WO2023121487A1 - Filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors - Google Patents

Filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors Download PDF

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Publication number
WO2023121487A1
WO2023121487A1 PCT/PL2021/000097 PL2021000097W WO2023121487A1 WO 2023121487 A1 WO2023121487 A1 WO 2023121487A1 PL 2021000097 W PL2021000097 W PL 2021000097W WO 2023121487 A1 WO2023121487 A1 WO 2023121487A1
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WO
WIPO (PCT)
Prior art keywords
filtering
absorbing material
filtration
backing layer
woven fabric
Prior art date
Application number
PCT/PL2021/000097
Other languages
French (fr)
Inventor
Beata Pąprowicz-Nędza
Ewelina Pąprowicz
Dawid POLAR
Piotr WOJNAR
Original Assignee
Pąprowicz, Jan
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Application filed by Pąprowicz, Jan filed Critical Pąprowicz, Jan
Priority to PCT/PL2021/000097 priority Critical patent/WO2023121487A1/en
Publication of WO2023121487A1 publication Critical patent/WO2023121487A1/en

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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
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N25/00—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests
    • A01N25/34—Shaped forms, e.g. sheets, not provided for in any other sub-group of this main group
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01P—BIOCIDAL, PEST REPELLANT, PEST ATTRACTANT OR PLANT GROWTH REGULATORY ACTIVITY OF CHEMICAL COMPOUNDS OR PREPARATIONS
    • A01P1/00—Disinfectants; Antimicrobial compounds or mixtures thereof
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01P—BIOCIDAL, PEST REPELLANT, PEST ATTRACTANT OR PLANT GROWTH REGULATORY ACTIVITY OF CHEMICAL COMPOUNDS OR PREPARATIONS
    • A01P3/00—Fungicides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/10—Filter screens essentially made of metal
    • B01D39/12—Filter screens essentially made of metal of wire gauze; of knitted wire; of expanded metal
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2209/00—Aspects relating to disinfection, sterilisation or deodorisation of air
    • A61L2209/10—Apparatus features
    • A61L2209/14—Filtering means
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L2209/00—Aspects relating to disinfection, sterilisation or deodorisation of air
    • A61L2209/10—Apparatus features
    • A61L2209/16—Connections to a HVAC unit
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L9/00—Disinfection, sterilisation or deodorisation of air
    • A61L9/01—Deodorant compositions
    • A61L9/014—Deodorant compositions containing sorbent material, e.g. activated carbon
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L9/00—Disinfection, sterilisation or deodorisation of air
    • A61L9/16—Disinfection, sterilisation or deodorisation of air using physical phenomena
    • 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
    • B01D2239/0216—Bicomponent or multicomponent fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0258—Types of fibres, filaments or particles, self-supporting or supported materials comprising nanoparticles
    • 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
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0407—Additives and treatments of the filtering material comprising particulate additives, e.g. adsorbents
    • 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
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0442—Antimicrobial, antibacterial, antifungal additives
    • 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
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/045—Deodorising additives
    • 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
    • B01D2239/0627—Spun-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
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0681—The layers being joined by gluing
    • 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
    • B01D2239/08—Special characteristics of binders
    • B01D2239/083—Binders between layers of the filter
    • 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
    • B01D2239/1233—Fibre diameter
    • 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
    • B01D2239/1258—Permeability
    • 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
    • B01D2239/1291—Other parameters

Definitions

  • the subject of the invention is a filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors, intended for an absorption of pollutants from the air and for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry.
  • a filtering material with microbiological activity and its manufacturing method intended for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry.
  • the material has at least one filtration layer, containing active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: ⁇ silver, copper, gold, platinum, zinc, nickel ⁇ or in the form of the titanium dioxide nanoparticles or in the form of copper salts.
  • Active antibacterial or fungicidal particles are applied on the surface of the filtration layer of the filtering and absorbing material or in the entire mass of the filtration layer of the filtering and absorbing material.
  • antibacterial or fungicidal particles are on the surface of the filtration layer of the filtering material and selection of the silver nanoparticles, they are in an amount of 0,125 to 25 mg per 1 m 2 , what corresponds to the concentration of 125 to 25000 ppm counting per 1 g grammage of dry filtration layer, selection of the gold nanoparticles, they are in an amount of 0,25 to 25 mg per 1 m 2 , what corresponds to the concentration of 250 to 25000 ppm counting per 1 g grammage of dry filtration layer, selection of the platinum nanoparticles, they are in an amount of 0,25 to 25 mg per 1 m 2 , what corresponds to the concentration of 250 to 25000 ppm counting per 1 g grammage of dry filtration layer, selection of the copper nanoparticles, they are in an amount of 0,125 to 25 mg per 1 m 2 , what corresponds to the concentration of 125 to 25000 ppm counting per 1 g grammage of dry filtration layer, selection of the titanium dioxide
  • antibacterial or fungicidal particles are in the entire mass of the filtration layer of the filtering material and selection of the silver nanoparticles, they are in an amount of 0,007 to 0,5 mg per 1 m 2 and 1 g grammage of the filtration layer, this is the concentration of 7 to 500 ppm in relation to the mass of dry filtration layer
  • selection of the gold nanoparticles they are in an amount of 0,014 to 0,5 mg per 1 m 2 and 1 g grammage of the filtration layer, this is the concentration of 14 to 500 ppm in relation to the mass of dry filtration layer
  • selection of the platinum nanoparticles they are in an amount of 0,014 to 0,5 mg per 1 m 2 and 1 g grammage of the filtration layer, this is the concentration of 14 to 500 ppm in relation to the mass of dry filtration layer
  • selection of the copper nanoparticles they are in an amount of 0,007 to 0,5 mg per 1 m 2 and 1 g grammage of the filtration
  • the material is manufactured from at least one filtration layer, on which active antibacterial or fungicidal particles are applied in the form of the metal nanoparticles selected from the set: ⁇ silver, copper, gold, platinum, zinc, nickel ⁇ or in the form of the titanium dioxide nanoparticles or in the form of copper salts, moreover application of copper salts is executed in a separate operation relative to operation of application metal or titanium dioxide nanoparticles, wherein between these operations filtration layer drying process is executed.
  • a microbiologically active pleated filter intended for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry.
  • Its pleat has at least one active filtration layer containing active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: ⁇ silver, copper, titanium dioxide ⁇ or in the form of copper salts.
  • the active filtration layer of the pleat is made from the filtering non-woven fabric in the form of the filtering composite of cover fleece with dust or grain active carbon.
  • the layer of fine-grained or dusty carbon with binder in amount of 100 400 g/m 2 , which is covered with second layer of cover fleece, and both cover layers are slightly pressed and dried.
  • the summary grammage of the both cover layers is 100 150 g/m 2 and the entire grammage of the filtering composite amounts 200 550 g/m 2 , moreover on the filtering composite there are applied nanoparticles of titanium dioxide with a concentration of 150 ppm or the mixture of copper and silver nanoparticles with a concentration of 150 ppm or the mixture of titanium dioxide and silver nanoparticles with a concentration of 150 ppm or silver nanoparticles with a concentration of 160 ppm or copper nanoparticles with a concentration of 160 ppm or silver nanoparticles with a concentration of 110 ppm and after drying copper salts with a concentration of 10% by weight or copper salts alone with a concentration of 12% by weight.
