KR20010066352A - Functional Filter Media for Cartridge Type and The Manufacturing Method - Google Patents

Abstract

PURPOSE: Cartridge-type filter media of a functional air purifier are provided, which are excellent in water repellent and antistatic properties to perform pulsing process easily, have extended life cycle regardless of pulsing process and can be used without a cage for mounting the filter to an actual line. CONSTITUTION: The manufacturing method is as follows: (i) mix 50-90% of low melting point polyester, 10-50% of general polyester and 1-10% of carbon fiber or stainless steel fiber, the diameters of above raw fibers being 1.0-15denier; and (ii) belt-pressing the mixed fibers to a mesh of 80-500g per square meter for endowing the fiber with antistatic property.

Description

Functional filter for air filter in the form of cartridge type and manufacturing method thereof {Functional Filter Media for Cartridge Type and The Manufacturing Method}

The present invention relates to a method for producing filter media used in dust collectors, incinerators and other air purifiers.

Conventional raw material fibers used in the conventional air filter filter media is to produce a web by molding polyester, polypropylene fibers, etc. in a card machine, the manufactured web was made to bind by needle punching. The filter media prepared in this way was treated with water repellent on one side to reduce brushing on the surface, and then the filter media was completed by treating the water repellent agent.

The filter medium 32 manufactured as described above is finished with a product after the sewing in the form of a long bag, the cage (31) inside the bag form when the filter medium (32) made of the bar is actually mounted on the line Was used. In addition, the filter media used in dust collectors or incinerators filter air by surface filtration. The surface filtration should be performed at the outermost part of the filter media at the air inlet.

Dust contained in the air is shortened when the filter penetrates into the middle of the filter medium or deeper.

The filter life is shortened because the filter media used in the incinerator or dust collector is subjected to a process called pulsing. If pulsing is used for a certain period of time after the filter is installed in an incinerator or dust collector, if dust accumulates on the surface of the filter, the flow of air will be disturbed and the pressure loss will increase, and the amount of air passing through will be reduced.

When the amount of air is reduced, a large amount of air is introduced to increase the operating cost and the filter life is shortened accordingly. However, after installing the filter, it reaches a certain pressure loss, and it is a process to shake off the dust on the surface by giving a high pressure in the opposite direction to the air flow. At this time, if the dust is not located on the surface and penetrated deep into the filter media, the dust does not fall off during the pulsing process and sticks to it so that the pulsing process should be carried out several times. This will shorten the life of the filter.

Since the pulsing process is carried out with high pressure, a lot of energy is consumed and noise is generated greatly. Therefore, the pulsing process should be performed in a short time.

As described above, even in the conventional filter, even though the surface of the surface layer is burned with sparks evenly by the boring process, pores are largely formed due to problems in the filter manufacturing method, and dust contained in the air is not collected on the filter surface. There is a disadvantage of penetrating more than the middle portion of.

The present invention has been made in order to solve the conventional problems, by using a thermoplastic fiber to heat the surface of the filter medium through the thermal fusion to minimize the pore while minimizing the pore while a certain portion is not fused. To maintain pores, to have a certain level of air permeability, and to form a dense density to improve the filtration performance of the filter, to minimize the filter media penetration of dust, and to provide antistatic performance (antistatic) It is to provide an air purifier filter medium that can facilitate the pulsing process by minimizing the adhesion of dust to the filter medium.

1 is a manufacturing process chart of the filter medium according to the first embodiment of the present invention,

2 is a cross-sectional view showing a belt pressing method of the present invention,

3A and 3B are cross-sectional views showing the calender method of the present invention,

4 is a cross-sectional view showing a method using a hot air of the present invention,

5 is a manufacturing process chart of the filter medium according to the second embodiment of the present invention,

6 is a manufacturing process chart of the filter medium according to the third embodiment of the present invention,

7 is a cross-sectional view showing an impregnation method of the present invention,

8 is a cross-sectional view of the filter medium according to the first and third embodiments of the present invention.

9 is a manufacturing process chart of the filter medium according to the fourth embodiment of the present invention,

10 is a cross-sectional view of the filter medium according to the second and fourth embodiments of the present invention.

11 is a cross-sectional view showing a bending process of the filter medium of the present invention,

12 is a perspective view showing a unit of the filter medium according to the present invention,

13 is a perspective view showing a unit of a conventional filter medium.

