WO2006112563A2 - Filtre d'epuration de l'air et son procede de fabrication - Google Patents
Filtre d'epuration de l'air et son procede de fabrication Download PDFInfo
- Publication number
- WO2006112563A2 WO2006112563A2 PCT/KR2005/001135 KR2005001135W WO2006112563A2 WO 2006112563 A2 WO2006112563 A2 WO 2006112563A2 KR 2005001135 W KR2005001135 W KR 2005001135W WO 2006112563 A2 WO2006112563 A2 WO 2006112563A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- filter medium
- porous membrane
- medium according
- manufacturing
- membrane
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 39
- 238000004140 cleaning Methods 0.000 title abstract description 8
- 239000012528 membrane Substances 0.000 claims abstract description 96
- 238000000034 method Methods 0.000 claims abstract description 48
- 238000001523 electrospinning Methods 0.000 claims abstract description 28
- 239000000463 material Substances 0.000 claims abstract description 25
- 239000002121 nanofiber Substances 0.000 claims abstract description 25
- 230000008569 process Effects 0.000 claims abstract description 18
- 239000002245 particle Substances 0.000 claims abstract description 12
- 238000009987 spinning Methods 0.000 claims description 57
- 239000004745 nonwoven fabric Substances 0.000 claims description 29
- 238000009826 distribution Methods 0.000 claims description 20
- 239000002033 PVDF binder Substances 0.000 claims description 10
- -1 polyethylene terephthalate Polymers 0.000 claims description 10
- 229920002981 polyvinylidene fluoride Polymers 0.000 claims description 10
- 239000011148 porous material Substances 0.000 claims description 9
- 229920001577 copolymer Polymers 0.000 claims description 7
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 7
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 7
- 229920002678 cellulose Polymers 0.000 claims description 6
- 239000001913 cellulose Substances 0.000 claims description 6
- 239000000203 mixture Substances 0.000 claims description 6
- 229920002239 polyacrylonitrile Polymers 0.000 claims description 6
- 229920000131 polyvinylidene Polymers 0.000 claims description 5
- 229920000098 polyolefin Polymers 0.000 claims description 4
- 229920003171 Poly (ethylene oxide) Polymers 0.000 claims description 3
- 229920002319 Poly(methyl acrylate) Polymers 0.000 claims description 3
- 239000004952 Polyamide Substances 0.000 claims description 3
- 239000002202 Polyethylene glycol Substances 0.000 claims description 3
- 239000004642 Polyimide Substances 0.000 claims description 3
- 239000004734 Polyphenylene sulfide Substances 0.000 claims description 3
- 229920000297 Rayon Polymers 0.000 claims description 3
- 229920002301 cellulose acetate Polymers 0.000 claims description 3
- LYCAIKOWRPUZTN-UHFFFAOYSA-N ethylene glycol Natural products OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 claims description 3
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 claims description 3
- 238000010030 laminating Methods 0.000 claims description 3
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 3
- 229920002401 polyacrylamide Polymers 0.000 claims description 3
- 229920002647 polyamide Polymers 0.000 claims description 3
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 3
- 229920001223 polyethylene glycol Polymers 0.000 claims description 3
- 229920001721 polyimide Polymers 0.000 claims description 3
- 239000004926 polymethyl methacrylate Substances 0.000 claims description 3
- 229920000069 polyphenylene sulfide Polymers 0.000 claims description 3
- 229920002215 polytrimethylene terephthalate Polymers 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 229920002689 polyvinyl acetate Polymers 0.000 claims description 3
- 239000011118 polyvinyl acetate Substances 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 239000002964 rayon Substances 0.000 claims description 3
- 239000000835 fiber Substances 0.000 description 44
- 229920001410 Microfiber Polymers 0.000 description 26
- 239000003658 microfiber Substances 0.000 description 26
- 239000011521 glass Substances 0.000 description 15
- 239000002904 solvent Substances 0.000 description 8
- 230000006698 induction Effects 0.000 description 7
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 6
- YMWUJEATGCHHMB-UHFFFAOYSA-N Dichloromethane Chemical compound ClCCl YMWUJEATGCHHMB-UHFFFAOYSA-N 0.000 description 6
- 238000012856 packing Methods 0.000 description 6
- 229910052796 boron Inorganic materials 0.000 description 5
- 230000006870 function Effects 0.000 description 5
- 230000002776 aggregation Effects 0.000 description 4
- 238000004220 aggregation Methods 0.000 description 4
- 229920001519 homopolymer Polymers 0.000 description 4
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 4
- 239000004065 semiconductor Substances 0.000 description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 3
- FXHOOIRPVKKKFG-UHFFFAOYSA-N N,N-Dimethylacetamide Chemical compound CN(C)C(C)=O FXHOOIRPVKKKFG-UHFFFAOYSA-N 0.000 description 3
