Air purifying filter with dust collection and deodorization functions and its manufacturing method

Abstract

To provide an air cleaning filter which realizes low differential pressure while being excellent in dust collection and deodorization performance, a manufacturing method thereof, and an air cleaner including the same. [Solution] The air cleaning filter according to the present invention includes a nonwoven fabric for dust collection and a nonwoven fabric bound with activated carbon particles for deodorization. The particle size and content of the activated carbon particles are adjusted, and the filter is laminated with a nonwoven fabric coated with another gas adsorbent, thereby realizing a low differential pressure structure while simultaneously providing dust collection and deodorization functions.

Description

[Technical Field]

[0001] The present invention relates to an air purifying filter having dust collection and deodorizing functions and a manufacturing method thereof. More specifically, the present invention relates to an air purifying filter having both dust collection and deodorizing functions, a manufacturing method thereof, a deodorizing air purifying filter used therein, and an air purifier including them. [Background technology]

[0002] Recently, air pollution problems such as fine dust and yellow sand have emerged, making indoor air purification essential. Air purification devices such as air purifiers can provide fresh air by filtering polluting dust particles and harmful substances that are harmful to the human body using various types of filter systems.

[0003] The filter system uses various dust collection filters that use filter media to remove particulate contaminants contained in the gas, and such dust collection filters generally use filter media with polytetrafluoroethylene membranes or filter media using meltblown nonwoven fabrics.

[0004] In addition, a filter system may be equipped with a deodorizing filter to remove odorous components from the air, such as formaldehyde, toluene, ammonia, etc. For example, to remove formaldehyde, a filter medium has been developed that adsorbs odorous components by applying activated carbon to a thermal bond or spun bond nonwoven fabric.

[0005] Furthermore, with the recent trend toward multiple air purifiers, air purifying filters that combine dust collection, deodorization, and other additional functions have been developed. Summary of the Invention [Problem to be solved by the invention]

[0006] Conventional composite air purifying filters achieve dust collection and deodorization functions by simply combining a deodorizing filter layer using pelletized activated carbon particles with a dust-collecting filter layer using meltblown nonwoven fabric. However, such conventional filters have the problem of increasing the differential pressure, ultimately reducing the cleaning efficiency of the filter.

[0007] An object of the present invention is to provide an air cleaning filter that achieves low differential pressure while having excellent dust collection and deodorizing performance, a method for manufacturing the same, and an air purifier including the same. [Means for solving the problem]

[0008] The air cleaning filter according to the present invention includes a folded filter medium, and the filter medium includes a dust-collecting filter layer including a first nonwoven fabric, a second nonwoven fabric, and activated carbon particles having a particle size smaller than a 150 mesh particle size and bonded to the second nonwoven fabric at a concentration of 10 g / m. 2 ~60g / m 2 and a functional filter layer containing a third nonwoven fabric and one or more gas adsorbents, and the dust-collecting filter layer, the deodorizing filter layer and the functional filter layer are physically or chemically laminated together.

[0009] The method for producing an air cleaning filter according to the present invention includes the steps of producing a dust-collecting filter layer including a first nonwoven fabric, and distributing activated carbon particles having a particle size smaller than 150 mesh to a second nonwoven fabric at a rate of 10 g / m. 2 ~60g / m 2 a step of combining the third nonwoven fabric and the functional filter layer in an amount of 1000 to 15000 to prepare a deodorizing filter layer; a step of preparing a functional filter layer containing a third nonwoven fabric and one or more gas adsorbents; a step of physically or chemically laminating the dust-collecting filter layer, the deodorizing filter layer, and the functional filter layer to prepare a filter medium; and a step of folding the filter medium.

[0010] In addition, the air cleaning filter according to the present invention includes a nonwoven fabric and activated carbon particles bound to the nonwoven fabric with a binder, and the nonwoven fabric has a density of 30 g / m 2 ~80g / m 2 The activated carbon particles have a particle size smaller than 150 mesh and a basis weight of 10 g / m 2 ~60g / m 2 The binder is contained in an amount of 20 to 50 parts by weight based on 100 parts by weight of the activated carbon particles.

[0011] The present invention also provides an air purifier including the air cleaning filter. [Effects of the Invention]

[0012] The air purifying filter according to the present invention includes a nonwoven fabric for dust collection and a nonwoven fabric bonded with activated carbon particles for deodorization, and the particle size and content of the activated carbon particles are adjusted and laminated with a nonwoven fabric containing other gas adsorbents, thereby achieving a low differential pressure structure while simultaneously providing dust collection and deodorization functions.

[0013] Specifically, the air cleaning filter of the present invention is equipped with a deodorizing filter in which activated carbon particles having a particle size smaller than conventional particles are fixed to a nonwoven fabric with a binder, and can adsorb malodorous components such as toluene at a low differential pressure.

