Air purification material and production method thereof

Abstract

The invention discloses an air purification material and a production method thereof. The air purification material comprises a fiber net and a filtering material uniformly distributed in the fiber net, the fiber net is formed by pressing ES double-component fibers at 130-160 DEG C and then thermally synthesizing the ES double-component fibers among the fibers; the mesh number of the filter material is less than or equal to 20. According to the generation method of the air purification material, hot melt adhesive is not used, the filter material is wrapped by the fiber net, the filter material can be uniformly distributed in the fiber net, and the problem that unpleasant odor is dissipated in the use process of the hot melt adhesive is thoroughly solved. The gram weight of the air purification material ranges from 300 g / m < 2 > to 1500 g / m < 2 >, and the air purification material can be widely applied to special environments such as electronic plants, museums and archives and public commercial environments with high requirements for air quality. According to an air purification product made of the air purification material, the initial primary purification efficiency is higher than 90%, and no organic pollutants are released; and the product basically does not generate dust and completely meets the purification requirement of a clean room.

Description

Technical Field

[0001] The present invention relates to the field of air purification materials, and particularly to an air purification material and a production method thereof. Background Art

[0002] Currently, in the prior art, porous materials such as activated carbon are usually used to purify harmful gases, and there are mainly two product forms: bulk filling and carbon cloth.

[0003] (1) Bulk filling: Adsorbent granular materials such as activated carbon are filled into a prefabricated housing (metal or plastic housing). The advantages are a large amount of adsorbent material and good purification effect. The disadvantages are dust generation and high resistance.

[0004] (2) Carbon cloth: ① Conventional carbon cloth technology: A layer of hot melt adhesive filaments is sprayed on the surface of non-woven fabric, and then carbon is sprinkled. The spraying and sprinkling of filaments and carbon can be repeated multiple times. Finally, another layer of non-woven fabric is covered and cold-pressed into shape (as shown in Figure 1-2 ). The advantage is simple process, and the disadvantage is that in the later use of the product, bad smell will be emitted by the hot melt adhesive; at the same time, the adhesive will cover the surface of the activated carbon, resulting in a reduction in the adsorption performance of the carbon. The related process can be referred to CN201810721588.8 - A filter cloth compounding machine. ② The hot melt adhesive particles and activated carbon particles are fully mixed, then sprayed on the non-woven fabric, and then another layer of non-woven fabric is covered. After heating in an oven, it is hot-pressed into shape. The advantages and disadvantages are the same as above.

[0005] However, the above prior art still has the following disadvantages: (1) In the later use of the product, the hot melt adhesive will emit bad smell; (2) At the same time, the adhesive will cover the surface of the activated carbon, resulting in a reduction in the adsorption performance of the carbon; (3) Small carbon content: When the carbon content reaches 800 g / m 2 or more, the material has high hardness. When making the finished filter, the material will break, forming leakage points, resulting in defective filters.

[0006] Therefore, there is an urgent need in the art to develop an air purification material and a production process that do not release organic pollutants, have a large production gram weight range, and high purification efficiency. Summary of the Invention

[0007] The purpose of the present invention is to provide an air purification material and a production method thereof.

[0008] To achieve the above purpose, the technical solution adopted by the present invention is specifically as follows: An air purification material includes a fiber mesh and a filter material evenly distributed in the fiber mesh; the fiber mesh is formed by heat synthesis between fibers after pressing, where the skin layer of the ES bicomponent fiber can be slightly dissolved at 130 - 160 °C; the mesh number of the filter material ≤ 20 mesh.

[0009] Among them, the ES bicomponent fiber is a PE / PET bicomponent fiber. Preferably, the ES bicomponent fiber uses 2D-6D staple fiber.

[0010] Among them, the filter material is at least one of activated carbon, alumina balls, and molecular sieve balls.

[0011] The production method of the air purification material of the present invention includes the following steps: (1) Weigh the ES bicomponent fiber and put it into an opening machine. After being preliminarily dispersed by the opening machine, it is sent to a loosening machine. (2) The loosened fiber is sent into a pneumatic cotton box by a blower and fed into a carding machine by the pneumatic cotton box. (3) After the fiber is preliminarily formed into a web by the carding machine, it enters a lapping machine. The lapping machine performs multi-layer lapping according to the pre-set lapping process requirements, and the lapped web is sent onto a non-woven base cloth. (4) The non-woven base cloth and the fiber web are sent into a carbon spreading machine system together, and the filter material is spread into the fiber web. Then, a non-woven upper cloth is covered on the fiber web by a unwind machine, and the material prefabrication is completed; the carbon spreading machine system includes at least 2 carbon spreading machines; among them, the carbon spreading amount of the second carbon spreading machine is the highest; when the number of carbon spreading machines is greater than 2, the carbon spreading amount of the first carbon spreading machine ≤ the carbon spreading amount of the remaining carbon spreading machines after the second carbon spreading machine; among them, the carbon spreading amount refers to the mass of the filter material spread into the fiber web. Through a large number of experimental explorations, it is found that the first carbon spreading machine must adopt a low carbon spreading amount so as to achieve a uniform carbon layer distribution and low material resistance.

