Polymer air filter and its manufacturing method

Abstract

The present invention relates to a polymer air filter in which micropores having a predetermined pattern are formed in a filter film made of a polymer material by an etching process, and a manufacturing method thereof. According to the present invention, negatively charged dust collides with the polymer film, which also has a negative charge, and is repelled by electrostatic repulsion and filtered, thereby efficiently removing fine dust. Furthermore, by changing the shape of the micropore pattern formed in the polymer film, maintaining the minimum width of the micropores and increasing their length and the distance between the micropores, it is possible to filter particles larger than the minimum width of the micropores, thereby maintaining filter performance and improving air permeability.

Description

[Technical field]

[0001] The present invention relates to an air filter and a manufacturing method thereof, and more particularly to a polymer air filter that is designed to form micropores having a predetermined pattern by etching a filter film made of a polymer material, thereby preventing particles larger than the micropores from passing through while improving air permeability, and a manufacturing method thereof. [Background technology]

[0002] In order to save energy and improve the efficiency of air conditioning, heating, and soundproofing, people today are spending more time indoors, which are more sealed off from the outside air. As a result, they are exposed to various pollutants that are closely related to the internal living environment, and are complaining of symptoms caused by internal air pollution, such as headaches, eye problems, decreased concentration, dizziness, and nausea.

[0003] Furthermore, with the development of industry, the air in residential areas as well as industrial areas is becoming increasingly polluted due to urbanization and the rapid spread of automobiles, and the entire region is being polluted with fine dust due to the yellow sand blown in from mainland China. This fine dust can cause respiratory and skin-related diseases.

[0004] As a result, various air purifiers to purify the air are rapidly becoming popular not only in large buildings and industrial sites but also in ordinary homes, and various types of masks are available to prevent inhaling fine dust when going outside.

[0005] It is essential that the above air purifiers and masks include an air filter to filter out fine dust particles. In general, air filters that filter out pollutants in the air include simple filters made of wire mesh or thin nonwoven fabric that remove relatively large particles such as dust, dirt, and hair, deodorizing filters that remove more than 60% of harmful substances such as odors, volatile organic compounds, and formaldehyde, and high-performance HEPA filters that remove fine dust particles, cigarette smoke, bacteria, mold, pollen, etc.

[0006] FIG. 1 is a diagram illustrating a cross section of a conventional air filter, and FIG. 2 is a plan view taken along line AA in FIG.

[0007] 1 and 2, a conventional air filter 100 is simply manufactured into a film 110 having micropores 120 formed therein. Each micropore 120 has a predetermined horizontal width y and vertical width x, and adjacent micropores 120 are spaced apart by a predetermined distance z and w in the horizontal and vertical directions.

[0008] Such conventional air filters 100 are configured to allow air to pass through but block dust particles of a certain size or larger, with air permeability being proportional to the porosity of the micropores and the filter's ability to block fine dust particles being inversely proportional to the size of the micropores. In the case of such air filters, the smaller the size of the micropores 120 is made, the more fine dust particles can be filtered.

[0009] However, in order to make the size of the micropores of the air filter small, there are manufacturing difficulties and technical limitations, which results in a very high manufacturing cost. In addition, when the size of the micropores of the air filter is small, the filtering performance of filtering dust increases, but the air permeability decreases, which reduces usability. For example, when a mask is made with an air filter having a very small size of micropores, the pressure loss increases, making it difficult for the user to breathe, which results in the disadvantage that it is impossible to wear the mask for a long time.

[0010] Also, in order to increase the air permeability while maintaining a constant pore size, the distances z' and w' between the micropores must be reduced, as shown in FIG. 3. However, in order to reduce the distance between the micropores, a fine patterning process is required. In this fine patterning process, a photoresist with a thickness of 20 μm or more is required to etch a filter film with a thickness of 10 μm or more, which is costly. Furthermore, even with this structure, it is still difficult to ensure sufficient porosity. Summary of the Invention [Problem to be solved by the invention]

[0011] The technical problem to be solved by the present invention is to provide a polymer air filter and a manufacturing method thereof, which can improve air permeability while maintaining filter performance by forming micropores in a polymer film by a dry process and changing the shape of the pattern of the micropores to maintain the minimum width of the micropores, while increasing their length and the distance between the micropores, thereby filtering out particles larger than the minimum width of the micropores. [Means for solving the problem]

[0012] In order to achieve the above technical objectives, the polymer air filter according to the present invention includes a filter film made of a polymer material, the filter film has a plurality of rectangular micropores arranged in horizontal and vertical directions, and the ratio of the short side to the long side of the micropores is 1:1 to 1:10.

