CN101410162A - 能打褶的无纺材料及其制造方法和设备 - Google Patents

能打褶的无纺材料及其制造方法和设备 Download PDF

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CN101410162A
CN101410162A CNA2007800108781A CN200780010878A CN101410162A CN 101410162 A CN101410162 A CN 101410162A CN A2007800108781 A CNA2007800108781 A CN A2007800108781A CN 200780010878 A CN200780010878 A CN 200780010878A CN 101410162 A CN101410162 A CN 101410162A
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A·泽贝格尔
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Abstract

本发明涉及一种能打褶的无纺材料，该无纺材料包括支承的、使形状稳定的较粗的纤维和决定过滤效果的较细的纤维，其中规定，所述较细的纤维沿无纺材料表面的方向基本上均匀地并入较粗的纤维中，并且沿垂直于无纺材料表面的方向形成较细纤维的分布密度－梯度，使得较细纤维的集中度在中心区域内或两个外侧之一上最高，其中较粗的纤维和较细的纤维从熔融状态通过凝固而相互粘结以及由相同的材料制成。

Description

能打褶的无纺材料及其制造方法和设备
技术领域
本发明涉及一种能打褶的无纺材料及其制造方法和设备，所述无纺材料包括支承的、使形状稳定的较粗的纤维和决定过滤效果的较细的纤维。
背景技术
DE 103 10 435 B3公开了这种类型的无纺材料。在这种已知的过滤器元件中设有透气的支承材料，该支承材料在两侧涂覆有包括纳米纤维和微纤维的纤维层，其中涂层厚度从流入侧向流出侧增加从而形成渐进的过滤器元件。与当时已知的过滤材料相比，这种实施形式已经可以大大改善过滤性能。
在这种通常打褶的并以这种形状在机动车辆中用作空气过滤器的过滤材料中，在空气穿过时产生尽可能低的压降是很重要的，因为低的压降与小尺寸的鼓风机马达相对应，因此能量消耗相应低和噪音产生少。
这种对具有低压差的过滤系统的要求与要求的分离性能和所需的使用寿命相对立。
这两种要求主要通过不同粗度/直径——通常约20μm以及约4μm——的纤维来实现。
纤维密度的这种累进的实施形式这样实现，即在一种制造方法中，例如由DE 41 23 122 A1已知，在装入过滤器时将纤维网的一侧——纤维网在制造过程中被铺设在这一侧——用作流出侧。
为了进一步改进过滤器特性，人们致力于将直径越来越细的纤维用于过滤器制造。
所谓的熔吹方法是目前最普遍的制造细纤维的技术。由于结构的设计，这种方法限于尺寸大于2μm的纤维。其中，使用低粘性的介质，其在试图获得较小的纤维粗度时被撕裂。
为了提高过滤器的分离性能同时使与此相关的压力损失的增加最小，非常细的纤维是很重要的，因为由此增大了内表面，能分离出越来越细小的颗粒并延长了使用寿命。
从小于约500nm的纤维尺寸起，发生所谓的滑流效应(Slip-Flow-Effekt)，与较粗的纤维不同，该滑流效应使在非常细的纤维(纳米纤维)表面上的流速不会减少至零，并使空气流中包含的小颗粒更容易地扩散、被捕集和抑留。
