KR102755377B1 - Antibacterial and deodorizing composite nonwoven fabric for air purification and manufacturing method thereof - Google Patents

Abstract

The present invention relates to an antibacterial composite nonwoven fabric for an air purification filter and a manufacturing method thereof, and more specifically, it can be configured by combining an antibacterially treated support with an air purification material and a filter fiber. The filter of the present invention purifies various air pollutants including antibacterial agent emission amount, antibacterial effect, antifungal effect, airborne viruses, airborne bacteria, and malodorous gases such as volatile organic compounds (VOCs), ammonia, aldehydes, amines, strong acids, and organic acids, which are classified as harmful gases, as well as capturing ultrafine dust, and improving and maintaining a pleasant atmospheric environment by performing various antibacterial, virus-removing, and purifying harmful gases generated in industrial facilities, automobiles, or indoor spaces, thereby providing an antibacterial and deodorizing composite nonwoven fabric filter.

Description

{Antibacterial and deodorizing composite nonwoven fabric for air purification and manufacturing method thereof}

The present invention relates to an antibacterial composite nonwoven fabric for an air purification filter and a method for manufacturing the same, and more specifically, to an air purification antibacterial and deodorizing composite nonwoven fabric capable of purifying various air pollutants such as various harmful bacteria, airborne viruses, harmful air, and odor-causing components in the air and improving the environment to a pleasant one by forming a composite with an antibacterially treated support, an air purification material, and a filter fiber, and a method for manufacturing the same.

Recently, not only air quality but also air pollution is increasing due to industrial development and urbanization, and indoor and outdoor air are seriously polluted. In fact, bacterial particulate matter such as dust, dirt, and pollen, and various harmful substances such as benzene and toluene emitted from exhaust gas are flowing into indoor spaces. There is also a demand for antibacterial and odor gas removal in houses, buildings, and automobiles.

In general, air purifiers are designed to purify polluted air and provide fresh air. However, in modern society, where health and well-being are considered most important, the need for air purifiers that remove various harmful substances in air polluted by pollution is increasing.

Recently, it has been reported that the novel coronavirus infection (novel coronavirus) can be transmitted not only through droplets (small water droplets coming out of the mouth) but also through aerosols. Aerosols are fine particles less than 1 μm floating in the air. Airborne infection is transmitted through these aerosols. The main transmission routes of the novel coronavirus can be confirmed as direct transmission, aerosol transmission, and contact transmission. Among them, aerosol transmission means that the novel coronavirus spreads through the air in aerosols, which are very small water particles less than 1 μm.

Due to these problems, the desire to maintain indoor and personal hygiene in a comfortable state is gradually increasing. In addition, as a means to solve these problems, the performance of products is being improved for various purposes such as air purifiers, air conditioners, and masks for industrial, household, or personal use, and the development of excellent filters with antibacterial and deodorizing functions is becoming active.

In general, filter types can be sequentially classified into pre-filters, medium filters, HEPA (High Efficiency Particulate Air Filter) filters, and ULPA (Ultra Low Penetration Air) filters based on their ability to capture dust.

Korean Patent No. 10-2039512 discloses a harmful air purification filter that purifies various air pollutants including volatile organic compounds (VOCs), ammonia, aldehydes, amines, strong acids, organic acids, and other malodorous gases classified as harmful gases, and purifies various harmful gases generated in industrial facilities, automobiles, or indoor spaces to improve and maintain a pleasant atmospheric environment.

Korean Patent No. 10-1563595 discloses a filter comprising polyvinylidene fluoride nanofibers and a meltblown nonwoven fabric, the technical features of which are disclosed as follows: forming a polyvinylidene fluoride nanofiber nonwoven fabric layer on a two-component substrate, forming a polyethylene terephthalate substrate on the other side of the two-component substrate, and forming a meltblown nonwoven fabric on one side of the polyvinylidene fluoride nanofiber nonwoven fabric layer.

Korean Patent Publication No. 10-2021-0121849 discloses a filter layer coupled to a support layer, wherein the filter layer is formed by melt blowing an antibacterial agent comprising a thermoplastic resin into a melt and includes an antibacterial metal or an antibacterial metal oxide.

However, although these existing filters show some antibacterial effects, they are not effective enough against various harmful bacteria or viruses, and their filtering efficacy against harmful gases is also insufficient, leaving much room for improvement. In particular, it was difficult to expect removal of odors such as bad smells.

Korean Patent Registration No. 10-2039512 Korean Patent No. 10-1563595 Korean Patent Publication No. 10-2021-0121849

The present invention aims to solve the problems of the prior art as described above and to provide a high-quality antibacterial support for a filter having superior filter performance.

Accordingly, the inventors of the present invention have made efforts to solve the problem of improving the performance of filters used for air purification, and as a result, have provided a multilayer air purification gas filtration layer formed of a single fabric by laminating a plurality of media with different filtration efficiencies on an antibacterial support, thereby confirming that the multilayer air purification gas filtration layer has improved antibacterial function, virus removal, particle and gas efficiency, and pressure loss, thereby completing the present invention.

Accordingly, the purpose of the present invention is to provide a novel air purification antibacterial and deodorizing composite nonwoven fabric filter having excellent purification performance by compositely forming a support provided with antibacterial properties, an air purification material including activated carbon, and a filter fiber in a layered structure.