- 238000004378 air conditioning Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000002657 fibrous material Substances 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000003475 lamination Methods 0.000 description 3
- 229920005569 poly(vinylidene fluoride-co-hexafluoropropylene) Polymers 0.000 description 3
- 229920000642 polymer Polymers 0.000 description 3
- 229920007485 Kynar® 761 Polymers 0.000 description 2
- 102000002151 Microfilament Proteins Human genes 0.000 description 2
- 108010040897 Microfilament Proteins Proteins 0.000 description 2
- 229920002292 Nylon 6 Polymers 0.000 description 2
- 238000005452 bending Methods 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 229910052810 boron oxide Inorganic materials 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 238000011161 development Methods 0.000 description 2
- 230000018109 developmental process Effects 0.000 description 2
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- OXZOLXJZTSUDOM-UHFFFAOYSA-N fluoro 2,2,2-trifluoroacetate Chemical compound FOC(=O)C(F)(F)F OXZOLXJZTSUDOM-UHFFFAOYSA-N 0.000 description 2
- 239000010410 layer Substances 0.000 description 2
- 238000002844 melting Methods 0.000 description 2
- 230000008018 melting Effects 0.000 description 2
- 210000003632 microfilament Anatomy 0.000 description 2
- 239000012046 mixed solvent Substances 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 230000009467 reduction Effects 0.000 description 2
- BQCIDUSAKPWEOX-UHFFFAOYSA-N 1,1-Difluoroethene Chemical compound FC(F)=C BQCIDUSAKPWEOX-UHFFFAOYSA-N 0.000 description 1
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 1
- 229920006370 Kynar Polymers 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 230000009172 bursting Effects 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000011362 coarse particle Substances 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010036 direct spinning Methods 0.000 description 1
- 230000009977 dual effect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000005684 electric field Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000003912 environmental pollution Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 238000009940 knitting Methods 0.000 description 1
- 230000033001 locomotion Effects 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000002365 multiple layer Substances 0.000 description 1
- 244000052769 pathogen Species 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000002957 persistent organic pollutant Substances 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 241000894007 species Species 0.000 description 1
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- 238000009827 uniform distribution Methods 0.000 description 1
- 238000005406 washing Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
- B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
- B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
- B01D2239/0258—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanoparticles
Definitions
- the present invention relates to a filter medium having nano fibers capable of being used for air cleaning, and its manufacturing method.
- the filter medium which has a high-efficiency collection performance so as to remove suspended micropollutants, is generally used for HEPA (High efficiency particle Air) and ULPA (Ultra low penetration air) filters.
- HEPA High efficiency particle Air
- ULPA Ultra low penetration air
- Such a high-efficiency filter may collect low-density submicron particles at a significantly high collection efficiency (Military specifications and standards (U.S.): HEPA filter: 99.97 % for 0.3 D particle size; ULPA filter: at least 99.999 % for 0.1 D particle size).
- airflow resistance acts as an important factor. If the airflow resistance is high, the expected life span of a filter may become shorter due to continuous pressure applied to the filter medium, the air conditioning cost may be increased due to the pressure loss, and it may be difficult to breathe when the respirator is put on. Accordingly, a filter medium having a high collection efficiency as well as a low airflow resistance remains to be developed.
- the high-efficiency filter medium has been manufactured by various methods known in the art, for example a manufacturing method using a glass microfiber, a manufacturing method using a high-molecular microfiber by a melt-blown spinning process, and a manufacturing method using a porous polytetrafluorethylene.
- the filter medium of the glass microfiber has been widely used for a semiconductor clean room.
- its fiber diameter ranges from about 0.2 D to 2 D, and about at least 10 % by weight of boron oxide (B) ) is added to the glass materials so that its relatively lower viscosity/temperature relation can be promoted to micronize a glass fiber.
- B boron oxide
- the boron oxide reacts with a hydrogen fluoride (HF) vapor, used for washing the semiconductor wafer, to generate boron gas, which causes a serious defect in the semiconductor wafer.