[0014] In addition, the air cleaning filter according to the present invention may further include one or more functional filter layers or metal catalyst layers depending on the components to be removed from the air, and the layers may be stacked in various orders to exhibit composite performance. [Brief explanation of the drawings]

[0015] [Figure 1] 1 shows a perspective view of an air cleaning filter according to an embodiment of the present invention. [Figure 2] 2 shows a cross-sectional view taken along line AA' in FIG. 1 and an enlarged view. [Figure 3]3 shows a cross-sectional view taken along line BB' in FIG. [Figure 4] 10 shows a cross-sectional view of a filter medium according to another embodiment. [Figure 5] 10 shows a cross-sectional view of a filter medium according to another embodiment. [Figure 6] 10 shows a cross-sectional view of a filter medium according to another embodiment. [Figure 7] 1 shows the results of a gas removal test of an air cleaning filter in Test Example 1. [Figure 8] 1 shows the results of a test on the deodorizing durability of the air cleaning filter in Test Example 2. [Figure 9] 1 shows the results of a dust collection efficiency test of an air cleaning filter in Test Example 3. [Figure 10] 1 shows the reduction in pollutant concentration by the air cleaning filter in Test Example 4. [Figure 11] 1 shows the results of measuring the differential pressure of the air cleaning filter in Test Example 5. DETAILED DESCRIPTION OF THE INVENTION

[0016] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[0017] In describing the present invention, if a detailed description of related known structures or functions is deemed to detract from the gist of the present invention, the detailed description will be omitted. In addition, the size of each component in the drawings may be exaggerated or omitted for the purpose of explanation, and may differ from the actual size.

[0018] In this specification, when a component is described as being formed above / below another component or being connected or joined to each other, this includes being formed, connected or joined between these components directly or indirectly through another component. It should also be understood that the reference to above / below each component may change depending on the direction from which the object is viewed.

[0019] In this specification, the terms used to refer to each component are used to distinguish it from other components and are not intended to limit the present invention. Furthermore, in this specification, the singular form "a," "an," or "the" includes the plural form unless the context clearly indicates otherwise.

[0020] As used herein, the term "comprises" is intended to embody features, regions, constants, steps, operations, elements and / or components, and does not exclude the presence or addition of other features, regions, constants, steps, operations, elements and / or components, unless specifically stated to the contrary.

[0021] Air Purifier Filter FIG. 1 shows a perspective view of an air cleaning filter according to one embodiment of the present invention, FIG. 2 shows a cross-sectional view taken along line A-A' in FIG. 1 and an enlarged view thereof, and FIG. 3 shows a cross-sectional view taken along line B-B' in FIG. 2.

[0022] 1 to 3, an air cleaning filter 10 according to an embodiment of the present invention includes a folded filter medium 100. The filter medium 100 includes a dust-collecting filter layer 130 including a first nonwoven fabric, a second nonwoven fabric, and activated carbon particles having a particle size smaller than a 150 mesh particle size and bonded to the second nonwoven fabric at a density of 10 g / m. 2 ~60g / m 2 and a functional filter layer 110 containing a third nonwoven fabric and one or more gas adsorbents.

[0023] An air purifying filter according to an embodiment of the present invention includes a nonwoven fabric for dust collection and a nonwoven fabric bound with activated carbon particles for deodorization, and the particle size and content of the activated carbon particles are adjusted and laminated with a nonwoven fabric coated with another gas adsorbent, thereby simultaneously providing dust collection and deodorizing functions while achieving a low differential pressure structure. Specifically, the air purifying filter includes a deodorizing filter layer in which activated carbon particles having a smaller particle size than conventional filters are bound to the nonwoven fabric with a binder, and is able to adsorb malodorous components such as toluene at a low differential pressure.

[0024] In addition, the air purification filter according to the embodiment of the present invention may exhibit composite performance by adding one or more functional filter layers or metal catalyst layers and stacking them in various orders depending on the components to be removed from the air. Specifically, the air purification filter 10 may further include a metal catalyst layer 140.

[0025] Each constituent layer will be specifically described below.

[0026] Dust collection filter layer The dust-collecting filter layer includes a first nonwoven fabric.

[0027] For example, the first nonwoven fabric may be a meltblown type nonwoven fabric.

[0028] The basis weight of the first nonwoven fabric is, for example, 20 g / m 2 ~40g / m 2 Specifically, it may be 20 g / m 2 ~35g / m 2 , more specifically 25 g / m 2 ~35g / m 2 When the basis weight of the first nonwoven fabric is within the above-mentioned preferred range, it may be possible to achieve a HEPA (high efficiency particulate air) rating, ensure durability, and be more advantageous in the folding process for producing a filter.

[0029] Specifically, the first nonwoven fabric has a density of 20 g / m 2 ~35g / m 2 The nonwoven fabric may be a meltblown type nonwoven fabric having a basis weight of 10 ...

