JP2002028417A - Deodorizing filter medium - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a deodorizing filter medium having neither structural problems such as interlayer exfoliation nor problems in productivity and exhibiting the deodorizing performance more excellent than that of the filter medium obtained by using a polyurethane base material because of the laminar effect equal to that of the filter medium having a honeycomb structure. SOLUTION: This deodorizing filter medium is obtained by arranging a pair of two-dimensional netted skeletons 2, 2 at the prescribed intervals in parallel with each other, connecting the skeletons 2, 2 to each other with innumerable connecting threads 3 to obtain a three-dimensional fiber skeleton 1 and sticking a deodorizing agent to the skeleton 1.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a filter for removing trace gas components for a clean room, an air purifier, an air conditioner, a filter for ventilation and air conditioning, an air purifying filter (cabin filter) for introducing outside air into a vehicle cabin, Further, the present invention relates to a deodorizing filter material suitably used for a filter for removing impurities from the outside air when supplying oxygen for a fuel cell.

Conventionally, various deodorizing filters such as a filter for removing a trace gas component for a clean room, an air purifier, an air conditioner, a filter for ventilation and air conditioning, and an air purifying filter (cabin filter) for introducing outside air into a vehicle cabin have been used. For example, fuel cells that have been used and have attracted attention recently require a filter for removing impurities from the outside air when supplying oxygen to the cell, and the use of the deodorizing filter is expanding. In addition,
The deodorizing filter mentioned here does not necessarily remove only the odor component, but includes a filter that collects and removes a gas component other than the odor component.

[0003] Conventionally, various filter materials have been proposed and implemented in accordance with the intended use of such a deodorizing filter, but all of them have a deodorizing agent attached to a gas-permeable base material. It is a target. In this case, as the air-permeable base material, a honeycomb structure having paper or aluminum foil as a base material, various resin nets, and a polyurethane foam having a three-dimensional network skeleton are used. A deodorizing filter material is formed by attaching a deodorizing agent to the skeleton.

[0004]

However, a filter using a honeycomb structure base material based on paper or aluminum foil has the advantage that the pressure loss is low due to the laminar flow effect of the honeycomb structure. It is necessary to coat a flat base material with a deodorant in advance and to corrugate it, and then to laminate and cut the cross section. Therefore, there is a problem that the deodorant cannot be sufficiently adhered. In addition, the honeycomb eyes are liable to be crushed during the cutting, and there is a problem of delamination in the laminating direction.

Further, after the base material is processed into a honeycomb structure, the honeycomb structure may be impregnated with a deodorant slurry or a deodorant using a binder. It is possible,
In this case, the slurry obtained by kneading the deodorizer and the binder component, or the binder is dipped in the honeycomb substrate, and the honeycomb is crushed, the shape does not recover, or the roll impregnation method cannot be adopted, so that batch production is performed. There is a problem that productivity is poor. Here, as a filter having a honeycomb structure, a filter in which a slurry obtained by kneading an adsorbent (a deodorant) and a binder component is formed into a honeycomb shape by extrusion molding has been proposed, but this filter has a brittle characteristic. Therefore, there is a drawback that they are weak in impact and extremely inferior in handleability.

Further, when a polyurethane foam having a three-dimensional network skeleton is used as a base material, the cells are generally formed by chemical foaming to form a foamed body, so that it is difficult to control the cells, and the honeycomb structure is difficult. Since a large laminar flow effect cannot be obtained, there is a problem that the pressure loss to the honeycomb structure increases.

[0007] The present invention has been made in view of the above circumstances, and does not cause structural problems such as delamination, productivity problems, and problems such as strength. An object of the present invention is to provide a deodorizing filter capable of exhibiting excellent deodorizing performance superior to the case of using a polyurethane foam substrate by a laminar flow effect equivalent to that of the above.

[0008]

According to the present invention, in order to achieve the above object, a pair of two-dimensional network skeletons are arranged in parallel at a predetermined distance from each other, and an infinite number of connections are made between the pair of two-dimensional network skeletons. A deodorizing filter material characterized in that a deodorizing agent is attached to a three-dimensional fiber skeleton connected by a yarn.

