CN105964059B - 一种增能的聚乙烯/聚丙烯双组分纺粘滤料及其制备方法 - Google Patents
一种增能的聚乙烯/聚丙烯双组分纺粘滤料及其制备方法 Download PDFInfo
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Abstract
本发明涉及一种增能的聚乙烯/聚丙烯双组分纺粘滤料及其制备方法,所述滤料包括相互粘合的三层纤维网,依次为细旦纤维网、中旦纤维网、粗旦纤维网;纤维网中的纤维为皮芯复合纤维。通过聚合物纺粘装置纺制出三层纤维网,然后按自上而下依次为细旦纤维网、中旦纤维网、粗旦纤维网的方式叠合铺网,粘合加固,光棍热轧、卷绕,然后电晕驻极并卷绕,即得增能的聚乙烯/聚丙烯双组分纺粘滤料。本发明所得的产品具有蓬松柔软的结构、高效的过滤效率,同时保持较低阻力。另外,该制备方法绿色环保,工艺简单可行,适合工业化生产。
Description
技术领域
本发明属于纺粘滤料及其制备领域,特别涉及一种增能的聚乙烯/聚丙烯双组分纺粘滤料及其制备方法。
背景技术
随着经济的发展,工业化污染越来越严重,空气质量明显下降,给人们的交通出行、生产生活、以及身体健康造成严重的不良影响。其中颗粒物作为空气污染的主要组成吸附了大量有毒有害物,对人体呼吸系统、心血管系统等产生严重损害,导致支气管炎、哮喘、心肌梗死等疾病的发病率显著增高。在个体防护和室内净化方面对空气污染最直接有效的控制就是过滤材料的使用。
专利CN103285663A公开了一种纺粘长丝过滤材料,仅涉及到单组分纺粘长丝,没有提出皮芯型双组分的应用。专利CN102296426A公开了一种用于生产双组分纺粘非织造布的设备及制造方法,没有涉及双组分纤网梯度结构的叠合以及后续的热风加固、电晕驻极等工艺。专利CN101721856A公开了一种PLA/PP双组分纤维过滤材料的制备方法及其制品,但是其采用的方法是分别制备PLA梳理纤维流和PP熔喷纤维流再叠加复合的方式,并非采用皮芯型双组分纤维制备过滤材料。
目前应用在过滤上的非织造材料主要有针刺材料、熔喷材料、静电纺丝非织造材料以及纺粘材料。现有的针刺短纤过滤材料在空气粉尘治理上的应用较多,但电晕驻极时为提高电荷的稳定性,需要脱去短纤生产过程中残留的油剂,工艺繁琐,费时费力;熔喷驻极材料纤维直径较细可以满足高效的过滤材料,但其过滤阻力较高,另外纤网抗压性、压缩回弹性差;静电纺丝非织造材料由于其纳米级别纤维的特点,比表面积大,增多了过滤颗粒与纤维碰撞的机会,过滤效率一般很高,但是阻力较大,且静电纺丝技术产业化应用还不够成熟,纤维分布均匀性与产量也制约了其在过滤材料的上应用发展。传统的纺粘过滤材料采用热轧加固方式大多和熔喷材料结合在一起使用,手感较硬、滤效较低,只做初效过滤和保护支撑作用。
发明内容
本发明所要解决的技术问题是提供一种增能的聚乙烯/聚丙烯双组分纺粘滤料及其制备方法,解决了现有技术制成的过滤材料电晕驻极前要脱去油剂;阻力较高,回弹性差;产业化应用不够成熟;手感较硬、滤效较低等问题。
本发明的双组分过滤材料通过在皮层和芯层添加增能助剂,采用热风穿透粘合加固,光棍热轧控制厚度,经过电晕驻极后提高过滤效率。该材料具有蓬松柔软的结构、高效的过滤效率,同时保持较低阻力。另外,该制备工艺简单可行,原料来源方便,适合工业化生产。本发明的一种增能的聚乙烯/聚丙烯双组分纺粘滤料,所述滤料包括相互粘合的三层纤维网,依次为细旦纤维网、中旦纤维网、粗旦纤维网;纤维网中的纤维为皮芯复合纤维;
