Nano-mesh net for blocking fine dust, and manufacturing method thereof

Abstract

A nano insect screen for blocking fine dust and a method for manufacturing the same are provided. A nano insect screen according to one embodiment of the present invention comprises the steps of: preparing a raw material by mixing a masterbatch containing a UV stabilizer with a polymer resin; and preparing a nanofilament by melt-spinning the raw material. The method may include the steps of: weaving the nanofilaments to produce a mesh with a mesh size of 90 mesh or more and 110 mesh or less; applying a coating solution containing SiO2, a silicate binder, and PGME to the mesh; and applying a waterproof coating solution by spray coating to the surface of the heat-treated mesh.

Description

Technology Field

[0001] The present invention relates to a nano insect screen for blocking fine dust and a method for manufacturing the same, and more specifically, to a nano insect screen that simultaneously achieves excellent breathability and visibility while having a fine dust blocking effect, and a method for manufacturing the same. Background Technology

[0003] Recently, as environmental pollution caused by various particulate harmful substances such as fine dust, pollen, yellow dust, and dust has become increasingly serious, the demand for insect screens capable of effectively blocking these substances from entering indoors is rising. Since not only these external incoming substances but also various fine dust and airborne particles generated indoors can have adverse effects on health, there is a growing requirement for insect screens to go beyond simple pest blocking functions and incorporate air purification capabilities.

[0004] Conventional fine dust-blocking insect screens are primarily manufactured in a filter-like form to block fine particles, offering the advantage of securing a certain level of capture performance. However, as the capture rate of these filter-type screens increases, air resistance grows, resulting in very low breathability and hindering smooth indoor air circulation.

[0005] Furthermore, due to the filter's structure, fine dust easily adheres to and accumulates, making it prone to clogging, which makes maintenance difficult and cleaning impossible. This also reduces visibility, posing a problem that lowers the comfort of the usage environment.

[0006] Accordingly, there is a growing need for insect screen technology that possesses not only fine dust blocking performance but also breathability, visibility, and ease of maintenance. The problem to be solved

[0008] The technical problem to be solved by the present invention is to provide a nano-insect screen for blocking fine dust and a method for manufacturing the same, which effectively blocks harmful particles such as fine dust while maintaining breathability, thereby ensuring smooth indoor air circulation.

[0009] Another technical problem to be solved by the present invention is to provide a nano-insect screen that improves the problem of reduced visibility by optimizing the structure and material of the insect screen and does not obstruct the view from inside and outside, as well as a method for manufacturing the same.

[0010] Another technical problem to be solved by the present invention is to provide a high-performance insect screen capable of long-term use and a method for manufacturing the same by improving the durability, ease of cleaning, and UV resistance of the product by imparting functions such as UV blocking, anti-fouling, and water-repellent properties.

[0011] The technical problems of the present invention are not limited to those mentioned above, and other unmentioned technical problems will be clearly understood by a person skilled in the art from the description below. means of solving the problem

[0013] A method for manufacturing a nano insect screen according to embodiments of the present invention to solve the above technical problem may include the steps of: preparing a raw material by mixing a masterbatch containing a UV stabilizer with a polymer resin; preparing a nanofilament by melt-spinning the raw material; weaving the nanofilament to produce a mesh with a size of 90 mesh or more and 110 mesh or less; applying a coating solution containing SiO2, a silicate binder, and PGME to the mesh; feeding the mesh coated with the coating solution into a tenter machine to heat-treat the mesh; and applying a waterproof coating solution to the surface of the heat-treated mesh by spray coating.

[0014] In one embodiment, the coating solution may comprise 1.15% by weight of the SiO2 based on solid content, 1.15% by weight of the Silicate binder based on solid content, and 97.7% by weight of the PGME based on solid content, relative to the total weight of the composition.

[0015] In one embodiment, the polymer resin may include at least one of polyvinylidene fluoride (PVDF), polyamide (PA), and polyester (PET).

[0016] As one embodiment, the waterproof coating liquid may include at least one of silicone-based, fluorine-based, and fluorine-based polymers.

[0017] As one embodiment, the step of heat-treating the mesh may include a first heat treatment step of heat-treating the mesh at a temperature of 90°C or higher and 110°C or lower for 5 minutes or more and 10 minutes or less, and a second heat treatment step of heat-treating the mesh that has undergone the first heat treatment at a temperature of 140°C or higher and 180°C or lower for 1 minute or more and 3 minutes or less.

