Process for the preparation of a fully synthetic fiber f9 grade air filter material and product

Abstract

The application provides a preparation method and product of a full synthetic fiber F9 grade air filter material, and the preparation method comprises the following steps: a. taking raw materials of synthetic fibers and ultrafine fibers according to weight ratios, adding water into the mixed raw materials, mixing, and stirring and dispersing into a slurry; b. preparing a filter material from the slurry according to an existing wet forming method; c. after the filter material is dehydrated, acrylic resin liquid is coated on the surface of the filter material; and d. the filter material coated with the acrylic resin liquid is sequentially passed through three groups of drying cylinders, so that the water content of the dried filter material is less than 5%. The application provides a new type of filter material for filtering and isolating bacteria in air, and effectively solves the problem of African swine fever.

Description

Technical Field

[0001] This invention relates to the field of air filter material preparation, specifically to a method and product for preparing a fully synthetic fiber air filter material, and more particularly to a method and product for preparing a fully synthetic fiber F9 grade air filter material. Background Technology

[0002] African swine fever virus (ASFV) is an ancient virus, first discovered in Kenya, Africa in 1921, and has a history of approximately 100 years. African swine fever is an acute, febrile, and highly contagious animal disease caused by the African swine fever virus in domestic and wild pigs. All breeds and ages of pigs can be infected, with morbidity and mortality rates reaching up to 100%. The World Organisation for Animal Health (OIE) lists it as a notifiable animal disease, and China also classifies it as a Class A animal disease.

[0003] African swine fever virus (ASFV) is an important member of the genus ASFV in the family ASFVeidae. It shares some characteristics with the families Iridoviridae and Poxviridae. The virus particle has a diameter of 175–215 nanometers, exhibits icosahedral symmetry, and has an envelope. The genome is a double-stranded linear DNA, 170–190 kb in size.

[0004] The existing livestock farming industry does not effectively isolate the environment, and the breeding environment is not filtered and purified. Therefore, germs in the air can easily spread to pigs. Once a swine fever epidemic occurs, it will cause a large-scale outbreak, resulting in heavy losses for farms and a rise in pork prices in the market.

[0005] Therefore, to solve the African swine fever problem, a good filter material is needed to filter and isolate airborne pathogens, effectively addressing the issue. Because farms are generally large in area and require significant investment, a high-efficiency, low-resistance air filter material is needed to meet filtration needs. Furthermore, with the national policy of low-carbon and environmental protection, the required filter material must be recyclable or biodegradable. Therefore, to address the current situation, there is an urgent need for a high-efficiency, low-resistance air filter material, making the development of fully synthetic fiber air filter materials imperative.

[0006] In summary, the existing technology has the following problems: the existing livestock farming environment does not filter and isolate airborne pathogens, so airborne pathogens can easily infect pigs. Once a swine fever epidemic occurs, it will cause a large-scale outbreak, resulting in heavy losses for farms. Summary of the Invention

[0007] This invention provides a method for preparing F9 grade all-synthetic fiber air filter material and a product to solve the problem that in the existing technology, the livestock breeding environment does not filter and isolate airborne pathogens, which leads to the transmission of airborne pathogens to pigs, resulting in large-scale swine fever outbreaks and causing heavy losses to farms.

[0008] Therefore, this invention proposes a method for preparing a fully synthetic fiber air filter material and a product thereof, particularly a method for preparing a fully synthetic fiber F9 grade air filter material and a product thereof. The method for preparing the fully synthetic fiber F9 grade air filter material includes the following steps:

[0009] a. Take raw materials according to the weight ratio. The raw material composition includes: 60-70% synthetic fiber with a diameter of (1.3-1.7)D×6mm, 5-10% synthetic fiber with a diameter of (0.6-0.8)D×12mm, and 20-35% microfiber. Add water with a pH value of 2.6-3.2 to the mixed raw materials, mix, stir and disperse into a slurry, and ensure that the pH value of the slurry is acidic.

[0010] b. The slurry is processed into filter media using existing wet molding methods;

[0011] c. After the filter media is dehydrated, acrylic resin solution is coated onto the surface of the filter media to prepare a filter media coated with acrylic resin solution;

[0012] d. The filter media coated with acrylic resin solution is fed through three sets of drying cylinders at a paper feeding speed of 50-80 m / min to dry the filter media so that the moisture content of the dried filter media is less than 5%.

