A water and oil removing air filter material and a method for preparing the same

Abstract

The application belongs to the field of air filtration, and specifically discloses a kind of water and oil removal air filtration material and its preparation method, the preparation method is to mix and react octadecyl methacrylate, isobutyl methacrylate, acrylic acid, ethylene glycol ester and styrene for a preset time to form modified methacrylic acid resin, then the first fiber short filament is prepared by using modified methacrylic acid resin;The second fiber short filament is prepared by using polyacrylate resin;Glass wool, the first fiber short filament and the second fiber short filament are mixed to prepare to obtain water and oil removal air filtration material.The application can achieve the effect of water and oil removal while maintaining efficient filtration of solid particles in the air, greatly prolonging the service life of the air filtration material, reducing the filter replacement cost and manual work intensity.

Description

Technical Field

[0001] This application belongs to the field of air filtration, and more specifically, relates to a water and oil removal air filter material and its preparation method. Background Technology

[0002] Air filters are essential components in various fields such as electronics, biomedicine, power, and beverage and food. They effectively improve air cleanliness and ensure product quality and equipment operation stability.

[0003] The core factor determining the performance of an air filter is the filter material. Traditional air filter materials primarily filter solid particles in the air. However, in many situations, the air contains not only solid particles but also moisture and oil particles. Moisture easily causes dust to agglomerate, forming particle clusters that clog the pores; while oil particles easily form an oil film in the pores, blocking airflow. Therefore, both types of contaminants cause the filter material's resistance to increase rapidly, shortening its lifespan. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this application provides a water and oil removal air filter material and its preparation method, aiming to solve the problem that moisture and oil particles shorten the service life of air filter materials.

[0005] According to one aspect of this application, a method for preparing a water- and oil-removing air filter material is provided, specifically as follows:

[0006] By weight, 30-40 parts of octadecyl methacrylate, 30-40 parts of isobutyl methacrylate, 5-10 parts of acrylic acid, 5-10 parts of ethylene glycol ester, and 10-20 parts of styrene are mixed and reacted for a preset time to obtain modified methacrylic resin.

[0007] By mass, 60 to 70 parts of the modified methacrylic resin, 15 to 20 parts of toughening agent and 15 to 20 parts of hot melt adhesive are mixed evenly, dried and then melt-extruded and stretched with air to obtain the first fiber filament. Finally, the first fiber filament is cut short to obtain the first fiber short filament.

[0008] By mass, 60 to 70 parts of polyacrylate resin, 15 to 20 parts of toughening agent and 15 to 20 parts of hot melt adhesive are mixed evenly, dried and then formed by melt extrusion and air stretching to obtain the second fiber filament. Finally, the second fiber filament is cut short to obtain the second fiber short filament.

[0009] Glass wool, first short fiber, and second short fiber are mixed to prepare a water- and oil-removing air filter material.

[0010] Compared with the prior art, the technical solution conceived in this application, by preparing modified methacrylic resin and using it to prepare the first short fiber, can adsorb oil particles in the air to be filtered during filtration, while using the second short fiber prepared by polyacrylic resin to remove moisture in the air to be filtered, thereby achieving the effect of removing water and oil while filtering solid particles in the air, and greatly extending the service life of the air filter material.

[0011] As a further preferred option, the reaction time for preparing the modified methacrylic resin is 30 min to 40 min.

[0012] As a further preferred embodiment, when preparing the first fiber filament, cold air at 15°C to 20°C is used for traction and shaping.

[0013] As a further preferred embodiment, the second fiber filament is prepared by drawing and shaping with hot air at 200°C to 220°C.

[0014] As a further preferred embodiment, the hot melt adhesive includes one or more of EVA, PO, PUR, PA, TPU, and PE, and the toughening agent is an organosilicon acrylic resin.

[0015] As a further preferred embodiment, the diameters of the first and second fiber filaments are 8 μm to 12 μm, and the lengths of the first and second fiber filaments are 4 mm to 6 mm.