[0013] In order to achieve the above technical objectives, the polymer air filter according to the present invention is characterized by including a metal plate having a plurality of micropores formed thereon, and a filter film made of a polymer material formed on the upper part of the metal plate.

[0014] In order to achieve the above technical objectives, the manufacturing method of the polymer air filter according to the present invention is characterized by including a polymer film attachment step of attaching a polymer film onto a substrate, a photoresist application step of applying a photoresist onto the polymer film, an exposure step of irradiating light onto the photoresist to form a pattern in the polymer film, and an etching step of etching the polymer film with the pattern formed thereon to form micropores. Effect of the Invention

[0015] The polymer air filter according to the present invention has the advantage that fine dust can be efficiently removed by using a filter made of a polymer film having micropores formed therein with a predetermined pattern, whereby negatively charged dust collides with the polymer film, which also has a negative charge, and is repelled by electrostatic repulsion and filtered.

[0016] In addition, according to the polymer air filter of the present invention, the shape of the pattern of the micropores formed in the polymer film is changed to maintain the minimum width of the micropores, while increasing their length and increasing the distance between the holes. This has the effect of filtering out particles larger than the minimum width of the micropores, thereby improving air permeability while maintaining filter performance.

[0017] Meanwhile, according to the polymer air filter of the present invention, a filter film made of a negatively charged polymer material is formed on the top of a positively charged metal plate, thereby strengthening static electricity and providing a more excellent effect in blocking moisture that has both positive and negative charges. [Brief description of the drawings]

[0018] [Figure 1] FIG. 1 is a diagram showing an example of a cross section of a conventional air filter. [Diagram 2] FIG. 2 is a plan view taken along the line AA in FIG. [Diagram 3] FIG. 3 is a diagram showing a state in which the distance between micropores is reduced compared to FIG. 2. [Figure 4] FIG. 1 is an exemplary cross-sectional view of a polymer air filter according to the present invention. [Diagram 5] 5 is an exemplary plan view of a polymer air filter according to an embodiment of the present invention taken along line BB in FIG. 4. FIG. [Figure 6] 5 is an exemplary plan view of a polymer air filter according to another embodiment of the present invention taken along line BB in FIG. 4. FIG. [Figure 7] 5 is an exemplary plan view of a polymer air filter according to yet another embodiment of the present invention taken along line BB in FIG. 4. FIG. [Figure 8] FIG. 13 is a diagram showing a schematic configuration of a polymer air filter according to another embodiment of the present invention. [Figure 9] 1 is a process flow chart of a method for producing a polymer air filter according to the present invention. [Figure 10] 2A to 2C are diagrams illustrating process steps of a method for manufacturing a polymer air filter according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0019] Hereinafter, specific embodiments of the present invention will be described in detail with reference to the drawings.

[0020] FIG. 4 is a diagram illustrating an example of a cross-section of a polymer air filter according to the present invention, and FIGS. 5 to 7 are diagrams illustrating an example of a plane of a polymer air filter according to an embodiment of the present invention taken along line BB in FIG. 4.

[0021] 4 and 5, the polymer air filter 400 according to the present invention includes a filter film 410 made of a polymer material, and a plurality of rectangular micropores 420 are formed in the filter film 410 in the horizontal and vertical directions.

[0022] The filter film 410 may be a thin film made of any one polymer selected from synthetic resin materials such as polyimide, polypropylene, polyethylene, polytetrafluorehylene, polyvinyl chloride (PVC), etc., or a mixture of these polymers.

[0023] Due to the characteristics of the above polymer material, it has excellent electrostatic properties and is negatively charged, so that negatively charged particles such as dust contained in the air are repelled by the electrostatic repulsion and filtered, thereby efficiently removing fine dust.

[0024] The polymer air filter 400 according to the present invention is characterized in that the ratio of the short side to the long side of the plurality of micropores 420 is 1:1 to 1:10.

[0025] The present invention is characterized in that, while maintaining the minimum length of the width x of the micropores, the length of the width y of the micropores is increased, and the lengths z and w between the micropores are increased, thereby filtering out particles larger than the minimum width x of the micropores, while maintaining the filter performance, and improving the air permeability.