  • a filtering and absorbing material for filtration and removal of pollutants from the air particularly chemical pollutants harmful to health and unpleasant odors, intended for an absorption of pollutants from the air and for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry, characterized by that material has at least one active non-woven layer, at least single-ply, containing a non-woven backing layer and highly effective absorbing sorbent in the form of aluminosilicate.
  • the filtering and absorbing material contains active carbon as the absorbing sorbent, wherein its non-woven backing layer is spatial with sorbent embedded in space between the fibers of this non-woven backing layer or its sorbent is embedded on the non-woven backing layer.
  • the filtering and absorbing material is microbiological active and contains applied active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: ⁇ silver, copper, gold, platinum, zinc, nickel ⁇ or in the form of the titanium dioxide nanoparticles or in the form of copper salts, preferably copper sulfate.
  • non-woven backing layer is made from the non-needle-punched, shrunk non-woven fabric, which is made from the plastic fiber mixture, polyester or polypropylene, from 1,7 to 15 dtex thick, with heat- shrinkable fibers 4 dtex thick and from 38 to 100 mm length, while grammage of the non-woven fabric of backing layer is from the 75 to 750 g/m 2 , while its thickness from 4 to 30 mm, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer.
  • the non-woven backing layer is made from the needle-punched, non-woven fabric with grammage 150 600 g/m 2 , from 3 to 15 mm thick, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer or the non-woven backing layer is made from the non-woven fabric spunbond with grammage 20 - 100 g/m 2 , 0,1 2 mm thick, air flow resistance 0,2 1 mbar, filtration efficiency 20 60% and air permeability by the pressure 200 Pa - 800 6000 l/m 2 /s, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer.
  • the filtering and absorbing material is three- layer with two layers of cover non-woven fabric made of polyester or polypropylene, between which, there is a layer of sorbents in the form of finegrained active carbon, grain aluminosilicates and binder, wherein the layer of sorbents is in quantity of 100 400 g/m 2 , and the total grammage of the filtering material amounts 200 550 g/m 2 or the filtering and absorbing material contains separate filtration layers permanently connected to each other, one of which is with sorbents in the form of active carbon and aluminosilicates, one of which is dustabsorbing and two are cover-layers made from the non-woven fabric of spunbond type.
  • Hiherto methods of air purification allow removal of dust pollutants using filtering materials of different classes, including absolute filters (HEPA and ULPA), organical, nonpolar chemical pollutants (non-ionized), which are removed using sorption on active carbons and bacterial contamination using biologically active nano-substances. Whereas they left in the air chemical pollutants (fragrant and non-fragrant), polar and non-ionized, and inorganic compounds, which are not removed using known methods.
  • filtering materials of different classes including absolute filters (HEPA and ULPA), organical, nonpolar chemical pollutants (non-ionized), which are removed using sorption on active carbons and bacterial contamination using biologically active nano-substances.
  • the purpose of the invention is the development of technology of pollutants removal: polar (ionized) organic compounds, inorganic compounds including heavy metals, which are toxic and carcinogenic to human health and other living organisms. These pollutants occur in the form of aerosols, they could be imperceptible in the air or cause a whole range of organoleptic smells.
  • pollutants occur in the form of aerosols, they could be imperceptible in the air or cause a whole range of organoleptic smells.
  • an innovative technology was developed using aluminosilicates, as for instance halloysite with developed internal surface and different polarization level, which contains different functional groups (polar) on their surface, where the mechanism of pollutants removal is based on the ion-exchange and chemisorption, binding pollutants on their surface. Therefore, they remove heavy metals and the whole group of odour pollutants (fragrant and non-fragrant).
  • Natural sorbents could be surface modified for adaptation to efficient removal of different types of pollutants. Using of this sorbents causes human health protection, prevents diseases, including reduction the emission of environmental pollutants and application of them in livestock industry (breeding farms) reduces death rate, whereas increases growth of livestock mass by the same nutritional conditions. Economic effects are multimillion.
  • filtering and absorbing material is air-pollutants removal, particularly chemical pollutants harmful to human health and environment, wherein this material is intended for air purification in agri-food industry, food processing, waste disposal, fermentation of sewage sludge and livestock industry, where the odour emission to the air is reduced up to 90%.
  • sorbents concentrations and active antibacterial or fungicidal particles concentration in the form of metal nanoparticles or nanoparticles of titanium dioxide or in the form of copper salts are given by the description of the technological operations, as mass concentrations of solutions of these active antibacterial or fungicidal particles, while by the description of ready filtration materials, as concentrations of these active particles expressed by weight in relation to dry mass of filtration layer of filtering and absorbing material, wherein in the mixture the ingredients are preferably of equal weight.
  • the filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors, according to the invention in the embodiments is described below.
  • the filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors, for filtration panels.
  • the filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors contains coarse-grained sorbent placed in bags.
  • Two layers of non-woven fabric spunbond with a surface mass of 60 g/m 2 are ultrasonically connected alongside, forming bags with a desired width (3, 4 or 5 cm). So created material is cutted across to sections with suitable length, next lower openings of sections are closed.
  • sorbent of a certain type: aluminosilicate or mixture of active carbon and aluminosilicate After pouring of sorbent, the bags are closed from the top.
  • So created composites from the filtering and absorbing material according to the invention are placed in metal frames protected with metal mesh for creation of filters in the form of filtration panels.
  • Example 2 (covers variants included in examples 2.1 2.4)
  • Non-woven fabric for filtering and absorbing material non-needle- punched, shrunk non-woven fabric
  • non-woven filter-absorbing fabric are non-needle-punched, shrunk non-woven fabric or pre-punching non-woven fabric, which most common are manufactured from the mixture of plastics, for instance polyester, polypropylene from 1,7 to 15 dtex thick, with heat-shrinkable fibers (biocomponents) 4 dtex thick and from 38 to 100 mm length. Grammage of these non-woven fabric are most commonly from the 75 to 750 g/m 2 , while their thickness from 4 to 30 mm, air permeability by the pressure 200 Pa - 400 2500 l/(m 2 s), initial resistance 40 300 Pa with a filtration class from EU1 to EU4.
  • non-woven fabric On the precursor non-woven fabric there are applied, using the shaking method, sorbents in the form of the active carbon and aluminosilicates, mixed in a ratio of 1 :1 in dried state in amount of 25% to 50% of non-woven fabric mass. On the applied layer of sorbent, it could be applied an additional external layer of nonwoven fabric connected with the other layers, mechanically or thermically. On these non-woven fabric there were applied metal nanoparticles in the form of water or alcohol solutions, titanium dioxide nanoparticles in the form of water or alcohol solutions and copper salts in the form of water solutions.
  • Such non-woven fabric could be applied to industrial filtration purposes.
  • the non-woven fabric for the filtering and absorbing material for industrial filters for ventilation and for ventilation and air conditioning equipment is made from the mixture of fibers in the form of 80% polyester fibers PES 15 dtex thick and 60 mm length and 20% polyester heat-shrinkable fibers PES Biko 4 dtex thick and 51 mm length, pre-needle punched 2 ⁇ 3 needles/cm 2 and shrunken in temperature 125°C.
  • Grammage of the non-woven fabric is 160 g/m 2 , thick 6 mm, air flow resistance is 0,1 0,2 mbar, filtration efficiency is 40% and filtration class is EU2.
