CN105688511A - 一种超低排放超细面层聚酰亚胺纤维复合针刺毡及其制备方法 - Google Patents

一种超低排放超细面层聚酰亚胺纤维复合针刺毡及其制备方法 Download PDF

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CN105688511A
CN105688511A CN201610060942.8A CN201610060942A CN105688511A CN 105688511 A CN105688511 A CN 105688511A CN 201610060942 A CN201610060942 A CN 201610060942A CN 105688511 A CN105688511 A CN 105688511A
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layer
fiber
carpet veneer
acupuncture carpet
polyimide fiber
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CN105688511B (zh
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崔渊文
钱立根
李跃
侯伟利
祁正虎
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JIANGSU BLUE SKY ENVIRONMENTAL PROTECTION GROUP CO Ltd
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Abstract

本发明公开一种超低排放超细面层聚酰亚胺纤维复合针刺毡，包括基布层、上复合针刺毡层和下复合针刺毡层，所述上复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层、上混合纤维层、聚酰亚胺纤维层和第二超细纤维针刺毡层；所述下复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层、下混合纤维层和第二超细纤维针刺毡层；本发明中，将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维按一定比例混合得到耐高温、阻燃性能好的混合纤维，将混合纤维与超细PS-PA海岛纤维连用，制得了极限氧指数为≥42%、捕获微尘效果好、拉伸强度高，耐磨性能好，使用寿命长的复合针刺毡，对工业粉尘中的PM2.5的捕获率可达99.99%，可有效预防雾霾的形成。

Description

一种超低排放超细面层聚酰亚胺纤维复合针刺毡及其制备方法
技术领域
本发明涉及一种针刺毡，具体涉及一种超低排放超细面层聚酰亚胺纤维复合针刺毡及其制备方法。
背景技术
随着工业社会的发展，人们对环境的保护意识也在逐渐增强，对于工业产出的各种废液、废气和固体废弃物残渣的处理方法也在不断的优化中，近来，PM2.5的出现引起了大家的关注，其主要源于生活或生产中的各种废气，为了减少空气中PM2.5的含量，提高空气质量，需要对各种废气进行处理，特别是工业废气。
超细纤维是指直径在0.4mu以下的微纤维，是普通纤维的1/200，具有特殊的楔形截面积，使它能有效地捕获微尘，吸尘效果较普通纤维好，可应用于工业燃料尾气的过滤非织造材料用于过滤除尘历史悠久。由于纺织材料的结构是具有无数微小孔隙的纤维三维网状结构，尘埃微粒必须沿着纤维弯弯曲曲的网状路径行进，随时都有可能与纤维发生碰撞而被截留，因此过滤效率很高。海岛超细纤维是超细纤维中的一种，是将一种聚合物分散于另一种聚合物中，在纤维截面中分散相呈“岛”状态，而母体则相当于“海”，可兼具两种材料的性能，且具有较高的中空率，是高性能的吸滤材料，将超细纤维材料应用于过滤针刺毡中，可大幅度提高针刺毡的吸滤效果，具有较好的应用前景。
目前，对工业废气的处理主要采用针刺毡过滤的方法，在钢铁、冶金、水泥、电力、化工、制药等行业的烟气温度较高，很容易导致自燃现象，造成生产事故，普通的针刺毡难以满足其高温颗粒物对滤袋的灼烧和腐蚀性气体对滤料的破坏，不仅使用寿命缩短、企业的生产成本增加，还容易造成火灾等生产事故。
发明内容
发明目的：本发明目的在于针对现有技术的不足，提供一种使用寿命长、吸滤效果好、耐高温的超低排放超细面层聚酰亚胺纤维复合针刺毡及其制备方法。