[0030] The material of the first nonwoven fabric preferably has a melt index within a certain range, and the melt index may be, for example, 800 g / 10 min to 1,500 g / 10 min at 265° C., specifically 900 g / 10 min to 1,200 g / 10 min, more specifically 950 g / 10 min to 1,200 g / 10 min at 265° C. When the melt index is within this range, processability and productivity at low temperatures can be further improved.

[0031] For example, the material of the first nonwoven fabric may be polypropylene, specifically polypropylene having a melt index of 800 g / 10 min to 1,500 g / 10 min at 265°C.

[0032] The dust-collecting filter layer contains ultrafine fibers that have high collection efficiency even when the particle size of fine dust is several microns or less. Therefore, it can remove particles smaller than the pores using an electrical charge, thereby increasing the pollutant removal efficiency. Furthermore, the high porosity allows operation at low differential pressure (pressure loss).

[0033] Deodorizing filter layer The deodorizing filter layer is made of a second nonwoven fabric and activated carbon particles having a particle size smaller than 150 mesh bound to the second nonwoven fabric at a density of 10 g / m 2 ~60g / m 2 Contains the amount of.

[0034] The material of the second nonwoven fabric may be a polymer resin with excellent heat resistance, for example, polyethylene terephthalate (PET). When the second nonwoven fabric contains PET with excellent heat resistance, it is possible to minimize performance degradation after lamination due to heating and further improve adhesive strength with adjacent layers.

[0035] The basis weight of the second nonwoven fabric is, for example, 20 g / m 2 ~90g / m 2 , specifically 30 g / m 2 ~80g / m 2 , specifically 40 g / m 2 ~70g / m 2Within the above-mentioned preferred range, the supportability, processability, bendability, high-temperature processability, and adhesive strength of the filter medium can be further improved.

[0036] Specifically, the second nonwoven fabric has a density of 30 g / m 2 ~80g / m 2 The nonwoven fabric may be a spunbond or thermalbond type nonwoven fabric having a basis weight of 10 ...

[0037] The sum of the basis weight of the first nonwoven fabric and the basis weight of the second nonwoven fabric is 35 g / m 2 ~85g / m 2 For example, the sum of the basis weight of the first nonwoven fabric and the basis weight of the second nonwoven fabric may be 40 g / m 2 ~80g / m 2 or 50g / m 2 ~80g / m 2 When the content is within the above-mentioned preferred range, it may be advantageous to ensure excellent durability as well as bendability and processability.

[0038] The activated carbon particles are derived from coal or coconut shells and can function to adsorb and remove tobacco smoke, volatile organic compounds, and other malodorous substances.

[0039] The particle size of the activated carbon particles is smaller than 150 mesh, which is advantageous for achieving excellent deodorizing performance and low differential pressure. For example, the particle size of the activated carbon particles may be 150 mesh or less, 100 mesh or less, or 50 mesh or less, or may be 300 mesh or more, 250 mesh or more, or 200 mesh or more. Specifically, the particle size of the activated carbon particles may be 50 mesh to 300 mesh, 100 mesh to 300 mesh, or 150 mesh to 250 mesh. The particle sizes of the activated carbon particles exemplified above may be average particle sizes.

[0040] The surface area of ​​the activated carbon particles is not particularly limited as long as they have physical or chemical properties that are suitable for the purpose of removing malodors. However, in consideration of applicability to fields such as air purifiers, the surface area of ​​the activated carbon particles is preferably about 1000 m. 2 / g or more, preferably about 1000 to 1200m 2 / g BET surface area.

[0041] The activated carbon particles may be bound to the second nonwoven fabric by a binder, such as an acrylic or polyurethane binder.

[0042] The amount of the binder used may be 10 parts by weight or more, 20 parts by weight or more, or 30 parts by weight or more, based on 100 parts by weight of the activated carbon particles, and may be 60 parts by weight or less, 50 parts by weight or less, or 40 parts by weight or less, and preferably 20 to 50 parts by weight, which is advantageous in terms of fixing the activated carbon particles while not increasing the differential pressure.

[0043] The deodorizing filter layer exhibits superior deodorizing performance compared to conventional deodorizing filters while achieving a low differential pressure structure, and therefore the deodorizing filter layer can be provided as an air cleaning filter that is differentiated from conventional filters.

[0044] Specifically, the deodorizing filter layer includes a nonwoven fabric and activated carbon particles bound to the nonwoven fabric with a binder, and the nonwoven fabric has a density of 30 g / m 2 ~80g / m 2 The activated carbon particles have a particle size smaller than 150 mesh and a basis weight of 10 g / m 2 ~60g / m 2 The binder is contained in an amount of 20 to 50 parts by weight based on 100 parts by weight of the activated carbon particles.

[0045] Functional filter layer The functional filter layer includes a third nonwoven fabric and one or more gas adsorbents.

