KR20180112175A - Complex filter for automobile cabin air filter capable of simultaneously removing particulate matter and gaseous matter - Google Patents

Abstract

The present invention relates to a complex filter for an automobile cabin air filter capable of simultaneously removing particulate matter and gaseous matter. The provided complex filter includes: an activated carbon fiber filter; a thermally bonded fibrous filter laminated to one side of the activated carbon fiber filter; and a melt-blown fibrous filter laminated on the other side of the activated carbon fiber filter. According to the present invention, the complex filter has low differential pressure so as to maintain the wind volume, and can effectively remove complex materials simultaneously.

Description

TECHNICAL FIELD [0001] The present invention relates to a composite filter for an automobile cabin air filter which simultaneously removes particulate matter and gaseous substances,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filter for purifying an indoor air of an automobile, and more particularly, to a composite filter for efficiently purifying particulate matter and gaseous matter at the same time as a conventional filter for purifying only particulate matter.

Conventionally, low-priced filter products that mainly filter only dust are mainstream.

Dust, dust, and the like, it is very important to secure the health of the driver in the indoor environment.

Some complex combination filters are being proposed to the market, but their effectiveness is inferior due to their high price and low performance.

Further, due to the complex structure, a large differential pressure is generated, which lowers the air volume of the air conditioner and the heater.

It is an object of the present invention to provide a composite filter for an automobile cabin air filter which can simultaneously remove particulate matter and gaseous matter.

The present invention, in order to achieve the above-mentioned object, comprises an activated carbon fiber (ACF) filter; A thermal bond fiber filter laminated on one side of the activated carbon fiber filter; And a Melt Blown fibrous filter laminated to the other side of the activated carbon fiber filter.

In the present invention, the activated carbon fiber filter is produced by impregnating 10 to 30% by weight of natural paper with 70 to 90% by weight of activated carbon fibers having a specific surface area of 700 to 1,500 m 2 / g, adding 5 to 20% by weight of phosphoric acid and 5 to 20% %, And may have a thickness of 0.5 to 1 mmT.

In the present invention, the thermal-bonded fibrous filter includes polypropylene fibers and may have a basis weight of 100 to 140 g / m 2.

In the present invention, the meltblown fibrous filter comprises polypropylene fibers and may have a basis weight of 10 to 30 g / m 2.

The composite filter according to the present invention may further comprise a spun bond fabric bonded to the meltblown fibrous filter.

The composite filter according to the present invention has a multiple circuit folded wrinkle structure, and the rim of the wrinkle structure can be finished with a nonwoven fabric.

The composite filter developed according to the present invention can maintain the air volume because the differential pressure is low and can effectively remove the composite materials simultaneously.

1 is a configuration diagram of a composite filter according to the present invention.
Figure 2 is a photograph of a composite filter according to the invention.
3 shows a laminating process of a composite filter according to the present invention.

Hereinafter, the present invention will be described in detail.

Referring to FIG. 1, the composite deodorization according to the present invention may be composed of a thermal bond fiber filter 1, an activated carbon fiber filter 2, a melt blown fiber filter 3, and the like. The thermal-bonded fibrous filter 1 and the meltblown fibrous filter 3 can efficiently collect dust, pollen, tire powder and the like having a diameter of 0.3 μm or more. The activated carbon fiber filter 2 can effectively remove harmful gases such as ammonia and toluene.

Thermal Bond fibrous filter 1 may be laminated on one side of activated carbon fiber filter 2. The thermal-bonded fibrous filter 1 can be produced by mixing fibers such as polypropylene (PP) having a low melting point and plasticity, or by melting or melting the fibers by heat or pressure, It is hygienic.

The preferred basis weight of the thermal-bonded fibrous filter 1 is 100 to 140 g / m 2, because it effectively removes particulate matter such as fine dust and dust having a particle size of 0.3 탆 and maintains a low pressure loss To maintain the air volume of the automobile heater and the air conditioner, and to maintain the shape and firmness of the filter by using the thermal bond.

