KR20210109555A - air filter - Google Patents

Abstract

Provided is an air filter filled with a filler in charge of activation, which improved adsorption efficiency and durability while suppressing an increase in pressure loss. The air filter of the present invention is a planar air filter having a first surface and a second surface, and includes a corrugated honeycomb structure (1) dividing a plurality of cells (30) arranged in a planar direction, and the plurality of A plurality of porous fillers 50 filled in the cells 30 are provided, wherein the plurality of cells 30 include a plurality of smallest-diameter cells 31 and a plurality of large-diameter cells (first large-diameter cells 32 ). , second large-diameter cells 33), wherein the plurality of smallest-diameter cells is a cell having the smallest diameter of an inscribed circle, and the plurality of large-diameter cells has an inscribed circle diameter of an inscribed circle of the plurality of smallest-diameter cells. a cell larger than the diameter of , wherein the ratio of the number of the smallest-diameter cells (31) filled with the filler to the number of the smallest-diameter cells (31) is 50% or less, and occupied by the number of the large-diameter cells The proportion of the number of large-diameter cells filled with filler is 25-100%.

Description

air filter

The present invention relates to an air filter used for purposes such as deodorization.

This application claims priority on the basis of Application No. 201910020245.3, filed with the State Intellectual Property Office of China on January 9, 2019, the content of which is incorporated herein by reference.

As an air filter used for the purpose of deodorization or the like in an air cleaner or the like, a corrugated honeycomb structure in which a plurality of cells is constituted by alternately overlapping a plurality of liner members and a plurality of corrugated members is known.

The air to be treated is purified by adsorbing odor components and the like to the corrugated honeycomb structure while passing through the cell.

As a material of the corrugated honeycomb structure, paper to which an adsorbent is attached or contained is usually used.

Further, for the purpose of improving adsorption efficiency and durability, a deodorizing filter in which cells of a corrugated honeycomb structured body are filled with activated carbon or the like has also been proposed (Patent Document 1).

Japanese Patent Laid-Open No. 2003-47649

However, as in Patent Document 1, in order to fill the cell with activated carbon or the like, a somewhat large cell is required. In this case, the air to be treated cannot sufficiently contact the corrugated honeycomb structured body while passing through the cell, making it difficult to exhibit the adsorption performance with immediate effect, which is an advantage of the corrugated honeycomb structured body.

When activated carbon or the like is made fine, it is possible to charge the cell without making it too large. However, in that case, the cell is clogged with fine activated carbon or the like, and the pressure loss becomes very high.

For this reason, as in Patent Document 1, an air filter in which cells of a corrugated honeycomb structure are filled with activated carbon or the like has not been put to practical use.

The present invention has been made in view of the above circumstances, and an object of the present invention is to provide an air filter having improved adsorption efficiency and durability by filling with a filler such as activated carbon while suppressing an increase in pressure loss.

In order to achieve said subject, this invention employ|adopted the following structures.

[1] A planar air filter having a first surface and a second surface, comprising:

A corrugated honeycomb structure partitioning a plurality of cells arranged in a plane direction, and a plurality of porous fillers filled in the plurality of cells,

The plurality of cells consists of a plurality of smallest-diameter cells and a plurality of large-diameter cells,

The plurality of smallest-diameter cells are cells having the smallest diameter of the inscribed circle,

In the plurality of large-diameter cells, a diameter of an inscribed circle is larger than a diameter of an inscribed circle of the plurality of smallest-diameter cells,

The ratio of the number of the smallest diameter cells filled with the filler to the number of the smallest diameter cells is 50% or less,

The ratio of the number of the large-diameter cells filled with the filler to the number of the large-diameter cells is 25 to 100%.

[2] The air filter according to [1], wherein the ratio of the smallest-diameter cells to the plurality of cells is 10 to 90 area%.

[3] The corrugated honeycomb structure is configured by bonding a plurality of liner members and a plurality of corrugated members to each other;

The plurality of liner members have a linear shape when viewed from a direction perpendicular to the plane direction,

The plurality of corrugated members have a wavy shape in which peaks and valleys are repeated along a direction in which the liner member extends when viewed from a direction perpendicular to the plane direction,

The air filter according to [1] or [2], wherein the plurality of corrugated members include two or more types of corrugated members different in one or both of the height and pitch of the wave shape.