  • non-woven fabric On the precursor non-woven fabric there are applied, using the shaking method, sorbents in the form of the active carbon and aluminosilicates, mixed in a ratio of 1 :1 in dried state in amount of 40 80 g/m 2 .
  • solution of silver nanoparticles with a concentration of 40 ppm, or copper with a concentration of 50 ppm, or the mixture of silver and copper nanoparticles with a concentration of 40 ppm, or the mixture of silver and zinc nanoparticles with a concentration of 60 ppm, or the mixture of silver and nickel nanoparticles with a concentration of 70 ppm using the spraying method with an efficiency of 20 30 m 2 /l or using the immersion method by utilizing the solution in amount of 0,7 of mass of the dried non-woven fabric and squeezing of the solution from the nonwoven fabric between the calanders, whereupon in next operation, the non-woven fabric is drying after the spraying
  • the non-woven fabric are received, on the surface of which they are applied silver nanoparticles with concentration of 4 25 ppm or copper nanoparticles with concentration of 4 30 ppm, or gold nanoparticles with concentration of 8 24 ppm, or platinum nanoparticles with concentration of 8 ⁇ 25 ppm, or titanium dioxide nanoparticles with concentration of 4 7 ppm, or there is applied a mixture of silver and copper nanoparticles with concentration of 8 20 ppm, or a mixture of silver and zinc
  • SUBSTITUTE SHEET (RULE 26) nanoparticles with concentration of 12 19 ppm, or a mixture of silver and nickel nanoparticles with concentration of 14 22 ppm, or a mixture of silver and titanium dioxide nanoparticles with concentration of 11 19 ppm, or a mixture of gold and copper nanoparticles with concentration of 14 ⁇ 22 ppm, or a mixture of platinum and copper nanoparticles with concentration of 15 23 ppm and moreover advantageously on the surface of the non-woven fabric there are applied copper salts with concentration of 0,33 1,33% by weight.
  • the non-woven fabric for industrial filters for ventilation, as well as for the ventilation and air conditioning equipment which is made from the mixture of fibers in the form of 70% PES polyester fibers, , 15 dtex, 60 mm or 76 mm and 30% PES Biko polyester heat shrinkable fibers, 4 dtex, 51 mm, wherein the non-woven fabric is not needle-punched or pre-needle punched 2+3 needles/cm 2 and shrunken in temperature of 125°C or additionally calandered one- or two-sided.
  • Grammage of the non-woven fabric is 400 g/m 2 , thick 20 mm, air flow resistance is 0,2+ 0,7 mbar, filtration efficiency is 80% and filtration class is EU5.
  • nonwoven fabric On the precursor nonwoven fabric there are applied, using the shaking method, sorbents: the active carbon and aluminosilicates, mixed in a ratio of 1 : 1 in dried state in amount of 100 + 200 g/m 2 .
  • sorbents the active carbon and aluminosilicates, mixed in a ratio of 1 : 1 in dried state in amount of 100 + 200 g/m 2 .
  • the non-woven fabric it is applied, using spraying or immersion method, in different embodiments, the solution of the mixture of titanium dioxide and silver nanoparticles with a concentration of 150 ppm, or the solution of the mixture of silver and copper nanoparticles with a concentration of 160 ppm, or the solution of silver nanoparticles with a concentration of 170 ppm, or the solution of the mixture of platinum and copper nanoparticles with a concentration of 180 ppm.
  • such prepared non-woven fabric could be modified using the method described in the example 2.3.
  • the non-woven fabric, together with sorbents, prepared as it is described in example 2.1 or 2.2, is connected with one or two layers of a spunbond type non- woven fabric this way that the layer, which contains sorbents is inside.
  • the spunbond type non-woven fabric, used in described example is characterized by the surface mass of 20 80 g/m 2 and thickness of 0,5 mm. Connection of layers is performed using thermal method on the calander in the temperature approximately 150°C and the feed speed of the non-woven fabric about 2 - ⁇ 3 m/min.
  • the non-woven fabric, together with sorbents, prepared as it is described in example 2.1 or 2.2, is connected with one or two layers of a spunbond type nonwoven fabric this way that the layer, which contains sorbents is inside.
  • the spunbond type non-woven fabric, used in described example is characterized by the surface mass of 20 80 g/m 2 and thickness of 0,5 mm. Connection of layers is performed using mechanical method on the needle machine. The both layers, essential and cover, are needle-punched to the depth of 10 mm, 80 needles/cm 2 .
  • Example 3 (covers detailed variant included in example 3.1)
  • the essential element of the filtering and absorbing material in this embodiment is the needle-punched non-woven fabric, with grammage 150 ⁇ 600 g/m 2 , thickness from 3 to 15 mm, air flow resistance is 0,2 ⁇ - 0,3 mbar, filtration efficiency is 40% 90%, air permeability by the pressure of 200 Pa - 700 2500 l/(m 2 s) b) Manufacturing method of filtering and absorbing material
  • the mixture of polymers and the mixture of sorbents active carbon and aluminosilicates, mixed in a ratio of 1 : 1 , in amount of 25% to 50% of the precursor non-woven fabric mass.
  • the applied layer of sorbent it could be applied an additional external layer of non-woven fabric connected with the other layers, mechanically or thermically.
  • metal nanoparticles in the form of water or alcohol solutions titanium dioxide nanoparticles in the form of water or alcohol solutions and copper salts in the form of water solutions.
  • Such fdtrating and absorbing materials with active carbon and aluminosilicates are intended to use as prefilters, prefilters with an initial cover layer of flat non-woven fabric and end filters, wherein they are using mainly to removal of unpleasant odors, to a lesser extent there are removed dust contamination as well.
  • the features of chemical contaminants and unpleasant odors removal, that is the sorption features of the filtering and absorbing material depend on amount and sorption features of applied coal and aluminosilicates. It is advisable to use active carbon with a large specific surface, because it affects the filtration efficiency.
  • the precursor non-woven fabric of the load-bearing layer of the filtering and absorbing material is made from the mixture of the fibers: 85% PES fibers with the thickness of 15 dtex and 15% PES Biko fibers with the thickness of 4 dtex, wherein the stacked fleece is needle-punched 40 needles/cm 2 , next shrunken in temperature of 125 °C, by what the precursor non-woven fabric is obtained with a grammage of 160 g/m 2 and the thickness of 8 mm, on which it is applied using the immersion method, the mixture of polymers and the mixture of sorbents active carbon and aluminosilicates, mixed in a ratio of 1 :1, in their dose of 40- ⁇ 80 g/m 2 .
  • SUBSTITUTE SHEET (RULE 26) added only the solution of copper salt with concentration of 12% by weight.
  • the non-woven fabric is dried in the temperature of 190°C obtaining the filtering and absorbing nanocomposite.
  • the solution of active antibacterial and fungicidal particles is applied on the dried carbon non-woven fabric with a sorbent with previously applied, using spraying or immersion method, independently on previous application of active antibacterial or fungicidal particles together with a solution of active carbon and sorbent, for instance on the carbon and sorbent non-woven fabric it is applied the solution of silver nanoparticles with concentration of 70 ppm, and next after the drying of the carbon and sorbent nonwoven fabric, it is applied the solution of copper salts with concentration of 10% by weight.
  • the grammage, thickness, amount and type of the applied active carbon and aluminosilicates are chosen depending on the filtrating and absorbing needs.