[0026] In this case, the length x of the short side corresponding to the width of the micropore is preferably 1 μm to 10 μm, and the length y of the long side corresponding to the width of the micropore is preferably 1 μm to 100 μm. If the length of the long side y corresponding to the width of the micropore is too short, there is a problem that sufficient air permeability cannot be ensured. Also, if the length of the long side y exceeds 100 μm, there is a problem that the air filter itself cannot ensure sufficient rigidity and may be torn.

[0027] The shortest distance z between any one of the micropores 420a1 arranged in the horizontal direction and another adjacent micropore 420a2 among the plurality of micropores is preferably 3 μm to 20 μm. Also, the shortest distance w between any one of the micropores 420a1 arranged in the vertical direction and another adjacent micropore 420b1 among the plurality of micropores is preferably 3 μm to 20 μm.

[0028] Meanwhile, in the polymer air filter according to the present invention, the thickness t of the filter film 410 for improving the air permeability while maintaining the filter performance is preferably 10 μm to 100 μm.

[0029] If the thickness of the filter film 410 is 10 μm or less, sufficient rigidity cannot be ensured, and the film may be torn during the etching process, etc. On the other hand, if the thickness of the filter film 410 is more than 100 μm, not only is the cost of the filter film itself high, but the etching process, etc. also takes a lot of time and money.

[0030] When the above-mentioned width x and width y of the micropores and distances z and w between the micropores are applied, the polymer air filter according to the present invention can ensure a porosity of at least 25%.

[0031] 5, in the polymer air filter 400 according to the embodiment of the present invention, one of the micropores 420a1 arranged in the vertical direction and another adjacent micropore 420b1 are arranged at positions corresponding to each other in the vertical direction, and one of the micropores 420a1 arranged in the horizontal direction and another adjacent micropore 420a2 are arranged at positions corresponding to each other in the horizontal direction.

[0032] FIG. 6 is an exemplary plan view of a polymer air filter according to another embodiment of the present invention taken along line BB in FIG.

[0033] Referring to FIG. 6, in a polymer air filter 400 according to another embodiment of the present invention, one of the plurality of micropores arranged in the vertical direction, 420a1, is offset from another adjacent micropore, 420b1, and the other micropore, 420b1, is also offset from another adjacent micropore, 420c1.

[0034] That is, in FIG. 6, a plurality of micropores 420a1, 420b1, 420c1... arranged in the vertical direction are shifted from one another in the vertical direction and arranged in a zigzag pattern.

[0035] FIG. 7 is an exemplary plan view of a polymer air filter according to yet another embodiment of the present invention taken along line BB in FIG.

[0036] Referring to FIG. 7, in a polymer air filter 400 according to yet another embodiment of the present invention, one of the plurality of micropores arranged in the vertical direction, 420a1, is offset from another adjacent micropore, 420a2, and micropore 420a2 is also offset from another adjacent micropore, 420a3.

[0037] That is, in FIG. 7, a plurality of micropores 420a1, 420a2, 420a3... arranged in the horizontal direction are shifted from one another in the horizontal direction and arranged in a zigzag pattern.

[0038] As shown in Figs. 6 and 7, when a plurality of micropores are arranged in a zigzag pattern, shifted from one another in the horizontal or vertical direction, there is an advantage in that the performance of removing foreign matter can be further improved.

[0039] FIG. 8 is a diagram showing a schematic configuration of a polymer air filter according to another embodiment of the present invention.

[0040] Referring to FIG. 8, a polymer air filter 800 according to another embodiment of the present invention includes a metal plate 810 and a filtering film 820 .

[0041] A plurality of micropores 811 are formed in the horizontal and vertical directions in the metal plate 810. At this time, the metal plate 810 has positive static electricity.

[0042] The filter film 820 is formed on the metal plate 810 and is made of a polymer material such as polyester or polyimide. At this time, the filter film 820 has negative static electricity.

[0043] The polymer air filter 800 according to another embodiment of the present invention has a structure in which a metal plate 810 having a positive static charge and a filter film 820 having a negative static charge are combined, and therefore exhibits a more excellent effect in blocking moisture that is both positively and negatively charged.

[0044] The polymer air filters according to the above-described other embodiments of the present invention can be used in a variety of applications, such as masks and industrial applications.

[0045] FIG. 9 is a process flow chart of the method for producing a polymer air filter according to the present invention, and FIG. 10 is a diagram for explaining the process steps of the method for producing a polymer air filter according to the present invention.

