KR20150021685A - Gaseous filter using porous material and the method thereof - Google Patents

Abstract

The present invention relates to a gaseous filter using porous materials and, more specifically, a gaseous filter using porous materials and a manufacturing method thereof, comprising the steps of manufacturing gaseous filter by using fiber materials whose melting point is lower instead of using an adhesive and which has porous materials in a stable manner without using a specific type bubble papers, thereby resolving the problem that the porosity of porous materials are blocked in an existing method of laminating porous materials with use of an adhesive, leading to a good efficiency in an aspect of cost and process without using a specific composite threads. The manufacturing method of the gaseous filter comprises steps of i) manufacturing a mixture by mixing porous materials with fibers whose melting point is lower; ii) scattering the mixture on a first bubble paper; iii) laminating a second bubble paper on the first bubble paper on which the mixture is scattered; and iv) connecting the laminated first bubble paper and second bubble paper with use of heat fusion.

Description

TECHNICAL FIELD [0001] The present invention relates to a gas filter using a porous material,

The present invention relates to a gas filter using a porous material, and a gas filter is manufactured using a fiber material having a low melting point in place of an adhesive, and a gas filter in which a porous material is stably contained even without using a specific type of bubble paper is manufactured , It is possible to overcome the problem of blocking pores of a porous material, which is a problem of a conventional method of laminating a porous material by using an adhesive, and to overcome the problem of a gas that can achieve cost efficiency and process efficiency without using a specific composite yarn And a gas filter according to the method.

In various industrial sites, exhaust gas containing dust is generated, and dust and the like contained in such exhaust gas are exhausted to the atmosphere only through the dust-removing apparatus, . A gas filter is used to purify the air by filtration, and a gas filter is used in a filtration and dust collecting apparatus used for removing fine dust to adsorb or adhere dust in the air. Such gas filters are widely used. A gas filter for an automobile engine or an air-conditioning system is adopted to improve the efficiency and cleanliness efficiency of the engine by filtering dust such as dust mixed with the air. In addition, a filter for a gas turbine filter, a semiconductor air filter, The use of gas filters and the market are increasing in response to the development of the industry and the improvement of awareness of life hygiene.

Such a gas filter has been widely used in nonwoven fabrics. However, starting from an initial simple structure, the gas filter has been steadily diversified and developed in terms of its layer structure, bonding method, and material. Nonwoven fabrics made of fibers of several tens to several hundreds of micrometers obtained through conventional nonwoven fabrication processes such as melt-blown, spunbonding, and needle punching have high air permeability, low dust collection efficiency but low resistance to airflow, It is possible to minimize the pressure loss due to the pressure. On the other hand, in addition to dust removal, there has been developed a type including a porous material (material containing voids) for adsorption of toxic substances and the like. According to IUPAC definition, voids are classified as follows. The micropores are less than 2 nm, the intermediate pores are 2 to 50 nm in diameter, and the pores are greater than 50 nm in diameter. When porous materials having such voids are used, they may be used as an insulating material due to low thermal conductivity, or may be used as acoustic absorbing materials due to their sound-canceling ability, but they are also useful as absorbing materials for harmful gases due to their high porosity and specific surface area.

Examples of the porous material include activated carbon, aerogels and the like, and aerogels are representative. On the other hand, several approaches have been used in the manner in which the porous material is laminated or bonded to the fibrous web. The sheet form containing the porous material may be prepared by impregnating a fiber or fiber web with a solution of an aerogel precursor in a sol state and proceeding the gelation reaction inside the fiber web to prepare a wet gel and then preparing an airgel- . This method is disadvantageous in that the process required in aerogel production such as gelation and supercritical drying is carried out on a fiber / fiber web, and thus the production cost is significantly increased due to difficulty in the process. For example, the supercritical equipment uses a high pressure of 100 atm for simplicity, and the price of process equipment increases significantly when the size is increased to increase the productivity. In addition, it takes much time to dry the wet gel impregnated in the fibers.

A dry method was also introduced to overcome this. A method of forming a porous material-polymer composite by using a porous material and a thermoplastic resin as a binder (adhesive) on a fiber web used as a foam paper, or a method of forming a porous material- There is a method of laminating a porous material therebetween by using a bicomponent fiber having a high melting point region and a high melting point region.

In the method of forming a composite, thermoplastic resin is usually used as a binder. Therefore, when the porous material is fused, the thermoplastic binder clogs the nanoporous material and loses its meaning of using the porous material. The degree of such a phenomenon becomes considerably serious. Particularly, when a liquid binder is used, the porous material having a high specific surface area absorbs a large amount of the binder, so that it is difficult to increase the filling rate of the porous material.