- HF hydrogen fluoride
- the binder was used for adhesion between the glass mi- crofibers, but the binder has a problem that organic pollutants were generated at an early stage, and therefore the airflow resistance of a filter medium was increased due to its chemically unstable properties. Also in the case of the filter medium constituting the glass microfiber, the filter medium was bent to reduce the airflow resistance by increasing a surface area of the filter. At this time, the filter might be damaged at an early stage since cracks appear in a bending region.
- U.S. Patent Nos. 5,789,329, 6,277,777 and 6,358,871 disclose a method for manufacturing a filter medium, wherein boron is used in a lower amount, or substituted with other materials in manufacturing a glass microfiber.
- the low-boron glass microfiber filter and the boron-free glass microfiber filter medium were difficult to be manufactured and very expensive, and therefore its use was rather limited up to the present.
- a filter medium composed of polypropylene mi- crofibers using a melt-blown spinning process is a method for manufacturing a nonwoven fabric by discharging a molten high molecule solution at a high pressure through a micronozzle and applying high-temperature and high-pressured air around the nozzle to extend a high-molecular fiber. That is, U.S. Patent Nos. 6,123,752, 4,824,451, 5,273,565 and Korean Utility Model Registration No. 0289693 disclose a high-efficiency filter medium using such a melt-blown spinning process.
- the method for manufacturing a nonwoven fabric using the melt-blown spinning process is difficult to be commercialized since it has a problem of increasing the cost of the process for manufacturing a fiber having a mean fiber diameter of 2 D or less. Therefore, if a filter having a diameter of at least 2 D is use, it contributes to enhance the collection efficiency by electrifying constant voltage with the filter medium because its collection efficiency is not high. However, it has a problem that the electrified charges disappear with the passage of time, and therefore its collection efficiency was deteriorated.
- the melt-blown spinning process causes a problem on an aggregation rate between the microfibers upon their spinning, and therefore an effect of micronization of the fiber may be reduced, and local problems may appear in the aspect of collection efficiency due to ununiform distribution of the microfiber, and therefore its ununiform thickness distribution in manufacturing its membrane.
- the microfiber membrane prepared by the melt-blown spinning process has problems that its strength is deteriorated due to a short length of the single fiber, and detached materials are increased with the passage of time when it is used as the filter medium.
- a filter medium was bent to reduce the airflow resistance by increasing its surface area in the constant space upon manufacturing a filter.
- the filter medium constituting the glass microfiber component and the filter medium prepared by the melt-blown spinning process it is impossible to manufacture a filter having a value below the certain airflow resistance because the filter medium has a thickness of at least 380 D and also it may be bent in limited times within a certain space.
- U.S. Patent Nos. 5,507,847 and 6,302,934 disclose a method for manufacturing a filter medium by manufacturing a porous thin-film polytetrafluorethylene membrane, followed by laminating it with a polyolefin-based nonwoven fabric.
- the filter medium prepared by the process is considered to be the most ideal filter medium since it has a high collection efficiency, a low airflow resistance and a small thickness.
- the filter medium prepared by the process has a problem that it is difficult to use multiple species of the high molecules, and therefore the filter medium may not be used for various application, and also it is very expensive since it is made of only one kind of the high molecule polytetrafluorethylene.
- JP. Patent No. S57-147412 discloses a method for manufacturing a filter medium with a low air resistance value whose fiber diameters are dually separated by mixing 0.1 D to 2 D of microfibers with fibers having 2 to 10 times thickness of the microfibers using a melt-blown spinning process, wherein the fiber with 2 to 10 times thickness of the microfibers is included at an amount of at most 30 %, more favorably 2 to 20 %, to prevent a fiber having a relatively thicker diameter from being aggregated between the microfibers.
- the patent also relates to a manufacturing method using the melt-blown spinning process, and the problems of the increased manufacturing cost due to micronization of the fiber and the ununiform distribution of the microfibers are not fundamentally solved in the manufacturing method. Disclosure of Invention Technical Problem
- the present invention is designed to solve the problems of the prior art, and therefore it is an object of the present invention to provide a filter medium having a high-efficiency collection performance as well as a low airflow resistance, and a method for manufacturing the filter medium.
- a filter medium includes a porous membrane in which a fiber is cut ul- trafinely and stacked.
- a porous membrane in which a fiber is cut ul- trafinely and stacked.