-Explanation of symbols for the main parts of the drawings-

31: cage 32: filter media

3: filter unit 10: web

11: roller 16: water repellent

17: Bath 24: Stacker

25: dryer

The raw material fiber of the present invention is a thermoplastic synthetic fiber (polyester, low melting point polyester, polypropylene, PP-PE copolymer, nylon, etc.) according to the melting point and components, and the diameter of the raw material fiber in consideration of the use, ventilation, efficiency, etc. It is used by mixing at a predetermined ratio, and carbon fiber, stainless steel fiber (SUS fiber) or high heat-resistant fiber (aromatic polyamide, aromatic polyaramid, polyphenylene sulfide, teflon, etc.) is used for antistatic performance. The mixture is used in the range of -20%.

The diameter of the raw material fiber is 1.0-15 denier and the total weight of the product is manufactured in the range of 80-500 g / m 2.

The composition of the thermoplastic synthetic fiber is mixed at a predetermined ratio according to the use of the product and the place where it is actually mounted and used. In the first, second, third, and fourth embodiments of the present invention, the mixing of low melting point polyester and general polyester will be described.

Hereinafter, a first embodiment of the present invention will be described in detail with reference to the drawings.

Melting | fusing point of low-melting-point polyester is about 110-150 degreeC, and melting | fusing point of general polyester fiber is 250-260 degreeC. The purpose of using a mixture of low melting point polyester and general polyester is to require high temperature and pressure when only general polyester is used to heat fusion when the raw fiber is formed into a web.

In this case, there is a disadvantage in that the equipment cost and operating cost of the device is increased and the production speed is slowed down when the actual product is produced. In case of using only low melting point polyester, excessive melting occurs during thermal fusion, and the thickness of the product is so thin that it breaks in the bending process or decreases productivity, and also the shape of melting of the entire raw fiber occurs, resulting in low air permeability. To increase the pressure loss when the actual filter is mounted.

Low-melting polyesters have a lower strength and abrasion performance than ordinary polyesters, and the filter is more likely to be damaged during use. For the above reasons, it is preferable to use low melting point polyester and general polyester in a proper ratio in consideration of the performance of heat-sealing equipment, productivity, workability, and filter.

In the present invention, the low-melting point polyester fibers are those having a diameter of 2.0 to 10 denier and the general polyester are selected to 1.0 to 15 denier in consideration of the air permeability according to the use conditions of the product, and the mixing ratio is low by weight ratio. Melting point 50 to 90% of polyester, 10 to 50% of general polyester, and 1 to 10% of carbon fiber or stainless steel fiber are used for antistatic properties.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

As shown in Figure 1, the web forming (a1) is a filter used in a dust collector or an incinerator, etc. must be subjected to a pulsing process, so the antistatic performance is essential. If there is no antistatic performance, the dust is attached to the filter medium due to the electrostatic force, so dust is not easily detached during pulsing. The raw material fibers are mixed in the same composition as described above, and the weight of the raw fiber is 80 to 500 g / m 2 to be added to the carding machine to form a web.

The web 10 which has undergone the above manufacturing process should proceed directly to the heat fusion process (a3). When the production equipment is required to go through the needle punching process (a2), the first binding is performed by the needle punching (a2). .

In the needle punching process (a2), it is desirable to proceed with the minimum needle density during needle punching. If the sedimentation density is high, the phenomenon that the web 10 is slowed down due to the speed difference between the punching machine inlet and the discharge port is generated, which causes the uniformity of the web 10 to be disturbed.

In the present invention, it is preferable to omit the primary binding by needle punching, but the uniformity of the web 10 is increased when there is no needle process (a2). If the production line of the filter medium must go through the needle punching step (a2), the uniformity of the web 10 may be improved only when the operation is performed with a minimum speed difference between the punching machine inlet and the outlet.

The web 10 thus formed binds the web 10 through a heat fusion step (a3).

There are three methods of thermal fusion process using belt press method, calender method, and hot air.

As shown in FIG. 7, two belts are used in the belt press method, and the position of the belt passes through the web 10 between the upper belt 12 and the lower belt 13 positioned above and below the web 10. While squeezing the web (10a) while pressing the compression roller (11). The heat source uses an electric heater, an infrared heater, and the like, and the temperature at this time requires a temperature of 160 ° C. or more and a pressure of 3 bar or more. Adjust the temperature and pressure to adjust the necessary ventilation and thickness.

Temperature and pressure are controlled by the composition of the raw fiber and the performance and use of the filter media. The advantage of the belt press method is that the shrinkage of the width during heat fusion of the web has the advantage of obtaining a uniform product.

