Air purification material and method for producing the same

Abstract

The application discloses an air purification material and a production method thereof, and belongs to the technical field of air purification materials. The air purification material generation method of the application does not use hot melt adhesive, but uses fiber webbing to hold the filter material, and the filter material can be uniformly distributed in the fiber web, which completely avoids the problem of bad smell emission in the use of hot melt adhesive. The air purification material of the application has a weight range of 300-1500g / m 2 and can be widely applied to special environments such as electronic workshops, museums and archives and public commercial environments with high requirements on air quality. The air purification product made of the air purification material of the application has an initial purification efficiency higher than 90% and does not release organic pollutants, and the product basically does not generate dust, completely meeting the purification requirements of clean rooms.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of air purification materials, in particular to an air purification material and a production method thereof. BACKGROUND

[0002] At present, porous materials such as activated carbon are commonly used in the prior art to purify harmful gases, and the product types mainly include two types: loose filling and carbon sandwich cloth.

[0003] (1) Loose filling: fill adsorbing particulate materials such as activated carbon into a prefabricated shell (metal or plastic shell), which has the advantages of large amount of adsorbing materials and good purification effect. The disadvantage is that there is dust and large resistance.

[0004] (2) Carbon sandwich cloth: ① Conventional carbon sandwich cloth technology: spray a layer of hot melt glue filament on the surface of non-woven fabric, then sprinkle carbon, which can be sprayed and sprinkled multiple times, and finally cover a layer of non-woven fabric, and cold-press into shape (as shown in Fig. 1-2 ). The advantage is that the process is simple, and the disadvantage is that the hot melt glue will emit an unpleasant odor during the use of the product in the later stage; at the same time, the glue will cover the surface of the activated carbon, resulting in a decrease in the adsorption performance of the carbon. The related process can be seen in CN201810721588.8 - a filter cloth compounding machine. ② Mix hot melt glue particles and activated carbon particles thoroughly, then spray them on non-woven fabric, then cover a layer of non-woven fabric, and then heat-press into shape after heating in an oven. The advantages and disadvantages are the same as above.

[0005] However, the above prior art still has the following disadvantages: (1) the hot melt glue will emit an unpleasant odor during the use of the product in the later stage; (2) at the same time, the glue will cover the surface of the activated carbon, resulting in a decrease in the adsorption performance of the carbon; (3) low carbon content: when the carbon content is 800g / m 2 When the above is achieved, the material hardness is high, and the material will be broken when making the filter finished product, resulting in leakage points and filter waste.

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

[0007] The purpose of the present application 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 application is as follows:

[0009] An air purification material, comprising a fiber net and filter material uniformly distributed in the fiber net; the fiber net is formed by ES double-component fibers at 130-160℃, the skin layer can be slightly soluble, and the fibers are heat-bonded into a net after pressing; the filter material has a mesh size of ≤20 meshes.

[0010] The ES double-component fiber is preferably a PE / PET double-component fiber. Preferably, the ES double-component fiber is a 2D-6D staple fiber.

[0011] The filter material is at least one of activated carbon, alumina balls, and molecular sieve balls.

[0012] The production method of the air purification material comprises the following steps:

[0013] (1) The ES double-component fiber is weighed and then put into an opener, and after being preliminarily dispersed by the opener, the fiber is sent into an opener;

[0014] (2) The opened fiber is sent into a pneumatic cotton box by a fan, and then fed into a carding machine by the pneumatic cotton box;

[0015] (3) After the fiber is preliminarily formed into a web by the carding machine, the fiber web is sent into a lapper, and the lapper performs multi-layer lapping according to a pre-set lapping process requirement, and the lapped web is sent onto a non-woven base fabric;

[0016] (4) The non-woven base fabric and the fiber web are sent into a carbon scattering machine system together, the filter material is scattered into the fiber web, and then a non-woven top fabric is covered on the fiber web by a unwinder, and the material is pre-prepared; the carbon scattering machine system comprises at least two carbon scattering machines; the carbon scattering amount of the second carbon scattering machine is the highest; when the number of carbon scattering machines is greater than two, the carbon scattering amount of the first carbon scattering machine is less than or equal to the carbon scattering amount of the remaining carbon scattering machines after the second carbon scattering machine; the carbon scattering amount refers to the mass of the filter material scattered into the fiber web. It is found through a large number of experiments that the first carbon scattering machine must use a low carbon scattering amount, so that the carbon layer is uniformly distributed and the material resistance is low.

