MULTIFUNCTIONAL FILTER MEDIUM, AND METHOD AND APPARATUS FOR MANUFACTURING SAME

Abstract

The present application relates to a multifunctional filter medium and a method of manufacturing the same. The multifunctional filter medium of the present application is capable of significantly reducing fine dust, harmful microorganisms, and toxic gases and reducing a pressure decrease during filtration due to exclusion of high-density nanofiber, thereby minimizing energy required for filtration and exhibiting sufficient filtration performance as a single filter medium.

Claims

1. A multifunctional filter medium, comprising a fiber; and photocatalyst particles including carbon nanotubes grown on surfaces thereof, wherein the photocatalyst particles including carbon nanotubes grown on surfaces thereof are attached to a surface of the fiber.

2. The multifunctional filter medium according to claim 1, wherein the fiber includes a carbon fiber.

3. The multifunctional filter medium according to claim 1, wherein the fiber is a porous fiber.

4. The multifunctional filter medium according to claim 3, wherein the pores in the fiber have a diameter of 1 to 100 nm.

5. The multifunctional filter medium according to claim 1, wherein the fiber forms a woven or knitted fabric or a nonwoven fabric.

6. The multifunctional filter medium according to claim 1, wherein photocatalyst particles include one or more selected from the group consisting of titanium oxide, zinc oxide, tungsten oxide, cerium oxide, tin oxide, zirconium oxide and zinc sulfide.

7. The multifunctional filter medium according to claim 6, wherein photocatalyst particles further include one or more transition metals selected from the group of scandium (Sc), vanadium (V), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), yttrium (Y), niobium (Nb), molybdenum (Mo), ruthenium (Ru), rhodium (Rh), palladium (Pd), silver (Ag), cadmium (Cd), hafnium (Hf), tantalum (Ta), rhenium (Re), osmium (Os), iridium (Ir), platinum (Pt), and gold (Au).

8. A method of manufacturing a multifunctional filter medium, the method comprising: a step of producing photocatalyst particles using a low-temperature plasma particle generator; a step of attaching the photocatalyst particles to a fiber; and a step of allowing carbon nanotubes to grow on surfaces of the photocatalyst particles attached to the fiber.

9. A method of manufacturing a multifunctional filter medium, the method comprising: a step of producing photocatalyst particles using a low-temperature plasma particle generator; a step of allowing carbon nanotubes to grow on surfaces of photocatalyst particles; and a step of attaching the photocatalyst particles including the carbon nanotubes grown thereon to the fiber.

10. The method according to claim 8, wherein the step of producing and the step of attaching are performed in a flow of an inert gas.

11. The method according to claim 10, wherein the inert gas flow includes oxygen or hydrogen sulfide (H.sub.2S).

12. The method according to claim 10, wherein, in the step of attaching, the photocatalyst particles reach the fiber by the inert gas flow and are attached thereto.

13. The method according to claim 10, wherein the step of attaching is performed by at least one of a thermophoretic method and an electrostatic attraction method.

14. The method according to claim 8, wherein the step of allowing is performed at 500 to 2000 C.

15. The method according to claim 8, wherein the step of allowing is performed under a pressure of 0.05 to 500 torr.

16. The method according to claim 8, further comprising, after production of the photocatalyst particles, a step of classifying the photocatalyst particles by particle diameters thereof.

17. An apparatus for manufacturing a multifunctional filter medium, comprising: a discharge part configured to generate photocatalyst particles from electrodes made of a metal through discharge of low-temperature plasma; a deposition part configured to allow carbon nanotubes to grow on surfaces of the photocatalyst particles; and a collection part configured to attach the metal nanoparticles to a porous fiber.

18. The apparatus according to claim 17, wherein the metal includes one or more selected from the group consisting of titanium, tungsten, cerium, tin, zirconium, and zinc.

19. The apparatus according to claim 17, wherein a particle diameter separation part for classifying photocatalyst particles is additionally provided between the spray part and the deposition part.

20. The apparatus according to claim 17, wherein the discharge part, the deposition part, and the collection part are maintained under an inert gas atmosphere including oxygen or hydrogen sulfide (H.sub.2S).

21. The method according to claim 9, wherein the step of producing and the step of attaching are performed in a flow of an inert gas.

22. The method according to claim 9, wherein the step of allowing is performed at 500 to 2000 C.

23. The method according to claim 9, wherein the step of allowing is performed under a pressure of 0.05 to 500 torr.

24. The method according to claim 9, further comprising, after production of the photocatalyst particles, a step of classifying the photocatalyst particles by particle diameters thereof.