In addition, another object of the present invention is to provide an antibacterial and deodorizing composite nonwoven fabric useful for air purification, which is manufactured by a method of forming a support imparted with antibacterial properties under specific conditions, laminating an air purification material including activated carbon by forming particles under specific conditions, and compositely forming electrostatic fibers, nanofibers, and Teflon porous films as additional filter fibers.

In order to solve the above problems, the present invention provides an air-purifying antibacterial and deodorizing composite nonwoven fabric, which comprises a first support fiber layer containing 0.1-3 wt% of a metal oxide antibacterial component in low-melting-point fibers, an air-purifying material layer including activated carbon and an ion exchange resin having an average particle diameter of 90-600 ㎛, a second support fiber layer on which an air-purifying material forming the air-purifying material layer is scattered, and a HEPA layer including at least one of low-melting-point fibers, electrostatic fibers, nanofibers, and Teflon porous films.

According to a preferred embodiment of the present invention, the first support (1) fiber layer may be a fiber of a sheath/core structure of polyester/polyethylene, and may be attached to at least one support of a thermal bond, a span bond, a wet-laid nonwoven fabric, and an air-laid nonwoven fabric by impregnating, spraying, or gravure coating an antibacterial component of a metal oxide at 0.5% to 2.0%.

According to a preferred embodiment of the present invention, the fiber layer of the first support (1) can be made of a fiber that is bendable, weighs 45 to 70 g/m ² , has a thickness of 0.3 to 1.0 mm, and has a breathability of 100 to 700 cc/cm ² /sec at a flow rate of 5.3 cm/sec.

According to a preferred embodiment of the present invention, zinc oxide nanoparticles having an average diameter of 10 nm to 50 nm can be used as the metal oxide antibacterial component.

According to a preferred embodiment of the present invention, the air purifying material layer can be used by scattering activated carbon, ion exchange resin, powder ion exchange resin, and low melting point powder resin.

Alternatively, the air purifying material layer can be made of single fibers and contain activated carbon by scattering it on the second support fiber layer at a content of 40 to 120 g/ ^m2 .

Afterwards, the second support fiber layer can be mutually bonded to the first support fiber layer by passing through a hot air dryer or by a compression roll and a square frame roller.

According to a preferred embodiment of the present invention, after the second support (2) fiber layer, a HEPA layer can be formed by combining one or more of a hydro-charged or corona-charged meltblown electrostatic material; one or more nanofibers selected from polyvinylidene fluoride (PVDF) and polymethyl methacrylate (PMMA); a Teflon porous film, etc., in a polypropylene span bond layer, with an efficiency of 95 to 99.9%, a pressure loss of 0.5 to 5.0 mmAq, and a weight of 0.1 to 25 g/ ^m2 .

According to a preferred embodiment of the present invention, the antibacterial and deodorizing composite nonwoven fabric may satisfy at least one of the following conditions: a weight of 100 to 300 g/m ² , a thickness of 0.3 to 1.2 mm, a breathability of 1 to 70 cm ³ /cm ² /sec, a 0.3 μm particle efficiency of 95 to 99.999%, and a pressure loss of 1.0 to 6 mmAq.

In addition, the present invention comprises the steps of impregnating, spraying or gravure coating a polyester/polyester sheath/core low-melting fiber with an aqueous solution containing 0.5% to 2.0% of zinc oxide nanoparticles having an average diameter of 10 nm to 50 nm to attach zinc oxide nanoparticles to the sheath portion of the fiber, drying the fiber in a hot air dryer at a temperature of 140°C to 180°C, and then pressing the fiber with a pressing roll to produce a first support fiber layer;

A step of forming an air purifying material layer with a content of 40 to 120 g/m ² including low-melting-point single fibers and activated carbon or ion exchange resin having an average particle size of 90 to 600 ㎛; or a step of forming an air purifying material layer with a content of 40 to 120 g/m ² including low-melting-point powder resin having a content of 90 to 450 ㎛ and activated carbon or ion exchange resin having an average particle size of 30 to 600 ㎛;

A step of forming a second support fiber layer that scatters the air purifying material of the above-mentioned purifying material layer;

A step of forming a HEPA layer by performing at least one of the processes of forming a Teflon porous film by manufacturing a hydro-charged or corona-charged top fiber as a dry (short fiber, spunbond, meltblown, airlaid) or wet nonwoven fabric, manufacturing one or more nanofiber layers selected from polyvinylidene fluoride (PVDF) and polymethyl methacrylate (PMMA), or bonding a Teflon porous film to a polypropylene spunbond layer with an efficiency of 95 to 99.9%, a pressure loss of 0.5 to 5.0 mmAq, and a weight of 0.1 to 25 g/m2 ^.

The present invention includes a method for manufacturing an air purifying antibacterial and deodorizing composite nonwoven fabric.

According to a preferred embodiment of the present invention, the air purifying antibacterial and deodorizing composite nonwoven fabric can have an antibacterial agent release amount of 0, an antibacterial effect of 99.9%, a mold-proofing effect of 0, and can remove 99.9% of floating viruses and 99.9% of floating bacteria.

