Renewable filter element, regeneration method thereof and filter

Abstract

The invention discloses a renewable filter element, a regeneration method thereof and a filter, and belongs to the technical field of air filtration. The renewable filter element comprises a mesh substrate, a filter material layer and a glue layer, wherein the filter material layer is adhered to the surface of the mesh substrate through the glue layer; the mesh base is a polyurethane sponge base, the filter material layer is made of activated carbon dust and / or resin, and the glue layer is made of waterborne polyurethane glue or waterborne acrylic acid glue. The polyurethane sponge is adopted as the substrate, and the filter material layer is adhered to the surface of the mesh substrate through the glue layer, so that the filter area is remarkably increased, the air filter efficiency is improved, meanwhile, regeneration can be realized through the dispergator, and the environment friendliness and sustainability are realized.

Description

Technical Field

[0001] The invention belongs to the technical field of air filtration, and in particular relates to a regenerable filter element, a regeneration method thereof and a filter. Background Art

[0002] With the rapid development of industrial production, air filters are increasingly used in various industries, especially in the semiconductor and microelectronics industries, where air quality requirements are particularly stringent. Currently, common air filters mainly use activated carbon dust as the filter material, which absorbs pollutants through its high specific surface area and porosity.

[0003] However, traditional activated carbon dust filters have numerous drawbacks: their structural design limits the filtration area, resulting in low adsorption efficiency and a short service life. During production, transportation, and installation, adsorbed particles easily accumulate, leading to poor ventilation and low adsorption efficiency. Furthermore, existing air filters mostly use disposable filter elements, which are not environmentally friendly. Summary of the Invention

[0004] The purpose of the present invention is to overcome the deficiencies in the prior art and provide a regenerable filter element, a regeneration method thereof and a filter, which effectively reduce the resistance of the filter, increase the filtration area, and improve the air filtration efficiency. At the same time, it can be regenerated by a disintegrator, and is environmentally friendly and sustainable.

[0005] The present invention provides the following technical solutions: In a first aspect, a regenerable filter element is provided, comprising a mesh base, a filter material layer, and a glue layer, wherein the filter material layer is adhered to the surface of the mesh base via the glue layer; The mesh base is a polyurethane sponge base, the filter material of the filter material layer is activated carbon dust and / or resin, and the glue layer is water-based polyurethane glue or water-based acrylic glue.

[0006] As an optional technical solution of the present invention, the polyurethane sponge base has a density of 10-60 ppi and a thickness of 0.3-0.5 mm.

[0007] As an optional technical solution of the present invention, the thickness of the filter material layer is 0.5-5 mm.

[0008] As an optional technical solution of the present invention, the activated carbon dust is made of coconut shell charcoal, palm charcoal or coal carbon, and the particle size of the activated carbon dust is 30-60 μm or 20-50 μm; The resin is an anionic resin or a cationic resin.

[0009] As an optional technical solution of the present invention, the mass ratio of activated carbon dust to resin in the filter material layer is 1:1-1:4.

[0010] As an optional technical solution of the present invention, the thickness of the glue layer is 0.1-0.5 mm.

[0011] In a second aspect, a method for regenerating the regenerable filter element according to the first aspect is provided, comprising: Completely immersing the regenerable filter element in the disintegrator for 20-60 minutes; After soaking, kneading the mesh substrate to separate the filter material and the mesh substrate; After washing the filter material and the mesh base with water 3-5 times respectively, the mesh base is dried in a cool and ventilated place for next use; When activated carbon dust is used as the filter material, the activated carbon dust is placed in a ventilation heater and heated at a high temperature of 100-200 degrees for 12-48 hours; when resin is used as the filter material, the anion resin is washed with a 3-8% strong alkaline solution and the cationic resin is washed with a 3-8% strong acid solution for 1-2 hours, then washed with pure water until neutral, and dried at 30-60 degrees for 2-5 hours; when the filter material is a mixture of activated carbon dust and resin, the activated carbon dust and resin are separated with a sieve and then dried separately; Immerse the mesh base in water-based polyurethane glue or water-based acrylic glue again. When the mesh base no longer absorbs water-based polyurethane glue or water-based acrylic glue, stick the filter material until the surface of the glue layer is filled with filter material, and then dry or air-dry it.

