KR20190017838A - Filter incluing nanofiber, manufacturing mehtod thereof and mask using filter incluing nanofiber - Google Patents

Abstract

The present invention relates to a filter using nanofibers, a method for manufacturing the same, and a mask using the same. More particularly, the filter is characterized in that a first base material, a nanofiber layer of a web structure having a fiber diameter of 5-50 nm and a network structure, and a second base material are sequentially laminated. According to the present invention, the collecting efficiency for fine contaminants of 300 nm or less is excellent, the pressure loss is low to enable comfortable breathing when applied as a mask, the energy consumption and the noise can be reduced when applied as various air filters, and the manufacturing cost is low.

Description

TECHNICAL FIELD [0001] The present invention relates to a filter using nanofibers, a method of manufacturing the filter, and a mask using the same. BACKGROUND OF THE INVENTION 1. Field of the Invention [0001]

The present invention relates to a filter using nanofibers, a method of manufacturing the same, and a mask using the nanofibers. More particularly, the present invention relates to a filter using nanofibers having excellent collection efficiency for fine contaminants of 300 nm or less and low pressure loss, And a mask using the same.

As the industrialization progresses, the atmospheric environment is getting worse and the kinds of pollutants are becoming more diverse, and the rate of occurrence of harmful gases and odor components including heavy metals, fine dusts, and VOCs is rapidly increasing . Therefore, as the interest in the atmospheric environment around the world grows, a highly efficient air filter is used as a means for maintaining a comfortable living environment, as well as for the development of electric, electronic, and semiconductor industries, as well as for maintaining a highly clean production process.

Air filter is classified into 1) air filter for ventilation, 2) air filter for transportation, 3) dust filter for industrial use, ie, dust filter, and 4) various filter filters used in household appliances. Various automobiles are also equipped with air filters.

In addition, people individually wear a mask containing such an air filter to prevent germs and fine dust in the air.

On the other hand, the fine contaminants are a complex mixture of very small particles and liquid droplets, which are classified into PM2.5 and PM10 based on the particle size, and they have particle sizes of 2.5 μm and 10 μm or less, respectively. The pollutants of PM2.5 are particularly harmful because of their small size, which can penetrate the human bronchi and lungs. Particularly, the ultrafine dust which is most easily permeable to the human body has a level of about 100 to 300 nm, but it is in the range of 100 to 300 nm The fine contaminants having a size are the most difficult to collect, and conventional air filters and mask filters can not block the fine contaminants in these areas.

For reference, KF80 has 80% or more of the fine particles (average particle size of 0.6㎛), pressure loss of 60Pa or less, and KF94 is 94% or more of fine particles (average particle size of 0.4㎛) And the pressure loss is not more than 70 Pa. KF99 is not less than 99% of fine particles (average particle size of 0.4 ㎛) and the pressure loss is 100 Pa or less. The collection efficiency of the fine contaminants at the level of 100 to 300 nm is not known at all, The pressure loss also increases, which makes it difficult to breathe.

In the case of the air filter, the HEPA class has a high efficiency of 99.97% PM2.5 (2.5㎛) and a very high pressure loss of about 260Pa, which causes energy consumption and noise increase when applied to various industrial sites and electronic products have.

Therefore, a filter using nanofibers has recently been proposed for trapping and blocking microfine contaminants at the ultrafine dust level.

The nanofiber refers to a microfiber having a diameter of only a few tens to several hundreds of nanometers, and is manufactured through electrospinning deposition (ESD).