[0013] Furthermore, the sum of the components of 60-70% synthetic fiber with (1.3-1.7)D×6mm, 5-10% synthetic fiber with (0.6-0.8)D×12mm and 20-35% microfiber is 100%.

[0014] Further, in step a, water with a pH value of 2.6-3.2, which is 20-30 times the weight of the raw materials, is added to the mixed raw materials.

[0015] Furthermore, in step a, the pH value of the slurry is ensured to be 2.5-3.0.

[0016] Further, in step c, the acrylic resin solution is prepared by mixing 1 part acrylic resin and 5 parts water by weight and stirring.

[0017] Furthermore, the microfiber in step a is glass fiber.

[0018] Furthermore, in step d, the temperatures inside the three drying cylinders are 60℃-90℃, 110℃-150℃, and 120℃-90℃ respectively (meaning the temperature drops from 120℃ to 90℃, as a cooling process is required later in the process, so a lower temperature is set).

[0019] Furthermore, in step d, the temperatures inside the three drying cylinders are 80℃, 140℃, and 100℃, respectively.

[0020] The present invention also provides a fully synthetic fiber F9 grade air filter product, which is manufactured by any of the methods described in the preceding steps, wherein the fully synthetic fiber F9 grade air filter product is in the form of a cloth sheet.

[0021] The sheet-like, fully synthetic fiber F9 grade air filter product can be rolled up to form a roll product.

[0022] Furthermore, the thickness of the fabric sheet is 0.30-0.40 mm, and the roll product is made of multiple layers of fabric sheet-shaped fully synthetic fiber F9 grade air filter products, with the thickness of a single layer of fabric sheet being 0.30-0.40 mm.

[0023] Further, the raw material composition is: 65% synthetic fiber with a diameter of (1.3-1.7)D×6mm, 5% synthetic fiber with a diameter of (0.6-0.8)D×12mm, and 30% microfiber. Water with a pH of 2.8, equal to 25 times the weight of the raw material, is added to the mixed raw material, mixed, stirred, and dispersed into a slurry, ensuring the slurry's pH is 2.6. The filter material coated with acrylic resin is fed sequentially through three sets of drying cylinders at a paper feeding speed of 75m / min. The temperatures of the three sets of drying cylinders are 90℃, 145℃, and 110℃, respectively. The thickness of the fully synthetic fiber F9 grade air filter product is 0.325mm, the air resistance is 8.0mmH2O, the efficiency is 10mN.m, the stiffness is 445Mg, the MD tensile strength is 1.35KN / m, and the CD tensile strength is 0.95KN / m.

[0024] Further, the raw material composition is: 60% synthetic fiber with a diameter of (1.3-1.7)D×6mm, 10% synthetic fiber with a diameter of (0.6-0.8)D×12mm, and 30% microfiber. Water with a pH of 2.6, equal to 20 times the weight of the raw material, is added to the mixed raw material, and the mixture is stirred and dispersed into a slurry, ensuring the slurry has a pH of 2.5. The filter material coated with acrylic resin is fed sequentially through three sets of drying cylinders at a paper feeding speed of 50m / min. The temperatures of the three sets of drying cylinders are 70℃, 125℃, and 90℃, respectively. The thickness of the fully synthetic fiber F9 grade air filter product is 0.31mm, the air resistance is 7.9mmH2O, the efficiency is 11mN.m, the stiffness is 460Mg, the MD tensile strength is 1.20KN / m, and the CD tensile strength is 0.98KN / m.

[0025] Further, the raw material composition is: 70% synthetic fiber with a diameter of (1.3-1.7)D×6mm, 8% synthetic fiber with a diameter of (0.6-0.8)D×12mm, and 22% microfiber. Water with a pH of 3.2, equal to 30 times the weight of the raw material, is added to the mixed raw material, and the mixture is stirred and dispersed into a slurry, ensuring the slurry's pH is 3.0. The filter material coated with acrylic resin solution is fed sequentially through three sets of drying cylinders at a paper feeding speed of 60m / min. The temperatures of the three sets of drying cylinders are 80℃, 140℃, and 100℃, respectively. The thickness of the fully synthetic fiber F9 grade air filter product is 0.3mm, the air resistance is 8.2mmH2O, the efficiency is 11.5mN.m, the stiffness is 477Mg, the MD tensile strength is 1.32KN / m, and the CD tensile strength is 0.85KN / m.