[0018] A nano insect screen according to embodiments of the present invention for solving the above technical problem can be manufactured by any one of the manufacturing methods described above.

[0019] A nano insect screen according to embodiments of the present invention for solving the above technical problem comprises a frame and a nano insect screen fixed to the frame; and the nano insect screen may be manufactured by a method comprising the steps of: preparing a raw material by mixing a masterbatch with a polymer resin; preparing a nanofilament by melt-spinning the raw material; preparing a mesh by weaving the nanofilament; applying a coating solution to the mesh; and heat-treating the mesh coated with the coating solution. Effects of the invention

[0021] When the nano insect screen for blocking fine dust according to the present invention described above is applied, particulate harmful substances such as fine dust, yellow dust, pollen, and dust are effectively captured, and at the same time, through the weaving density of the mesh and the structural characteristics of the nanofiber, an air permeability of 10,000 m³ / m² / h or more is secured, thereby enabling smooth indoor air circulation.

[0022] In addition, by applying a weaving density of 100 mesh and a nanofiber structure, the problem of reduced visibility in existing filter-type insect screen products can be improved, and transparency and a sense of openness can be provided without obstructing the view of the inside and outside.

[0023] In addition, by applying a UV stabilizer with UV blocking effects and a coating agent with water and stain repellency, a UV blocking rate of 45% or more, a rainwater blocking rate of 90%, and a lightfastness LEVER 4 are secured, thereby enabling the realization of a high-performance insect screen that is resistant to external environments, easy to clean, and usable for a long period of time. Brief explanation of the drawing

[0025] FIG. 1 is a drawing showing a nano insect screen with a nano insect screen applied thereto according to one embodiment of the present invention. FIG. 2 is a flowchart illustrating a method for manufacturing a nano insect screen according to one embodiment of the present invention. FIG. 3 is a flowchart illustrating an embodiment that further specifies step S500 of FIG. 2. Specific details for implementing the invention

[0026] Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings. The advantages and features of the present invention, and the methods for achieving them, will become clear by referring to the embodiments described below in detail together with the attached drawings. It should be noted that in assigning reference numerals to the components of each drawing, the same components are given the same reference numeral whenever possible, even if they are shown in different drawings. Furthermore, in describing the present invention, if it is determined that a detailed description of related known components or functions may obscure the essence of the present invention, such detailed description is omitted.

[0027] Unless otherwise defined, all terms used herein (including technical and scientific terms) may be used in a meaning commonly understood by those skilled in the art to which the present invention pertains. Furthermore, terms defined in commonly used dictionaries are not to be interpreted ideally or excessively unless explicitly and specifically defined otherwise. The terms used herein are for describing embodiments and are not intended to limit the present invention. In this specification, the singular form includes the plural form unless specifically stated otherwise in the text.

[0028] In addition, terms such as first, second, A, B, (a), (b), etc., may be used when describing the components of the present invention. These terms are intended merely to distinguish the components from other components, and the essence, order, or sequence of the components is not limited by these terms. Where it is stated that a component is “connected,” “combined,” or “joined” to another component, it should be understood that the component may be directly connected or joined to the other component, but that another component may also be “connected,” “combined,” or “joined” between each component.

[0029] Hereinafter, a nano insect screen and a method for manufacturing the same, according to some embodiments of the present invention, will be described.

[0030] FIG. 1 is a drawing showing a nano insect screen according to one embodiment of the present invention. Referring to FIG. 1 (a), the nano insect screen (100) may be composed of a frame (110) and a nano insect screen (120).

[0031] The frame (110) is formed to the same dimensions as the window and can be attached to the window frame, and can be configured to be sliding as needed. The frame (110) is formed to allow the nano insect screen (120) to be mounted, and may have a structure that supports the nano insect screen (120) with a constant tension to maintain it stably without sagging. Additionally, the frame (110) may be formed from materials such as aluminum, PVC, and plastic.

[0032] The specifications of the frame (110) may vary depending on the specifications of the window, and the specifications of windows having various specifications may be applied to the specifications of the frame (110) according to the present invention, and the frame (110) of the present invention is not limited by the specifications of the window.