[0016] As a further preferred embodiment, 60 to 70 parts by weight of glass wool, 15 to 20 parts by weight of first fiber short filaments and 15 to 20 parts by weight of second fiber short filaments are mixed and combed by airflow to form a mesh structure, then vacuum-suctioned to form a uniform mesh mat, and finally the uniform mesh mat is heated and bonded to obtain a water-removing and oil-removing air filter material.

[0017] As a further preferred embodiment, the heating temperature of the uniform mesh is 220℃~240℃, and the heating time is 30s~60s, and / or,

[0018] The quantitative amount of the uniform mesh is 60 g / m. 2 ~80 g / m 2 .

[0019] As a further preferred embodiment, the glass wool includes one or more glass wools with a beating degree of 34°, 39°, 44°, 49°, 54°, 59°, and 64°.

[0020] According to another aspect of this application, a water- and oil-removing air filter material obtained by the above preparation method is provided.

[0021] In summary, compared with the prior art, the technical solutions conceived in this application have the following main technical advantages:

[0022] 1. This application prepares modified methacrylic acid resin and uses it to prepare the first short fiber, which can adsorb oil particles in the air to be filtered during filtration, preventing oil particles from forming an oil film in the pores and blocking the air from passing through. At the same time, the second short fiber prepared by polyacrylic acid resin adsorbs moisture in the air to be filtered, preventing the excessive moisture content on the filter material from causing ash agglomeration and clogging of the pores. Thus, while maintaining high efficiency in filtering solid particles in the air, it achieves the effect of removing water and oil, greatly extending the service life of the air filter material and reducing the filter element replacement cost and manual labor intensity.

[0023] 2. In particular, this application adds hot melt adhesive when preparing the first and second short fiber filaments and forms fiber filaments through melting, so that the fiber filaments themselves have a certain degree of adhesiveness. No additional adhesive is needed when preparing the filter material in the subsequent process, and the original air channels will not be blocked. This makes the prepared water and oil removal air filter material have good overall filtration performance and high air permeability, which greatly extends the service life of the filter material.

[0024] 3. At the same time, the air filter material provided in this application not only ensures the economic use requirement of long service life, but also ensures that it can be used for any filtration efficiency requirement, while avoiding the problem of excessive resistance increase in harsh environments caused by the poor water and oil removal ability of traditional air filter materials. Attached Figure Description

[0025] Figure 1 This is a flowchart illustrating the preparation process of the water- and oil-removing air filter material provided in the embodiments of this application.

[0026] Figure 2 This is a scanning electron microscope image of the water-removing and oil-removing air filter material prepared in Example 1 of this application. Detailed Implementation

[0027] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0028] like Figure 1 As shown, this application provides a method for preparing a water and oil removal air filter material, specifically:

[0029] Octadecyl methacrylate, isobutyl methacrylate, acrylic acid, ethylene glycol ester and styrene are mixed and reacted at room temperature for a preset time to form a modified methacrylate resin. Then, the modified methacrylate resin is used to prepare the first fiber short filament. The first fiber short filament is used to adsorb oil particles in the air to be filtered during subsequent filtration, so as to avoid the formation of an oil film in the pores that blocks the air from passing through, causing the filter material resistance to rise too quickly.

[0030] Secondary fiber short filaments are prepared using polyacrylate resin to adsorb moisture in the air to be filtered, thus avoiding excessive moisture content on the filter material, which can lead to ash agglomeration and blockage of pores.

[0031] Glass wool, first short fiber, and second short fiber are mixed to prepare a water- and oil-removing air filter material.

[0032] This application prepares modified methacrylic resin and uses it to prepare first short fibers, which can adsorb oil particles in the air during filtration. At the same time, the second short fibers prepared with polyacrylic resin remove moisture from the air. Thus, while filtering solid particles in the air, it achieves the effect of removing water and oil, which greatly extends the service life of the air filter material and reduces the filter element replacement cost and manual labor intensity.