纤维皮层组分包括:聚乙烯、增能助剂a;其中增能助剂a为硬脂酸锌和硬脂酸钡的混合物;
纤维芯层组分包括:聚丙烯、增能助剂b,其中增能助剂b为硬脂酸锌、硬脂酸钡和氮化硅的混合物。
所述细旦纤维网为:由纤度为1.4~1.7旦尼尔的纺粘长丝在线铺网而成,面密度为40~45克/平方米;中旦纤维网为:纤度为2.2~2.5旦尼尔的纺粘长丝在线铺网而成,面密度为50~55克/平方米;粗旦纤维网为:纤度为3~3.5旦尼尔的纺粘长丝在线铺网而成,密度为65~75克/平方米。
所述纤维皮层中增能助剂a的质量百分含量为6%;纤维芯层中增能助剂b的质量百分含量为8%。
所述增能助剂a中,按质量百分比,硬脂酸锌60%和硬脂酸钡40%;增能助剂b中,按质量百分比,硬脂酸锌50%、硬脂酸钡30%和氮化硅20%。
增能的聚乙烯/聚丙烯双组分纺粘滤料的厚度为2~3毫米,面密度为155~170克/平方米。本发明的一种增能的聚乙烯/聚丙烯双组分纺粘滤料的制备方法,包括:
(1)将增能助剂a与聚乙烯切片混合,造粒,得到改性聚乙烯母粒,然后与纺粘聚乙烯切片混合,得到皮层原料;
(2)将增能助剂b与聚丙烯切片混合,造粒,得到改性聚丙烯母粒,然后与纺粘聚丙烯切片混合,得到芯层原料;
(3)通过聚合物纺粘装置纺制出三层纤维网,按自上而下依次为用作滤料底层的细旦纤维网、用作滤料中间层的中旦纤维网、用作滤料迎尘层的粗旦纤维网的方式在线叠合铺网,粘合加固,光棍热轧控制厚度、卷绕,得到的三层纤网叠合体卷材,退卷,喂入电晕驻极装置,进行电晕驻极并卷绕,即得增能的聚乙烯/聚丙烯双组分纺粘滤料。
所述的步骤(1)中的造粒为通过造粒机进行,将增能助剂a与聚乙烯切片分别加入造粒机的两个喂料斗,在160℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂a的改性聚乙烯母粒。
所述的步骤(2)中的造粒为通过造粒机进行,将增能助剂b与聚丙烯切片分别加入造粒机的两个喂料斗,在190℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂b的改性聚丙烯母粒。
所述步骤(1)中增能助剂a占改性聚乙烯母粒的质量比为20%;改性聚乙烯母粒占皮层原料的质量比为30%。
所述步骤(2)中增能助剂b占改性聚丙烯切片的质量比为20%;改性聚丙烯母粒占芯层原料的质量比为40%。
步骤(3)中通过聚合物纺粘装置纺制出三层纤维网为:通过常规的三台皮芯型双组分聚合物纺粘装置直接成网。
所述步骤(3)中粘合加固为热风穿透粘合加固,热风温度为135℃。
所述步骤(3)中光棍热轧为:轧辊温度为133-135℃,下轧辊温度为132-134℃,热轧后厚度为2-3毫米。
所述步骤(3)中电晕驻极为针尖放电,布针密度为1000枚/m2,电场强度为7-8kV/cm,驻极时间为30-40秒。
