Skeleton filter material non-woven fabric for removing acetaldehyde

Abstract

The utility model relates to the technical field of air purification, in particular to an acetaldehyde removal skeleton filter material non-woven fabric, which comprises a short fiber skeleton layer, a non-woven fabric layer, a non-woven fabric layer and a non-woven fabric layer, the carbon adsorption layer comprises activated carbon particles, and the activated carbon particles are uniformly dispersed in a flexible matrix and attached to the short fiber skeleton layer; a formaldehyde removal agent is added into the formaldehyde removal additive layer, and a formaldehyde removal agent solution is uniformly loaded on the surfaces and internal pores of the short fiber skeleton layer and the carbon adsorption layer through a spraying process; and the protective filter layer is prepared from fine denier polypropylene fibers through a melt-blowing process, covers the outermost layer and is used for intercepting small-particle floating dust. In conclusion, efficient filtration and formaldehyde removal can be achieved in an automobile air conditioner and a fresh air system, the air quality is improved, and the health of a user is guaranteed.

Description

TECHNICAL FIELD

[0001] The utility model relates to the technical field of air purification, especially to a kind of acetaldehyde skeleton filter material nonwoven fabric. BACKGROUND

[0002] With the improvement of life quality and the attention of people to air quality, the demand for air filtration materials in automobile air conditioning and fresh air systems is increasing. In particular, the emission of volatile organic compounds such as formaldehyde and acetaldehyde has attracted widespread attention. These harmful gases not only affect people's health, but also can cause a series of air pollution problems. Therefore, developing efficient and economical air filtration materials has become an important technical challenge.

[0003] Traditional air filtration materials often cannot effectively remove low-concentration harmful gases, especially aldehyde gases (such as acetaldehyde). Common filter materials may have preliminary particulate matter filtration capability, but their performance in gas capture and removal is significantly lower than expected. This is mainly due to the following reasons:

[0004] Structural defects of filtration materials: Traditional filter materials mostly use single weaving or molding technology, lack of good three-dimensional structure, resulting in insufficient filtration surface area when airflow passes through, thereby limiting the gas contact and adsorption capacity.

[0005] Uneven distribution of reagents: During the process of treating filter materials with reagents, the coating and loading of reagents often have uneven phenomena, resulting in poor effect of capturing harmful gases.

[0006] Cost and effect mismatch: High-efficiency adsorption materials usually have high cost, and existing materials on the market are difficult to balance between gas adsorption effect and economy.

[0007] Durability problem: Relatively low durability makes these filtration materials rapidly lose performance during long-term use, affecting user experience. SUMMARY

[0008] The utility model is aimed at providing a technical solution that can solve the above problems.

[0009] The utility model provides a kind of acetaldehyde skeleton filter material nonwoven fabric, comprising:

[0010] Short fiber skeleton layer, polyester short fiber is laid into three-dimensional network structure in disordered interlacing mode, to provide support for filter material;

[0011] Carbon adsorption layer, containing activated carbon particles, the activated carbon particles are uniformly dispersed in flexible matrix, attached to the short fiber skeleton layer;

[0012] In addition to the aldehyde additive layer, an aldehyde removal agent is added, and the aldehyde removal agent solution is uniformly loaded on the surface and internal pores of the short fiber framework layer and the carbon adsorption layer through a spraying process.

[0013] The protective filter layer is made of fine denier polypropylene fibers through a melt blowing process, covers the outermost layer, and is used for intercepting small particle dust.

[0014] As a further scheme of the utility model, the diameter of the polyester short fiber of the short fiber framework layer is 10-20 microns, and the surface is rough, which is used for enhancing the adhesion capacity.

[0015] As a further scheme of the utility model, the activated carbon particles in the carbon adsorption layer adopt columnar activated carbon particles with a particle size of about 0.5-1 mm, which are used for adsorbing harmful gases.

[0016] As a further scheme of the utility model, the flexible matrix is composed of an acrylate polymer adhesive.