[4] The air filter according to [3], wherein the plurality of corrugated members include one or more pairs of corrugated members directly bonded to each other without interposing the liner member.

[5] The air filter according to any one of [1] to [4], wherein the adsorbent is held in the corrugated honeycomb structure.

[6] The air filter according to any one of [1] to [5], wherein the plurality of fillers are spherical.

[7] The air filter according to any one of [1] to [6], wherein the filler is activated carbon.

[8] The air filter according to any one of [1] to [7], wherein a breathable sheet is disposed on one or both of the first surface and the second surface.

According to the air filter filled with fillers, such as activated carbon, of this invention, adsorption efficiency and durability can be improved, suppressing an increase in pressure loss.

1 is a plan view of a corrugated honeycomb structure used in an air filter according to an embodiment of the present invention.
FIG. 2 is a partially enlarged view of the corrugated honeycomb structure of FIG. 1 .
3 is a cross-sectional view of an air filter according to an embodiment of the present invention.
4 is an enlarged photograph of an air filter according to the embodiment.

The air filter of the present invention includes a corrugated honeycomb structure that partitions a plurality of cells arranged in a plane direction, and a plurality of porous fillers filled in the plurality of cells.

1 is a view of a corrugated honeycomb structure 1 used for an air filter according to an embodiment of the present invention viewed from a direction perpendicular to the plane direction. The corrugated honeycomb structured body 1 is composed of a liner member 10 and a corrugated member 20. In Fig. 1 , the paper surface front side is the first surface 61, and the paper surface back side is the second surface side. It is a planar body used as the surface 62.

The thickness of the corrugated honeycomb structured body (the length in the depth direction of the cells of the corrugated honeycomb structured body described later) may be adjusted in the range of 5 to 100 mm, and is usually 5 to 50 mm.

As shown in FIG. 1 , the liner member 10 has a linear or substantially linear shape when viewed from a direction perpendicular to the plane direction, and is a thin band-shaped member having a width in the sheet thickness direction of FIG. 1 .

As shown in FIG. 1, in the corrugated member 20, a thin strip-shaped member is repeatedly bent, and peaks and valleys are formed along the direction in which the liner member 10 extends when viewed from a direction perpendicular to the plane direction. A member with a repeating wavy shape.

In the present embodiment, two types of corrugated members 20 are used: a small corrugated member 21 and a large corrugated member 22 . The pitch and the height of the large corrugated member 22 are larger than the pitch and the height of the small corrugated member 21 .

As shown in FIG. 2 , the valleys 21b of the small corrugated member 21 are adhered to one liner member 10 , and the peaks 21a are adhered to the other liner member 10 .

On the other hand, the valleys 22b of the large corrugated member 22 are adhered to one liner member 10, but the peaks 22a are not interposed with the other large corrugated member 10 through the other large corrugated member (10). 22) directly attached to the peak 22a.

1 and 2, in the corrugated honeycomb structured body 1, a plurality of cells 30 partitioned by a liner member 10 and a corrugated member 20 are formed so as to be arranged in a planar direction. .

In the present embodiment, a minimum-diameter cell 31 and two types of large-diameter cells (a first large-diameter cell 32 and a second large-diameter cell 33) are formed as the cell 30 .

The minimum diameter cell 31 is a space partitioned by the liner member 10 and the small corrugated member 21 . The first large-diameter cell 32 is a space partitioned by the liner member 10 and the large corrugated member 22 . In addition, the second large-diameter cell 33 is a space partitioned by a pair of large corrugated members 22 to which the peaks 22a are directly bonded to each other.

In FIG. 2 , the smallest inscribed circle 41 is an inscribed circle of the smallest-diameter cell 31 , the first large-diameter inscribed circle 42 is the inscribed circle of the first large-diameter cell 32 , and the second large-diameter inscribed circle 43 ) is the inscribed circle of the second large-diameter cell 33 .

Within these inscribed circles, the smallest diameter inscribed circle 41 has the smallest diameter, and the diameters of the first large-diameter inscribed circle 42 and the second large-diameter inscribed circle 43 are larger than the diameters of the minimum-diameter inscribed circle 41 . In addition, the diameter of the second large-diameter inscribed circle 43 is larger than the diameter of the first large-diameter inscribed circle 42 .

