WO2013168883A1 - Filter medium having dual-layer structure consisting of high-density layer and low-density layer - Google Patents

Filter medium having dual-layer structure consisting of high-density layer and low-density layer Download PDF

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Publication number
WO2013168883A1
WO2013168883A1 PCT/KR2013/000737 KR2013000737W WO2013168883A1 WO 2013168883 A1 WO2013168883 A1 WO 2013168883A1 KR 2013000737 W KR2013000737 W KR 2013000737W WO 2013168883 A1 WO2013168883 A1 WO 2013168883A1
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Prior art keywords
filter
layer
weight
diameter
fibers
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PCT/KR2013/000737
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French (fr)
Korean (ko)
Inventor
한정철
박성은
이재민
김형범
김길섭
권순덕
Original Assignee
주식회사 엔바이오니아
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Priority to CN201380024228.8A priority Critical patent/CN104271215A/en
Publication of WO2013168883A1 publication Critical patent/WO2013168883A1/en

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    • 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/54—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
    • B01D46/546—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms using nano- or microfibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • 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
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2003—Glass or glassy material
    • B01D39/2017—Glass or glassy material the material being filamentary or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/54—Particle separators, e.g. dust precipitators, using ultra-fine filter sheets or diaphragms
    • 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
    • B01D2239/025—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanofibres
    • 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
    • B01D2239/065—More than one layer present in the filtering material
    • 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
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1208—Porosity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
    • B01D2275/10—Multiple layers

Definitions

  • the present invention relates to a filter medium having a high concentration and a low concentration of a two-layer structure, in detail 55 to 75% by weight of ultra-fine short fibers having a diameter of 0.1 ⁇ 1.0 ⁇ m (hereinafter referred to as ultra-fine fibers), 10 to 25 wt% of ultrafine short fibers (hereinafter referred to as microfibers) having a diameter of 1.0 to 5.0 ⁇ m, 1.5 to 2.5 wt% of a filter composition composed of 0 to 35 wt% of glass fibers, and 97.5 to water
  • a slurry hereinafter referred to as filter slurry
  • the prepared filter slurry is sprayed at a concentration of 0.05 to 1.0 mass% of the headbox concentration to form a dense layer, and the top of the dense layer
  • the filter composition is sprayed at a concentration of 0.03 to 0.06% by mass of the headbox to form a two-layer structure, and then heated, thereby tightly binding the dense layer
  • Filter filter medium is a device for filtering fine dust and foreign matter, it is installed in the passage through which air is introduced and discharged for dust-free dust-proof environment is a device that allows the filtered clean air flows into the inside.
  • these filter filters are used in various fields such as semiconductor industry, air purifier, semiconductor industry, electronics industry, and vacuum cleaners. It is used to reduce the defect rate of equipment and products as well as to prevent clean efficiency from being lowered by dust by introducing into a specific space.
  • Non-woven filter, paper filter, and air filter are generally used as the filter medium, and the paper filter has a thin and dense single layer structure, and is collected because it has an excellent collection efficiency for filtering dust in the air. There is a shortage of space to accommodate dust, which has to be replaced frequently.
  • air filters are roughly classified into a dust filter, a neutral filter, a semi-high filter, a HEPA filter, a ULPA filter, and the like according to the particle diameter and the vibration damping efficiency of the fiber.
  • the HEPA filter is a filter that can remove fine dust with a particle diameter of 0.3 ⁇ m or less, and is formed of ultra-fine short fibers having a diameter of less than 1 ⁇ m to collect 99.97% or more of fine particles having a particle size of 0.3 ⁇ m. It is being installed where high-precision hygiene facilities are required, such as semiconductors, pharmaceutical companies, and hospitals.
  • the HEPA filter is formed in a single layer structure like the paper filter, the dust capacity is low and the collection efficiency is lowered.
  • the filter has a four-layer structure consisting of a bulky layer, an intermediate layer, a dense layer, and a film layer in order from the air inlet side to the air outlet side to uniform the voids in the fiber layer. It is possible to increase the collection efficiency and capacity of the dust in the air to be filtered, but due to the surfactant used to bind the layers to prevent the pores of each fibrous layer, the life is shortened, the collection efficiency is lowered .
  • the filter is formed in a three-layer structure of a dense layer, an intermediate layer, and a bulky layer, and the bonding between the layers is performed by thermal fusion. Pore clogging occurs due to resin adhesive, which has the advantage of shortening the lifespan or reducing the collection efficiency, but such a filter not only is complicated to perform the heat fusion process between layers but also increases the manufacturing cost. The problem is that the fiber prototype is broken.
  • each layer is laminated in a chemical crystal solid state. Since they adhere to each other, separate devices and processes such as needle punching machines, resin adhesives, surfactants, and heat fusion, etc. must be carried out, and this method not only deforms and destroys the circular and original properties of the fibers, but also makes the manufacturing process cumbersome. Is generated.
  • the fibers forming the dense layer and the bulky layer are laminated in a liquid state, and then dehydrated and cured so that the fibers between the layers are entangled at the contact surface, so that the collection efficiency may be excellent without performing an additional bonding means and process.
  • various studies have been conducted on filters having strong interlayer bonds.
  • FIG. 1 is a cross-sectional view showing a hepa filter described in the prior art US Patent Publication No. 20070163218 (name: hepa filter having a two-layer structure).
  • the HEPA filter 100 (hereinafter, referred to as a conventional HEPA filter) of FIG. 1 is a finely divided layer 101 having a diameter of 2.0 to 8.0 ⁇ m and a thickness of 50 to 625 ⁇ m, and a diameter of 0.2 to 0.8 ⁇ m and 125 to Hepa layer 103 having a thickness of 750 ⁇ m formed on the lower portion of the fine powder layer 101, and is formed to a thickness of 3 to 20% of the total thickness between the fine powder layer 101 and the hepa layer 103 It is formed of a transition region 105 is formed by mixing the fine powder layer 101 and the hepatic layer 103.
  • a transition region 105 composed of a mixture of the HEPA layer 103 and the fine powder layer 101 is formed between the HEPA layer 103 and the fine powder layer 101 so that the HEPA layer 103 is formed.
  • the fine powder layer 101 are firmly bound by the transition region 105 without using a separate bonding member such as a separate resin adhesive or the like.
  • the conventional HEPA filter 100 not only binds the fine powder layer 103 and the HEPA layer 101 so that the transition region 105 firmly binds the HEPA layer 103 and the fine powder layer 101, as well as the hepa filter material.
  • the pleating process ensures that the two layers do not separate during the pleating process.
  • the conventional HEPA filter 100 has an advantage of increasing the binding strength between layers increases the collection efficiency, the dust capacity increases.
  • the conventional HEPA filter 100 is manufactured because the fibers of the fine powder layer and the fibers of the hepa layer are separated and sprayed into two head boxes during manufacturing to separate and laminate the fine powder layer 101 and the hepa layer 103. Complex and costly problems arise.
  • the present invention is to solve this problem, the problem of the present invention is 55 to 75% by weight of ultrafine fibers with a diameter of 0.1 to 1.0 ⁇ m, 10 to 25% by weight of microfibers with a diameter of 1.0 to 5.0 ⁇ m, ⁇ glass fiber
  • the filter composition composed of 0 to 35% by weight with different head box concentrations to form a two-layer structure of stacked dense layer and bulky layer, it provides a filter medium with low pressure loss and high dust collection efficiency and dust content. It is to.
  • another problem of the present invention is a resin adhesive by spraying a filter slurry of 1.5 ⁇ 2.5% by weight of the filter composition with water 97.5 ⁇ 98.5% by weight on the screen during the filter composition lamination process and then dehydration and curing process And it is to provide a filter filter medium that not only does not have a high interlayer binding force, but also voids and circles of the filter composition is not broken or deformed without a separate device such as a surfactant.
  • the present invention for solving the above problems is more than 55% by weight to 75% by weight of ultrafine fibers having a diameter of 0.1 ⁇ 1.0 ⁇ m and 10% by weight to 25% by weight of microfibers having a diameter of 1.0 ⁇ 5.0 ⁇ m
  • the filter slurry is composed of a bulky layer formed by spraying the upper portion of the dense layer at a concentration of 0.03 to 0.06 mass% of the head box concentration.
  • the filter slurry forming the dense layer and the bulky layer is preferably laminated in a liquid phase, and the fibers forming the dense layer and the bulky layer are entangled through a dehydration and curing process.
  • the filter filter material is 60 ⁇ 120 g / m 2 It is preferable to have a weight of and a thickness of 0.2 to 1.0 mm.
  • the filter slurry is preferably an acid or dispersant having a PH 2 ⁇ 4 concentration is added.
  • the pressure loss is reduced and the collection efficiency is increased by spraying the dense layer and the bulky layer at different head box concentrations.
  • the filter since the filter is formed in a two-layer structure, the dust capacity is increased, thereby increasing the filter life.