[0012] (5) The prefabricated material enters a multi-stage oven for heating; the temperature control range of each stage of the oven is 130-220°C; the height of the internal space of the oven is not higher than 600 mm; the circulation air volume is not less than 1000 times / hour, and the air flow form adopts laminar flow air supply; the blower is controlled by a frequency converter, and the electric heater is controlled by a power regulator. (6) After the material is heated, it passes through a composite pressure roller for pressing and shaping after coming out of the oven, and then the material is cooled by air cooling.

[0013] (7) After cooling, the material is trimmed and slit, and finally wound up, and the material production is completed.

[0014] Further, in the step (2), the pneumatic cotton box realizes quantitative cotton supply by setting the pressure, and the pressure adjustment range is 80-230 Pa; the web weight range of the carding machine is 8-60 g / m 2 , and the web output speed is 8-40 m / min (the conventional carding machine is usually 20-100 m / min).

[0015] In step (3), a cross-laying web forming machine is used, with a web output speed of 1 - 5 m / min and a maximum reciprocating frequency of 7 times / min; according to production requirements, through multiple reciprocating web laying, the number of laid webs is 2 - 4 layers.

[0016] In step (4), the carbon spreading machine is controlled by the rotation speed of the feeding roller, and the rotation speed of the feeding roller is 1 - 30 r / min; the speed of the unwinding machine is 1 - 5 m / min; preferably, 3 carbon spreading machines are used, and the carbon spreading amount ratio of the 3 carbon spreading machines is 2 - 7:5 - 15:2 - 11.

[0017] In step (6), axial flow fans are used for air cooling, and natural air is utilized for cooling, with a wind speed not lower than 3 m / s.

[0018] Compared with the prior art, the prominent effects of the present invention are as follows: (1) The method for producing the air purification material of the present invention does not use hot melt adhesive, but uses fiber web formation to hold the filter material, and the filter material can be evenly distributed in the fiber web, completely avoiding the problem of the release of bad odors during the use of hot melt adhesive; through the arrangement of the carding machine and the web forming machine, the three-dimensional structure of the fiber web is ensured, and the gram weight of the fiber web is ensured.

[0019] (2) The gram weight range of the air purification material of the present invention is 300 - 1500 g / m 2 , which can be widely applied to special environments such as electronic factories, museums, and archives, as well as public commercial environments with high requirements for air quality.

[0020] (3) For the air purification products made of the air purification material of the present invention, the initial primary purification efficiency is higher than 90%, and there is no release of organic pollutants. Moreover, the products basically do not generate dust, fully meeting the purification requirements of clean rooms.

[0021] (4) The production method of the present invention requires no less than 2 groups of carbon spreading machines. The first carbon spreading machine must use a low carbon spreading amount, and the second carbon spreading machine has the highest carbon spreading amount. Only in this way can the carbon layer be evenly distributed and the material resistance be low.

[0022] The following further describes the air purification material and its production method of the present invention in conjunction with the accompanying drawings and specific embodiments. Description of the Drawings

[0023] Figures 1-2 The carbon cloth made by the traditional rubber powder or rubber filament process, with white being the hot melt adhesive cured on the surface of the carbon.

[0024] Figure 3 It is a flow schematic diagram of the production method of the air purification material of the present invention.

[0025] Figure 4Schematic diagram of the production line of the air purification material of the present invention (from the bale opener to the lapper).

[0026] Figure 5 Schematic diagram of the production line of the air purification material of the present invention (from the lapper to the coiler). Among them, three groups of carbon spreaders are taken as an example.

[0027] Figure 6 Product photo of the air purification material of Example 2. Detailed implementation manners

[0028] An air purification material, comprising a fiber web and a filtering material uniformly distributed in the fiber web; the fiber web is formed by thermally bonding between fibers of ES bicomponent fibers at 130-160°C after pressing; the mesh number of the filtering material is ≤20 mesh.

[0029] Among them, the ES bicomponent fiber is a PE / PET bicomponent fiber, and 2D-6D staple fiber is adopted. Among them, the filtering material is at least one of activated carbon, alumina balls and molecular sieve balls.