The activated carbon fiber (ACF) filter 2 can be manufactured in the form of a sheet impregnated with fibrous activated carbon (ACF) in a raw natural paper material, which is an eco-friendly material. Activated carbon can be applied as ACF, which is in the form of fiber powder. The amount of the natural paper may be 10 to 30 wt%, and the amount of the activated carbon fiber may be 70 to 90 wt%. In the range of the amount of the ACF added, when natural Korean paper fibers and ACF fibrous powder are mixed and formed into a sheet form, the ACF fiber content is dispersed to the maximum and the workability can be ensured. The specific surface area of ACF is a very important factor for the removal of harmful gas adsorption and may be, for example, 700 to 1,500 m 2 / g, preferably 800 to 1,300 m 2 / g.

The ACF filter (2) can be produced by impregnating and drying an aqueous catalyst solution in order to enhance the adsorption performance of aldehyde and butane. Specifically, the catalyst aqueous solution may be doped to Korean paper ACF (Korean paper + ACF powder) by spraying, impregnation or the like, followed by drying at 90 to 110 캜 for activation. The impregnated amount of the catalyst aqueous solution may be 1 to 100 parts by weight based on 100 parts by weight of Korean paper ACF (Korean paper + ACF powder). The catalyst aqueous solution may contain 5 to 20 wt% of phosphoric acid and 5 to 20 wt% of ethylene urea, and the balance may be composed of water. The performance against toluene, butane, etc. is most effective in the range of phosphoric acid and ethylene urea content.

The preferred thickness of the ACF filter 2 is 0.5 to 1 mmT because it can minimize the bond strength and peeling between the natural non-polymeric ACF of the non-polymer series and other constituents in this thickness range.

The meltblown fibrous filter 3 may be laminated to the other side of the activated carbon fiber filter. The meltblown fibrous filter 3 can be produced by spinning a synthetic polymer polypropylene and making it into microfine fibers by high pressure hot air to form a melt-blown nonwoven fabric. The manufacturing process generally involves the introduction of raw materials → extrusion, spinning → web forming → web cooling → web combining. The nonwoven fabric manufactured by the meltblown process can be used. Since the used web is ultra-fine fiber, it can be advantageous in that it can not be obtained in general nonwoven fabrics such as softness, warmth and high filtration performance. This is a disadvantage in that the web strength is very weak. Since the web strength is limited by itself, it can be used in combination with a web, pulp or staple fiber by a spun bond method. The most commonly used raw fiber is polypropylene. Excellent in flexibility, impermeability and insulation, it is suitable for filters and so on.

The preferred basis weight of the meltblown fibrous filter 3 is 10 to 30 g / m 2 because it effectively removes particulate matter such as fine dust and dust having a particle size of 0.3 탆, This is to maintain the airflow of the car heater and the air conditioner by maintaining the loss.

The composite filter according to the present invention may further comprise a spun bond fabric bonded to the meltblown fibrous filter 3. The spunbond fabric is a layer for maintaining the strength and rigidity of the product, and in particular, can be laminated for securing the durability of the meltblown fibrous filter 3. The spunbond fabric can be produced by spun a raw material such as polypropylene (PP) or polyethylene terephthalate (PET) and self-adhered by heat to form a web.

Referring to Figures 1 and 2, the composite filter according to the present invention can have a multiple circuit folded structure for filtration area and breathability expansion. Specifically, the upper and lower ends may be folded and folded while being alternately bent.

Referring to FIG. 2, the composite filter according to the present invention may have the corrugated structure rimmed with a nonwoven fabric. The rimless nonwoven fabric is formed by processing a PP fiber material into a sheet having a thickness of 0.8 to 1.2 mm and can be manufactured so as to facilitate maintenance of external dimensions and external appearance, and separation and detachment of the automotive air conditioner filter case.

