Photocatalyst high-dust-holding antibacterial air filter

Abstract

The utility model discloses a photocatalyst high-dust-holding antibacterial air filter. Comprising a filtering structure which is in a vertical layered layout and sequentially comprises a photocatalyst coating, a carbon crystal particle layer, high-capacity dust mesh cloth and antibacterial flannelette from top to bottom; the outer frame wraps the side edge of the filtering structure; the sealing strips are used for wrapping the side edges of the outer frame to form a honeycomb structure of the novel carbon crystal particle layer and have the physical filtering effect of the high-capacity dust screen cloth, pollutants such as tiny particles, dust and pollen in the air can be efficiently intercepted, and the air cleanliness is improved. Due to the design of the high-dust-capacity screen cloth, the filter can contain more dust and particulate matters, the service life is prolonged, and the replacement frequency and the maintenance cost are reduced; the reasonable selection and structural design of each layer of material ensure that the filter can still keep good air permeability and maintain smooth air circulation while ensuring high-efficiency filtration.

Description

Technical Field

[0001] This utility model is a photocatalytic high dust-holding and antibacterial air filter, belonging to the field of filters. Background Technology

[0002] With the acceleration of modern industrialization and urbanization, air pollution has become increasingly serious, and indoor air quality has become a major concern. Airborne pollutants such as particulate matter, harmful gases, bacteria, and viruses not only affect people's respiratory health but can also trigger various diseases. Therefore, developing efficient and durable air filtration technologies is of paramount importance.

[0003] Currently, although various air filters exist on the market, most products only have a single filtration function, making it difficult to simultaneously meet multiple needs such as high-efficiency filtration, antibacterial properties, and dust containment. While some high-end filters integrate multiple technologies, they often suffer from complex structures, high costs, and inconvenient maintenance, limiting their widespread application.

[0004] Furthermore, existing air filters still have shortcomings in handling organic pollutants, bacteria, and viruses in the air, especially in environments with insufficient or no light, where their antibacterial performance and self-cleaning ability are significantly reduced. Therefore, developing an air filter that can maintain high-efficiency filtration, antibacterial, and dust-holding performance in various environments has become an urgent problem to be solved in the field of air purification. Utility Model Content

[0005] In view of the shortcomings of the existing technology, the purpose of this utility model is to provide a photocatalytic high dust holding capacity and antibacterial air filter to solve the problem.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a photocatalytic high dust-holding and antibacterial air filter, comprising:

[0007] The filter structure features a vertically layered layout, consisting of a photocatalytic coating, a honeycomb layer formed by stacked hollow plastic tubes, a high-dust-holding mesh cloth wrapping the top and bottom of the honeycomb layer, and an antibacterial fleece cloth, with the edges of the plastic tubes heat-fused together. The honeycomb layer is filled with mineral crystal particles.

[0008] The outer frame wraps around the sides of the filter structure;

[0009] Sealing strips are used to wrap the sides of the outer frame.

[0010] Preferably, the mineral crystal particles fill 50% to 70% of the plastic tube.

[0011] Preferably, the high dust-holding mesh is made of, but is not limited to, glass fiber or polyester fiber.

[0012] Preferably, the outer frame is made of plastic.

[0013] Preferably, the sealing strip is made of rubber and fits tightly against the outer frame.

[0014] Beneficial effects

[0015] The honeycomb structure of the carbon crystal particle layer and the physical filtration effect of the high dust-holding mesh cloth of this utility model can effectively intercept pollutants such as fine particles, dust, and pollen in the air, thereby improving air cleanliness. The design of the high dust-holding mesh cloth allows the filter to hold more dust and particles, extending its service life and reducing the frequency of replacement and maintenance costs. The reasonable selection of materials and structural design of each layer ensures that the filter can maintain good air permeability while achieving high-efficiency filtration, thus maintaining smooth air circulation. Attached Figure Description

[0016] Other features, objects, and advantages of this invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0017] Figure 1 This is a schematic diagram of the structure of a photocatalytic high dust-holding and antibacterial air filter according to the present invention;

[0018] Figure 2 This is a schematic diagram of the filter structure of this utility model;

[0019] Figure 3 This is a top view of the structure of the first processed part of this utility model;

[0020] Figure 4 This is a top view of the structure of the second processed part of this utility model;

[0021] Figure 5 This is a side view of the structure of the second processed part of this utility model. Detailed Implementation

[0022] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the present utility model will be further described below in conjunction with specific embodiments.