技术方案：本发明所述的一种超低排放超细面层聚酰亚胺纤维复合针刺毡为层状结构，包括基布层、上复合针刺毡层和下复合针刺毡层，所述上复合针刺毡层和下复合针刺毡层对称分布于所述基布层的上、下表面；所述上复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层、上混合纤维层、聚酰亚胺纤维层和第二超细纤维针刺毡层；所述下复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层、下混合纤维层和第二超细纤维针刺毡层；
所述基布层为以聚酰亚胺纤维为经线，以玻璃纤维为纬线的机织布层；所述第一超细纤维针刺毡层包括超细PS-PA海岛纤维层和聚酰亚胺纤维层；所述第二超细纤维针刺毡层包括超细PS-PA海岛纤维层、PTFE纤维层和玄武岩纤维层。
优选地，为提高复合针刺毡的耐高温和阻燃性能，所述上复合针刺毡层上设置防护层。
优选地，所述上混合纤维层和下混合纤维层均为芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合纤维层。
优选地，为达到较好的阻燃效果，所述上混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:2~4:1~2。
优选地，为达到较好的阻燃效果，所述下混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:3~5:2~3。
优选地，为提高所述针刺毡的捕获微尘的效果，所述超细PS-PA海岛纤维的细度为1.5~2.5D。
一种超低排放超细面层聚酰亚胺纤维复合针刺毡的制备方法，包括以下步骤：
（1）制备混合纤维层：将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维经梳理、成网工艺制备上混合纤维层和下混合纤维层；
（2）制备超细纤维针刺毡层：依次铺设聚酰亚胺纤维层超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第一超细纤维针刺毡层；依次铺设玄武岩纤维层、PTFE纤维层和超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第二超细纤维针刺毡层；所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为8±2mm，刺针频率为350~450刺/min，输入速度为3.4~3.65m/min，输出速度为3.6~4.0m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为6±2mm，刺针频率为550~650刺/min，输入速度为3.4~3.6m/min，输出速度为3.5~3.7m/min；
（3）制备复合针刺毡半成品：依次铺设第二超细纤维针刺毡层、下混合纤维层、第一超细纤维针刺毡层、基布层、第一超细纤维针刺毡层、聚酰亚胺纤维层、上混合纤维层、第二超细纤维针刺毡层，再次进行预针刺和主针刺处理，然后经超声波点焊工艺制成复合针刺毡半成品，所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为16±4mm，刺针频率为550~650刺/min，输入速度为3.0~3.8m/min，输出速度为3.5~4.0m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为14±4mm，刺针频率为750~850刺/min，输入速度为3.0~3.6m/min，输出速度为3.4~3.7m/min；
（4）后处理：对步骤（3）中制得的过滤毡半成品的上表面即迎尘面进行浸渍处理，烘干后进行热压处理得到复合针刺毡成品，所述热轧过程中上辊温度为200～250℃，中辊温度为200～220℃，下辊温度为180～200℃，压强为1.0~2.5MPa热压过程中速度为15～20m/min。
优选地，所述浸渍处理过程中输出速度为3~8m/min，带液量为15～50g/m2，预烘温度为215～355℃，时间为6～15min，焙烘固化温度为205～325℃，时间为10～15min。
优选地，所述浸渍处理过程采用的乳液配方如下：
防水剂：12wt%～17wt%；
防油剂：6wt%～10wt%；
PTFE乳液：15wt%～25wt%；
聚丙烯酸酯乳液：2wt%～5wt%；
防酸防碱剂：4wt%～7wt%；
偶联剂：0.1wt%～0.5wt%；
水：35.5wt%~60.9wt%。
有益效果：（1）本发明中，将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维按一定比例混合得到耐高温、阻燃性能好的混合纤维，将混合纤维与超细PS-PA海岛纤维连用，制得了极限氧指数为≥42%、捕获微尘效果好、拉伸强度高，耐磨性能好，使用寿命长的复合针刺毡，对工业粉尘中的PM2.5的捕获率可达99.99%，可有效预防雾霾的形成；（2）通过选择适宜的针刺频率、针刺深度、输入、输出速度等参数，再进一步通过超声波点焊工艺、迎尘面功能化处理以及热压等处理，使所得的复合针刺毡结构稳定，综合性能好。