[0033] Furthermore, the specific preparation method of the modified methacrylic resin is as follows: by mass, 30-40 parts of octadecyl methacrylate, 30-40 parts of isobutyl methacrylate, 5-10 parts of acrylic acid, 5-10 parts of ethylene glycol ester, and 10-20 parts of styrene are mixed, and then reacted for 30-40 minutes to obtain the modified methacrylic resin. By optimizing the proportion of each component, a better synthesis reaction effect can be obtained, and the oil absorption effect of the modified methacrylic resin can be avoided.

[0034] Furthermore, the specific preparation method of the first short fiber is as follows: 60-70 parts by weight of modified methacrylic resin, 15-20 parts by weight of toughening agent, and 15-20 parts by weight of hot melt adhesive are mixed evenly, dried, and then melt-extruded and drawn into shape using cold air at 15°C-20°C to obtain the first long fiber. Finally, the first long fiber is cut short to obtain the first short fiber. Specifically, an excessive proportion of modified methacrylic resin will reduce the fiber strength and adhesion, while an insufficient proportion will reduce the oil absorption effect; an excessive proportion of toughening agent will reduce the oil absorption effect, while an insufficient proportion will reduce the fiber strength; an excessive proportion of hot melt adhesive will reduce the oil absorption effect, while an insufficient proportion will reduce the adhesion. Simultaneously, based on the characteristics of modified methacrylic resin, drawing in cold air results in better fiber dispersion. Too low a cold air temperature will cause the fiber diameter to exceed the upper limit, while too high a cold air temperature will cause the fiber diameter to exceed the lower limit.

[0035] The specific preparation method of the second fiber short filament is as follows: 60-70 parts by weight of polyacrylate resin, 15-20 parts by weight of toughening agent, and 15-20 parts by weight of hot melt adhesive are mixed evenly. After drying, the mixture is melt-extruded and drawn into shape using hot air at 200℃-220℃ to obtain the second fiber long filament. Finally, the second fiber long filament is cut short to obtain the second fiber short filament. Based on the characteristics of polyacrylate resin, the fiber dispersion obtained in hot air is better; however, if the hot air temperature is too low, the fiber diameter will exceed the upper limit, and if the hot air temperature is too high, the fiber diameter will exceed the lower limit.

[0036] In the preparation of the first and second short fiber filaments, this application adds hot melt adhesive and melts it to form fiber filaments, giving the fiber filaments a certain degree of adhesiveness. This eliminates the need for additional adhesives during subsequent overall molding, preventing clogging of the original pore channels. Consequently, the resulting water and oil removal air filter material possesses excellent overall filtration performance while maintaining high air permeability, significantly extending its lifespan.

[0037] More preferably, the hot melt adhesive includes one or more of EVA, PO, PUR, PA, TPU, and PE, and the toughening agent is an organosilicon acrylic resin. The diameter of the first and second fiber filaments is 8μm to 12μm, and the length of the first and second fiber stubs is 4mm to 6mm. If the diameter is too small, it will increase the filter media resistance; if the diameter is too large, it will reduce the oil or water absorption effect. If the length is too small, it will increase the filter media resistance; if the length is too large, it will reduce the airflow combing effect and result in uneven distribution of the mesh fibers.

[0038] Further, by weight, 60-70 parts glass wool, 15-20 parts first-fiber short filaments, and 15-20 parts second-fiber short filaments are mixed and combed through an airflow to form a mesh structure. Then, vacuum suction is used to form a uniform mesh pad. Finally, the uniform mesh pad is heated and bonded to obtain a water and oil removal air filter material. Too much glass wool will reduce the oil and water absorption effect, while too little glass wool will reduce the filter material's filtration efficiency. Similarly, too much first-fiber short filament will reduce the water absorption effect, while too little will reduce the oil absorption effect; and too much second-fiber short filament will reduce the oil absorption effect, while too little will reduce the water absorption effect.

[0039] More preferably, the heating temperature for the uniform mesh pad is 220℃~240℃, and the heating time is 30s~60s. If the heating temperature is too low, it will reduce the overall adhesion of the filter material; if the heating temperature is too high, it will cause the hot melt adhesive contained in the fiber filaments to melt, increasing the bonding area and increasing the resistance of the filter material; if the heating time is too short, the fiber filaments will not soften sufficiently, resulting in poor adhesion; if the heating time is too long, it will reduce production efficiency and increase energy consumption.