[0023] Please see Figures 1-5 This utility model provides a photocatalytic high dust-holding and antibacterial air filter technical solution, including:

[0024] The filter structure features a vertically layered layout, consisting of, from top to bottom, a photocatalytic coating 11, a honeycomb separator 12, a high-dust-holding mesh cloth 13, and an antibacterial fleece cloth 14. Specifically:

[0025] The photocatalytic coating 11, located on the top layer of the filter, is made by coating with existing photocatalytic materials.

[0026] Photocatalysts can generate highly oxidizing free radicals under light conditions, effectively decomposing organic pollutants in the air, such as formaldehyde and benzene, while inhibiting the growth of bacteria and viruses, improving air quality, and giving the filter self-cleaning and long-lasting antibacterial capabilities.

[0027] The honeycomb separator 12 is filled with carbon crystal particles. The honeycomb separator 12 is prepared by the following steps:

[0028] Step 1: Forming of porous substrate:

[0029] Multiple hollow plastic tubes 3 are precisely stacked and arranged to form a first processed part 1 with a porous structure.

[0030] In one embodiment, a high-precision mold is used to ensure consistent spacing between the plastic tubes 3, improving the uniformity of the porosity of the pores 4, and a slight compression is applied to the side of the first processed part 1 to ensure a tight fit between the plastic tubes 3. The diameter of the hollow plastic tube 3 is 5mm to 20mm, and the length of the hollow plastic tube is unlimited and can be selected according to actual needs. Preferably, the diameter of the hollow plastic tube 3 should not be too small, as it cannot fully fill the porous loaded mineral crystal particles and is prone to clogging the hollow plastic tube 3 during subsequent hot melt cutting, making the product unable to breathe; the diameter of the hollow plastic tube 3 should also not be too large, as it results in a smaller contact area and weaker adhesion during subsequent hot melt cutting, which may prevent the formation of a tight adhesion, leading to low product strength and easy damage. The material of the hollow plastic tube 3 can be selected from thermoplastic plastics such as polyvinyl chloride, polyethylene, polypropylene, polymethyl methacrylate, polystyrene, polyamide, polycarbonate, and ABS.

[0031] Step Two: Hot-melt cutting and honeycomb molding:

[0032] The first processed part 1 is cut using existing heat beam cutting technology (the cutting thickness is according to design requirements). During the process, the edges of the plastic tube 3 are thermally melted and bonded to form a porous honeycomb-shaped second processed part 2.

[0033] The use of heat beam cutting technology not only achieved precise cutting but also promoted the thermal fusion bonding between the plastic tubes 3. The honeycomb structure effectively increased the surface area, providing a larger contact surface for the subsequent loading of mineral crystal particles 8 and improving adsorption efficiency.

[0034] As a further improvement, the thickness of the final air filter layer can be controlled by controlling the cutting distance. Preferably, the final air filter layer with a thickness of 5mm to 20mm can be controlled by controlling the cutting distance to 5mm to 20mm.

[0035] As a further improvement, the bonding strength of the air filter layer can be controlled by adjusting the temperature and speed of the heat beam cutting. This prevents the plastic tubes 3 from melting excessively and becoming blocked or deformed, or from failing to form a tight adhesion between the plastic tubes 3, resulting in low product strength and easy damage. This is because when the heat beam cutting speed is too fast, although rapid cutting can be achieved and productivity increased, the heat-melting portion between the plastic tubes 3 is limited, resulting in insufficient heat-melting adhesion between the plastic tubes 3. Conversely, when the heat beam cutting speed is too slow, although the bonding strength can be improved, the plastic tubes 3 are prone to melting excessively and blocking the hollow plastic tubes 3. The temperature and speed of the heat beam cutting affect the quality of the first processed part 1.