本发明的增能的聚乙烯/聚丙烯皮芯型双组分纺粘滤料是由三层纤维网叠合后依次经热风穿透粘合加固、光辊热轧控制厚度、电晕驻极而制成的,形成具有梯度结构的纺粘滤料,厚度为2~3毫米,面密度为155~170克/平方米;其中,构成增能的聚乙烯/聚丙烯皮芯型双组分纺粘滤料的三层纤维网,由上而下依次为用作滤料底层的细旦纤维网、用作滤料中间层的中旦纤维网、用作滤料迎尘层的粗旦纤维网;所述的纤维网中的纤维为聚合物纺丝直接成网的皮芯型复合纤维,纤维皮层是由聚乙烯构成,添加有质量百分数为6%的增能助剂a,纤维芯层是由聚丙烯构成,添加有质量百分数为8%的增能助剂b;所述的增能助剂a为硬脂酸锌和硬脂酸钡的混合物,硬脂酸锌和硬脂酸钡的质量百分数分别为60%和40%;所述的增能助剂b为硬脂酸锌、硬脂酸钡和氮化硅的混合物,硬脂酸锌、硬脂酸钡和氮化硅的质量百分数分别为50%、30%和20%。
有益效果
(1)从发明的工艺路线角度来讲,常规的短纤静电棉空气过滤材料,化纤的生产的过程中添加有油剂,在驻极时为提高电荷的稳定性又不得不脱去油剂;本发明通过聚合物纺丝直接成网制备纤网,即纺粘工艺成网,热风穿透粘合加固光辊热轧控制厚度,不使用化学粘合剂和油剂,可直接进行电晕驻极,并且无任何副产品及污染物产生,操作简单方便,效率高,具有很高的可行性;
(2)从本发明的材料结构角度来讲,本发明的创新是纤维皮芯层添加有增能助剂;在热风粘合的过程中,皮层熔融粘合加固,芯层不受影响起骨架作用,芯层内的无机氮化硅也不会脱落,另外,该材料结构与同类的针刺短纤静电棉过滤材料相比,将细旦纤维网,中旦纤维网,粗旦纤维网自上而下依次设置,形成三明治梯度结构过滤材料,提高过滤效率,降低过滤阻力;
(3)本发明所得的产品具有较高的过滤效率,过滤阻力较低;工艺路线简单,生产过程中不使用任何化学粘合剂,绿色环保;首次提出使用皮芯型双组分纤维制备过滤材料,给过滤材料领域带来一个突破;
(4)采用TSI8130滤料综合性能测试台测试,在流速为32L/min,氯化钠气溶胶质量中值直径为0.26μm时,材料的厚度为2.1~2.8毫米,过滤效率为75~84%,过滤阻力为33~46Pa。
具体实施方式
下面结合具体实施例,进一步阐述本发明。应理解,这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解,在阅读了本发明讲授的内容之后,本领域技术人员可以对本发明作各种改动或修改,这些等价形式同样落于本申请所附权利要求书所限定的范围。
实施例1
将增能助剂a与聚乙烯切片分别加入造粒机的两个喂料斗,在160℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂a的改性聚乙烯母粒,增能助剂a占改性聚乙烯母粒的质量比为20%,增能助剂a为硬脂酸锌和硬脂酸钡的混合物,其中硬脂酸锌和硬脂酸钡的质量百分数为60%和40%;
将增能助剂b与聚丙烯切片分别加入造粒机的两个喂料斗,在190℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂b的改性聚丙烯母粒,增能助剂b占改性聚丙烯母粒的质量比为20%,增能助剂b为硬脂酸锌、硬脂酸钡和氮化硅的混合物,其中硬脂酸锌、硬脂酸钡和氮化硅的质量百分数分别为50%、30%和20%。
改性过后的聚乙烯母粒和常规纺粘聚乙烯切片混合作为皮层原料,改性聚乙烯占皮层原料的质量比为30%;改性过后的聚丙烯母粒和常规纺粘聚丙烯切片混合作为芯层原料,改性聚丙烯占芯层原料的质量比为40%;