As shown in FIGS. 3A and 3B, the calendering method is a method of passing the web 10 between up and down rollers 11 to obtain fused webs 10b and 10c. The temperature is 50 KN or more.

The material of the roller 11 uses a steel material both up and down. The advantage of the calendar method is that the production speed is the fastest among the three methods.

As shown in FIG. 4, the hot air 14 is applied to the hot air 14 while passing the web 10 through a drier having a temperature of 160 ° C. and a rpm of the hot air fan of 500 or more. After forming the hot air suction port 15 to suck the melted web 10 and press the surface with the upper and lower press roller 11 made of rubber or curtain located at the end of the dryer to obtain a web (10d). Since this method is the most severe method of the width shrinkage of the web 10, it should be noted that the uniformity is reduced by the width shrinkage, it is difficult to control the process conditions for optimally maintaining the process conditions.

Hereinafter, a second embodiment of the present invention will be described in detail with reference to the drawings.

The manufacturing method of the first embodiment is suitable when the production equipment is in-line, but in the situation where the individual equipments are separated and the collective equipment is not provided, the binding state of the web becomes weak and the movement of the web becomes weak. Not easy If the web is manufactured by reinforcing thermoplastic spunbond, spunlace, or other fabrics between the webs or on one side of the web, the web can be easily moved. Therefore, it is possible to manufacture the equipment with separate processes. .

As shown in Fig. 5, the composition and ratio of the raw material fibers are the same as in the manufacturing method of the first embodiment, and non-woven fabrics such as thermoplastic spun bonds, spunlaces, and other fabrics are laminated on the intermediate layer or one side of the web. The method of laminating a similar thing to the mesh (b2) in the middle layer of the web requires the number of carding machines forming the web to be two or more.

A web b1 is formed in the dust first carding machine, and then a mesh b2, such as a spunbond, is placed on the web b1, and the web b3 is formed and laminated again in the second carding machine to form a web. The web thus formed is subjected to needle punching b4 to the extent that the web can be moved in the needle process to perform the first binding.

At this time, the binding of the web b3 is sufficiently performed so as to be able to move to the facilities of the separated processes. If the punching density is high, there is a large difference in speed between the inlet and outlet of the punching machine. However, when the mesh b2 is laminated on the intermediate layer or one side, the mesh prevents the mesh from being stretched due to the speed difference of the web, thereby maintaining uniformity of the web.

If you have only one carding machine, first form the web in the carding machine and put the mesh on top, then send the web which is slightly bound in the punching machine again from the carding machine and then form the web on it again. The punching machine can be used to complete the primary binding. However, this method is a complex process and causes a slow production. If there is only one carding machine, it is advantageous to place the mesh on one side rather than the middle layer of the web.

When placing the mesh on one side, two methods of forming the web can be considered.

There are two ways to place the mesh on the bottom and the top of the web. Considering the workability, it is better to place the mesh on the bottom of the web. In this case, first, the mesh is flowed out, and then the fabric is formed in the carding machine, and the needle is stacked on the mesh. When the mesh is placed on the upper side, the web is first formed, and then the mesh is laminated thereon. When the primary binding is completed by needle punching, the filter medium is manufactured by performing thermal welding in the same manner as in the first embodiment.

Hereinafter, a third embodiment of the present invention will be described in detail with reference to the drawings.

In order to impart water repellency to the filter media manufactured in the first embodiment as shown in FIG. 6, the water repellent treatment (a'4) is performed by encoding a fluorine-based or silicone-based water repellent into the web to impart functionality to water repellency in addition to antistatic properties. After drying, it is dried (a'5).

Water repellency is the basic element of the filter in the air conditioner installed outdoors, the air conditioner installed in a humid area such as the shore or lake side, or in the region where the temperature difference between the air conditioner and the outside is severe. When it rains or snows, a large amount of moisture enters the air conditioner together with the air. When the moisture generated infiltrates into the filter media, pores of the filter media that have been moistened are blocked, and the pressure loss is increased to reduce the air permeability of the filter, which shortens the life of the filter.

There are two methods of water repellent treatment. The first method is a dipping process, and the manufacturing method is as follows.

In Example 1, the solid content of fluorine or silicone-based water repellent is mixed with 80 to 98% of water and 20 to 2% of water repellent to fill the water repellent so that the bath is submerged 2/3 or more. After soaking the prepared filter medium sufficiently squeezed with the upper and lower press rolls and dried. There are two methods of drying by a method of drying by hot air (Band dryer) and can dryer (Can dryer) method.