附图说明
图1为本发明中超低排放超细面层聚酰亚胺纤维复合针刺毡的结构示意图；
其中，1.基布层，2.第一超细纤维针刺毡层，3.上混合纤维层，4.聚酰亚胺纤维层，5.第二超细纤维针刺毡层，6.下混合纤维层，7.防护层。
具体实施方式
下面通过附图对本发明技术方案进行详细说明，但是本发明的保护范围不局限于所述实施例，实施例中方法如无特殊说明均为常规方法，使用的试剂如无特殊说明均为常规市售。
实施例1：一种层状结构的超低排放超细面层聚酰亚胺纤维复合针刺毡，包括基布层1、上复合针刺毡层、下复合针刺毡层和防护层7，所述上复合针刺毡层和下复合针刺毡层对称分布于所述基布层1的上、下表面；所述上复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层2、上混合纤维层3、聚酰亚胺纤维层4和第二超细纤维针刺毡层5；所述下复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层2、下混合纤维层6和第二超细纤维针刺毡层5；
所述基布层为以聚酰亚胺纤维为经线，以玻璃纤维为纬线的机织布层；所述第一超细纤维针刺毡层包括超细PS-PA海岛纤维层和聚酰亚胺纤维层；所述第二超细纤维针刺毡层包括超细PS-PA海岛纤维层、PTFE纤维层和玄武岩纤维层；所述上混合纤维层和下混合纤维层均为芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合纤维层；所述上混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:3:2；所述下混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:4:2；所述超细PS-PA海岛纤维的细度为1.65D。
上述超低排放超细面层聚酰亚胺纤维复合针刺毡的制备方法，包括以下步骤：
（1）制备混合纤维层：将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维按混合比例为1:3:2经梳理、成网工艺得到上混合纤维层；将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维按混合比例为1:4:2经梳理、成网工艺得到下混合纤维层；
（2）制备超细纤维针刺毡层：依次铺设聚酰亚胺纤维层超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第一超细纤维针刺毡层；依次铺设玄武岩纤维层、PTFE纤维层和超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第二超细纤维针刺毡层；所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为8±2mm，刺针频率为420刺/min，输入速度为3.6m/min，输出速度为3.8m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为6±2mm，刺针频率为620刺/min，输入速度为3.5m/min，输出速度为3.6m/min；
（3）制备复合针刺毡半成品：依次铺设第二超细纤维针刺毡层5、下混合纤维层6、第一超细纤维针刺毡层2、基布层1、第一超细纤维针刺毡层2、聚酰亚胺纤维层4、上混合纤维层3、第二超细纤维针刺毡层5，再次进行预针刺和主针刺处理，然后经超声波点焊工艺制成复合针刺毡半成品，所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为16±4mm，刺针频率为630刺/min，输入速度为3.65m/min，输出速度为3.85m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为14±4mm，刺针频率为830刺/min，输入速度为3.45m/min，输出速度为3.65m/min；
（4）后处理：对步骤（3）中制得的过滤毡半成品的上表面即迎尘面进行浸渍处理，烘干后得到防护层7，然后进行热压处理得到复合针刺毡成品，所述热轧过程中上辊温度为235℃，中辊温度为218℃，下辊温度为195℃，压强为2.35MPa，热压过程中速度为17m/min。
本实施例中所述浸渍处理过程采用的乳液配方如下：
防水剂：16wt%；
防油剂：8wt%；
PTFE乳液：22wt%；
聚丙烯酸酯乳液：3wt%；
防酸防碱剂：5wt%；
偶联剂：0.2wt%；