通过三台皮芯型双组分聚合物纺粘装置,分别制备出纤维纤度为3旦尼尔、面密度为65g/m2用作滤料迎尘层的粗旦纤维网,纤度为2.2旦尼尔、面密度为50g/m2用作滤料中间层的中旦纤维网,纤度为1.4旦尼尔、面密度为40g/m2用作滤料底层的细旦纤维网,且在线层叠铺网,形成由上而下依次为细旦纤维网、中旦纤维网、粗旦纤维网的三层纤网叠合体;将三层纤网叠合体在热风穿透式烘箱中进行热粘合加固,热风温度为135℃;再通过光辊热轧机进行热轧控制厚度并卷绕,上光棍的温度为133℃,下光辊的温度为132℃,热轧后厚度为2.1毫米;然后将热轧后的三层纤网叠合体退卷,在7kV/cm的静电场中电晕驻极30秒,再卷绕形成增能的聚乙烯/聚丙烯双组分纺粘滤料。
采用TSI8130滤料综合性能测试台测试所得双组分纺粘滤料的过滤效率和过滤阻力:在流速为32L/min,氯化钠气溶胶质量中值直径为0.26μm时,其过滤阻力为33Pa,过滤效率为75%。
实施例2
将增能助剂a与聚乙烯切片分别加入造粒机的两个喂料斗,在160℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂a的改性聚乙烯母粒,增能助剂a占改性聚乙烯母粒的质量比为20%,增能助剂a为硬脂酸锌和硬脂酸钡的混合物,其中硬脂酸锌和硬脂酸钡的质量百分数为60%和40%;
将增能助剂b与聚丙烯切片分别加入造粒机的两个喂料斗,在190℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂b的改性聚丙烯母粒,增能助剂b占改性聚丙烯母粒的质量比为20%,增能助剂b为硬脂酸锌、硬脂酸钡和氮化硅的混合物,其中硬脂酸锌、硬脂酸钡和氮化硅的质量百分数分别为50%、30%和20%。
改性过后的聚乙烯母粒和常规纺粘聚乙烯切片混合作为皮层原料,改性聚乙烯占皮层原料的质量比为30%;改性过后的聚丙烯母粒和常规纺粘聚丙烯切片混合作为芯层原料,改性聚丙烯占芯层原料的质量比为40%;
通过三台皮芯型双组分聚合物纺粘装置,分别制备出纤维纤度为3.4旦尼尔、面密度为70g/m2用作滤料迎尘层的粗旦纤维网,纤度为2.3旦尼尔、面密度为55g/m2用作滤料中间层的中旦纤维网,纤度为1.4旦尼尔、面密度为40g/m2用作滤料底层的细旦纤维网,且在线层叠铺网,形成由上而下依次为细旦纤维网、中旦纤维网、粗旦纤维网的三层纤网叠合体;将三层纤网叠合体在热风穿透式烘箱中进行热粘合加固,热风温度为135℃;再通过光辊热轧机进行热轧控制厚度并卷绕,上光棍的温度为134℃,下光辊的温度为133℃,热轧后厚度为2.3毫米;然后将热轧后的三层纤网叠合体退卷,在7.5kV/cm的静电场中电晕驻极35秒,再卷绕形成增能的聚乙烯/聚丙烯双组分纺粘滤料。
采用TSI8130滤料综合性能测试台测试所得双组分纺粘滤料的过滤效率和过滤阻力:在流速为32L/min,氯化钠气溶胶质量中值直径为0.26μm时,其过滤阻力为39Pa,过滤效率为81%。
实施例3
将增能助剂a与聚乙烯切片分别加入造粒机的两个喂料斗,在160℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂a的改性聚乙烯母粒,增能助剂a占改性聚乙烯母粒的质量比为20%,增能助剂a为硬脂酸锌和硬脂酸钡的混合物,其中硬脂酸锌和硬脂酸钡的质量百分数为60%和40%;
