WO2007011089A1 - Element filtrant utile pour epurer l'air, procede de preparation de ce dernier - Google Patents

Element filtrant utile pour epurer l'air, procede de preparation de ce dernier Download PDF

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Publication number
WO2007011089A1
WO2007011089A1 PCT/KR2005/002398 KR2005002398W WO2007011089A1 WO 2007011089 A1 WO2007011089 A1 WO 2007011089A1 KR 2005002398 W KR2005002398 W KR 2005002398W WO 2007011089 A1 WO2007011089 A1 WO 2007011089A1
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Prior art keywords
woven fabric
layer
meltblown
resin
filter
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Application number
PCT/KR2005/002398
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English (en)
Inventor
Gyu-Beom Gwag
Jae-Min Lee
Min-Hwan Chang
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Clean & Science Co., Ltd.
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Filing date
Publication date
Application filed by Clean & Science Co., Ltd. filed Critical Clean & Science Co., Ltd.
Publication of WO2007011089A1 publication Critical patent/WO2007011089A1/fr

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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
    • 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
    • B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
    • 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
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0618—Non-woven
    • 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
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0622—Melt-blown
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/02—Loose filtering material, e.g. loose fibres

Definitions

  • the present invention relates to a filter material for cleaning air from contaminants for an extended period of time and a process for preparing the same. More particularly, it relates to a filter material comprising one layer or two or more layer(s) with a density gradient, in which at least one layer is a final layer comprising a meltblown layer coated with a resin, and a process for preparing the same.
  • Background Art
  • an internal combustion engine is driven by supplying liquid fuel such as gasoline and diesel or gaseous fuel such as LPG to a combustion chamber, in which the fuel becomes into a gas mixture with oxygen in the air and undergoes combustion/ explosion.
  • liquid fuel such as gasoline and diesel or gaseous fuel such as LPG
  • LPG gaseous fuel
  • the air introduced to the engine to form the gas mixture contains foreign substances such as dust, which induces incomplete combustion, impeding smooth operation of au to mobiles or equipments.
  • the foreign substances may flow in to the engine and be piled on the cylinder wall of the engine, causing deterioration in durability of the engine.
  • Such filter medium comprises various types of filter paper which is technically designed in accordance with sizes and amounts of materials to be removed.
  • the filter medium should satisfy sufficient filtration efficiency and life span for maximizing the fluidity and amount of air or lubricating oil which is needed while the engine is driven.
  • filter paper and non-woven fabric are widely used as a filter material.
  • the filter paper is prepared by blending natural pulp and synthetic fiber in accordance with the final application field and subjecting the blend to the dissociation- beating-sheet forming-impregnation-drying- winding process.
  • the non- woven fabric is classified in to various types according to its preparation method, such as spun-bond, spunlace, chemical bond, thermal bond, needle punching and meltblown.
  • the non-woven fabric those which are largely used as a materialfor internal combustion engines are prepared by carding a proper combination of fibers, followed by lamination in a multi-layered structure and subjecting the laminate to subsequent processes such as needle punching, heat pressing, chemical treatment, drying and the like.
  • the filter paper prepared according to the above-described method has a thin thickness, a high density and a low air permeability and shows excellent particle holding efficiency.
  • the filter paper has a defect in that it requires a large area upon application as a filter material but has an excellent processibility.
  • the non-woven fabric has a great thickness, a low density and a low air permeability, and thereby, shows a long effective dust holding life. However, it has defects of a low holding efficiency of micro-particles and poor post-processibility.
  • micro fiber which is widely used as various filter materials such as air purification system.
  • micro fiber has many problems of strength, fiber shedding and fiber breakage upon bending, whereby it cannot be used along.
  • German Patent Publication No. 4,443,158 discloses a method for making a filter material having excellent purification property by using meltblown fiber as an internal material.
  • the filter material cannot provide sufficiently high dust holding capacity or depth filtration due to its poor strength, air permeability and fiber breakaway.
  • US Patent No. 6,315,805 discloses a use of a meltblown layer as an outdoor material.
  • the present inventors have conducted search for developing a filter material to solve the problems involved in the conventional non-woven fabric and filter paper, and found an air filter material which can solve the problems of strength, air permeability increase and fiber shedding, involved in a meltblown filter material comprising a non- woven fiber layer or at least two non-woven fiber layers having a density gradient in an air inlet layer (outer layer) and a micro meltblown material in a fluid outlet layer (innerlayer), in which the meltblown layer is impregnated to be used as a final layer (inner layer), and has an excellent micro particle holding efficiency and holding capacity as compared to the conventional filter material.
  • the material for air purification coated with a resin according to the present invention solves the problems associated with strength and fiber shedding which occur when a meltblown material is used in a final layer (back layer). Also, it shows excellent processibility, dust holding efficiency and dust holding capacity, and post- processibility such as bending property and strength and thus, can be used in various filtering apparatuses for automobiles or air handling units in buildings.