- the filter medium may maintain the high collection efficiency, as well as the low airflow resistance when optimal conditions for the fibrous porous membrane are set by adjusting diameter of the component fiber, its membrane porosity and its thickness.
- the diameter of the component fiber, its membrane porosity and its thickness show the same effect in the collection efficiency of the fibrous filter medium since thethree factors are in proportion or in inverse proportion to each other.
- the most important factor is the membrane porosity
- the next is the fiber diameter and the thickness in order since the 3 factors do not show the same effect in the airflow resistance. That is, the airflow resistance is mainly affected by the membrane porosity.
- the porosity and the thickness are reduced due to aggregation between the stacked fibers. Reduction of such porosity functions as the more important factor than reduction of the thickness, which causes a relatively higher airflow resistance.
- a filter medium which may reduce the airflow resistance while maintaining collection efficiency similar to that of the filter medium prepared previously, may be manufactured by adding component fibers having more thicker diameter than that of the microfiber to the microfibrous porous membrane. It is supposed that this results from the fact that the porosity is increased although its thickness is increased, and therefore its airflow resistance is reduced since a relatively thicker fiber functions to prevent aggregation between mi- crofibers and secure a space between the microfibers.
- microfiber When the microfiber is manufactured using such an electrospinning process, fiber diameter distribution is varied according to a kind of high molecules, their weight ratio, a compositional ratio of solvents, discharge capacity of such a high molecule solution, and voltage applied to a nozzle. Accordingly, the parameters should be suitably adjusted to manufacture a microfiber having the desired physical properties.
- a filter medium according to the present invention includes air-permeable supporting materials and a porous membrane.
- the filter medium may be formed into a 2-layer structure in which the porous membrane is stacked on the air- permeable supporting materials; a 3 -layer structure in which porous membrane is interposed between the air-permeable supporting materials; or a multiple-layer structure in which the air-permeable supporting materials and the porous membrane are stacked alternately.
- the porous membrane is manufactured by an electrospinning apparatus as shown in
- Fig. 1 is composed of nano fiber webs having a collection efficiency of at least 99.9 % for the particle ranging from 0.1 D to 0.3 D in size, and an airflow resistance of 30
- packing density of a porous membrane, diameter and thickness of a fiber should be suitably adjusted so as to manufacture a fiber having an excellent collection efficiency as well as a low airflow resistance.
- the inventors manufactured a web-shaped porous membrane having a uniform distribution by using a repulsive force between the fibers to prevent aggregation between the fibers by means of the electrospinning process.
- Membrane thickness of the porous membrane is preferably 5 D to 100 D, and more preferably 25 D to 100 D. The thickness of the porous membrane is suitably adjusted, considering the total thickness of the filter medium to be finally manufactured.
- porosity (or, porous ratio) of the porous membrane is preferably 80 % to 95
- packing density of the porous membrane is preferably 5 % to 20 %, and more preferably 10 % to 15 %.
- the porous membrane has a mean flow pore diameter of 0.5 to 2 D, and more preferably 0.9 to 1.5 D, and a maximum pore diameter of 1.5 to 10 D, and more preferably 2 to 6 D.
- the porous membrane preferably has the mean flow pore diameter or the maximum pore diameter, as described above, because its collection efficiency may be increased but its airflow resistance may be also increased if its pore diameter is extraordinarily small, while its collection efficiency may be reduced if its pore diameter is extraordinarily high.
- the diameter of the nano fiber constituting the porous membrane may have a single-range distribution of 50 to 700 D, or dually separated distributions of 50 to 700 D and 700 to l,500 D.
- the nano fiber having the diameter of 700 to 1,500 D desirably has 50 % by weight or less, based on the total weight of the web.
- Mechanical strength of the porous membrane should be designed to have a tensile strength of at least 50 Df/D in a machine direction, and a tensile strength of at least 20 Df/D in a lateral direction.
- the porous membrane is preferably formed by the electrospinning process, and then passed through a pressure roll so as to give strength and conformational stability to the membrane.
- the pressure preferably ranges from 0.1 Df/D to 10 Df/D upon pressuring the membrane.