According to a preferred embodiment of the present invention, the activated carbon can be impregnated activated carbon capable of capturing acetaldehyde, formaldehyde, ammonia, SO ₂ , NO _{2 ,} etc., or a mixture of activated carbon and ion exchange resin, and in order to overcome the limitation of thickness, it is advantageous to have a range of 40x100 mesh (90~400㎛) ~ 30x60mesh (300~600㎛) and a weight of about 40~120g/m ^{2 ,} and can capture 99.5% or more of the five major gases (ammonia, acetic acid, acetaldehyde, formaldehyde, toluene).

According to a preferred embodiment of the present invention, the electrostatic material may be at least one selected from hindered amine light stabilizers (HALS), triazine light stabilizers, polyvinylidene fluoride (PVDF), and polymethyl methacrylate (PMMA).

According to a preferred embodiment of the present invention, the nanofibers may be at least one selected from polyvinylidene fluoride (PVDF) and polymethyl methacrylate (PMMA).

According to the present invention, the second support fiber layer may include a nanofiber layer in the form of nanofibers being sprinkled on the second support fiber layer.

According to a preferred embodiment of the present invention, the nanofibers having an average diameter of 50 to 150 nm can be used.

According to a preferred embodiment of the present invention, the nanofibers may be contained in an amount of 0.1 to 15 g/m ² based on the total weight of the nanocomposite nonwoven fabric.

According to a preferred embodiment of the present invention, a nanofiber layer may be laminated on the second support fiber layer, and then a HEPA layer may be sequentially laminated in the form of a Teflon porous film bonded to a polypropylene spanbond layer.

In addition, the first support fiber layer, which is an antibacterial support (1), and the second support fiber layer (2) can be configured and used in positions that are swapped with each other.

According to a preferred embodiment of the present invention, a Teflon porous film can be used as a HEPA layer by attaching a porous Teflon film to a polypropylene spunbond.

According to a preferred embodiment of the present invention, the HEPA layer can contain a weight of 15 to 80 g/m ² and an electrostatic efficiency of 95 to 99.97%.

According to a preferred embodiment of the present invention, the nonwoven fabric forming the HEPA layer may have properties such as a unit weight of 15 to 60 g/m ² , a thickness of 0.1 to 0.5 mm, and a breathability of 1 to 70 cm ³ /cm ² /sec. As an example, it may have properties such as a 0.3 μm particle efficiency of 95 to 99.97% and a pressure loss of 0.5 to 6.0 mmAq.

According to a preferred embodiment of the present invention, the above-mentioned air purifying antibacterial and deodorizing composite nonwoven fabric can be used as a filter.

The air purifying antibacterial and deodorizing composite nonwoven fabric using the antibacterial support according to the present invention exhibits various filter functions such as adsorption and removal efficiency of various harmful bacteria and viruses, harmful gases, and malodorous gases entering the filter by applying a HEPA layer (electrostatic fiber, nanofiber, or Teflon porous film) to maintain antibacterial agent release amount, antibacterial activity, antifungal activity, floating viruses, floating bacteria, deodorization, and electrostatic force, so that it can be used as an excellent antibacterial and deodorizing composite nonwoven fabric.

Figure 1 is an exemplary drawing of a compression roller and a square frame belt according to the present invention.
FIG. 2 is a diagram showing an example of the composition of the fabric of an air-purifying antibacterial and deodorizing composite nonwoven fabric, which comprises a first support (1) fiber layer treated with antibacterial treatment according to the present invention, a second support (2) fiber layer on which activated carbon, ion exchange resin, and low melting point powder resin are scattered, and a HEPA layer comprising nanofibers is combined with a hot melt spray after heat compression.
FIG. 3 is a diagram showing an example of the fabric composition of an air-purifying antibacterial and deodorizing composite nonwoven fabric including a first support (1) fiber layer treated with an antibacterial composite according to the present invention, a second support (2) fiber layer formed by carding low-melting-point fibers as an air-purifying material layer and scattering activated carbon, ion exchange resin particles, powdered ion exchange resin particles, and low-oil-point powdered resin, and a HEPA layer (electrostatic fibers, nanofibers, and Teflon porous film) through a hot air dryer and heat compression.
Figure 4 is a photograph exemplarily showing the actual manufacturing form of a composite filter according to the present invention.

Hereinafter, the present invention will be described in more detail as an embodiment.

The present invention is not limited to the embodiments disclosed below, but can be modified or implemented in various different forms. The following embodiments and examples are provided to ensure that the disclosure of the present invention is complete and to fully inform a person having ordinary skill in the art of the scope of the invention.

Therefore, the implementation examples or embodiments of the present invention should not be construed as being limited to specific shapes or components of the areas disclosed in this specification, and should include, for example, changes in shape resulting from manufacturing.

The present invention relates to an antibacterial and deodorizing composite nonwoven fabric for air purification, which is laminated and includes activated carbon bound to an antibacterial support, and at least one of low-melting-point fibers and HEPA layers (electrostatic fibers, nanofibers, and Teflon porous films).

The present invention features an air purifying antibacterial and deodorizing composite nonwoven fabric having improved composite functions, such as coating an antibacterial component on a support or injecting an antibacterial agent into a cis-core portion of a radiating fiber, heat-setting, preferably adding activated carbon or an ion exchange resin thereto, and laminating one or more of melt-blown (HEPA), electrostatic fiber, nanofiber, Teflon porous film fabric, etc., thereby enabling mini-pleating with a simple manufacturing process, increasing the filtration area to lower the pressure loss, and improving antibacterial, particle efficiency, and gas performance.