In the electrospinning method, the starting material is dissolved in a solvent, and a high-voltage electric field is applied thereto to generate an electric repulsive force inside, thereby causing the solvent to evaporate and divide the starting material into nano-sized fibers. In this method, only a small amount of nanofibers can be produced from a single injection nozzle for spraying the starting material. In order to increase the production amount, when a plurality of injection nozzles are installed, a wide emission region is required to avoid electrical interference between the nozzles , And mass production is difficult. Further, when a combustible organic solvent is used as the solvent, there is a fear that the solvent may explode due to high voltage. In case of using a nonflammable solvent, production at normal temperature and pressure is not possible and the manufacturing cost is high. In addition, this method is not only affected by ambient temperature, humidity, electrical interference, etc., but also produces nanofibers having a fiber diameter of about 200 nm and a fiber diameter of about 50 nm required for trapping fine contaminants having a particle size of 300 nm or less There is a disadvantage that it can not be done. In addition, in the electrospinning method, since the starting material is elongated by an electric repulsive force, that is, a potential difference, a charge is given to the nanofiber, and the nanofiber having the charge has a large hole at the center, So that it is disadvantageous in that it is not efficient as a filter. Further, since such nanofibers collect fine contaminants through collision of gas molecules as shown in FIG. 2, there is a limitation in increasing the collecting efficiency even when a plurality of layers are stacked, and a disadvantage that only the pressure loss is increased have.

Accordingly, it is required to develop a filter having nanofibers that have excellent collection efficiency for fine contaminants of 300 nm or less, low pressure loss, and low manufacturing cost without using multiple layers.

KR 10-1130788 B1 KR 10-2017-0071882 A WO 2015-145880 A1 JP 05637479 B1 CN 106133213 A

Therefore, the object of the present invention is to provide a method of manufacturing a photocatalyst, which is excellent in the collection efficiency for fine contaminants of 300 nm or less without using multiple layers, and has low pressure loss, A filter using nanofibers having a low manufacturing cost, a manufacturing method thereof, and a mask using the same.

In order to achieve the above object, the present invention provides a filter using nanofibers, which comprises a first substrate, a nanofiber layer on a web having a fiber diameter of 5 to 50 nm and a network structure, and a second substrate sequentially laminated .

Wherein the fiber precursor is a polyethersulfone, and the first and second substrates are made of a material selected from the group consisting of PE, PET, Co-PE / PET, and PU.

A second base material, a nanofiber layer on a web having a fiber structure having a fiber diameter of 5 to 50 nm and a network structure, and a first base material are further laminated on the second base material.

And a nanofiber layer on the web having a fiber diameter of 5 to 50 nm and a network structure is further interposed between the nanofiber layer having a fiber diameter of 5 to 50 nm and the second base material.

Wherein a binder layer is formed on the side of the first base material, the second base material or both of them contacting the nano fiber layer.

A method of manufacturing a filter according to the present invention comprises the steps of collecting a fiber precursor into nanofibers of a web having a fiber diameter of 5 to 50 nm and a network structure on a first substrate using a nanofiber manufacturing apparatus of a zeta spinning manufacturing method, And laminating the second substrate on the nanofiber side of the first substrate on which the nanofibers are collected.

And laminating the laminated two sheets of the first substrate, the nanofiber and the second substrate laminated so that the second substrate is in contact with each other.

Collecting the fiber precursor into nanofibers of a web having a fiber diameter of 5 to 50 nm and a network structure on the first substrate using a nanofiber manufacturing apparatus of the zeta spinning manufacturing method; Collecting the nanofibers in the web with nanofibers having a fiber diameter of 5 to 50 nm and a network structure on a second substrate using a fiber manufacturing apparatus; And laminating each of the nanofibers so that they are in contact with each other.

The first base material, the second base material, or both are characterized in that the nanofibers are collected or coated with a binder on the side where the nanofibers are collected or abutted.

Wherein the fiber precursor is polyethersulfone and the first and second substrates are nonwoven fabrics of any one of PE, PET, Co-PE / PET, and PU.

The mask according to the present invention is characterized by including the filter described above.

According to the present invention, it is possible to reduce the energy consumption and the noise when applying with various air filters, and to reduce the manufacturing cost because of the excellent trapping efficiency for the fine pollutants of 300 nm or less and the low pressure loss. There are advantages.

