WO2016013836A1

WO2016013836A1 - Deodorizing filter material, and deodorizing-dustproof composite filter using same

Info

Publication number: WO2016013836A1
Application number: PCT/KR2015/007523
Authority: WO
Inventors: 변성원; 위철호; 김연상; 여상영
Original assignee: 한국생산기술연구원
Priority date: 2014-07-21
Filing date: 2015-07-21
Publication date: 2016-01-28
Also published as: CN106794403A; KR101659820B1; KR20160011288A; CN106794403B

Abstract

The present invention provides a deodorizing filter material and a deodorizing-dustproof composite filter using the same, the deodorizing filter material comprising: a first thermally bonded carded web (TBCW) formed by thermally bonding carded webs; a bulky layer formed by carding a short fiber on the TBCW and then needle-punching the same; an activated carbon powder scattered and included in the bulky layer; and a second thermally bonded carded web laminated on the bulky layer. The deodorizing filter material according to the present invention has superior air permeability wherein the air permeability measured by the method of ISO 9237 is 200 cm³/cm²-sec or more.

Description

Deodorizing filter material and deodorization dustproof filter using same

The present invention relates to a deodorizing filter material and a deodorization dustproof composite filter using the same, and more particularly, a thermally bonded carded web manufactured by using a herbicidal composite yarn as a support for supporting activated carbon particles for deodorization. By forming a bulky layer on the present invention, it relates to a deodorizing filter material having improved breathability and a deodorizing and dustproof filter produced using the same.

In general, a method of including activated carbon in an air filter used for automobile air conditioning for deodorization or for removing hydrocarbons (eg, styrene) is to insert an activated carbon layer between two nonwoven fabrics.

However, in the case of forming the activated carbon layer according to this method, it is common to disperse together with an adhesive, for example, hot-melt powder, which is fixed therein in order to prevent the falling of the activated carbon to be inserted, and then thermally bond to the adhesive. As a result, the effective amount of activated carbon was reduced, and the air permeability of the entire filter material was inevitable. In addition, in this method, in order to fix as much activated carbon as necessary, the structure of the "active carbon layer / adhesive layer" has often to be repeated, which has caused a worsening of breathability.

As a method for solving the above problem, various prior arts are known with respect to the air-conditioning filter material formed in multiple layers including a bulky layer.

For example, KR2009-0015347A discloses a dense layer, a middle layer, a bulky layer, and an air cleaner filter for automobiles, which are thermally fused by activated carbon fibers on the dense layer including Cisco-type low melting polyethylene terephthalate fibers. In this document, the formation of the dense layer, the intermediate layer and the bulky layer is controlled by the method of varying the fineness of the fibers constituting each layer.

The method of forming the bulky layer by varying the fineness of the fibers may be additionally referred to as disclosed in KR1998-072079A, KR2001-0089865A KR2006-0016283A, and the like.

Meanwhile, KR2007-0035344A prepares a web made of short fibers in which high melting point yarns and low melting point yarns are mixed, and then heats to form a bulky nonwoven fabric having a lower surface where the high melting point yarns are bound to each other due to the molten low melting point yarns. A method of manufacturing a composite filter by spraying a deodorizing powder on a bulky nonwoven fabric and then laminating a meltblown nonwoven fabric and a spunbond nonwoven fabric is disclosed.

As a method similar to the above-mentioned patent document, KR2006-0108418A carded and molded the fiber surface mixed with low-melting point fibers according to a conventional nonwoven fabric manufacturing method and supplied in a short fiber web state, and a meltblown nonwoven fabric sheet was introduced thereunder. A method for producing a multi-layer composite nonwoven fabric for a high efficiency gas filter characterized in that the two-layer structure, and needle punching and thermal calendering continuously.

On the other hand, KR2008-0112560 discloses a nonwoven fabric produced by using a fiber obtained by stretching a polyolefin resin and then crimping it.

However, even in the case of the prior arts, the problem of reducing aeration volume is still not solved.

It is an object of the present invention to provide a deodorizing filter material having improved breathability by forming a bulky layer on a support.

Another object of the present invention is to provide a deodorizing and dustproof composite filter using the filter material.

The present invention provides a thermally bonded carded web (TBCW) formed by thermally bonding a carded web; A bulky layer formed by carding short fibers on the card TBCW and then needle punching; Activated carbon powder dispersed in the bulky layer; And a second thermal adhesive card web laminated on the bulky layer.

Preferably, the fibrous material of the first thermal adhesive card web, the bulky layer, and the second thermal adhesive card web is a sheath type PP / PE composite yarn or LM-PET.