The composite nonwoven fabric of the present invention can be applied as a filter that purifies various air pollutants including volatile organic compounds (VOCs), ammonia, aldehydes, amines, strong acids, organic acids, etc. classified as antibacterial agent emission amount, antibacterial activity, antifungal activity, airborne viruses, airborne bacteria, and odorous gases, and can improve and maintain a pleasant air environment by removing various antibacterial substances, viruses, and purifying harmful gases generated in industrial facilities, automobiles, or indoor spaces.

According to a preferred embodiment of the present invention, the first support (1) fiber layer is manufactured by an antibacterial coating method using a hot air dryer, or by injecting an antibacterial agent into the cis portion of the radiated cis core and heat-setting it, so that the antibacterial agent is not released and the manufacturing process is simple. In addition, since activated carbon is combined with a general compression circular roller or activated carbon is combined with a belt roller fixed to a square frame, the second support (2) fiber layer has a thin thickness and high density, so that the captured viruses in the composite nonwoven fabric have a short contact distance with the antibacterial agent and excellent antibacterial power. In addition, it can be manufactured as a composite filter for an air purification filter that is capable of mini-pleating, has a low weight deviation, and can be manufactured with a uniform thickness.

In addition, according to a preferred embodiment of the present invention, the first support fiber layer can be made of a fiber that is bendable, weighs 45 to 70 g/m ² , has a thickness of 0.3 to 1.0 mm, and has a breathability of 100 to 700 cc/cm ² /sec at a flow rate of 5.3 cm/sec. This support can be manufactured in the form of a nonwoven fabric of low-melting fibers, and the antibacterial coated support can completely attach the antibacterial agent to the support (1) at a temperature of 150° C. for a residence time of 1 minute or longer and can have a property of no release amount even after the filter is manufactured. In addition, the second support (2) fiber layer of the present invention can be used alone as a support layer made of low-melting fibers, or can be used as a support layer with nanofibers attached thereto.

In addition, a first support fiber layer (antibacterial support) with antibacterial properties can be manufactured by spun 0.5 to 2.0% nanopowder particles of zinc oxide into the cis portion of a low-melting-point fiber ciscore, carding the antibacterial fibers, laminating them in multiple layers, and then compressing the fibers and heat-setting them in the same process without antibacterial coating.

According to a preferred embodiment of the present invention, the electrostatic fibers of the HEPA layer may be hydro-charged or corona-charged with electrostatic material before bonding the fabric.

According to a preferred embodiment of the present invention, the first support fiber layer, which is an antibacterial support (1), can use Huvis LM, RM fibers or Toray PET/co-PET spanbond fabric, etc., and for example, 0.5% to 2.0% of an aqueous solution of 10 nm to 50 nm zinc oxide nanoparticles is applied to 45 to 70 g/ ^m2 of such fabric and heat-setting is performed in a hot air dryer at 150°C to 180°C so that the antibacterial agent is not released. In addition, in a low-melting-point fiber ciscore, 0.5 to 1.0% nanopowder particles of zinc oxide are fiber-spun onto the sheath portion, and then carded to form a multi-layered fiber layer, and then compressed and heat-setting is performed in the same process without antibacterial agent coating to manufacture an antibacterial support.

Afterwards, the upper first support fiber layer, activated carbon, ion exchange resin, low melting point powder resin, lower second support fiber layer or nanofiber bonded second support fiber layer can be laminated in the form of heat fusion or hot melt spray bonding by bonding a HEPA layer fabric or Teflon porous film to minimize the thickness.

According to a preferred embodiment of the present invention, as a synthetic fiber used as a fiber fabric constituting an electrostatic nonwoven fabric, a fiber fabric having high volume resistivity and a process moisture content of '0', such as polyethylene, polypropylene, and polycarbonate, or at least one selected therefrom may be used. More preferably, as an electrostatic fiber, a fiber having a volume resistivity of 10 ¹⁰ Ω or more, preferably 1×10 ¹³ Ω to 1×10 ¹⁵ Ω, and a process moisture content of '0' may be used. If the volume resistivity is too low, the amount of charge is insufficient, which reduces electrostatic efficiency, and if the process moisture content is not zero, moisture is introduced, which rapidly reduces electrostatic efficiency. Such fibers can be produced by weight loss processing.

According to a preferred embodiment of the present invention, the electrostatic fiber fabric may have one or more structures selected from the group consisting of circular, irregular, core-sheath, island-shaped, and split fiber cross sections. In this case, the surface area of the nonwoven fabric can be expanded or the pressure loss can be improved to be lowered. In addition, the nonwoven electrostatic fiber fabric may be formed of a single layer or multiple layers.

As for meltblown fibers, which are dry nonwoven fabrics that can be used as these electrostatic fibers for radiation, it is preferable to use polyethylene or polypropylene resin having a melting index of 250 to 1500 g/10 min.

In addition, it is preferable to use a polyethylene or polypropylene resin that can be used as a dry nonwoven staple fiber, spunbond, and electrostatic fiber for wet nonwoven spinning, which preferably has a melting index of 15 to 40 g/10 min.