  • the binding efficiency is not only high because the interlayer binding force is high, and the voids and the circular shape of the fiber layer are not deformed without a separate coupling member, thereby increasing the collection efficiency.
  • the raw material of the bulky layer is used as a fiber having a larger diameter than the dense layer, thereby reducing the cost.
  • FIG. 1 is a cross-sectional view showing a hepa filter described in the prior art US Patent Publication No. 20070163218 (name: hepa filter having a two-layer structure).
  • Figure 2 is a cross-sectional view showing a filter medium of an embodiment of the present invention.
  • FIG 3 is a cross-sectional view showing a filter medium of an embodiment of the present invention.
  • FIG. 4 is a flowchart illustrating a manufacturing process of the filter medium of FIG. 3.
  • FIG. 2 is a conceptual view showing the components of the filter composition applied to an embodiment of the present invention.
  • the filter composition 30 of FIG. 2 is a fiber composition applied to a filter filter material of one embodiment of the present invention, and has an ultrafine short fiber 31 having a diameter of 0.1 to 1.0 ⁇ m (hereinafter, referred to as an ultrafine fiber) 55 weight 10% or more to 75% by weight or less, 10 to 25% by weight or less of fine short fibers 33 (hereinafter referred to as microfibers) having a diameter of 1.0 to 5.0 ⁇ m and a diameter of 5 ⁇ m or more
  • the glass fiber 35 is more than 0% by weight to 35% by weight or less.
  • the microfine fibers 31 and the fine fibers 33 are short glass fibers, borosilicate glass, C glass having acid resistance, E glass (alkali glass) having electrical insulation, low boron glass, to reduce boron contamination and boron contamination, And short glass fibers mixed with one or at least two of the silica glasses.
  • the ultrafine fibers 31 are ultrafine short fibers having a diameter of 0.1 to 1.0 ⁇ m, and because the diameter thereof is small, the collection efficiency of the filter medium 1 of FIG. 3 to be described later is increased.
  • the ultrafine fiber 31 is composed of 55% by weight or more and 75% by weight or less of the filter composition 30, and if the content of the microfine fiber 31 is less than 55% by weight, the properties of the ultrafine fiber 31 are lowered and collected. The efficiency is lowered, and if the content is 75% by weight or more, the content of the ultrafine fibers 31 is increased to increase the pressure loss.
  • the glass fiber 35 is a glass fiber thicker than the microfine fiber 31 and the fine fiber 33, and it is preferable that the glass fiber 35 has a diameter of 5 micrometers or more in detail.
  • the glass fiber 35 is composed of more than 0% by weight to 35% by weight or less.
  • the filter composition 30 applied to the present invention increases the collection efficiency by mixing the ultrafine short fibers 31 and 33 and the glass fibers 35 having different diameters.
  • FIG 3 is a cross-sectional view showing a filter medium of an embodiment of the present invention.
  • the filter medium 1 of FIG. 3 is a device for filtering fine addresses and dust introduced from the outside by stacking the filter composition 30 of FIG. 2 after being sprayed with different head box concentrations.
  • the filter medium (1) is formed on the dense layer (3) is formed by spraying the filter composition 30 of Figure 2 described above in the head box concentration of 0.05 ⁇ 1.0 mass%, and the dense layer (3)
  • the filter composition 30 is composed of a bulky layer 5 formed by spraying at a headbox concentration of 0.03 to 0.06 mass%.
  • a liquid filter slurry obtained by mixing and stirring 1.5 wt% or more and 2.5 wt% or less of the filter composition 30 of FIG. 2 to 97.5 wt% or more and 98.5 wt% or less of water has a headbox concentration of 0.03 to 0.06.
  • the bulky layer 5 is formed by spraying at a head box concentration of 0.03 to 0.06 mass%, the diameter is larger than that of the dense layer 3, and thus, a large dust or foreign substance is installed in the passage through which air is introduced. Will be filtered.
  • the dense layer 3 is a filter material produced by spraying the filter slurry onto the screen at a headbox concentration of 0.05 to 1.0 mass%, followed by dehydration and curing.
  • the dense layer 3 has a higher head box concentration compared to the bulky layer 5, the diameter is smaller, thereby filtering fine dust and dust that the bulky layer 5 cannot filter.
  • FIG. 4 is a flowchart illustrating a manufacturing process of the filter medium of FIG. 3.
  • the filter composition 30 is 55 wt% or more and 75 wt% or less, as described above with reference to FIG. 2, and 10 wt% or more and 25 wt% or less, and glass fiber ( 35) more than 0 wt% to 35 wt% or less (S10).
  • Dispersion is prepared by adding acid (hydrochloric acid) or dispersant having a concentration of PH 2 to 4 to water as a dissolving solution, and putting it in a pulp (S20).
  • the filter slurry is composed of a dispersion of 97.5% by weight or more and 98.5% by weight or less, and 1.5 to 2.5% by weight of the filter composition 30.
  • the filter slurry prepared in step 30 (S30) is accommodated in each headbox and then sprayed onto the screen at a concentration of 0.03 to 0.06 mass% of the headbox to form a dense layer 3 (S40).
  • the filter slurry is sprayed onto the filter slurry injected through the step 40 (S40) at a concentration of 0.05 to 1.0 mass% of the headbox concentration so that a bulky layer is formed on the dense layer 3 (S50).
  • a filter filter material (1) is an embodiment of the present invention (S60).
  • the filter medium (1) thus prepared is cured by laminating the dense layer (3) and the bulky layer (5) in a liquid state, and the fibers are entangled so that the dense layer (3) and the bulky layer (5) do not need any additional adhesive means. This can be combined firmly.
  • step 50 a binder impregnation or spray process may be further included so as to be plated by post-processing. The description will be omitted.
  • filter filter material 1 which is one embodiment of the present invention will be described in more detail with reference to Examples.
  • the following embodiments are for the purpose of explanation and do not limit the protection scope of the present invention.
  • Table 1 shows the components of the filter composition applied to the Examples and Comparative Examples.
  • Sample No. 1 (FC1) in Table 1 is 70% by weight of the microfibers 31 having a diameter of 0.6 ⁇ m, 20% by weight of the microfibers 33 having a diameter of 2.70 ⁇ m, and 10 weights of the glass fibers 35.
  • a filter composition 30 composed of%.
  • sample number 2 (FC2) of Table 1 is 70% by weight of microfibers 31 having a diameter of 0.5 ⁇ m, 20% by weight of microfibers 33 having a diameter of 2.70 ⁇ m, and 10 weights of glass fibers 35.
  • a filter composition 30 composed of%.
  • Sample No. 3 (FC3) in Table 1 was 76 wt% for the microfibers 31 having a diameter of 0.6 ⁇ m, 16 wt% for the microfibers 33 having a diameter of 2.70 ⁇ m, and 8 wt% for the glass fiber 35.
  • a filter composition 30 composed of%.
  • Sample No. 4 (FC4) of Table 1 is composed of 58 wt% of microfibers 31 having a diameter of 0.5 ⁇ m, 28 wt% of fine fibers 33 having a diameter of 2.70 ⁇ m, and 14 wt% of glass fibers. Filter composition.
  • sample number 5 (FC5) of Table 1 is 75% by weight of the microfibers 31 having a diameter of 0.6 ⁇ m, 20% by weight of the microfibers 33 having a diameter of 2.70 ⁇ m, and 5 weights of the glass fiber 35.
  • a filter composition 30 composed of%.
  • sample number 6 (FC6) of Table 1 is 70% by weight of microfibers 31 having a diameter of 0.5 ⁇ m, 25% by weight of microfibers 33 having a diameter of 2.70 ⁇ m, and 5% by weight of glass fibers 35.
  • a filter composition 30 composed of%.
  • Table 2 below shows other examples and comparative examples of the filter medium (1) to which the filter composition of Table 1 is applied.
  • Example 1 shows 47.5 wt% of the dense layer 3 formed of the sample number 1 (FC1), 47.5 wt% of the bulky layer 5 formed of the sample number 2 (FC2), and the binder 5 %,
  • the dense layer 3 is formed at a headbox concentration of 0.07 mass%
  • the bulky layer 5 is formed at a headbox concentration of 0.07 mass%.
  • Example 2 consisted of 47.55 wt% of the dense layer 3 formed of the sample number 1 (FC1), 47.5 wt% of the bulky layer 5 formed of the sample number 2 (FC2), and 5% of the binder.
  • the layer 3 is formed at a headbox concentration of 0.07 mass%
  • the bulky layer 5 is formed at a headbox concentration of 0.04 mass%.
  • Example 3 consists of 47.55 weight% of dense layer 3 formed of sample number 3 (FC3), 47.5 weight% of the bulky layer 5 formed of sample number 4 (FC4), and 5% of a binder, and The layer 3 is formed at a headbox concentration of 0.07 mass%, and the bulky layer 5 is formed at a headbox concentration of 0.04 mass%.
