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CN116887902A - 具有集尘和除臭功能的空气净化过滤器及其制造方法 - Google Patents

具有集尘和除臭功能的空气净化过滤器及其制造方法 Download PDF

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Publication number
CN116887902A
CN116887902A CN202280017002.4A CN202280017002A CN116887902A CN 116887902 A CN116887902 A CN 116887902A CN 202280017002 A CN202280017002 A CN 202280017002A CN 116887902 A CN116887902 A CN 116887902A
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CN
China
Prior art keywords
filter
filter layer
woven fabric
air cleaning
layer
Prior art date
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Pending
Application number
CN202280017002.4A
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English (en)
Inventor
尹显埈
李炳赫
金钟澈
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Kaweiyi Co ltd
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Kaweiyi Co ltd
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Application filed by Kaweiyi Co ltd filed Critical Kaweiyi Co ltd
Publication of CN116887902A publication Critical patent/CN116887902A/zh
Pending legal-status Critical Current

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    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
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Abstract

根据本发明的空气净化过滤器包括用于集尘的无纺布和结合有活性炭颗粒以用于除臭的无纺布，通过调整活性炭颗粒的粒径和含量并与涂布有气体吸附剂的其他无纺布层压，可以在同时提供集尘和除臭功能的同时，实现低压差结构。

Description

具有集尘和除臭功能的空气净化过滤器及其制造方法
技术领域
本发明涉及一种具有集尘和除臭功能的空气净化过滤器及其制造方法。更具体地，本发明涉及一种同时具有集尘和除臭功能的空气净化过滤器、其制造方法、用于其中的除臭用空气净化过滤器以及包括其的空气净化器。
背景技术
近期，随着颗粒物、黄沙等大气污染问题的出现，过滤室内空气的空气净化已成为必须。诸如空气净化器的空气净化装置可通过使用各种类型的过滤系统过滤空气中所含的污染灰尘或对人体有害的有害物质来提供新鲜空气。
在上述过滤系统中，使用利用过滤介质来去除气体中含有的颗粒污染物的各种集尘过滤器。通常使用具有聚四氟乙烯膜的过滤材料或利用熔喷(melt blown)方式的无纺布的过滤材料作为这种集尘过滤器。