Further, the filter network is not clogged due to the cleanabillity characteristic inherent to the nanofibers at the level of 50 nm, and there is an advantage that the collection efficiency is not lowered even when the filter cloth is washed several times.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a graph showing the collection efficiency of fine contaminants of filter fibers constituting a conventional filter according to particle size. FIG.
Fig. 2 is a view schematically showing a structure for collecting fine contaminants of filter fibers constituting a conventional filter; Fig.
3 is a cross-sectional view of a filter according to a first embodiment of the present invention;
4 is a schematic view showing a direction in which air passes through a filter according to the first embodiment of the present invention.
5 is a cross-sectional view of a filter according to a second embodiment of the present invention;
6 is a cross-sectional view of a filter according to a third embodiment of the present invention;
7 is a view schematically showing the principle of manufacturing nanofibers on a web by using the apparatus for producing zeta spinning according to the present invention.
8 is an electron micrograph of a nanofiber layer according to the present invention.
9 is a view schematically showing a manufacturing process of a filter according to the present invention.
10 and 11 are diagrams showing the results according to Test Example 1 of the present invention.

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

The filter according to the present invention can be applied not only to a mask but also to various electronic products such as an air cleaner and an air conditioner, an automobile, an air filter for ventilation, a transportation air filter, an industrial filter, It should be understood that the scope of use thereof is not limited within the scope.

As shown in Figs. 3 and 4, the filter according to the first embodiment of the present invention includes a first base material 1, a nanofiber layer 2 of a web having a fiber diameter of 5 to 50 nm and a network structure Fiber layer "), and a second base material 3 are laminated in this order.

In the present invention, as shown in FIG. 4, the first base material 1 is a surface facing air inflow side, and primarily plays a role of removing dust or the like having a relatively large particle size such as yellow dust, pollen or the like, , And protects the nano fiber layer 2 to prevent damage. More specifically, the first base material 1 is a nonwoven fabric made of any one of PE, PET, Co-PE / PET, and PU. The first base material 1 has a fiber diameter of 0.1 to 100 탆, But it is not limited thereto. At this time, since the second base material 3 is located on the side opposite to the first base material 1, a further description thereof will be omitted.

The nanofiber layer 2 laminated on the first base material 1 has an average fiber diameter of 5 to 50 nm and is a web having a network structure. This is because the nanofibers produced by the conventional electrospinning method have a shape in which they are uniformly arranged in one direction and thus can not be applied to the mask as it is. Moreover, since the fiber diameter can not be fabricated at a level of 50 nm, And it is difficult to collect and block fine contaminants. That is, since the nanofiber layer 2 according to the present invention is a web having a network structure, it can collect fine contaminants in the form of a net even if the thickness of the nanofiber layer 2 is increased or a plurality of nanofiber layers 2 are not used. It is possible to collect fine contaminants of 300 nm or less at a fiber diameter of 50 nm level, and thus it is possible to cope with PM0.1.

The nanofiber layer 2 according to the present invention has a nanofiber diameter of 5 to 50 nm. Therefore, even if the thickness of the nanofiber layer 2 is at least 0.1 to 10 g / m 2 as an example, the collecting efficiency can be increased, There is an advantage of not doing. That is, the nanofiber layer 2 according to the present invention has an advantage that the pressure loss can be reduced by 60 to 90% as compared with the conventional HEPA or ULPA. FIG. 8 is an electron microscope photograph of the nanofiber layer 2 according to the present invention. It can be confirmed that nanofibers are formed on a web of a dense network structure, and particles having a particle size of 300 nm or less are collected by a mesh method.

2, since the conventional filter collides with fine contaminants and collects fine contaminants, it is impossible to collect 100% of fine contaminants even if a plurality of layers are overlapped. In contrast, the nano fiber layer 2 according to the present invention, It uses nanofibers at 50nm level and can be collected in a network form because it is web based network structure. Therefore, it is possible to collect 100% of fine pollutants by a single layer.

The nanofiber layer 2 according to the present invention for this effect is manufactured on a web having a network structure using a nanofiber manufacturing apparatus of the zeta spinning manufacturing method, The manufacturing apparatus is an apparatus developed by the present inventor and is described in detail in WO 2015-145880 A1 (hereinafter referred to as "pre-patent"). Therefore, a detailed description of a specific method for manufacturing the nanofiber layer using the zeta spinning manufacturing apparatus is omitted, and it is revealed that this method is based on a pre-patent.