Since the minimum-diameter cell 31 inscribed by the minimum-diameter inscribed circle 41 has a small opening area, it is difficult to fill the filler, and the gas can pass smoothly. In addition, since the minimum-diameter cell 31 has a small opening area, the gas passing through the minimum-diameter cell 31 can sufficiently contact the liner member 10 and the sorbate member 21, and odor components and the like are removed. It is easy to make it adsorb|suck to these members.

In addition, the first large-diameter cells 32 and the second large-diameter cells 33 inscribed with an inscribed circle having a larger diameter than the minimum-diameter inscribed circle 41 are filled with a filler having a sufficient size that is difficult to enter into the minimum-diameter cell 31 . can do. For this reason, adsorption efficiency and durability can be improved by a filler, suppressing the rise of a pressure loss.

In addition, as in the present embodiment, when a plurality of types of large-diameter cells (first large-diameter cells 32 and second large-diameter cells 33) having different diameters of inscribed circles exist, an effect of suppressing an increase in pressure loss It is possible to prevent clogging from occurring at the same time when used for a long period of time with higher . In addition, it is easy to fill a plurality of types of fillers having different sizes. For this reason, it is easy to use several types of fillers with different adsorption characteristics.

Ratio of the total area of the smallest-diameter cells 31 to the total area (100%) of the cells 30 in the corrugated honeycomb structured body 1 (plural cells 30 of the corrugated honeycomb structured body 1) The ratio (meaning area %) of the minimum-diameter cells 31 occupied in ? is preferably 10 to 90%, more preferably 15 to 75%, and still more preferably 20 to 50%.

If the said ratio is more than a preferable lower limit, air permeability is ensured and it is easy to suppress the rise of a pressure loss. Moreover, if the said ratio is below a preferable upper limit, it is easy to fill the 1st large-diameter cell 32 and the 2nd large-diameter cell 33 with a sufficient amount of filler.

The total area of the first large-diameter cell 32 and the total area of the second large-diameter cell 33 may be appropriately adjusted according to the size-specific compounding amount of the filler to be filled.

The minimum-diameter cells 31 , the first large-diameter cells 32 , and the second large-diameter cells 33 are preferably distributed as evenly as possible in the direction in which the liner members 10 are arranged. Thereby, it is possible to partially prevent the pressure loss from increasing.

It is preferable that the diameter of the minimum diameter inscribed circle 41 is 0.5-3 mm, It is more preferable that it is 1-2.5 mm, It is more preferable that it is 1.5-2.0 mm.

When the diameter of the minimum diameter inscribed circle 41 is equal to or greater than the lower limit of the preferred range, it is difficult to prevent passage of gas through the minimum diameter cell 31 . When the diameter of the minimum diameter inscribed circle 41 is equal to or less than the upper limit of the preferable range, the gas passing through the minimum diameter cell 31 is sufficiently brought into contact with the corrugated honeycomb structure 1 to remove odor components and the like from the corrugated honeycomb structure ( 1) can be adsorbed.

The diameters of the first large-diameter inscribed circle 42 and the second large-diameter inscribed circle 43 are preferably 1.1 times or more of the diameter of the minimum diameter inscribed circle 41, and more preferably 1.5 times or more.

When it is more than the said preferable ratio, it is easy to fill the 1st large-diameter cell 32 and the 2nd large-diameter cell 33 with a filler, suppressing the filling of the filler with respect to the minimum-diameter cell 31.

It is preferable that the diameter of the 1st large-diameter inscribed circle 42 is 1-6 mm, It is more preferable that it is 1-4 mm, It is more preferable that it is 2-3 mm.

If the diameter of the first large-diameter inscribed circle 42 is equal to or greater than the lower limit of the preferred range, the first large-diameter cell 32 is easily filled with a filler. When the diameter of the first large-diameter inscribed circle 42 is equal to or less than the upper limit of the preferred range, the area of the first large-diameter cell 32 is not excessive, and the strength of the corrugated honeycomb structure 1 is easily secured.