[0046] The material of the third nonwoven fabric may be a polymer resin with excellent heat resistance, for example, polyethylene terephthalate (PET). When the third nonwoven fabric contains PET with excellent heat resistance, it is possible to minimize performance degradation after lamination due to heating and further improve adhesive strength with adjacent layers.

[0047] The basis weight of the third nonwoven fabric is, for example, 20 g / m 2 ~90g / m 2 , specifically 30 g / m 2 ~80g / m 2 , specifically 40 g / m 2 ~70g / m 2 Within the above-mentioned preferred range, the supportability, processability, foldability, high-temperature processability, and adhesive strength of the filter medium can be further improved. Specifically, the third nonwoven fabric may have a thickness of 30 g / m 2 ~80g / m 2 The nonwoven fabric may be a spunbond or thermalbond type nonwoven fabric having a basis weight of 10 ...

[0048] The functional filter layer can remove one or more gases by using a gas adsorbent contained therein. For example, the functional filter layer can remove one or more gases selected from the group consisting of ammonia, aldehydes, acetic acid, toluene, and terpenes. The gas adsorbent may also include at least one selected from the group consisting of organic acids, inorganic acids, urea, silica, zeolites, and metal catalysts.

[0049] For example, the functional filter layer may contain an organic or inorganic acid to remove basic gases such as ammonia gas. For another example, the functional filter layer may contain urea such as ethylene urea to remove aldehydes. For yet another example, the functional filter layer may contain urea together with an organic or inorganic acid to simultaneously remove basic gases and aldehydes.

[0050] The content of the gas adsorbent in the functional filter layer may be 1 wt % or more, 2 wt % or more, or 5 wt % or more, and may be 50 wt % or less, 30 wt % or less, or 20 wt % or less.

[0051] Specifically, the functional filter layer may contain one or more selected from 2% by weight to 20% by weight of phosphoric acid for removing ammonia and 5% by weight to 30% by weight of ethylene urea for removing aldehydes.

[0052] metal catalyst layer The filter medium may further include a metal catalyst layer, and the metal catalyst layer may include a fourth nonwoven fabric and a metal catalyst.

[0053] The material of the fourth nonwoven fabric may be a polymer resin with excellent heat resistance, for example, polyethylene terephthalate (PET). When the fourth nonwoven fabric contains PET with excellent heat resistance, it is possible to minimize performance degradation after lamination due to heating and further improve adhesive strength with adjacent layers.

[0054] The basis weight of the fourth nonwoven fabric is, for example, 20 g / m 2 ~90g / m 2 , specifically 30 g / m 2 ~80g / m 2 , specifically 40 g / m 2 ~70g / m 2 Within the above-mentioned preferred range, the supportability, processability, bending property, high-temperature processability and adhesive strength of the filter medium can be further improved.

[0055] The metal catalyst layer can decompose and remove gases that are difficult to adsorb and remove through a reaction of the metal catalyst.

[0056] For example, the gas removed by the metal catalyst layer may be one or more gases selected from the group consisting of formaldehyde, acetaldehyde, and acetic acid.

[0057] The metal catalyst may be one or more selected from the group consisting of platinum, copper, and manganese.

[0058] The content of the metal catalyst in the metal catalyst layer may be, for example, 0.1% by weight to 2% by weight.

[0059] As an example, the metal catalyst layer may contain 0.1% to 2% by weight of a platinum catalyst for removing formaldehyde gas.

[0060] As another example, the metal catalyst layer may include 0.1 wt % to 2 wt % of a manganese catalyst for removing acetaldehyde gas.

[0061] Laminated structure The filter medium of the air cleaning filter according to the present invention may have various laminated structures in which the above-mentioned layers are physically or chemically laminated.

[0062] Preferably, the deodorizing filter layer and the dust-collecting filter layer may be stacked adjacent to each other, and the functional filter layer may be stacked on the deodorizing filter layer or the dust-collecting filter layer. When the deodorizing filter layer and the dust-collecting filter layer are stacked adjacent to each other in this manner, even if activated carbon particles are detached from the deodorizing filter layer due to the inflow of air, they can be preserved by the dust-collecting filter layer. As shown in FIG. 3, a filter medium 100 according to one embodiment may have a functional filter layer 110, a deodorizing filter layer 120, a dust-collecting filter layer 130, and a metal catalyst layer 140 stacked in this order. When the functional filter layer is stacked on the deodorizing filter layer in this manner, it also serves a protective function for the deodorizing filter layer, thereby further improving the lifespan of the deodorizing filter layer.

[0063] 4 to 6 are cross-sectional views of filter media of air cleaning filters according to other embodiments. According to Fig. 4, filter media 101 may be formed by sequentially laminating a functional filter layer 110, a deodorizing filter layer 120, and a dust-collecting filter layer 130. According to Fig. 5, filter media 102 may be formed by sequentially laminating a deodorizing filter layer 120, a dust-collecting filter layer 130, and a functional filter layer 110. According to Fig. 6, filter media 103 may be formed by sequentially laminating a deodorizing filter layer 120, a dust-collecting filter layer 130, a functional filter layer 110, and a metal catalyst layer 140.