  • FIG. 1 is a schematic view showing an embodiment of the process for preparing air filter material according to the present invention. Best Mode for Carrying Out the Invention
  • a filter material for cleaning air comprising one layer or two or more layers having a density gradient, in which at least one layer comprises a meltblown layer impregnated with a resin as a final layer.
  • final layer refers to a layer through which air passes to the outside, where an air-inlet side layer is an outer layer or an external layer. It also can be called “fine layer” meaning that it is a layer having a very high fiber density and these two terms can be used reciprocally. Further, this layer refers to an air outlet layer or an inner layer in the art.
  • the final layer comprises a support layer at the fluid-outlet side, as needed, it is called a backup layer or a support layer but is not called "final layer”.
  • the filter material according to the present invention can be suitably used in various fields such as internal combustion engines or air cleaner in buildings.
  • the filter materialfor air purification according to the present invention is formed of at least one fiber layer having a density gradient with the lowest density at an air inlet side and the highest density at the final layer.
  • One of the fiber layers is preferably formed of a meltblown material impregnated with a resin.
  • a meltblown non-woven material which can form fine micro fibers to increase filtration efficiency and anon-woven fabric or filter paper to increase dust holding capacity, or a mixture thereof of are more preferably used, in which each layer has a density gradient to optimize the filter performance.
  • the resin impregnation (coating) it is possible to solve the problems of strength and air permeability increase and fiber shedding and to improve processibility, dust holding efficiency, dust holding capacity, bending property and pressureresistance, as compared to the conventional material.
  • the material according to the present invention has a final layer at the air outlet side whichcomprises meltblown fibers impregnatedwith a resin and having a fiber diameter of 0.5 to 20 D.
  • the meltblown fibers are selected from the group consisting of polyester, polyethylene, polypropylene, polybutylene terephthalate, nylon, polyphenyle- nesulphide, polycarbonate and polyester glycol (PETG), which can be used alone or as a mixture thereof.
  • the meltblown material used in the final layer is preferably 5 to 40 wt% based on the weight of the whole material and has a pore size in the range of 20 to 150 D, a weight in the range of 10 to 120 g/D, an air permeability in the range of 10 to 300 cfm, at 125 Pa, and a fiber diameter in the range of 0.5 to 20 D.
  • the resin may be a thermoplastic or thermosetting resin.
  • the resin which can be used in the present invention include, but are not limited to, phenols, acryls, polyvinyl acetates, melamines, epoxies and polyethylene terephthalates.
  • the material according to the present invention may further comprise a impregnated or non-impregnated pre-layerat the air inlet layer.
  • the pre-layer is formed of a non- woven material selected from the group consisting of spun-bond material, spunlace material, chemical bond material, thermal bond material, needle punched material, air laid material or meltblown material, or filter paper, or a mixture thereof.
  • the non-woven fabric used as the pre-layer has a weight of 30 to 400 g/D, air permeability of 50 to 450 cfm, at 125 Pa, a fiber diameter of 1 to 40 D and a pore size of 60 to 200 D and is preferably in a multi-layered structure.
  • Each of fiber layers forming the pre-layer may be one selected from the group consisting of acryl, polyethylene, polypropylene, viscose rayon, polyethylene terephthalate, polybutylene terephthalate, nylon, polyphenylenesulphide, polycarbonate and polyester glycol, or a mixture thereof.
  • the non- woven fabric used in the pre-layer may have various properties according to the type of the non-woven fabric and desired performance.
  • the non- woven fabric preferably has an air permeability of 50 to 450 cfm, at 125 Pa, a thickness of 1 to 3.5 mm and a weight of 30 to 400g/D.
  • the material according to the present invention preferably comprises a support in the back of the meltblown layer, as needed.
  • the support may be formed of the non- woven fabric as described above and preferably has a weight of 5 to 60 g/D.
  • the non-woven material is also prepared using a conventional preparation process.
  • it can be prepared by a well-known method or process such as spun bond, spunlace, needle punching, chemical bond, thermal bond, air-laid or meltblown method.
  • the finally prepared composite material has a total weight of 160 to 400 g/D, an air permeability of 30 to 150 cfm, at 125 Pa, and a thickness of 1.0 to 4 mm to show filter effect most suitable for an internal combustion engine.
  • the method for preparing the material according to the present invention, when the bonding is performed using a resin comprises the steps of:
  • steps a) to d) may be performed in a different order. That is, fibers which have been separately impregnated may be laminated, or non-impregnated materials for respective layers may be laminated and then, impregnated with a resin.
  • the method for preparing the material according to the present invention may be performed by combining conventional preparation methods.
  • a pre-layer comprising a single layer or two or more layers of non- woven fiber web or filter paper and (or) a support layer may be attached to the resin-impregnated meltblown layer which is employed as a final layer by impregnation.
  • impregnation and needle punching or thermal bonding may be performed in combination. That is, in this embodiment, the lamination and the impregnation can be performed simultaneously.
  • adhesion of each layer it is possible to perform impregnation with a resin, or to use low-melting point fiber or melting adhesive binder such as Hot-Melt.
  • the above-described adhesion method can be performed in combination of two or more.
  • a support layer may be preferably attached to the back of the meltblown layer in any one step of the process to further increase the strength of the back layer.