[0033] The nano insect screen (120) is cut to a size that fits the specifications of the frame (110) and is fixed to the inside of the frame (110) by fitting, pressing, or using a separate fixing member. The nano insect screen (120) can effectively capture particulate harmful substances such as fine dust, pollen, and yellow dust, block the entry of pests into the indoor space, and prevent rainwater penetration while blocking ultraviolet rays, thereby maintaining a pleasant indoor environment.

[0034] According to the configuration of the present invention illustrated in FIG. 1, a nano insect screen (100) is provided in which a nano insect screen (120) for blocking fine dust is detachably attached to a frame (110). According to this, it is easy to replace and install the nano insect screen (120) using an existing insect screen frame, and while maintaining the function of preventing existing pests like an existing insect screen, it additionally effectively captures particulate harmful substances such as fine dust, pollen, and yellow dust, has excellent breathability, blocks ultraviolet rays from entering the room, and prevents rainwater from penetrating the room even when the window is left open on rainy days.

[0035] Referring to FIG. 1(b), FIG. 1(b) is an enlarged image of a portion of the nano insect screen (120), showing that the nano insect screen (120) of the present invention is formed with a woven structure. While conventional filter-type fine dust insect screens have a non-woven structure such as non-woven fabric, which has a problem of reduced breathability, the present invention applies a woven structure to ensure both breathability and visibility simultaneously.

[0036] In addition, a water-repellent coating is applied to the surface of the nano insect screen (120), so the water-repellent properties of the nano insect screen (120) can be confirmed through the phenomenon where water does not seep into the insect screen but forms water droplets on the surface. This water-repellent property causes water to bounce off the surface of the nano insect screen (120), preventing rainwater or moisture from being absorbed into the insect screen. As a result, it is possible to prevent rainwater from entering the interior even if the window is left open during rain.

[0037] FIG. 2 is a flowchart illustrating a method for manufacturing a nano insect screen according to one embodiment of the present invention.

[0038] In step S100, a masterbatch containing a UV stabilizer is mixed with a polymer resin to prepare the raw material.

[0039] A masterbatch is a highly concentrated mixture of additives used to add colors or functional additives to raw materials such as plastics or fibers. By mixing this masterbatch with raw materials such as resins or yarns in a specific ratio, desired functions can be efficiently imparted to the final product. In the present invention, the masterbatch may include a UV stabilizer to protect the nano insect screen (120) from deterioration caused by ultraviolet rays. Accordingly, physical damage such as discoloration, reduced strength, and cracking of the nano insect screen (120) is mitigated, allowing for long-term use and improving durability.

[0040] As one example, the polymer resin may include at least one of polyvinylidene fluoride (PVDF), polyamide (PA), and polyester (PET).

[0041] In one embodiment, the masterbatch may further include a flame retardant, thereby enabling the nano-insect screen (120) to suppress flame propagation or slow down the combustion speed when a fire occurs.

[0042] As one embodiment, a raw material can be prepared by mixing a masterbatch and a polymer resin in a predetermined ratio, for example, it may consist of 5% by weight of the masterbatch and 95% by weight of the polymer resin.

[0043] In step S200, the above raw material is melt-spun to produce a nanofilament.

[0044] In one embodiment, the raw material may be extruded under high pressure within a melt spinning device heated to a temperature of 220°C or higher and 290°C or lower to form a nanofilament. The melt-spun nanofilament is rapidly cooled through a cooling roller or an air cooling device and may be wound at a speed of 500 to 3000 m / min.

[0045] As one embodiment, the diameter of the nanofilament may have a range of 100 nm or more and 1000 nm or less.

[0046] In step S300, the nanofilament is woven to produce a mesh with a mesh size of 90 or more and 110 or less.

[0047] In one embodiment, the nanofilament is woven in a plain weave manner, and as a basic weaving structure in which warp threads and weft threads intersect in a 1:1 ratio, excellent durability and breathability can be provided through the weaving structure. The nanofilaments in the warp and weft directions are arranged with uniform tension to form a weaving density of 100 mesh, in which 100 threads are arranged per inch. This allows for the simultaneous provision of a high fine dust blocking effect and smooth airflow.

[0048] In step S400, a coating solution is applied to the above mesh.

[0049] In the present invention, the coating solution is composed of a composition including SiO2, a silicate binder, and PGME.