It is preferable that the diameter of the 2nd large-diameter inscribed circle 43 is 1.1 times or more of the diameter of the 1st large-diameter inscribed circle 42, and it is more preferable that it is 1.25 times or more.

If it is more than the above-mentioned preferred ratio, it is easy to fill the fillers of different sizes using the first large-diameter cell 32 and the second large-diameter cell 33 .

The pitch and height of the corrugated shape of the small corrugated member 21 can be determined such that the diameter of the minimum diameter inscribed circle 41 is the above-mentioned preferred value.

Specifically, it is preferable that it is 2-7 mm, and, as for the pitch of the wave shape of the small corrugated member 21, it is more preferable that it is 3-6 mm.

Moreover, it is preferable that it is 0.5-3 mm, and, as for the height of the corrugated shape of the small corrugated member 21, it is more preferable that it is 1-2.5 mm.

On the other hand, the height of the corrugated shape of the small corrugated member 21 is the distance in the height direction between the valleys 21b and the peaks 21a on one surface of the small corrugated member 21 , and the height direction is the liner member (10) is the direction orthogonal to

In addition, the pitch and height of the corrugated shape of the large corrugated member 22 can be determined so that the diameters of the 1st large-diameter inscribed circle 42 and the 2nd large-diameter inscribed circle 43 may become the said preferable value.

Specifically, it is preferable that it is 4-12 mm, and, as for the pitch of the wave shape of the large corrugated member 22, it is more preferable that it is 5-10 mm.

Moreover, it is preferable that it is 2-6 mm, and, as for the height of the wave shape of the large corrugated member 22, it is more preferable that it is 2.5-5 mm.

On the other hand, the height of the corrugated shape of the large corrugated member 22 is the distance in the height direction between the valleys 22b and the peaks 22a on one surface of the large corrugated member 22, and the height direction is the liner member (10) is the direction orthogonal to

The liner member 10 and the corrugated member 20 of the corrugated honeycomb structured body 1 are preferably composed of a base material and an adsorbent held by the base material.

The substrate is not particularly limited as long as it is a sheet-like substrate such as paper, nonwoven fabric, or plastic film, but a fiber substrate is preferable from the viewpoint of easy retention of the adsorbent. As a fiber base material, the paper base material which has a cellulose fiber as a main component, and the plastic base material which has a synthetic fiber as a main component are mentioned. Especially, the paper base material which has a cellulose fiber as a main component is preferable.

In addition, "it is used as a main component" means that the ratio with respect to the whole base material is 50 mass % or more.

Paper substrates are typically composed of pulp comprising cellulosic fibers. Examples of the pulp containing cellulose fibers include wood pulp and non-wood pulp. As wood pulp, softwood pulp, hardwood pulp, etc. are mentioned. As non-wood pulp, hemp pulp, kenaf pulp, bamboo pulp, etc. are mentioned.

Wood pulp may have passed through a cooking process and/or a bleaching process. In general, wood pulp is used by performing various cooking processes or bleaching processes in order to remove components other than cellulose from raw wood. In this invention, a cooking process and a bleaching process are not specifically limited, A well-known method can be used suitably.

These pulps may be used individually by 1 type, and may be used in combination of 2 or more type.

The paper substrate may further contain fibers other than the cellulose fibers. Examples of the other fibers include synthetic fibers such as rayon fibers, polyethylene fibers, polypropylene fibers and polyester fibers, inorganic fibers such as glass fibers, ceramic fibers and mineral fibers, and animal fibers.

The paper base material may contain internal additives such as a size agent, an intellectual strength enhancer, a colorant, a preservative, and a flame retardant. As an internal additive, a well-known thing can be used.

As a plastic base material, what has as a main component 1 or more types of synthetic fibers, such as a rayon fiber, a polyethylene fiber, a polypropylene fiber, and a polyester fiber, is mentioned, for example.

It is preferable that the basis weight of a base material is 10-500 g/m<2>, It is more preferable that it is 10-400 g/m<2>, It is more preferable that it is 10-300 g/m<2>.

It is preferable that a fiber base material is obtained by the papermaking method.