Forms using bicomponent fibers are in the form of composite fibers having a low melting point region and a high melting point region. The composite fiber is produced by compressing two or more different polymer materials from the same spinneret. The cross section shows a structure in which the two components are spliced into two layers. Representative forms of conjugated fibers include side-by-side form, cis-core form, and the like. A method of laminating a porous material on a fiber web made of a composite fiber, laminating a fibrous web of the composite fiber on the web, and thermocompressing the fiber web is used. In this method, cost increase during fabrication is very large and fabrication process of fiber web of composite fiber is also complicated.

The present invention basically adopts a dry method, which is accomplished by solving the problems of the conventional dry method.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and it is an object of the present invention to provide a porous porous membrane which can maintain the porosity of the porous porous body, firmly deposit the porous porous body, fill the porous porous body with a sufficient amount, A method of manufacturing an increased gas filter and a gas filter according to the method.

For this purpose, the present invention provides a method for producing a composite fiber, comprising: i) mixing a porous material and a low melting point fiber to form a mixture; Ii) scattering the mixture over a first pre-purge; Iii) laminating the second bubble onto the scattered first bubble; And iv) thermally fusing the first base porcelain and the second base fabric to each other.

Preferably, the low melting point fibers are cut to 1 to 4 mm, and the porous material is preferably selected from the group consisting of activated carbon, xerogel, and airgel, and the mixture is selected from the group consisting of 100 parts by weight of the porous material And 30 to 60 parts by weight of the low melting point fibers.

The foamed woven fabric may be used or a nonwoven fabric may be used, and the first bubble and the second bubble may be of the same kind or may be used in a heterogeneous form. Preferably, the first bulge and the second bulge are the same kind of bulge, and the low melting point fiber is preferably a low melting point fiber of the same kind as the bulge.

Further, the present invention is a gas filter manufactured by the above-described method.

The present invention uses a cut-formed low-melting-point fiber and does not use a thermoplastic resin used as a conventional binder, so that it is possible to prevent the thermoplastic resin from entering the pores of the porous material during bonding and lowering the porosity, The problem that the packing ratio of the porous material can not be increased when the thermoplastic resin is used can be solved. Further, it has an effect of sufficiently achieving the efficiency of the process without causing the problem of complexity and economic efficiency in the case of using the conventional type of composite fiber. In addition, it is possible to use various types of filters, so that it can be applied to filters of various purposes.

Figure 1 illustrates the concept of porous material and low melting point fibers being scattered in a bubble state,
Fig. 2 conceptually illustrates the overall manufacturing process of the present invention.

The present invention relates to a gas filter, and includes a porous material for not only basic dust removal but also adsorption of harmful substances. In addition to being highly useful for absorbing harmful gases due to their high porosity and specific surface area, the porous material having a porous material has a low thermal conductivity due to porous materials having voids, There are various advantages when used as a gas filter.

Fig. 1 illustrates the concept that porous material and low melting point fibers are scattered in a bubble state. In the present invention, the porous material and the low-melting-point fiber are mixed well and mixed and uniformly sprayed in the bubble state. This act of sprinkling is called scattering. The porous material may be in the form of activated carbon or in the form of xerogels or aerogels, and the xerogels or aerogels may be in the form of dry gels. Xerogels are typically formed using the evaporation and drying steps under ambient pressure conditions and generally have a monolithic internal structure similar to low density foams having a porosity of 60 to 90%. Aerogels can be produced using methods such as supercritical drying, which do not shrink as much as x-gel during the drying step and thus tend to have lower densities (higher porosity). In the present invention, a carbonaceous xerogel or carbonaceous airgel is also preferable in consideration of physical properties and adsorptivity. The xerogels can be obtained by aqueous polycondensation of aromatic alcohols and aldehydes, and such methods are omitted in order to avoid obscuring the gist of the invention. That is, the above-mentioned porous material is supplied as an article. More preferably, when a xerogel is used, the xerogel can be more effective in the present invention because it can easily increase the specific gravity of the shape of the intermediate void. The porous material is not limited thereto, and may be various ones that can be adopted from the viewpoint of a person skilled in the art.

The low melting point fibers are those which are supplied in the form of a composite yarn and those in which a melting point is lowered by forming a short fiber by combining various materials when spinning a general fiber form. The compound yarn is a composite yarn in which a common resin is used as a core and a low melting point resin is used as a sheath. The two yarns having different viscosities and different compositions are combined to spin side by side, Or in a matrix-fibrillated form. Composite yarns may be cut and used in the form of low melting point fibers, rather than being made by weaving or weaving fabrics webs. And there are several short fiber types. For example, in the production of polypropylene staple fibers, when fibers are made by properly mixing vinyl chloride with a conventional polypropylene resin, the melting point of propylene is 160 ° C or higher, but lower than 100 ° C through mixing with vinyl chloride have. In the case of a polyester type, polyester staple fibers having a low melting point can be produced by using terephthalic acid and isophthalic acid as acid components and ethylene glycol and diethylene glycol as diol components and lowering the degree of polymerization. These low melting point fibers are being supplied as products. In the present invention, the melting point of the low melting point fiber should be lower than the softening point of the prepreg.