[0017] As a further scheme of the utility model, the aldehyde removal agent of the aldehyde additive layer is made of a metal organic framework material containing an amino group as raw material, so that the metal organic framework material realizes efficient capture of acetaldehyde by chemical reaction of the amino group with the carbonyl group in the acetaldehyde molecule.

[0018] As a further scheme of the utility model, the layers are closely attached through a hot pressing composite process, so as to form the overall structure of the non-woven fabric.

[0019] As a further scheme of the utility model, the fineness of the fine denier polypropylene fiber of the protective filter layer is 1-5 microns, and the filter screen made of the melt blowing is ultrathin and dense, which plays an initial filtration role.

[0020] As a further scheme of the utility model, it is used for the filter element of an automobile air conditioner air filter and a fresh air system.

[0021] Compared with the prior art, the utility model has the beneficial effects that:

[0022] 1. The short fiber framework layer forms a three-dimensional network structure through disordered interlaced polyester short fibers, not only provides superior support for the filter material, but also increases the channel of gas flow, improves the filtration efficiency of small particles, and at the same time, the rough surface design enhances the adhesion capacity of the aldehyde removal agent.

[0023] 2. The carbon adsorption layer adopts activated carbon particles uniformly dispersed in the flexible matrix, and the specific particle size design ensures that the activated carbon has good performance when adsorbing harmful gases (such as acetaldehyde), especially when capturing low-concentration aldehyde substances.

[0024] 3, the aldehyde removal additive layer introduces a metal organic framework material containing an amino group, which can chemically react with the carbonyl group in the acetaldehyde molecule, further improving the capture efficiency of acetaldehyde.

[0025] 4, the setting of the protective filter layer not only provides preliminary filtration for small particles, but also protects the adsorbent material in the inner layer from damage, thereby improving the overall service life and filtration effect.

[0026] In addition, the layers are tightly bonded by a hot pressing composite process, ensuring the overall structural stability of the filter material. The utility model can realize efficient filtration and aldehyde removal in automobile air conditioners and fresh air systems, improving air quality and ensuring user health.

[0027] Additional aspects and advantages of the present application will be given in part in the following description, and some will become apparent from the following description, or will be understood by those skilled in the art through practice of the present application. BRIEF DESCRIPTION OF DRAWINGS

[0028] In order to more clearly illustrate the technical scheme in the embodiments of the present application or the prior art, the following will briefly introduce the drawings needed to be used in the embodiment or the prior art description. Obviously, the drawings in the following description are only some embodiments of the present application, and those skilled in the art can obtain other drawings according to these drawings without creative labor.

[0029] Fig. 1 is a structure diagram of the non-woven fabric of the present application;

[0030] Fig. 2 is a structure diagram of the carbon adsorption layer and the aldehyde removal additive layer overlapping each other of the present application.

[0031] The reference signs and names in the drawings are as follows:

[0032] 10 short fiber skeleton layer; 20 carbon adsorption layer; 30 aldehyde removal additive layer; 40 protective filter layer. DETAILED DESCRIPTION

[0033] The technical scheme in the embodiments of the present application will be described clearly and completely below. Obviously, the described embodiments are only part of the embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the scope of protection of the present application.

[0034] Please refer to Figs. 1-2The utility model discloses an embodiment of a kind of acetaldehyde skeleton filter material nonwoven fabrics, comprising: short fiber skeleton layer 10, polyester short fiber with diameter in 10-20 microns is in disorder interlacing mode and is laid into three-dimensional network structure, provide support for filter material;Carbon adsorption layer 20, including the columnar activated carbon particle of particle size about 0.5-1 millimeter, the activated carbon particle is uniformly dispersed in the flexible matrix of acrylate polymer binder, adhere to short fiber skeleton layer 10 on;Aldehyde removal additive layer 30, metal organic framework material (MOFs) with amino group as aldehyde removal agent, by high-precision spray head set according to fiber density to and fro spray construction process, make aldehyde removal agent solution uniform loading on short fiber skeleton nonwoven fabric surface and internal pore;Protective filter layer 40, by fine denier polypropylene fiber with fineness in 1-5 microns is made by melt-blowing process, cover in outermost layer, for intercepting small particle dust.