Description

[0047] Hereinafter, a manufacturing apparatus according to the present application is described in more detail with reference to the accompanying drawings.

[0048] FIG. 1 illustrates a schematic view of an apparatus for manufacturing a functional fiber for heavy metal adsorption according to an embodiment of the present application. As illustrated in FIG. 1, the manufacturing apparatus of the present application includes a discharge part 10; a deposition part 20, and a collection part 30.

[0049] The discharge part 10 is provided to generate photocatalyst particles from electrodes. In the discharge part 10, low-temperature plasma is discharged, and photocatalyst particles are generated from electrodes made of a metal due to the low-temperature plasma discharge.

[0050] In an embodiment, the discharge part 10 includes a pair of electrodes 11 spaced apart from each other by a predetermined distance and, although not shown, may include a gas supplier, such as a carrier air supply system, and a flowmeter such as a mass flow controller (MFC). In addition, an inert gas, such as nitrogen, may be quantitatively supplied to a first chamber 1 through the gas supplier and the flowmeter.

[0051] When a high voltage is applied to the electrodes 11, the metal is vaporized or granulated due to discharge of the low-temperature plasma and thus may be discharged to the deposition part 20 along the flow of an inert gas or nitrogen flowing through a gap between the electrodes 11. For example, when a voltage is applied to the electrodes 11 of the discharge part 10, the metal is vaporized in a gap between the pair of electrodes 11 of the discharge part 10. The vaporized metal, which has been transported along a carrier gas such as an inert gas or nitrogen, departs from the gap and thus is condensed, so that metal particles are formed. The metal may include, without being limited to, one or more selected from the group consisting of titanium, tungsten, cerium, tin, zirconium, and zinc.

[0052] In an embodiment, the discharge part 10 may include an electric circuit 12 configured to apply a high voltage to the electrodes 11. The electric circuit 12 has a constant high voltage source structure constituted of a high voltage supply source (HV), an external capacitor (C), and a resistor (R), and may control the sizes of metal photocatalyst particles using multiple resistors, multiple capacitors, and a circuit capable of performing high-speed switching of a circuit current.

[0053] In addition, a voltage required for ignition is lowered as the gap between the electrodes 11, e.g., an electrode gap which is the shortest distance between the electrodes 11, is smaller, and the voltage required for ignition increases as the gap increases. In addition, when the electrode gap is narrow, a voltage required to generate a spark is reduced, but the short spark may transfer minimum ignition energy to a mixer to cause a misfire. Accordingly, it is necessary to set an appropriate distance through experiments. In an embodiment, the electrode gap may be, without being limited to, 0.5 mm to 10 mm.

[0054] Particle diameters of the photocatalyst particles generated from the discharge part 10 may be widely controlled to units of several nanometers to hundreds of nanometers depending upon the flow rate of the inert gas. For example, the concentration of the photocatalyst particles is decreased when the flow rate of the supplied inert gas increases, whereby aggregation among the particles is also reduced. Through such a process, the sizes of the photocatalyst particles may be reduced. In addition, the particle diameters, shapes, and densities of the photocatalyst particles may be changed by spark generation conditions, such as an applied voltage, a frequency, a current, a resistance, and a capacitance value, an inert gas type and the flow rate thereof, the shape of spark electrodes, etc.

[0055] The inert gas may be, without being limited to, nitrogen (N), argon (Ar), helium (He), or the like.

[0056] As described above, flow of the inert gas may include oxygen or hydrogen sulfide (H.sub.2S). The oxygen or the hydrogen sulfide (H.sub.2S) may be used as a reaction gas in the production of the photocatalyst particles. For example, a metal component reacts with oxygen or hydrogen sulfide when the oxygen or hydrogen sulfide is supplied to a low-temperature plasma particle generator in the flow of the inert gas, whereby photocatalyst particles derived from a metal oxide, a metal sulfide, or the like may be produced.

[0057] The deposition part 20 is provided to allow carbon nanotubes to grow on surfaces of the photocatalyst particles so as to introduce the carbon nanotubes to the photocatalyst particles. In an embodiment, the deposition part 20 may include a deposition chamber 2. Although not shown, the deposition chamber 2 may include a heat treatment means for heat-treating the photocatalyst particles. The heat treatment means may be, for example, a heating means such as a heater. The deposition chamber 2 may have, without being limited to, a temperature of 500 to 2000 C. and a pressure of 0.05 to 500 torr. When the temperature and pressure of the deposition chamber are controlled within these ranges, the carbon nanotubes may regularly grow. The deposition chamber may be, for example, a chemical vapor deposition chamber.