水：54.2wt%。
浸渍处理过程中输出速度为6.5m/min，带液量为35g/m2，预烘温度为285℃，时间为12min，焙烘固化温度为265℃，时间为13min。
实施例2：一种层状结构的超低排放超细面层聚酰亚胺纤维复合针刺毡，包括基布层1、上复合针刺毡层、下复合针刺毡层和防护层7，所述上复合针刺毡层和下复合针刺毡层对称分布于所述基布层1的上、下表面；所述上复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层2、上混合纤维层3、聚酰亚胺纤维层4和第二超细纤维针刺毡层5；所述下复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层2、下混合纤维层6和第二超细纤维针刺毡层5；
所述基布层为以聚酰亚胺纤维为经线，以玻璃纤维为纬线的机织布层；所述第一超细纤维针刺毡层包括超细PS-PA海岛纤维层和聚酰亚胺纤维层；所述第二超细纤维针刺毡层包括超细PS-PA海岛纤维层、PTFE纤维层和玄武岩纤维层；所述上混合纤维层和下混合纤维层均为芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合纤维层；所述上混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:2:2；所述下混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:3:2；所述超细PS-PA海岛纤维的细度为2.2D。
上述超低排放超细面层聚酰亚胺纤维复合针刺毡的制备方法，包括以下步骤：
（1）制备混合纤维层：将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维按混合比例为1:2:2经梳理、成网工艺得到上混合纤维层；将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维按混合比例为1:3:2经梳理、成网工艺得到下混合纤维层；
（2）制备超细纤维针刺毡层：依次铺设聚酰亚胺纤维层超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第一超细纤维针刺毡层；依次铺设玄武岩纤维层、PTFE纤维层和超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第二超细纤维针刺毡层；所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为8±2mm，刺针频率为360刺/min，输入速度为3.4m/min，输出速度为3.6m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为6±2mm，刺针频率为550刺/min，输入速度为3.4m/min，输出速度为3.5m/min；
（3）制备复合针刺毡半成品：依次铺设第二超细纤维针刺毡层5、下混合纤维层6、第一超细纤维针刺毡层2、基布层1、第一超细纤维针刺毡层2、聚酰亚胺纤维层4、上混合纤维层3、第二超细纤维针刺毡层5，再次进行预针刺和主针刺处理，然后经超声波点焊工艺制成复合针刺毡半成品，所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为16±4mm，刺针频率为550刺/min，输入速度为3.15m/min，输出速度为3.45m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为14±4mm，刺针频率为750刺/min，输入速度为3.1m/min，输出速度为3.4m/min；
（4）后处理：对步骤（3）中制得的过滤毡半成品的上表面即迎尘面进行浸渍处理，烘干后得到防护层7，然后进行热压处理得到复合针刺毡成品，所述热轧过程中上辊温度为215℃，中辊温度为205℃，下辊温度为185℃，压强为1.2MPa，热压过程中速度为15m/min。
本实施例中所述浸渍处理过程采用的乳液配方如下：
防水剂：12wt%；
防油剂：10wt%；
PTFE乳液：25wt%；
聚丙烯酸酯乳液：2wt%；
防酸防碱剂：4wt%；
偶联剂：0.1wt%；
水：46.9wt%。
浸渍处理过程中输出速度为3.5m/min，带液量为46g/m2，预烘温度为355℃，时间为15min，焙烘固化温度为325℃，时间为15min。