That is, the deodorizing filter material of the present invention is a three-dimensional fiber skeleton in which a pair of two-dimensional network skeletons arranged in parallel at predetermined intervals are connected by an infinite number of connecting yarns, as a substrate to which a deodorant is attached. Is used. For this reason, the slurry or binder of the deodorant can be easily applied to the base material by dipping or the like, and can be manufactured with high productivity by continuous production, and causes structural problems such as delamination and crushing during cutting. It is possible to obtain a filter with a honeycomb-like structure that is excellent in productivity and strength without any problems, and it can exhibit excellent deodorization performance superior to that when using a polyurethane foam base material by good laminar flow effect. is there. In this case, in the present invention, the slurry of the adsorbent can be impregnated between the fibers of the three-dimensional fiber skeleton base material, and more deodorant can be attached,
The deodorizing performance can be improved as compared with the case where a conventional honeycomb structure is used.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in more detail. The deodorizing filter of the present invention, as described above,
The above-described special three-dimensional fiber skeleton is used as a base material, and a deodorant is attached to the skeleton. For example, as shown in FIG. 1, a pair of two-dimensional net skeletons 2 and 2 having a hexagonal net shape are formed. Are arranged in parallel at a predetermined distance from each other, and a three-dimensional fiber skeleton 1 in which the pair of two-dimensional network skeletons 2 and 2 are connected by countless connecting yarns 3 is used as a base, and a deodorant is attached to the base. Things.

The material of the fibers forming the three-dimensional fiber skeleton 1 is not particularly limited, and is appropriately selected depending on the use of the filter. Specifically, polyester fibers, polyamide fibers, polypropylene fibers, polyethylene fibers, acrylic fibers Synthetic fibers such as fibers are exemplified, and one or more of these can be used. In particular, viewpoints of workability in forming a three-dimensional fiber skeleton structure, deodorizing filter workability, filter durability, and the like. And polyester fibers, polyamide fibers, polypropylene fibers, or composite fibers using two or more of these.

The two-dimensional network skeletons 2 and 2 forming the three-dimensional fiber skeleton 1 may be made of one single fiber. In particular, a plurality of fibers are twisted to have a predetermined thickness. Fibers are preferably used, whereby the skeletons of the two-dimensional network skeletons 2 and 2 can be impregnated with a deodorant slurry described later to increase the amount of the deodorant attached.

The fiber diameter of the fibers constituting the skeletons of the two-dimensional network skeletons 2 and 2 is not particularly limited, but is usually 0.001 to 0.5 mm, particularly 0.01 to 0.1 mm.
Preferably, in this case, in the case of forming this skeleton with fibers obtained by twisting a plurality of fibers,
A skeleton having the above-mentioned fiber diameter can be formed by twisting about 10 to 100 fibers of 5 to 1000 denier, particularly 100 to 500 denier.

The two-dimensional net-like skeletons 2, 2 are formed in a net shape as shown in FIG. 1. The lattice shape of the two-dimensional net-like skeletons 2, 2 is triangular, quadrangular, pentagonal, hexagonal. Although any shape such as a polygon or the like may be used, it is particularly preferable to have a hexagonal lattice network structure as shown in FIG. 1, thereby forming a honeycomb-like filter. It is preferable from the viewpoints of shape stability at the time of processing and pressure loss when used as a filter effectively.

The lattice diameter of the two-dimensional network skeletons 2 and 2 is appropriately set according to the use of the filter and is not particularly limited, but is usually 1 to 15 mm, particularly preferably about 4 to 7 mm. If the lattice diameter is less than 1 mm, the pressure loss may increase depending on the application, and if it exceeds 15 mm, the contact efficiency between the gas component and the adsorbent (deodorant) decreases, and the gas removal performance decreases. May be.

The two-dimensional network skeletons 2 and 2 form the front and back portions of the filter, respectively. Usually, the fiber system, lattice shape, lattice diameter and the like of the two-dimensional network skeletons 2 and 2 are substantially the same. It is preferable that the two-dimensional net skeletons 2 and 2 have different shapes depending on the case. , 2 may have different shapes to improve the deodorization performance in some cases.

The two-dimensional network skeletons 2, 2 are arranged parallel to each other at a predetermined distance from each other and are connected by the connecting yarn 3. The distance between the two-dimensional network skeletons 2, 2 is determined by the thickness of the filter material. Becomes The interval between the two-dimensional net-like skeletons 2 and 2, that is, the thickness of the filter material is appropriately selected according to the use and the like, and is not particularly limited.
It is 30 mm, especially 5 to 20 mm.