[0036] In one embodiment, the hollow plastic tube 3 is made of polyethylene, and the temperature and speed of the heat beam heat cutting are determined by the following formula:

[0037] T_cut=T_melt+1.56(K*T_melt)54 / (C*L*V)34.5

[0038] Where T_cut is the heat beam cutting temperature, T_melt is the melting temperature of polyethylene, K is the thermal conductivity coefficient, i.e. the ability of polyethylene material to conduct heat, C is the specific heat capacity, i.e. the heat required to raise the temperature of polyethylene material by 1 degree Celsius, L is the wall thickness of the plastic pipe, and V is the cutting speed.

[0039] This shows that the cutting temperature (T_cut) is inversely proportional to the cutting speed (V_cut) and also inversely proportional to the plastic tube wall thickness (L). This means that, at the same melting temperature, the faster the cutting speed or the thicker the plastic tube wall, the higher the required cutting temperature.

[0040] Before processing, the factory needs to verify the material properties to obtain the values ​​of T_melt, K, C, and L. Based on the pressure requirements of the order, the cutting speed is adjusted, i.e., the V value is determined. This allows for the calculation of the heat beam cutting temperature.

[0041] In this embodiment, the melting temperature of polyethylene (T_melt = 135 degrees Celsius), thermal conductivity (K = 0.4 W / (m*K)), specific heat capacity (C = 2300 J / (kg*K)), plastic pipe wall thickness (L = 0.5 mm), and cutting speed (V = 0.03 m / s) are used.

[0042] That is, T_cut = 135 + (0.4 * 135) / (2300 * 0.5 * 0.03) ≈ 137 degrees Celsius.

[0043] Step 3: Initial sealing and filling with mineral crystal particles:

[0044] One side of the second processed part 2 is sealed with a high-dust-holding mesh 5, and the other side is filled with mineral crystal particles 8, ensuring that each hole 4 is completely filled. Preferably, the mineral crystal particles 8 are carbon crystal particles. In one embodiment, one side of the second processed part 2 can be sealed by coating it with an environmentally friendly adhesive and then covering it with the high-dust-holding mesh 5. The pore size of the high-dust-holding mesh 5 is less than or equal to the particle size of the mineral crystal particles 8.

[0045] The high-dust-holding mesh 5 not only effectively prevents leakage of mineral crystal particles 8, but also has good air permeability, ensuring air circulation. Furthermore, the mineral crystal particles 8 are finely scraped by a scraper to make the filling height flush with the opening of the hole 4, ensuring uniform particle distribution within each hole 4. In other embodiments, to ensure the filling rate, the scraper can be tilted at a certain angle during the scraping process to apply a certain compressive force to the mineral crystal particles 8, thereby increasing the filling rate and making the filling height of the mineral crystal particles 8 flush with the height of the hole 4. The scraper can form an angle of 30° to 70° relative to the surface of the second workpiece 2. In one embodiment, the scraper forms an angle of approximately 60° relative to the surface of the second workpiece 2.

[0046] Step 4: Scraping off surface mineral grains 8 and cleaning the inside of holes 4:

[0047] Remove excess mineral crystal particles 8 from the surface of the second processed part 2, ensuring that the particle volume in each hole 4 is similar and the filling height is consistent. Step 5: Tilting vibration treatment:

[0048] Specifically, in order to control the filling rate of mineral crystal particles 8 in the holes 4 of the second processed part 2, the second processed part 2 is placed at an angle and subjected to slight vibration using an existing vibrator to adjust the distribution of mineral crystal particles 8 in the holes 4. Vibration can accelerate the shaking out of excess mineral crystal particles 8 when the second processed part 2 is tilted.

[0049] The tilt angle is inversely proportional to the required proportion of mineral crystal particles 8. A larger tilt angle results in a smaller proportion of mineral crystal particles 8 within the pore 4. Therefore, to meet filtration requirements, the tilt angle can be between 20° and 80°, controlling the filling rate of mineral crystal particles 8 within the pore 4 to approximately 90% to 10%. In several embodiments, the tilt angle can be between 40° and 60°, controlling the filling rate of mineral crystal particles 8 within the pore 4 to 60% to 40%. In one embodiment, the tilt angle is approximately 50°, controlling the filling rate of mineral crystal particles 8 within the pore 4 to approximately 50%.