The principle of the zeta spinning manufacturing method will be briefly described with reference to FIG. 7. The polymer as a starting material is heated or dissolved in a solvent to prepare a liquid polymer solution, which is then heated to a high temperature through an air heater nozzle By jetting at a high speed, a gentle pressure layer attracted by the high-speed, high-temperature air stream and the high-speed and high-temperature air stream are generated in the peripheral portion of the high-speed and high- At this time, the hot air is sprayed at a temperature of 250 to 350 DEG C and a velocity of 200 to 350 m / s, and the gentle pressure layer has a lower atmospheric pressure than a hot air and is formed into a gentle stream. When the polymer solution is injected into the gentle pressure-generating layer through the injection nozzle, the injected liquid polymer solution moves in a gentle pressure-pressure layer while being placed on the high-speed, high-temperature air, And is stretched in a slow pressure layer and high-speed, high-temperature air during the movement, and the stretched polymer is collected in the collector as nanofibers.

Unlike the prior art, the zeta spinning type nanofiber manufacturing apparatus of this type does not require a high voltage and is advantageous in that it can be manufactured at a low cost and at a low production cost without being influenced by the manufacturing environment. In addition, the nanofibers can be prepared by controlling the fiber diameter within the range of 5 to 1000 nm, and the nanofibers are arranged randomly in a single direction, And it is possible to control the thickness of the nano fiber layer.

Here, polyether sulfone (PES) is preferably used as a raw material of the fiber precursor, and it is possible to exhibit a better collection efficiency when the PES is used.

The solvent used in the production of the nanofibers may include, but is not limited to, methanol, ethanol, 1-propanol, 2-propanol, hexafluoroisopropanol, tetraethylene glycol, triethylene glycol, dibenzyl alcohol, , Dipropylene glycol, methyl isobutyl ketone, methyl n-hexyl ketone, methyl n-propyl ketone, diisopropyl ketone, diisobutyl ketone, acetone, hexafluoroacetone, phenol, formic acid, methyl methyl formate , Propyl formate, methyl benzoate, dimethyl, diethyl phthalate, dipropyl phthalate, methyl chloride, ethyl chloride, methylene chloride, chloroform, methyl bromide, ethyl bromide, acetic acid, benzene, toluene, hexane and cyclohexane All are available. In addition, the amount of the solvent used is not limited. The amount of the solvent may be 1 to 1,000 parts by weight based on 100 parts by weight of the fiber precursor.

The second base material 3 laminated on the nanofiber layer 2 serves to protect the nanofiber layer 2. The second base material 3 may be a nonwoven fabric of any one of PE, PET, Co-PE / PET, and PU. , A fiber diameter of 0.1 to 100 mu m, and a thickness of 0.1 to 1.1 mm may be used, but the present invention is not limited thereto.

The filter of the present invention configured as described above can cope with PM0.1, which is difficult to collect by conventional filter, and has a low pressure loss, so it is comfortable to breathe when applied to a mask, and energy consumption and noise It is advantageous in that the collection efficiency is not lowered and the manufacturing cost is low even if it is washed 100 times by the JIS 106 washing standard.

5 is a cross-sectional view of a filter according to a second embodiment of the present invention. As shown in Fig. 5, a first base material 1, a nano fiber layer 2 and a second base material 3 are laminated, The second base material 3 ', the nanofiber layer 2' and the first base material 1 'on the web having a network diameter of 5 to 50 nm and a network structure may be additionally laminated on the base material 3 of the base material 3. This is to increase the collection efficiency of the filter, in which the nanofiber layers 2 and 2 'are stacked in layers. Since the structures of the first base material 1 ', the nano fiber layer 2' and the second base material 3 'are the same as those of the first embodiment, It is omitted. However, it is natural that the unit weight of the nanofiber layers 2 and 2 'may be lowered to 0.05 to 5 g / m < 2 > in the second embodiment as compared with the first embodiment. Here, the unit weight of the nano fiber layer 2 or 2 'is for the purpose of illustration, and the nano fiber layer 2' is not limited thereto.