- the porous membrane is obtained by electrospinning a high molecule solution selected from the group consisting of polyvinylidene fluoride, polyvinylidene fluoride- hexafluorpropylene copolymer, polyacrylonitrile, polyvinylidene chloride- aery lonitrile copolymer, polyethyleneoxide, polyurethane, polymethylacrylate, polymethylmethacrylate, polyacrylamide, polyvinylchloride, polyvinylacetate, polyvinylpyrolidone, polytetraethylene glycol diacrylate, polyethyleneglycol dimethacrylate, cellulose, cellulose acetate, rayon, polyamide, polyethylene terephthalate, polytrimethyleneterephthalate, polybutyleneterephthalate, polyimide, polyphenylenesulfide, or mixtures thereof.
- a high molecule solution selected from the group consisting of polyvinylidene fluoride, polyvinylidene fluoride- hexa
- the air-permeable supporting material is adhered to at least one side of the porous membrane and used to strengthen and protect the porous membrane and to filter coarse particles. Therefore, a handling property of the filter medium as well as its pro- cessability are improved if elements such as a filter medium unit are processed.
- the air-permeable supporting material should have high impact strength, tensile and bursting strengths, and a low thermal shrinkage.
- the air-permeable supporting material advisably has a lower pressure loss than that of the porous membrane.
- the air-permeable supporting materials are selected from the group consisting of a nonwoven fabric, a woven fabric, a mesh, a porous membrane, a knitting, etc., and a nonwoven fabric is especially preferred.
- the air-permeable supporting material is preferably a nonwoven fabric having a thickness of 80 to 120 D, and a porosity (or, porous ratio) of 10 to 40 %.
- the air-permeable supporting material preferably has a fiber diameter of 5 to 30 D, and a tensile strength of 100 to 200 Df/D in a machine direction and 50 to 100 Df/D in a lateral direction.
- polyethyleneterephthalate, polyolefin-based and cellulose-based nonwoven fabrics, or mixed nonwoven fabrics thereof is preferably used as the air- permeable supporting material according to the present invention.
- FIG. 1 is a perspective view showing an electrospinning apparatus for manufacturing a porous membrane according to the present invention. Best Mode for Carrying Out the Invention [45]
- a method for manufacturing a filter medium of the present invention will be described in detail referring to the accompanying drawings.
- an electrospinning apparatus 100 includes a supplying unit 110 for supplying a melt high-molecular material for fiber materials; a spinning unit 120 including a plurality of spinning nozzles 122 for discharging, in the form of charged filaments, a high molecule solution supplied from the supplying unit 110; a collector 130 spaced apart by a predetermined gap from the spinning nozzles 122 to accumulate, in a predetermined thickness, the filaments spun from the spinning unit 120; a control unit 140 mounted at least to the both sides of the spinning unit 120; an induction unit 150 mounted between the control unit 140 and the collector 130 so as to surround a filament stream S; and an air conditioning unit 160 for injecting air into a space between the spinning unit 120 and the collector 130 and evaporating solvents in the space to release the evaporated solvents outside.
- the supplying unit 110 includes a reservoir 112 for storing a solution in which a high-molecular material used for a fiber material is dissolved; a pump 114 for pressuring the solution stored in the reservoir 112 to quantitatively supply the solution into the spinning unit 120; and a distributor 116 for distributing the solution into each nozzle.
- the spinning unit 120 functions to spin the fiber material solution, supplied from the supplying unit 110 and in a charged state, in a direction of the collector 130 to form a microfilament.
- the high- voltage unit 170 outputs a DC voltage ranging from 10 kV to 120 kV.
- the spinning unit 120 includes at least one spinning nozzle pack 126 in which a plurality of the spinning nozzles 122 are arranged.
- the number of the spinning nozzles 122 constituting the spinning nozzle pack 126, or the number of the spinning nozzle pack 126 constituting the spinning unit 120 is determined in total consideration of size or thickness of a web to be manufactured, a production rate, etc.
- the collector 130 may be earthed so that it can have a potential difference against a voltage applied to the spinning unit 120 (see Fig. 1), or be applied with a negative (-) voltage.
- the collector 130 may be configured to stack the charged filaments discharged from the spinning unit 120, for example to move continuously in a conveyor-belt manner by a locomotion means such as a roller 132.
- the control unit 140 functions to prevent filament streams S spun from each spinning nozzle 122 from being escaped from a path, for example to prevent the filament streams S from being spread by repulsing each other, and the control unit 140 is mounted at least to both sides of the spinning nozzle pack 126 in a longitudinal direction.
- a voltage having the same polarity as the control unit 140 is applied to the induction unit 150.