  • DOP permeability was measured by the TSI 8130 Model from upstream and downstream when air containing 0.3 ⁇ m-sized DOP (dioctyl phthalate) was ventilated through a filter filter medium having an effective area of 100 cm 2 at a surface velocity of 5.3 cm / sec.
  • Dispersibility is visually observed after collecting 1 L of the raw material mixture in the headbox. At this time, when the fiber was not agglomerated or bound, it was judged that the dispersibility was good, and when the dispersibility was good, O was indicated and when it was poor, ⁇ was indicated.
  • the average weight was measured after extracting 10 filter mediums having an effective area of 100 cm 2.
  • Table 3 shows detection values of Examples and Comparative Examples measured by Experimental Examples 1 to 5.
  • Example 1 to Example 3 having a two-layer structure in which the head box concentration is differently applied as shown in Table 3, the pressure loss is reduced compared to Comparative Examples 1 to 6, which are formed in a single layer structure, and the sampling efficiency does not decrease. It can be seen that the dispersion is secured.

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Abstract

The present invention relates to the manufacture of a filter medium which has a dense layer and a bulky layer rigidly combined together without using a separate coupling member, and which exhibits low pressure loss and high collecting efficiency, by: mixing 55 to 75 parts by weight of ultrafine fibers having a diameter of 0.1 to 1.0 μm (hereinafter referred to as microfibers), 10 to 25 parts by weight of ultrafine fibers having a diameter of 1.0 to 5.0 μm (hereinafter referred to as fine fibers), 1.5 to 2.5 parts by weight of a filter composition consisting of 0 to 30 parts by weight of glass fibers, and 97.5 to 98.5 parts by weight of water; manufacturing a slurry (hereinafter referred to as a filter slurry); then spraying the manufactured filter slurry until achieving a headbox concentration of 0.05 to 1.0 parts by weight so as to form a dense layer; and spraying the filter composition onto the upper portion of the dense layer until achieving a headbox concentration of 0.03 to 0.06 parts by weight so as to form a dual-layer structure, and heating same.

Description

고농도 및 저농도의 2층 구조를 갖는 필터 여과재Filter medium with high concentration and low concentration two layer structure
본 발명은 고농도 및 저농도의 2층 구조를 갖는 필터 여과재에 관한 것으로서, 상세하게로는 0.1 ~ 1.0㎛의 직경을 갖는 초극세 단섬유(이하, 극세섬유라고 하기로 함) 55 ~ 75 중량%와, 1.0 ~ 5.0㎛의 직경을 갖는 초극세 단섬유(이하, 미세섬유라고 하기로 함) 10 ~ 25 중량%와, 유리섬유 0 ~ 35 중량%로 구성되는 필터조성물 1.5 ~ 2.5 중량%와, 물 97.5 ~ 98.5 중량%로 혼합시켜 슬러리(이하, 필터 슬러리라고 하기로 함)를 제조한 후 제조된 필터 슬러리를 헤드박스농도 0.05 ~ 1.0 질량%의 농도로 분사시켜 조밀층을 형성하며, 상기 조밀층의 상부에 상기 필터조성물을 헤드박스농도 0.03 ~ 0.06 질량%의 농도로 분사시켜 2층 구조를 형성한 다음 가열시킴으로써 별도의 결합부재 없이도 조밀층과 벌키층이 견고하게 결속될 뿐만 아니라 압력손실이 낮으며, 포집효율이 높은 필터 여과재에 관한 것이다. The present invention relates to a filter medium having a high concentration and a low concentration of a two-layer structure, in detail 55 to 75% by weight of ultra-fine short fibers having a diameter of 0.1 ~ 1.0㎛ (hereinafter referred to as ultra-fine fibers), 10 to 25 wt% of ultrafine short fibers (hereinafter referred to as microfibers) having a diameter of 1.0 to 5.0 μm, 1.5 to 2.5 wt% of a filter composition composed of 0 to 35 wt% of glass fibers, and 97.5 to water After mixing to 98.5% by weight to prepare a slurry (hereinafter referred to as filter slurry), the prepared filter slurry is sprayed at a concentration of 0.05 to 1.0 mass% of the headbox concentration to form a dense layer, and the top of the dense layer The filter composition is sprayed at a concentration of 0.03 to 0.06% by mass of the headbox to form a two-layer structure, and then heated, thereby tightly binding the dense layer and the bulky layer without a separate bonding member, and having a low pressure loss. High collection efficiency filter It relates to a filter medium.
필터 여과재는 미세 먼지 및 이물질을 필터링하는 장치로서, 먼지가 없는 방진환경을 위해 공기가 유입 및 유출되는 통로에 설치되어 내부로 필터링 된 청정공기가 유입되도록 하는 장치이다. 특히 산업이 발달하여 환경오염 및 건강에 대한 관심이 증가함에 따라 이러한 필터 여과재는 반도체 산업, 공기청정기, 반도체 산업, 전자산업 및 청소기 등의 다양한 분야에 사용되고 있고, 특정 공간에 설치되어 필터링 된 청정 공기를 특정 공간 내부로 유입시킴으로써 분진에 의하여 청정효율이 낮아지는 것을 예방할 뿐만 아니라 기기 및 제품의 불량률을 절감시키기 위해 사용되고 있다.Filter filter medium is a device for filtering fine dust and foreign matter, it is installed in the passage through which air is introduced and discharged for dust-free dust-proof environment is a device that allows the filtered clean air flows into the inside. In particular, as the development of the industry increases interest in environmental pollution and health, these filter filters are used in various fields such as semiconductor industry, air purifier, semiconductor industry, electronics industry, and vacuum cleaners. It is used to reduce the defect rate of equipment and products as well as to prevent clean efficiency from being lowered by dust by introducing into a specific space.
이러한 필터 여과재는 일반적으로 부직포 필터, 종이 필터 및 에어 필터 등이 사용되고 있고, 종이 필터는 얇고 조밀한 단층구조로 이루어지는 것으로서, 공기 중의 먼지를 필터링 하는 포집효율이 우수한 장점을 구조로 형성되기 때문에 포집되는 분진을 수용하는 공간이 부족하여 자주 교체되어야 하는 단점을 갖는다.Non-woven filter, paper filter, and air filter are generally used as the filter medium, and the paper filter has a thin and dense single layer structure, and is collected because it has an excellent collection efficiency for filtering dust in the air. There is a shortage of space to accommodate dust, which has to be replaced frequently.
또한 에어필터는 섬유의 입자직경이나 제진효율에 따라 조진용(粗塵用) 필터, 중성능 필터, 준고성능 필터, 헤파(HEPA) 필터, 울파(ULPA) 필터 등으로 대별된다.In addition, air filters are roughly classified into a dust filter, a neutral filter, a semi-high filter, a HEPA filter, a ULPA filter, and the like according to the particle diameter and the vibration damping efficiency of the fiber.
특히 헤파필터는 입경이 0.3㎛ 이하의 미세먼지를 제거할 수 있는 필터로서, 직경이 1㎛ 보다 작은 초극세 단섬유로 형성되어 입경 0.3㎛인 미세먼지를 99.97% 이상 포집할 수 있는 장점으로 인해 항공관련, 반도체, 제약회사, 병원 등과 같이 고도의 정밀 위생시설이 필요로 하는 곳에 설치되고 있다.In particular, the HEPA filter is a filter that can remove fine dust with a particle diameter of 0.3 μm or less, and is formed of ultra-fine short fibers having a diameter of less than 1 μm to collect 99.97% or more of fine particles having a particle size of 0.3 μm. It is being installed where high-precision hygiene facilities are required, such as semiconductors, pharmaceutical companies, and hospitals.
그러나 헤파필터는 종이필터와 마찬가지로 단층 구조로 형성되기 때문에 분진 수용량이 적으며, 포집효율이 떨어지는 문제점을 발생시킨다. However, since the HEPA filter is formed in a single layer structure like the paper filter, the dust capacity is low and the collection efficiency is lowered.
이에 따라 헤파필터를 복층구조로 형성하여 포집효율 및 분진 수용량을 증가시키기 위한 다양한 연구가 진행되고 있다.Accordingly, various studies have been conducted to increase the collection efficiency and the dust capacity by forming a hepa filter in a multilayer structure.
국내등록특허 제10-1000366호(명칭 : 공기 청정용 필터)에서는 필터를 공기 유입측에서 공기 유출측으로 순서대로 벌키층, 중간층, 조밀층 및 필름층의 4층 구조로 구성함으로써 섬유층의 공극을 균일하게 유지하여 필터링 되는 대기 중의 분진에 대한 포집효율 및 수용량을 높일 수 있으나, 각 층들의 결속을 위해 사용되는 계면활성제가 각 섬유층들의 공극을 막기 때문에 수명이 짧아지고, 포집효율이 떨어지는 문제점이 발생된다.In Korean Registered Patent No. 10-1000366 (name: air cleaning filter), the filter has a four-layer structure consisting of a bulky layer, an intermediate layer, a dense layer, and a film layer in order from the air inlet side to the air outlet side to uniform the voids in the fiber layer. It is possible to increase the collection efficiency and capacity of the dust in the air to be filtered, but due to the surfactant used to bind the layers to prevent the pores of each fibrous layer, the life is shortened, the collection efficiency is lowered .