6 is a cross-sectional view of a filter according to a third embodiment of the present invention. As shown in Fig. 6, a first base material 1, a nano fiber layer 2 and a second base material 3 are laminated, A web nanofiber layer 2 'having a fiber diameter of 5 to 50 nm and a network structure may be further laminated between the fibrous layer 2 and the second substrate 3. [ It is also possible to lower the unit weight of the nanofiber layers 2 and 2 'in comparison with the first embodiment. In this case, the pressure loss is the lowest and the collecting efficiency is the most excellent as compared with the first and second embodiments.

In addition, a binder layer may be formed on the side of the first substrate 1 (1 '), the second substrate 2 (2'), or both of the nanofiber layers (2) and 2 '. At this time, the binder layer is for fixing the nanofibers, and an acrylic binder having a low viscosity may be used.

Hereinafter, a method for manufacturing a filter using nanofibers according to the present invention will be described in detail. However, in order to avoid redundant description, the description of the configuration described in the filter is omitted.

A method of manufacturing a filter using nanofibers according to the present invention comprises the steps of: preparing a fiber precursor by using a nanofiber manufacturing apparatus of a zeta spinning manufacturing method, And laminating the second base material (3) to the nanofiber side of the first base material (1) from which the nanofibers have been collected.

That is, as described above, the fiber precursor is collected into nanofibers of the web having a fiber diameter of 5 to 50 nm and a network structure on the first substrate 1 by using the nanofiber manufacturing apparatus of the jet spinning manufacturing method. In the nanofiber manufacturing apparatus, the base material provided in the collector is used as the first base material (1) of the filter. This is explained in detail in the inventor's prior art patent. At this time, the fiber precursor is preferably polyethersulfone, and it is preferable to use the fiber precursor in a solvent. At this time, usable solvents are fully described in the prior art filter as well as the inventor's prior art patent.

Next, the second base material 3 is laminated on the nanofiber side of the first base material 1 from which the nanofibers are collected. At this time, the laminating method is general in the field to which this technique belongs, and a description thereof will be omitted.

Further, in order to manufacture a filter having the same structure as that of the second embodiment, the step of laminating two sheets of the laminate thus manufactured may be performed such that the second substrates 3 and 3 'are in contact with each other.

In order to manufacture a filter having the same structure as that of the third embodiment, a fiber precursor is formed on a first base material 1 by using a nanofiber manufacturing apparatus of the zeta spinning manufacturing method, and a web material having a fiber diameter of 5 to 50 nm and a network structure Collecting the fiber precursor into nanofibers of a web having a fiber diameter of 5 to 50 nm and a network structure on the second substrate 3 by using a nanofiber manufacturing apparatus of the zeta spinning production method; And laminating the first base material 1 on which the nanofibers are collected and the second base material 3 on which the nanofibers have been collected such that the respective nanofibers are in contact with each other.

Namely, as shown in Fig. 9, two nanofiber manufacturing apparatuses are arranged up and down, and the first substrate 1 and the second substrate 3 are supplied to the respective nanofiber manufacturing apparatuses to collect the nanofibers , And laminating the first base material (1) and the second base material (3) on which the nanofibers have been collected by a heater roll in the laminator.

Here, the first substrate 1 (1 '), the second substrate 3 (3'), or both may be coated with a binder on the side where the nanofibers are collected or abutted, (1 ') and the second substrate (3) (3') may be made of PE, PET, Co-PE / PET and PU.

The filter manufacturing method of the present invention as described above is advantageous in that the manufacturing process is simple, the manufacturing cost is low, and mass production is possible.

On the other hand, as described above, the filter of the present invention can be applied to a mask, and can be applied to the body of the mask as it is, or as a filter to be inserted into the body.

(Example 1)

Polyethersulfone was dissolved in methanol at a weight ratio of 1:10. Using a zeta spinning type nanofiber manufacturing apparatus, the first substrate (PET nonwoven fabric: fiber diameter: 2 탆, nonwoven fabric thickness: 0.3 mm) Respectively. Then, the second base PET nonwoven fabric: fiber diameter 2 mu m, nonwoven fabric thickness 0.3 mm) was laminated by a heater roll.