It is preferable that the composite yarn has a fineness of 2 to 20 denier.

The weight of the first thermal adhesive card web and the second thermal adhesive card web is independently 20 to 150g / m ² It is preferable.

The weight of the bulky layer is preferably 20 to 90 g / m ² .

The activated carbon particles fixed in the bulky layer are preferably 200-400 g / m ² .

The first thermal adhesive card web and the second thermal adhesive card web each have an air permeability of at least 600 cm ³ / cm ² -sec measured by the ISO 9237 method; The air permeability after the bulky layer fixed on the first and thermally bonded carded webs is formed is 500 cm ³ / cm ² -sec or more; The air permeability after the second heat adhesive filter material is laminated is preferably 200 cm ³ / cm ² -sec or more.

In addition, the present invention provides a deodorization-dustproof composite filter in which a melt blown nonwoven fabric is laminated on one surface of the deodorizing filter material.

It is preferable that the air permeability measured by the ISO 9237 method of the composite filter is 80 cm ³ / cm ² -sec or more.

Deodorizing filter material according to the present invention by forming a bulky layer on the support and fixing the activated carbon in the formed bulky layer, the air permeability measured by the ISO 9237 method has an excellent breathability of 200cm ³ / cm ² -sec or more, By using the dust-absorbing melt blown nonwoven fabric laminated on one surface of the filter material for deodorization, a composite filter for deodorization and dustproof having an air permeability of 80 cm ³ / cm ² -sec or more can be manufactured.

BRIEF DESCRIPTION OF THE DRAWINGS It is typical sectional drawing about embodiment of the deodorizing filter material of this invention.

2 is a schematic cross-sectional view of another embodiment of the deodorization-dust filter of the present invention.

Hereinafter, a deodorizing filter material according to the present invention will be described with reference to the accompanying drawings.

Referring to FIG. 1, a deodorizing filter material 10 according to an embodiment of the present invention includes a first thermally bonded carded web (TBCW) 11 formed by thermally bonding a carded web. ; A bulky layer 12 formed by carding short fibers 14 on the card TBCW and then needle punching; Activated carbon powder 15 included in the bulky layer 12; And a second heat-adhesive card web 13 stacked on the bulky layer 12.

1. First thermal adhesive card web 11

A first feature in an embodiment of the present invention is the use of thermally bonded

carded webs

11, 13 as a support for supporting the bulky layer 12 comprising activated carbon powder 15. The thermally bonded carded web may be manufactured by carding a fibrous material and then thermally bonding according to a conventional method. Preferably, a sheath-core type composite yarn is used to obtain a low breathable high heat adhesive card web. As for the sympo composite yarn used for this purpose, the one disclosed in Republic of Korea Registration No. 1296615 may be used. Preferably it is prepared using PP / PE composite yarn or LM-PET.

In the present invention, the fiber material used to manufacture the heat-bonded card web is preferably used 2 to 20 denier. When using less than 2 denier fibrous material, the heat-adhesive card web manufactured is inferior in breathability. This is considered to be because the density is too high or the space formed between the fibers is small. On the other hand, in the case of using more than 20 denier fibrous material may drop out of the activated carbon particles scattered thereon.

On the other hand, the weight of the heat-adhesive card web made of the above-described material and fineness is preferably 20 to 150g / m ² . When the weight of the web does not reach 20 g / m ² , not only is not suitable for use as a support due to the decrease in strength, but also dropout of activated carbon particles may occur due to breakage occurring during needle punching described later. On the other hand, when exceeding 150 g / m < ² >, the air permeability fall will become clear.

More preferably, the air permeability of the heat-adhesive card web itself used as a support in the deodorizing filter material composed of a multilayer should be at least 600 cm ³ / cm ² -sec.

The material generally used as the support in the prior art is a spunbond nonwoven of polypropylene or polyester. However, when the nonwoven fabric is used as a support, the filter medium produced therefrom also has a large differential pressure due to its low breathability. According to the inventors' repeated experiments, a heat-adhesive card web manufactured by using a polyethylene terephthalate (PET) spunbond nonwoven fabric of the same weight and a deep-sealing low melting point composite yarn (LM-PET) also made of polyethylene terephthalate is used as a support. In comparison, it was confirmed that the amount of aeration may vary by about 2 times or more.

2. Bulky layer (12)

In the deodorizing filter material 10 according to an embodiment of the present invention, the bulky layer 12 is a layer for fixing the activated carbon particles 15. The bulky layer 14 is formed by carding short fibers 14 on the thermally bonded carded web 11 described above and then needle punching.