另外，过滤系统可包括除臭过滤器，以便去除空气中的甲醛、甲苯、氨等异味成分。例如，为了去除甲醛，开发了通过在热粘合(thermal bond)或纺粘无纺布(spun bond)上施加活性炭来吸附异味成分的过滤介质。
进一步地，随着近期空气净化器的复合化趋势，正在开发结合了除尘和除臭功能以及其他附加功能的空气净化过滤器。
发明内容
技术问题
传统的复合式空气净化过滤器通过简单地结合利用颗粒型活性炭颗粒的除臭过滤层和利用熔喷无纺布的集尘过滤层来实现集尘和除臭功能。然而，这种传统的过滤器由于压差增大，因此存在过滤器的清洁效率下降的问题。
本发明的目的在于提供一种具有优异的集尘和除臭性能并且实现低压差的空气净化过滤器、其制造方法以及包括其的空气净化器。
解决问题的手段
根据本发明的空气净化过滤器包括弯曲过滤介质，所述过滤介质包括：集尘过滤层，该集尘过滤层包括第一无纺布；除臭过滤层，包括第二无纺布和10g/m2至60g/m2的量的活性炭颗粒，所述活性炭颗粒就与所述第二无纺布结合的粒径小于150目的粒径；以及功能性过滤层，该功能性过滤层包括第三无纺布和一种以上的气体吸附剂，其中，所述集尘过滤层、除臭过滤层和功能性过滤层通过物理或化学层压而成。
根据本发明的空气净化过滤器的制造方法包括：制造集尘过滤层的步骤，该集尘过滤层包括第一无纺布；制造除臭过滤层的步骤，该除臭过滤层通过将10g/m2至60g/m2的粒径小于150目的活性炭颗粒结合到第二无纺布来制造；制造功能性过滤层的步骤，该功能性过滤层包括第三无纺布和一种以上的气体吸附剂；以及制造过滤介质的步骤，该过滤介质通过物理或化学层压所述集尘过滤层、所述除臭过滤层和所述功能性过滤层而成。
此外，根据本发明的空气净化过滤器包括无纺布和通过粘合剂结合到该无纺布上的活性炭颗粒，所述无纺布是基重为30g/m2至80g/m2的纺粘型或热粘合型无纺布，所述活性炭颗粒具有含量为10g/m2至60g/m2的小于150目的粒径的粒径，其中，基于100重量份的所述活性炭颗粒，所述粘合剂的含量为20至50重量份。
此外，本发明提供一种包括上述空气净化过滤器的空气净化器。
发明的效果
根据本发明的空气净化过滤器包括用于集尘的无纺布和结合有活性炭颗粒以用于除臭的无纺布，通过调整活性炭颗粒的粒径和含量并与含有其他气体吸附剂的无纺布层压，可以在同时提供集尘和除臭功能，并且实现低压差结构。
具体地，根据本发明的空气净化过滤器具备使用粘合剂将具有比现有技术更小的粒径的活性炭颗粒固定在无纺布的除臭过滤器，从而可以在低压差下吸附甲苯等异味成分。
此外，根据本发明的空气净化过滤器还可以根据要从空气中去除的成分包括一个以上的功能性过滤层或金属催化剂层并以各种顺序堆叠以发挥复合性能。
附图说明
图1示出了根据本发明的一个实施例的空气净化过滤器的立体图。
图2示出了沿图1中的线A-A’截断后的截面图和放大图。
图3示出了沿图2中的线B-B'截断后的截面图。
图4至图6示出了根据另一实施例的过滤介质的截面图。
图7示出了试验例1的空气净化过滤器的气体去除试验结果。
图8示出了试验例2的空气净化过滤器的除臭耐久性试验结果。
图9示出了试验例3的空气净化过滤器的集尘效率测试结果。
图10示出了试验例4中由空气净化过滤器带来的污染物浓度的降低情况。
图11示出了试验例5的空气净化过滤器的压差测量结果。
最佳实施方式
以下，将参照附图描述本发明的实施例。
在详细描述本发明时，如果对于相关的已知结构或功能的具体描述被认为是偏离本发明的主旨，则会省略其详细描述。此外，为了便于描述，附图中各个构件的尺寸可能被夸大或省略，并且可能与实际应用的尺寸不同。
在本说明书中，一个组件形成在另一组件之上/下或者彼此连接或联接的记载包括这些组件之间直接或间接通过其他组件的间接的形成、连接或联接。此外，应当理解，各组件的上/下的标准可以根据观察对象的方向而变化。
在本说明书中指代各组件的术语仅用于与其他组件进行区分，并且不旨在限制本发明。此外，在本说明书中，除非上下文另有说明，否则单数形式也包括复数形式。
在本说明书中，使用的术语“包括”用于具体地指出特定特征、区域、整数、步骤、操作、元素和/或成分，除非另有说明，否则不排除存在或添加其他特征、区域、整数、步骤、操作、元素、成分和/或组的情况。
空气净化过滤器