According to a preferred embodiment of the present invention, the electrostatic material attached to the electrostatic fiber for radiation may be contained in an amount of 0.03 to 3 wt% with respect to the fiber.

According to a preferred embodiment of the present invention, as the electrostatic material, one or more dielectric electrostatic materials selected from hindered amine light stabilizers (HALS), triazine light stabilizers, polyvinylidene fluoride (PVDF), and polymethyl methacrylate (PMMA) can be used. However, since electrostatic materials other than these can also be used, the present invention is limited thereto. In particular, the HALS usable in the present invention is used as a light stabilizer that prevents deformation of a polymer by reducing or stopping a photochemical reaction caused by UV, and most HALS are known to have properties as dielectrics.

According to the present invention, such electrostatic material can be mixed and contained during the manufacture of various electrostatic nonwoven fabrics, and the electrostatic material can be contained in an amount of 0.3 to 10 wt%, more preferably 0.3 to 5 wt%.

If the content is too small, the electrostatic effect is insufficient to achieve the purpose, and if it is too large, the electrostatic force is high, causing the fibers to become entangled during manufacturing, making it impossible to spin the fibers.

In the present invention, the nanofibers may be at least one selected from polyvinylidene fluoride (PVDF) and polymethyl methacrylate (PMMA). The application of nanofibers is very efficient and economical in the composition of the entire electrostatic nonwoven fabric and the filtering effect of fine dust, and can bring about excellent new changes in durability, etc.

According to the present invention, since the surface area of the nanofibers in the outer layer of the electrostatic nonwoven fabric is large, the contact surface area for ultrafine particles is expanded and the water repellency is improved, so the filtering effect is particularly excellent for cigarette smoke, oil, and alcohol particles.

The method for manufacturing an antibacterial and deodorizing composite nonwoven fabric for air purification according to the present invention will be described in more detail.

According to the present invention, an electrostatic nonwoven fabric can be manufactured through a step of preparing a fiber fabric material including one or more raw materials such as polyethylene, polypropylene, and polycarbonate as synthetic fibers, a step of preparing one or more electrostatic substances selected from a hindered amine light stabilizer (HALS), a triazine light stabilizer, a benzotriazole-based light stabilizer, polyvinylidene fluoride (PVDF), and polymethyl methacrylate (PMMA) as electrostatic substances, a step of manufacturing a fiber fabric material by a dry or wet method, a step of spinning nanofibers onto a support fabric, and a step of hot melt-bonding the nanofibers to the electrostatic fiber fabric.

According to a preferred embodiment of the present invention, such electrostatic fibers can be manufactured while maintaining an average fiber diameter of 500 nm to 5 μm and a nanofiber structure of 50-100 nm.

According to a preferred embodiment of the present invention, an electrostatic nonwoven fabric manufactured by the electrostatic nonwoven fabric manufacturing process of the present invention can be preferably manufactured to have a unit weight of 20 to 60 g/m ² , a thickness of 0.1 to 0.5 mm, and a breathability of 15 to 50 cm ³ /cm ² /sec when considering filtration efficiency, breathability, economic efficiency, etc.

According to a preferred embodiment of the present invention, when the unit weight of the electrostatic nonwoven fabric is less than 20 g/㎡, there is a concern that the strength may become excessively weak because the nonwoven fabric is too thin, and when it exceeds 60 g/㎡, there is a concern that the pressure loss of the nonwoven fabric may become excessively high.

According to one example of the present invention, the weight of the nanofiber is suitably 50 nm to 150 nm and within 0.5 to 5 g/ ^m2 .

In addition, according to a preferred embodiment of the present invention, the dry electrostatic nonwoven fabric has the best pressure loss and filtration efficiency when the thickness is in the range of 0.1 to 0.5 mm.

In addition, according to a preferred embodiment of the present invention, the wet electrostatic nonwoven fabric includes fibers whose cross-sections are one or more structures selected from circular, irregular, core-sheath, island-in-the-sea, and split fibers, and may have a single-layer or more laminated structure and may be configured. It can be manufactured as a wet electrostatic nonwoven fabric filter composed of fibers whose single-filament fineness is 0.1 ㎛ to 40 ㎛.

According to the present invention, the electrostatic nonwoven fabric manufactured according to the present invention as described above can be electrostatically treated through a corona discharge treatment process using hydrocharging or wire-shaped or plate-shaped electrodes in a conventional manner.

As described above, when hydrocharging or corona discharge treatment is performed, the efficiency of 0.3㎛ particles before electrostatic treatment can be increased from 30% to 99%, and the electrostatic power can be increased from 99.5% to 99.97%.

According to a preferred embodiment of the present invention, an antibacterial and deodorizing composite nonwoven fabric can be electrostatically treated before manufacturing.

According to the present invention, the electrostatic nonwoven fabric manufactured through this series of processes has excellent electrostatic retention capacity and, since the loss of static electricity is small even when used for a long period of time, the dust collection efficiency does not decrease, so it can be manufactured into an antibacterial and deodorizing composite nonwoven fabric with excellent filtering effect.

The configuration examples of the antibacterial and deodorizing nonwoven fabric of the present invention are shown in Fig. 2, and Fig. 2 compares and illustrates the state in which the positions of the first and second support fiber layers are changed in different laminate structures.