The low melting point fibers are provided as fibers having the same thickness as the hair, and it is preferable to cut them to a length of about 1 to 4 mm. The low melting point fiber is used to fix the porous material and to coalesce with the porous material, and thus it is difficult to achieve the low melting point fiber because it has the function of bonding the porous material and the foam material, and if too small, it can act as an obstacle. More preferably about 2 to 3 mm, in which case the characteristics are further improved. The low melting point fibers and the porous material mix well to form the mixture. Mixing should be done well to assure uniformity, so after sufficiently kneading in mixer, use hopper to scatter to bubble paper. As shown in FIG. 1, the mixture is sprayed onto hopper 10 through hopper 20. The circular shape represents a porous material, and the triangular shape represents a low melting point fiber.

Fig. 2 conceptually illustrates the overall manufacturing process of the present invention. The first primer 11 is wound on the first winding roll 30 and supplied thereto. The hopper 20 contains a mixture of the porous material and the low melting point fibers and is constantly scattered over the moving first bulge 11. The second take-up roll 40 is wound with the second provisional bulge 12 and is laminated thereon after scattering of the mixture. After laminating, heat supply and pressure bonding are performed by the heat fusion roller 50. Heat is applied at a temperature equal to or higher than the melting point of the low-melting-point fiber, and the low-melting-point fiber is pressed to coalesce the bubble fibers. Porous materials are uniformly seated between the bubbles. This process is summarized as follows: i) mixing a porous material and a low melting point fiber to form a mixture; Ii) scattering the mixture over a first pre-purge; Iii) laminating the second bubble onto the scattered first bubble; Iv) thermally fusing the laminated first and second base paper; .

On the other hand, the mixing ratio of the porous material and the low melting point fibers may vary depending on the use, thickness, etc. of the gas filter. In consideration of adhesion and porosity, it is preferable to mix the porous material in a ratio of 30 to 60 parts by weight to 100 parts by weight of the porous material. If the low melting point fiber is too small, the adhesion force exhibited by the low melting point fiber may be insufficient, and if too much, it may be difficult to exhibit the functionality of the porous substance. In the preferred ratio, the porous material and the low melting point fibers are approximately 7% w / w and the ratio of the low melting point fibers is about 43% by weight based on 100% by weight of the porous material.

The present invention has an advantage that a wide variety of shapes can be used as a base paper. In general, the impregnated form of the porous material is in the form of a nonwoven fabric. A nonwoven fabric having a general type of nonwoven fabric or a mixture of fibers having different melting points is used. In the present invention, a woven fabric as well as a nonwoven fabric can be used. Further, a different kind of the first primer and the second base may be used. And the low melting point fiber is easily formed in the form of a short fiber composed of the first bubble or a material similar to that of the second bubble. More preferably, the first bulge and the second bulge are of the same type, and the low melting point fiber is made of a homogeneous material having a melting point different from that of the bulge.

The present invention also provides a gas filter according to the above method. Various modifications of the gas filter manufactured by the above method are possible, and additional sheet attachment or additional functional addition will be possible. In the case of the gas filter of the present invention, it is more preferable that the gas filter is used in a large air conditioner or in a dust collecting facility of a factory.

It is to be understood that both the foregoing general description and the following detailed description of the present invention are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. .

10: Supporting paper
11: First Forge
12: Second Forge
20: Hopper
30, 40: a first take-up roll, a second take-up roll
50: heat fusion roller

Claims (7)

I) mixing the porous material with the low melting point fibers to form a mixture;
Ii) scattering the mixture over a first pre-purge;
Iii) laminating the second bubble onto the scattered first bubble;
And iv) thermally fusing the first base porcelain and the second base fabric that are joined together. The method according to claim 1,
Wherein the low melting point fibers are cut to 1 to 4 mm. The method according to claim 1,
Wherein the porous material is selected from the group consisting of activated carbon, xerogels, and aerogels. The method according to claim 1,
Wherein the mixture is 30 to 60 parts by weight of low melting point fibers per 100 parts by weight of the porous material. The method according to claim 1,
Wherein the foamed woven or nonwoven fabric is characterized in that the first and second bubbles are homogenous or different from each other. The method according to claim 6,
Wherein the first bulge and the second bulge are the same kind of bulge, and the low melting point fiber is a low melting point fiber of the same kind as the bulge. A gas filter produced by a process selected from the processes of claims 1 to 6.

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