  • the essential element of the filtering and absorbing material in this embodiment is the spunbond non-woven fabric, with grammage 20 ⁇ 100 g/m 2 , thickness of 0,1 ⁇ - 2 mm, air flow resistance is 0,2 - 1 mbar, filtration efficiency is 20% 60% and air permeability by the pressure of 200 Pa - 800 6000 l/(m 2 s).
  • the active carbon and aluminosilicates are applied using immersion or spraying method in their solution. There are applied using immersion method, from 25% to 50% of the mass of the precursor non-woven fabric, the mixture of polymers, the mixture of sorbents: active carbon and aluminosilicates, mixed in a ratio of 1 :1.
  • the filtering and absorbing material is intended to manufacture end filters, less often sorption prefilters, for composite, multilayer vacuum bags, pocket and industrial filters, flat filters to household appliances, car filters and to ventilation and air conditioning.
  • the non-woven fabric it is applied, using spraying or immersion method in different embodiments, the solution of titanium dioxide nanoparticles with concentration of 60 ppm or silver nanoparticles with concentration of 70 ppm, or copper nanoparticles with concentration of 70 ppm, or the mixture of copper and silver nanoparticles with concentration of 70 ppm, or carbon dioxide and silver nanoparticles with concentration of 70 ppm, or the solution of silver nanoparticles with concentration of 60 ppm, and next after the drying, the solution of copper salt with concentration of 5% by weight.
  • the immersion method from 25% to 50% of active carbon and sorbent, whereupon the non-woven fabric is dried in the temperature of 150°C.
  • the active carbon, sorbent and active antibacterial or fungicidal particles are applied using spraying or immersion method.
  • the grammage of such obtained non-woven fabric amounts 30 g/m 2 , the thickness is 0,5 mm, air flow resistance is 0,3 mbar and filtration efficiency is 30%.
  • Example 6 The filtering and absorbing material in the form of the three-layer composite, containing sorbents: active coal and grain aluminosilicates, applied using powder method.
  • the filtering and absorbing material, three-layered, with active carbon and grain aluminosilicates for pleated filters is obtained by the application on the polyester or polypropylene non-woven fabric, layer of fine-grained coal and aluminosilicates with a binder in amount of 100 400 g/m 2 , and next the covering with the second non-woven fabric, light pressing and drying.
  • the summary grammage of both cover layers are most often of the order of 100 - 200 g/m 2
  • the total grammage of the coal composite are of the order of 200 550 g/m 2 .
  • the cover layer states the filtration non-woven fabric made of the mixture of polyester fibers with thickness from 1,7 to 15 dtex and length of 60 mm, in amount of 45%, and 55% Biko fibers with thickness 4 dtex and length of 51 mm, needle-punched 140 needles/cm 2 and calandering in temperature of 135° C, wherein the grammage of the non-woven fabric amounts 50 100 g/m 2 .
  • the non-woven fabric On the surface of the non-woven fabric, it is applied evenly the mixture of the sorbents: active coal and aluminosilicates, mixed in a ratio of 1 : 1 , which could be mixed with a binder or the binder could be applied on the non-woven fabric previously, and the mixture of sorbents is applied using the powder method.
  • the composite filtering and absorbing material having 3 - 5 layers for bag filters to household appliances consists of the separate filtration layers, arranged loosely or spot welded or connected permanently during the manufacturing process, and filtration layers state a combined whole with a range of grammages 60 200 g/m 2 , wherein: a) composite filtration materials 3 -layered consist from the two spunbond cover layer with a grammage 20 30 g/m 2 , wherein one of these layers is with active carbon and aluminosilicates with a grammage 20 40 g/m 2 and meltblown internal layer with a grammage 20 40 g/m 2 , b) composite filtration materials 4-layered consist from the two spunbond cover layer with a grammage 20 30 g/m 2 , wherein one of these layers is with active carbon and aluminosilicates with a grammage 20 40 g/m 2 , dust absorbing internal layer with a grammage 30 g/m 2 , and meltblown internal layer with a
  • Active carbon, aluminosilicates and active antibacterial or fungicidal particles are applied using spraying or immersion method in an identical way, as in the above example 5.

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Abstract

The filtering and absorbing material is intended for an absorption of pollutants from the- air and for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry. The filtering and absorbing material has at least one active non-woven layer, at least single-ply, containing a non-woven backing layer and highly effective absorbing sorbent in the form of aluminosilicate. Moreover, the filtering and absorbing material contains active carbon or it is microbiological active and contains applied active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: (silver, copper, gold, platinum, zinc, nickel) or in the form of the titanium dioxide nanoparticles or in the form of copper salts.

Description

Filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors
The subject of the invention is a filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors, intended for an absorption of pollutants from the air and for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry.
From the publication of patent application PL 419083 Al it is known a filtering material with microbiological activity and its manufacturing method, intended for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry. The material has at least one filtration layer, containing active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: {silver, copper, gold, platinum, zinc, nickel} or in the form of the titanium dioxide nanoparticles or in the form of copper salts. Active antibacterial or fungicidal particles are applied on the surface of the filtration layer of the filtering and absorbing material or in the entire mass of the filtration layer of the filtering and absorbing material. In case, when antibacterial or fungicidal particles are on the surface of the filtration layer of the filtering material and selection of the silver nanoparticles, they are in an amount of 0,125 to 25 mg per 1 m2, what corresponds to the concentration of 125 to 25000 ppm counting per 1 g grammage of dry filtration layer, selection of the gold nanoparticles, they are in an amount of 0,25 to 25 mg per 1 m2, what corresponds to the concentration of 250 to 25000 ppm counting per 1 g grammage of dry filtration layer, selection of the platinum nanoparticles, they are in an amount of 0,25 to 25 mg per 1 m2, what corresponds to the concentration of 250 to 25000 ppm counting per 1 g grammage of dry filtration layer, selection of the copper nanoparticles, they are in an amount of 0,125 to 25 mg per 1 m2, what corresponds to the concentration of 125 to 25000 ppm counting per 1 g grammage of dry filtration layer, selection of the titanium dioxide nanoparticles, they are in an amount of 0,125 to 25 mg per 1 m2, what corresponds to the concentration of 125 to 25000 ppm counting per 1 g grammage of dry filtration layer and selection of the copper salt, they are in an amount of 0,375 to 5 g per 1 m2, what corresponds to the concentration of 37,5 to 500% of weight, counting per 1 g grammage of dry filtration layer. In turn, in case when antibacterial or fungicidal particles are in the entire mass of the filtration layer of the filtering material and selection of the silver nanoparticles, they are in an amount of 0,007 to 0,5 mg per 1 m2 and 1 g grammage of the filtration layer, this is the concentration of 7 to 500 ppm in relation to the mass of dry filtration layer, selection of the gold nanoparticles, they are in an amount of 0,014 to 0,5 mg per 1 m2 and 1 g grammage of the filtration layer, this is the concentration of 14 to 500 ppm in relation to the mass of dry filtration layer, selection of the platinum nanoparticles, they are in an amount of 0,014 to 0,5 mg per 1 m2 and 1 g grammage of the filtration layer, this is the concentration of 14 to 500 ppm in relation to the mass of dry filtration layer, selection of the copper nanoparticles, they are in an amount of 0,007 to 0,5 mg per 1 m2 and 1 g grammage of the filtration layer, this is the concentration of 7 to 500 ppm in relation to the mass of dry filtration layer, selection of the titanium dioxide nanoparticles, they are in an amount of 0,007 to 0,5 mg per 1 m2 and 1 g grammage of the filtration layer, this is the concentration of 7 to 500 ppm in relation to the mass of dry filtration layer and selection of the copper salts, they are in an amount of 15 to 150 mg per 1 m2 and 1 g grammage of the filtration layer, this is the concentration of 1,5 to 15% of weight in relation to the mass of dry filtration layer, moreover zinc and nickel nanoparticles are selected only together with the remaining nanoparticles from the aforementioned set. In turn, in the filtering material manufacturing method, the material is manufactured from at least one filtration layer, on which active antibacterial or fungicidal particles are applied in the form of the metal nanoparticles selected from the set: {silver, copper, gold, platinum, zinc, nickel} or in the form of the titanium dioxide nanoparticles or in the form of copper salts, moreover application of copper salts is executed in a separate operation relative to operation of application metal or titanium dioxide nanoparticles, wherein between these operations filtration layer drying process is executed.