[0012] As an optional technical solution of the present invention, when the glue layer adopts water-based polyurethane glue, the debonding agent adopts PU foam cleaning agent or 401 debonding agent; When the glue layer is made of water-based acrylic glue, the disintegrator is an acetone-ethyl acetate mixture or DB1 disintegrator, wherein the mass ratio of acetone to ethyl acetate in the acetone-ethyl acetate mixture is 1:1-1:3.

[0013] In a third aspect, a filter is provided, comprising an outer frame and the regenerable filter element described in the first aspect, wherein the regenerable filter element is installed in the outer frame.

[0014] As an optional technical solution of the present invention, a sponge seal is provided on the outer side surface of the outer frame, and the sponge seal is made of polyurethane sponge.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The regenerable filter element provided by the present invention adopts polyurethane sponge as the base, and adheres the filter material layer to the surface of the mesh base through a glue layer, which significantly increases the filtration area, improves the air filtration efficiency, and solves the problem of low adsorption efficiency of traditional air filters; adopts water-based glue as the adhesive, effectively reduces the resistance of the filter, significantly reduces energy consumption, extends the service life, and solves the problems of high energy consumption and high life cycle cost; at the same time, by being able to achieve regeneration through a debonding agent, it is environmentally friendly and sustainable. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] Figure 1 1 is a front view schematic diagram of a filter according to an embodiment of the present invention; Figure 2 is a cross-sectional view of a filter according to an embodiment of the present invention; Figure 3 4 is a bar graph of the mass adsorption rate of the regenerable filter element after regeneration in an embodiment of the present invention.

[0017] The following are marked in the figure: 1. Regenerable filter element; 2. Outer frame. DETAILED DESCRIPTION

[0018] The present invention will be further described below in conjunction with the accompanying drawings. The following embodiments are only used to more clearly illustrate the technical solutions of the present invention and are not intended to limit the scope of protection of the present invention.

[0019] Example 1 The filter core 1 comprises a mesh base, a filter material layer, and a glue layer. The filter material layer is adhered to the surface of the mesh base via the glue layer. The mesh base is a polyurethane sponge base, the filter material layer is made of activated carbon dust and / or resin, and the glue layer is made of water-based polyurethane glue or water-based acrylic glue.

[0020] The filter material layer is composed of activated carbon dust or resin, which can be used alone or in combination. The activated carbon dust is made of coconut shell charcoal, palm charcoal or coal carbon, with a particle size of 30-60μm or 20-50μm. The resin is an anionic resin or a cationic resin. If the activated carbon dust and resin are mixed in the filter material layer, the mass ratio of the activated carbon dust to the resin is 1:1-1:4. The thickness of the filter material layer is 0.5-5mm, and it is obtained by mixing the activated carbon dust and the resin evenly and then coating them on the surface of the sponge base. The uniformity and density of the filter material layer are crucial to the filtering effect, ensuring that the gas can be fully blocked and filtered when passing through the filter material layer.

[0021] Furthermore, in the filter layer, activated carbon dust primarily adsorbs acidic gases, alkaline gases, organic gases, and particulate impurities, while resin filters acidic and alkaline gases. The choice of activated carbon dust and resin is determined by the type of gas being filtered. By rationally selecting and optimizing the composition of the filter layer, the filter's filtration efficiency for different gas components can be significantly improved. This hybrid filter can remove more than one target pollutant, effectively removing multiple pollutants.

[0022] The mesh base is made of polyurethane sponge with a density of 10-60 ppi. This is done by soaking the polyurethane sponge in water-based glue. When the sponge no longer absorbs the glue, the filter layer is removed and adhered to the mesh base until the surface is completely filled with filter material. The thickness of the sponge base ranges from 10-80 mm. The selection and processing of the mesh base ensures the stability and durability of the filter during use. The soaking and adhering process further enhances the retention of the filter layer.

[0023] Furthermore, the outer cylindrical surface of the mesh base is fixed with two parallel annular protrusions that project away from the filter layer and are concentric with the mesh base. The protrusions are 0.5-2 mm in height and 1-5 mm in width. By inserting the protrusions into the annular grooves on the inner wall of the pipe, they form an interference fit with the inner wall of the pipe. This design increases the stability and safety of the filter during use and ensures easy installation and removal.