또한 국내등록특허 제10-0405318호(명칭 : 공기 청정기용 필터 여재와 그 제조방법)에서는 필터가 조밀층, 중간층 및 벌키층의 3층 구조로 형성되되 각 층간의 결합이 열융착에 의해 이루어짐으로써 수지접착제에 의해 공극이 막히는 현상이 발생되어 수명이 짧아지거나 또는 포집효율이 떨어지지 않는 장점을 가지나, 이러한 필터는 각 층간의 열융착 공정을 수행하기 위해서는 공정이 복잡할 뿐만 아니라 제조비용을 증가시키며, 섬유 원형이 파괴되는 문제점이 발생된다.In addition, in Korean Patent No. 10-0405318 (name: filter media for air cleaners and a method of manufacturing the same), the filter is formed in a three-layer structure of a dense layer, an intermediate layer, and a bulky layer, and the bonding between the layers is performed by thermal fusion. Pore clogging occurs due to resin adhesive, which has the advantage of shortening the lifespan or reducing the collection efficiency, but such a filter not only is complicated to perform the heat fusion process between layers but also increases the manufacturing cost. The problem is that the fiber prototype is broken.
이와 같이 종래의 벌키층 및 조밀층의 2층 구조 및 벌키층, 중간층 및 조밀층의 3층 구조 등과 같이 다층구조를 갖는 종래의 필터 여과재는 각 층이 화학정 t고체상(固體相)으로 적층된 후 이들을 접착시키기 때문에 니들펀칭기, 수지접착제, 계면활성제 및 열융착 등과 같은 별도의 장치 및 공정을 수행해야 하고, 이러한 방식은 섬유의 원형 및 원성질을 변형 및 파괴시킬 뿐만 아니라 제조 과정이 번거로운 문제점이 발생된다. As described above, in the conventional filter medium having a multilayer structure such as the two-layer structure of the bulky layer and the dense layer and the three-layer structure of the bulky layer, the intermediate layer and the dense layer, each layer is laminated in a chemical crystal solid state. Since they adhere to each other, separate devices and processes such as needle punching machines, resin adhesives, surfactants, and heat fusion, etc. must be carried out, and this method not only deforms and destroys the circular and original properties of the fibers, but also makes the manufacturing process cumbersome. Is generated.
이러한 문제점을 극복하기 위해 조밀층 및 벌키층을 형성하는 섬유를 액상으로 적층시킨 후 탈수 및 경화시켜 각 층간의 섬유들이 접촉면에서 엉키게 되어 별도의 접착수단 및 공정을 수행하지 않고도 포집효율이 우수할 뿐만 아니라 층간결속이 견고한 필터에 대한 연구가 다양하게 진행되고 있다.In order to overcome this problem, the fibers forming the dense layer and the bulky layer are laminated in a liquid state, and then dehydrated and cured so that the fibers between the layers are entangled at the contact surface, so that the collection efficiency may be excellent without performing an additional bonding means and process. In addition, various studies have been conducted on filters having strong interlayer bonds.
도 1은 종래의 미국공개특허 제20070163218호(명칭 : 2층 구조를 갖는 헤파필터)에 기재된 헤파필터를 나타내는 단면도이다.1 is a cross-sectional view showing a hepa filter described in the prior art US Patent Publication No. 20070163218 (name: hepa filter having a two-layer structure).
도 1의 헤파필터(100)(이하, 종래의 헤파필터라고 하기로 함)는 직경 2.0 ~ 8.0㎛이며 50 ~ 625㎛의 두께를 갖는 미세분층(101)과, 직경 0.2 ~ 0.8㎛이며 125 ~ 750㎛의 두께를 갖되 상기 미세분층(101)의 하부에 형성되는 헤파층(103)과, 전체 두께의 3 ~ 20%의 두께로 형성되며 상기 미세분층(101)과 헤파층(103) 사이에 형성되되 미세분층(101)과 헤파층(103)이 혼합되어 형성되는 전이영역(105)으로 구성된다.The HEPA filter 100 (hereinafter, referred to as a conventional HEPA filter) of FIG. 1 is a finely divided layer 101 having a diameter of 2.0 to 8.0 μm and a thickness of 50 to 625 μm, and a diameter of 0.2 to 0.8 μm and 125 to Hepa layer 103 having a thickness of 750㎛ formed on the lower portion of the fine powder layer 101, and is formed to a thickness of 3 to 20% of the total thickness between the fine powder layer 101 and the hepa layer 103 It is formed of a transition region 105 is formed by mixing the fine powder layer 101 and the hepatic layer 103.
또한 종래의 헤파필터(100)는 헤파층(103)과 미세분층(101)의 혼합물로 구성되는 전이영역(105)이 헤파층(103)과 미세분층(101) 사이에 형성되어 헤파층(103)과 미세분층(101)을 결속시킴으로써 별도의 수지접착제등과 같은 별도의 결합부재를 사용하지 않고도 전이영역(105)에 의해 견고하게 결속된다.In addition, in the conventional HEPA filter 100, a transition region 105 composed of a mixture of the HEPA layer 103 and the fine powder layer 101 is formed between the HEPA layer 103 and the fine powder layer 101 so that the HEPA layer 103 is formed. ) And the fine powder layer 101 are firmly bound by the transition region 105 without using a separate bonding member such as a separate resin adhesive or the like.
또한 종래의 헤파필터(100)는 전이영역(105)이 헤파층(103)과 미세분층(101)이 견고하게 결속되도록 미세분층(103)과 헤파층(101)을 결속시킬 뿐만 아니라 헤파 필터 재료 안으로 주름이 잡힐 수 있기 때문에 주름 공정 시 2개의 층이 분리되지 않게 된다.In addition, the conventional HEPA filter 100 not only binds the fine powder layer 103 and the HEPA layer 101 so that the transition region 105 firmly binds the HEPA layer 103 and the fine powder layer 101, as well as the hepa filter material. The pleating process ensures that the two layers do not separate during the pleating process.
또한 종래의 헤파필터(100)는 층간 결합력이 높아져 포집효율이 증가하며, 분진 수용량이 증가하는 장점을 갖는다.In addition, the conventional HEPA filter 100 has an advantage of increasing the binding strength between layers increases the collection efficiency, the dust capacity increases.
그러나 종래의 헤파필터(100)는 미세분층(101)과 헤파층(103)을 분리시켜 적층시키기 위해 제조 시 미세분층의 섬유 및 헤파층의 섬유가 2개의 헤드박스에 분리되어 분사되기 때문에 제조가 복잡하고, 비용이 증가하는 문제점이 발생된다.However, the conventional HEPA filter 100 is manufactured because the fibers of the fine powder layer and the fibers of the hepa layer are separated and sprayed into two head boxes during manufacturing to separate and laminate the fine powder layer 101 and the hepa layer 103. Complex and costly problems arise.
본 발명은 이러한 문제를 해결하기 위한 것으로, 본 발명의 해결과제는 직경 0.1 ~ 1.0㎛의 극세섬유 55 ~ 75 중량%와, 직경 1.0 ~ 5.0㎛의 미세섬유 10 ~ 25중량%와, 촙 유리섬유 0 ~ 35 중량%로 구성되는 필터조성물을 각기 다른 헤드박스농도로 분사하여 적층된 조밀층 및 벌키층의 2층 구조를 형성함으로써 압력손실이 낮을 뿐만 아니라 포집효율 및 분진 수용량이 높은 필터 여과재를 제공하기 위한 것이다.The present invention is to solve this problem, the problem of the present invention is 55 to 75% by weight of ultrafine fibers with a diameter of 0.1 to 1.0㎛, 10 to 25% by weight of microfibers with a diameter of 1.0 to 5.0㎛, 촙 glass fiber By spraying the filter composition composed of 0 to 35% by weight with different head box concentrations to form a two-layer structure of stacked dense layer and bulky layer, it provides a filter medium with low pressure loss and high dust collection efficiency and dust content. It is to.
또한 본 발명의 다른 해결과제는 필터조성물 적층공정 시 시 필터조성물 1.5 ~ 2.5 중량%를 물 97.5 ~ 98.5 중량%로 교반시킨 액상의 필터 슬러리를 스크린 위로 분사시킨 후 탈수 및 경화공정을 수행함으로써 수지접착제 및 계면활성제 등과 같은 별도의 장치 없이도 층간 결속력이 높을 뿐만 아니라 필터조성물의 공극 및 원형이 파괴되거나 변형되지 않는 필터 여과재를 제공하기 위한 것이다.In addition, another problem of the present invention is a resin adhesive by spraying a filter slurry of 1.5 ~ 2.5% by weight of the filter composition with water 97.5 ~ 98.5% by weight on the screen during the filter composition lamination process and then dehydration and curing process And it is to provide a filter filter medium that not only does not have a high interlayer binding force, but also voids and circles of the filter composition is not broken or deformed without a separate device such as a surfactant.