[0030] As Figure 3 shown, a production method of an air purification material specifically comprises the following steps: 1. Preparation work (1) All the equipment on the production line is powered on and runs with an empty vehicle. (2) Fill the three groups of carbon spreaders with carbon. (3) Raise the temperature of the oven to the preset temperature (150-200°C). (4) Turn on the chiller, and the outlet water temperature of the cold water is adjustable at 17-32°C.

[0031] 2. After all the above work is completed, start the formal production.

[0032] (1) Weigh the ES bicomponent fiber (4D staple fiber) and put it into the bale opener. After being preliminarily dispersed by the bale opener, it is sent to the opener.

[0033] (2) The opened fibers are sent into the pneumatic cotton box by a blower and fed into the carding machine by the pneumatic cotton box; among them, the pneumatic cotton box realizes quantitative cotton feeding by setting the pressure, and the pressure adjustment range is 80-230 Pa; the web weight range of the carding machine is 8-60 g / m 2 adjustable, and the web output speed is 8-40 meters per minute.

[0034] (3) After the fibers are initially formed into a web by a carding machine, they enter a lapping machine. The lapping machine performs multi-layer lapping according to the preset lapping process requirements, and the lapped web is sent onto a non-woven base fabric (fed in by electric unrolling); among them, a cross-lapping lapping machine is used, with a web output speed of 1 - 5 m / min and a maximum reciprocating frequency of 7 times / min; according to production requirements, through multiple reciprocating lappings (generally 2 - 4 layers of webs), the usage requirements are met.

[0035] (4) The non-woven base fabric and the fiber web are sent into a carbon spreading machine system together. According to the preset process requirements, different performance filter materials (uniform size not greater than 20 mesh; performance varies according to requirements, including filter materials for purifying acidic gases, alkaline gases, odors, VOC gases, and mixed gases of the above gases, etc.) are spread into the fiber web, and then a non-woven top fabric is covered on the fiber web by an unrolling machine, and the material prefabrication is completed; Three carbon spreading machines are used, and the carbon spreading amount ratio of the three carbon spreading machines is 2 - 7:5 - 15:2 - 11. Among them, the second carbon spreading machine has the highest carbon spreading amount; when the number of carbon spreading machines is greater than 2, the carbon spreading amount of the first carbon spreading machine ≤ the carbon spreading amount of the remaining carbon spreading machines after the second carbon spreading machine; the carbon spreading machine is controlled by the rotation speed of the feeding roller, and the rotation speed of the feeding roller is adjustable from 1 - 30 r / min; the speed of the unrolling machine is 1 - 5 m / min.

[0036] (5) The prefabricated material enters a multi-stage oven for heating; the temperature control range of each stage of the oven is adjustable from 130 - 220 °C; the internal space height of the oven is not higher than 600 mm; the circulation air volume is not less than 1000 times / h, and the air flow form adopts laminar flow air supply; the fan is controlled by a frequency converter, and the electric heater is controlled by a power regulator.

[0037] (6) After the material is heated, it passes through a composite pressure roller for pressing and shaping after coming out of the oven, and then air cooling is used to dissipate heat from the material. Air cooling uses an axial flow fan and utilizes natural air for cooling, with a wind speed not lower than 3 m / s.

[0038] (7) After heat dissipation, according to the preset process requirements, the material is trimmed and slit, and finally wound up, and the material production is completed.

[0039] In the production line of this air purification material, the upstream equipment from the opening machine to the lapping machine (as Figure 4 shown) and the downstream equipment from the lapping machine to the winding (as Figure 5 shown) are arranged perpendicular to each other at 90°, ensuring that the direction of the downstream equipment is consistent with the web output direction.

[0040] Example 1 (product with a grammage of 300 g / m 2 and a production speed of 1.5 m / min; 2D staple fiber is used) A product with a grammage of 300 g / m 2Production process of carbon-containing cloth, the specific steps are as follows: (1)Start the production line linkage, run the empty vehicle, turn on the oven heating system, preset at 150 °C, and preheat the oven.

[0041] (2)Put the upper and lower base cloths on the corresponding unwinding machines respectively; (3)Weigh the cotton, confirm the weight of the PE / PET net required for the daily production volume, put it into the cotton opening machine at one time, then turn on the net output system, debug the unit, and ensure that the net output gram weight of the lapping machine is 30 - 35 g / m 2 .

[0042] (4)Fill the carbon spreading machine with the corresponding carbon material (activated carbon with a mesh size not greater than 20). Test the feeding amounts of the 1st, 2nd, and 3rd carbon spreading machines at different rotation speeds. According to the daily production line speed (1 - 5 meters per minute), confirm that the feeding ratios of the 1st, 2nd, and 3rd carbon spreading machines are 2:5:2.