[0017] (5) The pre-prepared material is sent into 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 600 mm; the circulation air amount is not less than 1000 times / hour, and the air flow form is a laminar flow type; the fan is controlled by a frequency converter, and the electric heater is controlled by a power regulator;

[0018] (6) After the material is heated, the material is pressed and shaped by a compound press roller after being taken out of the oven, and then the material is cooled by air cooling.

[0019] (7) After cooling, the material is edge cut and slitted, and finally wound, and the material is prepared.

[0020] Further, in the step (2), the pneumatic cotton box realizes quantitative cotton supply by setting a pressure, the pressure adjustment range is 80-230 Pa, and the carding machine web weight range is 8-60 g / m 2 , and the web speed is 8-40 m / min (the conventional carding machine is usually 20-100 m / min).

[0021] In the step (3), a cross-laying type net laying machine is used, the net laying speed is 1-5 m / min, and the maximum reciprocating frequency is 7 times / min; according to the production requirement, the net laying quantity is 2-4 layers of nets through multiple reciprocating laying.

[0022] In the step (4), the carbon scattering machine is controlled by the rotating speed of the discharging roller, the rotating speed of the discharging roller is 1-30 r / min, and the unwinding machine speed is 1-5 m / min; preferably, 3 carbon scattering machines are used, and the carbon scattering quantity proportion of the 3 carbon scattering machines is 2-7:5-15:2-11.

[0023] In the step (6), the air cooling adopts an axial flow fan, and the air cooling is realized by using natural air, and the air speed is not less than 3 m / s.

[0024] Compared with the prior art, the outstanding effects of the present application are:

[0025] (1) The generation method of the air purification material does not use hot melt adhesive, but uses fiber net to hold the filter material, the filter material can be uniformly distributed in the fiber net, and the problem of bad smell emission in the use of hot melt adhesive is completely avoided; through the arrangement mode of the carding machine and the net laying machine, the three-dimensional structure of the fiber net is ensured, and the fiber net gram weight is ensured.

[0026] (2) The gram weight of the air purification material ranges from 300-1500 g / m 2 , and can be widely used in special environments such as electronic workshops, museums and archives, and public commercial environments with high requirements on air quality.

[0027] (3) The air purification product made of the air purification material has an initial purification efficiency higher than 90%, and no organic pollutants are released. Moreover, the product basically does not generate dust, and completely meets the purification requirements of a clean room.

[0028] (4) The production method needs to use not less than 2 groups of carbon scattering machines, the first carbon scattering machine must use a low carbon scattering quantity, and the carbon scattering quantity of the second carbon scattering machine is the highest, so that the carbon layer is uniformly distributed, and the material resistance is low.

[0029] The air purification material and the production method thereof described in the present application will be further described in combination with the accompanying drawings and specific embodiments. BRIEF DESCRIPTION OF DRAWINGS

[0030] Fig. 1-2 The carbon sandwich cloth made by the traditional powder or filament process is white, and the hot melt adhesive is solidified on the surface of the carbon.

[0031] Fig. 3 It is a flowchart of the production method of the air purification material of the present application.

[0032] Fig. 4The schematic diagram of the air purification material production line (from the cotton opener to the net laying machine) of the present application.

[0033] Fig. 5 The schematic diagram of the air purification material production line (from the net laying machine to the winding) of the present application. Among them, taking 3 groups of carbon spreading machines as an example.

[0034] Fig. 6 The product photo of the air purification material of Example 2. DETAILED DESCRIPTION

[0035] An air purification material, comprising a fiber net and a filter material uniformly distributed in the fiber net; the fiber net is synthesized by heat bonding between fibers after pressing the ES bicomponent fibers at 130-160℃; the mesh number of the filter material is ≤20 meshes.

[0036] Among them, the ES bicomponent fiber is a PE / PET bicomponent fiber, and 2D-6D staple fibers are used. Among them, the filter material is at least one of activated carbon, alumina balls and molecular sieve balls.

[0037] As shown in Fig. 3 , a production method of an air purification material, the specific steps are:

[0038] 1. Preparation

[0039] (1) All the equipment on the production line is powered on and the air cart is running;

[0040] (2) Fill the 3 groups of carbon spreading machines with carbon;

[0041] (3) Increase the temperature of the oven to the preset temperature (150-200℃);

[0042] (4) Turn on the water chiller, and the outlet water temperature is adjustable at 17-32℃.