[0046] 9 and 10, the method for manufacturing a polymer air filter according to the present invention includes a polymer film deposition step S100, a photoresist coating step S200, an exposure step S300, an etching step S400, a photoresist removal step S500, and a cleaning step S600.

[0047] In the polymer film attachment step S100, a filter film 20 made of a polymer material is attached on the substrate 10. The filter film 20 may be a thin film made of any one polymer selected from synthetic resin materials such as polyimide, polypropylene, polyethylene, polytetrafluorehylene, polyvinyl chloride (PVC), etc., or a mixture thereof.

[0048] In the photoresist application step S200, a photoresist 30 is applied onto the polymer film 20. The thickness of the applied photoresist 30 varies depending on the thickness of the filter film 20, and is preferably about 20 μm to 50 μm.

[0049] In the exposure step S300, light is irradiated onto the photoresist 30 to form a pattern on the filter film 20.

[0050] In the etching step S400, the filter film 20 on which the pattern is formed is etched to form micropores in the polymer film 20.

[0051] Thereafter, the photoresist 30 is removed in a photoresist removing step S500, the substrate 10 is removed, and the polymer film 20 is cleaned in a cleaning step S600, thereby completing the manufacture of the polymer air filter according to the present invention.

[0052] Although the technical concept of the present invention has been described above with reference to the accompanying drawings, this is merely a description of the preferred embodiment of the present invention and is not intended to limit the present invention. In addition, it is obvious that anyone with ordinary knowledge in the technical field to which the present invention pertains can make various modifications and imitation of the present invention without departing from the scope of the technical concept of the present invention. <Additional Notes> (Technical Thought 11) A metal plate having a plurality of micropores formed therein; a filter film made of a polymer material formed on the metal plate. (Technical Thought 12) The plurality of micropores are The polymer air filter according to technical idea 11, characterized in that it is formed in a horizontal and vertical direction. (Technical Thought 13) The material of the filter film is a polymer film such as polyester or polyimide, The polymer air filter according to Technical Idea 11, characterized in that the material of the metal plate is aluminum. (Technical Thought 14) The metal plate has a positive electrostatic charge, The polymer air filter according to technical idea 11, characterized in that the filter film has a negative static charge. (Technical Thought 15) The polymer air filter comprises: A polymer air filter according to Technical Idea 11, characterized by blocking moisture and dust. (Technical Thought 16) The size of the plurality of micropores is The polymer air filter according to Technical Concept 11, characterized in that the particle size is 100 μm to 1 cm. (Technical Thought 17) a filter film attachment step of attaching a filter film made of a polymer material on the substrate; a photoresist coating step of coating a photoresist on the filter film; an exposure step of irradiating light onto the photoresist to form a pattern in the polymer film; and etching the patterned filter film to form micropores. (Technical Thought 18) a photoresist removing step of removing the photoresist; The method for producing a polymer air filter described in Technical Idea 17 further comprises a cleaning step of cleaning the filter film.

Claims

1. A substance having a negative electrostatic charge, It includes a polymeric filter film, The filter film has a plurality of rectangular micropores formed in horizontal and vertical directions, The ratio of the short side to the long side of the micropore is 1:1 to 1:10 (but excluding 1:1), The length of the short side of the micropore is 1 μm to 10 μm, The length of the long side of the micropore is 1 μm to 100 μm, A polymer air filter, characterized in that the shortest distance between any one of the plurality of micropores arranged in the horizontal direction and another adjacent micropore is 3 μm to 20 μm.

2. The polymer air filter according to claim 1, characterized in that the shortest distance between any one of the plurality of micropores arranged in the vertical direction and another adjacent micropore is 3 μm to 20 μm.

3. Among the plurality of micropores, any one of the micropores arranged in the vertical direction and another adjacent micropore are arranged at positions corresponding to each other, The polymer air filter according to claim 1, characterized in that among the plurality of micropores, any one of the micropores arranged in the horizontal direction and another adjacent micropore are arranged in corresponding positions to each other.

4. 2. The polymer air filter according to claim 1, wherein any one of the plurality of micropores arranged in the vertical direction and another adjacent one of the micropores are arranged in a mutually offset manner.

5. The polymer air filter according to claim 1, wherein among the plurality of micropores, any one of the micropores arranged in the horizontal direction and another adjacent micropore are arranged in a mutually offset manner.

6. 10. The polymeric air filter of claim 1, wherein the polymeric air filter has a porosity of 25% or greater.

7. 2. The polymer air filter of claim 1, wherein the thickness of the filter film is from 10 μm to 100 μm.

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