  • the meltblown fabric which is used as a final layer is separately prepared by a conventional method (ex.Korean Patent No. 10-0438331, in an order of material mixing-extrusion-spinning-web bonding-winding) and combined with a material for the non-woven fabric, followed by carding.
  • the meltblown web is then introduced in a step prior to the impregnation of the chemical bonding process (ex. in an order of material mixing for chemical bond fiber, fila- mentation, filament blending, carding, wrapping, impregnation, drying and winding) and bonded by resin bonding to form the material according to the present invention.
  • the meltblown material (weight: 10 to 120 g/D, air permeability: 10 to 300 cfm, at 125 Pa, fiber diameter: 0.5 to 20 D) is prepared by a conventional method as described above, introduced in a step prior to the impregnation of the method for preparing multi-layer or single-layer chemical bond media (in an order of filamentation, blending, carding, web formation, impregnation, drying and winding: see, Korean Patent Publication No.
  • the non-woven fabric is not a chemical bond non-woven fabric (for example, needle punched, thermal bonded, air-laid, spun-bonded non-woven fabric)
  • the non-woven fabric layer and the meltblown layer may be separately produced and laminated to each other while being impregnated with a resin. Also, it is possible to perform the lamination in a separation process after impregnation of the meltblown layer and other non- woven fabric layers.
  • the material according to the present invention may be prepared by laminating the respective layers of the material by needle punching, thermal bonding, chemical bonding, resin impregnation, hot-melt lamination by dotting and spraying or ultrasonic bonding or combination of two or more thereof, impregnating the laminate with a thermoplastic resin or curable resin solution and drying the impregnated laminate by heat treatment, followed by winding.
  • the ultrasonic bonding though may be used in the present invention, shows pressure loss by the dead space, as compared to the production of non- woven fabric by chemical bond in which the material is introduced in the impregnation process.
  • the non-woven fabric may be prepared by a conventional method such as needle punching method, thermal bonding method, chemical bonding method, spun bonding method, air-laid method, meltblown method, spunlace method and the like. Also, it can be prepared in an order of material mixing by air cleaner-multilayer carding-needle punching-impregnation (foam coating)-drying(can, hot air)-taking-up or alternatively in an order of material mixing-multilayer carding-needle punching-drying (can, hot air)-calendring-taking-up.
  • the filter paper is prepared according to a conventional method.
  • the fiber layers are impregnated with a solution of water-soluble or oil-soluble thermosetting resin at a solid content of 10% to 30% in a weight ratio of 10 to 30% relative to the total weight of the fiber layers of 10 to 400g/D.
  • a solution of water-soluble or oil-soluble thermosetting resin at a solid content of 10% to 30% in a weight ratio of 10 to 30% relative to the total weight of the fiber layers of 10 to 400g/D.
  • the method disclosed in Korean Registered Patent No. 10-0358651 may be used, which is incorporated herein by reference.
  • the impregnation of the material with a resin solution is preferably performed by using each fiber layer in a total weight of 160 to 400 g/D and the resin in a ratio of 10% to 30% based on the total weight of the material.
  • the resin is prepared into a water soluble or oil-soluble solution of thermosetting or thermoplastic resin at a solid content of 10 to 30%.
  • the resin which can be used in the present invention includes thermosetting resins such as phenol (resol), epoxy, novolak and the like or thermoplastic resins such as polyvinylacetate (PVAC), acryl and the like.
  • the resin impregnation solution may be combined with a surfactant, a penetrating agent, a catalyst, water and a pigment of light color such as pink, as needed.
  • the impregnation with the resin solution is performed by roller coating or foam coating while the impregnation rate is controlled so that the air pressure is not raised. That is, the impregnation is performed in the range of 10% to 30% to prepare the resin coated material.
  • thermoplastic resin may be preferably mono-spun or blend-spun or separately spun (side by side or sheath/core).
  • the drying process of the web is performed by heat treatment using a fusing oven, a belt press calender or hot air.
  • the prepared material may be further subjected to the steps of:
  • the additional steps may be selectively performed according tothe post-process procedure.
  • the present invention comprises a method for preparing a material for air pu- rif ⁇ cation by needle punching comprising the steps of: [58] a) transferring a non- woven fabric and an impregnated meltblown material from respective winding rolls; [59] b) laminating the non-woven fabric or meltblown layer and bonding the resulting laminate by a plurality of needles to form a web; and [60] c) winding the needle bonded material.
  • the prepared material may be further subjected to the steps of:
  • the present invention comprises a method for preparing a method for preparing a material for air purification by hot melt bonding comprising the steps of: [66] a) transferring a non-woven fabric and an impregnated meltblown material from respective winding rolls; [67] b) applying an adhesive to the non-woven fabric or meltblown layer by spray or dot application; [68] c) laminating a material with the adhesive applied on the other material by a tension roll;
  • the prepared material may be further subjected to the steps of:
  • the additional steps may be selectively performed according to the post-process procedure.
  • the materialaccording to the present invention can be bent. Therefore, the bending process includes bending the impregnated non-woven material in accordance with a desired shape, cutting the bent material to a corresponding size and curing the product at a predetermined temperature for a predetermined time.
  • the curing step can be omitted according to the used resin and process. Therefore, in an aspect of the present invention, there is provided a filter element prepared by bending the material.
  • the filter element may be in a star shape or a flat panel shape.