[0043] 2. After all the above work is completed, start formal production.

[0044] (1) Weigh the ES bicomponent fibers (4D staple fibers) and put them into the cotton opener, then send them into the opener after being preliminarily scattered by the cotton opener.

[0045] (2) The fibers after opening are sent into the air pressure cotton box by the fan, and then fed into the carding machine by the air pressure cotton box; among them, the air pressure cotton box realizes quantitative cotton feeding by setting the pressure, and the pressure adjustment range is 80-230Pa; the carding machine has a web weight range of 8-60g / m 2 adjustable, and the web speed is 8-40m / min.

[0046] (3) The fibers are preliminarily formed into a web by a carding machine and then enter a laying machine. The laying machine performs multi-layer laying according to the pre-set laying process requirements, and the laid web is sent onto a non-woven base cloth (fed in by an electric motor). The laying machine is a cross-laying machine, and the web output speed is 1-5 m / min, and the maximum reciprocating frequency is 7 times / min. According to production requirements, the web is laid multiple times (usually 2-4 layers) to meet the use requirements.

[0047] (4) The non-woven base cloth and the fiber web are sent into a carbon scattering machine system together, and different performance filter materials (uniform size, not greater than 20 mesh; different performance, such as purifying acidic gas, alkaline gas, odor, VOC gas, and mixed gas of the above gases) are scattered into the fiber web according to the pre-set process requirements. Then, a non-woven base cloth is covered on the fiber web by a feeding machine, and the material is pre-made.

[0048] Three carbon scattering machines are used, and the scattering amount of the three carbon scattering machines is in the proportion of 2-7:5-15:2-11. Among them, the second carbon scattering machine has the highest scattering amount. When the number of carbon scattering machines is greater than 2, the scattering amount of the first carbon scattering machine is less than or equal to the scattering amount of the remaining carbon scattering machines after the second carbon scattering machine. The carbon scattering machine is controlled by the rotating speed of the feeding roller, and the rotating speed of the feeding roller is adjustable at 1-30 r / min. The feeding machine speed is 1-5 m / min.

[0049] (5) The pre-made material enters a multi-stage oven for heating. The temperature control range of each stage of the oven is adjustable at 130-220°C. The internal space height of the oven is not higher than 600 mm. The circulation air quantity is not less than 1000 times / hour, and the air flow form is a laminar flow type. The fan is controlled by a frequency converter, and the electric heater is controlled by a power regulator.

[0050] (6) After the material is heated, it is pressed and shaped by a compound press roller after leaving the oven, and then air cooling is used to cool the material. The air cooling uses an axial flow fan to cool naturally, and the air speed is not less than 3 m / s.

[0051] (7) After cooling, the material is cut and slit according to the pre-set process requirements, and finally wound up, and the material is made.

[0052] In the production line of the air purification material, the upstream equipment (such as shown in Fig. 4 ) from the cotton opener to the laying machine is perpendicular to the downstream equipment (such as shown in Fig. 5 ) from the laying machine to the winding machine, and is placed at 90°, so as to ensure that the direction of the downstream equipment is consistent with the web output direction.

[0053] Example 1 (product with a grammage of 300 g / m 2 , production speed 1.5 m / min; 2D short fibers are used)

[0054] A product with a grammage of 300 g / m2 The production process of the carbon sandwich cloth, the specific steps are:

[0055] (1) The production line linkage is started, the empty car is operated, the oven heating system is started, and 150°C is preset. The oven is preheated.

[0056] (2) The upper and lower base cloths are respectively put into the corresponding unwinding machines;

[0057] (3) The cotton is weighed, the required PE / PET net weight for the production amount of the day is confirmed, and it is put into the cotton opener at one time. Then, the net system is started, the unit is debugged, and the net weight of the laying machine is ensured to be 30-35g / m 2 .

[0058] (4) The carbon scattering machine is filled with the corresponding carbon material (activated carbon not greater than 20 mesh), the feeding amount of the No. 1, No. 2 and No. 3 carbon scattering machines under different rotating speeds is tested, and according to the production speed of the production line of the day (1-5 meters per minute), the feeding ratio of the No. 1, No. 2 and No. 3 carbon scattering machines is confirmed to be 2:5:2.