On the other hand, the weight of the bulky layer 12 is preferably 20 to 90g / m ² . If the weight of the bulky layer does not reach 20g / m ^{2 It} is insufficient to fix the activated carbon particles to be described later to drop the particles when a large amount of activated carbon particles to be fixed. On the other hand, when it exceeds 90g / m ² may cause a decrease in breathability.

In the present invention, there is no particular limitation with respect to the needle density of needle punching for fixing the bulky layer 12 and the first thermally bonded carded web 11, for example, the conventional pre-punching and the present punching density. It can be carried out at 500 ~ 4000 pieces / m ² .

When activated carbon particles are sprayed on the bulky layer 12, the activated carbon particles 15 are positioned in a space formed between the short fibers 14 of the bulky layer 12. In part, the activated carbon particles 15 may pass through the bulky layer 12 to be distributed on the first thermally bonded carded web. On the other hand, when spraying, suction is performed under the first heat-adhesive card web 11 on the lower surface to increase the packing density of the deodorizing powders.

The activated carbon can be used without limitation so long as it has a function of removing hydrocarbon gas or other odors. For this purpose, an average particle diameter of 100 to 1500 µm is usually used.

Another advantage of the deodorizing filter material according to the present invention is that a large amount of activated carbon particles can be fixed without a separate adhesive such as hot melt powder. Specifically, it was confirmed that, according to experiments by the inventors of the weight of 30g / m ² and a particle application amount of activated carbon in the case of forming the bee kicheung 200g / m ² or more is possible, can be applied even 400g / m ^2.

In the conventional method, as a method of fixing activated carbon between nonwoven fabrics, a method of fixing an activated carbon / active carbon layer or an activated carbon / nonwoven fabric layer using hot melt powder has been used. However, when the hot melt adhesive is used, the present invention not only causes a decrease in breathability, but in particular, when fixing a large amount of activated carbon, there is a problem in that 'active carbon / hot melt powder' must be laminated in order in multiple layers. In the present invention, by solving the above-mentioned problems by fixing the activated carbon particles 15 in the space formed between the short fibers forming the bulky layer 12, while fixing a large amount of activated carbon particles without deterioration of air permeability filter material Can be prepared.

In the embodiment of the present invention, it is preferable to use the same material as that of the first heat-adhesive card web described above, for example, in consideration of the case where additional heat-bonding process is required. In addition, there is no restriction | limiting in particular regarding the fineness of the said short fiber.

On the other hand, it is preferable to use the thing of 30-100 mm in length of a short fiber. If the length of the short fibers does not reach 30 mm, inter-fiber entanglement is not sufficient, and if the length exceeds 100 mm, a process problem such as curling of the fiber on the roll during carding process increases.

On the other hand, in a preferred embodiment of the present invention, after the bulky layer 12 is laminated on the first heat-adhesive card web 11, the ventilation in the fixed state by needle punching is adjusted to 500 cm ³ / cm ² -sec or more It is desirable to be.

3. Second heat adhesive card web 13

The filter medium 10 according to the present invention is formed by laminating and then fixing a second thermal adhesive card web 13 on the bulky layer 12 fixed by the needle punching.

The fixing may be performed by needle punching or by pressing at the same time dissolving only the low-melting sheath portion of the core sheath composite yarn without intervening the adhesive.

The material and manufacturing method of the second thermal adhesive card web 13 are the same as those of the first thermal adhesive card web 13.

On the other hand, in the deodorizing filter material according to the present invention, the weights of the first and second thermally

adhesive card webs

11 and 13 may be the same or different. For example, when the manufactured deodorizing filter material is used alone, the weights of the first and second thermal

adhesive card webs

11 and 13 may be equally designed. As another example, as described below, when another material is laminated and used on the upper surface of the second thermal adhesive card web, the weight of the second thermal adhesive card web can be reduced to minimize the loss of air permeability.

In a preferred embodiment of the present invention, the weight of the first and second heat-adhesive card webs (11, 13) may be the same or different, and in any case, the deodorizing filter media (10) has a ventilation of 200 cm ³ / cm ² -sec or more is preferably adjusted.

4. Deodorization and Dustproof Composite Filter

2 is a schematic cross-sectional view illustrating the layer structure of a deodorizing dustproof composite filter according to the present invention. As shown in FIG. 2, the above-described deodorizing filter material 10 may be combined or stacked with the anti-vibration filter material 21 to be manufactured as a composite filter 20 having both deodorization and dustproof functions at the same time.

