CN101678254B - 在空气过滤器中应用的多层复合物 - Google Patents

在空气过滤器中应用的多层复合物 Download PDF

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CN101678254B
CN101678254B CN200880016801XA CN200880016801A CN101678254B CN 101678254 B CN101678254 B CN 101678254B CN 200880016801X A CN200880016801X A CN 200880016801XA CN 200880016801 A CN200880016801 A CN 200880016801A CN 101678254 B CN101678254 B CN 101678254B
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H·曼施泰因
R·格罗滕
A·霍林斯沃思
I·埃瓦尔德
J·亨德勒
K·维瑟尔
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Carl Freudenberg KG
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Abstract

本发明涉及一种在空气过滤器中应用的多层复合物，所述多层复合物至少包括一入流层(1)和一与所述入流层连接的支承层(2)，其中所述入流层(1)由无纺织物制成并且与所述支承层(2)相比具有更微小的多孔结构，本发明的目的是设计和改进在空气过滤器、特别是过滤袋中应用的多层复合物，从而在成本经济地生产的情况下实现入流层与支承层的稳定结合。本发明的技术特征在于，所述入流层(1)设计成纺粘型非织造织物，所述入流层的无端长丝(3)与所述支承层(2)至少部分地交织或编织在一起。

Description

在空气过滤器中应用的多层复合物
技术领域
本发明涉及一种在空气过滤器中应用的多层复合物，所述多层复合物至少包括一个入流层和一个与所述入流层结合的支承层，其中所述入流层由无纺织物制成，该入流层的多孔结构/多孔性/孔隙率(
Figure G200880016801XD00011
)比所述支承层更微小。
背景技术
这种类型的多层复合物在过滤袋和袋式过滤器装置中使用。袋式过滤器装置经常用于在发电站中净化含粉尘/灰尘的气体。在袋式过滤器装置中设置多个过滤袋，其中过滤袋被夹紧在位于净化气体侧的支承体上。在从未处理气体侧向净化气体侧流经过滤袋时，粉尘被挡在过滤袋的未处理气体侧。被净化的气体经由过滤袋到达净化侧。
这种类型的过滤袋在一定的工作时间后便被滤饼阻塞。该滤饼处于过滤袋的朝向未处理气体侧的一侧。过滤袋可以通过从净化气体侧进行的压力冲击而被清洁干净。通过这种压力冲击使附着在过滤袋上的滤饼脱离并落到在未处理气体侧的粉尘收集箱中。
已知在支承层上敷设纤维网作为入流层。已知由短纤维制成的无纺织物作为纤维网。由短纤维制成的无纺织物通常与支承层热结合，并加工成层压制品。为使多层复合物具有足以抵抗压力冲击的稳定性必需实施这种措施。应当防止入流层脱离支承层。
这种现有技术不利的是，由于所述热固定使所形成的多层复合物既易碎、难以移动，又仅能以复杂的方式制成。
为了制造过滤袋，此外经常选择包括一个支承层和两个短纤维无纺织物(层)的多层复合物。在所述多层复合物中，所述两个短纤维无纺织物通过机械针刺与支承层结合并彼此结合。
这种现有技术不利的是，多层复合物为进行制造而具有穿刺位置，所述穿刺位置提高了粉尘颗粒的渗透性。此外不利的是，为了制造这种多层复合物，仅能使用具有一允许对纤维进行梳理(Kardierung)的细度的较粗纤维。
发明内容
本发明的目的在于，设计和改进开头所述类型的用在空气过滤器中——特别是在过滤袋中——的多层复合物，从而能够在成本低的制造中实现入流层与支承层的稳定结合。
根据本发明，前述目的通过权利要求1的特征来实现。
为此，开头所述类型的、在空气过滤器中、特别是在过滤袋中应用的多层复合物的特征在于，所述入流层设计成纺粘型非织造织物，所述入流层的无端长丝与支承层至少部分地交织或编织在一起。