图1示出了根据本发明的一个实施例的空气净化过滤器的立体图，图2示出了沿图1中的线A-A’截断后的截面图和放大图，图3示出了沿图2中的线B-B'截断后的截面图。
参照图1至图3，根据本发明的实施例的空气净化过滤器10包括弯曲过滤介质100，所述过滤介质100包括：集尘过滤层130，该集尘过滤层130包括第一无纺布；除臭过滤层120，包括第二无纺布和10g/m2至60g/m2的量的活性炭颗粒，所述活性炭具有与所述第二无纺布结合的粒径小于150目的粒径；以及功能性过滤层110，该功能性过滤层110包括第三无纺布和一种以上的气体吸附剂。
根据本发明的实施例的空气净化过滤器包括用于集尘的无纺布和结合有活性炭颗粒以用于除臭的无纺布，通过调整活性炭颗粒的粒径和含量并与涂布有气体吸附剂的其他无纺布层压，可以在同时提供集尘和除臭功能，并且实现低压差结构。具体地，所述空气净化过滤器具有使用粘合剂将具有比现有技术更小的粒径的活性炭颗粒固定在无纺布的除臭过滤层，从而可以在低压差下吸附甲苯等异味成分。
此外，根据本发明的实施例的空气净化过滤器可以根据要从空气中去除的成分添加一个以上的功能性过滤层或金属催化剂层并以各种顺序堆叠以发挥复合性能。具体地，所述空气净化过滤器10还可以包括金属催化剂层140。
在下文中，将具体描述各结构层。
集尘过滤层
所述集尘过滤层包括第一无纺布。
例如所述第一无纺布可以是熔喷无纺布。
所述第一无纺布的基重可以为例如20g/m2至40g/m2，具体可以为20g/m2至35g/m2，更具体地，可以为25g/m2至35g/m2。当所述第一无纺布的基重在上述优选范围内时，在实现高效空气徽粒(HEPA，high efficiency particulate air)等级并在确保耐久性的的同时，可能更有利于用于制造过滤器的弯曲工艺。
具体地，所述第一无纺布可以是基重为20g/m2至35g/m2的熔喷型无纺布。
所述第一无纺布的材质优选地具有预定范围内的熔融指数(melt index)，所述熔融指数例如可以在265℃下为800克/10分钟至1500克/10分钟，具体可以在265℃下为900克/10分钟至1200克/10分钟，更具体地，可以为950克/10分钟至1200克/10分钟。当在所述熔融指数范围内时，可以进一步改善低温下的工艺性和生产性。
作为示例，所述第一无纺布的材质可以为聚丙烯，具体地，可以是在265℃下具有800克/10分钟至1500克/10分钟的熔融指数的聚丙烯。
由于所述集尘过滤层包含在颗粒物的粒径小于等于几微米的情况下仍然具有高捕集效率的超细纤维，因此可以利用电荷去除比气隙更小的颗粒以提高污染物的去除效率，并且由于孔隙率高，因此可以在低压差(压力损失)下操作。
除臭过滤层
所述除臭过滤层包括第二无纺布和10g/m2至60g/m2的量的活性炭颗粒，所述活性炭颗粒具有与所述第二无纺布结合的粒径小于150目的粒径。
所述第二无纺布的材料可以是具有优异的耐热性的聚合物树脂，并且可以包括例如聚对苯二甲酸乙二醇酯(PET)。当所述第二无纺布包括具有优异的耐热性的PET时，可以最小化由于加热导致的堆叠之后的性能劣化，并且可以进一步改善与相邻层的粘附力。
所述第二无纺布的基重可以为例如20g/m2至90g/m2，具体可以为30g/m2至80g/m2，具体可以为40g/m2至70g/m2。在上述优选范围内，可以进一步提高过滤介质的支撑性、加工性、弯曲性、高温加工性和粘附力。
具体地，所述第二无纺布可以是基重为30g/m2至80g/m2的纺粘型或热粘合型无纺布。
所述第一无纺布的基重和所述第二无纺布的基重之和可以为35g/m2至85g/m2。例如，所述第一无纺布的基重和所述第二无纺布的基重之和可以为40g/m2至80g/m2或50g/m2至80g/m2。当在上述优选范围内时，有利于在确保优异的耐久性的同时，确保弯曲性和加工性。
所述活性炭颗粒从煤或椰子壳中获得，其可以起到吸附和去除烟草烟雾、挥发性有机化合物和其他异味物质的作用。
所述活性炭颗粒的具有小于150目的粒径，因此有利于实现优异的除臭性能和低压差。例如，所述活性炭颗粒的粒径可以为150目的粒径以下、100目的粒径以下、或50目的粒径以下，并且，可以为300目的粒径以上、250目的粒径以上、或200目的粒径以上。具体地，所述活性炭颗粒的粒径可以为50目至300目的粒径、100目至300目的粒径、或150目至250目的粒径。以上示出的活性炭颗粒的粒径可以是平均粒径。