[0064] The filter medium may also include two or more functional filter layers, for example, the filter medium 101 of Figure 4 may have an additional functional filter layer laminated on the surface of the dust-collecting filter layer 130. By coating the two or more functional filter layers with different gas adsorbents, the filter medium can exhibit the combined ability to remove two or more types of gases.

[0065] In addition, the air cleaning filter can be used in an air purifier so that air flows in through the deodorizing filter layer and out through the dust-collecting filter layer, so that even if activated carbon particles contained in the deodorizing filter layer are detached from the second nonwoven fabric by the air flow, they can be captured in the dust-collecting filter layer.

[0066] housing The air cleaning filter according to the present invention may further include a housing for the filter medium. Referring to Figures 1 and 2, the air cleaning filter may include a housing 200 and a folded filter medium 100 disposed inside the housing.

[0067] The housing may function as a frame for supporting the filter medium, and may be assembled or molded to properly position and secure the filter medium. The shape and structure of the housing may be arbitrarily determined depending on the purpose and environment of use.

[0068] The housing may be made of a material commonly used for air purification filters. Specifically, the housing may be made of one or more materials selected from the group consisting of acrylonitrile butadiene styrene copolymer (ABS), polypropylene (PP), paper, nonwoven fabric, polycarbonate (PC), and elastomeric resins. More specifically, the housing may be made of ABS or PP, with ABS being preferred because it is easy to ensure dimensional accuracy and suppresses deformation during use. Furthermore, because polyethylene terephthalate (PET) and ABS have high adhesive properties, when PET is used as the material for the outer layer of the filter medium and ABS is used as the material for the housing, peeling between the filter medium and the housing can be prevented more effectively.

[0069] The filter media may be formed and then placed within the housing.

[0070] Air Purifying Filter Characteristics The air cleaning filter according to the present invention has excellent life characteristics because it achieves a low differential pressure while maintaining a high efficiency of removing pollutants from the air.

[0071] Generally, the lifespan of a filter and its differential pressure have a significant impact on each other. The differential pressure of a filter refers to the pressure difference between the upstream and downstream sides of the filter media. When a fluid containing contaminant particles passes through a filter, the particles are trapped in the filter's pores, causing the pores to close. This causes a gradual increase in pressure. In other words, the differential pressure of a filter increases over time or as particles are trapped in the filter. Therefore, the differential pressure of a filter is a major factor in determining when to replace a filter and can also be used as a measure to determine the lifespan of a filter.

[0072] If the filter differential pressure is too low, the contaminant removal performance may be reduced, and conversely, if the filter differential pressure is too high, the filter life may be shortened and power consumption may increase. Therefore, it is very advantageous for the filter to have a differential pressure within an appropriate range in order to simultaneously satisfy the characteristics of high performance, low power consumption, and long life of the filter.

[0073] For example, the differential pressure of the air cleaning filter may be 40 Pa or more, 50 Pa or more, 60 Pa or more, or 70 Pa or more under the condition that the amount of dust supplied is 50 g at a flow rate of 1 m / s, or may be 120 Pa or less, 110 Pa or less, 100 Pa or less, or 90 Pa or less. As a specific example, the air cleaning filter may have a differential pressure of 60 Pa to 100 Pa when the amount of dust supplied is 50 g at a flow rate of 1 m / s.

[0074] The air purifying filter was placed in a chamber with a temperature of 25°C, humidity of 50%, and a size of 8m 3 When a gas removal test is conducted for 30 minutes under the condition of an initial target gas concentration of 10 ppm, the removal rates for formaldehyde, toluene and ammonia are all 90% or more.

[0075] Specifically, when the gas removal test under the above conditions is carried out for 30 minutes, the air cleaning filter can have a formaldehyde removal rate of 93% or more, a toluene removal rate of 95% or more, and ammonia removal rate of 97% or more.

[0076] Furthermore, in a deodorizing durability test under the conditions of JEM1467:2009, the air purifying filter maintains removal rates of 80% or more for formaldehyde, toluene, and ammonia even when the number of cigarettes is increased to 100. In particular, the air purifying filter maintains removal rates of 95% or more for ammonia even when the number of cigarettes is increased to 200, potentially demonstrating excellent deodorizing durability.

[0077] The air cleaning filter may have a dust collection efficiency of 99% or more, 99.5% or more, 99.6% or more, 99.7% or more, or 99.8% or more under the conditions of 42 CFR part 84 using DEHS (di-ethyl-hexyl-sebacate) particles or NaCl particles.