Examples of the adsorbent to be held on the substrate include activated carbon in particulate form, powder form, and fibrous form, zeolite such as mordenite, ferrierite, and molecular sieve, and known adsorbents such as silica gel and alumina gel. A chemical that reacts with the component to be removed (for example, a compound that reacts with ammonia or formaldehyde) may be supported on these adsorbents. In addition, a chemical reacting with the component to be removed may be directly supported on the substrate.

The adsorbent held on the substrate may be held inside the substrate, adhered to the surface, or present in both the interior and the surface.

The adsorbent held on the substrate may be internally added during papermaking, or may be applied or impregnated after papermaking.

Although there is no particular limitation on the manufacturing method of the corrugated honeycomb structure 1, the single-sided corrugated cardboard (hereinafter referred to as "small single-sided corrugated cardboard") in which the small corrugated member 21 is adhered to the liner member 10, and the liner member 10 It is preferable to manufacture by laminating and adhering a single-sided corrugated cardboard (hereinafter referred to as "multi-sided corrugated cardboard") to which the large corrugated member 22 is adhered to the ).

In the large-sided corrugated cardboard, the peak portions 22a of the pair of large corrugated members 22 are adhered to each other, and the pair of large corrugated members 22 are interposed between the pair of liner members 10, and the pair of large corrugated members are provided. A structure in which the peaks 22a of the gate member 22 are sandwiched in an adhered state (hereinafter referred to as an "X-structured flute". In this embodiment, the X-structured flute 70 in Fig. 2) is set as this X-structured flute. (70) It is preferable to laminate and adhere the small single-sided corrugated cardboard.

In the case of laminating and bonding the X-structured flute 70 and the small single-sided corrugated cardboard, the liner member 10 of the X-structured flute 70 and the liner 10 of the small single-sided corrugated cardboard may overlap. Further, the small single-sided corrugated cardboard member 21 side is adhered to the liner member 10 of the X-structured flute 70, and the small single-sided corrugated cardboard liner member 10 is different from the small single-sided corrugated cardboard liner member 10 ) may be overlapped, and may be laminated and adhered.

That is, when the corrugated honeycomb structure 1 is manufactured by laminating and adhering a small single-sided corrugated cardboard and an X-structured flute, a portion in which the liner member 10 constituting one single-sided corrugated cardboard exists alone, and a pair of single-sided corrugated cardboard A portion is formed in which the two liner members 10 constituting the .

3 is a schematic cross-sectional view of an air filter according to an embodiment of the present invention. In the air filter of FIG. 3, a plurality of porous fillers 50 are filled in the cells 30 of the corrugated honeycomb structure 1 shown in FIGS. 1 and 2, and the first surface ( On the 61 ) and the second surface 62 , the air permeable sheet 71 and the air permeable sheet 72 are arranged, respectively.

Since the filler 50 is porous, it has the ability to adsorb|suck removal components, such as an odor. Examples of the filler 50 include activated carbon in particulate form, powder form, and fibrous form, zeolite such as mordenite, ferrierite, and molecular sieve, silica gel, alumina gel, and the like. Among them, activated carbon is preferable, particulate activated carbon is more preferable, and spherical or substantially spherical activated carbon is particularly preferable.

The filler 50 may be loaded with a chemical that reacts with a component to be removed, such as an inorganic acid.

The filler 50 is preferably particulate, more preferably substantially spherical, and particularly preferably spherical. If it is spherical or substantially spherical, filling into the cell 30 is easy, and an appropriate gap is created between the liner member 10 and the corrugated member 20 that partition the cell 30, so that ventilation is easy to ensure.

It is preferable that it is 500-10000 micrometers, and, as for the average particle diameter of the filler 50, it is more preferable that it is 1000-5000 micrometers. On the other hand, the average particle diameter is measured by a mass average particle diameter method in accordance with JIS K 1474 (Activated carbon test method-average particle diameter measurement method).

The specific surface area of the filler 50 is preferably 600 to 2200 m 2 /g. The specific surface area is the BET specific surface area measured by the nitrogen gas adsorption method.

When the specific surface area of the filler 50 is equal to or more than the above-mentioned preferred lower limit, it is easy to exhibit adsorption performance of odor components and the like. Moreover, when the specific surface area of the filler 50 is below the said preferable upper limit, it is easy to maintain the intensity|strength of the filler 50.