[0050] Step Six: Complete Closure

[0051] The other side of the second processed part 2 is also sealed with a high-dust-holding mesh fabric 5 to form a complete filter layer. In one embodiment, the other side of the second processed part 2 can also be sealed by coating it with an environmentally friendly adhesive and then covering it with the high-dust-holding mesh fabric 5.

[0052] The fully enclosed design effectively prevents the leakage of mineral crystal particles 8, while ensuring smooth airflow.

[0053] In other embodiments, to accommodate air filter elements with different structures, it may further include:

[0054] The planar air filter layer is enclosed to form a hollow three-dimensional structure.

[0055] In one embodiment, the planar air filter layer is enclosed to form a hollow cylindrical structure. Specifically, the hollow three-dimensional structure can be formed by fixing the seams together with environmentally friendly adhesive or fasteners.

[0056] In other embodiments, the present invention further provides a composite air filter layer, comprising:

[0057] Four-layer structure

[0058] Step 7: Functional layer coating and fixation:

[0059] The existing photocatalyst layer 6 is coated on one side of the second processed part 2 as the front side, and the antibacterial velvet cloth 7 is fixed on the other side as the back side.

[0060] The photocatalytic layer 6 can catalyze the decomposition of organic pollutants under light conditions, enhancing the air purification effect; the antibacterial fabric 7 can effectively inhibit bacterial growth and improve air hygiene quality. The combination of the two achieves a dual purification mechanism of physical adsorption and chemical catalysis, significantly improving the overall performance of the air filter layer.

[0061] The high-capacity dust-holding mesh fabric 13 is made of materials such as glass fiber and polyester fiber. As a physical filter layer, the high-capacity dust-holding mesh fabric 13 can effectively intercept larger particles, such as dust and pollen, preventing them from entering the lower filter media, protecting the subsequent filter layers from clogging, and extending the filter's service life. At the same time, its large mesh size ensures good air permeability and maintains smooth airflow.

[0062] Antibacterial velour cloth 14, located at the bottom of the filter, has antibacterial properties. Treated with a special antibacterial material, antibacterial velour cloth 14 effectively inhibits the growth of bacteria and mold, prevents the proliferation of microorganisms generated during the filtration process, keeps the inside of the filter clean, reduces the risk of secondary pollution, and provides users with a healthier breathing environment.

[0063] The outer frame 9 is made of plastic and wraps around the sides of the filter structure, providing structural support to ensure the overall stability of the filter and making it easy to install and replace.

[0064] The sealing strip 10 is made of rubber and fits tightly against the outer frame 9 and the installation location. It effectively prevents air from bypassing the filter, ensuring that all incoming air is filtered, improving the filtration effect, reducing noise, and enhancing the user experience.

[0065] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the scope of the invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0066] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A photocatalytic high dust-holding and antibacterial air filter, characterized in that: include: The filter structure features a vertically layered layout, consisting of a photocatalytic coating, a honeycomb layer formed by stacked hollow plastic tubes, a high-dust-holding mesh cloth wrapping the top and bottom of the honeycomb layer, and an antibacterial fleece cloth, with the edges of the plastic tubes heat-fused together. The honeycomb layer is filled with mineral crystal particles. The outer frame wraps around the sides of the filter structure; Sealing strips are used to wrap the sides of the outer frame.

2. The photocatalytic high dust-holding and antibacterial air filter according to claim 1, characterized in that: The mineral crystal particles are filled into the plastic tube at a ratio of 50% to 70%.

3. The photocatalytic high dust-holding and antibacterial air filter according to claim 1, characterized in that: The outer frame is made of plastic.

4. The photocatalytic high dust-holding and antibacterial air filter according to claim 1, characterized in that: The sealing strip is made of rubber and fits tightly against the outer frame.

5. The photocatalytic high dust-holding and antibacterial air filter according to claim 1, characterized in that: The high dust-holding mesh fabric includes, but is not limited to, being made of glass fiber or polyester fiber.

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