[0040] Glass wool includes one or more types of glass wool with a freeness of 34°, 39°, 44°, 49°, 54°, 59°, and 64°, and the basis weight (weight of the uniform mesh per unit area) is 60 g / m². 2 ~80 g / m 2 .

[0041] According to another aspect of this application, a water- and oil-removing air filter material prepared by the above method is provided. This air filter material not only ensures the economic use requirement of long service life, but also ensures that it is suitable for any filtration efficiency requirement. At the same time, it avoids the problem of excessively rapid resistance increase in harsh environments caused by the poor water and oil removal capabilities of traditional air filter materials.

[0042] The technical solutions provided in this application will be further described below with reference to specific embodiments.

[0043] Example 1

[0044] (1) By mass, 30 parts of octadecyl methacrylate, 30 parts of isobutyl methacrylate, 10 parts of acrylic acid, 10 parts of ethylene glycol ester and 20 parts of styrene are mixed and reacted for 30 min to generate modified methacrylic resin.

[0045] (2) By mass, 60 parts of modified methacrylic resin, 20 parts of organosilicon acrylic resin and 20 parts of EVA hot melt adhesive are mixed evenly, dried at 120°C for 3 hours, and then melt-extruded at 220°C and stretched by cold air at 15°C to obtain a first fiber filament with a diameter of 8μm.

[0046] (3) Cut the first fiber filament obtained in step (2) into first fiber short filaments with a length of 4 mm;

[0047] (4) By mass, 60 parts of polyacrylate resin powder, 20 parts of silicone acrylic resin and 20 parts of PA hot melt adhesive powder are mixed evenly, dried at 120°C for 3 hours, and then melt-extruded at 220°C and stretched by hot air at 200°C to obtain a second fiber filament with a diameter of 8μm.

[0048] (5) Cut the second fiber filament obtained in step (4) into second fiber short filaments with a length of 4 mm;

[0049] (6) By weight, 60 parts of 44° glass wool, 20 parts of first fiber staple fiber, and 20 parts of second fiber staple fiber are mixed together, combed by airflow, and then vacuumed at 0.05MPa to form a weight of 70g / m³. 2 Uniform mesh pad;

[0050] (7) The reinforcing mesh is bonded by heating with hot air at 220℃ for 60s to form a water- and oil-removing air filter material. Its scanning electron microscope image is shown below. Figure 2 As shown.

[0051] Example 2

[0052] (1) By mass, 35 parts of octadecyl methacrylate, 35 parts of isobutyl methacrylate, 8 parts of acrylic acid, 7 parts of ethylene glycol ester and 15 parts of styrene are mixed and reacted for 35 min to generate modified methacrylic resin.

[0053] (2) By mass, 65 parts of modified methacrylic resin, 15 parts of silicone acrylic resin and 20 parts of TPU hot melt adhesive are mixed evenly, dried at 110°C for 4 hours, and then melt-extruded at 230°C and stretched by cold air at 17°C to obtain a first fiber filament with a diameter of 10 μm.

[0054] (3) Cut the first fiber filament obtained in step (2) into first fiber short filaments with a length of 5 mm;

[0055] (4) By mass, 65 parts of polyacrylate resin powder, 15 parts of silicone acrylic resin and 20 parts of PUR hot melt adhesive powder are mixed evenly, dried at 110°C for 4 hours, and then melt-extruded at 230°C and stretched by hot air at 210°C to obtain a second fiber filament with a diameter of 10 μm.

[0056] (5) Cut the second fiber filament obtained in step (4) into second fiber short filaments with a length of 5 mm;

[0057] (6) By weight, 65 parts of 49° glass wool, 20 parts of first fiber staple fiber, and 15 parts of second fiber staple fiber are mixed together, combed by airflow, and then vacuumed at 0.055MPa to form a weight of 60g / m³. 2 Uniform mesh pad;

[0058] (7) The reinforcing mesh is bonded by heating it with hot air at 230°C for 45 seconds to form a water- and oil-removing air filter material.