상기 과제를 해결하기 위한 본 발명의 해결수단은 0.1 ~ 1.0㎛의 직경을 갖는 극세섬유 55 중량% 이상 내지 75 중량% 이하와, 1.0 ~ 5.0㎛의 직경을 갖는 미세섬유 10 중량% 이상 내지 25 중량% 이하와, 5㎛ 이상의 직경을 갖는 촙 유리섬유 0 중량% 초과 내지 35 중량% 이하로 구성되는 필터조성물을 적층시켜 미세먼지 및 분진을 필터링 시키는 필터여과재에 있어서: 상기 필터조성물 1.5 중량% 이상 내지 2.5 중량% 이하를 물 97.5 중량% 이상 내지 98.5 중량% 이하에 용해 및 교반시킨 필터슬러리가 헤드박스농도 0.05 ~ 1.0 질량%의 농도로 분사되어 형성되는 조밀층; 상기 필터슬러리가 헤드박스농도 0.03 ~ 0.06 질량%의 농도로 상기 조밀층의 상부에 분사되어 형성되는 벌키층으로 구성되는 것이다.Solution to Problem The present invention for solving the above problems is more than 55% by weight to 75% by weight of ultrafine fibers having a diameter of 0.1 ~ 1.0㎛ and 10% by weight to 25% by weight of microfibers having a diameter of 1.0 ~ 5.0㎛ A filter filter material for filtering fine dust and dust by laminating a filter composition composed of less than or equal to 0% by weight and less than or equal to 35% by weight of a glass fiber having a diameter of 5 μm or more, the filter filter comprising: 1.5% by weight or more of the filter composition A dense layer formed by dissolving and stirring 2.5 wt% or less of water in 97.5 wt% or more and 98.5 wt% or less of the filter slurry at a concentration of 0.05 to 1.0 mass% of the headbox concentration; The filter slurry is composed of a bulky layer formed by spraying the upper portion of the dense layer at a concentration of 0.03 to 0.06 mass% of the head box concentration.
또한 본 발명에서 상기 조밀층 및 상기 벌키층을 형성하는 필터슬러리는 액상으로 적층된 후 탈수 및 경화 공정을 통해 상기 조밀층 및 상기 벌키층을 형성하는 섬유들이 엉키게 되는 것이 바람직하다.In addition, in the present invention, the filter slurry forming the dense layer and the bulky layer is preferably laminated in a liquid phase, and the fibers forming the dense layer and the bulky layer are entangled through a dehydration and curing process.
또한 본 발명에서 상기 필터여과재는 60 ~ 120g/m2의 중량과, 0.2 ~ 1.0mm의 두께를 갖는 것이 바람직하다.In the present invention, the filter filter material is 60 ~ 120 g / m2It is preferable to have a weight of and a thickness of 0.2 to 1.0 mm.
또한 본 발명에서 상기 필터슬러리는 PH 2 ~ 4 농도를 갖는 산 또는 분산제가 첨가되는 것이 바람직하다.In addition, in the present invention, the filter slurry is preferably an acid or dispersant having a PH 2 ~ 4 concentration is added.
상기 과제와 해결수단을 갖는 본 발명에 따르면 조밀층 및 벌키층이 각기 다른 헤드박스농도로 분사되어 적층됨으로써 압력손실이 절감되며, 포집효율이 높아지게 된다.According to the present invention having the above problems and solutions, the pressure loss is reduced and the collection efficiency is increased by spraying the dense layer and the bulky layer at different head box concentrations.
또한 본 발명에 의하면 필터가 2층 구조로 형성되기 때문에 분진수용량이 증가하게 되고, 이에 따라 필터수명이 높아지게 된다.In addition, according to the present invention, since the filter is formed in a two-layer structure, the dust capacity is increased, thereby increasing the filter life.
또한 본 발명에 의하면 별도의 결합부재 없이도 층간 결속력이 높을 뿐만 아니라 섬유층의 공극 및 원형이 변형되지 않기 때문에 포집효율이 증가하게 된다.In addition, according to the present invention, the binding efficiency is not only high because the interlayer binding force is high, and the voids and the circular shape of the fiber layer are not deformed without a separate coupling member, thereby increasing the collection efficiency.
또한 본 발명에 의하면 벌키층의 원료를 조밀층보다 굵은 직경의 섬유로 사용함으로써 원가가 절감된다.In addition, according to the present invention, the raw material of the bulky layer is used as a fiber having a larger diameter than the dense layer, thereby reducing the cost.
도 1은 종래의 미국공개특허 제20070163218호(명칭 : 2층 구조를 갖는 헤파필터)에 기재된 헤파필터를 나타내는 단면도이다.1 is a cross-sectional view showing a hepa filter described in the prior art US Patent Publication No. 20070163218 (name: hepa filter having a two-layer structure).
도 2는 본 발명의 일실시예인 필터 여과재를 나타내는 단면도이다.Figure 2 is a cross-sectional view showing a filter medium of an embodiment of the present invention.
도 3은 본 발명의 일실시예인 필터 여과재를 나타내는 단면도이다.3 is a cross-sectional view showing a filter medium of an embodiment of the present invention.
도 4는 도 3의 필터 여과재의 제조과정을 나타내는 플로차트이다.FIG. 4 is a flowchart illustrating a manufacturing process of the filter medium of FIG. 3.
이하, 첨부된 도면을 참조하여 본 발명의 일실시예를 설명한다.Hereinafter, with reference to the accompanying drawings will be described an embodiment of the present invention.
도 2는 본 발명의 일실시예에 적용되는 필터조성물의 함유성분을 나타내는 개념도이다.2 is a conceptual view showing the components of the filter composition applied to an embodiment of the present invention.
도 2의 필터조성물(30)은 본 발명의 일실시예인 필터 여과재에 적용되는 섬유 조성물이며, 0.1 ~ 1.0㎛의 직경을 갖는 초극세 단섬유(31)(이하, 극세섬유라고 하기로 함) 55 중량% 이상 내지 75 중량% 이하와, 1.0 ~ 5.0㎛의 직경을 갖는 미세 단섬유(33)(이하, 미세섬유라고 하기로 함) 10 중량% 이상 내지 25 중량% 이하와, 직경이 5㎛ 이상인 촙 유리섬유(35) 0 중량% 초과 내지 35 중량% 이하로 이루어진다.The filter composition 30 of FIG. 2 is a fiber composition applied to a filter filter material of one embodiment of the present invention, and has an ultrafine short fiber 31 having a diameter of 0.1 to 1.0 μm (hereinafter, referred to as an ultrafine fiber) 55 weight 10% or more to 75% by weight or less, 10 to 25% by weight or less of fine short fibers 33 (hereinafter referred to as microfibers) having a diameter of 1.0 to 5.0 µm and a diameter of 5 µm or more The glass fiber 35 is more than 0% by weight to 35% by weight or less.
극세섬유(31) 및 미세섬유(33)는 유리 단섬유이며, 붕규산 유리, 내산성을 갖는 C 유리, 전기 절연성을 갖는 E 유리(무알칼리 유리), 붕소 오염 및 붕소 오염을 줄이기 위해 저붕소 유리, 및 실리카 유리들 중 하나이거나 또는 적어도 2개 이상이 혼합된 유리 단섬유로 형성된다.The microfine fibers 31 and the fine fibers 33 are short glass fibers, borosilicate glass, C glass having acid resistance, E glass (alkali glass) having electrical insulation, low boron glass, to reduce boron contamination and boron contamination, And short glass fibers mixed with one or at least two of the silica glasses.
또한 극세섬유(31)는 0.1 ~ 1.0㎛의 직경을 갖는 초극세 단섬유이며, 직경이 작기 때문에 후술되는 도 3의 필터 여과재(1)의 포집효율을 증가시킨다.In addition, the ultrafine fibers 31 are ultrafine short fibers having a diameter of 0.1 to 1.0 μm, and because the diameter thereof is small, the collection efficiency of the filter medium 1 of FIG. 3 to be described later is increased.
또한 극세섬유(31)는 필터조성물(30)의 55 중량% 이상 내지 75 중량% 이하로 구성되고, 만약 극세섬유(31)의 함유량이 55 중량% 미만이면 극세섬유(31)의 성질이 낮아져 포집효율이 떨어지게 되며, 만약 함유량이 75 중량% 이상이면 극세섬유(31)의 함유량이 높아져 압력손실이 증가하게 된다.In addition, the ultrafine fiber 31 is composed of 55% by weight or more and 75% by weight or less of the filter composition 30, and if the content of the microfine fiber 31 is less than 55% by weight, the properties of the ultrafine fiber 31 are lowered and collected. The efficiency is lowered, and if the content is 75% by weight or more, the content of the ultrafine fibers 31 is increased to increase the pressure loss.