  • the bending machine may be a rotary, minipleat, or knife bending machine. Among them, the knife bending machine is preferably used.
  • the curing temperature to fix the bent shape is in the range of 130 to 180°C , similar to the curing temperature of the non-woven fabric.
  • the final material thus obtained preferably has a pore size of 20 to 150 D, a total weight of 160 to 400 g/D DD, a total thickness of 1.0 to 4 mm and an air permeability of
  • Fibers having a fiber diameter of 0.5 to 40 D may be combined.
  • Dust used in the test was AC fine. The test was performed until the final pressure loss is 400 mmAg.
  • Example 1 Examination of material after single impregnation [81] Among media shown in Table 1, a CB (chemical bond) nln- woven fabric (2-layer) was prepared using the following composition.
  • meltblown non-woven fabric was prepared by a conventional preparation method of (extrusion-spinning-web bonding-drawing) using PET (TV:0.8) and PBT (IV:0.8) resin.
  • the fabric was impregnated with an acryl resin by impregnation and examined for its properties and filter performance. The result is shown below. [86] Table 1
  • Example 2 Test of chemical bond material (CB, 2-layer structure) and meltblown material (impregnation lamination) [90] The same meltblown material [4Og, 6Og, 8Og, 10Og, impregnation laminated) as used in Example 1 was used. Each meltblown material was subjected to the processfor preparing a chemical bond non-woven fabric under the same conditions as used in Example land impregnated with a resin of 15 to 30 wt% based on the weigh of the whole material to give a 3-layered composite material. The product was examined for its properties and filter performance. The result is shown below.
  • the composite material had an improved filtering efficiency which was a defect of the chemical bond non- woven fabric and dust holding capacity which was a defect of the meltblown non- woven fabric. Further, it was advantageously prepared by introducing meltblown in the impregnation process for preparing the chemical bond fiber without performing a separation lamination.
  • the pre-layer showed optimal effect when the meltblown material had a weight of lOOg/D or less before impregnation, thought it varied according to the material combination and the number of layer of the chemical bond non- woven fabric.
  • the material was examined for strength and bending property of the meltblown. As a result, the meltblown had a strength at breakage of 1.5 kgf or more improved from 0.5 kgf and showed improved tear phenomenon such as fiber breakage upon bending.
  • Example 3 Test of composite material of meltblown (MB) fabric and spun-bond (SB) fabric [96] The spun-bond non- woven fabric having a weight of 150 g/D and the impregnated product thereof which had been impregnated in an amount of about 16% based on the total weight were examined and the result is shown in Table 3.
  • the impregnated material showed a better filter efficiency. It was believed that this was because the pore size was reduced by impregnation and fibers of the impregnated material were fixed, whereby the extension of the pore size was eliminated. That is, the non-impregnated material (Spun-bond 1) showed a final efficiency reduced from the initial efficiency due to the fiber immigration while the impregnated filter paper (Spun-bond 2) showed a higher final efficiency.
  • meltblown 2 material weight before impregnation: 60g/D
  • No.3 of Example 1 the spun-bond non-woven fabric (Spun-Bond 1) having a weight of 150 g/D were bonded by impregnation with acryl resin(about 22% of the total weight).
  • the property and filter performance of the product are shown in Table 4.
  • Table 4 Property and filter performance of composite bonded by resin impregnation
  • Example 4 Preparation of composite material by hot-melt bonding.
  • the impregnated meltblown 2 material weight after impregnation: 80g/D
  • No. 3 of Example 1 and the spun-bond non-woven fabric (Spun-Bond 1) having a weight of 150 g/D were bonded to each other by Hot-Melt.
  • Theproperty and filter performance of the product are shown in Table 5.
  • the meltblown material used in the final layer was about 5to 40 wt%, relative to the total weight of the non- woven fabric and had a weight of about 10 to 120 g/D,an air permeability of 10 to 300 cfm and an average fiber diameter of 0.5 to 20 D to show optimal effect. Therefore, these composite materials had a total weight of 160 to 400 g/D, an air permeability of 30 to 150 cfm and a thickness of 1.0 to 4 mmto shown filter effects suitable for an internal combustion engine.
  • property of the non- woven fabric used in the pre-layer varies according to the type of the non-woven fabric and desired performance.
  • the non- woven fabric for an internal combustion engine had an air permeability of 50 to 450 cfm, a thickness of 1 to 3.5 mm and a weight of 30 to 400g/D to show optimal effects.
  • micro meltblown fiber As the final layer, through which the fluid discharged (outlet), micro meltblown fiber was impregnated and bonded to a spun-bond material to prepare a filter.
  • the filter showed excellent efficiency and life span, as compared to a conventional non-woven fabric filter or filter paper without a meltblown material applied, and satisfactory strength of the meltblown fabric and bending property. That is, as compared to a product comprising only a non- woven fabric, this filter showed increase of 10 to 100% or more in life span and 10 to 40% or more in filtration efficiency. Such increase in life span and filtration efficiency was because the filter material had a structure for deep filtration and the particles were collected in the final micro meltblown layer.
  • the final micro meltblown layer can perform the deep filtration. Also, problems of strength and bending (formability) of the meltblown material were improved.
  • Industrial Applicability As described above, the material for air purification coated with a resin does not have problems of strength and fiber shedding which occur when a meltblown material is used in a final layer (back layer). Also, it shows excellent processibility, dust holding efficiency and dust holding capacity, and post-processibility such as bending property and strength and thus can be used in various filtering apparatuses for automobiles or air handling units in buildings.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Filtering Materials (AREA)