[0026] The all-synthetic fiber product of this invention, due to its base material being synthetic fiber, does not exhibit fiber swelling from water absorption. Therefore, it can effectively maintain the integrity of the filter material structure under any extreme environment. By adding ultrafine fibers to ensure the filtration accuracy of the material, high efficiency, low resistance, and high weather resistance can be simultaneously achieved. However, the raw materials of this invention contain ultrafine fibers and small-sized synthetic fibers, which are prone to bubble formation, difficulty in dispersion, and flocculation during the dispersing process. This method addresses this by adding highly acidic water to the raw materials for dispersion and pulping before the wet papermaking process, resulting in an extremely low concentration of raw materials (less than 0.05%) during wet forming, thus preventing flocculation during preparation. Furthermore, synthetic fibers are prone to breakage and poor bonding strength during preparation. This method uses acrylic resin liquid to coat the formed filter material and adds dual-melting-point synthetic fibers to the raw materials to enhance the filter paper's strength. This invention solves the key material problems in air filtration and pathogen filtration in my country's livestock industry, thereby preventing large-scale swine fever outbreaks and the resulting heavy losses for farms. Attached Figure Description

[0027] Figure 1 This invention relates to the practical application structure of products divided into small pieces (excluding support devices). Figure 1 ;

[0028] Figure 2 This invention relates to the practical application structure of products divided into small pieces (excluding support devices). Figure 2 ;

[0029] Figure 3 Here is the transmittance curve 1 for the product of this invention;

[0030] Figure 4 2 is the transmittance curve of the product of this invention;

[0031] Figure 53 is the transmittance curve of the product of this invention;

[0032] in, Figures 3-5 The horizontal axis represents particle size in micrometers; the vertical axis represents transmittance in percentage. The symbols in the attached diagram are explained as follows: 1. target (represents the target (or average) transmittance of the filter material); 2. max (represents the maximum transmittance of the filter material); 3. Products cut into small pieces; 4. Support device. Detailed Implementation

[0033] To provide a clearer understanding of the technical features, objectives, and effects of this invention, the invention is now described.

[0034] This invention provides a method for preparing F9 grade air filter material of fully synthetic fiber and a product thereof. The F9 grade air filter material product obtained by the method of this invention has high efficiency and low resistance. The development of this product can effectively suppress the development of African swine fever.

[0035] I. The specific implementation methods of this invention are as follows:

[0036] Example 1

[0037] The preparation process of a fully synthetic fiber F9 grade air filter material is as follows:

[0038] a. Take the following raw materials by weight ratio: 65% synthetic fiber with a denier of 1.3-1.7 (D×6mm) (denier of 1.3-1.7 and length of 6mm), 5% synthetic fiber with a denier of 0.6-0.8 (D×12mm) (denier of 0.6-0.8 and length of 12mm), and 30% microfiber (fiber with a denier of less than 0.3 denier (diameter of 5 micrometers) is called microfiber). The sum of the three components is 100%. Add 25 times the weight of the raw materials to water with a pH of 2.8, mix, stir and disperse into a slurry, and ensure that the pH of the slurry is 2.6.

[0039] b. The slurry is processed into filter media using existing wet molding methods;

[0040] c. After dehydration, apply the diluted acrylic resin solution to the surface of the filter material;

[0041] d. After the excess acrylic resin in the filter media coated with acrylic resin liquid is extracted by a vacuum pump, the filter media is fed through three sets of drying cylinders at a paper feeding speed of 75 m / min. The drying cylinders are heated by burning natural gas. The temperatures of the drying cylinders are 90℃, 145℃ and 110℃ respectively to dry the filter media so that the moisture content of the dried filter media is less than 5%.

[0042] Furthermore, in step c above, the acrylic resin solution is prepared by mixing 1 part acrylic resin and 5 parts water by weight and stirring.

[0043] Furthermore, the ultrafine fiber used in step a above is glass fiber.

[0044] The fully synthetic fiber F9 grade air filter product of the present invention is prepared by the above steps.

[0045] Example 2

[0046] The preparation process of a fully synthetic fiber F9 grade air filter material is as follows:

[0047] The raw materials are prepared according to the following weight ratios: 60% synthetic fiber with a diameter of (1.3-1.7)×6mm, 10% synthetic fiber with a diameter of (0.6-0.8)×12mm, and 30% glass fiber. Water with a pH of 2.6, equal to 20 times the weight of the raw materials, is added to the raw materials, mixed, and stirred into a slurry, ensuring the pH of the slurry is 2.5. The slurry is then processed into filter material using existing wet papermaking methods. Acrylic resin solution (composed of 1 part acrylic resin and 5 parts water by weight) is applied to the surface of the filter material. The filter material is then passed sequentially through three drying cylinders at a speed of 50m / min. The temperatures of the three drying cylinders are 70℃, 125℃, and 90℃, respectively, to dry the filter material until the moisture content of the dried filter material is less than 5%, thus obtaining the fully synthetic fiber F9 grade air filter product of this invention.