The ratio (filling rate) of the number of the smallest-diameter cells 31 filled with the filler 50 to the number (100%) of the smallest-diameter cells 31 is preferably 50% or less, more preferably 25% or less, , more preferably 10% or less.

When the filling rate of the smallest-diameter cell 31 is below the preferable upper limit, it is easy to ensure air permeability.

In order to make the filling rate of the minimum-diameter cell 31 a preferable upper limit or less, the ratio of the filler 50 smaller in diameter than the minimum-diameter inscribed circle 41 to the filler 50 as a whole may be made low.

The lower limit of the filling factor of the smallest-diameter cell 31 may be 0%. That is, the minimum-diameter cell 31 does not need to be filled with the filler 50 .

On the other hand, the number of large-diameter cells filled with the filler 50 in the number (100%) of the large-diameter cells (in the case of the present embodiment, the first large-diameter cells 32 and the second large-diameter cells 33) It is preferable that it is 25 to 100 %, as for the ratio (filling factor) of , it is more preferable that it is 50 to 100 %, It is more preferable that it is 75 to 100 %.

When the filling rate of the large-diameter cell is equal to or more than the preferable lower limit, the adsorption efficiency and durability are likely to be improved by the filler 50 . If the filling rate of a large-diameter cell is below a preferable upper limit, a charging operation is easy.

On the other hand, in determining the filling rate, regardless of the size of the filler 50 , a cell in which even one is filled is assumed to be a filled cell.

FIG. 3 schematically shows an example in which a spherical small filler 51 and a large filler 52 larger than the small filler 51 are filled as the filler 50 .

The diameter of the small filler 51 is preferably larger than the smallest diameter inscribed circle 41 . This makes it difficult for the small filler 51 to fill the smallest-diameter cell 31 .

On the other hand, even if the diameter of the filler 50 is larger than the minimum diameter inscribed circle 41, the filler 50 etc. which became fragments in the minimum diameter cell 31 may be filled by a crack etc. by a crack.

Since the filler 50 is filled in the cell 30 , either diameter is smaller than the second large-diameter inscribed circle 43 . In addition, it is preferable that the diameter of the large filler 52 is larger than that of the first large diameter inscribed circle 42 . Thereby, it becomes easy to fill the 2nd large-diameter cell 33 with the large filler 52, and the filling rate of the 2nd large-diameter cell 33 can be improved.

The air permeable sheet 71 and the air permeable sheet 72 are made of air permeable material such as nonwoven fabric or mesh cloth. Rayon, polyester, nylon, etc. are mentioned as a material which comprises a nonwoven fabric, a mesh cloth, etc.

The air permeable sheet 71 and the air permeable sheet 72 are respectively adhered to the first surface 61 and the second surface 62 of the corrugated honeycomb structure 1 and disposed.

By positioning the air permeable sheet 71 and the air permeable sheet 72 , it is possible to prevent the filler 50 from falling off from the air filter. In addition, dust or the like can be removed from the gas passing through the air filter.

On the other hand, in FIGS. 1 and 2, the corrugated honeycomb structure 1 having the X-structured flute 70 is used, but having the X-structured flute 70 is not necessarily essential. For example, it may be a configuration in which three types of single-sided corrugated cardboard having different sizes are combined and laminated.

In addition, as shown in FIGS. 1 and 2, the large-diameter cell is not limited to two types, One type or three or more types may be sufficient as it.

Also, the shape of the cell 30 is not particularly limited.

1 and 2, the large corrugated member 22 and the small corrugated member 21 are configured to be different in both pitch and height, but a plurality of types of corrugated member 20 in which only one of the pitch and height differs. may be used.

In addition, as long as the cell 30 can contain cells of different sizes, one type of corrugated member 20 may be used. For example, a plurality of X-structured flutes prepared using one type of single-sided corrugated cardboard may be laminated.

In addition, the shape and size of the filler 50 are not limited to two types as shown in FIG. 3, Three or more types may be sufficient.

Example

[Example 1]

A glass fiber blended paper having a basis weight of 50 g/m2 (manufactured by Oji Ftex) was used as a liner base paper, and an adsorbent dispersion containing activated carbon, an inorganic adsorbent, a chemical adsorbent, etc. at a ratio of 200 g/L was impregnated to obtain a liner member.