A filter using an electrostatic nano nonwoven fabric manufactured according to the present invention has excellent electrostatic retention capacity due to the presence of an electrostatic nonwoven fabric and a nanofiber layer, and in particular, has a very large surface area, so that the filtration efficiency for ultrafine particles is significantly superior to that of conventional filters.

The electrostatic nonwoven fabric of the present invention can be manufactured very economically through a simple manufacturing process using a manufacturing method of a dry nonwoven fabric such as meltblown, spunbond, airlaid, thermalbond, or electrostatic nonwoven fabric, thereby increasing the price competitiveness of electrostatic nonwoven fabrics.

In addition, since electrostatic nonwoven fabrics can be produced with wet nonwoven fabrics, they can be manufactured and mass-produced in various ways, such as heterogeneous fibers, mixing of fibers with different thicknesses, and mixing of more than one layer of fibers. They can suppress harmful substances such as fine dust and ultrafine dust with low pressure loss and high efficiency, and in particular, they can greatly improve performance compared to particles of cigarette smoke, oil, and alcohol.

The antibacterial and deodorizing composite nonwoven fabric according to the present invention is not only economically manufactured as described above, but also has the effect of exhibiting very high dust collection efficiency without loss of dust collection efficiency even in places where the air purification flow rate is fast or where the flow rate changes greatly due to the presence of nanofibers in the electrostatic nonwoven fabric in a preferred configuration, thereby providing a large surface area.

In particular, the antibacterial support is thin and is captured by meltblown, nanofiber and Teflon porous films, and the antibacterial support exhibits antibacterial activity, so that both antibacterial properties and deodorizing properties can be exhibited.

Hereinafter, the present invention will be described in detail by examples, but the present invention is not limited to the examples.

Example 1

A 0.5% aqueous solution of 10 nm zinc oxide nano particles was placed on a thermal bond support with a weight of 50 g/ ^m2 and a permeability of 450 cm/ ^cm2 /sec using 100% RM 4D single fiber from Hyosung, and the solution was heat-set by staying in a hot air dryer at a temperature of 160°C for 1 minute, and then placed on the support (1).

The single fibers are carded, activated carbon is scattered at 85 g/ ^m2 , and a low-melting-point support (2) is attached by thermal bonding.

Afterwards, a meltblown nonwoven fabric with an average fiber diameter of 3㎛, a unit weight of 25g/ ^m2 , a thickness of 0.25mm, a pressure loss of 1.5mmAq (air permeability of 50cc/ ^cm2 /sec), and an efficiency of 99.5% was combined.

In this way, an antibacterial and deodorizing composite nonwoven fabric with a unit weight of 230 g/ ^m2 , a thickness of 0.75 mm, a pressure loss of 2.2 mmAq (ventilation of 35 cc/ ^cm2 /sec), and an efficiency of 99.9% was manufactured.

Example 2

With 100% RM 4D of 100% of Hyosung single fiber, a thermal bond support weight of 50 g/m ² , a permeability of 450 cm/cm ² /sec, a 1.0% aqueous solution of 10 nm zinc oxide nanoparticles is left in a hot air dryer at a temperature of 160°C for 1 minute to heat set, and on the support (1), 40 g/m ² of single fibers are carded, 100 g/m ² of activated carbon is scanned, and 30 g/m ² of low-melting-point support (2) is attached by thermal bonding.

Afterwards, a meltblown nonwoven fabric with an average fiber diameter of 1.5 ㎛, a unit weight of 25 g/m ² , a thickness of 0.25 mm, a pressure loss of 2.5 mmAq (air permeability of 30 cc/cm ² /sec), and an efficiency of 99.97% was combined.

In this way, a composite nonwoven fabric with a unit weight of 245 g/ ^m2 , a thickness of 0.75 mm, a pressure loss of 3.5 mmAq (ventilation of 20 cc/ ^cm2 /sec), and an efficiency of 99.97% antibacterial and deodorizing was manufactured.

Example 3

A 0.5% aqueous solution of 10 nm zinc oxide nanoparticles was added to a 100% Toray spunbond polyester support having a weight of 55 g/ ^m2 and an air permeability of 550 cm/ ^cm2 /sec, and heat-set at a hot air dryer temperature of 160℃ for 1 minute, and activated carbon and low-melting-point powder resin were mixed and scattered at 85 g/ ^m2 , and a meltblown method was used to radiate an average fiber diameter of 1.5 ㎛, and a meltblown nonwoven fabric having a unit weight of 25 g/ ^m2 , a thickness of 0.25 mm, a pressure loss of 2.5 mmAq (air permeability of 30 cc/ ^cm2 /sec), and an efficiency of 99.97% was bonded by hot melt spray.

In this way, a composite nonwoven fabric with a unit weight of 185 g/ ^m2 , a thickness of 0.65 mm, a pressure loss of 3.0 mmAq (ventilation of 25 cc/ ^cm2 /sec), and an efficiency of 99.97% antibacterial and deodorizing was manufactured.

