Long-life air filter for automobiles and method of manufacturing the long-life air filter

Patent metadata

Field	Value
Publication number	US-10399026-B2
Application number	US-201615270724-A
Country	US
Kind code	B2
Filing date	Sep 20, 2016
Priority date	Feb 5, 2016
Publication date	Sep 3, 2019
Grant date	Sep 3, 2019

Abstract

An air filter for automobiles includes, a main filter and a prefilter, wherein the prefilter comprises a nonwoven synthetic fiber having an average density of 0.01 to 0.5 g/cm 3 and a moisture absorbent is adsorbed to the prefilter.

First claim

What is claimed is:

1. An air filter for automobiles comprising:
a main filter; and
a prefilter,
wherein the prefilter comprises a nonwoven synthetic fiber having an average density of 0.01 to 0.5 g/cm 3 ,
a moisture absorbent is adsorbed to the main filter and the prefilter,
a total adsorption amount of the moisture absorbent adsorbed to the main filter is 70 to 80 g/cm 2 , and
a total adsorption amount of the moisture absorbent adsorbed to the prefilter is 20 to 30 g/cm 2 .

2. An air filter for automobiles comprising:
a main filter;
a prefilter,
wherein the prefilter comprises a first nonwoven synthetic fiber layer having an average density of 0.031 to 0.5 g/cm 3 ; and
a second nonwoven synthetic fiber layer having an average density of 0.01 to 0.03 g/cm 3 ,
wherein a moisture absorbent is adsorbed to the main filter and the prefilter,
a total adsorption amount of the moisture absorbent adsorbed to the main filter is 70 to 80 g/cm 2 , and
a total adsorption amount of the moisture absorbent adsorbed to the prefilter is 20 to 30 g/cm 2 .

3. The air filter according to claim 1 , wherein the moisture absorbent is silica.

4. The air filter according to claim 1 , wherein the moisture absorbent has an average particle diameter of 1 to 25 nm.

5. The air filter according to claim 1 , wherein a thickness of the prefilter is 20 to 70 mm.

6. The air filter according to claim 1 , wherein the nonwoven synthetic fiber comprises 60 to 70% by weight of polyethylene terephthalate and 30 to 40% by weight of polymethylmethacrylate.

7. The air filter according to claim 1 , wherein an average pore size of the nonwoven synthetic fiber is 300 to 1000 μm.

8. The air filter according to claim 2 , wherein a thickness of each of the first and second nonwoven synthetic fiber layers is 10 to 35 mm.

9. The air filter according to claim 1 , wherein the main filter comprises:
a compact layer comprising a nonwoven synthetic fiber having an average pore size of 30 to 50 μm;
an intermediate layer comprising a nonwoven synthetic fiber having an average pore size of 50 to 150 μm and being formed on the compact layer; and
a bulky layer comprising a nonwoven synthetic fiber having an average pore size of 250 to 350 μm and being formed on the intermediate layer.

10. The air filter according to claim 9 , wherein the compact layer has an average density of 0.08 to 0.15 g/cm 3 and a thickness of 0.3 to 1.5 mm.

11. The air filter according to claim 9 , wherein the intermediate layer has an average density of 0.04 to 0.1 g/cm 3 and a thickness of 0.5 to 1.5 mm.

12. The air filter according to claim 9 , wherein the bulky layer has an average density of 0.02 to 0.07 g/cm 3 and a thickness of 1 to 2.5 mm.

13. A method of manufacturing a long-life air filter for automobiles, the method comprising:
forming a nonwoven web after carding a synthetic fiber;
combining the web by a needle punching process;
respectively forming a main filter and a prefilter by passing the combined web through a press roll;
respectively impregnating the main filter and the prefilter with a moisture absorbent solution;
respectively drying the impregnated main filter and prefilter; and
manufacturing an air filter by laminating the prefilter on the main filter,
wherein a moisture absorbent is adsorbed to the main filter and the prefilter,
a total adsorption amount of the moisture absorbent adsorbed to the main filter is 70 to 80 g/cm 2 , and
a total adsorption amount of the moisture absorbent adsorbed to the prefilter is 20 to 30 g/cm 2 .

14. The method according to claim 13 , wherein, in the steps of respectively forming the main filter and prefilter, the prefilter is made of a nonwoven synthetic fiber having an average density of 0.01 to 0.5 g/cm 3 .

15. The method according to claim 13 , wherein, in the steps of respectively forming the main filter and prefilter, the prefilter is made of a first nonwoven synthetic fiber having an average density of 0.031 to 0.5 g/cm 3 and a second nonwoven synthetic fiber having an average density of 0.01 to 0.03 g/cm 3 .

16. The method according to claim 13 , wherein, in the steps of respectively forming the main filter and prefilter, the main filter comprises:
a compact layer comprising a nonwoven synthetic fiber having an average pore size of 30 to 50 μm;
an intermediate layer comprising a nonwoven synthetic fiber having an average pore size of 50 to 150 μm and being formed on the compact layer; and
a bulky layer comprising nonwoven synthetic fiber having an average pore size of 250 to 350 μm and being formed on the intermediate layer.

17. The method according to claim 13 , wherein, in the step of impregnating the main filter and the prefilter with a moisture absorbent solution, the moisture absorbent solution is a solution in which a moisture absorbent composed of silica is dispersed in a colloidal state.

18. The method according to claim 13 , wherein, in the step of respectively drying the impregnated main filter and prefilter, the drying s carried out at 40 to 100° C. for three to seven hours.

Assignees

• Hyundai Motor Co Ltd
• Kia Motors Corp

Inventors

• Seo Yong Gyo
• Lee Ju Yong
• Kwak Seong Youn

Classifications

• B01D39/163

  sintered or bonded · CPC title

• B01D2239/065

  More than one layer present in the filtering material · CPC title

• B01D2239/0407

  comprising particulate additives, e.g. adsorbents · CPC title

• B01D2239/064

  The fibres being mixed · CPC title

• B01D2239/1233

  Fibre diameter · CPC title