Referring to FIG. 3, the composite filter according to the present invention is manufactured by applying a hot melt in the order of an upper thermal bond fabric, a middle natural rubber sheet ACF, and a lower melt blown fabric in this order, In the same way, the spunbond fabric is joined to the rear end. Specifically, first, the thermal bond fabric and the ACF fabric are laminated through a laminating process, followed by laminating a meltblown fabric effective for fine dust removal. Thereafter, in order to ensure durability of the meltblown fabric, a spun bond fabric is lapped to produce a circular roll sheet. Thereafter, the rolled sheet is folded to form a corrugated filter in order to increase the filtration area and air permeability. Thereafter, in order to maintain the rigidity of the product, the nonwoven fabric frame is closed to manufacture the automotive combination filter.

The composite filter according to the present invention has a performance satisfying the automobile air filter test standard, and can remove both particulate matter and gaseous matter at the same time. Particularly, the composite filter according to the present invention has a lower weight (g / And the pressure difference is low while maintaining the function of the fabric as much as possible.

Antibacterial degree of 95 to 100% of the component filters according to the present invention, the antifungal castle Class 1 or Class 0, talchwiyul is 90 to 100%, the pressure loss is 20 ㎜Aq (㎜H ₂ O) or less (200 Pa or less) one . In addition, the fine dust removing efficiency of the composite filter according to the present invention is 80 to 100% for a size of 0.3 to 0.5 탆, 85 to 100% for a size of 0.5 to 1 탆, 90 to 100% for a size of 1 to 3 탆, Can be 90 to 100% in the case of a size of 3 to 5 mu m, and 93 to 100% in the case of a size of 5 to 10 mu m. In addition, the harmful gas removal efficiency of the composite filter according to the present invention may be 80 to 100% at 5 minutes of the adsorption period and 85 to 100% at 5 minutes of the desorption period. Volatile organic compounds (VOCs) are either undetectable or less than 1 ppm.

[Example]

As shown in Fig. 1, a composite filter composed of a thermal bond fiber filter 1, an activated carbon fiber filter 2, a meltblown fibrous filter 3 and the like was produced.

The thermal bond fiber filter (1) was made of PP fibers at a basis weight of 120 g / m 2. The activated carbon fiber filter (2) was prepared in the form of a sheet impregnated with 20 wt% of natural paper and 80 wt% of ACF having a specific surface area of 800 m 2 / g, and an aqueous catalyst solution containing 10 wt% phosphoric acid and 10 wt% ethylene urea Impregnated with 10 parts by weight of 100 parts by weight of Korean paper ACF, and dried at 100 DEG C to give a thickness of 0.8 mmT. The meltblown fibrous filter (3) was made of PP fiber at a basis weight of 20 g / m 2.

As shown in Fig. 3, a hot melt was applied in the order of an upper thermal bond fabric, a middle natural rubber sheet ACF, and a lower meltblow fabric, followed by laminating by a roller, followed by laminating a spunbond fabric to the rear end by the same method. Specifically, after the thermal bond fabric and the ACF fabric were joined together through a laminating process, a meltblown fabric effective for removing fine dust was laminated. Thereafter, a spunbond fabric made of PP fiber was joined to the meltblown fabric to ensure the durability of the meltblown fabric, thereby manufacturing a circular roll sheet. Thereafter, the rolled sheet was bent to enlarge the filtration area and air permeability, and was formed into a corrugated filter form as shown in Fig. Thereafter, to maintain the rigidity of the product, the automobile combination filter was manufactured by finishing with a 1 mm thick nonwoven frame made of PP fiber.

[Test Example]

Antifungal property, antifungal property, deodorization rate, initial pressure loss, fine dust removal efficiency, harmful gas removal efficiency, odor test (deodorization) and volatile organic compounds (VOCs) were measured on the prepared composite filter. ≪ / RTI > Antimicrobial activity was measured according to ASTM E 2149, deodorization and gas removal characteristics according to KS I 2218: 2009.