根据现有技术，这种纳米纤维由溶液通过所谓的电子纺丝工艺制成，如例如在DE 103 10 435 B3中描述的那样。其中，通过溶媒溶解聚合物，并通过施加高压制造最小直径达50nm的纤维。
这种电子纺丝工艺的重要的缺点是使用大量的溶媒。由于在该工艺中产生的蒸汽和同时施加的高压，存在较大的爆炸危险。另外，蒸汽对环境有害并且因此对操作人员的健康带来危险。另一重要缺点是过滤材料的涂敷在一特别/单独的步骤中进行，使得纳米纤维实际上仅位于涂层的表面。这种多层性使得无纺材料很难打褶。据此，材料的可折叠性通常仅通过点-连接实现。
还已知纤维粗度低于1μm的玻璃纤维媒介。由于这种脆材料在承受机械载荷时会断裂并由此释放颗粒，所以该材料被归为致癌物质。此外，玻璃纤维媒介相对于分离性能具有非常高的压差。
DE 10 2004 036 440A1公开了在支承架内分布有纳米纤维的过滤材料。电子纺丝是可能的制造方法。WO 2006/049664A1也描述了类似的过滤材料。
JP 02-264057A公开了一种由熔吹工艺制造的无纺材料，其中不同的材料被从不同的纺丝喷嘴中挤压出。第一组纺丝喷嘴的直径大约为8μm，另一组纺丝喷嘴的直径小于等于8μm。
DE 693 22 572T2描述了一种纺丝喷嘴彼此成角度布置的实施形式。
EP 0 674 035A2公开了一种从侧面提供空气的纺丝箱体。
发明内容
在此基础上，本发明的目的是创造一种能打褶的无纺材料，该无纺材料一方面具有特别好的过滤特性，特别是在具有高分离性能的同时具有低的压差，另一方面，该无纺材料可以环保地并以高的通过能力/生产能力、因而经济地制造。
根据本发明，该目的这样得以实现，即，将较细的纤维沿无纺材料的表面的方向基本上均匀地并入较粗的纤维中，并且使得较细纤维的分布密度-梯度沿垂直于无纺材料表面的方向这样产生，即较细纤维的集中度在中心区域内或者两个外侧之一处最高，其中较粗纤维和较细纤维从熔融状态通过凝固粘结在一起并且包括相同的材料。
在此优选规定，较粗纤维的直径大于2μm，而较细纤维的直径小于1000nm。特别是，较粗纤维的直径应当在2μm到200μm之间，而较细纤维的直径应当在50nm到1000nm之间。这种十分细的纳米纤维能够实现特别好的过滤效果。
纤维可以优选由聚酰胺、聚丙烯、聚酯或者其共混物组成。
本发明还涉及一种用于制造能打褶的纤维网/无纺材料的方法，其中聚合物被熔化并且被挤压通过纺丝箱体的纺丝喷嘴，由此形成的聚合物线被铺放在输送带上以便形成纤维网层，其中根据本发明规定，使用不同直径的纺丝喷嘴并由此在单一的工艺步骤中制造和铺放较粗和较细的聚合物线，其中使用不同直径的纺丝喷嘴并同时在单一的工艺步骤中制造和铺放较粗和较细的聚合物线，其中纺丝喷嘴的直径小于0.2mm，优选0.15mm，对于较粗的纤维，直径大于0.2mm，优选0.3-0.4mm，并且使用熔融流动指数“mfi”明显低于500的高粘性聚合物熔融物。
由此实现期望的、较细纤维在由较粗纤维形成的支承架中的均匀分布。
优选地，设置有至少两个彼此以一定角度布置的纺丝箱体，其中由每个纺丝箱体的纺丝喷嘴中出来的聚合物线在与撞到基底上之前，但最迟在撞到基底上时相混合并相互缠结。
特别地，可以使用两个纺丝箱体，其中第一纺丝箱体包括直径较大的喷嘴，而第二纺丝箱体包括直径较小的喷嘴。
为了得到直径非常细的长纤维，使用熔融流动指数“mfi”明显低于500的高粘性聚合物熔融物是很重要的。
另一个重要的方面在于，引至纺丝箱体的空气具有数量级为500mbar的较小的过压。