[0059] (5) Whether the oven temperature reaches 150°C is observed, if so, the formal production is started. Among them, three-stage ovens are used, each stage is set to 150°C, the circulating air amount is 1200 times, 1000 times and 1000 times per hour respectively, the temperature control of the oven is set to constant temperature, and the electric heating power is adjusted by the electric power regulator.

[0060] (6) According to the order requirements, the material is cut into a roll every 150 meters.

[0061] Example 2 (product with a grammage of 800g / m 2 , production speed 1.5 meters per minute; 4D short fibers are used)

[0062] A production process of carbon sandwich cloth with a grammage of 800g / m 2 , the specific steps are:

[0063] (1) The production line linkage is started, the empty car is operated, the oven heating system is started, and 160°C is preset. The oven is preheated.

[0064] (2) The upper and lower base cloths are respectively put into the corresponding unwinding machines;

[0065] (3) The cotton is weighed, the required PE / PET net weight for the production amount of the day is confirmed, and it is put into the cotton opener at one time. Then, the net system is started, the unit is debugged, and the net weight of the laying machine is ensured to be 60-80g / m 2 .

[0066] (4) Fill the carbon spreader with the corresponding carbon material (use activated carbon not greater than 20 mesh). Test the feeding amount of the No. 1, No. 2 and No. 3 carbon spreaders at different rotating speeds, and according to the production speed of the production line on the day (1-5 meters per minute), confirm the feeding ratio of the No. 1, No. 2 and No. 3 carbon spreaders as 5:9:7.

[0067] (5) Observe whether the oven temperature reaches 160℃, if so, start formal production. Among them, a three-stage oven is used, each stage is set to 160℃, the circulating air amount is 1200 times, 1200 times and 1100 times per hour respectively, and the temperature control of the oven is set to constant temperature, and the electric heating power is adjusted by the electric power regulator.

[0068] (6) According to the requirements, the material is cut into a roll every 96 meters.

[0069] The product photo of the air purification material is shown in Fig. 6 . The pressure drop and initial removal efficiency test results of the chemical filter using the air purification material of Example 2 are shown in Table 1, Table 2.

[0070] Table 1

[0071]

[0072] Table 2

[0073]

[0074] The particle leakage test results of the chemical filter using the air purification material of Example 2 are shown in Table 3.

[0075] Table 3

[0076]

[0077] The VOC gas release test results of the chemical filter using the air purification material of Example 2 are shown in Table 4.

[0078] Table 4

[0079]

[0080] Example 3 (product with a grammage of 1500g / m 2 , production speed 1.5 meters per minute; use 6D short fibers)

[0081] A production process of a carbon sandwich cloth with a grammage of 1500g / m 2 , the specific steps are:

[0082] (1) Start the production line linkage, run the empty car, start the oven heating system, preset 160℃, and preheat the oven.

[0083] (2) Put the upper and lower base cloth into the corresponding unwinding machine respectively;

[0084] (3) Weigh the cotton, confirm the required weight of PE / PET net for the production of the day, and put it into the opening cotton machine at one time, then start the net system, debug the unit, and ensure that the net weight of the net machine is 100-115 g / m 2 .

[0085] (4) Fill the carbon machine with the corresponding carbon material (use activated carbon not greater than 20 mesh), test the feeding amount of No. 1, No. 2 and No. 3 carbon scattering machines at different speeds, and according to the production speed of the production line (1-5 meters / minute) of the day, confirm the feeding ratio of No. 1, No. 2 and No. 3 carbon scattering machines as 7:15:11.

[0086] (5) Observe whether the oven temperature reaches 160℃, if so, start formal production. Among them, 3-stage ovens are used, each stage is set to 160℃, the circulating air volume is 1500 times, 1200 times and 1200 times per hour respectively, the temperature control of the oven is set to constant temperature, and the electric heating power is adjusted by the electric power regulator.

[0087] (6) According to the requirements, cut the material into rolls every 50 meters.

[0088] In order to highlight the beneficial effects of the present application, the following comparative examples are given.

[0089] Comparative Example 1

[0090] Compared with Example 2, the difference lies in that only No. 1 carbon scattering machine is used. The rest of the production line equipment and process parameters remain unchanged.