Next, the connecting yarn 3 for connecting the two-dimensional net-like skeletons 2 and 2 may be a fiber made of a different material from the fibers constituting the two-dimensional net-like skeletons 2 and 2, but is usually the same. It is preferable that the fiber is made of the following material. The connecting yarns 3 are provided innumerably between the two-dimensional net-like skeletons 2 and 2. Even if these are independent fibers, one or a plurality of fibers are folded back to form the two-dimensional network. What bridge | crosslinked between the network skeletons 2 and 2 may be sufficient.

The fiber diameter of the connecting yarn 3 is appropriately selected depending on the material and the like, and is not particularly limited. However, it is usually preferably 5 to 1000 denier, particularly preferably 100 to 500 denier. If the fiber diameter of the connection yarn 3 is less than 5 denier, the connection strength between the two-dimensional network skeletons 2 and 2 may be insufficient, which may cause so-called “sagging” in the thickness direction. If the number exceeds 2, it may be difficult to reliably connect the two two-dimensional network skeletons 2 and 2, and it may be difficult to configure the three-dimensional fiber skeleton 1.

The deodorizing filter material of the present invention is obtained by adhering a deodorizing agent to a three-dimensional fiber skeleton 1 in which the pair of two-dimensional network skeletons 2 and 2 are connected by the connecting yarn 3.

The deodorant is not particularly limited and may be appropriately selected depending on the use of the filter. For example, various activated carbons such as coconut shell activated carbon, woody activated carbon, petroleum pitch-based spherical activated carbon, and pelletized activated carbon may be used. Activated clay, zeolite, sepiolite, silica, alumina, SiO ₂ , Z
Inorganic synthetic chemical deodorant based on nO, TiO _2, etc. as a raw material, TiO ₂ -based catalyst which generates catalytic activity by photoexcitation, Au, Ag, Ru, Rh, Rh, Pd, Pt,
Metal catalyst-carrying type deodorant carrying a noble metal or base metal catalyst such as Mn, Ni, Co, alkali metal, alkaline earth metal, etc. Targeted by using a chemical reaction such as neutralization reaction or dehydration condensation reaction on a porous body Deodorizers carrying compounds that chemically decompose and deodorize gas components, chelating resins, chelating compounds bonded to metal ions by coordination bonds, styrene-based resins and acrylic resins, etc. Exchange resin having a carboxylic acid group or a carboxylic acid group, anion exchange resin having a quaternary ammonium group or a primary to primary amino group, zeolite having a cation exchange function, Zr, Sn, Sb, Ti, Zn-based Cation-exchange type inorganic synthetic chemical adsorbent, or Bi, Zr, P
Inorganic synthetic chemical adsorbents of b type anion exchange type or inorganic ion adsorbents of inorganic type of both ion exchange type such as Sb, Bi type, SiO ₂ , ZnO and the like can be mentioned.

The method of attaching the deodorant to the three-dimensional fiber skeleton 1 is not particularly limited, and a known method can be employed. For example, the deodorant is kneaded with a binder component to prepare a slurry, A method of immersing and impregnating this in the three-dimensional fiber skeleton 1 or a method of immersing and impregnating only the binder component in the three-dimensional fiber skeleton 1 to form a binder layer in advance and attaching the deodorant thereto Further, a method in which a slurry obtained by kneading a binder component and a deodorant is impregnated into the three-dimensional fiber skeleton 1, and the same or another deodorant is further attached to the slurry before drying to dry the slurry is preferably adopted. You.

The binder for fixing the deodorizer to the three-dimensional fiber skeleton 1 includes a colloidal silica-based inorganic binder such as silica sol, water glass (a concentrated aqueous solution of sodium silicate), and the like. When the use temperature is relatively low, an acrylic, urethane-based, SBR-based, NBR-based, or chloroprene-based binder having tackiness and adhesiveness can also be used.

The deodorizing filter material of the present invention can be formed with a film having air permeability on one side, both sides or inside thereof as necessary. The film is not particularly limited. Fluororesin, polyamide resin, polyimide resin, polyester resin, polystyrene resin, polyolefin resin, polycarbonate resin, polysulfone resin, acrylic resin, cellulose resin, vinyl chloride resin, polyacetal resin, polyurethane resin, and copolymers thereof, and these Derivatives and the like,
One or more of these can be used. Further, among these, as the fluororesin, polytetrafluoroethylene, polyhexafluoride propylene, polydifluoroethylene, polyvinylidene fluoride, polyvinyl fluoride, and copolymers thereof, and the like, One or more kinds can be used.