本发明还涉及一种用于实施上述方法的设备，该设备包括具有多个彼此依次布置的纺丝喷嘴的纺丝箱体以及用于铺放从纺丝喷嘴出来的聚合物线的输送带，所述设备的突出之处在于，设有至少两个纺丝箱体，所述纺丝箱体相对彼此布置成，使得出来的聚合物线在撞到输送带上之前，但最迟在撞到输送带上之后相互混合，其中第一纺丝箱体具有直径较大的纺丝喷嘴，而第二纺丝箱体具有直径较小的纺丝喷嘴，直径较小的纺丝喷嘴的直径小于0.2mm，优选约0.15mm，直径较大的纺丝喷嘴的直径大于0.2mm，优选03.-0.4mm。
特别是规定，所述纺丝箱体彼此成角度布置，使得出来的较细的纤维和较粗的纤维彼此混合并相互缠结。
特别地，第一纺丝箱体包括直径较大的纺丝喷嘴，而第二纺丝箱体包括直径较小的纺丝喷嘴。
最后，可以在纺丝喷嘴的出口区域内设置鼓风机，用于产生数量级为500mbar的空气流。
纺丝喷嘴特别有利地通过激光来生产，并具有小于0.20mm的直径。这使得能够以经济的方式制造高密度的小直径纺丝喷嘴。
具体实施方式
下面参照用扫描电子显微镜拍摄的照片和附图对本发明进行更加详细的说明。
下面的图像1和2示出各种尺寸的纤维的分布(参照图像1和图像2)。
粗纤维(直径大约15μm)大部分表现为复合纤维。在此，粗的单纤维连接成复合纤维，其中纤维缠结(物)(直至200μm)不仅仅是彼此松散接触，而且其表面大部分熔接在一起。
中等直径的纤维(大约1-2μm)通常表现为单纤维的形式，很少表现为最多3根纤维的缠结的形式。
在概况照片中可清楚地看出，明显较细的纤维(小于1μm的纳米纤维)的网穿过粗的和中等纤维直径的纤维结构。最细的纤维仅以单纤维的形式出现。(参见图像3)
细纤维的直径分别为733nm或者857nm。直径明显低于1μm的纤维明确地是指纳米纤维。(参见图像4)
在高放大倍率下，直径约为11μm的“标准”纤维与周围的直径约为750nm的纳米纤维之间的极小区别变得很明显。(参见图像5)
照片以70°的倾角拍摄，以便示出纤维网横截面内的纤维结构。
在照片的下部可看到粘结的粗纤维的基本结构。在照片的中部示出包括细纤维和纳米纤维的部分。覆盖层由中等直径的纤维形成。(参见图像6)
纳米纤维(测量值：522nm)邻近直径约为1-2μm的纤维。(参见图像7)
在对过滤媒介施加氯化钠颗粒后(在颗粒过滤器实验台架(Rondenprüfstand)中大约15分钟)：
背景中是粗纤维(直径大约10-15μm)。非常小的氯化钠颗粒(明显小于0.5μm)部分地沉积在粗纤维的表面上。
尽管最细的纤维的直径仅约为粗纤维的1/25，但是沉积在前面部分中的非常细的纳米纤维(测量值：直径426nm)上的颗粒的数量与沉积在粗纤维上的颗粒数量相似。
上述的图像8示出在施加氯化钠颗粒后的粗纤维、中等纤维和纳米纤维的概况照片。(参见图像8)
下面结合图1和图2对按照本发明的设备进行说明：
下述的图1示出纺丝箱体1的示意性剖视图，该纺丝箱体1包括多个并排布置的纺丝喷嘴2，液体聚合物的锥形体4在(一定)压力下通过这些纺丝喷嘴流出，如箭头3所示。由鼓风机产生的、压力约为500mbar的空气流通过空气通道5沿着箭头6的方向被提供。
图2示出两个纺丝箱体1的示意图，这两个纺丝箱体彼此之间成锐角β并且相对于与布置在纺丝箱体1下方的输送带7垂直的方向成α角。
图2左侧的纺丝箱体1包括直径较大的纺丝喷嘴2，而图2右侧的纺丝箱体1包括直径较小的纺丝喷嘴2，从而直径较大的聚合物线8与直径较小的聚合物线9在区域10中彼此混合并相互缠结，然后被铺放在输送带7上，以形成无纺过滤材料11。该方法确保较细的聚合物线9基本上均匀地分布在较粗的聚合体线8之间。