只要所述活性炭颗粒具有适合于去除异味的目的的物理或化学性质，其表面积不受特别限制，然而，考虑到应用于空气净化器等领域的可能性，可具有约1000m2/g以上的BET表面积，优选地，可具有约1000至1200m2/g以上的BET表面积。
活性炭颗粒可以通过粘合剂结合到所述第二无纺布。所述粘合剂例如可以使用丙烯酸类或聚氨酯类。
此外，基于100重量份的所述活性炭颗粒，所述粘合剂的使用量可以为10重量份以上、20重量份以上、或者30重量份以上，并且可以为60重量份以下、50重量份以下、或者40重量份以下，优选地，20重量份至50重量份的粘合剂有益于在固定活性炭颗粒的同时不增加压差。
与传统的除臭过滤器相比，所述除臭过滤层可以在表现出优异的除臭性能的同时，实现低压差结构。因此，所述除臭过滤层本身可以被提供为与现有技术存在差异的空气净化过滤器。
具体地，所述空气净化过滤层包括无纺布和通过粘合剂结合到所述无纺布的活性炭颗粒，所述无纺布是基重为30g/m2至80g/m2的纺粘型或热粘合型无纺布，所述活性炭颗粒的含量为10g/m2至60g/m2的量，并且具有小于150目的粒径的粒径，其中，基于100重量份的所述活性炭颗粒，所述粘合剂的含量为20至50重量份。
功能性过滤层
所述功能性过滤层包括第三无纺布和一种以上气体吸附剂。
所述第三无纺布的材料可以是具有优异的耐热性的聚合物树脂，并且可以包括例如聚对苯二甲酸乙二醇酯(PET)。当所述第三无纺布包括具有优异的耐热性的PET时，可以最小化由于加热导致的堆叠之后的性能劣化，并且可以进一步改善与相邻层的粘附力。
所述第三无纺布的基重可以为例如20g/m2至90g/m2，具体可以为30g/m2至80g/m2，并且具体可以为40g/m2至70g/m2。在上述优选范围内，可以进一步提高过滤介质的支撑性、加工性、弯曲性、高温加工性和粘附力。具体地，第三无纺布可以是基重为30g/m2至80g/m2的纺粘型或热粘合型无纺布。
根据所包含的气体吸附剂，所述功能性过滤层可以去除一种以上的气体。例如，所述功能性过滤层可以去除选自由氨、醛、乙酸、甲苯和萜烯组成的组中的一种以上气体。另外，所述气体吸附剂可以包含选自由有机酸、无机酸、尿素、二氧化硅、沸石和金属催化剂组成的组中的至少一种。
作为示例，所述功能性过滤层可以通过包含有机酸或无机酸来去除诸如氨气的碱性气体。作为另一示例，功能性过滤层可以通过包含诸如亚乙基脲的尿素来去除醛。作为又一示例，所述功能性过滤层可以通过包含尿素以及有机酸或无机酸来同时去除碱性气体和醛类。
所述功能性过滤层中的气体吸附剂的含量可以为1重量％以上、2重量％以上、或5重量％以上，并且，可以为50重量％以下、30重量％以下、或20重量％。
具体地，所述功能性过滤层可以包括选自用于去除氨的2重量％至20重量％的磷酸和用于去除醛的5重量％至30重量％的亚乙基脲中的一种以上。
金属催化剂层
所述过滤介质还可以包括金属催化剂层，所述金属催化剂层可以包括第四无纺布和金属催化剂。
所述第四无纺布的材料可以是具有优异的耐热性的聚合物树脂，并且可以包括例如聚对苯二甲酸乙二醇酯(PET)。当所述第四无纺布包括具有优异的耐热性的PET时，可以最小化由于加热导致的堆叠之后的性能劣化，并且可以进一步改善与相邻层的粘附力。
所述第四无纺布的基重可以为例如20g/m2至90g/m2，具体可以为30g/m2至80g/m2，并且具体可以为40g/m2至70g/m2。在上述优选范围内，可以进一步提高过滤介质的支撑性、加工性、弯曲性、高温加工性和粘附力。
所述金属催化剂层可以通过所述金属催化剂的反应来分解和去除难以吸附和去除的气体。
例如，由所述金属催化剂层去除的气体可以是选自由甲醛、乙醛和乙酸组成的组中的一种以上。
所述金属催化剂可以是选自由铂、铜和锰组成的组中的一种以上。
所述金属催化剂层内部的金属催化剂的含量例如可以为0.1重量％至2重量％。
作为示例，所述金属催化剂层可以包括用于去除甲醛气体的0.1重量％至2重量％的铂催化剂。
