CN106048899A - 具有高刚度的纤维网 - Google Patents
具有高刚度的纤维网 Download PDFInfo
- Publication number
- CN106048899A CN106048899A CN201610548911.7A CN201610548911A CN106048899A CN 106048899 A CN106048899 A CN 106048899A CN 201610548911 A CN201610548911 A CN 201610548911A CN 106048899 A CN106048899 A CN 106048899A
- Authority
- CN
- China
- Prior art keywords
- fleece
- fibre
- resin
- permeability
- weight
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
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Classifications
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- D04H1/542—Adhesive fibres
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
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- B01D2239/064—The fibres being mixed
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- B01D2239/065—More than one layer present in the filtering material
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- B01D2239/086—Binders between particles or fibres
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C53/00—Shaping by bending, folding, twisting, straightening or flattening; Apparatus therefor
- B29C53/22—Corrugating
- B29C53/24—Corrugating of plates or sheets
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/20—Fibres of continuous length in the form of a non-woven mat
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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Abstract
本发明涉及具有高刚度的纤维网,其渗透率大于约500cfm/sf,刚度大于约500mg,厚度小于约25密耳。所述纤维网可以引入过滤介质和过滤元件中。所述网在低厚度下可以具有高渗透率和刚度。所述刚度可以足以使网打褶为包括尖的界限分明的峰,其在使用过程中可以保持稳定的构形。
Description
本申请是申请日为2010年6月17日,申请号为“201080026587.3”,发明名称为“具有高刚度的纤维网”的中国专利申请的分案申请。
技术领域
本发明一般涉及过滤,更特别地涉及可用于过滤元件的纤维网。
背景技术
过滤元件可用于去除多种应用中的污染物。这类元件可以包括一个或多个纤维网。所述纤维网提供允许流体(例如,气体、液体)流过所述元件的多孔结构。流体中所含的污染物颗粒可以被纤维网捕集。在包括多个纤维网的过滤元件中,不同的网可以被设计为执行不同的功能,由此可以具有不同的特征和性质。例如,过滤元件可以包括主要被设计为过滤污染物的纤维网(例如,效率网)和主要被设计为提供机械整体性的另一纤维网(例如,背衬)。