The deodorizing filter material of the present invention is obtained by adhering the above-mentioned deodorizing agent to the above-mentioned three-dimensional fiber skeleton 1, and this filter material alone can exhibit good deodorizing performance. In addition, one or two or more kinds of other filter materials can be laminated and used. For example, a deodorizing filter layer based on a polyurethane foam having a three-dimensional network skeleton structure is laminated on the filter material of the present invention, or a dust collecting filter layer having a dust collecting function is laminated to add a dust collecting function together with a deodorizing function. be able to.

Here, the other filter layer to be laminated may be on one side or both sides of the filter material of the present invention, and the laminated state may be a clipped state even if the laminated state is an adhesive state using an adhesive or the like. Or a non-adhesive state using a frame-like filter connector may be used. In this case, when laminated in a non-adhered state using the above-described filter connector, the filter material can be easily separated for each structure, which can contribute to improvement in recyclability by regeneration or the like.

[0027]

EXAMPLES Hereinafter, the present invention will be described more specifically with reference to examples and comparative examples, but the present invention is not limited to the following examples. [Example] A 250-denier polyester fiber was twisted and twisted into a net-like fiber having an average thickness of 1 mm, which was knitted in a net shape, and was a hexagon having an average inner dimension of 5.5 mm in the major axis direction and 3.2 mm in the minor axis direction. A large number of lattices were formed to form a pair of two-dimensional network skeletons. This pair of two-dimensional mesh skeletons is 5 mm
The two two-dimensional network skeletons are arranged in parallel with a distance, and connected by a polyester monofilament of 150 denier.
A filter substrate made of a three-dimensional fiber skeleton having the same structure as in Example 1 was obtained.

On the other hand, a coconut shell active substance having an average particle size of 300 mesh was added to an acrylic binder "AE-932" (product having a solid content of 53%) manufactured by E-Tech Co., Ltd. at a solid content ratio of 1: 3.
After mixing and kneading to a ratio of 5, the solid content is 45%
Water was added so as to obtain a deodorant slurry. A substrate made of the above three-dimensional network skeleton is immersed in the slurry, the substrate is impregnated with the slurry, dried, and coconut shell activated carbon is attached thereto. The honeycomb-like structure deodorizing filter has an activated carbon attachment amount of 500 g / m ^2. I got

Comparative Example Polyurethane foam having a three-dimensional network skeleton [HR-0 manufactured by Bridgestone Corporation]
8 "] (8 mm thick), using the same deodorant slurry as in the example, coconut shell activated carbon was adhered in the same manner as in the example to obtain a 225 g / m ² deodorizing filter.

The deodorizing filters obtained in the above Examples and Comparative Examples were subjected to the following tests to evaluate the pressure loss and the benzene deodorizing performance. Table 1 shows the results. [Test Method] Pressure drop test A test piece (250 mm × 250 mm) is set as a sample in the tester shown in FIG. In this state, adjust the fan while checking the orifice differential pressure gauge (anemometer) to reduce the wind speed to 1
It is set to m / sec, and the pressure loss at this time is read by a differential pressure gauge. Benzene deodorization performance test Samples (5 mm thick) produced in the Examples and Comparative Examples were
The sample is cut to 0φ, and two of these samples are superimposed on each other and placed almost at the center of a glass column having a length of 200 mm and an inner diameter of 40φ shown in FIG. Using a standard gas generator manufactured by Gastech Co., Ltd., the gas generation temperature was set to 35 ° C., one diffusion tube D-03 was set, and a standard grade nitrogen cylinder was used as a diluting gas. Set the dilution gas flow rate to 1 L / min. As shown in FIG. 3, three-way cocks were attached to the upper and lower ends of the glass column, and when the inlet gas concentration became 30 ± 5 PPM, the gas was ventilated in the direction of the sample. The gas concentration and the benzene gas on the sample inlet side were measured using a gas detector tube No. Measure at 121 to evaluate the benzene removal rate.

[0031]

[Table 1]

As shown in Table 1, the deodorizing filter of the embodiment according to the present invention has a low pressure loss due to a laminar flow effect due to the honeycomb-like structure, and has excellent deodorizing performance because a large amount of activated carbon can be adhered. It was confirmed to have.

[0033]

As described above, the deodorizing filter material of the present invention does not cause structural problems such as delamination and productivity problems, and has the same layer thickness as that obtained when the above-mentioned honeycomb structured substrate is used. Due to the flow effect, excellent deodorizing performance can be exhibited, which is superior to the case where a polyurethane foam substrate is used.