[0058] The deposition chamber 2 may be provided with a reaction gas supplier 21. A reaction gas for forming carbon nanotubes may be supplied to the deposition chamber 2 through the reaction gas supplier 21. The reaction gas may be a carbon-based gas. The carbon-based gas is not specifically limited so long as it is a gas including carbon. For example, the carbon-based gas may be, without being limited to, one or more selected from the group consisting of methane, ethane, propane, ethylene, and acetylene. In an embodiment, the reaction gas may be, for example, supplied through the reaction gas supplier 21 after the photocatalyst particles are attached to the fiber in the collection part 30 described below. In this case, carbon nanotubes may grow from surfaces of the photocatalyst particles, which have been attached to the fiber, in the collection part 30. In another embodiment, the reaction gas may be supplied through the reaction gas supplier 21 before the photocatalyst particles are attached to the fiber in the collection part 30. In this case, photocatalyst particles, on surfaces of which carbon nanotubes have been grown, may be attached to the fiber in the collection part 30.

[0059] The manufacturing apparatus of the present application includes the collection part 30 serving to attach the photocatalyst particles, on which the carbon nanotubes have been grown, to a porous fiber. In an embodiment, the collection part 30 may be located on an inner wall of the aforementioned deposition part 20, as illustrated in FIG. 1. In the collection part 30, the photocatalyst particles are attached to the porous fiber, whereby a porous fiber including the photocatalyst particles attached thereto may be obtained.

[0060] In an embodiment, the manufacturing apparatus may include a particle diameter separation part 40 between the discharge part 10 and the deposition part 20. The particle diameter separation part 40 may include a filter or an electrostatic separator used for filtration and the like. The filter may be made of, for example, a fluororesin such as polytetrafluoroethylene (PTFE); a polyamide-based resin such as nylon-6 or nylon-6,6; a polyolefinic resin such as polyethylene, polypropylene (PP); or the like.

[0061] In addition, a pore diameter of the filter is not specifically limited and may be, for example, 2 to 2000 nm. Photocatalyst particles having a uniform average particle diameter may be produced by controlling the pore diameter of the filter within the range. Photocatalyst particles with a desired size isolated in such a manner may be attached to a surface of the fiber to a more uniform thickness.

[0062] In an embodiment, the discharge part 10, the deposition part 20 and the collection part 30 may be maintained under an inert gas atmosphere. The expression maintained under an inert gas atmosphere may also mean that the photocatalyst particles according to the present application sequentially move to the discharge part 10, the deposition part 20, and the collection part 30 along the flow of an inert gas.

Advantageous Effects

[0063] A multifunctional filter medium according to the present application can significantly reduce fine dust, harmful microorganisms, and toxic gases and reduce a pressure decrease during filtration due to exclusion of high-density nanofiber, thereby minimizing energy required for filtration and exhibiting sufficient filtration performance as a single filter medium.

DESCRIPTION OF DRAWINGS

[0064] FIG. 1 is a schematic diagram illustrating an apparatus for manufacturing a multifunctional filter medium according to an embodiment of the present application.

[0065] FIG. 2 is a result illustrating a face velocity-dependent pressure drop measured using filter mediums of Example 1 and Comparative Examples 1 to 2.

[0066] FIG. 3 is a graph illustrating a dust particle size-dependent collection efficiency increase rate of a filter medium of Example 1 with respect to a conventional filter medium in which carbon nanotubes are not grown.

DESCRIPTION OF SYMBOLS

[0067] 1: FIRST CHAMBER [0068] 10: DISCHARGE PART [0069] 11: ELECTRODE [0070] 12: ELECTRIC CIRCUIT [0071] 2: DEPOSITION CHAMBER [0072] 20: DEPOSITION PART [0073] 30: COLLECTION PART [0074] 40: PARTICLE DIAMETER SEPARATION PART

BEST MODE

[0075] Now, the present application will be described in more detail with reference to the following preferred examples. However, these examples are provided for illustrative purposes only and are not intended to limit the appended claims. Those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the application. Therefore, it is obvious that the modifications, additions and substitutions are within the scope of the present application.

Example 1

[0076] Zinc oxide particles, as photocatalyst particles, were produced by means of a low-temperature plasma particle generator while flowing nitrogen gas at 2.97 L/min and oxygen gas at 0.03 L/min. Here, the low-temperature plasma particle generator was operated under the following conditions: resistance: 0.5 M, capacitance: 1.0 nF, load current: 2 mA, applied voltage: 3 kV, and frequency: 667 Hz, and positive electrode material and negative electrode material: zinc.

