims (6)

In preparing an air purifier filter medium; A density gradient is formed to have two or more fiber layers from the inflow side to the outflow side of the air, and the fibers of each layer have a diameter of 0.5 to 15 deniers and a weight of 50 to 500 g / m 2, and have a difference in melting temperature. A short fiber layer made of a synthetic fiber mixture such as propylene, a non-woven sheet of mesh that can be heat-sealed with a breathable sheet or short fiber, a long fiber nonwoven sheet (Spunbond), a meltblown nonwoven fabric, Non-woven fabric consisting of wet-laid, spunlace non-woven fabrics, breathable film, and woven cloth are laminated together to form at least two or more composite layers, and each layer is heat-sealed. Method for producing a filter medium for an air purifier, characterized in that made. The method of claim 1, The method of manufacturing a filter medium for an air cleaner, further comprising applying a hot melt resin to the breathable sheet in advance and then laminating in the heat fusion process before the breathable sheet is introduced into the heat fusion process. In air filter medium used for automobile engines or air conditioning; The dense layer, the intermediate layer, and the bulky layer are formed of a single fiber nonwoven layer bonded to each other without using a resin adhesive with a density gradient of at least a single layer, and a breathable sheet is thermally fused to the surface of the dense layer to form a multilayer structure. Filter media for air cleaners. The method of claim 3, wherein The filter sheet for air purifier, characterized in that the breathable sheet is made by laminating at least one layer with a single fiber nonwoven fabric layer. The method of claim 3, wherein The breathable sheet is a filter medium for an air cleaner, characterized in that the sheet is not the same, but different types of sheets are laminated with at least two layers of short fiber nonwoven fabric. The method of claim 3 The breathable sheet is a filter medium for an air cleaner, characterized in that the hot melt sheet sandwiched between the bonding portion.