- the induction unit 150 is installed around a charged filament strea m S being extended to guide a traveling direction of the stream.
- the induction unit 150 is provided in the form of a conductor plate or a conductor rod.
- the induction unit 150 is induced so that filaments can be stacked in a certain region of an upper surface of the collector 130 by electrifying with the same polarity as the charged filaments.
- the air conditioning unit 160 functions to evaporate solvents, dissolved in the charged filaments, in the space between the spinning unit 120 and the collector 130 to release the evaporated gases outside, and it has, for example, a solvent- intake/exhaust means such as an intake fan and an exhaust fan, and a plurality of air-inflow slots 162.
- the intake fan installed in an air intake passage, takes dry air from the outside of the apparatus to inject the dry air into the space between the spinning unit 120 and the collector 130 through the air-inflow slots 162 provided in an upper portion of the spinning nozzle pack 126.
- the introduced air evaporates solvents, dissolved in the charged filaments P spun from the spinning nozzle 122, and then is released outside through an air outlet passage in which the exhaust fan is mounted.
- a material solution stored in the supplying unit 110 is quantitatively supplied into the spinning unit 120 through the pump 114 and a distributor 116, the solution is charged by a current-carrying unit in each spinning nozzle pack 126 of the spinning unit 120.
- the current-carrying unit with it being provided inside an body of the spinning nozzle pack 126, is installed so as to prevent direct electrical interaction with a collector 130.
- the charged solution is discharged in the form of microfilament into the collector 130 while it is passed through a capillary tube of the spinning nozzle 122.
- the filaments are extended and spun to have a nano-grade diameter by a strong electric field formed between the collector 130 and the charged filaments.
- the stream escaping from the path is induced into a stacking region in the collector 130 by means of the induction unit 150 since the induction unit 150 is installed to an upper side of the collector 130 to surround the discharged stream.
- the filaments induced thus are continuously stacked on the collector 130 having a conveyor-belt or rotating-drum type, or stacked on an upper surface of an air- permeable supporting material 182, and therefore the filaments are manufactured in the form of a web-shaped porous membrane composed of nano fibers.
- the porous membrane according to the present invention composed of the nano fiber web is manufactured by spinning the charged filaments on the collector 17 of Fig. 1.
- a nonwoven fabric may be installed on the collector 17 as an air-permeable supporting material according to the present invention, and then the charged filaments may be spun on the nonwoven fabric to directly form a porous membrane on the nonwoven fabric.
- the web-shaped porous membrane manufactured by the electrospinning process forms long fibers and has a relatively narrower fiber diameter distribution. Also, because the electrospun nano fiber itself is charged and spun, it may not be aggregated due to a repulsive force between fibers upon its spinning, and the web-shaped porous membrane may be manufactured to have a uniform thickness distribution.
- Strength-supporting nonwoven fabrics are stacked on one or both side(s) of the porous membrane prepared above, and then a filter medium is manufactured through the lamination process where a predetermined pressure and a predetermined temperature are applied.
- strength-supporting nonwoven fabrics are stacked on a porous membrane of the nonwoven fabric in which the porous membrane is manufactured by a direct spinning process, and then a filter medium is formed through the lamination process where a predetermined pressure and a predetermined temperature are applied.
- the lamination is preferably carried out under a linear pressure of 0.1 to 30 Df/D at 3 to 70 0 C lower temperature than a melting point of the component high molecule.
- a spinning solution was conveyed from a tank to a spinning nozzle pack using a precision conveyer provided with a metering pump.
- a capillary-type nozzle whose tip has an inner diameter of 0.2 D, an outer diameter of 0.4 D and a capillary length of 10 D was installed in the spinning nozzle pack, and a distance between the nozzle tips was 26 D.
- a distance between the spinning nozzle packs was set to 20 D.
- the spinning nozzle pack reciprocally moves right and left at a rate of 6 m/min.
- Each spinning nozzle pack was connected to a high- voltage generator unit [DEL
- a web-shaped porous membrane was manufactured with a PVDF high molecule using the electrospinning apparatus as described above. That is, a high molecule solution, in which 15 % by weight of 100 % PVDF homopolymer [Elf Atochem North America, Inc., Product Name: Kynar 761] was dissolved in a mixed solvent including acetone and dimethylacetamide at a weight ratio of 5:5, was prepared, and then electrospun. The applied voltage was 28 kV, and its discharge capacity was 20 D/min per nozzle. Also, the membrane thickness was adjusted by increasing the time to be spun.