[0059] Example 3

[0060] (1) By mass, 40 parts of octadecyl methacrylate, 40 parts of isobutyl methacrylate, 5 parts of acrylic acid, 5 parts of ethylene glycol ester and 10 parts of styrene are mixed and reacted for 40 min to generate modified methacrylic resin.

[0061] (2) By mass, 70 parts of modified methacrylic resin, 15 parts of organosilicon acrylic resin and 15 parts of PE hot melt adhesive are mixed evenly, dried at 100°C for 5 hours, and then melt-extruded at 240°C and stretched by cold air at 20°C to obtain a first fiber filament with a diameter of 12 μm.

[0062] (3) Cut the first fiber filament obtained in step (2) into first fiber short filaments with a length of 6 mm;

[0063] (4) By mass, 70 parts of polyacrylate resin powder, 20 parts of silicone acrylic resin and 15 parts of PA hot melt adhesive powder are mixed evenly, dried at 100°C for 5 hours, and then melt-extruded at 240°C and stretched by hot air at 220°C to obtain a second fiber filament with a diameter of 12μm.

[0064] (5) Cut the second fiber filament obtained in step (4) into second fiber short filaments with a length of 6 mm;

[0065] (6) By weight, 70 parts of 54° glass wool, 15 parts of first fiber staple fiber, and 15 parts of second fiber staple fiber are mixed together, combed by airflow, and then vacuumed at 0.06MPa to form a weight of 80g / m³. 2 Uniform mesh pad;

[0066] (7) The reinforcing mesh is bonded and reinforced by heating with hot air at 240°C for 30 seconds to form a high-efficiency air filter material.

[0067] Comparative Example 1

[0068] The other conditions are the same as in Example 1, except that steps (1), (2), and (3) are omitted.

[0069] Comparative Example 2

[0070] The other conditions are the same as in Example 1, except that steps (4) and (5) are omitted.

[0071] Comparative Example 3

[0072] Other conditions are the same as in Example 1, except that there is no hot melt adhesive in steps (2) and (4), and in step (7) the mesh is reinforced by spraying adhesive to form a high-efficiency air filter material.

[0073] Comparative Example 4

[0074] Other conditions are the same as in Example 1, except that there is no hot melt adhesive in steps (2) and (4), and in step (7) the mesh is reinforced by hot rolling process to form a high-efficiency air filter material.

[0075] Comparative Example 5

[0076] Other conditions are the same as in Example 1, except that in steps (3) and (5), the first and second fiber filaments are cut to a length of 3 mm.

[0077] Comparative Example 6

[0078] Other conditions are the same as in Example 1, except that in steps (3) and (5), the first and second fiber filaments are cut to a length of 7 mm.

[0079] Comparative Example 7

[0080] Other conditions are the same as in Example 1, except that no silicone acrylic resin is used in steps (2) and (4).

[0081] The air filter materials prepared in Examples 1-3 and Comparative Examples 1-7 were tested, and the test items and methods are as follows:

[0082] Filtration efficiency: As per test standard: EN1822-3:2009;

[0083] Initial resistance: As per test standard: EN1822-3:2009;

[0084] Water removal efficiency: According to the test standard: QC / T1134-2020;

[0085] Degreasing efficiency: According to the test standard: ISO 8573-1:2010;

[0086] Tensile strength: According to the test standard: GB / T12914-2018.

[0087] Table 1 Test Results

[0088]

[0089] As can be seen from the table above, compared with Examples 1, 2 and 3, as the diameter of glass wool fibers decreases (the higher the degree, the smaller the fiber diameter), the filtration efficiency and initial resistance increase accordingly; at the same time, as the proportion of modified methacrylic resin and polyacrylate resin increases, the water removal efficiency and oil removal efficiency are both improved.

[0090] Comparing Example 1 with Comparative Examples 1 and 2, it can be seen that without the addition of modified methacrylic resin, the oil removal efficiency of the filter material is significantly reduced; without the addition of polyacrylate resin, the water removal efficiency of the filter material is significantly reduced. This is because both modified methacrylic resin and polyacrylate resin must be present to obtain good water removal and oil removal efficiencies.