촙 유리섬유(35)는 극세섬유(31) 및 미세섬유(33)보다 굵은 유리섬유이며, 상세하게로는 5㎛ 이상의 직경을 갖는 유리섬유인 것이 바람직하다.The glass fiber 35 is a glass fiber thicker than the microfine fiber 31 and the fine fiber 33, and it is preferable that the glass fiber 35 has a diameter of 5 micrometers or more in detail.
또한 촙 유리섬유(35)는 0 중량% 초과 내지 35 중량% 이하로 구성된다.In addition, the glass fiber 35 is composed of more than 0% by weight to 35% by weight or less.
이와 같이 본 발명에 적용되는 필터조성물(30)은 각기 직경이 다른 초극세 단섬유(31), (33)들과 촙 유리섬유(35)들이 혼합됨으로써 포집효율이 증가하게 된다.As described above, the filter composition 30 applied to the present invention increases the collection efficiency by mixing the ultrafine short fibers 31 and 33 and the glass fibers 35 having different diameters.
도 3은 본 발명의 일실시예인 필터 여과재를 나타내는 단면도이다.3 is a cross-sectional view showing a filter medium of an embodiment of the present invention.
도 3의 필터 여과재(1)는 도 2의 필터조성물(30)이 각기 다른 헤드박스농도로 분사된 후 적층됨으로써 외부로부터 유입되는 미세번지 및 분진을 필터링 하는 장치이다.The filter medium 1 of FIG. 3 is a device for filtering fine addresses and dust introduced from the outside by stacking the filter composition 30 of FIG. 2 after being sprayed with different head box concentrations.
또한 필터 여과재(1)는 전술하였던 도 2의 필터조성물(30)이 헤드박스농도 0.05 ~ 1.0 질량%로 분사되어 형성되는 조밀층(3)과, 상기 조밀층(3)의 상부에 형성되되 상기 필터조성물(30)이 헤드박스농도 0.03 ~ 0.06 질량%로 분사되어 형성되는 벌키층(5)으로 이루어진다. In addition, the filter medium (1) is formed on the dense layer (3) is formed by spraying the filter composition 30 of Figure 2 described above in the head box concentration of 0.05 ~ 1.0 mass%, and the dense layer (3) The filter composition 30 is composed of a bulky layer 5 formed by spraying at a headbox concentration of 0.03 to 0.06 mass%.
벌키층(5)은 도 2의 필터조성물(30) 1.5 중량% 이상 내지 2.5 중량% 이하를 물 97.5 중량% 이상 내지 98.5 중량% 이하에 혼합 및 교반시킨 액상의 필터슬러리가 헤드박스농도 0.03 ~ 0.06 질량%로 스크린 위로 분사된 후 탈수 및 경화되어 제조되는 여과재이다.In the bulky layer 5, a liquid filter slurry obtained by mixing and stirring 1.5 wt% or more and 2.5 wt% or less of the filter composition 30 of FIG. 2 to 97.5 wt% or more and 98.5 wt% or less of water has a headbox concentration of 0.03 to 0.06. A filter medium produced by spraying onto a screen by mass% followed by dehydration and curing.
또한 벌키층(5)은 헤드박스농도 0.03 ~ 0.06 질량%로 분사되어 형성되기 때문에 구경이 조밀층(3)에 비해 크게 형성되고, 이에 따라 공기가 유입되는 통로에 설치되어 구경이 큰 분진이나 이물질을 필터링 하게 된다.In addition, since the bulky layer 5 is formed by spraying at a head box concentration of 0.03 to 0.06 mass%, the diameter is larger than that of the dense layer 3, and thus, a large dust or foreign substance is installed in the passage through which air is introduced. Will be filtered.
조밀층(3)은 필터슬러리를 헤드박스농도 0.05 ~ 1.0 질량%로 스크린 위로 분사된 후 탈수 및 경화되어 제조되는 여과재이다.The dense layer 3 is a filter material produced by spraying the filter slurry onto the screen at a headbox concentration of 0.05 to 1.0 mass%, followed by dehydration and curing.
또한 조밀층(3)은 벌키층(5)에 비교하여 헤드박스농도가 높기 때문에 구경이 작게 형성됨으로써 벌키층(5)이 필터링 하지 못한 미세먼지 및 분진을 필터링 하게 된다.In addition, since the dense layer 3 has a higher head box concentration compared to the bulky layer 5, the diameter is smaller, thereby filtering fine dust and dust that the bulky layer 5 cannot filter.
도 4를 참조하여 필터 여과재의 제조과정을 살펴보기로 한다.Referring to Figure 4 will be described the manufacturing process of the filter filter medium.
도 4는 도 3의 필터 여과재의 제조과정을 나타내는 플로차트이다.FIG. 4 is a flowchart illustrating a manufacturing process of the filter medium of FIG. 3.
필터조성물(30)을 제조한다. 이때 필터조성물(30)은 도 2에서 전술하였던 바와 같이 극세섬유(31) 55 중량% 이상 내지 75 중량% 이하와, 미세섬유(33) 10 중량% 이상 내지 25 중량% 이하와, 촙 유리섬유(35) 0 중량% 초과 내지 35 중량% 이하로 구성된다(S10).To prepare a filter composition (30). At this time, the filter composition 30 is 55 wt% or more and 75 wt% or less, as described above with reference to FIG. 2, and 10 wt% or more and 25 wt% or less, and glass fiber ( 35) more than 0 wt% to 35 wt% or less (S10).
용해액인 물에 PH 2 ~ 4의 농도의 산(염산) 또는 분산제를 첨가하여 펄퍼에 넣어 분산액을 제조한다(S20).Dispersion is prepared by adding acid (hydrochloric acid) or dispersant having a concentration of PH 2 to 4 to water as a dissolving solution, and putting it in a pulp (S20).
펄퍼(Pulper)로 단계 10을 통해 준비된 필터조성물(30)을 넣은 후 단계 20(S20)을 통해 제조된 분산액을 교반시킨 필터슬러리를 제조한다. 이때 필터슬러리는 97.5 중량% 이상 내지 98.5 중량% 이하의 분산액과, 1.5 ~ 2.5 중량%의 필터조성물(30)로 구성된다.After putting the filter composition 30 prepared in step 10 to the pulper (Pulper) to prepare a filter slurry with stirring the dispersion prepared in step 20 (S20). At this time, the filter slurry is composed of a dispersion of 97.5% by weight or more and 98.5% by weight or less, and 1.5 to 2.5% by weight of the filter composition 30.
단계 30(S30)을 통해 제조된 필터슬러리를 각 헤드박스에 수용시킨 후 헤드박스농도 0.03 ~ 0.06 질량%의 농도로 스크린 위로 분사시켜 조밀층(3)이 형성되도록 한다(S40).The filter slurry prepared in step 30 (S30) is accommodated in each headbox and then sprayed onto the screen at a concentration of 0.03 to 0.06 mass% of the headbox to form a dense layer 3 (S40).
또한 필터슬러리를 헤드박스농도 0.05 ~ 1.0 질량%의 농도로 단계 40(S40)을 통해 분사된 필터슬러리 위로 분사시켜 조밀층(3) 상부에 벌키층이 형성되도록 한다(S50).In addition, the filter slurry is sprayed onto the filter slurry injected through the step 40 (S40) at a concentration of 0.05 to 1.0 mass% of the headbox concentration so that a bulky layer is formed on the dense layer 3 (S50).
단계 50(S50)을 통해 적층된 필터슬러리를 탈수 시킨 후 120℃에서 30분 동안 가열시켜 필터슬러리에 포함되는 수분을 제거함으로써 본 발명의 일실시예인 필터 여과재(1)가 제조된다(S60).After dehydrating the filter slurry stacked in step 50 (S50) and heated for 30 minutes at 120 ℃ to remove the water contained in the filter slurry is a filter filter material (1) is an embodiment of the present invention (S60).
이와 같이 제조되는 필터 여과재(1)는 조밀층(3) 및 벌키층(5)이 액상으로 적층된 후 경화됨으로써 섬유들이 엉키게 되어 별도의 접착수단 없이도 조밀층(3)과 벌키층(5)이 견고하게 결합할 수 있게 된다.The filter medium (1) thus prepared is cured by laminating the dense layer (3) and the bulky layer (5) in a liquid state, and the fibers are entangled so that the dense layer (3) and the bulky layer (5) do not need any additional adhesive means. This can be combined firmly.
또한 도면에는 도시되지 않았지만 단계 50(S50) 이후에는 후 가공에 의해 프리팅(Pleating)할 수 있도록 바인더 함침 또는 스프레이 공정이 더 포함될 수 있으며, 이러한 공정은 필터여과재 제조에 있어서 통상적인 기술이기 때문에 상세한 설명은 생략하기로 한다.In addition, although not shown in the drawings, after step 50 (S50), a binder impregnation or spray process may be further included so as to be plated by post-processing. The description will be omitted.