[0043] (5)Observe whether the oven temperature reaches 150 °C. If it reaches, start the formal production. Among them, a 3-stage oven is adopted, each stage is set at 150 °C, the circulating air volumes are 1200 times, 1000 times, and 1000 times per hour respectively, the oven temperature is controlled to be a constant temperature setting, and the electric heating power is adjusted through a power regulator.

[0044] (6)According to the order requirements, cut the materials into rolls at 150 meters per roll.

[0045] Example 2 (product with a gram weight of 800 g / m 2 , production speed of 1.5 meters per minute; 4D staple fiber is adopted) A production process of carbon-containing cloth with a gram weight of 800 g / m 2 , the specific steps are as follows: (1)Start the production line linkage, run the empty vehicle, turn on the oven heating system, preset at 160 °C, and preheat the oven.

[0046] (2)Put the upper and lower base cloths on the corresponding unwinding machines respectively; (3)Weigh the cotton, confirm the weight of the PE / PET net required for the daily production volume, put it into the cotton opening machine at one time, then turn on the net output system, debug the unit, and ensure that the net output gram weight of the lapping machine is 60 - 80 g / m 2 .

[0047] (4)Fill the carbon spreading machine with the corresponding carbon material (activated carbon with a mesh size not greater than 20). Test the feeding amounts of the 1st, 2nd, and 3rd carbon spreading machines at different rotation speeds. According to the daily production line speed (1 - 5 meters / minute), confirm that the feeding ratios of the 1st, 2nd, and 3rd carbon spreading machines are 5:9:7.

[0048] (5) Observe whether the oven temperature reaches 160 °C. If it reaches, start the formal production. Among them, a 3-stage oven is adopted, and each stage is set at 160 °C. The circulating air volumes are 1,200 times, 1,200 times, and 1,100 times per hour respectively. The temperature of the oven is controlled to be a constant temperature setting, and the electric heating power is adjusted by a power regulator.

[0049] (6) According to the requirements, the material is rolled into a roll every 96 meters and cut into rolls.

[0050] The product photo of the air purification material is as Figure 6 shown. The test results of the pressure drop and initial removal efficiency of the chemical filter of the air purification material in Example 2 are shown in Table 1 and Table 2.

[0051] Table 1

[0052] Table 2

[0053] The test results of the particulate matter leakage of the chemical filter of the air purification material in Example 2 are shown in Table 3.

[0054] Table 3

[0055] The test results of the VOC gas release of the chemical filter of the air purification material in Example 2 are shown in Table 4.

[0056] Table 4

[0057] Example 3 (product with a gram weight of 1500 g / m 2 and a production speed of 1.5 meters per minute; 6D staple fiber is adopted) A production process of a carbon-loaded cloth with a gram weight of 1500 g / m 2 is as follows: (1) Start the production line linkage and run the empty vehicle. Turn on the oven heating system and preset it to 160 °C to preheat the oven.

[0058] (2) Put the upper and lower base cloths into the corresponding unwinders respectively; (3) Weigh the cotton, confirm the weight of the PE / PET net required for the daily production volume, put it into the bale opener at one time, and then turn on the net output system and debug the unit to ensure that the net output gram weight of the lapper is 100 - 115 g / m 2 .

[0059] (4) Fill the carbon spreading machine with the corresponding carbon material (activated carbon with a mesh size not greater than 20), test the feeding amounts of the 1st, 2nd, and 3rd carbon spreading machines at different rotational speeds, and confirm the feeding ratios of the 1st, 2nd, and 3rd carbon spreading machines as 7:15:11 according to the production line speed of the day (1 - 5 m / min).

[0060] (5) Observe whether the oven temperature reaches 160°C. If it reaches, start formal production. Among them, a 3-stage oven is used, and each stage is set at 160°C. The circulating air volumes are 1500 times, 1200 times, and 1200 times per hour respectively. The oven temperature is controlled to be a constant temperature setting, and the electric heating power is adjusted through a power regulator.

[0061] (6) According to the requirements, the material is rolled into a roll every 50 meters and cut into rolls.

[0062] To highlight the beneficial effects of the present invention, the following comparative examples are given.

[0063] Comparative Example 1

[0064] Compared with Example 2, the difference is that only the 1st carbon spreading machine is used. The other production line equipment and process parameters remain unchanged.

[0065] Comparative Example 2 Compared with Example 2, the difference is that the feeding ratios of the 3 carbon spreading machines are 9:5:7. The other production line equipment and process parameters remain unchanged.