[0078] Air purifying filter manufacturing method The method for producing an air cleaning filter according to the present invention includes the steps of producing a dust-collecting filter layer including a first nonwoven fabric, and distributing activated carbon particles having a particle size smaller than 150 mesh to a second nonwoven fabric at a rate of 10 g / m. 2 ~60g / m 2 a step of combining the third nonwoven fabric and the functional filter layer in an amount of 1000 to 15000 to prepare a deodorizing filter layer; a step of preparing a functional filter layer containing a third nonwoven fabric and one or more gas adsorbents; a step of physically or chemically laminating the dust-collecting filter layer, the deodorizing filter layer, and the functional filter layer to prepare a filter medium; and a step of folding the filter medium.

[0079] The first nonwoven fabric of the dust-collecting filter layer may be manufactured using the materials exemplified above. For example, the first nonwoven fabric may be manufactured using polypropylene by a melt-blown method at a density of 20 g / m 2 ~35g / m 2The sheet may be manufactured to have a basis weight of 1000 gram.

[0080] The deodorizing filter layer may be manufactured by binding activated carbon particles to a second nonwoven fabric using a binder. Specifically, the activated carbon particles may be mixed with a binder and a solvent to prepare a dispersion, which may then be coated on the second nonwoven fabric and dried.

[0081] In this case, 20 to 50 parts by weight of the binder may be used based on 100 parts by weight of the activated carbon particles.

[0082] As the solvent, distilled water, purified water, or the like may be used in an amount of 200 to 500 parts by weight based on 100 parts by weight of the activated carbon particles.

[0083] The coating may be performed by spraying the prepared dispersion onto the second nonwoven fabric or by immersing the second nonwoven fabric in the dispersion. Specifically, the coating may be performed by immersing the second nonwoven fabric in the dispersion for 3 to 10 seconds.

[0084] The drying may be carried out at a temperature of 50°C to 70°C for 5 to 10 minutes.

[0085] The functional filter layer may be prepared by coating one or more gas adsorbents on the third nonwoven fabric, and may be coated with the gas adsorbents and in the amounts exemplified above.

[0086] The second nonwoven fabric and the third nonwoven fabric may be manufactured using the materials exemplified above, and for example, may be manufactured using polyethylene terephthalate by a spunbond or thermal bond method, each at 30 g / m 2 ~80g / m 2 The sheet may be manufactured to have a basis weight of 1000 gram.

[0087] The lamination may be carried out by a physical or chemical method. For example, the lamination may be carried out by physical lamination using pressure or by chemical lamination using an adhesive or hot melt.

[0088] Specifically, when a hot melt is used in the lamination, the lamination may be performed at a temperature of 130° C. to 170° C. More specifically, the lamination using the hot melt may be performed at a temperature of 130° C. to 170° C., 140° C. to 160° C., or 150° C. to 170° C.

[0089] When the hot melt is used, the amount of hot melt used is 1 g / m 2 ~10g / m 2 , 2g / m 2 ~10g / m 2 , or 3 g / m 2 From 8g / m 2 When the hot melt is used in the above range, the adhesive strength can be improved. As the hot melt, for example, an acrylic-based, polyolefin-based, polyester-based, polyamide-based, polyurethane-based, etc. may be used.

[0090] The filter medium is then folded, which increases the filtering area, reduces pressure loss, and strengthens the structure, thereby improving the durability and lifespan of the filter.

[0091] 2, the filter medium 100 may be folded into a pleated shape using a rotary corrugator or the like. For example, the pleated shape may be a structure in which pleats are formed by bending. The pleated shape may be various, such as a zigzag angled bend or a rounded bend, and the shape and size of the pleats are not particularly limited.

[0092] The pleats may have a peak height of 10 mm to 60 mm. Here, the peak height may refer to the amplitude of the pleats, i.e., the distance between the peak and the valley. The distance between the peaks may be 2 mm to 8 mm.

[0093] air purifier The present invention provides an air purifier including the air cleaning filter described above.

[0094] As an example, the air purifier includes an inlet for drawing in polluted air, an outlet for discharging purified air, and a filter unit disposed between the inlet and the outlet, and the filter unit includes the air purification filter described above.

[0095] Specifically, the air purifier may have an intake port at the front for drawing in indoor air, an outlet port at the top for discharging purified air, and a filter unit including the air purification filter inside.

[0096] The air purifier may also include a blower fan that draws in indoor air by rotating force and discharges the purified air back into the room. The blower fan may draw air through an inlet at the front and discharge it through an outlet at the top. The outlet may be provided with a dense lattice-shaped outlet grille, which can prevent injury to the user's body from the rotating blower fan.

[0097] The filter unit may further include an additional filter in addition to the air cleaning filter. For example, the filter unit may further include a pre-filter made of an antibacterial material for removing relatively large dust particles, mold, hair, pet hair, etc., and / or a dehumidifying filter having a large number of pores for removing moisture from the air. [Example]

[0098] Examples of the present invention will be described below, but the feasible scope of the present invention is not limited to these examples.