实施例3：一种层状结构的超低排放超细面层聚酰亚胺纤维复合针刺毡，包括基布层1、上复合针刺毡层、下复合针刺毡层和防护层7，所述上复合针刺毡层和下复合针刺毡层对称分布于所述基布层1的上、下表面；所述上复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层2、上混合纤维层3、聚酰亚胺纤维层4和第二超细纤维针刺毡层5；所述下复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层2、下混合纤维层6和第二超细纤维针刺毡层5；
所述基布层为以聚酰亚胺纤维为经线，以玻璃纤维为纬线的机织布层；所述第一超细纤维针刺毡层包括超细PS-PA海岛纤维层和聚酰亚胺纤维层；所述第二超细纤维针刺毡层包括超细PS-PA海岛纤维层、PTFE纤维层和玄武岩纤维层；所述上混合纤维层和下混合纤维层均为芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合纤维层；所述上混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:4:1；所述下混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:5:3；所述超细PS-PA海岛纤维的细度为2.5D。
上述超低排放超细面层聚酰亚胺纤维复合针刺毡的制备方法，包括以下步骤：
（1）制备混合纤维层：将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维按混合比例为1:4:1经梳理、成网工艺得到上混合纤维层；将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维按混合比例为1:5:3经梳理、成网工艺得到下混合纤维层；
（2）制备超细纤维针刺毡层：依次铺设聚酰亚胺纤维层超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第一超细纤维针刺毡层；依次铺设玄武岩纤维层、PTFE纤维层和超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第二超细纤维针刺毡层；所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为8±2mm，刺针频率为450刺/min，输入速度为3.65m/min，输出速度为3.95m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为6±2mm，刺针频率为650刺/min，输入速度为3.6m/min，输出速度为3.7m/min；
（3）制备复合针刺毡半成品：依次铺设第二超细纤维针刺毡层5、下混合纤维层6、第一超细纤维针刺毡层2、基布层1、第一超细纤维针刺毡层2、聚酰亚胺纤维层4、上混合纤维层3、第二超细纤维针刺毡层5，再次进行预针刺和主针刺处理，然后经超声波点焊工艺制成复合针刺毡半成品，所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为16±4mm，刺针频率为650刺/min，输入速度为3.75m/min，输出速度为3.95m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为14±4mm，刺针频率为850刺/min，输入速度为3.6m/min，输出速度为3.7m/min；
（4）后处理：对步骤（3）中制得的过滤毡半成品的上表面即迎尘面进行浸渍处理，烘干后得到防护层7，然后进行热压处理得到复合针刺毡成品，所述热轧过程中上辊温度为250℃，中辊温度为220℃，下辊温度为200℃，压强为2.45MPa，热压过程中速度为20m/min。
本实施例中所述浸渍处理过程采用的乳液配方如下：
防水剂：16wt%；
防油剂：6wt%；
PTFE乳液：15wt%；
聚丙烯酸酯乳液：5wt%；
防酸防碱剂：6wt%；
偶联剂：0.5wt%；
水：51.5wt%。
浸渍处理过程中输出速度为7.5m/min，带液量为18g/m2，预烘温度为215℃，时间为7min，焙烘固化温度为205℃，时间为10min。
本方法制备的过滤针刺毡极限氧指数为≥42%，达到较好的阻燃效果，连续工作温度为180～250℃，瞬间工作温度为280℃，经向强力≥2000N/5*20cm，纬向强力≥2000N/5*20cm，经向断裂伸长率≤10%，纬向断裂伸长率≤10%，透气度10～12m3/m2·min,除尘滤可达99.99%，使用寿命可达3年。
如上所述，尽管参照特定的优选实施例已经表示和表述了本发明，但其不得解释为对本发明自身的限制。在不脱离所附权利要求定义的本发明的精神和范围前提下，可对其在形式上和细节上作出各种变化。

Claims (9)