[0024] The glue layer, made of water-based polyurethane or acrylic glue, is used to bond the filter media layer to the sponge base. The thickness of the glue layer is 0.1-0.5 mm. By soaking the polyurethane sponge in the water-based glue, the glue layer is evenly distributed between the mesh base and the filter media layer. The uniformity and adhesion of the glue layer are crucial to the overall structure and service life of the filter, ensuring a secure bond between the filter media layer and the sponge base.

[0025] The preparation method of the regenerable filter element comprises the following steps: 1) Soak the polyurethane sponge in water-based glue for 30 minutes so that the sponge no longer absorbs more water-based glue; 2) Evenly adhere the filter material to the surface of the polyurethane sponge so that the filter material fills the surface of the polyurethane sponge; 3) Place the polyurethane sponge filled with filter material in an oven at 50°C for drying.

[0026] Example 2 Based on Example 1, this embodiment provides a regeneration method for a regenerable filter element. This regeneration process not only reduces production costs but also improves resource utilization efficiency, conforming to the concept of green environmental protection. It includes: Completely immerse the regenerable filter element 1 in the disintegrator for 20-60 minutes; After soaking, kneading the mesh substrate to separate the filter material and the mesh substrate; After washing the filter material and the mesh base with water 3-5 times respectively, the mesh base is dried in a cool and ventilated place for next use; When activated carbon dust is used as the filter material, the activated carbon dust is placed in a ventilation heater and heated at a high temperature of 100-200 degrees for 12-48 hours to ensure the recovery and modification of its active sites; when resin is used as the filter material, the anion resin is rinsed with a 3-8% strong alkali solution (the strong alkali can be potassium hydroxide or sodium hydroxide), and the cationic resin is rinsed with a 3-8% strong acid solution (the strong acid can be sulfuric acid or hydrochloric acid) for 1-2 hours, then washed with pure water until neutral, and dried at 30-60 degrees for 2-5 hours to ensure surface modification and performance recovery; when the filter material is a mixture of activated carbon dust and resin, the activated carbon dust and resin are separated with a sieve, and the above operations are then performed separately; Immerse the mesh base in water-based polyurethane glue or water-based acrylic glue again. When the mesh base no longer absorbs water-based polyurethane glue or water-based acrylic glue, stick the filter material until the surface of the glue layer is filled with filter material. Then dry or air-dry it. The drying temperature should be 30-70 degrees. Air-drying should be done in a cool and ventilated place, avoiding direct sunlight.

[0027] When the adhesive layer is made of water-based polyurethane adhesive, the disintegrator is a PU foam cleaner or 401 adhesive remover. When the adhesive layer is made of water-based acrylic adhesive, the disintegrator is an acetone-ethyl acetate mixture or DB1 disintegrator, wherein the mass ratio of acetone to ethyl acetate in the acetone-ethyl acetate mixture is 1:1-1:3. The disintegrator does not damage the sponge or corrode the filter material, and is volatile and leaves no residue.

[0028] Furthermore, for stubborn adhesive layers or high-load carbon, the stubborn area can be heated for 10-30 seconds using a 40-60 degree heating fan, rubbed after softening, or removed by ultrasonic vibration.

[0029] like Figure 3 As shown in the figure, under the conditions that the filter material is activated carbon dust and the thickness of the polyurethane sponge is 40mm, the mass adsorption rate of toluene is tested at a face wind speed of 0.1m / s when the efficiency drops to 70%. After the regenerable filter element is regenerated 10 times, the mass adsorption rate still remains above 90% of the original.

[0030] Example 3 This embodiment provides a filter based on the first embodiment.

[0031] like Figure 1 and 2 As shown, the filter includes an outer frame 2 and a regenerable filter element 1 , and the regenerable filter element 1 is installed in the outer frame 2 .

[0032] The inner side of the outer frame 2 is provided with a groove adapted to the outer contour of the filter element 1 for mounting the filter element 1. The outer side of the outer frame 2 is provided with a sponge seal made of polyurethane sponge to enhance the sealing performance between the filter and the mounting components. The outer frame is made of aluminum plate.