作为另一示例，所述金属催化剂层可以包括用于去除乙醛气体的0.1重量％至2重量％的锰催化剂。
堆叠结构
根据本发明的空气净化过滤器的过滤介质可以具有上述层以物理或化学方式层压而成的各种堆叠构造。
优选地，所述除臭过滤层和所述集尘过滤层可以彼此相邻地堆叠，并且所述功能性过滤层可以堆叠在所述除臭过滤层或所述集尘过滤层上。如上所述，当除臭过滤层和集尘过滤层彼此相邻地堆叠时，即使活性炭颗粒由于空气的流入而从除臭过滤层脱离，也可以被集尘过滤层保存。如图3所示，根据一个实施例的过滤介质100可以由功能性过滤层110、除臭过滤层120、集尘过滤层130和金属催化剂层140依次堆叠而成。如上所述，当功能性过滤层堆叠在除臭过滤层上时，发挥除臭过滤层的保护功能，能够进一步提高除臭过滤层的寿命。
图4至图6示出了根据另一实施例的过滤介质的截面图。如图4所示，过滤介质101可以由功能性过滤层110、除臭过滤层120和集尘过滤层130依次堆叠而成。如图5所示，过滤介质102可以由除臭过滤层120、集尘过滤层130和功能性过滤层110依次堆叠而成。如图6所示，过滤介质103可以由除臭过滤层120、集尘过滤层130、功能性过滤层110和金属催化剂层140依次堆叠而成。
此外，所述过滤介质可包括两个以上的功能性过滤层，例如，可以在图4的过滤介质101中的集尘过滤层130的表面堆叠有附加的功能性过滤层。通过在两个以上的所述能性过滤层上分别涂布不同的气体吸附剂，可以发挥去除两种以上的气体的复合性能。
另外，所述空气净化过滤器可以用在空气净化器中，并且可以应用为使得空气从所述除臭过滤层流入并从所述集尘过滤层流出。由此，即使除臭过滤层中包含的活性炭颗粒由于气流而从第二无纺布脱离，也可以被收集在集尘过滤层中。
外壳
根据本发明的空气净化过滤器还可以包括所述过滤介质的外壳。参照图1和图2，所述空气净化过滤器可包括外壳200和设置在所述外壳内的弯曲的过滤介质100。
所述外壳可以起到支撑所述过滤介质的框架(frame)的作用，并且可以被组装或成型为使得所述过滤介质被适当地设置和安置。所述外壳的形状或结构可以根据使用目的或使用环境任意设置。
所述外壳的材料可以是用于空气净化过滤器的常规的外壳的材料。具体地，作为所述外壳的材料，可以使用选自由丙烯腈-丁二烯-苯乙烯共聚物(ABS)、聚丙烯(PP)、纸、无纺布、聚碳酸酯(PC)和弹性体基树脂组成的组中的一种以上。更具体地，ABS或PP可以用作所述外壳的材料，其中，易于确保尺寸精度并且可以抑制使用期间的变形的ABS可以是优选的。另外，由于聚对苯二甲酸乙二醇酯(PET)和ABS彼此之间具有较高的粘合力，因此当使用PET作为所述过滤介质的外层材料并且使用ABS作为所述外壳的材料时，可以提高防止过滤介质与壳体分离的效果。
所述过滤介质可以在被模制之后设置在所述外壳的内部。
空气净化过滤器的特性
根据本发明的空气净化过滤器可以在维持对于空气中的污染物的高的去除效率的同时实现低压差，因此可具有优异的寿命特性。
一般来说，过滤器的寿命(life time)和过滤器的压差(differential pressure)之间的相互影响较大。过滤器的压差是指过滤介质的上游(upstream)与下游(downstream)之间的压力差。当含有污染物颗粒的流体通过过滤器时，过滤器的孔隙随着颗粒的聚集而被堵塞，当孔隙被堵塞时，压力将逐渐升高。即，过滤器的压差随着时间的推移或者随着颗粒被收集在过滤器中而逐渐增大。因此，过滤器的压差是用于判断过滤器的更换时期的主要因素，并且可以作为用于判断过滤器的寿命的标准。
如果过滤器的压差过低，污染物去除性能可能下降，反之，如果过滤器的压差过高，则过滤器的寿命可能会缩短并且功耗可能会增加。因此，过滤器具有适当范围内的压差，对于同时满足过滤器的高性能、低功耗和长寿命的特点是非常有利的。
例如，在1m/s流速下的灰尘供给量为50g的条件下，所述空气净化过滤器的压差可以为40Pa以上、50Pa以上、60Pa以上、或者70Pa以上，并且，可以为120Pa以下、110Pa以下、100Pa以下、或者90Pa以下。作为具体示例，当在1m/s流速下的灰尘供给量为50g时，所述空气净化过滤器的压差可以为60Pa至100Pa。