number Test Items Evaluation standard Test Methods One Pressure loss 450 m3 / h 20 mmAq or less 7.1 2 Dust removal
Efficiency test
(Geometric diameter) 0.3 탆 to 0.5 탆 More than 50% 7.2 0.5 탆 to 1.0 탆 More than 70% 1.0 탆 to 3.0 탆 More than 85% 3.0 탆 to 5.0 탆 95% or more 5.0 탆 to 10.0 탆 100% 3 Harmful gas
Removal efficiency test
(1 minute / 5 minutes) Toluene (80 ppm) More than 80% / 75% 7.3 n-butane (80 ppm) More than 70% / 45% Sulfurous acid (30 ppm) 70% / 55% or more Ozone (100 ppb) 90% / 80% or more 4 Environmental stability test Pressure loss test Initial pressure loss Within ± 5% 7.4 Fractional removal efficiency test Evaluation criteria for item 1 5 Hazardous gas desorption test Less than 5% 7.5 6 Combustibility test FMVSS302
Or DIN 53438 Self-extinguishing
(Self-extinguishing) 7.6 7 Antifungal test ASTM G21 1 or more 7.7 8 Microbiological test ASTM G22 Bacteria on the surface of the sample
No growth 7.8 9 Maximum dust collection capacity test  15 g / ㎡ or more 7.9

division The present invention product Company A Antimicrobial activity Strain 99.9% 0% Antifungal 0 ratings 0 ratings Deodorization rate 94.5% 80.7% Initial pressure loss 100 m3 / h 18.6 Pa 13.1 Pa 200 m3 / h 29.5 Pa 28.1 Pa 300 m3 / h 52.0 Pa 48.6 Pa 400 m3 / h 82.3 Pa 71.6 Pa 500 m3 / h 98.1 Pa 97.6 Pa 600㎥ / h 131.6 Pa 128.8 Pa Fine dust removal efficiency 0.3 to 0.5 탆 81.4% 65.1% 0.5 to 1.0 탆 87.4% 65.3% 1.0 to 3.0 μm 92.1% 74.2% 3.0 to 5.0 μm 92.0% 83.3% 5.0 to 10.0 탆 94.5% 89.8% Hazardous gas removal efficiency Duration of adsorption 1 min 79.5% 80.5% 5 min 84.0% 77.5% Duration of desorption 1 min 63.2% 49.0% 5 min 87.2% 70.2% Odor test (deodorization) Wet 1.0 1.0 key 2.0 2.0 VOCs (detailed) benzene Not detected Not detected toluene Not detected Not detected Ethylbenzene Not detected Not detected Xylene Not detected Not detected Styrene Not detected Not detected Formaldehyde Not detected 0.1 ppm Acetaldehyde Not detected 0.1 ppm Acrolein Not detected Not detected

As can be seen from Table 2, the product of the present invention showed better physical properties than those of other products.

1: Thermal bond fiber filter
2: activated carbon fiber filter
3: Meltblown fibrous filter

Claims (6)

Activated carbon fiber (ACF) filters;
A thermal bond fiber filter laminated on one side of the activated carbon fiber filter; And
A composite filter comprising a meltblown fibrous filter laminated to the other side of an activated carbon fiber filter. The method according to claim 1,
The activated carbon fiber filter comprises 10 to 30% by weight of natural paper impregnated with 70 to 90% by weight of activated carbon fibers having a specific surface area of 700 to 1,500 m2 / g, 5 to 20% by weight of phosphoric acid and 5 to 20% by weight of ethylene urea , And has a thickness of 0.5 to 1 mmT. ≪ RTI ID = 0.0 > 8. < / RTI > The method according to claim 1,
Wherein the thermal bond fibrous filter comprises polypropylene fibers and has a basis weight between 100 and 140 g / m < 2 >. The method according to claim 1,
Wherein the meltblown fibrous filter comprises polypropylene fibers and has a basis weight between 10 and 30 g / m < 2 >. The method according to claim 1,
A composite filter further comprising a spun bond fabric bonded to the meltblown fibrous filter. The method according to claim 1,
Wherein the composite filter has a plurality of circuit folded wrinkle structures, and the rim of the wrinkle structure is finished with a nonwoven fabric.

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