[0048] Example 3

[0049] The preparation process of a fully synthetic fiber F9 grade air filter material is as follows:

[0050] The raw materials are prepared according to the following weight ratios: 70% synthetic fiber with a diameter of (1.3-1.7)×6mm, 8% synthetic fiber with a diameter of (0.6-0.8)×12mm, and 22% glass fiber. Water with a pH of 3.2, equal to 30 times the weight of the raw materials, is added to the raw materials, mixed, and stirred into a slurry, ensuring the pH of the slurry is 3.0. The slurry is then processed into filter material using existing wet papermaking methods. Acrylic resin solution (composed of 1 part acrylic resin and 5 parts water by weight) is applied to the surface of the filter material. The filter material is then passed sequentially through three drying cylinders at a speed of 60m / min. The temperatures of the three drying cylinders are 80℃, 140℃, and 100℃, respectively, to dry the filter material until the moisture content of the dried filter material is less than 5%, thus obtaining the fully synthetic fiber F9 grade air filter product of this invention.

[0051] The raw material composition of each of the above embodiments is shown in Table 1, and the specific process parameters are shown in Table 2.

[0052] Table 1. Product Raw Material Composition (by weight)

[0053]

[0054]

[0055] Table 2 Specific process parameters for each embodiment

[0056]

[0057] II. All-synthetic fiber F9 grade air filter products prepared from Examples 1-3 above

[0058] (1) Performance parameters of the product of this invention

[0059] The all-synthetic fiber F9-grade air filter product prepared by this invention is in the form of a single-layer cloth sheet. (The all-synthetic fiber F9-grade air filter product can also be designed in roll form for convenient packaging and transportation.) In practical applications, for example, this product can be divided into multiple groups of small sheets, and the divided small sheets can be fixed with a support device 4 and the multiple groups of small sheets can be supported in parallel. Figure 1 and Figure 2 As shown in Table 3 below, the technical specifications of the product are listed. The target values ​​in the table are the ranges set by the company to control product quality during the production process. Figure 1 , Figure 2 As shown in Table 3, the thickness of the fully synthetic fiber F9 grade air filter product is 0.30-0.40mm, the air resistance is ≤8.5mmH2O, the efficiency is ≤14mN.m, the MD tensile strength is ≥0.9KN / m, and the CD tensile strength is ≥0.6KN / m. All the test indicators of each example are within the qualified range.

[0060] Table 3 Performance parameters of this product (Examples 1-3)

[0061]

[0062]

[0063] Note: mN.m (0.3μm, 5.33cm / sec-32L / min) refers to aerosol particles or oil mist particles with a diameter of 0.3 micrometers and an air velocity of 32 liters per minute (i.e., wind speed of 5.33 cm / sec, representing the transmittance of aerosol particles).

[0064] (2) Effects of use

[0065] The filtration data curves of the all-synthetic fiber F9-grade air filter product prepared by this invention are as follows: Figures 3-5In each figure, MF0907 is the model number of the air filter material, indicating F9 filter material; MPPS represents the most easily penetrating particle size, a test method for filter materials; @1cm / s, 2cm / s, and 3cm / s refer to the filtration speeds of the filter material at filtration speeds of 1cm / s, 2cm / s, and 3cm / s, respectively; curve 1 is the Target curve, representing the target value (or average value) of the filter material's transmittance; curve 2 is the Max curve, representing the maximum value of the filter material's transmittance. Figure 3-5 The three transmittance curves are 1, 2, and 3, respectively, for the F9 filter material of model MF0907 at filtration speeds of 1cm / s, 2cm / s, and 3cm / s. It can be seen from the above three transmittance curves that the maximum transmittance of MF0907 (Max (curve)) at different filtration speeds is greater than the target transmittance (Target (curve)). This proves that the product of this invention fully meets the filtration efficiency of F9, has a good filtration effect, high efficiency, low resistance, and a greatly extended service life, and can better filter germs in the air.