当在温度25℃、湿度50％、腔室大小8m3和目标气体初始浓度10ppm的条件下执行30分钟气体去除试验时，所述空气净化过滤器对于甲醛、甲苯和氨的去除率均可以达到90％以上。
具体地，当在上述条件下执行30分钟气体去除试验时，所述空气净化过滤器对于甲醛的去除率可以达到93％以上、对于甲苯的去除率可以达到95％以上、对于氨的去除率可以达到97％以上。
此外，在JEM1467：2009条件下的除臭耐久性试验中，即使将香烟数量增加到100支，所述空气净化过滤器对甲醛、甲苯、氨的去除率也可均维持在80％以上。尤其，即使将香烟数量增加到200支，所述空气净化过滤器对氨的去除率仍维持在95％以上，因此除臭耐久性可以非常优异。
此外，在使用癸二酸二异辛酯(DEHS，di-ethyl-hexyl-sebacat)所述空气净化过滤器颗粒或NaCl颗粒的42CFR part 84条件下的集尘效率可以为99％以上、99.5％以上、99.6％以上、99.7％以上或99.8％以上。
空气净化过滤器的制造方法
根据本发明的空气净化过滤器的制造方法包括：制造集尘过滤层的步骤，该集尘过滤层包括第一无纺布；制造除臭过滤层的步骤，该除臭过滤层通过将10g/m2至60g/m2的量的小于150目的活性炭颗粒结合到第二无纺布来制造；制造功能性过滤层的步骤，该功能性过滤层包括第三无纺布和一种以上的气体吸附剂；以及制造过滤介质的步骤，该过滤介质通过物理或化学层压所述集尘过滤层、所述除臭过滤层和所述功能性过滤层而成。
所述集尘过滤层的第一无纺布可以使用以上示出的材料来制造，并且例如可以通过使用聚丙烯的熔喷法来制造为具有20g/m2至35g/m2的基重。
所述除臭过滤层可以通过使用粘合剂将活性炭颗粒结合到第二无纺布来制造，具体地，在通过将活性炭颗粒与粘合剂和溶剂混合来制备分散液之后，可以通过涂布到第二无纺布并进行干燥来制造。
此时，基于100重量份的所述活性炭颗粒，可以使用20重量份至50重量份的粘合剂。
此外，基于100重量份的所述活性炭颗粒，可以使用200重量份至500重量份的蒸馏水、净水等作为所述溶剂。
所述涂布可以通过将制备的所述分散液喷射到第二无纺布上或将所述第二无纺浸入分散液中来进行。具体地，可以通过将第二无纺布在所述分散液中浸渍3秒至10秒来进行所述涂布。
另外，所述干燥可以在50℃至70℃的温度下进行5分钟至10分钟。
所述功能性过滤层可以通过在第三无纺布上涂布一种以上的气体吸附剂来制造，并且可以涂布有以上示出的含量的气体吸附剂。
所述第二无纺布和所述第三无纺布可以分别使用以上示出的材料来制造，并且例如可以通过使用聚对苯二甲酸乙二醇酯以纺粘法或热粘合法分别制备成分别具有30g/m2至80g/m2的基重。
所述层压以物理或化学方式进行，例如，可以通过执行施加压力的物理层压或使用粘合剂或热熔胶的化学层压来进行。
具体地，当使用热熔胶进行层压时，可以在130℃至170℃的温度下执行。更具体地，使用所述热熔胶的层压可以在130℃至170℃、140℃至160℃或150℃至170℃的温度下进行。
在使用所述热熔胶时，所述热熔胶的使用量可以为1g/m2至10g/m2、2g/m2至10g/m2、或者3g/m2至8g/m2。当在上述范围内使用所述热熔胶时，可以提高粘合力。所述热熔胶例如可以使用丙烯酸、聚烯烃、聚酯、聚酰胺、聚氨酯等。
此后，所述过滤介质被弯曲。当所述过滤介质弯曲时，由于过滤面积宽，因此可以减少压力损失，并且由于结构变得坚固，因此可以提高过滤器的耐久性和寿命特性。
参照图2，可以使用旋转打褶机等将所述过滤介质100弯曲成褶状。例如，所述褶皱形状可以是通过弯曲而形成褶皱的结构。并且，所述褶皱的形状可以多种多样，例如锯齿形角曲线或圆形曲线，并且褶皱的形状和尺寸没有特别限制。
此外，所述褶皱的峰的高度可以为10mm至60mm。其中，峰的高度可以指褶皱的幅度，即峰和谷之间的距离。此外，所述峰之间的距离可以为2mm至8mm。
空气净化器
本发明提供一种包括上述空气净化过滤器的空气净化器。
作为示例，所述空气净化器包括：吸入口，用于吸入污染的空气；排放口，用于排放净化空气；以及过滤单元，设置在所述吸入口与所述排放口之间，其中，所述过滤单元包括如上所述的空气净化过滤器。