渗透率涉及纤维网透过流体的能力。它可以表示为在固定压差下每单位时间通过单位面积纤维网的流体体积。包括多个纤维网的过滤元件可以包括具有不同渗透率的网。例如,提供机械整体性但一般不依赖于其过滤性能的网(例如,背衬)可以被设计为具有高渗透率,使得这类网不降低过滤介质的总渗透率。
纤维网可以被折叠为包括尖的界限分明的褶皱,其增加纤维网表面积,从而可以提高总的效率和性能。褶打得不好的纤维网在折叠时可能形成圆的不均匀的褶皱。这类不均匀性可以使褶皱之间的空间塞满,最终限制空气流动,导致效率降低且流体流过纤维网的阻力增加。纤维网的几种性质可以有助于其褶皱能够打得很好,包括刚度和厚度。一般地,可能难以使渗透率高且厚度低的纤维网打褶,这是因为除了别的因素以外这类网通常可能不具有足够的刚度。
发明内容
描述了可用于过滤元件的纤维网。
在一个实施方案中,提供纤维网。所述纤维网的渗透率大于约500cfm/sf,刚度大于约500mg,厚度小于约25密耳。
在一个实施方案中,提供纤维网。所述纤维网的渗透率大于约500cfm/sf,刚度大于约500mg。所述纤维网包含多组分纤维,其中所述多组分纤维占纤维网中纤维总重量的大于50重量%。
在一个实施方案中,提供纤维网。所述纤维网的渗透率大于约500cfm/sf,厚度小于约25密耳。所述纤维网包含粘结纤维和树脂。所述粘结纤维包含聚合物,所述树脂包含聚合物,并且所述粘结纤维的聚合物与所述树脂的聚合物的种类相同。
在一个实施方案中,提供过滤流体的方法。所述方法包括:用包含纤维网的过滤元件过滤流体。所述纤维网的渗透率大于约500cfm/sf,刚度大于约500mg,厚度小于约25密耳。
在一个实施方案中,提供制造纤维网的方法。所述方法包括:形成渗透率大于约500cfm/sf、刚度大于约500mg、厚度小于约25密耳的纤维网。
由下面的详细描述本发明的其他方面、实施方案、优点和特征将变得明显。在本说明书和通过引用并入本文的参考资料之间不一致的情况下,以本说明书为准。
附图说明
附图并非意在按比例绘制。在附图中,在各幅图中所示的各个相同或基本相同的组成部分以同样的附图标记表示。为清楚起见,并不是每个组成部分都在每幅图中标出。在附图中:
图1示出根据一些实施方案的打褶的纤维网;和
图2示出根据一些实施方案的包括打褶的纤维网背衬和打褶的有效纤维网的过滤介质。
具体实施方式
本文所述的纤维网可以引入过滤介质和过滤元件中。所述网在低厚度下可以具有高渗透率和刚度。所述刚度可以足以使所述网打褶成包括尖的界限分明的峰,其在使用过程中可以保持稳定的构形。如下面进一步描述的,纤维网可以包含选择并组合以赋予所需性质的多种组分,例如粘结纤维、非粘结纤维、树脂和其它添加剂。在一些情况下,当引入过滤介质和过滤元件中时具有上述特征的纤维网可以与一个或多个另外的纤维网组合(例如,作为背衬)。所述过滤元件可用于多种应用,包括尤其是房间空气清洁、发动机/舱空气清洁、燃气轮机过滤、灰尘收集、液体过滤以及加热、通风和空气调节(HVAC)和高效率微粒空气(HEPA)应用。
如上所述,纤维网由一种或多种类型的纤维、树脂和一种或多种任选的添加剂形成。纤维网可以是非织造的。也就是说,纤维网是采用得到非织造网的技术加工而成的,如下面进一步描述。
在一些情况下,纤维可以是纤维网的主要组分。也就是说,总纤维重量百分比可以大于网中任意其它组分的重量百分比。例如,纤维组分可以占纤维网总重量的大于约50%(例如,约50%至约99.9%,约70%至约95%)。在一些实施方案中,树脂组分占纤维网总重量的大于约0.1%(例如,约0.1%至约50%,约5%至约40%,约5%至约30%)。另外的添加剂(当存在时)可以占纤维网总重量的小于约15%(例如,小于约5%)。
应理解,在一些实施方案中纤维网可以包含在上述范围之外的纤维组分、树脂和/或添加剂。
一般地,网的纤维组分可以包括非粘结纤维和粘结纤维。如本文所用的,非粘结纤维是指除粘结纤维之外的所有其它类型的纤维。在一些实施方案中,纤维网可以包含多于一种类型的纤维。例如,在一些实施方案中,纤维网可以包含非粘结纤维和粘结纤维的共混物。在这些实施方案的一些中,粘结纤维可以是主要的纤维类型。也就是说,粘结纤维的重量百分比可以大于非粘结纤维的重量百分比。例如,非粘结纤维可以占网中纤维组分总重量的小于50重量%(例如,5~40重量%,0~5重量%),而粘结纤维可以占网中纤维组分总重量的大于50重量%(例如,60~95重量%)或大于75重量%(例如,90~100重量%)。在一些实施方案中,纤维网仅包含粘结纤维,而不包含非粘结纤维。