From the publication of patent application P.434611 it is known a microbiologically active pleated filter, intended for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry. Its pleat has at least one active filtration layer containing active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: {silver, copper, gold, platinum, zinc, nickel} or in the form of the titanium dioxide nanoparticles or in the form of copper salts, wherein the active filtration layer of the pleat is made from the filtering non-woven fabric.
From the publication of patent application P.434612 it is known a microbiologically active pleated filter, intended for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry. Its pleat has at least one active filtration layer containing active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: {silver, copper, titanium dioxide} or in the form of copper salts. The active filtration layer of the pleat is made from the filtering non-woven fabric in the form of the filtering composite of cover fleece with dust or grain active carbon. On the layer of cover fleece it is applied the layer of fine-grained or dusty carbon with binder in amount of 100 400 g/m2, which is covered with second layer of cover fleece, and both cover layers are slightly pressed and dried. The summary grammage of the both cover layers is 100 150 g/m2 and the entire grammage of the filtering composite amounts 200 550 g/m2, moreover on the filtering composite there are applied nanoparticles of titanium dioxide with a concentration of 150 ppm or the mixture of copper and silver nanoparticles with a concentration of 150 ppm or the mixture of titanium dioxide and silver nanoparticles with a concentration of 150 ppm or silver nanoparticles with a concentration of 160 ppm or copper nanoparticles with a concentration of 160 ppm or silver nanoparticles with a concentration of 110 ppm and after drying copper salts with a concentration of 10% by weight or copper salts alone with a concentration of 12% by weight.
To increase the efficiency of pollutants removal from the air, including chemical pollutants harmful to health and unpleasant odors, solutions according to the invention were developed.
A filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors, intended for an absorption of pollutants from the air and for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry, characterized by that material has at least one active non-woven layer, at least single-ply, containing a non-woven backing layer and highly effective absorbing sorbent in the form of aluminosilicate.
Favorably, the filtering and absorbing material contains active carbon as the absorbing sorbent, wherein its non-woven backing layer is spatial with sorbent embedded in space between the fibers of this non-woven backing layer or its sorbent is embedded on the non-woven backing layer.
Further benefits are obtained, if the filtering and absorbing material is microbiological active and contains applied active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: {silver, copper, gold, platinum, zinc, nickel} or in the form of the titanium dioxide nanoparticles or in the form of copper salts, preferably copper sulfate. Other benefits are obtained, if the non-woven backing layer is made from the non-needle-punched, shrunk non-woven fabric, which is made from the plastic fiber mixture, polyester or polypropylene, from 1,7 to 15 dtex thick, with heat- shrinkable fibers 4 dtex thick and from 38 to 100 mm length, while grammage of the non-woven fabric of backing layer is from the 75 to 750 g/m2, while its thickness from 4 to 30 mm, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer.
Further benefits are obtained, if the non-woven backing layer is made from the needle-punched, non-woven fabric with grammage 150 600 g/m2, from 3 to 15 mm thick, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer or the non-woven backing layer is made from the non-woven fabric spunbond with grammage 20 - 100 g/m2, 0,1 2 mm thick, air flow resistance 0,2 1 mbar, filtration efficiency 20 60% and air permeability by the pressure 200 Pa - 800 6000 l/m2/s, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer.
Other benefits are obtained, if the filtering and absorbing material is three- layer with two layers of cover non-woven fabric made of polyester or polypropylene, between which, there is a layer of sorbents in the form of finegrained active carbon, grain aluminosilicates and binder, wherein the layer of sorbents is in quantity of 100 400 g/m2, and the total grammage of the filtering material amounts 200 550 g/m2 or the filtering and absorbing material contains separate filtration layers permanently connected to each other, one of which is with sorbents in the form of active carbon and aluminosilicates, one of which is dustabsorbing and two are cover-layers made from the non-woven fabric of spunbond type.
There are plenty of dust, microbiological and chemical pollutants in the air of different origin - organic and inorganic, with different ionization level (polar and nonpolar), occurring in the form of solid particles and gases. Hiherto methods of air purification allow removal of dust pollutants using filtering materials of different classes, including absolute filters (HEPA and ULPA), organical, nonpolar chemical pollutants (non-ionized), which are removed using sorption on active carbons and bacterial contamination using biologically active nano-substances. Whereas they left in the air chemical pollutants (fragrant and non-fragrant), polar and non-ionized, and inorganic compounds, which are not removed using known methods.
The purpose of the invention is the development of technology of pollutants removal: polar (ionized) organic compounds, inorganic compounds including heavy metals, which are toxic and carcinogenic to human health and other living organisms. These pollutants occur in the form of aerosols, they could be imperceptible in the air or cause a whole range of organoleptic smells. For removal of these pollutants, an innovative technology was developed using aluminosilicates, as for instance halloysite with developed internal surface and different polarization level, which contains different functional groups (polar) on their surface, where the mechanism of pollutants removal is based on the ion-exchange and chemisorption, binding pollutants on their surface. Therefore, they remove heavy metals and the whole group of odour pollutants (fragrant and non-fragrant). Natural sorbents could be surface modified for adaptation to efficient removal of different types of pollutants. Using of this sorbents causes human health protection, prevents diseases, including reduction the emission of environmental pollutants and application of them in livestock industry (breeding farms) reduces death rate, whereas increases growth of livestock mass by the same nutritional conditions. Economic effects are multimillion.
Additional application of filtering and absorbing material according to the invention is air-pollutants removal, particularly chemical pollutants harmful to human health and environment, wherein this material is intended for air purification in agri-food industry, food processing, waste disposal, fermentation of sewage sludge and livestock industry, where the odour emission to the air is reduced up to 90%.
In the solutions according to the invention, described in this patent description, patent claims and abstract, sorbents concentrations and active antibacterial or fungicidal particles concentration in the form of metal nanoparticles or nanoparticles of titanium dioxide or in the form of copper salts are given by the description of the technological operations, as mass concentrations of solutions of these active antibacterial or fungicidal particles, while by the description of ready filtration materials, as concentrations of these active particles expressed by weight in relation to dry mass of filtration layer of filtering and absorbing material, wherein in the mixture the ingredients are preferably of equal weight.
The filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors, according to the invention in the embodiments is described below.