(Example 2)

Polyethersulfone was dissolved in methanol at a weight ratio of 1:10. Using a zeta spinning type nanofiber manufacturing apparatus, a first base material (PET nonwoven fabric: fiber diameter: 2 탆, nonwoven fabric thickness: 0.3 mm) Lt; / RTI > Then, polyethersulfone was dissolved in methanol at a weight ratio of 1:10. Using a zeta spinning type nanofiber manufacturing apparatus, a second unit (PET nonwoven fabric: fiber diameter: 2 m, nonwoven fabric thickness: 0.3 mm) Lt; / RTI > Then, the nanofibers were laminated to each other by a heater roll.

(Test Example 1)

The samples of Examples 1 and 2 were tested for their collecting efficiency by the ASTM F 2299 method. The results are shown in FIGS. 10 and 11 attached hereto.

As can be seen from FIG. 10 (the result of Example 1) and FIG. 11 (the result of Example 2), it was confirmed that the filter of the present invention exhibited the collecting efficiency corresponding to PM0.1. Here, FIG. 8 is an electron microscope photograph of fine contaminants collected in the nanofiber layer according to Example 1. FIG.

When the pressure loss of this sample (when a flow rate of 28.3 L / min was passed through the area of 49 cm 2 of the sample) was measured, the pressure loss was about 20 Pa in Example 1 and about 21 Pa in Example 2, Respectively.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. Therefore, the spirit of the present invention should not be construed to be limited to the above-described embodiments, and all of the equivalents or equivalents of the claims, as well as the claims of the following claims belong to the scope of the present invention.

1: first substrate 2: nanofiber layer
3: Second substrate

Claims (11)

A nanofiber-based filter comprising a first substrate, a nanofiber layer on a web having a fiber diameter of 5 to 50 nm and a network structure, and a second substrate laminated in this order.
The method according to claim 1,
The nano-
The fiber precursor is manufactured on the web by the nanofiber manufacturing apparatus of the zeta spinning manufacturing method,
The fiber precursor is polyethersulfone,
Wherein the first base material and the second base material are nonwoven fabric made of any one of PE, PET, Co-PE / PET, and PU.
3. The method of claim 2,
In the second substrate,
A second base material, a nanofiber layer on a web having a fiber diameter of 5 to 50 nm and a network structure, and a first base material are further laminated.
3. The method of claim 2,
Between the nanofiber layer having a fiber diameter of 5 to 50 nm and a network structure and the second substrate,
Wherein the nanofiber layer has a fiber diameter of 5 to 50 nm and a nanofiber layer on the web having a network structure is further interposed.
5. The method according to any one of claims 1 to 4,
Wherein a binder layer is formed on a side of the first base material, the second base material, or both of the first base material and the second base material in contact with the nanofiber layer.
Collecting a fiber precursor into nanofibers of a web having a fiber diameter of 5 to 50 nm and a network structure on a first substrate using a nanofiber manufacturing apparatus of a zeta spinning manufacturing method;
And laminating the second base material on the nanofiber side of the first base material from which the nanofibers are collected.
8. The method of claim 7,
After the laminating step,
Further comprising laminating two laminated layers of the laminated first substrate, the nanofiber, and the second substrate so that the second substrate is in contact with each other.
Collecting a fiber precursor into nanofibers of a web having a fiber diameter of 5 to 50 nm and a network structure on a first substrate using a nanofiber manufacturing apparatus of a zeta spinning manufacturing method;
Collecting the fiber precursor into nanofibers of a web having a fiber diameter of 5 to 50 nm and a network structure on a second substrate by using a nanofiber manufacturing apparatus of the zeta spinning manufacturing method;
And laminating the first base material on which the nanofibers are collected and the second base material on which the nanofibers are collected so that the respective nanofibers are in contact with each other.
9. The method according to any one of claims 6 to 8,
Wherein the first base material, the second base material, or both of the nanofibers are collected or coated with a binder on the side where the nanofibers are collected.
9. The method according to any one of claims 6 to 8,
The fiber precursor is polyethersulfone,
Wherein the first base material and the second base material are nonwoven fabrics of any one of PE, PET, Co-PE / PET, and PU.
A mask comprising the filter of any one of claims 1 to 4.

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