[0091] Comparative Example 2

[0092] Compared with Example 2, the difference lies in that the feeding ratio of the three carbon scattering machines is 9:5:7. The rest of the production line equipment and process parameters remain unchanged.

[0093] Comparative Example 3

[0094] Compared with Example 2, the difference lies in that the feeding ratio of the three carbon scattering machines is 9:7:5. The rest of the production line equipment and process parameters remain unchanged.

[0095] The carbon cloth prepared in Example 2 and Comparative Examples 1-3 is tested for resistance performance, and the detection method is EN ISO29463-3:2018 "High Efficiency Particulate Air Filters and Filter Media for Removing Particulate Matter from Air" Part 3: Test of Flat Panel Filter Media, and the test results are as follows in Table 5.

[0096] Table 5

[0097]

[0098] From the above results, it can be seen that the first carbon distributor must use a low carbon distribution amount, and the carbon distribution amount of the second carbon distributor is the highest, so that the carbon layer is uniformly distributed and the material resistance is low.

[0099] The above-described embodiments are merely preferred embodiments of the present application and are not intended to limit the scope of the present application. Various modifications and improvements to the technical solutions of the present application made by those of ordinary skill in the art without departing from the design spirit of the present application shall fall within the protection scope of the present application.

Claims

1. A method for producing an air cleaning material, characterized by: The air purification material comprises a fiber web and a filter material uniformly distributed in the fiber web, the fiber web is formed by hot bonding between fibers after the ES bicomponent fibers are pressed, and the filter material has a mesh size of less than or equal to 20 meshes; the ES bicomponent fibers are PE / PET bicomponent fibers, the ES bicomponent fibers are 2D-6D short fibers, and the filter material is at least one of activated carbon, alumina balls and molecular sieve balls; The method comprises the following steps: (1) The ES bicomponent fibers are weighed and then put into an opener, and the fibers are preliminarily dispersed by the opener and then sent to an opener; (2) The fibers after opening are sent to a pneumatic cotton box by a fan, and then fed into a carding machine by the pneumatic cotton box; (3) The fibers are preliminarily formed into a web by the carding machine and then enter a lapper, the lapper performs multi-layer lapping according to a pre-set lapping process requirement, and the lapped web is sent to a non-woven base cloth; (4) The non-woven base cloth and the fiber web are sent to a carbon scattering machine system together, the filter material is scattered into the fiber web, then a non-woven top cloth is covered on the fiber web by a unwinder, and the material is pre-prepared; the carbon scattering machine system comprises three carbon scattering machines, the second carbon scattering machine has the highest carbon scattering amount, the carbon scattering amount of the three carbon scattering machines is in a ratio of 2-7:5-15:2-11, and the carbon scattering amount of the first carbon scattering machine is less than or equal to the carbon scattering amount of the remaining carbon scattering machines after the second carbon scattering machine; (5) The pre-prepared material enters a multi-stage oven for temperature rising, wherein the temperature control range of each stage of the oven is 130-220 DEG C, the internal space height of the oven is not higher than 600 mm, the circulating air amount is not less than 1000 times / hour, the air flow form is a laminar flow type, the fan is controlled by a frequency converter, and the electric heater is controlled by a power regulator; (6) After the material is heated, the material is pressed and shaped by a compound press roll after being taken out of the oven, and then the material is cooled by air cooling; (7) After cooling, the material is cut and slit, and finally wound, and the material is prepared.

2. The method for producing an air cleaning material according to claim 1, characterized by: In the step (2), the air pressure cotton box realizes quantitative cotton supply by setting pressure, the pressure adjustment range is 80-230 Pa; the carding machine net weight range is 8-60 g / m 2 , and the net speed is 8-40 m / min.

3. The method for producing an air cleaning material according to claim 1, characterized by: In the step (3), a cross-lapping lapper is used, the web output speed is 1-5 m / min, and the maximum reciprocating frequency is 7 times / min; according to production requirements, the lapping number is 2-4 layers by multiple reciprocating lapping.

4. The method for producing an air cleaning material according to claim 1, characterized by: In the step (4), the rotation speed of a discharging roller of the carbon scattering machine is controlled, the rotation speed of the discharging roller is 1-30 r / min, and the unwinder speed is 1-5 m / min; In the step (6), the air cooling adopts an axial flow fan, and the air speed is not less than 3 m / s.

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