Claims (15)

1.一种能打褶的无纺材料，包括支承的、使形状稳定的较粗的纤维和决定过滤效果的较细的纤维，其特征在于，所述较细的纤维沿无纺材料表面的方向基本上均匀地并入较粗的纤维中，并且沿垂直于无纺材料表面的方向形成较细的纤维的分布密度-梯度，使得较细的纤维的集中度在中心区域内或两个外侧之一上最高，其中较粗的纤维和较细的纤维从熔融状态通过凝固而相互粘结以及由相同的材料制成。
2.根据权利要求1所述的能打褶的无纺材料，其特征在于，较粗的纤维的直径大于2μm，较细的纤维的直径小于1000nm。
3.根据权利要求2所述的能打褶的无纺材料，其特征在于，较粗的纤维的直径在2到200μm之间。
4.根据权利要求2所述的能打褶的无纺材料，其特征在于，较细的纤维的直径在50nm到1000nm之间。
5.根据权利要求1所述的能打褶的无纺材料，其特征在于，所述纤维包括聚酰胺、聚丙烯、聚酯或者其共混物。
6.一种用于制造能打褶的纤维网的方法，其中聚合物被熔化并被挤压通过纺丝箱体的纺丝喷嘴，由此产生的聚合物线被铺放在输送带上从而形成纤维网层，其特征在于，使用直径不同的纺丝喷嘴(2)，并且同时在单一的工艺步骤中制造和铺放粗度较大和粗度较小的聚合物线(8，9)，其中对于细纤维，纺丝喷嘴(2)的直径小于0.2mm，优选0.15mm，对于粗度较大的纤维，纺丝喷嘴(2)的直径大于0.2mm，优选0.3-0.4mm，并使用熔融流动指数“mfi”明显低于500的高粘性聚合物熔融物。
7.根据权利要求6所述的方法，其特征在于，使用至少两个彼此成角度布置的纺丝箱体(1)，其中由每个纺丝箱体(1)的纺丝喷嘴(2)出来的聚合物线(9)在撞到基底上之前混合并相互缠结。
8.根据权利要求6所述的方法，其特征在于，使用两个纺丝箱体(1)，其中第一纺丝箱体(1)具有直径较大的喷嘴，而第二纺丝箱体(1)具有直径较小的喷嘴。
9.根据权利要求6所述的方法，其特征在于，使用高粘性的聚合物熔融物。
10.根据权利要求9所述的方法，其特征在于，熔融流动指数“mfi”明显低于500。
11.根据权利要求6所述的方法，其特征在于，向纺丝箱体提供压力数量级为500mbar的空气。
12.一种用于实施根据权利要求6至11所述的方法的设备，该设备包括具有多个并排布置的纺丝喷嘴的纺丝箱体以及用于铺放从纺丝喷嘴出来的聚合物线的输送带，其特征在于，设有至少两个纺丝箱体(1)，所述纺丝箱体相对于彼此布置成，使得出来的聚合物线在铺放在输送带(7)上之前相混合，其中第一纺丝箱体(1)具有直径较大的纺丝喷嘴(2)，而第二纺丝箱体(1)具有直径较小的纺丝喷嘴(2)，直径较小的纺丝喷嘴(2)的直径小于0.2mm，优选约0.15mm，而直径较大的纺丝喷嘴(2)的直径大于0.2mm，优选0.3-0.4mm。
13.根据权利要求12所述的设备，其特征在于，至少两个纺丝箱体(1)彼此成角度(β)布置。
14.根据权利要求12所述的设备，其特征在于，在纺丝喷嘴(2)的出口区域内设有鼓风机，用于产生压力数量级为500mbar的空气流。
15.根据权利要求12所述的设备，其特征在于，通过激光钻孔制造纺丝喷嘴(2)。
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JP2009531554A (ja) 2009-09-03
DE102006014236A1 (de) 2007-10-04
US20090117803A1 (en) 2009-05-07
ES2533961T3 (es) 2015-04-16
WO2007112877A3 (de) 2008-03-13
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US8834762B2 (en) 2014-09-16
US20120187593A1 (en) 2012-07-26
EP1998867A2 (de) 2008-12-10
US20150061175A1 (en) 2015-03-05
CA2647800C (en) 2015-02-03
RU2418615C2 (ru) 2011-05-20
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CA2647800A1 (en) 2007-10-11
US10273611B2 (en) 2019-04-30
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