[0099] Example 1: Manufacture of air cleaning filter (composite filter) (1) Manufacturing of dust-collecting filter layers Made of polypropylene (PP) resin, meltblown to a basis weight of approximately 27 g / m 2 The first nonwoven fabric was produced.

[0100] (2) Manufacturing of deodorizing filter layers Made of polyethylene terephthalate (PET) resin, spunbonded to a basis weight of approximately 55 g / m 2 A second nonwoven fabric was produced. A dispersion was prepared by mixing 100 parts by weight of coconut shell activated carbon having an average particle size of approximately 200 mesh, 40 parts by weight of a binder (acrylic polyol resin), and 400 parts by weight of a solvent (purified water). The second nonwoven fabric was immersed in the dispersion for 10 seconds, then removed and dried at a temperature of 60°C for 10 minutes. As a result, the second nonwoven fabric was coated with coconut shell activated carbon at a concentration of approximately 35 g / m. 2 A deodorizing filter layer coated with the amount of

[0101] (3) Manufacturing of functional filter layers Made of polyethylene terephthalate (PET) resin, spunbonded to a basis weight of approximately 55 g / m 2 Two sheets of the third nonwoven fabric were produced.

[0102] A functional filter layer A was produced by coating phosphoric acid onto one third nonwoven fabric in an amount of about 11% by weight.

[0103] The remaining third nonwoven fabric was coated with ethylene urea (2-imidazolidone) in an amount of about 17% by weight to prepare a functional filter layer B.

[0104] (4) Lamination The functional filter layer A, deodorizing filter layer, dust-collecting filter layer, and functional filter layer B were arranged from the bottom up with the coated surface facing upward, and laminated at 150°C using a polyolefin hot melt to obtain a filter medium.

[0105] (5) Bending The filter medium was pleated using a rotary corrugator (DBWP-W700, DoubleWin) to a pleat peak height of 25 mm and a pleat spacing of approximately 3.5 mm. After pleating, the filter medium was insert-molded into an ABS housing using a molding machine (Filter Assy M / C, DoubleWin) to produce an air cleaning filter.

[0106] Comparative Example 1 A dust-collecting filter layer was manufactured by repeating step (1) of Example 1. Also, a deodorizing filter layer containing pellet-shaped activated carbon particles in a mesh was manufactured. The dust-collecting filter layer and the deodorizing filter layer were simply combined to manufacture an air purifying filter.

[0107] Example 2 The procedure of Example 1 was repeated, but without carrying out the production of the functional filter layer in step (3), to produce an air cleaning filter in which a deodorizing filter layer and a dust-collecting filter layer were laminated.

[0108] Test Example 1: Gas Removal Test The gas removal test was carried out using the air purification filter of Example 1, in accordance with KACA002 132:2018, at a temperature of 25°C, humidity of 50%, and a chamber size of 8m. 3 The test was carried out under the condition that the initial concentration of the target gas was 10 ppm.

[0109] The results are shown in Figure 7. As shown in Figure 7, the air cleaning filter of Example 1 showed removal rates of 90% or more for formaldehyde, toluene, and ammonia gas after 30 minutes, and in particular showed the highest removal rate of 99.9% for ammonia gas after 30 minutes.

[0110] Test Example 2: Deodorization endurance test The durability test was carried out using the air cleaning filter of Example 1 under test conditions in accordance with JEM1467:2009.

[0111] The results are shown in Figure 8. As shown in Figure 8, the air cleaning filter of Example 1 showed a gradual decrease in the removal efficiency of formaldehyde, toluene, and ammonia gas as the number of cigarettes increased, and in particular, the removal efficiency for ammonia gas showed almost no decrease, and it was evaluated as having the best deodorizing durability.

[0112] Test example 3: Dust collection efficiency test The dust collection efficiency test was carried out using the air cleaning filter of Example 1 in accordance with 42 CFR part 84 using NaCl particles.

[0113] The results are shown in Figure 9. As shown in Figure 9, the air cleaning filter of Example 1 exhibited an extremely high dust collection efficiency of 99.98%.

[0114] Test Example 4: Changes in Contaminant Concentration The pollutant concentration change test was carried out using the air purifying filter of Example 1 in accordance with KACA002 132:2018.

[0115] The results are shown in Figure 10. As shown in Figure 10, the air cleaning filter of Example 1 showed a decrease in the KCl concentration (m 3 / min) was decreased exponentially and linearly.

[0116] Test example 5: Filter differential pressure test Using a Topas PAF-113 cabin filter test system, the differential pressure was measured while supplying ISO A2 dust at a flow rate varying from 0.5 m / s to 1.25 m / s. The results of the differential pressure measurement of the filter as a function of the dust supply amount are shown in Figure 11.