[0066] The F9-grade air filter product prepared by the method of this invention has high efficiency and low resistance, and can effectively filter and isolate the air in the livestock breeding environment, preventing airborne pathogens from infecting pigs, thereby avoiding large-scale swine fever outbreaks and the resulting heavy losses to farms.

[0067] The present invention has the following advantages:

[0068] 1. The fully synthetic fiber has a solid structure and good weather resistance. It will not change shape in humid weather. As a material, it will not cause the reduction of pores or the deformation of the filter media. Therefore, there will be no significant increase in resistance or deformation of the filter in any harsh environment.

[0069] 2. The synthetic fiber raw materials contain small-diameter fibers. The main body of the synthetic fiber used is about 6μm, and it also contains a large number of ultrafine fibers smaller than 1μm, which can provide a large specific surface area, porosity and small pore size, resulting in a better virus filtration effect.

[0070] 3. Filters made of synthetic fibers can be sorted and disposed of, plastic parts can be recycled, and filter materials can be incinerated, so they will not harm the environment.

[0071] The development of this product can effectively curb the spread of African swine fever, protect the livestock industry, better address livelihood issues, and effectively suppress pork price increases. This invention fills the gap in the domestic filter industry for fully synthetic fiber air filtration materials, solves the key material problems of air filtration and pathogen filtration in my country's livestock industry, and promotes the further development of the livestock industry.

[0072] The above description is merely an illustrative embodiment of the present invention and is not intended to limit the scope of the invention. The various components of the present invention can be combined with each other without conflict. Any equivalent changes and modifications made by those skilled in the art without departing from the concept and principles of the present invention should fall within the scope of protection of the present invention.

Claims

1. A method for preparing a fully synthetic fiber F9 grade air filter material, characterized in that, Includes the following steps: a. Take raw materials according to the weight ratio. The raw material composition includes: 60-70% synthetic fiber with a diameter of (1.3-1.7)D×6mm, 5-10% synthetic fiber with a diameter of (0.6-0.8)D×12mm, and 20-35% microfiber. Add water with a pH value of 2.6-3.2 to the mixed raw materials, mix, stir and disperse into a slurry, and ensure that the pH value of the slurry is acidic. b. The slurry is processed into filter media using existing wet molding methods; c. After the filter media is dehydrated, acrylic resin liquid is coated on the surface of the filter media to prepare a filter media coated with acrylic resin liquid; d. The filter media coated with acrylic resin solution is fed through three sets of drying cylinders at a paper feeding speed of 50-80 m / min to dry the filter media so that the moisture content of the dried filter media is less than 5%.

2. The method for preparing a fully synthetic fiber F9 grade air filter material according to claim 1, characterized in that, The sum of the components, namely 60-70% synthetic fiber with (1.3-1.7)D×6mm, 5-10% synthetic fiber with (0.6-0.8)D×12mm and 20-35% microfiber, is 100%.

3. The method for preparing a fully synthetic fiber F9 grade air filter material according to claim 1, characterized in that, In step a, water with a pH of 2.6-3.2 is added to the mixed raw materials at a ratio of 20-30 times the weight of the raw materials.

4. The method for preparing a fully synthetic fiber F9 grade air filter material according to claim 1, characterized in that, In step a, the pH value of the slurry is ensured to be 2.5-3.

0.

5. The method for preparing a fully synthetic fiber F9 grade air filter material according to claim 1, characterized in that, In step c, the acrylic resin solution is prepared by mixing 1 part acrylic resin and 5 parts water by weight and stirring.

6. The method for preparing a fully synthetic fiber F9 grade air filter material according to claim 1, characterized in that, The ultrafine fibers in step a are glass fibers.

7. The method for preparing a fully synthetic fiber F9 grade air filter material according to claim 1, characterized in that, In step d, the temperatures of the three drying cylinders are 60℃-90℃, 110℃-150℃, and 120℃-90℃, respectively.

8. The method for preparing a fully synthetic fiber F9 grade air filter material according to claim 1, characterized in that, In step d, the temperatures of the three drying cylinders are 80℃, 140℃, and 100℃, respectively.

9. A fully synthetic fiber F9 grade air filter product, characterized in that, The fully synthetic fiber F9 grade air filter product is manufactured using the method described in any one of claims 1-8 and is in the form of a cloth sheet.

10. The all-synthetic fiber F9 grade air filter product according to claim 9, characterized in that, The thickness of the cloth-like sheet is 0.30-0.40 mm.

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