应理解,一些实施方案可以包括在上述范围之外的纤维组成和重量百分比。
对于非粘结纤维合适的组成包括合成材料、玻璃和纤维素。在一些实施方案中,优选合成纤维。适合用作非粘结纤维的合成材料包括热塑性和非热塑性材料。合适的合成材料的实例包括聚烯烃(例如,聚丙烯)、聚酯(例如,聚对苯二甲酸乙二醇酯、聚对苯二甲酸丁二醇酯)、共聚酯、聚酰胺(例如,尼龙6、66、11、12、612;间位芳族聚酰胺)、聚丙烯腈、聚四氟乙烯(PTFE)、PEEK、PEK、PPS、三聚氰胺、聚碳酸酯、聚杂环化合物、聚苯并二唑(PBI)和聚乳酸。其它合适的合成材料包括再生纤维素材料(例如,人造纤维素纤维,Lyocell)和一些无机材料(例如,碳、硼、氧化铝、碳化硅)。应理解,也可以使用上述材料和其它类型合成纤维的共混物。
如上所述,非粘结纤维可以由纤维素形成。合适的纤维素纤维组成包括软木纤维、硬木纤维及其组合。软木纤维素纤维的实例包括由松树、雪松、阿尔卑斯冷杉、道格拉斯冷杉和云杉的木材得到的纤维。硬木纤维素纤维的实例包括由桉树(例如,Grandis)、枫树、桦树和其它落叶树的木材得到的纤维。
如上所述,非粘结纤维可以由玻璃形成。合适的玻璃纤维可以包括短切原丝玻璃纤维或微玻璃纤维。
一般地,非粘结纤维可以具有任何合适的尺寸。在一些实施方案中,非粘结纤维的平均直径为约1微米至约100微米;在一些情况下,约8微米至40微米。在一些实施方案中,非粘结纤维的长径比为约10至约10000;在一些情况下,约750至约6000。
如上所述,纤维网可以包含粘结纤维。粘结纤维可以具有任何合适的组成。在一些实施方案中,粘结纤维可以具有单一组成;或者,在其它实施方案中,粘结纤维可以具有多种组成。也就是说,在一些实施方案中单独的粘结纤维可以具有单一组成;或者,在其它实施方案中,单独的粘结纤维可以具有多种组成。当纤维具有多种组成时,该纤维可以称为多组分纤维。多组分纤维的实例为双组分纤维,其包括第一材料和第二材料。第一材料的熔点可以比第二材料的熔点低,并且可以熔融使得其在网形成的过程中起到粘结剂的作用。例如,第一材料的熔融温度可以低于225℃、低于180℃、低于110℃或者低于80℃。多组分纤维的组分可以具有多种空间布置,包括芯-鞘构造(例如,第一材料可以为包围作为芯材料的第二材料的鞘材料)、并列构造、橘瓣形(segmented pie)布置、三叶形布置(例如,第一材料可以在叶片的顶端)和一种组分在另一种组分中的局部化区域布置(例如,“在海中的岛”)。
对于粘结纤维合适的组成包括聚酯(例如,共聚酯、PET、未拉伸的PET、共PET)、乙烯基化合物(例如,聚氯乙烯、聚乙烯基醇、醋酸乙烯酯、聚醋酸乙烯酯、乙烯-醋酸乙烯酯)、聚烯烃(例如,PE、PP)、聚氨酯和聚酰胺(例如,共聚酰胺)材料。这些组成可以以单组分或以多组分粘结纤维使用。合适的多组分纤维的实例包括聚烯烃(例如,聚乙烯(HDPE、LLDPE)、聚丙烯)/聚酯、共PET(例如,熔融非晶的、熔融结晶的)/聚酯、共PET/尼龙和PET/PPS。在该多组分纤维清单中,按惯例用“/”将熔融温度较低的材料(例如,第一材料)与熔融温度较高的材料(例如,第二材料)分开。其它合适的组成是本领域技术人员已知的。
一般地,粘结纤维可以具有任何合适的尺寸。在一些实施方案中,粘结纤维的平均直径为约5微米至约50微米;在一些情况下,约10微米至40微米。在一些实施方案中,粘结纤维的长径比为约10至约10000;在一些情况下,约750至约6000。应理解,粘结纤维的其它尺寸可能也是合适的。
如上所述,除了纤维组分之外,纤维网还可以包含树脂组分。一般地,任何合适的树脂均可以使用。合适的树脂的实例包括聚酯、聚烯烃、乙烯基化合物(例如,丙烯酸类、苯乙烯化丙烯酸类、醋酸乙烯酯、乙烯基丙烯酸类、聚苯乙烯丙烯酸酯、聚丙烯酸酯、聚乙烯基醇、聚乙烯醋酸乙烯酯、聚乙烯氯乙烯、苯乙烯丁二烯橡胶、聚氯乙烯、聚乙烯基醇衍生物)、聚氨酯、聚酰胺、聚腈、弹性体、天然橡胶、脲甲醛、三聚氰胺甲醛、酚甲醛、淀粉聚合物及其组合。应理解,其它树脂组成可能也是合适的。在一些实施方案中树脂可以是热固性树脂,而在一些实施方案中是热固性树脂/热塑性树脂的组合。