[0077] The zinc oxide particles reached a carbon fiber (KF-1600, Toyobo, Japan) by flow of the nitrogen gas and then were attached thereto.

[0078] Next, acetylene gas was supplied at 30 mL/min, in a nitrogen gas flow at 3 L/min, to a chemical vapor deposition chamber at 650 C. under a pressure of 2.5 torr to allow carbon nanotubes to grow on surfaces of the zinc oxide particles attached to the fiber. As a result, a filter medium was manufactured.

Example 2

[0079] Zinc oxide particles, as photocatalyst particles, were produced by means of a low-temperature plasma particle generator while flowing nitrogen gas at 2.97 L/min and oxygen gas at 0.03 L/min. Here, the low-temperature plasma particle generator was operated under the following conditions: resistance: 0.5 M, capacitance: 1.0 nF, load current: 2 mA, applied voltage: 3 kV, and frequency: 667 Hz, and positive electrode material and negative electrode material: zinc.

[0080] Next, photocatalyst particles were fed into the chemical vapor deposition chamber, and then acetylene gas was supplied at 30 mL/min, in a nitrogen gas flow at 3 L/min, to a chemical vapor deposition chamber at 650 C. under a pressure of 2.5 torr to allow carbon nanotubes to grow on surfaces of zinc oxide particles.

[0081] Next, a temperature difference between the zinc oxide particles, on which the carbon nanotubes grew, and the fiber was adjusted to 35 C. to attach the photocatalyst particles, on which the carbon nanotubes grew, to the carbon fiber. As a result, a filter medium was produced.

Comparative Example 1

[0082] A carbon fiber, to which photocatalyst particles were not attached, was prepared.

Comparative Example 2

[0083] An experiment was performed in the same manner as in Example 1 except that a process of allowing carbon nanotubes to grow on surfaces of zinc oxide particles was not performed. The zinc oxide particles, on which carbon nanotubes were not grown, were attached to a carbon fiber, thereby producing a filter medium.

Experimental Examples

[0084] <Evaluation of Pressure Drop Dependent Upon Face Velocity>

[0085] To evaluate a pressure drop dependent upon a face velocity, an air hydraulic pressure difference before and after passing through a filter medium was measured by means of a digital differential pressure gauge (PLT-D5000 Pa, ULFA Technology, Korea).

[0086] FIG. 2 illustrates results of a pressure drop dependent upon a face velocity measured using filter mediums of Example 1 and Comparative Examples 1 to 2. As illustrated in FIG. 2, it can be confirmed that the carbon fiber of Comparative Example 1 and the carbon fiber, to a surface of which photocatalyst particles were attached, of Comparative Example 2 exhibit a pressure drop value similar to that of a theoretical carbon fiber filter medium as the face velocity increases. In addition, as illustrated in FIG. 2, it can be confirmed that a pressure drop degree of the filter medium of Example 1 is maintained at almost the same level without any difference in the pressure drop degree as a face velocity increases, compared to the filter mediums of the comparative examples.

[0087] That is, it can be confirmed that, in the case of the filter medium of Example 1, energy required for ultrafine dust filtration can be minimized because an additional pressure drop does not occur although the carbon nanotubes were grown, and sufficient filtration performance can be provided even using a single filter medium because a high-density filter medium is not additionally required for ultrafine dust filtration.

[0088] <Evaluation of Collection Efficiency Dependent Upon Dust Particle Size>

[0089] To evaluate collection efficiency dependent upon a dust particle size, the sizes of supplied particles were measured before and after passing through a filter medium by means of a scanning mobility particle sizer (SMPS, 3936, TSI, USA). The collection efficiency was calculated using a size difference before and after passing through the filter medium.

[0090] FIG. 3 is a graph illustrating a dust particle size-dependent collection efficiency increase rate of the filter medium of Example 1 with respect to a conventional filter medium in which carbon nanotubes were not grown. As illustrated in FIG. 3, it can be confirmed that the conventional filter medium including a fiber, on which carbon nanotubes have not been grown, exhibits decreased diffusion, interception, and inertial impaction due to Brownian motion in the presence of ultrafine dust with a particle diameter of about 20 nm to 500 nm, thereby exhibiting decreased filtration efficiency. However, it can be confirmed that the filter medium of Example 1 exhibits excellent collection efficiency for ultrafine dust having a particle diameter of about 20 nm to 500 nm.

[0091] That is, it was confirmed that the filter medium of Example 1 can significantly reduce fine dust, harmful microorganisms, and toxic gases.