根据本发明认识到：可以以连续的挤压纺丝法由纺粘型非织造织物来制造入流层。在所述挤压纺丝法中形成无端长丝，通过利用水射流将所述无端长丝引入支承层的方式，可使所述无端长丝与支承层至少部分地交织或编织在一起。根据本发明特别是认识到：将入流层设计成纺粘型非织造织物允许连续地制造多层复合物。此外认识到：特别是无端长丝实现了入流层与支承层特别牢固的结合。最后认识到：任何多孔结构大于入流层的多孔结构的织物、针织物或任何纺织的网状结构都可以用作支承层。将入流层设计成纺粘型非织造织物实现了根据要求的特点来调节入流层的多孔结构。在此可以将入流层的多孔结构调节成，使得存在尽可能多的小孔，其中孔直径的分布曲线尽可能地窄。由此实现了上文所述的目的。
根据本申请，微小的多孔结构理解为一种孔结构，该孔结构的特征为孔直径非常小，其中尽可能多的孔具有类似的孔直径，由此具有很窄的分布曲线。在此如果入流层的平均孔直径小于支承层的平均孔直径，则入流层与所述支承层相比具有更微小的多孔结构。优选地，入流层的孔直径分布曲线与支承层相比是非常窄的。优选地，支承层的平均孔直径至少是入流层的平均孔直径的两倍。通过这样的多层复合物可以实现有效的粉尘分离，而支承层不会被未在入流层上被分离的颗粒阻塞。
支承层可以设计成纺粘型非织造织物，其无端长丝具有与入流层平均直径相比更大的平均直径。通过这个具体设计方案可以实现入流层与支承层特别牢固的结合，因为无端长丝可以容易地彼此交织在一起。从背景技术出发可以具体考虑，支承层和入流层都以挤压纺丝法连续制造，并通过水射流彼此交织在一起。通过水射流处理可以使特别纤细的无端长丝均匀地与支承层编织在一起，而不会形成如在机械针刺技术中出现的通道。
所述入流层可以包括平均直径为0.3μm至10μm、优选＜7μm的无端长丝。已证明从0.3μm至10μm的范围中选出无端长丝特别有利于使入流层具有微小的多孔结构。通过从所述直径范围选出无端长丝实现了有效的粉尘分离。特别是认识到：当入流层的无端长丝的平均直径小于7μm时，可以实现特别良好的细微粉尘分离。
多层复合物可以具有500g/m2以下的单位面积重量，优选300g/m2以下的单位面积重量。已证明这样的单位面积重量有利于防止多层复合物被被进入的粉尘机械地阻塞。此外，这样的单位面积重量可以减少制造多层复合物所需的原料量。
从背景技术出发可以考虑，所述入流层具有20g/m2至100g/m2的单位面积重量。通过这个具体设计方案，可以使用特别少量的原料来制造具有高分离性能的多层复合物。
所述支承层可以包括纤度大于3dtex、优选大于5dtex的无端长丝。通过从所述范围选出无端长丝的纤度，实现了孔足够粗大的支承层，所述支承层允许未由入流层分离的颗粒通过，而不会被阻塞。此外利用所述纤度的无端长丝可构造出足够稳定的支承层，所述支承层能可靠地支承单位面积重量特别小、稳定性低的入流层，还能在较高的压力冲击时使入流层结合在其上。
入流层的无端长丝可以设计成膜裂纤维/原纤化纤维，即设计成多组分无端长丝的至少部分地彼此隔开的组成部分。通过这个具体设计方案可以实现，通过水射流针刺或水射流处理分开或分裂入流层的无端长丝、减小长丝直径。可以在一个步骤中使入流层的无端长丝分裂，同时与支承层编织在一起。
从背景技术出发可以考虑，无端长丝设计成双组分无端长丝的至少部分地彼此隔开的组成部分。双组分无端长丝容易买到。从背景技术出发可十分具体地考虑，将双组分无端长丝设计成分层无端长丝(Pie-Endlosfilament)或海岛无端长丝。所述类型的双组分无端长丝可以通过水射流容易地分开。由此可以由原本较厚的无端长丝制造成多个非常薄的无端长丝。
从背景技术出发可以考虑，所述无端长丝通过机械处理、热处理或化学处理由多组分无端长丝形成或分成。
所述无端长丝可以通过水射流处理、由多组分无端长丝形成。通过水射流处理可以小心地、几乎无损害地将原本较厚的无端长丝分裂成非常细的无端长丝。由此可以制成具有非常微小的多孔结构的纺粘型非织造织物。此外水射流处理有利地实现：不会形成粉尘颗粒能穿过的通道。