Example 1
The filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors, for filtration panels.
In this embodiment, the filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors contains coarse-grained sorbent placed in bags. Two layers of non-woven fabric spunbond with a surface mass of 60 g/m2 are ultrasonically connected alongside, forming bags with a desired width (3, 4 or 5 cm). So created material is cutted across to sections with suitable length, next lower openings of sections are closed. Into so prepared bags there is poured sorbent of a certain type: aluminosilicate or mixture of active carbon and aluminosilicate. After pouring of sorbent, the bags are closed from the top. So created composites from the filtering and absorbing material according to the invention are placed in metal frames protected with metal mesh for creation of filters in the form of filtration panels.
Example 2 (covers variants included in examples 2.1 2.4)
The filtering and absorbing material for filtration mats, containing sorbents in the form of active carbon and aluminosilicates, applied using a dry method a) Non-woven fabric for filtering and absorbing material: non-needle- punched, shrunk non-woven fabric
The simplest non-woven filter-absorbing fabric are non-needle-punched, shrunk non-woven fabric or pre-punching non-woven fabric, which most common are manufactured from the mixture of plastics, for instance polyester, polypropylene from 1,7 to 15 dtex thick, with heat-shrinkable fibers (biocomponents) 4 dtex thick and from 38 to 100 mm length. Grammage of these non-woven fabric are most commonly from the 75 to 750 g/m2, while their thickness from 4 to 30 mm, air permeability by the pressure 200 Pa - 400 2500 l/(m2 s), initial resistance 40 300 Pa with a filtration class from EU1 to EU4. The filtration efficiency and mechanical durability of these non-woven fabric could be increased through the one-sided or two-sided surface hardening using calandering or hardening with chemical substances, latex and other hardening substance increasing the filtration class up to F5. b) Method of manufacture of filtering and absorbing material
On the precursor non-woven fabric there are applied, using the shaking method, sorbents in the form of the active carbon and aluminosilicates, mixed in a ratio of 1 :1 in dried state in amount of 25% to 50% of non-woven fabric mass. On the applied layer of sorbent, it could be applied an additional external layer of nonwoven fabric connected with the other layers, mechanically or thermically. On these non-woven fabric there were applied metal nanoparticles in the form of water or alcohol solutions, titanium dioxide nanoparticles in the form of water or alcohol solutions and copper salts in the form of water solutions.
SUBSTITUTE SHEET (RULE 26) c) Application
Such non-woven fabric could be applied to industrial filtration purposes.
Example 2.1
The non-woven fabric for the filtering and absorbing material for industrial filters for ventilation and for ventilation and air conditioning equipment is made from the mixture of fibers in the form of 80% polyester fibers PES 15 dtex thick and 60 mm length and 20% polyester heat-shrinkable fibers PES Biko 4 dtex thick and 51 mm length, pre-needle punched 2 ^ 3 needles/cm2 and shrunken in temperature 125°C. Grammage of the non-woven fabric is 160 g/m2, thick 6 mm, air flow resistance is 0,1 0,2 mbar, filtration efficiency is 40% and filtration class is EU2. On the precursor non-woven fabric there are applied, using the shaking method, sorbents in the form of the active carbon and aluminosilicates, mixed in a ratio of 1 :1 in dried state in amount of 40 80 g/m2. On the non-woven fabric it was applied, in different embodiments of filtering and absorbing material, solution of silver nanoparticles with a concentration of 40 ppm, or copper with a concentration of 50 ppm, or the mixture of silver and copper nanoparticles with a concentration of 40 ppm, or the mixture of silver and zinc nanoparticles with a concentration of 60 ppm, or the mixture of silver and nickel nanoparticles with a concentration of 70 ppm, using the spraying method with an efficiency of 20 30 m2/l or using the immersion method by utilizing the solution in amount of 0,7 of mass of the dried non-woven fabric and squeezing of the solution from the nonwoven fabric between the calanders, whereupon in next operation, the non-woven fabric is drying after the spraying or immersion. In result, the non-woven fabric are received, on the surface of which they are applied silver nanoparticles with concentration of 4 25 ppm or copper nanoparticles with concentration of 4 30 ppm, or gold nanoparticles with concentration of 8 24 ppm, or platinum nanoparticles with concentration of 8 ^ 25 ppm, or titanium dioxide nanoparticles with concentration of 4 7 ppm, or there is applied a mixture of silver and copper nanoparticles with concentration of 8 20 ppm, or a mixture of silver and zinc
SUBSTITUTE SHEET (RULE 26) nanoparticles with concentration of 12 19 ppm, or a mixture of silver and nickel nanoparticles with concentration of 14 22 ppm, or a mixture of silver and titanium dioxide nanoparticles with concentration of 11 19 ppm, or a mixture of gold and copper nanoparticles with concentration of 14 ■ 22 ppm, or a mixture of platinum and copper nanoparticles with concentration of 15 23 ppm and moreover advantageously on the surface of the non-woven fabric there are applied copper salts with concentration of 0,33 1,33% by weight.
Example 2.2
The non-woven fabric for industrial filters for ventilation, as well as for the ventilation and air conditioning equipment, which is made from the mixture of fibers in the form of 70% PES polyester fibers, , 15 dtex, 60 mm or 76 mm and 30% PES Biko polyester heat shrinkable fibers, 4 dtex, 51 mm, wherein the non-woven fabric is not needle-punched or pre-needle punched 2+3 needles/cm2 and shrunken in temperature of 125°C or additionally calandered one- or two-sided. Grammage of the non-woven fabric is 400 g/m2, thick 20 mm, air flow resistance is 0,2+ 0,7 mbar, filtration efficiency is 80% and filtration class is EU5. On the precursor nonwoven fabric there are applied, using the shaking method, sorbents: the active carbon and aluminosilicates, mixed in a ratio of 1 : 1 in dried state in amount of 100 + 200 g/m2. On the non-woven fabric it is applied, using spraying or immersion method, in different embodiments, the solution of the mixture of titanium dioxide and silver nanoparticles with a concentration of 150 ppm, or the solution of the mixture of silver and copper nanoparticles with a concentration of 160 ppm, or the solution of silver nanoparticles with a concentration of 170 ppm, or the solution of the mixture of platinum and copper nanoparticles with a concentration of 180 ppm. Depending on the needs, such prepared non-woven fabric could be modified using the method described in the example 2.3.
Example 2.3
The non-woven fabric, together with sorbents, prepared as it is described in example 2.1 or 2.2, is connected with one or two layers of a spunbond type non- woven fabric this way that the layer, which contains sorbents is inside. The spunbond type non-woven fabric, used in described example, is characterized by the surface mass of 20 80 g/m2 and thickness of 0,5 mm. Connection of layers is performed using thermal method on the calander in the temperature approximately 150°C and the feed speed of the non-woven fabric about 2 -^ 3 m/min.
Example 2.4
The non-woven fabric, together with sorbents, prepared as it is described in example 2.1 or 2.2, is connected with one or two layers of a spunbond type nonwoven fabric this way that the layer, which contains sorbents is inside. The spunbond type non-woven fabric, used in described example, is characterized by the surface mass of 20 80 g/m2 and thickness of 0,5 mm. Connection of layers is performed using mechanical method on the needle machine. The both layers, essential and cover, are needle-punched to the depth of 10 mm, 80 needles/cm2.