- the high molecule solutions were supplied into separate spinning nozzle packs and spun using the same electrospinning apparatus as in Embodiment 1.
- the high molecule solution including 100 % PVDF alone has a discharge capacity of 20 D/min per spinning nozzle, and the high molecule solution including 88 % PVDF copolymer has a discharge capacity of 20 D/min per spinning nozzle.
- Sample A represents Sample A of Table 2
- Sample B is a membrane integrated into the collector using a combined spinning process, whose the component fibers have a diameter of 100 to 400 D and a diameter of 700 to 1,000 D, with theirs thin diameter and thick diameter mingled each other.
- the manufactured membrane had a thickness of 30 D.
- For Sample C its thickness was 50 D under the same condition as in Sample B.
- the weight ratio of the component fiber with a relatively larger diameter was increased to 60 % by weight by increasing the discharge capacity of the PVDF-HFP copolymer to 40 D/min under the same condition as in Sample C.
- the optimal membrane was manufactured in the case of Sample C, and the web having the highest collection efficiency and the low airflow resistance might be manufactured if the ratio of the fiber with the relatively larger diameter was set to less than 50 % by weight.
- a web-shaped porous membrane was manufactured with a PAN high molecule using the electrospinning apparatus of Fig. 1. That is, a high molecule solution, prepared by dissolving 12 % by weight of 100 % PAN homopolymer [Polyscience, Inc., Product Name: Poly(acrylonitrile)] in a 100 % solvent of dimethylacetamide, was electrospun. At this time, a discharge capacity per spinning nozzle was 50 D/min. A distance of the tip and the collector was 20 D.
- the component fiber of the membrane integrated in the collector had a diameter of 100 to 700 D, and the manufactured membrane had a porosity of 80 % and a thickness of 30 D. Its collection efficiency was 99.993 % for 0.3 D particle size, and its airflow resistance value was 25 DH 2O at 20 SCFH.
- a web-shaped porous membrane was manufactured with a Nylon 6 high molecule using the aforementioned electrospinning apparatus. That is, a high molecule solution, prepared by dissolving 12 % by weight of 100 % Nylon 6 homopolymer in a solvent containing tetrafluoroacetic acid (TFA) and dichloromethane (DCM) at a weight ratio of 5:5, was electrospun. At this time, a discharge capacity per spinning nozzle was 50 D/min. A distance of the tip and the collector was 20 D.
- TFA tetrafluoroacetic acid
- DCM dichloromethane
- the component fiber of the membrane integrated in the collector had a diameter of 100 to 500 D, and the manufactured membrane had the porosity of 80 % and the thickness of 30 D.
- Airflow resistance was measured in the range of 20 to 200 SCFH (Standard cubic feet per hour). At this time, the measured area had a diameter of 81.6 D, and the airflow resistance value was expressed in a unit of DHO.
- the filter medium for air cleaning according to the present invention has a web- shaped porous membrane composed of nano fibers integrated using the electrospinning apparatus.
- the web-shaped porous membrane composed of the nano fibers according to the present invention has a uniform fiber diameter distribution, a high-efficiency collection performance and a low airflow resistance.
- performance of the filter may be improved since the airflow resistance may be more reduced by dually separating the fiber diameter distribution and further reduced by bending the fiber in a certain space due to its thin thickness to increase its surface area when the filter is manufactured.
- the strength of the filter medium may be improved by coupling the strength-supporting nonwoven fabric with one or both side(s) of the web-shaped porous membrane composed of the nano fibers manufactured by the electrospinning process.