Abstract

La présente invention concerne une matière filtrante utilisée pour extraire des contaminants présents dans l'air pendant une durée prolongée et un procédé de préparation correspondant. Cette invention porte plus particulièrement sur une matière filtrante comprenant une couche ou bien au moins deux couches présentant un gradient de densité, au moins une des couches étant une couche terminale comprenant une couche soufflée par extrusion recouverte d'une résine et un procédé de production de cette dernière. La matière recouverte de résine présente une excellente aptitude au post-traitement telle qu'une propriété de cintrage et de résistance, par conséquent, on peut l'utiliser dans divers appareils filtrants destinés aux automobiles ou à des unités de conditionnement de l'air installées dans des bâtiments.
PCT/KR2005/002398 2005-07-15 2005-07-25 Element filtrant utile pour epurer l'air, procede de preparation de ce dernier WO2007011089A1 (fr)

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KR10-2005-0064418 2005-07-15

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KR101156784B1 (ko) * 2010-07-08 2012-06-18 도레이첨단소재 주식회사 중공의 폴리에틸렌테레프탈레이트와 폴리프로필렌의 복합 재질을 사용한 니들 펀칭 부직포 및 그 제조방법
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KR102485704B1 (ko) * 2020-07-31 2023-01-05 김수연 부직포와 망체를 이용한 나노섬유필터 및 그 제조방법
KR102609388B1 (ko) * 2020-08-27 2023-12-01 윤태석 기능성 마스크 부직포 필터 제조장치

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