[0035] In another embodiment, the polyester short fiber surface of the short fiber skeleton layer 10 is rough, for enhancing the adhesion capacity. The columnar activated carbon particles in the carbon adsorption layer 20 are used for adsorbing various harmful gases including acetaldehyde due to their high specific surface area. The metal organic framework material (MOFs) of the aldehyde removal additive layer 30 utilizes the amino group to react with the carbonyl group in the acetaldehyde molecule, realizing efficient capture of acetaldehyde.

[0036] In yet another embodiment, the filter screen made of fine denier polypropylene fiber of the protective filter layer 40 is ultra-thin and dense, playing a role in primary filtration. The concentration of the aldehyde removal additive solution is determined by multiple experiments according to the target adsorption amount, ensuring that the medicament is evenly covered on the short fiber skeleton nonwoven fabric.

[0037] Embodiment one: preparation of acetaldehyde skeleton filter material nonwoven fabric

[0038] 1, short fiber skeleton layer 10:

[0039] Material: polyester short fiber, diameter range is 10-20 microns, the surface is treated to increase roughness, enhance the adhesion capacity.

[0040] Manufacturing method: use disorder interlacing technology, combine long and short fibers, lay into three-dimensional network structure by special equipment.

[0041] 2, carbon adsorption layer 20:

[0042] Material: columnar activated carbon particles, particle size is about 0.5-1 millimeter, dispersed in flexible matrix.

[0043] Manufacturing method: mix activated carbon particles with acrylate polymer binder, ensure that the particles are uniformly dispersed, then coat on the short fiber skeleton layer 10.

[0044] 3, aldehyde removal additive layer 30:

[0045] Material: Metal-organic framework material containing amino groups.

[0046] Manufacturing method: The aldehyde removal agent solution is uniformly loaded on the surface and internal pores of the short fiber framework layer 10 and the carbon adsorption layer 20 through a spraying process, ensuring that each structural unit can capture acetaldehyde.

[0047] 4. Protective filter layer 40:

[0048] Material: Fine denier polypropylene fibers with a fineness range of 1-5 microns.

[0049] Manufacturing method: Use melt-blown process to make ultra-thin and dense filter mesh, covering the outermost layer of the final product.

[0050] Finally, the film materials are connected using a hot pressing process to ensure that the different material layers are tightly bonded, enhancing the stability and filtration performance of the overall structure. The temperature, pressure, and time during the hot pressing process can be set using the corresponding values in existing technology, and through precise control, the product quality is ensured.

[0051] Example Two: Filtration Performance Test

[0052] Use conventional air filtration test equipment to test filtration efficiency, airflow resistance, and acetaldehyde removal rate.

[0053] Install the prepared acetaldehyde removal framework filter non-woven fabric in the test equipment and set the test airflow rate and acetaldehyde concentration.

[0054] Monitor the air quality after passing through the filter material through a gas sampling device and record the acetaldehyde removal concentration at different time periods.

[0055] Compare the unfiltered and filtered samples to evaluate their filtration efficiency and airflow resistance.

[0056] During the test, the expected acetaldehyde removal rate can reach more than 90%, the particulate matter filtration efficiency is ≥95%, and the airflow resistance is within the industry standard range, meeting the application requirements of automobile air conditioning and fresh air systems.

[0057] Example Three: Application Example: Use the above acetaldehyde removal framework filter non-woven fabric in the filter core of automobile air conditioning systems and fresh air systems.

[0058] Specific implementation process:

[0059] The prepared filter material is assembled into the air intake system of the vehicle air conditioner, ensuring that the filter layer faces outward and the protective filter layer 40 effectively isolates external pollutants. The vehicle is tested under different environmental conditions to evaluate changes in indoor air quality, including urban roads, highways, and enclosed parking lots. The service life and performance of the filter cartridge are regularly evaluated to ensure that it effectively captures harmful gases and particulate matter throughout its service life, ensuring indoor air quality.

[0060] Analysis results:

[0061] After the vehicle is used, the concentration of harmful gases in the vehicle is significantly reduced, and the driver's health feedback is positive, proving that the filter material can effectively improve air quality in practical applications.