[0091] Comparing Example 1 and Comparative Example 3, it can be seen that the fiber filaments formed by adding hot melt adhesive to modified methacrylic resin and polyacrylate resin have a self-adhesive effect, which can reduce the initial resistance compared with the traditional process of adding adhesive.

[0092] Comparing Example 1 and Comparative Example 4, it can be seen that the fiber filaments formed by adding hot melt adhesive to modified methacrylic resin and polyacrylate resin have a self-adhesive effect, which can reduce the initial resistance compared with the traditional hot rolling process.

[0093] Comparing Example 1 with Comparative Examples 5 and 6, it can be seen that the lengths of the first and second short fiber filaments need to be within a certain range. Too short or too long will affect the uniformity of the molding, thereby increasing the initial resistance of the filter material.

[0094] Comparing Example 1 and Comparative Example 7, it can be seen that the tensile strength of the air filter material is reduced without the addition of silicone acrylic resin. This indicates that the addition of silicone acrylic resin (toughening agent) in this application is essential and beneficial to improving the tensile strength of the air filter material.

[0095] In the description of this application, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of this application, "multiple" means two or more, unless otherwise explicitly specified.

[0096] Furthermore, throughout this specification, references to "an embodiment"; "an embodiment," "an example," or similar language indicate that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment of this application. Therefore, the appearance of the phrase "in one embodiment;" throughout this specification, and similar language, may, but not necessarily, refer to the same embodiment.

[0097] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of this application and is not intended to limit this application. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A method of making a water and oil removal air filter material, characterized by, The preparation method is specifically as follows: 30-40 parts of octadecyl methacrylate, 30-40 parts of isobutyl methacrylate, 5-10 parts of acrylic acid, 5-10 parts of ethylene glycol ester, and 10-20 parts of styrene are mixed, and then reacted for a preset time to obtain a modified methacrylic acid resin; 60-70 parts of the modified methacrylic acid resin, 15-20 parts of a toughening agent, and 15-20 parts of a hot melt adhesive are uniformly mixed, dried, and then melt-extruded and air-drawn to form a first fiber filament, and finally the first fiber filament is cut to obtain a first fiber short filament; 60-70 parts of the modified methacrylic acid resin, 15-20 parts of a toughening agent, and 15-20 parts of a hot melt adhesive are uniformly mixed, dried, and then melt-extruded and air-drawn to form a second fiber filament, and finally the second fiber filament is cut to obtain a second fiber short filament; 60-70 parts of glass wool, 15-20 parts of the first fiber short filament, and 15-20 parts of the second fiber short filament are mixed and air-laid to form a net structure, and then vacuum suction is performed to form a uniform net pad, and finally the uniform net pad is heated and bonded to obtain a water and oil removal air filter material.

2. The production method according to claim 1, wherein The reaction time for preparing the modified methacrylic acid resin is 30-40 min.

3. The production method according to claim 1, wherein When preparing the first fiber filament, cold air at 15-20℃ is used for drawing and forming.

4. The production method according to claim 1, wherein When preparing the second fiber filament, hot air at 200-220℃ is used for drawing and forming.

5. The production method according to claim 1, wherein The hot melt adhesive comprises one or more of EVA, PO, PUR, PA, TPU, and PE, and the toughening agent is an organic silicone acrylic resin.

6. The production method according to claim 1, wherein The diameters of the first fiber filament and the second fiber filament are 8-12μm, and the lengths of the first fiber short filament and the second fiber short filament are 4-6mm.

7. The production method according to claim 1, wherein The heating temperature of the uniform net pad is 220-240℃, the heating time is 30-60s, and / or The basis weight of the uniform web mat is 60 g / m 2 ~ 80 g / m 2 .

8. The production method according to any one of claims 1 to 7, characterized by, The glass wool comprises one or more of glass wool with a beating degree of 34°, 39°, 44°, 49°, 54°, 59°, and 64°.

9. A water and oil removal air filter material obtained by the preparation method according to any one of claims 1-8.

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