无端长丝可以具有三角形横截面。这种无端长丝可以通过水射流处理由分层无端长丝分成。三角形横截面的无端长丝的表面是圆形横截面的无端长丝的1.75倍。由此可以制造出形成非常大的表面进而形成大粘附面积的入流层。
无端长丝可以形成一表面，所述表面由于所述无端长丝的至少一部分的机械结合或热结合而形成。通过这个具体设计方案，可以获得一平滑且抗腐蚀的表面。此外，这样的表面具有抗粘附特性，从而使从过滤袋上取下滤饼更加容易，所述过滤袋由在此所述类型的多层复合物制成。
在所述支承层中除了形成结构的无端长丝外还可设有粘合纤维，所述粘合纤维与支承层的无端长丝相比可具有更低的熔点。支承层的形成结构的无端长丝使所述支承层具有一定结构和多孔性。粘合纤维可以优选设计成芯皮纤维或并列型复合纤维/并列型双组分纤维，其在热作用下与无端长丝结合。通过这个具体设计方案，可以制成稳定的支承层。还可以考虑，全部支承层仅由双组分无端长丝制成，其中低熔点组分在无端长丝之间形成结合。有利地，不形成无粘合纤维的区域，从而可以实现特别稳定的均匀结构的支承层。根据对多层复合物的机械要求来选择支承层的单位面积重量。将较粗的无端长丝布置到开孔较大(offenporig)的无纺织物结构中防止了：细微的粉尘堆集在所述支承层中进而阻塞支承层。这一点(阻塞支承层)会导致在未处理气体侧和净化气体侧之间的压差急剧升高。
多层复合物可以具有三层结构，其中第三层类似于入流层设计。由此可以获得特别高的过滤效率。从背景技术出发可以考虑，支承层由松织织物/纱线粘合非织造布(Scrim)制成。松织织物的特征在于稳定性高，并能容易地通过水射流与无端长丝交织在一起。
可以在入流层上设置包括纳米纤维或微纤维的第三层。根据本申请，纳米纤维理解成平均直径为50nm至300nm的纤维。微纤维理解为纤度＜1detx的纤维。通过这个具体设计方案，可在不显著地提高在未处理气体侧和净化气体侧之间的压差的情况下进一步提高过滤效率。稳定性低的纳米纤维或微纤维可以通过粗纤维覆层来保护。
从背景技术出发可以考虑，在支承层后(下游)设有包括纳米纤维或微纤维的层。在这种具体情况下，支承层被夹置在包括纳米纤维或微纤维的第三层与入流层之间。
可以考虑，在具有多个喷嘴排的纺粘型非织造纺织织物设备(Spinnvliesstoffanlage)上由喷嘴排的一部分纺制粗的芯皮型的双组分无端长丝，其在所制造的多层复合物中用作支承层。可以利用剩余的喷嘴排制造分层无端长丝，其中入流层和支承层通过水射流彼此结合。此外，通过水射流针刺使入流层的分层无端长丝分开或分裂成多个单独的无端长丝。
为了制造入流层的分层无端长丝或者说桔瓣式无端长丝、或海岛无端长丝，使用能够容易地使所述无端长丝分裂的聚合物。为了制造支承层的无端长丝优选使用使无端长丝彼此良好地结合的聚合物。此外，支承层以较粗的孔而具有大的多孔结构。优选在此应用芯皮无端长丝。
从背景技术出发可以十分具体地考虑，纺粘型非织造织物由聚合物如聚酯、聚酰胺、聚酰胺6、聚酰胺6.6、聚乙烯、间规聚苯乙烯和/或这些聚合物的混合物制成。
以＜300g/m2的单位面积重量，所述多层复合物可以满足在过滤器设备或过滤袋中的机械和过滤技术要求。与此相反，标准的针刺无纺织物具有＞500g/m2的(单位面积)重量，并必须利用纺织物或针织物来加强以改善其机械稳定性。有利地，在单级工艺(一个步聚的过程)中便能由聚合物粒颗纺成无端长丝并将所述无端长丝堆叠和固定成无纺织物。
从背景技术出发可以考虑，对多层复合物进行据油整理。在此，不需要随后进行浸透，因为用于据油的添加剂在生产无端长丝时已被输入挤压机中。这同样适用于据水整理。在染色时也不需要附加地染色，因为颜料在生产无端长丝时已被装入挤压机中。
还可以具体考虑，在单级工艺中通过逐渐建立入流层和支承层来制造双层的多层复合物。在此，逐渐建立理解为在无端长丝的厚度、密度或者多孔结构方面形成梯度。
在此描述的多层复合物和用于制造这种多层复合物的方法特别适合于制造薄的、刚性的进而能打褶的过滤介质，所述过滤介质与针刺无纺织物相比具有较小的单位面积重量、较小的厚度、较高的刚性。
存在各种不同的可能方案来对本发明的教导进行有利的扩展和改进。对此一方面参考权利要求，另一方面参照下面借助附图和图表对本发明优选实施例的阐述。
附图说明
结合对本发明优选实施例的阐述，借助附图和图表还概括地阐述了本发明理论的优选设计方案和改进方案。在附图中：