将增能助剂b与聚丙烯切片分别加入造粒机的两个喂料斗,在190℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂b的改性聚丙烯母粒,增能助剂b占改性聚丙烯母粒的质量比为20%,增能助剂b为硬脂酸锌、硬脂酸钡和氮化硅的混合物,其中硬脂酸锌、硬脂酸钡和氮化硅的质量百分数分别为50%、30%和20%。
改性过后的聚乙烯母粒和常规纺粘聚乙烯切片混合作为皮层原料,改性聚乙烯占皮层原料的质量比为30%;改性过后的聚丙烯母粒和常规纺粘聚丙烯切片混合作为芯层原料,改性聚丙烯占芯层原料的质量比为40%;
通过三台皮芯型双组分聚合物纺粘装置,分别制备出纤维纤度为3.3旦尼尔、面密度为65g/m2用作滤料迎尘层的粗旦纤维网,纤度为2.2旦尼尔、面密度为55g/m2用作滤料中间层的中旦纤维网,纤度为1.7旦尼尔、面密度为45g/m2用作滤料底层的细旦纤维网,且在线层叠铺网,形成由上而下依次为细旦纤维网、中旦纤维网、粗旦纤维网的三层纤网叠合体;将三层纤网叠合体在热风穿透式烘箱中进行热粘合加固,热风温度为135℃;再通过光辊热轧机进行热轧控制厚度并卷绕,上光棍的温度为134℃,下光辊的温度为133℃,热轧后厚度为2.3毫米;然后将热轧后的三层纤网叠合体退卷,在7.5kV/cm的静电场中电晕驻极35秒,再卷绕形成增能的聚乙烯/聚丙烯双组分纺粘滤料。
采用TSI8130滤料综合性能测试台测试所得双组分纺粘滤料的过滤效率和过滤阻力:在流速为32L/min,氯化钠气溶胶质量中值直径为0.26μm时,其过滤阻力为41Pa,过滤效率为82%。
实施例4
将增能助剂a与聚乙烯切片分别加入造粒机的两个喂料斗,在160℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂a的改性聚乙烯母粒,增能助剂a占改性聚乙烯母粒的质量比为20%,增能助剂a为硬脂酸锌和硬脂酸钡的混合物,其中硬脂酸锌和硬脂酸钡的质量百分数为60%和40%;
将增能助剂b与聚丙烯切片分别加入造粒机的两个喂料斗,在190℃温度下共混熔融挤出,经水浴冷却后切割成粒,在经过干燥处理后得到添加有增能助剂b的改性聚丙烯母粒,增能助剂b占改性聚丙烯母粒的质量比为20%,增能助剂b为硬脂酸锌、硬脂酸钡和氮化硅的混合物,其中硬脂酸锌、硬脂酸钡和氮化硅的质量百分数分别为50%、30%和20%。
改性过后的聚乙烯母粒和常规纺粘聚乙烯切片混合作为皮层原料,改性聚乙烯占皮层原料的质量比为30%;改性过后的聚丙烯母粒和常规纺粘聚丙烯切片混合作为芯层原料,改性聚丙烯占芯层原料的质量比为40%;
通过三台皮芯型双组分聚合物纺粘装置,分别制备出纤维纤度为3旦尼尔、面密度为75g/m2用作滤料迎尘层的粗旦纤维网,纤度为2.3旦尼尔、面密度为55g/m2用作滤料中间层的中旦纤维网,纤度为1.7旦尼尔、面密度为40g/m2用作滤料底层的细旦纤维网,且在线层叠铺网,形成由上而下依次为细旦纤维网、中旦纤维网、粗旦纤维网的三层纤网叠合体,;将三层纤网叠合体在热风穿透式烘箱中进行热粘合加固,热风温度为135℃;再通过光辊热轧机进行热轧控制厚度并卷绕,上光棍的温度为135℃,下光辊的温度为134℃,热轧后厚度为2.8毫米;然后将热轧后的三层纤网叠合体退卷,在8kV/cm的静电场中电晕驻极40秒,再卷绕形成增能的聚乙烯/聚丙烯双组分纺粘滤料。