[0062] Therefore, the above examples detail the preparation, performance testing, and practical application of the acetaldehyde skeleton filter material non-woven fabric, demonstrating its high efficiency in filtering harmful gases (such as acetaldehyde) and particulate matter, meeting the needs of vehicle air conditioners and fresh air systems.

[0063] The specific preparation process of the non-woven fabric of the utility model is as follows:

[0064] Preparation of short fiber skeleton layer 10: First, select high-strength polyester short fibers with rough surfaces, with diameters controlled between 10-20 microns. These short fibers are transported to a carding machine, where they are initially stretched and arranged in parallel through the carding action of the carding machine. Subsequently, the carded short fibers are randomly interwoven under the action of airflow, and finally laid into a uniform thickness sheet, forming a three-dimensional network structure. This structure not only ensures the stability of the subsequent layers, but also allows air to flow through the filter material in a suitable channel.

[0065] Manufacture and compounding of carbon adsorption layer 20: Select high specific surface area cylindrical activated carbon particles with a particle size of about 0.5-1 mm. Place an appropriate amount of cylindrical activated carbon particles in a stirred tank, add an environmentally friendly acrylic ester polymer binder in a certain proportion, and start the stirring device to evenly disperse the activated carbon particles in the binder matrix to form a mixture. Use coating equipment to evenly coat the mixture on the prepared short fiber skeleton layer 10, and after drying treatment, the binder solidifies, thereby firmly attaching the carbon adsorption layer 20 to the short fiber skeleton layer 10. This carbon adsorption layer 20, with its rich pore structure, can adsorb various harmful gases, including acetaldehyde.

[0066] Construction of the aldehyde removal additive layer 30: A metal organic framework (MOF) containing amino groups is selected as the aldehyde removal agent. The MOF is first dissolved in a suitable organic solvent to prepare an aldehyde removal agent solution with a concentration optimized through multiple experiments. According to the fiber density of the short fiber skeleton layer 10, the high-precision nozzle is adjusted, and the back-and-forth spraying process parameters of the nozzle, such as nozzle moving speed and spraying flow, are set. The liquid spraying device is started, and the aldehyde removal agent solution is accurately and uniformly sprayed on the surface of the short fiber skeleton non-woven fabric. The solution penetrates into the fiber gap and the activated carbon pores under the action of its own gravity and capillary force. After the organic solvent volatilizes, the aldehyde removal additive is firmly attached to the corresponding position, and the amino groups are ready to chemically react with the carbonyl group in the acetaldehyde molecule to achieve efficient aldehyde removal.

[0067] Formation and compounding of the protective filter layer 40: Fine denier polypropylene fibers with a fineness of 1-5 microns are selected and fed into the hopper of the melt-blown device. Under the action of high-temperature and high-pressure airflow, the polypropylene fibers are rapidly stretched, refined, and randomly deposited on the conveyor belt to form an ultra-thin and dense filter screen structure, i.e., the protective filter layer 40. Then, the protective filter layer 40 is covered on the semi-finished product made of the first three layers, and through a hot-pressing compounding process, the hot-pressing temperature is accurately controlled between 160°C and 220°C, the pressure is between 0.5MPa and 3MPa (about 5 to 30 kgf / cm2), and the hot-pressing time is maintained between 5 seconds and 30 seconds, so that the layers are tightly bonded together to form a complete short fiber skeleton non-woven fabric.

[0068] Usage scenario of the utility model:

[0069] The aldehyde removal skeleton filter material non-woven fabric is specially designed for air filtration of automobile air conditioners and filter cartridges of fresh air systems. During actual installation and use, the cut non-woven fabric filter cartridge is installed in the air conditioner filter box or the filter cartridge slot of the fresh air system according to the installation guide of the corresponding equipment. When air flows through the filter cartridge, the outermost protective filter layer 40 first intercepts small particle dust, preliminarily purifying the air; then, the air containing harmful gases such as acetaldehyde penetrates into the carbon adsorption layer 20 and the aldehyde removal additive layer 30, the activated carbon adsorbs part of the harmful gases, and the aldehyde removal additive captures acetaldehyde, and the purified air finally enters the vehicle or indoor environment, meeting people's demand for air cleanliness and improving air quality.