Glass fiber blended paper (manufactured by Oji Ftex) with a basis weight of 50 g/m2 is used as a corrugated base paper, and is impregnated with an adsorbent dispersion containing activated carbon, inorganic adsorbent, chemical adsorbent, etc. did.

The corrugated base material was subjected to a corrugation process to form a corrugated member, and then bonded to a liner member to form a single-sided corrugated cardboard. For single-sided corrugated cardboard, two types of small single-sided corrugated cardboard and large single-sided corrugated cardboard having different heights and pitches were prepared. A small corrugated member having a pitch of 4.9 mm and a height of 2 mm was used for the small single-sided corrugated cardboard, and a large corrugated member having a pitch of 5.9 mm and a height of 3 mm was used for the large-sided corrugated cardboard.

The two obtained large-sided corrugated cardboard sheets were joined together with the ridges of the large-sided corrugated cardboard and adhered so that the liner members were on both sides, and the corrugated members of the small-sided corrugated cardboard were adhered to the liner members on both sides, respectively, to obtain a laminate. A plurality of these laminates were stacked to obtain a corrugated honeycomb structured body equivalent to that shown in FIG. 1 . On the other hand, each single-sided corrugated cardboard was laminated by aligning the ridge line direction of the corrugated member. In addition, the thickness (length in the depth direction of a cell) of the corrugated honeycomb structure was set to 15 mm.

A breathable sheet was adhered to one side of the obtained corrugated honeycomb structure and, from the other side, 23 g of Osaka Gas Chemical Co., Ltd. chemical-supported spherical activated carbon (average particle size 2 mm, BET specific surface area 930 m 2 /g) as a filler was charged Thereafter, the air-permeable sheet was also adhered to the other surface to obtain the air filter of Example 1.

As the air-permeable sheet, a polyester mesh (with a scale interval of 1 mm) was used.

[Comparative Example 1]

An air filter was obtained in the same manner as in Example 1, except that only the large-sided corrugated board used in Example 1 had a structure in which a plurality of layers were laminated by adhering a liner member and a corrugated member to each other. On the other hand, a plurality of large-sided corrugated cardboard was laminated by aligning the ridgeline direction of the corrugated member.

[Pressure loss evaluation]

After putting the obtained air filter in the resin case of the opening of 100 mm x 100 mm, it set in the wind tunnel apparatus, and the pressure loss at the time of each line speed of 0.5 m/s, 1.0 m/s, 1.5 m/s, and 2.0 m/s. was measured.

A result is shown in Table 1.

As shown in Table 1, it turned out that the air filter of Example 1 was excellent compared with the comparative example 1 in the point of a pressure loss.

4 is an enlarged photograph taken from the other side of the air filter of Example 1 before the air-permeable sheet is adhered to the other side. As shown in Fig. 4, it was confirmed that the minimum-diameter cell was hardly filled with a filler, and the filling rate did not exceed 50%. Moreover, it was confirmed that the filler could be filled in most of the large-diameter cells, and the filling ratio was at least 25% or more. In particular, the filling rate of the large-diameter cell (corresponding to the second large-diameter cell 33 in Fig. 1) having a large inscribed circle diameter was high.

That is, in Example 1, it was confirmed that a filler such as activated carbon was filled while suppressing an increase in pressure loss by securing a cell through which gas easily passes without being filled with a filler.

[Comparative Example 2]

In Example 1, an air filter was obtained in the same manner as in Example 1, except that spherical activated carbon was not filled.

[Evaluation of Formaldehyde Removal Performance]

Adopting an evaluation test based on the Chinese GB standard (GB/T 18801-2015), the clean air supply rate (CADR) and clean air supply rate after a formaldehyde load in the air filter by a simple test with a laboratory size of 1 m By measuring the retention rate (CADR retention rate), formaldehyde removal performance evaluation was performed.

(measurement of initial CADR)

An air purifier fan equipped with the air filter obtained in Example 1 and Comparative Example 2 was set, and the air purifier fan was sealed in a test room so that the concentration of formaldehyde in the air was 1 ppm, and the air purifier fan was subjected to the same flux (LV) ) of 1.0 m/s, and using a formaldehyde meter (htv), measure the concentration of formaldehyde in air at 5-minute intervals for 60 minutes, and from the relationship between the elapsed time and the concentration of formaldehyde in air, the initial clean air The feed rate (initial CADR) was measured.