Example 4

A 0.5% aqueous solution of 10 nm zinc oxide nano particles is placed on a thermal bond support weighing 50 g/ ^m2 and having a permeability of 450 cm/ ^cm2 /sec using 100% RM 4D short fibers of Hyosung, and the solution is heat-set at a temperature of 160°C in a hot air dryer for 1 minute, and 40 g/ ^m2 of short fibers is carded on the support (1), 85 g/ ^m2 of activated carbon is scattered, and 35 g/ ^m2 of low-melting-point support (2) is attached by thermal bonding.

Afterwards, a Teflon porous film with an efficiency of 99.9%, a pressure loss of 5.0 mmAq, and a weight of 25 g/ ^m2 was combined with a polypropylene spanbond layer to produce a composite nonwoven fabric with a unit weight of 235 g/ ^m2 , a thickness of 0.65 mm, a pressure loss of 6.0 mmAq (ventilation of 5 cc/ ^cm2 /sec), and an efficiency of 99.9% antibacterial and deodorizing.

Example 5

The support (1) is coated with a 50 nm 1% aqueous solution of zinc oxide on a 2D 100% thermal bond support, and a weight of 50 g/m ² and a permeability of 450 cm/cm ² /sec are produced, and heat-set is performed by staying in a hot air dryer at a temperature of 150°C for 1 minute.

A mixture of activated carbon and ion exchange resin was scattered at 100 g/ ^m2 on the support (1), and nanofibers were spun onto the thermal bond support (2) using 100% Huvis short fiber RM 4D so that the average fiber diameter of polyvinylidene fluoride (PVDF) was 50 nm and the air permeability was 80 cc/ ^cm2 /sec.

A wet-laid nonwoven fabric with a unit weight of 60 g/m2, a thickness of 0.25 mm, a pressure loss of 2.5 mmAq (air permeability of 30 cm3/cm2/sec) and an efficiency of 99.5% was manufactured by mixing 50% of polypropylene (PP 100%) with an average fiber diameter of 2.5 μm and 20% of polyethylene/polypropylene (PE/PP 40%: 60%) with a Y-shaped cross-section fiber diameter of ² denier/ ⁶ mm with a weight of ⁶⁰ g/m2, and a thickness of 0.25 mm. The wet-laid nonwoven fabric was manufactured with a hot melt spray to produce an antibacterial and deodorizing nonwoven fabric with a unit weight of 250 g/ ^m2 , a thickness of 0.70 mm, a pressure loss of 5.8 mmAq (air permeability of 10 cc/ ^cm2 /sec) and an efficiency of 99.9%.

Comparative Example 1

The short fibers are carded on the support (1) with a thermal bond support weight of 50 g/m ² and air permeability of 450 cm/cm ² /sec using 70% of Hyosung short fiber RM 4D and 30% of PP antibacterial fiber 2D containing 2% of antibacterial agent, and 85 g/m ² of activated carbon is scattered and a low melting point support (2) is attached by thermal bonding. Thereafter, an average fiber diameter of 3 ㎛ is spun and a meltblown nonwoven fabric having an average fiber diameter of 1.5 ㎛, a unit weight of 25 g/m ² , a thickness of 0.25 mm, a pressure loss of 2.5 mmAq (air permeability of 30 cc/cm ² /sec), and an efficiency of 99.97% is bonded. We manufactured an antibacterial and deodorizing composite nonwoven fabric with a unit weight of 245 g/ ^m2 , a thickness of 0.75 mm, a pressure loss of 3.5 mmAq (ventilation of 20 cc/ ^cm2 /sec), and an efficiency of 99.97%.

Comparative Example 2

A ^1.0 % aqueous solution of 10 nm zinc oxide nano particles is placed in a hot air dryer at a temperature of 100 ^℃ for 1 minute to heat-set the support (1) by carding the single fibers to 40 g/ ^m2 , scattering 85 g/ ^m2 of activated carbon, and attaching 35 g/ ^m2 of a low-melting-point support (2) by thermal bonding. Afterwards, a Teflon porous film with an efficiency of 99.9%, a pressure loss of 5.0 mmAq, and a weight of 25 g/ ^m2 was combined with a polypropylene spanbond layer to produce a composite nonwoven fabric with a unit weight of 235 g/ ^m2 , a thickness of 0.65 mm, a pressure loss of 6.0 mmAq (ventilation of 5 cc/ ^cm2 /sec), and an efficiency of 99.9% antibacterial and deodorizing.

Experimental Example 1

In order to test the ultrafine dust filtration ability of the electrostatic nano nonwoven fabric, micro glass fiber HEPA, and PTFE membrane HEPA fabric manufactured by the above examples and comparative examples, a filtration test was conducted according to the NaCl aerosol test method.

The test was conducted at a surface velocity of 5.3 cm/sec with NaCl particles of 0.3 μm. The test equipment used was a model TSI 8130A filter tester.

This experiment measured the filtration efficiency, which is the filtration rate of the test specimens, using the nonwoven test specimens of the above examples and comparative examples. The filtration efficiency of the test specimens was measured using the above method and is shown in Table 1 below.

Experimental example 2

The antibacterial and deodorizing composite nonwoven fabrics manufactured according to the above examples and comparative examples were measured for five major gas capture efficiencies, zinc oxide release, airborne virus reduction rate, and airborne bacteria reduction rate, and the results are shown in Table 2 below.

* Zinc oxide release amount: Tested according to the standards and methods for testing and inspection of biochemical products subject to safety confirmation.