이하, 본 발명의 일실시예인 필터여과재(1)에 관해 실시예를 들어 더욱 상세하게 설명한다. 또한 다음의 실시예들은 설명의 목적을 위한 것으로, 본 발명의 보호범위를 제한하지 않는다.Hereinafter, the filter filter material 1 which is one embodiment of the present invention will be described in more detail with reference to Examples. In addition, the following embodiments are for the purpose of explanation and do not limit the protection scope of the present invention.
표 1은 실시예 및 비교예들에 적용되는 필터조성물의 함유성분을 나타내는 것이다.Table 1 shows the components of the filter composition applied to the Examples and Comparative Examples.
표 1
항 목 구 성 FC1 FC2 FC3 FC4 FC5 FC6
배합 극세섬유 70(0.6㎛) 70(0.5㎛) 76(0.6㎛) 58(0.5㎛) 75(0.6㎛) 70(0.5㎛)
미세섬유 20(2.70㎛) 20(2.70㎛) 16(2.70㎛) 28(2.70㎛) 20(2.70㎛) 25(2.70㎛)
촙 유리섬유 10 10 8 14 5 5
Table 1
Item Configuration FC1 FC2 FC3 FC4 FC5 FC6
combination Microfiber 70 (0.6 μm) 70 (0.5 μm) 76 (0.6 μm) 58 (0.5 μm) 75 (0.6 μm) 70 (0.5 μm)
Fine fiber 20 (2.70 μm) 20 (2.70 μm) 16 (2.70 μm) 28 (2.70 μm) 20 (2.70 μm) 25 (2.70 μm)
촙 glass fiber 10 10 8 14 5 5
* 상기 함량은 중량% 임* The content is weight percent
상기 표 1의 시료번호 1(FC1)은 직경 0.6㎛의 극세섬유(31)가 70 중량%로, 직경 2.70㎛의 미세섬유(33)가 20 중량%로, 촙 유리섬유(35)가 10 중량%로 구성되는 필터조성물(30)이다.Sample No. 1 (FC1) in Table 1 is 70% by weight of the microfibers 31 having a diameter of 0.6 μm, 20% by weight of the microfibers 33 having a diameter of 2.70 μm, and 10 weights of the glass fibers 35. A filter composition 30 composed of%.
또한 표 1의 시료번호 2(FC2)는 직경 0.5㎛의 극세섬유(31)가 70 중량%로, 직경 2.70㎛의 미세섬유(33)가 20 중량%로, 촙 유리섬유(35)가 10 중량%로 구성되는 필터조성물(30)이다.In addition, sample number 2 (FC2) of Table 1 is 70% by weight of microfibers 31 having a diameter of 0.5 μm, 20% by weight of microfibers 33 having a diameter of 2.70 μm, and 10 weights of glass fibers 35. A filter composition 30 composed of%.
또한 표 1의 시료번호 3(FC3)은 직경 0.6㎛의 극세섬유(31)가 76 중량%로, 직경 2.70㎛의 미세섬유(33)가 16 중량%로, 촙 유리섬유(35)가 8 중량%로 구성되는 필터조성물(30)이다.In addition, Sample No. 3 (FC3) in Table 1 was 76 wt% for the microfibers 31 having a diameter of 0.6 µm, 16 wt% for the microfibers 33 having a diameter of 2.70 µm, and 8 wt% for the glass fiber 35. A filter composition 30 composed of%.
또한 표 1의 시료번호 4(FC4)는 직경 0.5㎛의 극세섬유(31)가 58 중량%로, 직경 2.70㎛의 미세섬유(33)가 28 중량%로, 촙 유리섬유가 14 중량%로 구성되는 필터 조성물이다.In addition, Sample No. 4 (FC4) of Table 1 is composed of 58 wt% of microfibers 31 having a diameter of 0.5 μm, 28 wt% of fine fibers 33 having a diameter of 2.70 μm, and 14 wt% of glass fibers. Filter composition.
또한 표 1의 시료번호 5(FC5)는 직경 0.6㎛의 극세섬유(31)가 75 중량%로, 직경 2.70㎛의 미세섬유(33)가 20 중량%로, 촙 유리섬유(35)가 5 중량%로 구성되는 필터조성물(30)이다.In addition, sample number 5 (FC5) of Table 1 is 75% by weight of the microfibers 31 having a diameter of 0.6 μm, 20% by weight of the microfibers 33 having a diameter of 2.70 μm, and 5 weights of the glass fiber 35. A filter composition 30 composed of%.
또한 표 1의 시료번호 6(FC6)은 직경 0.5㎛의 극세섬유(31)가 70 중량%로, 직경 2.70㎛의 미세섬유(33)가 25 중량%로, 촙 유리섬유(35)가 5 중량%로 구성되는 필터조성물(30)이다.In addition, sample number 6 (FC6) of Table 1 is 70% by weight of microfibers 31 having a diameter of 0.5 μm, 25% by weight of microfibers 33 having a diameter of 2.70 μm, and 5% by weight of glass fibers 35. A filter composition 30 composed of%.
다음 표 2는 상기 표 1의 필터조성물이 적용되는 필터 여과재(1)의 다른 실시예 및 비교예들을 나타내는 것이다.Table 2 below shows other examples and comparative examples of the filter medium (1) to which the filter composition of Table 1 is applied.
표 2
항목 실시예1 실시예2 실시예3 비교예1 비교예2 비교예3 비교예4 비교예5 비교예6
조밀층 필터조성물 FC1(47.5%) FC1(47.5%) FC3(47.5%) FC5(47.5%) FC5(47.5%) FC5(47.5%) FC6(47.5%) FC6(47.5%) FC6(47.5%)
헤드박스농도 0.07질량% 0.07질량% 0.07질량% 0.1질량% 0.07질량% 0.04질량% 0.7질량% 0.04질량% 0.04질량%
염산 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5
벌키층 필터조성물 FC2(47.5%) FC2(47.5%) FC4(47.5%) X X X X X X
헤드박스농도 0.07질량% 0.04질량% 0.04질량% X X X X X X
염산 PH 2.5 PH 2.5 PH 2.5 X X X X X X
바인더 5% 5% 5% 5% 5% 5% 5% 5% 5%
TABLE 2
Item Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Comparative Example 3 Comparative Example 4 Comparative Example 5 Comparative Example 6
Dense layer Filter composition FC1 (47.5%) FC1 (47.5%) FC3 (47.5%) FC5 (47.5%) FC5 (47.5%) FC5 (47.5%) FC6 (47.5%) FC6 (47.5%) FC6 (47.5%)
Head Box Concentration 0.07 mass% 0.07 mass% 0.07 mass% 0.1 mass% 0.07 mass% 0.04 mass% 0.7 mass% 0.04 mass% 0.04 mass%
Hydrochloric acid PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5 PH 2.5
Bulky layer Filter composition FC2 (47.5%) FC2 (47.5%) FC4 (47.5%) X X X X X X
Head Box Concentration 0.07 mass% 0.04 mass% 0.04 mass% X X X X X X
Hydrochloric acid PH 2.5 PH 2.5 PH 2.5 X X X X X X
bookbinder 5% 5% 5% 5% 5% 5% 5% 5% 5%
* 상기 함량은 중량% 임 * The content is weight percent
표 2를 참조하여 살펴보면 실시예 1은 시료번호 1(FC1)로 형성되는 조밀층(3) 47.5 중량%와, 시료번호 2(FC2)로 형성되는 벌키층(5) 47.5 중량%와, 바인더 5%로 구성되고, 조밀층(3)은 헤드박스농도 0.07 질량%로 형성되며, 벌키층(5)은 헤드박스농도 0.07 질량%로 형성된다.Referring to Table 2, Example 1 shows 47.5 wt% of the dense layer 3 formed of the sample number 1 (FC1), 47.5 wt% of the bulky layer 5 formed of the sample number 2 (FC2), and the binder 5 %, The dense layer 3 is formed at a headbox concentration of 0.07 mass%, and the bulky layer 5 is formed at a headbox concentration of 0.07 mass%.
실시예 2는 시료번호 1(FC1)로 형성되는 조밀층(3) 47.55 중량%와, 시료번호 2(FC2)로 형성되는 벌키층(5) 47.5 중량%와, 바인더 5%로 구성되고, 조밀층(3)은 헤드박스농도 0.07 질량%로 형성되며, 벌키층(5)은 헤드박스농도 0.04 질량%로 형성된다.Example 2 consisted of 47.55 wt% of the dense layer 3 formed of the sample number 1 (FC1), 47.5 wt% of the bulky layer 5 formed of the sample number 2 (FC2), and 5% of the binder. The layer 3 is formed at a headbox concentration of 0.07 mass%, and the bulky layer 5 is formed at a headbox concentration of 0.04 mass%.