In the present invention, the can drying method is preferred to the hot air drying method. Can dryer uses heat steam as a heat source, which puts steam into the can and makes direct contact with the filter media on the surface of the can.It has better drying performance than the hot air drying method and produces filter effect by the can surface. Because it is more effective.

The second method is a method of directly treating the water repellent to the raw material fiber, and mixing the water repellent to the same composition as the impregnation, and spraying the water repellent directly on the raw material by spraying before forming the web. There is a method of molding the web by injecting the raw fiber treated with the above to the carding machine.

Hereinafter, a fourth embodiment of the present invention will be described in detail with reference to the drawings.

9 is a manufacturing process diagram of the filter medium according to the fourth embodiment of the present invention, Figure 10 is a cross-sectional view of the filter medium according to the second and fourth embodiments of the present invention.

There are three methods of drying the filter medium, which has been imparted with water repellency to the filter medium manufactured in the second embodiment, after the water repellent treatment (b'5) and drying (b'6).

The first and second methods are the same as those in the third embodiment, and the description thereof is the same as in the third embodiment.

The third method includes two methods of treating the water repellent agent before the heat fusion process in the state of the first binding is completed by needle punching in the second embodiment. The above method is superior in water repellency than the method of treating the water repellent agent in the third embodiment. The reason is that the third embodiment impregnates the water repellent in the state in which the web 10e is densely formed in the state where the filter medium is completed, so that the water repellent adheres mainly to the surface and does not penetrate deeply into the medium so that the water repellency is inferior. have. However, the needle repellent has a high water repellency because the water repellent can penetrate deeply into the filter medium after the impregnation process in the first binding only.

Hereinafter, the same manufacturing process after web shaping of the first, second, third and fourth embodiments of the present invention will be described in detail with reference to the drawings.

The filter medium manufactured according to the above four embodiments is completed by the same filter unit manufacturing method.

In the manufacturing method of the unit, the manufactured filter medium is first bent to have a certain height and width. Bending is performed by the knife pleating method, which is a general method.

As shown in FIG. 11, the filter medium is cut to the required width by the cutter 21 and then cut out by the knife 22 to the required mountain height, and then bent by the two upper and lower knives 23 (a4 and b6). , a'6, b'7), the bent filter medium is laminated in the laminator 24, and then thermally stabilized in the band dryer 25 to complete the bending. The bent filter medium is rolled in a cylindrical shape, and the end of the filter medium net is finished with adhesive or double-sided tape, and then sealed at both ends with hot melt resin to assemble the filter unit 13.

The advantages of the filter units (a5, b7, a'7, b'8) manufactured in this way are that the filtration area is at least three times higher than that of the conventional filter media which are sewn into bags using non-woven fabric or fabric felt. It can be extended to several tens of times, reducing the number of filter units required by existing incinerators or dust collectors to one-third.

In addition, it is possible to reduce the size of the incinerator, dust collector, and air conditioner newly manufactured, thereby significantly reducing the installation cost and the size of the site. In addition, the surface of the existing filter media has raised and large pores are formed so that dust contained in the air penetrates into the middle of the filter media or more.

In this case, the operation cost increases because a lot of energy and noise are generated when pulsing, which is a process of raising the pressure loss of the filter and also dusting off the dust adhered to the filter surface.

The preferred mixing and composition of the first, second, third and fourth embodiments of the present invention are compared and examined.

Example 1

<Raw fiber>

Low Melting Polyester 4d 80%

General Polyester 2d 15%

5% stainless steel fiber

Weight: 250g / ㎡

<Process>

Card machine (web forming) → heat welding (belt pressing method: temperature-180 ℃, pressure-5bar)

Gross weight: 250g / ㎡

Example 2

<Raw fiber>

Low Melting Polyester 4d 80%

General Polyester 2d 15%

5% stainless steel fiber

Weight: 230g / ㎡

<Mesh>

Polyester Spunbond 20g / ㎡

<Process>

Card machine (web forming) → heat welding (belt pressing method: temperature-180 ℃, pressure-5bar)

Gross weight: 250g / ㎡

Example 3

<Raw fiber>

Low Melting Polyester 4d 80%

General Polyester 2d 15%

5% stainless steel fiber

Weight: 250g / ㎡

<Water repellent>

Silicone-based water repellent (solid content 20%) 10%

90% of water

Weight of water repellent when dry: 10 g / ㎡

<Process>

Card machine (web shaping) → heat fusion (belt pressing method: temperature-180 ℃, pressure-5bar) → impregnation (using can dryer, temperature 160 ℃)