[0050] SiO2 is a nano-sized inorganic particle that is uniformly dispersed on the mesh surface to improve surface hardness and wear resistance, and to provide a UV blocking effect. Additionally, it can impart antifouling and self-cleaning effects, thereby suppressing the adhesion of external dust or contaminants to the mesh surface and facilitating the cleaning of flying debris or natural cleaning. This is because the SiO2 particles form a fine uneven structure on the mesh surface, contributing to the reduction of contaminant adhesion; for this purpose, the present invention includes a predetermined amount of SiO2 in the coating solution.

[0051] The silicate binder serves to firmly fix SiO2 particles to the surface of the mesh, thereby improving the dispersion stability of the SiO2 particles within the coating solution. Additionally, the silicate binder imparts durability, such as water resistance and heat resistance, which can increase resistance to the external environment. Accordingly, in the present invention, a coating solution is prepared by adding a silicate binder together with SiO2.

[0052] PGME acts as a solvent for the coating solution and can disperse SiO2 and silicate binders. Since PGME has low viscosity, it improves the applicability of the coating solution and enables the formation of a thin, uniform film without filling the pores of the insect screen. As a result, the breathability and visibility of the screen are maintained without degradation even after coating.

[0053] In one embodiment, the coating solution may comprise 1.15% by weight of the SiO2 based on solid content, 1.15% by weight of the Silicate binder based on solid content, and 97.7% by weight of the PGME based on solid content, relative to the total weight of the composition. According to such a formulation ratio, the SiO2 and Silicate binder constitute a substantial functional material that remains on the mesh surface after coating as solid components, and the PGME evaporates after application.

[0054] The purpose of keeping the weight ratio of SiO2 and Silicate binder low is to prevent the pores of the insect screen from being blocked during the coating process. In other words, since the total solid content of the coating solution composition is low, a thin coating layer can be formed without blocking the pores of the screen during coating, thereby maintaining excellent visibility and high air permeability. To this end, it is desirable that the combined weight ratio of SiO2 and Silicate binder does not exceed 5%.

[0055] However, if the weight ratio of SiO2 and Silicate binder is too low, there is a concern that the effects on durability and antifouling properties will be too low. Therefore, it is desirable for SiO2 and Silicate binder to each have a weight ratio of at least 1 weight%, and in particular, the best test results were obtained when the mixing ratio between the two was 1:1.

[0056] Through this process, the present invention finally determined the formulation ratio of the coating solution to include 1.15 wt% of the SiO2 based on solid content, 1.15 wt% of the Silicate binder based on solid content, and 97.7 wt% of the PGME.

[0057] As one embodiment, the method of applying the coating solution to the mesh may include dip coating, spray coating, and roll coating. Additionally, after applying the coating solution to the mesh, the method may further include a process of passing the mesh between compression rollers to uniformly remove excess coating solution remaining on the mesh surface.

[0058] This allows for precise control of the coating layer thickness and prevents the mesh pores from becoming clogged by the coating solution, thereby minimizing the degradation of visibility and breathability.

[0059] In step S500, the mesh coated with the above coating solution is fed into a tenter machine to perform heat treatment.

[0060] By performing heat treatment on the mesh coated with the above coating solution, the quality of the coating layer can be stably secured while preventing thermal deformation of the mesh and preserving the pore structure, thereby effectively maintaining air permeability and visibility.

[0061] As an example, the heat treatment can be carried out in two stages. By dividing the heat treatment process into two stages in this way, the coating solution can be fixed more stably to the insect screen.

[0062] Refer to FIG. 3 for a clearer understanding of this. FIG. 3 is a flowchart illustrating an embodiment that embodies step S500 of FIG. 2. The embodiment of FIG. 3 illustrates a specific method for performing heat treatment on a mesh coated with the coating solution.

[0063] First, in step S510, a first heat treatment is performed. In the first heat treatment step, the first heat treatment can be performed at a temperature of 90°C or higher and 110°C or lower for 5 minutes or more and 10 minutes or less.

[0064] In the first heat treatment step, solvents such as PGME in the coating solution are evaporated so that only SiO2 and Silicate binder remain on the mesh surface, thereby enabling drying and initial curing.

[0065] Next, in step S520, a second heat treatment is performed. In the second heat treatment step, the second heat treatment can be performed at a temperature of 140°C or higher and 180°C or lower for 1 minute or more and 3 minutes or less.

[0066] In the second heat treatment step, the remaining SiO2 and Silicate binder adhere more strongly to the surface of the mesh, imparting properties such as hardness, heat resistance, and water resistance. In particular, the reaction in which the Silicate binder stably binds SiO2 particles to the mesh surface is promoted, thereby maximizing the durability and functionality of the coating.