采用TSI8130滤料综合性能测试台测试所得双组分纺粘滤料的过滤效率和过滤阻力:在流速为32L/min,氯化钠气溶胶质量中值直径为0.26μm时,其过滤阻力为46Pa,过滤效率为84%。
Claims (10)
1.一种增能的聚乙烯/聚丙烯双组分纺粘滤料,其特征在于:所述滤料包括相互粘合的三层纤维网,依次为细旦纤维网、中旦纤维网、粗旦纤维网;纤维网中的纤维为皮芯复合纤维;
纤维皮层组分包括:聚乙烯、增能助剂a;其中增能助剂a为硬脂酸锌和硬脂酸钡的混合物;
纤维芯层组分包括:聚丙烯、增能助剂b,其中增能助剂b为硬脂酸锌、硬脂酸钡和氮化硅的混合物。
2.根据权利要求1所述的一种增能的聚乙烯/聚丙烯双组分纺粘滤料,其特征在于:所述细旦纤维网为:纤度为1.4~1.7旦,面密度为40~45克/平方米;中旦纤维网为:纤度为2.2~2.5旦,面密度为50~55克/平方米;粗旦纤维网为:纤度为3~3.5旦,密度为65~75克/平方米。
3.根据权利要求1所述的一种增能的聚乙烯/聚丙烯双组分纺粘滤料,其特征在于:所述纤维皮层中增能助剂a的质量百分含量为6%;纤维芯层中增能助剂b的质量百分含量为8%。
4.根据权利要求1所述的一种增能的聚乙烯/聚丙烯双组分纺粘滤料,其特征在于:所述增能助剂a中,按质量百分比,硬脂酸锌60%和硬脂酸钡40%;增能助剂b中,按质量百分比,硬脂酸锌50%、硬脂酸钡30%和氮化硅20%。
5.一种如权利要求1-4任一所述的增能的聚乙烯/聚丙烯双组分纺粘滤料的制备方法,包括:
(1)将增能助剂a与聚乙烯切片混合,造粒,得到改性聚乙烯母粒,然后与常规纺粘聚乙烯切片混合,得到皮层原料;
(2)将增能助剂b与聚丙烯切片混合,造粒,得到改性聚丙烯母粒,然后与常规纺粘聚丙烯切片混合,得到芯层原料;
(3)通过聚合物纺粘装置纺制出三层纤维网,按自上而下依次为细旦纤维网、中旦纤维网、粗旦纤维网的方式叠合铺网,粘合加固,光棍热轧、卷绕,然后电晕驻极并卷绕,即得增能的聚乙烯/聚丙烯双组分纺粘滤料。
6.根据权利要求5所述的一种增能的聚乙烯/聚丙烯双组分纺粘滤料的制备方法,其特征在于:所述步骤(1)中增能助剂a占改性聚乙烯母粒的质量比为20%;改性聚乙烯母粒占皮层原料的质量比为30%。
7.根据权利要求5所述的一种增能的聚乙烯/聚丙烯双组分纺粘滤料的制备方法,其特征在于:所述步骤(2)中增能助剂b占改性聚丙烯母粒的质量比为20%;改性聚丙烯母粒占芯层原料的质量比为40%。
8.根据权利要求5所述的一种增能的聚乙烯/聚丙烯双组分纺粘滤料的制备方法,其特征在于:所述步骤(3)中粘合加固为热风穿透粘合加固,热风温度为135℃。
9.根据权利要求5所述的一种增能的聚乙烯/聚丙烯双组分纺粘滤料的制备方法,其特征在于:所述步骤(3)中光棍热轧为:上轧辊温度为133-135℃,下轧辊温度为132-134℃,热轧后厚度为2-3毫米。
10.根据权利要求5所述的一种增能的聚乙烯/聚丙烯双组分纺粘滤料的制备方法,其特征在于:所述步骤(3)中电晕驻极为针尖放电,布针密度为1000枚/m2,电场强度为7-8kV/cm,驻极时间为30-40秒。
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