Example 3 (covers detailed variant included in example 3.1)
The filtering and absorbing material, single-layer, spatial, containing sorbents: active carbon and aluminosilicates applied using the immersion method a) The non-woven fabric to the filtering and absorbing material: singlelayer, needle-punched non-woven fabric
The essential element of the filtering and absorbing material in this embodiment, as a non-woven load-bearing layer is the needle-punched non-woven fabric, with grammage 150 ^ 600 g/m2, thickness from 3 to 15 mm, air flow resistance is 0,2^- 0,3 mbar, filtration efficiency is 40% 90%, air permeability by the pressure of 200 Pa - 700 2500 l/(m2 s) b) Manufacturing method of filtering and absorbing material
On the precursor non-woven fabric there are applied, using the immersion method, the mixture of polymers and the mixture of sorbents: active carbon and aluminosilicates, mixed in a ratio of 1 : 1 , in amount of 25% to 50% of the precursor non-woven fabric mass. On the applied layer of sorbent, it could be applied an additional external layer of non-woven fabric connected with the other layers, mechanically or thermically. On these non-woven fabric there were applied metal nanoparticles in the form of water or alcohol solutions, titanium dioxide nanoparticles in the form of water or alcohol solutions and copper salts in the form of water solutions. c) Application
Such fdtrating and absorbing materials with active carbon and aluminosilicates are intended to use as prefilters, prefilters with an initial cover layer of flat non-woven fabric and end filters, wherein they are using mainly to removal of unpleasant odors, to a lesser extent there are removed dust contamination as well. The features of chemical contaminants and unpleasant odors removal, that is the sorption features of the filtering and absorbing material depend on amount and sorption features of applied coal and aluminosilicates. It is advisable to use active carbon with a large specific surface, because it affects the filtration efficiency.
Example 3.1
The precursor non-woven fabric of the load-bearing layer of the filtering and absorbing material is made from the mixture of the fibers: 85% PES fibers with the thickness of 15 dtex and 15% PES Biko fibers with the thickness of 4 dtex, wherein the stacked fleece is needle-punched 40 needles/cm2, next shrunken in temperature of 125 °C, by what the precursor non-woven fabric is obtained with a grammage of 160 g/m2 and the thickness of 8 mm, on which it is applied using the immersion method, the mixture of polymers and the mixture of sorbents active carbon and aluminosilicates, mixed in a ratio of 1 :1, in their dose of 40-^80 g/m2. To this solution with the active carbon and sorbent, it is added, in different embodiments, the solution of the mixture of titanium dioxide and silver nanoparticles with concentration of 70 ppm, or the mixture of copper and silver nanoparticles with concentration of 90 ppm, or silver nanoparticles with concentration of 100 ppm, or copper nanoparticles with concentration of 100 ppm, or in another embodiment to the solution with an active carbon and sorbent, it is
SUBSTITUTE SHEET (RULE 26) added only the solution of copper salt with concentration of 12% by weight. Next, the non-woven fabric is dried in the temperature of 190°C obtaining the filtering and absorbing nanocomposite. In another embodiments, the solution of active antibacterial and fungicidal particles is applied on the dried carbon non-woven fabric with a sorbent with previously applied, using spraying or immersion method, independently on previous application of active antibacterial or fungicidal particles together with a solution of active carbon and sorbent, for instance on the carbon and sorbent non-woven fabric it is applied the solution of silver nanoparticles with concentration of 70 ppm, and next after the drying of the carbon and sorbent nonwoven fabric, it is applied the solution of copper salts with concentration of 10% by weight. The grammage of such obtained carbon and sorbent non-woven fabric in the form of the carbon and sorbent filtering and absorbing nanocomposite amounts 200 240 g/m2, thickness 5 mm, air flow resistance is 0,4^- 0,5 mbar, dust filtration efficiency is greater than 70%. The grammage, thickness, amount and type of the applied active carbon and aluminosilicates are chosen depending on the filtrating and absorbing needs.
Example 4
The filtering and absorbing material, single-layer, spatial, containing sorbents: active carbon and aluminosilicates applied using the immersion method.
The essential element of the filtering and absorbing material in this embodiment, is the spunbond non-woven fabric, with grammage 20 ^ 100 g/m2, thickness of 0,1 ^- 2 mm, air flow resistance is 0,2 - 1 mbar, filtration efficiency is 20% 60% and air permeability by the pressure of 200 Pa - 800 6000 l/(m2 s). The active carbon and aluminosilicates are applied using immersion or spraying method in their solution. There are applied using immersion method, from 25% to 50% of the mass of the precursor non-woven fabric, the mixture of polymers, the mixture of sorbents: active carbon and aluminosilicates, mixed in a ratio of 1 :1. In this embodiment, the filtering and absorbing material is intended to manufacture end filters, less often sorption prefilters, for composite, multilayer vacuum bags, pocket and industrial filters, flat filters to household appliances, car filters and to ventilation and air conditioning. On the non-woven fabric, it is applied, using spraying or immersion method in different embodiments, the solution of titanium dioxide nanoparticles with concentration of 60 ppm or silver nanoparticles with concentration of 70 ppm, or copper nanoparticles with concentration of 70 ppm, or the mixture of copper and silver nanoparticles with concentration of 70 ppm, or carbon dioxide and silver nanoparticles with concentration of 70 ppm, or the solution of silver nanoparticles with concentration of 60 ppm, and next after the drying, the solution of copper salt with concentration of 5% by weight.
Example 5
The filtering and absorbing material, single-layer, containing sorbents: active carbon and aluminosilicates applied using the immersion method.
On the flat non-woven fabric of spunbond or SMS type with a grammage of 20 g/m2, there are applied using the immersion method from 25% to 50% of active carbon and sorbent, whereupon the non-woven fabric is dried in the temperature of 150°C. The active carbon, sorbent and active antibacterial or fungicidal particles are applied using spraying or immersion method. The grammage of such obtained non-woven fabric amounts 30 g/m2, the thickness is 0,5 mm, air flow resistance is 0,3 mbar and filtration efficiency is 30%. On the non-woven fabric it is applied using spraying or immersion method, in different embodiments, the solution of titanium dioxide nanoparticles with concentration of 60 ppm or silver nanoparticles with concentration of 70 ppm, or copper nanoparticles with concentration of 70 ppm, or the mixture of copper and silver nanoparticles with concentration of 70 ppm, or titanium dioxide and silver nanoparticles with concentration of 70 ppm, or the solution of silver nanoparticles with concentration of 60 ppm, and next, after drying, the solution of copper salts with concentration 5% by weight.
Example 6 The filtering and absorbing material in the form of the three-layer composite, containing sorbents: active coal and grain aluminosilicates, applied using powder method.