A result is shown in Table 2.

(Measurement of CADR after loading with formaldehyde)

Next, an air purifier fan equipped with the air filter obtained in Example 1 and Comparative Example 2 was set, and the filter paper on the volatilization fan was impregnated with a formaldehyde solution so that the mass of formaldehyde was 20 mg, and the air purifier fan and volatilization The fan was operated and left to stand for 12 hours.

In addition, an air purifier fan equipped with an air filter subjected to the above treatment is set, and the air purifier fan is sealed in a test room (1 m 3 ) so that the concentration of formaldehyde in the air is 1 ppm, and the air purifier fan has the same flux as the target air purifier. (LV) of 1.0 m/s, and using a formaldehyde meter (htv), measure the concentration of formaldehyde in air at 5-minute intervals for 60 minutes. From the relationship between the elapsed time and the concentration of formaldehyde in the air, The clean air supply rate (CADR) after aldehyde 20 mg/enteral load was measured.

From the relationship between the initial clean air supply rate (initial CADR) and the clean air supply rate (CADR) after the formaldehyde 20 mg/enteral load, the clean air supply rate retention rate (CADR retention rate) after the 20 mg load was calculated.

As shown in Table 2, the air filter of Example 1 showed high adsorption performance not only in the initial stage but also after adsorption of 20 mg equivalent.

The air filter filled with fillers, such as activated carbon, of this invention can improve adsorption efficiency and durability, suppressing an increase in pressure loss.

The air filter of this invention aims at the removal of odor components, harmful components, etc., and can be used for an air cleaner, an air conditioner, a dehumidifier, etc.

1 Colgate honeycomb structure
10 No liner
20 Colgate absence
21 Socolgate absence
22 No anticolgate
30 cells
31 Minimum Diameter Cell
32 first large-diameter cell
33 second large-diameter cell
41 Minimum diameter inscribed circle
42 First large diameter inscribed circle
43 2nd large diameter inscribed circle
50 filler
51 small filler
52 anti-filler
61 page 1
62 side 2
71 breathable seat
72 breathable seat

Claims (8)

A surface-shaped air filter having a first surface and a second surface, the air filter comprising:
A corrugated honeycomb structure partitioning a plurality of cells arranged in a plane direction, and a plurality of porous fillers filled in the plurality of cells,
The plurality of cells consists of a plurality of smallest-diameter cells and a plurality of large-diameter cells,
The plurality of smallest-diameter cells are cells having the smallest diameter of the inscribed circle,
In the plurality of large-diameter cells, a diameter of an inscribed circle is larger than a diameter of an inscribed circle of the plurality of smallest-diameter cells,
The ratio of the number of the smallest diameter cells filled with the filler to the number of the smallest diameter cells is 50% or less,
An air filter, characterized in that the ratio of the number of the large-diameter cells filled with the filler to the number of the large-diameter cells is 25 to 100%. The method of claim 1,
The air filter whose ratio of the said minimum-diameter cell occupied in the said some cell is 10-90 area%. 3. The method according to claim 1 or 2,
The corrugated honeycomb structure is configured by bonding a plurality of liner members and a plurality of corrugated members to each other,
The plurality of liner members have a linear shape when viewed from a direction perpendicular to the plane direction,
wherein the plurality of corrugated members have a wavy shape in which peaks and valleys are repeated along a direction in which the liner member extends when viewed from a direction perpendicular to the plane direction;
The plurality of corrugated members includes two or more types of corrugated members different in one or both of the height and pitch of the wave shape. 4. The method of claim 3,
The plurality of corrugated members includes at least one pair of corrugated members to which peaks are directly attached to each other without interposing the liner member. 5. The method according to any one of claims 1 to 4,
An adsorbent is held in the corrugated honeycomb structure. 6. The method according to any one of claims 1 to 5,
wherein the plurality of fillers are spherical. 7. The method according to any one of claims 1 to 6,
The filler is activated carbon. 8. The method according to any one of claims 1 to 7,
An air filter, wherein a breathable sheet is disposed on one or both of the first surface and the second surface.

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