[0067] Returning to Fig. 2, in step S600, a waterproof coating solution is applied to the surface of the heat-treated mesh by spray coating.

[0068] Waterproof coatings protect the mesh from rainwater and moisture by converting the hydrophilic surface of the mesh into a hydrophobic one, causing water to repel rather than seep into the mesh. This coating prevents water droplets from forming on the mesh surface and improves stain resistance, allowing dust and contaminants to be easily washed away. As a result, it can block over 90% of rainwater, effectively suppressing water ingress into the interior even when windows are left open during rain and preventing mold growth caused by humidity.

[0069] In one embodiment, the waterproof coating solution may include at least one of silicone-based, fluorine-based, and fluorine-based polymers, and these polymers provide excellent water and oil repellency due to their low surface energy. In particular, the fluorine-based polymer also possesses UV resistance, which can suppress the deterioration and discoloration of the coating layer caused by UV exposure.

[0070] In one embodiment, after applying the waterproof coating solution to the mesh, it can be dried by natural drying, hot air drying, infrared drying, and low-temperature drying using a tenter machine. This drying process can be advantageous for forming a uniform coating layer, thereby increasing the adhesion and durability of the coating film.

[0071] Although embodiments of the present invention have been described above with reference to the attached drawings, those skilled in the art will understand that the present invention may be implemented in other specific forms without changing the technical concept or essential features thereof. Therefore, the embodiments described above should be understood as illustrative in all respects and not restrictive. The scope of protection of the present invention shall be interpreted by the claims below, and all technical concepts within the equivalent scope shall be interpreted as being included within the scope of rights of the technical concept defined by the present invention. Explanation of the symbols

[0073] 100: Nano insect screen 110: Frame 120: Nano insect screen

Claims

Claim 1 A method for manufacturing a nano insect screen comprises the steps of: preparing a raw material by mixing a masterbatch containing a UV stabilizer with a polymer resin; preparing a nanofilament by melt-spinning the raw material; weaving the nanofilament to produce a mesh with a mesh size of 90 mesh or more and 110 mesh or less; applying a coating solution containing SiO2, a silicate binder, and PGME to the mesh; feeding the mesh coated with the coating solution into a tenter machine to heat-treat the mesh; and applying a waterproof coating solution by spray coating to the surface of the heat-treated mesh, wherein the coating solution comprises 1.15 weight% of the SiO2 based on solid content, 1.15 weight% of the silicate binder based on solid content, and 97.7 weight% of the PGME based on solid content, relative to the total weight of the composition. Claim 2 delete Claim 3 A method for manufacturing a nano insect screen according to claim 1, wherein the polymer resin comprises at least one of polyvinylidene fluoride (PVDF), polyamide (PA), and polyester (PET). Claim 4 A method for manufacturing a nano insect screen according to claim 1, wherein the waterproof coating liquid comprises at least one of a silicone-based, a fluorine-based, and a fluorine-based polymer. Claim 5 A method for manufacturing a nano insect screen according to claim 1, wherein the step of heat-treating the mesh comprises: a first heat treatment step of heat-treating the mesh at a temperature of 90°C or higher and 110°C or lower for 5 minutes or more and 10 minutes or less; and a second heat treatment step of heat-treating the mesh heat-treated in the first step at a temperature of 140°C or higher and 180°C or lower for 1 minute or more and 3 minutes or less. Claim 6 Nano insect screen manufactured by the manufacturing method described in claim 1. Claim 7 A nano insect screen comprising: a frame; and a nano insect screen fixed to the frame; wherein the nano insect screen is manufactured by a method comprising: a step of preparing a raw material by mixing a masterbatch containing a UV stabilizer with a polymer resin; a step of preparing a nanofilament by melt-spinning the raw material; a step of preparing a mesh having a size of 90 mesh or more and 110 mesh or less by weaving the nanofilament; a step of applying a coating solution containing SiO2, a silicate binder, and PGME to the mesh; a step of feeding the mesh coated with the coating solution into a tenter machine to heat-treat the mesh; and a step of applying a waterproof coating solution by spray coating to the surface of the heat-treated mesh, wherein the coating solution comprises 1.15 weight% of the SiO2 based on solid content, 1.15 weight% of the silicate binder based on solid content, and 97.7 weight% of the PGME based on solid content, relative to the total weight of the composition.

Images