[Brief description of the drawings]

FIG. 1 is a partially enlarged view showing an example of a three-dimensional fiber skeleton constituting a deodorizing filter of the present invention.

FIG. 2 is a schematic diagram showing a test machine used for a pressure loss test.

FIG. 3 is a schematic view showing a test device used for a deodorization performance test.

[Explanation of symbols]

 Reference Signs List 1 3D fiber skeleton 2 2D mesh skeleton 3 Connecting yarn

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) A61L 9/16 A61L 9/16 D B01D 39/14 B01D 39/14 B D06M 11/46 D06M 13/50 11 / 74 15/263 11/77 11/00 G 11/83 11/12 13/50 11/18 15/263 F term (reference) 4C080 AA05 AA07 BB02 CC01 HH05 HH09 JJ03 KK08 LL10 LL12 LL13 MM04 MM05 MM07 NN28 4D019 AA01 BA13 BA18 BB07 BB10 BC10 CA10 CB06 DA03 DA08 4L031 AA14 AA18 AA20 AB01 BA02 BA04 BA09 DA00 DA13 4L033 AA06 AA07 AA08 AB01 AC10 AC15 BA92 CA18 DA00 DA03

Claims (13)

[Claims] 1. A deodorant is attached to a three-dimensional fiber skeleton in which a pair of two-dimensional network skeletons are arranged parallel to each other at a predetermined distance from each other, and the pair of two-dimensional network skeletons are connected by countless connecting yarns. A deodorizing filter material characterized by comprising: 2. The deodorizing filter material according to claim 1, wherein said pair of two-dimensional network skeletons have substantially the same shape. 3. The deodorant filter material according to claim 1, wherein the three-dimensional fiber skeleton is formed of a polyester fiber, a polyamide fiber, a polypropylene fiber, or a composite fiber thereof. 4. The pair of two-dimensional network skeletons are formed by twisting two or more fibers, and one continuous yarn or a plurality of yarns are formed between the two-dimensional network skeletons innumerably. The deodorizing filter material according to any one of claims 1 to 3, wherein the connecting yarn is formed by bridging the connecting yarn. 5. The method according to claim 1, wherein a binder layer is previously formed on the three-dimensional fiber skeleton, and the deodorant is attached to the binder layer.
5. The deodorizing filter material according to any one of items 4 to 4. 6. The method according to claim 1, wherein a slurry obtained by kneading a binder component and a deodorant is impregnated into the three-dimensional fiber skeleton, dried and adhered to the deodorant.
A deodorizing filter material according to the item. 7. A slurry obtained by impregnating a slurry obtained by kneading a binder component and a deodorant into the three-dimensional fiber skeleton, further attaching a deodorant to the slurry, drying the slurry, and attaching the deodorant. The deodorizing filter material according to any one of claims 1 to 4. 8. The deodorizing filter material according to claim 1, wherein a film having air permeability is formed on any or all of the front surface, the back surface, and the inside. 9. The deodorant includes coconut shell activated carbon, woody activated carbon, petroleum pitch-based spherical activated carbon, pelletized activated carbon, natural zeolite, activated clay, surfactant, cation or anion exchange resin, cation or Target gas components utilizing chemical reactions such as neutralization reaction and dehydration condensation reaction on anion exchange fiber, chelate resin, chelate compound, inorganic cation or anion adsorbent, inorganic synthetic chemical deodorant, and porous material A deodorant loaded with a compound that chemically decomposes and deodorizes a metal, a deodorant loaded with an oxidation or reduction catalyst made of a noble metal or a base metal on a porous body, and a photoexcited catalyst such as titanium oxide loaded on a porous body or The deodorizing filter material according to any one of claims 1 to 8, wherein one or more selected from coated deodorizing agents are used. 10. A deodorizing filter comprising one or two or more different types of filter layers laminated on at least one surface or both surfaces of the deodorizing filter material according to claim 1. 11. The deodorizing filter according to claim 10, wherein a deodorizing filter layer based on a polyurethane foam having a three-dimensional network skeleton structure is laminated as the different type of filter layer. 12. The deodorizing filter material according to claim 10, wherein a dust collecting filter layer having a dust collecting function is laminated as the different kinds of filter layers, and a dust collecting function is provided together with a deodorizing function. 13. The deodorizing filter material according to claim 1 and the different type of filter layer are laminated in a non-adhered state using a clip-shaped or frame-shaped filter coupler. The deodorizing filter material according to any one of the above.