[0117] As shown in Figure 11, the air purifying filter of the present invention, which is a laminate of a deodorizing filter layer thinly coated with fine activated carbon particles and a dust-collecting filter layer, exhibited a lower differential pressure than the conventional air purifying filter, which is a simple combination of a deodorizing filter layer using pelletized activated carbon particles and a dust-collecting filter layer. Specifically, the filter of Example 2 exhibited a differential pressure that was approximately 1 mmaq (approximately 9.8 Pa) lower than the filter of Comparative Example 1 when 50 g of dust was supplied at a flow rate of 1 m / s.

Claims

1. An air purifying filter including a folded filter medium, The filter medium is a dust-collecting filter layer including a first nonwoven fabric; A second nonwoven fabric and activated carbon particles having a particle size smaller than 150 mesh attached to the second nonwoven fabric are mixed at 10 g / m ２ ~60g / m ２ a deodorizing filter layer containing the compound in an amount of a functional filter layer comprising a third nonwoven fabric and one or more gas adsorbents; the dust-collecting filter layer, the deodorizing filter layer, and the functional filter layer are physically or chemically laminated together; The second nonwoven fabric has a density of 30 g / m ２ ~80g / m ２ having a basis weight of Air purifying filter.

2. The first nonwoven fabric has a density of 20 g / m ２ ~35g / m ２ It is a meltblown type nonwoven fabric having a basis weight of The third nonwoven fabric has a density of 30 g / m ２ ~80g / m ２ and 2. The air cleaning filter according to claim 1, wherein the second nonwoven fabric and the third nonwoven fabric are spunbond or thermal bond type nonwoven fabrics.

3. the functional filter layer removes one or more gases selected from the group consisting of ammonia, aldehydes, acetic acid, toluene, and terpenes; 2. The air cleaning filter according to claim 1, wherein the gas adsorbent comprises at least one selected from the group consisting of organic acids, inorganic acids, urea, silica, zeolites, and metal catalysts.

4. The functional filter layer is 2. The air cleaning filter according to claim 1, comprising one or more of 2% by weight to 20% by weight of phosphoric acid for removing ammonia and 5% by weight to 30% by weight of ethylene urea for removing aldehydes.

5. the deodorizing filter layer and the dust-collecting filter layer are stacked adjacent to each other, The air cleaning filter according to claim 1 , wherein the functional filter layer is laminated on the deodorizing filter layer or the dust-collecting filter layer.

6. The air cleaning filter is used in an air purifier, The air cleaning filter according to claim 5, wherein the filter is adapted so that air flows in from the deodorizing filter layer and flows out to the dust-collecting filter layer.

7. The filter medium further comprises a metal catalyst layer; The air cleaning filter according to claim 1 , wherein the metal catalyst layer comprises a fourth nonwoven fabric and a metal catalyst.

8. The air cleaning filter according to claim 7 , wherein the filter medium is formed by sequentially stacking the functional filter layer, the deodorizing filter layer, the dust-collecting filter layer, and the metal catalyst layer.

9. The air purifying filter was placed in a chamber with a temperature of 25°C, humidity of 50%, and a size of 8m ３ When the gas removal test was carried out for 30 minutes under the condition of an initial concentration of the target gas of 10 ppm, The removal rate for formaldehyde, toluene, and ammonia is over 90%. The air cleaning filter according to claim 1.

10. An air cleaning filter comprising a nonwoven fabric and activated carbon particles bound to the nonwoven fabric with a binder, The nonwoven fabric has a density of 30 g / m ２ ~80g / m ２ A spunbond or thermal bond type nonwoven fabric having a basis weight of The activated carbon particles have a particle size smaller than 150 mesh and a density of 10 g / m ２ ~60g / m ２ Contains in the amount of The binder is included in an amount of 20 to 50 parts by weight based on 100 parts by weight of the activated carbon particles, The particle size of the activated carbon particles is 250 mesh or more. Air purifying filter.

11. The air cleaning filter according to claim 10, wherein the air cleaning filter has a differential pressure of 60 Pa to 100 Pa when a dust supply amount of 50 g is supplied at a flow rate of 1 m / s.

12. An air purifier comprising the air cleaning filter according to any one of claims 1 to 11.

13. Producing a dust-collecting filter layer comprising a first nonwoven fabric; Activated carbon particles having a particle size smaller than 150 mesh were applied to the second nonwoven fabric at a rate of 10 g / m ２ ~60g / m ２ to prepare a deodorizing filter layer; preparing a functional filter layer comprising a third nonwoven fabric and one or more gas adsorbents; a step of physically or chemically laminating the dust-collecting filter layer, the deodorizing filter layer, and the functional filter layer to manufacture a filter medium; folding the filter medium; The second nonwoven fabric has a density of 30 g / m ２ ~80g / m ２ A method for producing an air cleaning filter having a basis weight of 1000 g / m².

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