The filtering and absorbing material, three-layered, with active carbon and grain aluminosilicates for pleated filters is obtained by the application on the polyester or polypropylene non-woven fabric, layer of fine-grained coal and aluminosilicates with a binder in amount of 100 400 g/m2, and next the covering with the second non-woven fabric, light pressing and drying. The summary grammage of both cover layers are most often of the order of 100 - 200 g/m2, and the total grammage of the coal composite are of the order of 200 550 g/m2. The cover layer states the filtration non-woven fabric made of the mixture of polyester fibers with thickness from 1,7 to 15 dtex and length of 60 mm, in amount of 45%, and 55% Biko fibers with thickness 4 dtex and length of 51 mm, needle-punched 140 needles/cm2 and calandering in temperature of 135° C, wherein the grammage of the non-woven fabric amounts 50 100 g/m2. On the surface of the non-woven fabric, it is applied evenly the mixture of the sorbents: active coal and aluminosilicates, mixed in a ratio of 1 : 1 , which could be mixed with a binder or the binder could be applied on the non-woven fabric previously, and the mixture of sorbents is applied using the powder method. On the non-woven fabric it is applied using spraying or immersion method, in different embodiments, titanium dioxide nanoparticles with concentration of 150 ppm or the mixture of copper and silver nanoparticles with concentration of 150 ppm, or the mixture of titanium dioxide and silver nanoparticles with concentration of 150 ppm, or silver nanoparticles with concentration of 160 ppm, or copper nanoparticles with concentration of 160 ppm, or silver nanoparticles with concentration of 110 ppm, and next, after drying, the solution of copper salts with concentration 10% by weight or copper salts alone with concentration of 12%.
Example 7
The composite filtering and absorbing material having 3 - 5 layers for bag filters to household appliances, consists of the separate filtration layers, arranged loosely or spot welded or connected permanently during the manufacturing process, and filtration layers state a combined whole with a range of grammages 60 200 g/m2, wherein: a) composite filtration materials 3 -layered consist from the two spunbond cover layer with a grammage 20 30 g/m2, wherein one of these layers is with active carbon and aluminosilicates with a grammage 20 40 g/m2 and meltblown internal layer with a grammage 20 40 g/m2, b) composite filtration materials 4-layered consist from the two spunbond cover layer with a grammage 20 30 g/m2, wherein one of these layers is with active carbon and aluminosilicates with a grammage 20 40 g/m2, dust absorbing internal layer with a grammage 30 g/m2, and meltblown internal layer with a grammage 20 30 g/m2 or they are made from the SMS non-woven fabric with an additional layer of non-woven fabric, c) composite filtration materials 5 -layered consist from the two spunbond cover layer with a grammage 20 - 30 g/m2, dust absorbing internal layer with a grammage 30 g/m2, meltblown internal layer with a grammage 20 30 g/m2 and internal layer with active carbon and aluminosilicates with a grammage 20 40 g/m2, or they are made from the SMS non-woven fabric with two additional non-woven fabric. In some cases, the dust-absorbing layer is replaced with a spunbond non-woven fabric, but then the composite presents worse filtration features.
Active carbon, aluminosilicates and active antibacterial or fungicidal particles are applied using spraying or immersion method in an identical way, as in the above example 5.
In such composite filtration materials, on at least one of spunbond external layer, from the side of the filtered air, there are applied active antibacterial or fungicidal particles, or on the larger amount of these filtration layers, to all inclusive, there are applied these active particles. On the composite material, it is applied, using spraying or immersion method in different embodiments, the solution of silver nanoparticlcs with concentration of 60 ppm and next the solution of copper salt with concentration of 5% by weight or in another embodiments, the solution of titanium dioxide with concentration of 60 ppm or the mixture of copper and silver with concentration of 70 ppm, or silver nanoparticles with concentration of 70 ppm, or copper nanoparticles with concentration of 80 ppm or copper salts with concentration of 7% by weight.

Claims

Patent claims
1. A filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors, intended for an absorption of pollutants from the air and for a filtration, ventilation and air conditioning of the air, particularly for a filtration in household appliances, cars, constructions and industry, characterized by that material has at least one active non-woven layer, at least single-ply, containing a non-woven backing layer and highly effective absorbing sorbent in the form of aluminosilicate.
2. The filtering and absorbing material according to the claim 1, characterized by that it contains active carbon as the absorbing sorbent.
3. The filtering and absorbing material according to the claim 1 or 2, characterized by that its non-woven backing layer is spatial with sorbent embedded in space between the fibers of this non-woven backing layer.
4. The filtering and absorbing material according to the claim 1 or 2 or 3, characterized by that its sorbent is embedded on the non-woven backing layer.
5. The filtering and absorbing material according to one of the claim from 1 to 4, characterized by that it is microbiological active and contains applied active antibacterial or fungicidal particles in the form of the metal nanoparticles selected from the set: {silver, copper, gold, platinum, zinc, nickel} or in the form of the titanium dioxide nanoparticles or in the form of copper salts, preferably copper sulfate.
6. The filtering and absorbing material according to the claim 2, characterized by that its non-woven backing layer is made from the non-needle- punched, shrunk non-woven fabric, which is made from the plastic fiber mixture, polyester or polypropylene, from 1,7 to 15 dtex thick, with heat-shrinkable fibers 4 dtex thick and from 38 to 100 mm length, while grammage of the non-woven fabric of backing layer is from the 75 to 750 g/m2, while its thickness from 4 to 30 mm, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer.
7. The filtering and absorbing material according to the claim 2, characterized by that its non-woven backing layer is made from the needle- punched, non-woven fabric with grammage 150 600 g/m2, from 3 to 15 mm thick, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer.
8. The filtering and absorbing material according to the claim 2, characterized by that its non-woven backing layer is made from the non-woven fabric spunbond with grammage 20 100 g/m2, 0,1 - 2 mm thick, air flow resistance 0,2 1 mbar, filtration efficiency 20 60% and air permeability by the pressure 200 Pa - 800 6000 l/m2/s, wherein on the backing layer there are sorbents in the form of the mixture of active carbon and aluminosilicates in quantity from 25% to 50% of mass of this backing layer.
9. The filtering and absorbing material according to the claim 2, characterized by that it is three-layer with two layers of cover non-woven fabric made of polyester or polypropylene, between which, there is a layer of sorbents in the form of fine-grained active carbon, grain aluminosilicates and binder, wherein the layer of sorbents is in quantity of 100 - 400 g/m2, and the total grammage of the filtering material amounts 200 550 g/m2.
10. The filtering and absorbing material according to the claim 2, characterized by that it contains separate filtration layers permanently connected to each other, one of which is with sorbents in the form of active carbon and aluminosilicates, one of which is dust-absorbing and two are cover-layers made from the non-woven fabric of spunbond type.
PCT/PL2021/000097 2021-12-21 2021-12-28 Filtering and absorbing material for filtration and removal of pollutants from the air, particularly chemical pollutants harmful to health and unpleasant odors WO2023121487A1 (en)

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0338212A (en) * 1989-07-05 1991-02-19 Yasuo Yokoi Air filter
PL288843A1 (en) * 1991-01-23 1992-07-27 Ct Innowacyjno Techniczne Spol Method of extracting dust from a production line for insulating materials made of aluminosilicate fibre
PL419083A1 (en) * 2016-10-12 2018-04-23 Pąprowicz Jan Podkarpackie Centrum Produkcyjno-Wdrożeniowe Eko-Karpaty Filter material with microbiological activity and method for producing it

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0338212A (en) * 1989-07-05 1991-02-19 Yasuo Yokoi Air filter
PL288843A1 (en) * 1991-01-23 1992-07-27 Ct Innowacyjno Techniczne Spol Method of extracting dust from a production line for insulating materials made of aluminosilicate fibre
PL419083A1 (en) * 2016-10-12 2018-04-23 Pąprowicz Jan Podkarpackie Centrum Produkcyjno-Wdrożeniowe Eko-Karpaty Filter material with microbiological activity and method for producing it

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