具体地，所述空气净化器的正面设置有用于吸入室内空气的吸入口，上部形成有用于排放净化空气的排放口，内部具有包括所述空气净化过滤器的过滤器单元。
另外，所述空气净化器可包括鼓风机，该鼓风机通过旋转力吸入室内空气并将净化空气重新排放到室内。空气可以通过所述鼓风机吸入到前吸入口并通过上侧的排放口被排出。具有细密的格子形状的排放格栅可以设置在所述排放口，从而可以防止用户的身体由于旋转的鼓风机而受伤。
除了空气净化过滤器之外，所述过滤器单元还可以包括附加的过滤器，例如还可以包括：预过滤器，该预过滤器由抗菌材料制成且用于去除较大的灰尘、霉菌、发丝、宠物毛发等；和/或具有多个孔隙的除湿过滤器，用于去除空气中的水分。
具体实施方式
【实施例】
在下文中，将对本发明的实施例进行描述，然而本发明的实施范围不限定于此。
实施例1：空气净化过滤器(复合过滤器)的制造
(1)集尘过滤层的制造
使用聚丙烯(PP)树脂通过熔喷法制造基重为约27g/m2的第一无纺布。
(2)除臭过滤层的制造
使用聚对苯二甲酸乙二醇酯(PET)树脂通过纺粘法制造基重为约55g/m2的第二无纺布。通过混合100重量份的平均粒径为约200目的椰壳活性炭、40重量份的粘合剂(丙烯酸多元醇树脂，acrylic polyol resi)和400重量份的溶剂(净化水)来制备分散液。将所述第二无纺布在所述分散液中浸渍10秒后取出，并在60℃下干燥10分钟。由此制造了在所述第二无纺布上涂布含量约为35g/m2的椰壳活性炭的除臭过滤层。
(3)功能性过滤层的制造
使用聚对苯二甲酸乙二醇酯(PET)树脂通过纺粘法制造两个基重为约55g/m2的第三无纺布。
在其中一个第三无纺布上涂布约11重量％的磷酸(phosphoric aci)以制造功能性过滤层A。
在另一个第三无纺布上涂布约17重量％的亚乙基脲(2-咪唑烷酮，2-imidazolidone)以制造功能性过滤层B。
(4)层压
按照从下到上的顺序依次放置涂布面朝上的功能性过滤层A/除臭过滤层/集尘过滤层/功能性过滤层B，并使用聚烯烃热熔胶在150℃下层压以获得过滤介质。
(5)弯曲
使用旋转打褶机(DBWP-W700，DoubleWin公司)以25mm的峰高和约3.5mm的峰之间的距离进行打褶处理。所述打褶处理后，使用成型机(Filter Assy M/C，DoubleWin公司)在ABS外壳内部嵌件成型以制造所述过滤介质。
比较例1
通过重复上述实施例1的步骤(1)的程序来制造集尘过滤层。另外，制造了在网格中装有颗粒型活性炭颗粒的除臭过滤层。通过简单地结合所述集尘过滤层和除臭过滤层来制造空气净化过滤器。
实施例2
重复所述实施例1的过程，但不制造步骤(3)的功能性过滤层，由此制造了层压除臭过滤层和集尘过滤层的空气净化过滤器。
试验例1：气体去除试验(gas removel test)
气体去除试验是使用实施例1的空气净化过滤器根据KACA002 132：2018在温度25℃、湿度50％、腔室大小8m3和目标气体初始浓度10ppm的条件下执行的。
其结果示于图7中。如图7所示，实施例1的空气净化过滤器在30分钟后对甲醛、甲苯和氨气均示出90％以上的去除率，尤其，在30分钟后对氨气的去除率显示出了99.9％的最高去除率。
试验例2：除臭耐久性试验(deodorization endurance test)
使用实施例1的空气净化过滤器，在根据JEM1467：2009的试验条件下进行了除臭耐久性试验。
其结果示于图8中。如图8所示，实施例1的空气净化过滤器对甲醛、甲苯、氨气的去除效率随着香烟数量的增加而缓慢地降低，其中，对氨气的去除效率几乎没有降低，因此对氨气的除臭耐久性获得了最优异的评价。
试验例3：集尘效率试验
使用实施例1的空气净化过滤器，使用NaCl颗粒并根据42CFR part 84执行了集尘效率试验。
其结果示于图9中。如图9所示，实施例1的空气净化过滤器示出了99.98％的非常高的集尘效率。
试验例4：污染物浓度变化
使用实施例1的空气净化过滤器，并且根据KACA002 132：2018执行了染物浓度变化试验。
其结果示于图10中。如图10所示，随着时间的推移，实施例1的空气净化过滤器带来了KCl浓度(m3/min)的指数函数递减。