Typical examples of the dustproof filter material 21 used for the above purpose are melt blown nonwoven fabrics. The meltblown nonwoven fabric exhibits excellent characteristics as a filter of medium and high performance. The medium and high performance filters refer to the filters corresponding to the MERV 7 to 16 level of the American Air Filter Standard ANSI / ASHRAE 52.2 (1999), and the dust-proof melt-blown nonwoven fabric of the present invention is not limited as long as it is a dust-proof filter conforming to this standard. Can be used as

On the other hand, when the dustproof filter material 21 is a meltblown nonwoven fabric, the support or fixing function for activated carbon particles may be simultaneously performed. In this case, the thermal adhesive card nonwoven fabric contacting the meltblown nonwoven fabric is omitted, and the composite The filter may be manufactured in a form in which the first heat-adhesive card web, the bulky layer to which activated carbon is fixed, and the meltblown nonwoven fabric are sequentially laminated and bonded.

The deodorizing filter material 10 and the dustproof filter material 21 may be, for example, a variety of known materials such as needle punching, heat bonding such as calendering, adhesive using a pressure-sensitive adhesive or an adhesive such as powder or non-woven hot melt adhesive. It can be glued by means.

On the other hand, one or both surfaces of the deodorization-dustproof composite filter 20 of the present invention consisting of the deodorizing filter material 10 and the dustproof filter material 21 may be provided with additional layers having various purposes. For example, a spunbond nonwoven fabric may be laminated on the dustproof filter material or between the deodorizing filter material and the dustproof filter material to protect the filter material or to impart the shape stability of the composite filter. In addition, the deodorization-dustproof filter may be further subjected to electrostatic treatment according to a known method after lamination. A widely used electrostatic treatment method is to process the wire type corona charging method at room temperature, but is not limited thereto.

Hereinafter, the present invention will be described in detail by way of examples. The following examples are merely illustrative of the present invention, but the scope of the present invention is not limited to the following examples.

Example 1

First, cardiac herbaceous composite yarn (LM-PET, 10 denier) whose supercomponent is co-PET and core component is PET, and then thermally bonded (130 ° C., 1ton / cm ² ) to 30 g / m ² first thermal adhesive Preparing a Card Web The air permeability of the first thermally adhesive card web was 700 cm ³ / cm ² -sec.

Next, 10 denier LM-PET was carded on the first thermal adhesive card web, and then needle punched at intervals of 15 to 30 mm to form a bulky layer. The air permeability of the two layers composed of the first thermally bonded carded web / bulky layer was 550 cm ³ / cm ² -sec.

The prepared needle punched nonwoven fabric was used as a lower supporter, and 20 to 40 mesh of activated carbon particles were uniformly dispersed in an amount of 200 g / m ² thereon.

A 20g / m ² polypropylene meltblown nonwoven fabric (1-10 denier) laminated with a spunbond nonwoven fabric was covered on the applied activated carbon and thermally bonded at a temperature of 200 ° C. using a laminate to prepare a filter for deodorization and dustproofing.

Example 2

Deodorizing and dustproof filters were prepared in the same manner as in Example 1 except that the amount of scattering of activated carbon particles was increased to 300 g / m ² .

Example 3

The first thermal adhesive card web / bulky layer made in the same manner as in Example 1 was dispersed with 20 to 40 mesh of activated carbon particles in an amount of 200 g / m ² , and then carded with a deep sheath composite yarn (LMPET 10 denier). Was covered with a second thermal adhesive card web (the same weight as the first thermal adhesive card web), and then thermally bonded at a temperature of 200 ° C. using a laminate to prepare a filter material for deodorization.

The melt blown nonwoven fabric was laminated on the prepared deodorizing filter material on the second heat-adhesive card web, and thermally bonded at a temperature of 200 ° C. using a laminate to prepare a deodorization-dustproof filter.

Comparative Example 1

Deodorizing and dust-proof filters were prepared in the same manner as in Example 1, except that 30 g / m ² PET spunbond nonwoven fabric was used as a support instead of the first heat-adhesive card web.

Comparative Example 2

Deodorizing and dustproof filters were prepared in the same manner as in Comparative Example 1 except that the amount of scattering of activated carbon particles was increased to 300 g / m ² .

Comparative Example 3

Without forming a bulky layer, a deodorization-dustproof filter was prepared by directly dispersing activated carbon particles at a weight of 300 g / m ² on a first heat-adhesive card web, then laminating a meltblown nonwoven fabric and thermally bonding it. .