실시예 3은 시료번호 3(FC3)으로 형성되는 조밀층(3) 47.55 중량%와, 시료번호 4(FC4)로 형성되는 벌키층(5) 47.5 중량%와, 바인더 5%로 구성되고, 조밀층(3)은 헤드박스농도 0.07 질량%로 형성되며, 벌키층(5)은 헤드박스농도 0.04 질량%로 형성된다.Example 3 consists of 47.55 weight% of dense layer 3 formed of sample number 3 (FC3), 47.5 weight% of the bulky layer 5 formed of sample number 4 (FC4), and 5% of a binder, and The layer 3 is formed at a headbox concentration of 0.07 mass%, and the bulky layer 5 is formed at a headbox concentration of 0.04 mass%.
- 실험예 1 : 압력손실 테스트Experimental Example 1 Pressure Loss Test
압력손실 테스트는 TSI사 8130 Model 시험기를 이용하여 유효면적 100㎠의 필터 여과재에 면 풍속 5.3cm/sec로 통풍하였을 때의 압력손실을 측정하였다.In the pressure loss test, a pressure loss of 5.3 cm / sec of cotton wind velocity was measured using a TSI 8130 Model tester.
- 실험예 2 : DOP(Dioctyl Phthalate) 포집효율 테스트Experimental Example 2 DOP (Dioctyl Phthalate) Collection Efficiency Test
0.3㎛ 크기의 DOP(프탈산다이옥틸)를 포함하는 공기를 유효면적 100㎠의 필터 여과재에 면 풍속 5.3cm/sec로 통풍하였을 때 상류 및 하류로부터 DOP 투과율을 TSI 8130 Model로 측정하였다.DOP permeability was measured by the TSI 8130 Model from upstream and downstream when air containing 0.3 μm-sized DOP (dioctyl phthalate) was ventilated through a filter filter medium having an effective area of 100 cm 2 at a surface velocity of 5.3 cm / sec.
- 실험예 3 : 분산성 평가Experimental Example 3: Evaluation of Dispersibility
분산성은 헤드박스 내의 원료 혼합물 1L을 수거한 후 육안으로 관찰한다. 이때 섬유가 덩어리지거나 결속되지 않을 때는 분산성이 양호하다고 판단하고, 분산성이 양호하면 O로, 불량하면 ×로 표기하였다.Dispersibility is visually observed after collecting 1 L of the raw material mixture in the headbox. At this time, when the fiber was not agglomerated or bound, it was judged that the dispersibility was good, and when the dispersibility was good, O was indicated and when it was poor, × was indicated.
- 실험예 4 : 중량Experimental Example 4: Weight
유효면적 100㎠의 필터 여과재 10개를 추출한 후 평균 중량을 측정하였다.The average weight was measured after extracting 10 filter mediums having an effective area of 100 cm 2.
- 실험예 5 : 두께Experimental Example 5: Thickness
유효면적 100㎠의 필터 여과재 10개를 추출한 후 두께 측정기를 이용하여 추출된 10개의 필터 여과재의 전폭의 평균값을 측정하였다.After extracting 10 filter filter media having an effective area of 100 cm 2, the average value of the total widths of the 10 filter filter media extracted using a thickness meter was measured.
표 3은 실험예 1 내지 5에 의해 측정된 실시예 및 비교예들의 검출값을 나타내는 것이다.Table 3 shows detection values of Examples and Comparative Examples measured by Experimental Examples 1 to 5.
표 3
시료 압력손실(mmAq) 효율(%) 분산성(O, X) 중량(g/㎡) 두께(㎜)
실시예 1 31.9 99.983 O 76 0.45
실시예 2 30.5 99.977 O 76.2 0.45
실시예 3 29.1 99.978 O 76.3 0.45
비교예 1 40.9 99.98 X 76 0.45
비교예 2 39.5 99.994 X 76.5 0.44
비교예 3 39.6 99.994 O 75.4 0.45
비교예 4 36.3 99.978 X 76.1 0.43
비교예 5 35.5 99.991 O 76.2 0.44
비교예 6 38.3 99.993 O 77.5 0.44
TABLE 3
sample Pressure loss (mmAq) efficiency(%) Dispersibility (O, X) Weight (g / ㎡) Thickness (mm)
Example 1 31.9 99.983 O 76 0.45
Example 2 30.5 99.977 O 76.2 0.45
Example 3 29.1 99.978 O 76.3 0.45
Comparative Example 1 40.9 99.98 X 76 0.45
Comparative Example 2 39.5 99.994 X 76.5 0.44
Comparative Example 3 39.6 99.994 O 75.4 0.45
Comparative Example 4 36.3 99.978 X 76.1 0.43
Comparative Example 5 35.5 99.991 O 76.2 0.44
Comparative Example 6 38.3 99.993 O 77.5 0.44
표 3과 같이 헤드박스농도가 다르게 적용된 2층 구조를 갖는 실시예 1 내지 실시예 3은 단층 구조로 형성되는 비교예 1 내지 비교예 6에 비교하여 압력손실이 절감되며, 표집효율이 떨어지지 않을 뿐만 아니라 분산성이 확보되는 것을 알 수 있다.Example 1 to Example 3 having a two-layer structure in which the head box concentration is differently applied as shown in Table 3, the pressure loss is reduced compared to Comparative Examples 1 to 6, which are formed in a single layer structure, and the sampling efficiency does not decrease. It can be seen that the dispersion is secured.
또한 실시예 1 내지 실시예 3은 비교예 1 내지 비교예 6에 비교할 때 중량 및 두께가 크게 증가되지 않는 것을 알 수 있다.In addition, it can be seen that Examples 1 to 3 do not significantly increase in weight and thickness when compared to Comparative Examples 1 to 6.

Claims (4)

  1. 0.1 ~ 1.0㎛의 직경을 갖는 극세섬유 55 중량% 이상 내지 75 중량% 이하와, 1.0 ~ 5.0㎛의 직경을 갖는 미세섬유 10 중량% 이상 내지 25 중량% 이하와, 5㎛ 이상의 직경을 갖는 촙 유리섬유 0 중량% 초과 내지 35 중량% 이하로 구성되는 필터조성물을 적층시켜 미세먼지 및 분진을 필터링 시키는 필터여과재에 있어서:55% by weight or more and 75% by weight or less of ultrafine fibers having a diameter of 0.1-1.0 μm, 10% by weight or more and 25% by weight or less of fine fibers having a diameter of 1.0-5.0 μm, and a glass having a diameter of 5 μm or more In the filter filter material for filtering fine dust and dust by laminating a filter composition consisting of more than 0% to 35% by weight of fibers:
    상기 필터조성물 1.5 중량% 이상 내지 2.5 중량% 이하를 물 97.5 중량% 이상 내지 98.5 중량% 이하에 용해 및 교반시킨 필터슬러리가 헤드박스농도 0.05 ~ 1.0 질량%의 농도로 분사되어 형성되는 조밀층;A dense layer formed by dissolving and stirring the filter composition of 1.5 wt% or more and 2.5 wt% or less in 97.5 wt% or more and 98.5 wt% or less of the filter composition at a concentration of 0.05 to 1.0 mass% of the headbox concentration;
    상기 필터슬러리가 헤드박스농도 0.03 ~ 0.06 질량%의 농도로 상기 조밀층의 상부에 분사되어 형성되는 벌키층으로 구성되는 것을 특징으로 하는 필터 여과재.The filter filter material, characterized in that the filter slurry is composed of a bulky layer is formed by spraying the upper portion of the dense layer at a concentration of 0.03 ~ 0.06 mass% of the head box concentration.
  2. 청구항 1에서, 상기 조밀층 및 상기 벌키층을 형성하는 필터슬러리는 액상으로 적층된 후 탈수 및 경화 공정을 통해 상기 조밀층 및 상기 벌키층을 형성하는 섬유들이 엉키게 되는 것을 특징으로 하는 필터 여과재.The filter filter medium as set forth in claim 1, wherein the filter slurry forming the dense layer and the bulky layer is entangled in a liquid state, and the fibers forming the dense layer and the bulky layer are entangled through a dehydration and curing process.
  3. 청구항 1 또는 2에서, 상기 필터여과재는 60 ~ 120g/m2의 중량과, 0.3~ 1.0mm의 두께를 갖는 것을 특징으로 하는 필터 여과재.The method of claim 1 or 2, wherein the filter filter material is 60 ~ 120 g / m2And a thickness of 0.3 to 1.0 mm.
  4. 청구항 3에서, 상기 필터슬러리는 PH 2 ~ 4 농도를 갖는 산 또는 분산제가 첨가되는 것을 특징으로 하는 필터 여과재.The filter medium as set forth in claim 3, wherein the filter slurry is added with an acid or a dispersant having a pH of 2-4.
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KR101323181B1 (en) * 2013-01-28 2013-10-30 주식회사 엔바이오니아 Laminating apparatus of fiber layer and method of filter medium with multi-layer therefor
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