试验例5：过滤器压差试验
使用Topas PAF-113-客舱空气过滤器测试系统(cabin filter test system)，在以从0.5m/s的流速改变为1.25m/s的的流速供应ISO A2粉尘(dust)的同时测量压差。根据粉尘供给量的过滤器的压差测量结果示于图11中。
如图11所示，根据测量结果，相比使用颗粒状活性炭颗粒的除臭过滤层与集尘过滤层单纯结合的现有的空气净化过滤器，较薄地涂布有微细的活性炭颗粒的除臭过滤层与集尘过滤层层压而成的本发明的空气净化过滤器的压差更小。具体地，当1m/s流速的粉尘供应量为50g时，实施例2的过滤器的压差测量结果相比比较例1的过滤器低约1mmaq(约9.8Pa)左右。

Claims (13)

1.一种空气净化过滤器，所述空气净化过滤器包括弯曲的过滤介质，
所述过滤介质包括：
集尘过滤层，包括第一无纺布；
除臭过滤层，包括第二无纺布和10g/m2至60g/m2的量的活性炭颗粒，所述活性炭颗粒具有与所述第二无纺布结合的粒径小于150目的粒径；以及
功能性过滤层，包括第三无纺布和一种以上的气体吸附剂，
所述集尘过滤层、所述除臭过滤层和所述功能性过滤层通过物理或化学层压而成。
2.根据权利要求1所述的空气净化过滤器，其中，
所述第一无纺布是基重为20g/m2至35g/m2的熔喷型无纺布，
所述第二无纺布和第三无纺布分别是基重为30g/m2至80g/m2的纺粘型或热粘合型无纺布。
3.根据权利要求1所述的空气净化过滤器，其中，
所述功能性过滤层去除选自由氨、醛、乙酸、甲苯和萜烯组成的组中的一种以上气体，
所述气体吸附剂包含选自由有机酸、无机酸、尿素、二氧化硅、沸石和金属催化剂组成的组中的至少一种。
4.根据权利要求1所述的空气净化过滤器，其中，
所述功能性过滤层含有用于去除氨的2重量％至20重量％的磷酸和用于去除醛的5重量％至30重量％的亚乙基脲中的一种以上。
5.根据权利要求1所述的空气净化过滤器，其中，
所述除臭过滤层和所述集尘过滤层彼此相邻地叠置，
所述功能性过滤层叠置于所述除臭过滤层或所述集尘过滤层上。
6.根据权利要求5所述的空气净化过滤器，其中，
所述空气净化过滤器用于空气净化器，
并且适用为空气从所述除臭过滤层流入并从所述集尘过滤层流出。
7.根据权利要求1所述的空气净化过滤器，其中，
所述过滤介质还包括金属催化剂层，
所述金属催化剂层包括第四无纺布和金属催化剂。
8.根据权利要求7所述的空气净化过滤器，其中，
所述过滤介质由所述功能性过滤层、所述除臭过滤层、所述集尘过滤层和所述金属催化剂层依次堆叠而成。
9.根据权利要求1所述的空气净化过滤器，其中,
当在温度25℃、湿度50％、腔室大小8m3和目标气体初始浓度10ppm的条件下执行30分钟气体去除试验时，
所述空气净化过滤器对甲醛、甲苯和氨的去除率均为90％以上。
10.一种空气净化过滤器，所述空气净化过滤器包括无纺布和通过粘合剂结合到所述无纺布的活性炭颗粒，
所述无纺布是基重为30g/m2至80g/m2的纺粘型或热粘合型无纺布，
所述活性炭颗粒具有粒径小于150目的粒径且含量为10g/m2至60g/m2，
基于100重量份的所述活性炭颗粒，所述粘合剂包含20重量份至50重量份的量。
11.根据权利要求10所述的空气净化过滤器，其中，
当在1m/s流速下的灰尘供给量为50g时，所述空气净化过滤器的压差为60Pa至100Pa。
12.一种空气净化器，包括：
权利要求1至11中任一项所述的空气净化过滤器。
13.一种空气净化过滤器的制造方法，包括：
制造集尘过滤层的步骤，所述集尘过滤层包括第一无纺布；
制造除臭过滤层的步骤，所述除臭过滤层通过将粒径小于150目的粒径的活性炭颗粒以10g/m2至60g/m2的量结合到第二无纺布来制造；
制造功能性过滤层的步骤，所述功能性过滤层包括第三无纺布和一种以上的气体吸附剂；
制造过滤介质的步骤，所述过滤介质通过物理或化学层压所述集尘过滤层、所述除臭过滤层和所述功能性过滤层而成；以及
弯曲所述过滤介质的步骤。
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