Comparative Example 4

Deodorizing and dustproof filters were prepared in the same manner as in Comparative Example 3 except that the activated carbon particles were directly dispersed on the first heat-adhesive card web at a weight of 200 g / m ² .

evaluation

1. Thickness and basis weight

The thickness of the sample was measured using a thickness gauge of MITUTOYO according to KS K ISO 9073-1, and the basis weight was calculated as g / m ² based on KS K 0514.

2. Air permeability

The air permeability of the prepared activated carbon composite filter media was measured three times by taking samples from the left, right, and middle parts except for the edge part using a Prezier type air permeability tester (AP-360) of ISO 9237 standard. Calculated. The air pressure used for the measurement was 125 Pa.

3. Degassing efficiency

The unit was manufactured with the media of the prepared sample, and the toxic gas removal efficiency was measured. Using the Hazardous Gas Removal Efficiency Evaluation Equipment (PAF 113, TOPAS GMBH), the flow rate was set to 150 m ³ / h and the toluene gas concentration was set to 80 ppm as the noxious gas. While measuring the inlet gas concentration after 5 minutes, the adsorption efficiency was measured.

4. Departure Status of Activated Carbon

In the pleating process of manufacturing the deodorization-dustproof media as a unit, it was recorded as 'good' if the activated carbon dropped below 50ea / m ² between the media and 'departure'.

The property evaluation results for Examples and Comparative Examples are summarized in the table below.

Table 1

	Air permeability cm ³ / cm ² -sec	Deactivated state of activated carbon	Degassing efficiency (%)
Example 1	157	Good	50
Example 2	120	Good	73
Example 3	166	Good	50
Comparative Example 1	85	Good	49
Comparative Example 2	49	Good	65
Comparative Example 3	159	Breakaway	40
Comparative Example 4	124	Breakaway	58

The deodorization-dustproof filter manufactured in the embodiments according to the present invention has good activated carbon leaving state, high gas removal efficiency, and high air permeability, so it is preferable to use as filter medium.

On the other hand, although the air permeability of Comparative Example 3 was the highest among the prepared filter media, the lack of a binder for fixing activated carbon showed a phenomenon that the activated carbon was released, which was not preferable for use as a filter media. In addition, the prototypes made in Comparative Examples 1 and 2 had good activated carbon leaving state, but because the air permeability is very low, it is expected to take a lot of differential pressure when used as a filter, this is also not preferable to use as a filter medium.

The composite filter of the present invention can be used as a cabin air filter, an air conditioner or an air cleaning filter for automobiles.

10. Deodorizing filter material 11 .. First heat adhesive card web

12. Bulky 13. Second Thermal Adhesive Card Web

14. Short fibers 15. Activated carbon particles

20 .. Deodorization and dustproof composite filter 21 .. Dustproof filter material

Claims

A first thermally bonded carded web (TBCW) formed by thermally bonding a carded web;

A bulky layer formed by carding short fibers on the card TBCW and then needle punching;

Activated carbon powder dispersed in the bulky layer; And

Deodorizing filter material comprising a; second thermal adhesive card web laminated on the bulky layer.
The deodorizing filter material according to claim 1, wherein the fibrous material of the first thermal adhesive card web, the bulky layer, and the second thermal adhesive card web is a sheath type PP / PE composite yarn or LM-PET.
The method of claim 2, wherein the composite yarn has a fineness of 2 to 20 denier; The weight of the first thermal adhesive card web and the second thermal adhesive card web is independently 20 to 150g / m 2 Deodorizing filter material, characterized in that.
The deodorizing filter material of claim 1, wherein the bulky layer has a weight of 20 to 90 g / m 2 .
The method of claim 1, wherein the activated carbon particles fixed to the bulky layer is deodorizing filter material, characterized in that 200 to 400g / m 2 .
The method of claim 1,

The first thermal adhesive card web and the second thermal adhesive card web each have an air permeability of at least 600 cm 3 / cm 2 -sec measured by the ISO 9237 method;

The air permeability after the bulky layer fixed on the first and thermally bonded carded webs is formed is 500 cm 3 / cm 2 -sec or more;

Air permeability after the second thermal adhesive filter material is laminated is 200cm 3 / cm 2 -s or more; Deodorizing filter material, characterized in that.
A deodorizing and dustproof composite filter in which a meltblown nonwoven fabric is laminated on one surface of the deodorizing filter material of claim 1.
The deodorizing and dustproof composite filter according to claim 7, wherein the air permeability measured by the ISO 9237 method is 80 cm 3 / cm 2 -sec or more.