Gross weight: 260g / ㎡

Example 4

<Raw fiber>

Low Melting Polyester 4d 80%

General Polyester 2d 15%

5% stainless steel fiber

Weight: 230g / ㎡

<Mesh>

Polyester Spunbond 20g / ㎡

<Water repellent>

Silicone-based water repellent (solid content 20%) 10%

90% of water

Weight of water repellent when dry: 10 g / ㎡

<Process>

Card machine (web shaping) → heat fusion (belt pressing method: temperature-180 ℃, pressure-5bar) → impregnation (using can dryer, temperature 160 ℃)

Gross weight: 260g / ㎡

Comparative example

<Raw fiber>

General Polyester 2d 50%

General polyester 3d 50%

Weight: 340g / ㎡

<Mesh>

Polyester Fabric Mesh 140g / ㎡

<Water repellent>

Silicone-based water repellent (solid content 20%) 10%

90% of water

Weight of water repellent when dry: 10 g / ㎡

<Process>

Card machine (web forming) → Needle punching → Impregnation (water repellent treatment) → Moso processing (surface processing)

Gross weight: 500g / ㎡

Weight (g / ㎡) Thickness (mm) Breathability (cc / ㎠ / sec) Water repellency Example 1 250 0.9 10 50 Example 2 250 0.8 9 50 Example 3 260 0.9 8 90 Example 4 260 0.8 8 100 Comparative example 500 2.2 15 90

In the above results, the comparative example is a conventional nonwoven felt filter medium and the measurement is measured in the filter state.

As shown in the above results, although the weight is 1/2 the weight level compared to the existing filter media, the air permeability was measured to be low. This is a conclusion that the filter media produced according to the present invention is denser than the conventional nonwoven felt media. This means that even when the pressure loss is high in the filter medium, the filter area is at least five times higher than the filter medium in the unit. The size of the air conditioner can be greatly reduced, and in terms of water repellency, it can be concluded that performance is not inferior to conventional filters.

The filter media produced according to the present invention melts the surface to make the surface smooth, to increase the density of the filter media, to impart water repellency and antistatic properties to facilitate the pulsing process to improve the disadvantages of the existing filter media Filter life is extended even when the air conditioner undergoes the pulsing process or the air conditioner does not perform the pulsing process, and the conventional filter media is felt manufactured by needle punching. An iron-welded frame called a cage is used to fit inside the media.

The filter media produced according to the present invention can be used without a cage when the filter is manufactured by thermal fusion and the feel of the media is hard so that the filter unit is mounted on an actual line after the filter unit is manufactured. Since it can be used without a cage, there is no need to manufacture a cage.

Claims (6)

The fiber diameter is 1.0 to 15 denier, 50 to 90% of low melting polyester, 10 to 50% of general polyester, and 1 to 10% of carbon fiber or stainless steel fiber. A method of manufacturing a cartridge-type functional air purifier filter medium, characterized in that it is produced at 80 to 500 g / m 2 to impart antistatic performance. The method according to claim 1, A method of manufacturing a functional air purifier filter media in the form of a cartridge, wherein the filter media is treated with a silicone or fluorine-based water repellent to impart water repellency. The fiber diameter is 1.0 to 15 denier, 50 to 90% of low-melting polyester, 10 to 50% of general polyester, 1 to 10% of carbon fiber or stainless steel fiber, and mixed in a predetermined ratio of spunbond thermoplastic fibers, A method for manufacturing a functional air purifier filter media in the form of a cartridge, characterized in that the mesh of spunlace, nonwoven fabric or fabric is laminated on the middle or one side to increase the antistatic performance and uniformity. The method according to claim 3, A method of manufacturing a functional air purifier filter media in the form of a cartridge, wherein the filter media is treated with a silicone or fluorine-based water repellent to impart water repellency. The fiber diameter is 1.0 to 15 denier, 50 to 90% of low melting polyester, 10 to 50% of general polyester, and 1 to 10% of carbon fiber or stainless steel fiber. A cartridge-type functional air purifier filter medium, which is manufactured at 80 to 500 g / m 2 to impart antistatic performance. The fiber diameter is 1.0 to 15 denier, 50 to 90% of low-melting polyester, 10 to 50% of general polyester, 1 to 10% of carbon fiber or stainless steel fiber, and mixed in a predetermined ratio of spunbond thermoplastic fibers, A cartridge type functional air purifier filter media, characterized in that the mesh of spunlace, nonwoven fabric or fabric is laminated on the middle or one side to increase the antistatic performance and uniformity.