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- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Filtering Materials (AREA)
- Separation Using Semi-Permeable Membranes (AREA)
- Nonwoven Fabrics (AREA)
Abstract
La présente invention se rapporte à un milieu filtrant pouvant être utilisé pour l'épuration de l'air, ainsi qu'à son procédé de fabrication. Ce milieu filtrant pour l'épuration de l'air conforme à la présente invention est un milieu filtrant comportant une membrane poreuse composée d'un voile de nanofibres selon un processus d'électrofilage ('electrospinning'); et une matière de support perméable à l'air stratifiée sur au moins un côté de la membrane poreuse, ladite membrane poreuse ayant un rendement de collecte d'au moins 99,9 % pour les particules ayant une taille comprise entre 0,1 D et 0,3 D, et une résistance à la circulation d'air inférieure ou égale à 30H2O à 20SCFH.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/KR2005/001135 WO2006112563A2 (fr) | 2005-04-20 | 2005-04-20 | Filtre d'epuration de l'air et son procede de fabrication |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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PCT/KR2005/001135 WO2006112563A2 (fr) | 2005-04-20 | 2005-04-20 | Filtre d'epuration de l'air et son procede de fabrication |
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WO2006112563A2 true WO2006112563A2 (fr) | 2006-10-26 |
WO2006112563A3 WO2006112563A3 (fr) | 2008-04-03 |
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PCT/KR2005/001135 WO2006112563A2 (fr) | 2005-04-20 | 2005-04-20 | Filtre d'epuration de l'air et son procede de fabrication |
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Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8584871B2 (en) | 2007-05-30 | 2013-11-19 | Dow Global Technologies Llc | High-output solvent-based electrospinning |
CN105135542A (zh) * | 2015-08-27 | 2015-12-09 | 张小江 | 一种设有纳米纤维过滤膜的空气净化器 |
EP2321029B1 (fr) | 2008-07-18 | 2016-02-24 | Clarcor INC. | Milieu filtrant à plusieurs composants avec un accessoire de nanofibres |
EP3056598A4 (fr) * | 2013-10-07 | 2016-10-26 | Finetex Ene Inc | Filtre comprenant une nanofibre et son procédé de fabrication |
WO2018005965A1 (fr) * | 2016-07-01 | 2018-01-04 | Hollingsworth & Vose Company | Milieux filtrants multicouches contenant des électrets |
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US6395046B1 (en) * | 1999-04-30 | 2002-05-28 | Fibermark Gessner Gmbh & Co. | Dust filter bag containing nano non-woven tissue |
KR20030031512A (ko) * | 2003-02-10 | 2003-04-21 | 김기동 | 공기 정화용 탄소 나노소재 복합 허니컴 필터 |
US6746517B2 (en) * | 2000-09-05 | 2004-06-08 | Donaldson Company, Inc. | Filter structure with two or more layers of fine fiber having extended useful service life |
KR20050009974A (ko) * | 2004-12-30 | 2005-01-26 | 이재근 | 기능성 나노섬유를 이용한 나노섬유 필터 및 나노섬유필터의 제조방법 |
US6872311B2 (en) * | 2002-01-31 | 2005-03-29 | Koslow Technologies Corporation | Nanofiber filter media |
-
2005
- 2005-04-20 WO PCT/KR2005/001135 patent/WO2006112563A2/fr active Application Filing
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
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US6395046B1 (en) * | 1999-04-30 | 2002-05-28 | Fibermark Gessner Gmbh & Co. | Dust filter bag containing nano non-woven tissue |
US6746517B2 (en) * | 2000-09-05 | 2004-06-08 | Donaldson Company, Inc. | Filter structure with two or more layers of fine fiber having extended useful service life |
US6872311B2 (en) * | 2002-01-31 | 2005-03-29 | Koslow Technologies Corporation | Nanofiber filter media |
KR20030031512A (ko) * | 2003-02-10 | 2003-04-21 | 김기동 | 공기 정화용 탄소 나노소재 복합 허니컴 필터 |
KR20050009974A (ko) * | 2004-12-30 | 2005-01-26 | 이재근 | 기능성 나노섬유를 이용한 나노섬유 필터 및 나노섬유필터의 제조방법 |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US8584871B2 (en) | 2007-05-30 | 2013-11-19 | Dow Global Technologies Llc | High-output solvent-based electrospinning |
EP2321029B1 (fr) | 2008-07-18 | 2016-02-24 | Clarcor INC. | Milieu filtrant à plusieurs composants avec un accessoire de nanofibres |
EP3056598A4 (fr) * | 2013-10-07 | 2016-10-26 | Finetex Ene Inc | Filtre comprenant une nanofibre et son procédé de fabrication |
CN105135542A (zh) * | 2015-08-27 | 2015-12-09 | 张小江 | 一种设有纳米纤维过滤膜的空气净化器 |
WO2018005965A1 (fr) * | 2016-07-01 | 2018-01-04 | Hollingsworth & Vose Company | Milieux filtrants multicouches contenant des électrets |
Also Published As
Publication number | Publication date |
---|---|
WO2006112563A3 (fr) | 2008-04-03 |
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