图1示出了多层复合物的扫描电子显微镜(REM)图像，其中入流层和支承层都由纺粘型非织造织物制成，
图2示出了包括入流层、支承层和第三层的三层多层复合物的REM图像，所述第三层类似于入流层制成，
图3示出了包括入流层、由松织织物制成的支承层和第三层的三层多层复合物的REM图像，所述第三层类似于入流层制成。
具体实施方式
图1示出了用在空气过滤器中、特别是过滤袋中的多层复合物的扫描电子显微镜图像，所述多层复合物具有由无纺织物制成的入流层1。所述入流层1的多孔结构比支承层2更微小。入流层1设计成纺粘型非织造织物，其无端长丝3与支承层2至少部分地交织或编织在一起。支承层2设计成纺粘型非织造织物，所述支承层的无端长丝4具有与入流层1的无端长丝3的平均直径相比更大的平均直径。入流层1的无端长丝3通过水射流处理与支承层2交织在一起。入流层1和支承层2都由纺粘型非织造织物制成，所述纺粘型非织造织物以挤压纺丝法制造。
入流层1具有平均直径为0.3μm至10μm的无端长丝3。根据图1的多层复合物具有272g/m2的单位面积重量。此外，所述多层复合物具有936N/50mm的纵向最大拉伸强力。所述多层复合物具有754N/50mm的横向最大拉伸强力。根据图1的多层复合物的厚度为1.06mm，所述多层复合物具有在200Pa下292m3/m2h的透气率。所述值根据DIN-标准(测试规定)根据图表来确定，并可以从所述图表中引用。根据图1的多层复合物在所述图表中称为双层依沃珑(Evolon)介质。
支承层2具有纤度大于3dtex的无端长丝4。无端长丝3设计成双组分无端长丝的至少部分地彼此隔离的组成部分。无端长丝3通过水射流处理由双组分无端长丝形成。作为该双组分无端长丝使用分层无端长丝。
图2示出了具有入流层1、支承层2和以类似于入流层1的方式制成的另一层1a的多层复合物。所述入流层1的多孔结构与支承层2相比更微小。入流层1设计成纺粘型非织造织物，其无端长丝3与支承层2至少部分地交织或编织在一起。支承层2设计成纺粘型非织造织物，其无端长丝4具有与入流层1的无端长丝3的平均直径相比更大的平均直径。入流层1和层1a的无端长丝3通过水射流处理与支承层2交织在一起。入流层1、层1a和支承层2由以挤压纺丝法制造的纺粘型非织造织物制成。从所述图表中可得到三层的多层复合物的厚度、单位面积重量和透气率。根据图2的多层复合物在所述图表中称为三层依沃珑介质。
根据图2的多层复合物具有269g/m2的单位面积重量。所述单位面积重量根据DIN EN 29073-01测定。此外，所述多层复合物具有在200Pa下353m3/m2h的透气率。所述透气率根据DIN EN ISO 9237测定。根据图2的多层复合物的厚度为1.03mm。根据图2的多层复合物具有796N/50mm的纵向最大拉伸强力。所述多层复合物具有622N/50mm的横向最大拉伸强力。所述最大拉伸强力根据DIN EN 29073-3得出。
图3示出了包括入流层1、设计成松织织物的支承层2的多层复合物。在支承层2上结合有另一层1a，其以类似于入流层1的方式制成。根据图3的入流层1的结构与在图1和图2中所描述的入流层1相同。
此外所述图表给出了一针刺毡的数据。所述针刺毡具有500g/m2的单位面积重量并包括两个纤维层，所述纤维层包围一单位面积重量为100g/m2的复丝网(Multifilamentgitter)。根据DIN 53855，所述复丝网具有80％的孔隙率。两个纤维层的纤维具有1.5至3dtex的纤度。
根据2004年10月版的VDI 3926标准，利用试验用粉尘石灰石粉(Mikrocalcilin)测定在净化气体侧的剩余压力损失(根据图表的静态压力损失)和粉尘浓度。在此在30次过滤循环后测定净化气体中的粉尘浓度和剩余压力损失的值，所述值在图表中示出。
实施两个系列试验，即在多层复合物老化前和老化后。在此，循环时间是多层复合物被粉尘堵塞以致达到1000Pa的最终静态压力损失所需的时间。根据图表，从153Pa的剩余压力损失达到1000Pa的最终静态压力损失，三层依沃珑介质需要729s。