[0033] The filter has an overall thickness of 3-15mm and an outer diameter of 10-50mm, making it suitable for use in confined spaces such as air conditioning units. This overcomes the difficulty of placing traditional air filters in narrow spaces, expands the filter's applicability, and meets the needs of diverse application scenarios. The filter can be reinforced with a stainless steel frame or a protective mesh and is integrally molded using an injection mold. During the filter manufacturing process, the temperature of the filter layer and mesh base is controlled at 30-70°C. Air drying is performed in a cool, well-ventilated area, out of direct sunlight. Precise control of the temperature and environment during the manufacturing process ensures consistent and stable filter performance and quality.

[0034] The filter material layer, mesh base, glue layer and outer frame 2 do not release gas, ensuring stability in use.

[0035] In the description of the present invention, it should be understood that the terms "center", "longitudinal", "lateral", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside" and the like indicate orientations or positional relationships based on the orientations or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", etc. are only used for descriptive purposes and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the indicated technical features. Therefore, features defined as "first", "second", etc. may explicitly or implicitly include one or more of the features. In the description of the present invention, unless otherwise specified, "multiple" means two or more.

[0036] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed connections, detachable connections, or integral connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on specific circumstances.

[0037] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and modifications can be made without departing from the technical principles of the present invention. These improvements and modifications should also be regarded as the scope of protection of the present invention.

Claims

1. A regenerable filter element, characterized in that: It comprises a mesh base, a filter material layer and a glue layer, wherein the filter material layer is adhered to the surface of the mesh base through the glue layer; The mesh base is a polyurethane sponge base, the filter material of the filter material layer is activated carbon dust and / or resin, and the glue layer is water-based polyurethane glue or water-based acrylic glue.

2. The regenerable filter element according to claim 1, characterized in that: The polyurethane sponge substrate has a density of 10-60 ppi and a thickness of 10-80 mm.

3. The regenerable filter element according to claim 1, characterized in that: The thickness of the filter material layer is 0.5-5 mm.

4. The regenerable filter element according to claim 1, characterized in that: The activated carbon dust is made of coconut shell carbon, palm carbon or coal carbon, and the particle size of the activated carbon dust is 30-60 μm or 20-50 μm; The resin is an anionic resin or a cationic resin.

5. The regenerable filter element according to claim 1, characterized in that: The mass ratio of activated carbon dust to resin in the filter material layer is 1:1-1:

4.

6. The regenerable filter element according to claim 1, characterized in that: The thickness of the glue layer is 0.1-0.5 mm.

7. A method for regenerating the regenerable filter element according to any one of claims 1 to 6, characterized in that: include: Completely immersing the regenerable filter element (1) in the disintegrator for 20-60 minutes; After soaking, kneading the mesh substrate to separate the filter material and the mesh substrate; After washing the filter material and the mesh base with water 3-5 times respectively, the mesh base is dried in a cool and ventilated place for next use; When activated carbon dust is used as the filter material, the activated carbon dust is placed in a ventilation heater and heated at a high temperature of 100-200 degrees for 12-48 hours; when resin is used as the filter material, the anion resin is washed with a 3-8% strong alkaline solution and the cationic resin is washed with a 3-8% strong acid solution for 1-2 hours, then washed with pure water until neutral, and dried at 30-60 degrees for 2-5 hours; when the filter material is a mixture of activated carbon dust and resin, the activated carbon dust and resin are separated with a sieve and then dried separately; Immerse the mesh base in water-based polyurethane glue or water-based acrylic glue again. When the mesh base no longer absorbs water-based polyurethane glue or water-based acrylic glue, stick the filter material until the surface of the glue layer is filled with filter material, and then dry or air-dry it.

8. The regeneration method according to claim 7, characterized in that: When the glue layer is made of water-based polyurethane glue, the debonding agent is PU foam cleaning agent or 401 debonding agent; When the glue layer is made of water-based acrylic glue, the disintegrator is an acetone-ethyl acetate mixture or DB1 disintegrator, wherein the mass ratio of acetone to ethyl acetate in the acetone-ethyl acetate mixture is 1:1-1:

3.

9. A filter, characterized in that: It comprises an outer frame (2) and a regenerable filter element (1) according to any one of claims 1 to 6, wherein the regenerable filter element (1) is installed in the outer frame (2).

10. The filter according to claim 9, characterized in that: The outer side surface of the outer frame (2) is provided with a sponge seal, and the sponge seal is made of polyurethane sponge.

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