[0066] Comparative Example 3 Compared with Example 2, the difference is that the feeding ratios of the 3 carbon spreading machines are 9:7:5. The other production line equipment and process parameters remain unchanged.

[0067] Conduct a resistance performance test on the carbon cloth prepared in Example 2 and Comparative Examples 1 - 3. The detection method is the test of flat filter media in Part 3 of EN ISO29463-3:2018 "High-efficiency filters and filter media for removing particles from air". The test results are shown in Table 5 below.

[0068] Table 5

[0069] It can be seen from the above results that the 1st carbon spreading machine must use a low carbon spreading amount, and the 2nd carbon spreading machine has the highest carbon spreading amount, so as to achieve a uniform carbon layer distribution and low material resistance.

[0070] The above-described embodiments are only descriptions of the preferred embodiments of the present invention, and do not limit the scope of the present invention. Without departing from the design spirit of the present invention, various deformations and improvements made by those of ordinary skill in the art to the technical solutions of the present invention shall fall within the protection scope determined by the claims of the present invention.

Claims

1. An air purification material, characterized in that: The invention comprises a fiber net and a filter material uniformly distributed in the fiber net; the fiber net is formed by pressing ES bicomponent fibers at 130-160°C to form a thermally synthesized network between the fibers; and the mesh number of the filter material is ≤20 meshes.

2. The air purification material according to claim 1, characterized in that: The ES bicomponent fiber is a PE / PET bicomponent fiber.

3. The air purification material according to claim 2, characterized in that: The ES bicomponent fiber adopts 2D-6D short fiber.

4. The air purification material according to claim 1, characterized in that: The filter material is at least one of activated carbon, alumina balls and molecular sieve balls.

5. The method for producing the air purification material according to any one of claims 1 to 4, characterized in that: The following steps are involved: (1) Weigh the ES bicomponent fiber and put it into the cotton opener. After being initially dispersed by the cotton opener, it is sent to the loosening machine; (2) The loosened fibers are sent into a pneumatic cotton box by a fan, and then fed into a carding machine by the pneumatic cotton box; (3) After the fibers are initially formed into a web by the carding machine, they enter the web laying machine. The web laying machine lays multiple layers of webs according to the pre-set web laying process requirements, and the laid webs are fed onto the non-woven base fabric; (4) The non-woven base fabric and the fiber web are fed into a charcoal spreader system together, and the filter material is spread into the fiber web. Then, the unwinder covers the fiber web with a non-woven upper fabric, and the material is prefabricated. The charcoal spreader system includes at least two charcoal spreaders; among them, the second charcoal spreader has the highest charcoal spreading amount; (5) The prefabricated materials enter a multi-stage oven for heating; the temperature control range of each stage of the oven is 130-220°C; the internal space height of the oven is not higher than 600mm; the circulating air volume is not less than 1000 times / hour, and the air flow form adopts laminar air supply; the fan is controlled by a frequency converter, and the electric heater is controlled by a power regulator; (6) After the material is heated up, it is pressed and shaped by a composite roller after leaving the oven, and then air cooling is used to dissipate the heat of the material; (7) After heat dissipation, the material is trimmed and slit, and finally rolled up to complete the material production.

6. The method for producing an air purification material according to claim 5, characterized in that: When the number of charcoal spreaders is greater than 2, the charcoal spreading amount of the first charcoal spreader is ≤ the charcoal spreading amount of the remaining charcoal spreaders after the second charcoal spreader.

7. The method for producing an air purification material according to claim 6, characterized in that: In the step (4), three charcoal spreaders are used, and the charcoal spreading ratio of the three charcoal spreaders is 2-7:5-15:2-11.

8. The method for producing an air purification material according to claim 5, characterized in that: In the step (2), the air pressure cotton box realizes quantitative cotton supply by setting the pressure, and the pressure adjustment range is 80-230Pa; the weight range of the carding machine is 8-60g / m 2 The net speed is 8-40 m / min.

9. The method for producing an air purification material according to claim 5, characterized in that: In the step (3), a cross-laying web laying machine is used, with a web output speed of 1-5 m / min and a maximum reciprocating number of 7 times / min; according to production requirements, the web is laid through multiple reciprocating web laying, with the number of webs laid being 2-4 layers.

10. The method for producing an air purification material according to claim 5, characterized in that: In the step (4), the charcoal spreader is controlled by the speed of the feed roller, and the speed of the feed roller is 1-30 rpm; the speed of the unwinding machine is 1-5 m / min; In the step (6), air cooling uses an axial flow fan and natural air cooling, with a wind speed of not less than 3 m / s.

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