* Antibacterial activity: Tested using KS K 0693: 2016 test method

* Bangmi-do: Tested using ISO 846:2019 test method

* Five major gases: ammonia, acetaldehyde, formaldehyde, acetic acid, and toluene gases were measured using the Korea Air Cleaning Association SPS-KACA 002-0132: 2018 test method.

* Reduction rate of floating viruses & reduction rate of floating bacteria: Measured using the KOUVA AS 02:2019 air purification device test method.

*

This experiment measured the filtration efficiency, which is the filtration rate of the test specimens, using the nonwoven test specimens of the above examples and comparative examples. The filtration efficiency of the test specimens was measured using the above method and is shown in Table 2 below.

division weight
(g/m ² ) thickness
(mm) Efficiency (%), NaCl
0.3㎛, 5.3cm/sec pressure loss
(%) Antibacterial
(%) Antibacterial properties
(%) Bangmi Island
(rating) Example 1 230 0.75 99.9 2.2 0.5 99.9 0 Example 2 245 0.75 99.97 3.5 1.0 99.9 0 Example 3 185 0.65 99.97 3.0 0.5 99.9 0 Example 4 235 0.65 99.9 6.0 0.5 99.9 0 Example 5 250 0.7 99.9 5.8 1.0 99.9 0 Comparative Example 1 245 0.75 99.97 3.5 2.0 85.0 4 Comparative Example 2 235 0.65 99.9 6.0 1.0 95.0 3

As a result of the above experiment, the antibacterial and deodorizing composite nonwoven fabrics of Examples 1-5 according to the present invention showed excellent results in antibacterial and antifungal properties.

From the results in Table 1 above, the antibacterial and deodorizing composite nonwoven fabric according to the present invention showed a low thickness relative to its weight. It was found that the filtration performance was significantly superior compared to conventional filters, while the antibacterial and antifungal properties were superior and the thickness was low, so that when folded and mini-pleated as a filter, the pressure loss was low, and it could be maintained for a long period of time compared to conventional filters.

division Filter size Activated carbon amount
(g/m ² ) 5 major gases
Capture efficiency
(%) Zinc oxide
Emission
(mg) floating virus
Reduction rate
(%) floating bacteria
Reduction rate
(%) Example 1 Width (450mm) x Height (42mm) x Number of mountains (170 mountains)
= Filtration area (6.4 m ² ) 85 99.1 1.0 99.4 99.3 Example 2 100 99.5 0.0 99.9 99.9 Example 3 85 99.8 0.0 99.9 99.9 Example 4 85 98.8 0.0 99.1 99.2 Example 5 100 98.5 1.0 99.0 99.1 Comparative Example 1 85 99.4 25 85.0 88.0 Comparative Example 2 85 98.7 65 75.0 80.1

From the results in Table 2 above, when using the antibacterial and deodorizing composite nonwoven fabric according to the present invention, containing it in a support or antibacterial agent sheath part that is heat-set at 150°C or higher and also heat-setting it at 150°C or higher improves the virus capture efficiency in terms of the release amount, the floating virus reduction rate, and the floating bacteria reduction rate compared to the conventional antibacterial filter.

In addition, the deodorizing filter performance improves the deodorizing efficiency as the pressure loss of the fabric is low and the circulation volume is large.

Although the present invention has been described as one embodiment, this is merely exemplary, and those skilled in the art will understand that various modifications and equivalent other experimental examples are possible from this. Therefore, the true technical protection scope of the present invention should be determined by the technical idea of the appended claims.

The antibacterial and deodorizing composite nonwoven fabric according to the present invention as described above can be applied to various filter materials. In particular, it can be applied to filters for removing harmful substances such as viruses or deodorizing filters in home appliance filters and vehicle air conditioner filters, and ultrafine dust, and can be applied to various industrial air purification filters.

Claims (5)

delete A first support fiber ^layer containing 0.1-3 wt% of a metal oxide antibacterial component by impregnating, spraying or gravure coating, and then heat-setting a low melting point fiber nonwoven fabric of polyester/polyethylene sheath/core structure, which is foldable and weighs 45-70 g/m2, has a thickness of 0.3-1.0 mm, and has a breathability of 100-700 cc/ ^cm2 /sec at a flow rate of 5.3 cm/sec; and
A second support fiber layer having an air purifying material layer in which low melting point single fibers are carded and activated carbon, ion exchange resin and low melting point powder resin are scattered at a content of 40 to 120 g/ ^m2 ; and
A HEPA layer comprising at least one of electrostatic fibers having a volume resistivity of 1×10 ¹³ Ω to 1×10 ¹⁵ Ω and a process moisture content of '0', nanofibers having a weight of 0.5 to 5 g/m ² and a size of 50 nm to 150 nm, and at least one selected from polyvinylidene fluoride (PVDF) and polymethyl methacrylate (PMMA), and a Teflon porous film bonded to a polypropylene spanbond layer.
Including,
Satisfies the conditions of weight 100~300g/ ^m2 , thickness 0.3~1.2mm, air permeability 1~ ^70cm3 / ^cm2 /sec, 0.3㎛ particle efficiency 95~99.999%, pressure loss 1.0~6mmAq
Air purifying antibacterial and deodorizing composite nonwoven fabric featuring: delete delete delete