[0070] The aldehyde removal skeleton filter material non-woven fabric can preliminarily filter small particle dust in the surrounding environment and effectively adsorb acetaldehyde gas in the air. This technology can be widely applied to filter cartridges of automobile air conditioners and some fresh air systems to filter harmful gases such as acetaldehyde in the air.

[0071] 1. The problem of low efficiency of aldehyde gas removal by carbon-containing non-woven fabric is solved, the excellent adhesion capacity of the skeleton is utilized, the loading of aldehyde removal agent is greatly improved through fiber modification, and meanwhile the other gas adsorption effect of the carbon layer is not affected.

[0072] 2. The technical bottleneck of high cost and poor gas adsorption effect of aldehyde removal non-woven fabric is solved, the considerable aldehyde gas adsorption effect is maintained, and the strength and support of the composite material are provided.

[0073] 3. The situation of uneven loading of reagent or no loading on the market is solved, and the process of back-and-forth spraying of reagent with corresponding fiber density is adopted.

[0074] It is obvious for those skilled in the art that the present application is not limited to the details of the above exemplary embodiments, and can be implemented in other specific forms without departing from the spirit or essential characteristics of the present application. Therefore, from any point of view, the embodiments should be regarded as exemplary and non-limiting, the scope of the present application is defined by the appended claims rather than the above description, and therefore all changes falling within the meaning and scope of the equivalent elements of the claims are intended to be included in the present application.

Claims

1. An acetaldehyde skeleton removing filter material nonwoven fabric, characterized by comprising a polyvinyl alcohol fiber and a polyethylene glycol fiber. It comprises: a short fiber skeleton layer (10) made of polyester short fibers in a three-dimensional network structure to provide support for the filter material; a carbon adsorption layer (20) containing activated carbon particles uniformly dispersed in a flexible matrix attached to the short fiber skeleton layer (10); an aldehyde removal additive layer (30) added with an aldehyde removal agent and loaded with an aldehyde removal agent solution on the surface and internal pores of the short fiber skeleton layer (10) and the carbon adsorption layer (20) by a spraying process; a protective filter layer (40) made of fine denier polypropylene fibers by a melt blowing process covering the outermost layer for intercepting small particle dust.

2. The acetaldehyde skeleton removing filter material nonwoven fabric according to claim 1, wherein The diameter of the polyester short fibers of the short fiber skeleton layer (10) is 10-20 microns, and the surface is rough to enhance the adhesion.

3. The acetaldehyde skeleton removing filter material nonwoven fabric according to claim 1, wherein The activated carbon particles in the carbon adsorption layer (20) are columnar activated carbon particles with a particle size of about 0.5-1 mm for adsorbing harmful gases.

4. The acetaldehyde skeleton removing filter medium nonwoven fabric according to claim 1, wherein The flexible matrix is made of an acrylate polymer adhesive.

5. The acetaldehyde skeleton removing filter material nonwoven fabric according to claim 1, wherein The aldehyde removal agent of the aldehyde removal additive layer (30) is made of a metal-organic framework material containing an amino group as raw material, so that the metal-organic framework material reacts with the carbonyl group in the acetaldehyde molecule through the amino group to achieve efficient capture of acetaldehyde.

6. The acetaldehyde skeleton removing filter medium nonwoven fabric according to claim 1, wherein The layers are tightly attached by a hot pressing process to form a whole structure of non-woven fabric.

7. The acetaldehyde skeleton removing filter material nonwoven fabric according to claim 1, wherein The fineness of the fine denier polypropylene fibers of the protective filter layer (40) is 1-5 microns, and the filter screen made by melt blowing is ultra-thin and dense, playing a primary filtering role.

8. The acetaldehyde skeleton removing filter medium nonwoven fabric according to claim 1, wherein It is used for air filter cartridges of automobile air conditioners and fresh air systems.

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