可以从图表中得出，与用于进行比较的多层复合物相比，根据本发明的多层复合物使净化气体中的粉尘浓度明显降低。特别在多层复合物老化后，根据本发明的多层复合物仍远低于在净化气体中粉尘浓度的测量极限。因此可以从图表中得出，与用于进行比较的多层复合物相比，根据本发明的多层复合物在不明显地降低纵向和横向最大拉伸强力的情况下显著降低了净化气体中的粉尘浓度。根据本发明的多层复合物在有效的过滤功率和连续的可制造性方面已证明的稳定性表明其适宜用作空气过滤器、特别是过滤袋的过滤介质。
关于本发明教导的其它有利的设计方案和改进方案，一方面参阅说明书的发明内容部分，另一方面参阅权利要求书。
最后要特别强调，前面纯粹任意选择的实施例仅用于解释根据本发明的教导，该理论并不局限于这些实施例。
Figure G200880016801XD00101

Claims (18)

1.一种在空气过滤器中应用的多层复合物，所述多层复合物至少包括一入流层(1)和一与所述入流层结合的支承层(2)，其中所述入流层(1)由无纺织物制成，所述入流层与所述支承层(2)相比具有更微小的多孔结构，其特征在于，所述入流层(1)设计成纺粘型非织造织物，所述入流层的无端长丝(3)与所述支承层(2)至少部分地交织或编织在一起，
其中，所述无端长丝(3)设计成膜裂纤维，即设计成多组分无端长丝的至少部分地彼此隔开的组成部分。
2.根据权利要求1所述的多层复合物，其特征在于，所述支承层(2)设计成纺粘型非织造织物，所述支承层的无端长丝(4)具有与所述入流层(1)的无端长丝(3)的平均直径相比更大的平均直径。
3.根据权利要求1或2所述的多层复合物，其特征在于，所述入流层(1)的无端长丝(3)通过水射流处理与所述支承层(2)交织在一起。
4.根据权利要求1或2所述的多层复合物，其特征在于，所述入流层(1)包括平均直径为0.3μm至10μm的无端长丝(3)。
5.根据权利要求4所述的多层复合物，其特征在于，所述入流层(1)的无端长丝(3)的平均直径小于7μm。
6.根据权利要求1或2所述的多层复合物，其特征在于，所述多层复合物具有500g/m2以下的单位面积重量。
7.根据权利要求1或2所述的多层复合物，其特征在于，所述多层复合物具有300g/m2以下的单位面积重量。
8.根据权利要求1或2所述的多层复合物，其特征在于，所述入流层(1)具有20g/m2至100g/m2的单位面积重量。
9.根据权利要求1或2所述的多层复合物，其特征在于，所述支承层(2)包括纤度大于3dtex的无端长丝(4)。
10.根据权利要求1或2所述的多层复合物，其特征在于，所述支承层(2)包括纤度大于5dtex的无端长丝(4)。
11.根据权利要求1所述的多层复合物，其特征在于，所述入流层(1)的无端长丝(3)设计成双组分无端长丝的至少部分地彼此隔开的组成部分。
12.根据权利要求1或11所述的多层复合物，其特征在于，所述入流层(1)的无端长丝(3)通过机械处理、热处理或化学处理由多组分无端长丝形成或分成。
13.根据权利要求1或11所述的多层复合物，其特征在于，所述入流层(1)的无端长丝(3)通过水射流处理由多组分无端长丝形成。
14.根据权利要求1或2所述的多层复合物，其特征在于，所述入流层(1)的无端长丝(3)具有三角形横截面。
15.根据权利要求1或2所述的多层复合物，其特征在于，所述入流层(1)的无端长丝(3)形成一表面，所述表面通过所述入流层(1)的无端长丝(3)的至少一部分的机械结合或热结合而形成。
16.根据权利要求1或2所述的多层复合物，其特征在于，在所述支承层(2)中除了无端长丝(4)外还设有粘合纤维，所述粘合纤维与支承层(2)的无端长丝(4)相比具有更低的熔点。
17.根据权利要求1或2所述的多层复合物，其特征在于，所述多层复合物具有三层结构，其中第三层(1a)设计成与所述入流层(1)相似。
18.根据权利要求1或2所述的多层复合物，其特征在于，在所述入流层(1)上设有一包括纳米纤维或微纤维的第三层。
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US20100119794A1 (en) 2010-05-13
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