1.一种超低排放超细面层聚酰亚胺纤维复合针刺毡，其特征在于：所述复合针刺毡为层状结构，包括基布层、上复合针刺毡层和下复合针刺毡层，所述上复合针刺毡层和下复合针刺毡层对称分布于所述基布层的上、下表面；所述上复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层、上混合纤维层、聚酰亚胺纤维层和第二超细纤维针刺毡层；所述下复合针刺毡层由内朝外依次包括第一超细纤维针刺毡层、下混合纤维层和第二超细纤维针刺毡层；
所述基布层为以聚酰亚胺纤维为经线，以玻璃纤维为纬线的机织布层；所述第一超细纤维针刺毡层包括超细PS-PA海岛纤维层和聚酰亚胺纤维层；所述第二超细纤维针刺毡层包括超细PS-PA海岛纤维层、PTFE纤维层和玄武岩纤维层。
2.根据权利要求1所述的超低排放超细面层聚酰亚胺纤维复合针刺毡，其特征在于：所述上复合针刺毡层上设置防护层。
3.根据权利要求1所述的超低排放超细面层聚酰亚胺纤维复合针刺毡，其特征在于：所述上混合纤维层和下混合纤维层均为芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合纤维层。
4.根据权利要求3所述的超低排放超细面层聚酰亚胺纤维复合针刺毡，其特征在于：所述上混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:2~4:1~2。
5.根据权利要求3所述的超低排放超细面层聚酰亚胺纤维复合针刺毡，其特征在于：所述下混合纤维层中芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维的混合比例为1:3~5:2~3。
6.根据权利要求1所述的超低排放超细面层聚酰亚胺纤维复合针刺毡，其特征在于：所述超细PS-PA海岛纤维的细度为1.5~2.5D。
7.权利要求1~3任一项所述的超低排放超细面层聚酰亚胺纤维复合针刺毡的制备方法，其特征在于包括以下步骤：
（1）制备混合纤维层：将芳砜纶纤维、聚酰亚胺纤维和玄武岩纤维经梳理、成网工艺制备上混合纤维层和下混合纤维层；
（2）制备超细纤维针刺毡层：依次铺设聚酰亚胺纤维层超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第一超细纤维针刺毡层；依次铺设玄武岩纤维层、PTFE纤维层和超细PS-PA海岛纤维层，然后进行预针刺和主针刺，制成第二超细纤维针刺毡层；所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为8±2mm，刺针频率为350~450刺/min，输入速度为3.4~3.65m/min，输出速度为3.6~4.0m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为6±2mm，刺针频率为550~650刺/min，输入速度为3.4~3.6m/min，输出速度为3.5~3.7m/min；
（3）制备复合针刺毡半成品：依次铺设第二超细纤维针刺毡层、下混合纤维层、第一超细纤维针刺毡层、基布层、第一超细纤维针刺毡层、聚酰亚胺纤维层、上混合纤维层、第二超细纤维针刺毡层，再次进行预针刺和主针刺处理，然后经超声波点焊工艺制成复合针刺毡半成品，所述预针刺过程中，刺针型号为15×18×38×3.5M222，刺针深度为16±4mm，刺针频率为550~650刺/min，输入速度为3.0~3.8m/min，输出速度为3.5~4.0m/min，主针刺过程中，刺针型号为15×18×38×3.5R222，刺针深度为14±4mm，刺针频率为750~850刺/min，输入速度为3.0~3.6m/min，输出速度为3.4~3.7m/min；
（4）后处理：对步骤（3）中制得的过滤毡半成品的上表面即迎尘面进行浸渍处理，烘干后进行热压处理得到复合针刺毡成品，所述热轧过程中上辊温度为200～250℃，中辊温度为200～220℃，下辊温度为180～200℃，压强为1.0~2.5MPa热压过程中速度为15～20m/min。
8.根据权利要求7所述的超低排放超细面层聚酰亚胺纤维复合针刺毡的制备方法，其特征在于：所述浸渍处理过程中输出速度为3~8m/min，带液量为15～50g/m2，预烘温度为215～355℃，时间为6～15min，焙烘固化温度为205～325℃，时间为10～15min。
9.根据权利要求7所述的超低排放超细面层聚酰亚胺纤维复合针刺毡的制备方法，其特征在于：所述浸渍处理过程采用的乳液配方如下：
防水剂：12wt%～17wt%；
防油剂：6wt%～10wt%；
PTFE乳液：15wt%～25wt%；
聚丙烯酸酯乳液：2wt%～5wt%；
防酸防碱剂：4wt%～7wt%；
偶联剂：0.1wt%～0.5wt%；
水：35.5wt%~60.9wt%。
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