树脂可以为胶乳的形式,例如基于水的乳液。在一些实施方案中,树脂可以为分散体、粉末、热熔体和/或溶液的形式。
在一些实施方案中,可以优选树脂的组成类似于至少一些粘结纤维(在一些情况下,基本全部粘结纤维)的组成。在一些实施方案中,树脂可以包含与形成部分(例如,当使用多组分粘结纤维时)或全部(例如,当使用单组分粘结纤维时)粘结纤维的聚合物种类相同的聚合物。例如,粘结纤维和树脂都可以包含来自以下种类的材料:聚酯、聚烯烃、聚酰胺、乙烯基化合物和聚氨酯。这类实施方案可能特别适合于提高纤维网的刚度。在一些情况下,树脂可以具有与至少一些粘结纤维(在一些情况下,基本全部粘结纤维)的至少一种组分相同的组成。在这些情况的一些中,粘结纤维可以为多组分纤维(例如,双组分纤维例如芯-鞘纤维)。例如,多组分纤维可以为共聚酯/PET纤维,而树脂为共聚酯。
在一些实施方案中,树脂可以包含交联剂。合适的交联剂是本领域技术人员已知的。在一些实施方案中,树脂不包含交联剂。
纤维网还可以包含其它合适的添加剂,其为赋予纤维网所希望的性质而添加和/或为加工目的而添加。合适的添加剂可以包括以下成分的一种或多种:阻燃剂、防油剂、防水剂、染料、颜料、光学增白剂、抗细菌剂、抗真菌剂、UV抑制剂、在加工过程中用于pH控制的酸、增稠剂、表面活性剂、消泡剂和抗氧化剂。应理解,其它添加剂也是可能的。在一些情况下,这些添加剂可以引入纤维组分中;或者,在其它情况下,添加剂作为单独组分添加。
图1示出根据一些实施方案的纤维网10。在如下面进一步描述的打褶工艺之后示出该网。该网包括沿该网延伸的一系列褶皱12。如所示的,褶皱可以包含一般来说尖且均匀的折痕。
一般地,褶皱可以以任何合适的出现率范围存在。例如,褶皱的出现率可以为约1个褶皱/英寸至约12个褶皱/英寸;在一些实施方案中,约2个褶皱/英寸至约6个褶皱/英寸。在一些实施方案中,纤维网可以包括褶皱出现率不同的区域;但是,在其它实施方案中,出现率沿纤维网保持相对恒定。
一般地,褶皱可以具有任何合适的高度。褶皱高度以一个峰(图1中的p)和一个相邻的谷(图1中的v)之间的垂直距离测量。褶皱高度可以为约0.5英寸至约14英寸;在一些情况下,约1英寸至约6英寸。在一些实施方案中,纤维网可以包括沿网相对恒定的褶皱高度;但是,在其它实施方案中,峰高度可以沿网变化。
应理解,其它褶皱出现率和高度可能也是合适的,并且将部分取决于纤维网所用于的应用。
纤维网的褶皱率可以根据测量技术来量化。一种合适的技术测量网的划线可折叠性指数(SFI,score foldability index),其采用与AATCC-66“Wrinkle Recovery ofFabrics:Recovery Angle Method”类似的方法。一般地,SFI是网接受并保持折痕的能力的度量。当测量SFI时,通过将6.875英寸×4.875英寸的矩形划线块垂直于网样品的机器方向放置并用压机施加50磅/平方英寸压力短于1秒的时间来在纤维网上划线。样品和划线块的温度均保持在环境温度(24℃)下。准备1英寸×4英寸的较小样品,使得划线垂直于该样品的宽度延伸以将该样品分成两个尺寸相等的部分。然后沿划线折叠样品,将1853克的静止重物放在折痕的中心并施加30秒。在移走重物后,在恢复5秒和30秒后测量折叠角(即,样品两个部分之间的角度)。测得的角度和时间(例如,5秒、30秒)作为SFI报告。
在一些实施方案中,纤维网在5秒后的SFI小于约70°;在一些实施方案中,小于约60°;在一些实施方案中,小于约50°;在一些实施方案中,小于约40°;在一些实施方案中,小于约30°;在一些实施方案中,小于约25°。在一些实施方案中,纤维网在30秒后的SFI小于约80°;在一些实施方案中,小于约70°;在一些实施方案中,小于约60°;在一些实施方案中,小于约50°;在一些实施方案中,小于约40°;在一些实施方案中,小于约35°。
如上所述,纤维网可以具有高渗透率。渗透率涉及纤维网透过流体的能力。它可以表示为在固定压差下每单位时间通过单位面积纤维网的流体体积。例如,纤维网的渗透率可以大于约400立方英尺/分钟/平方英尺(cfm/sf)。在一些实施方案中,渗透率可以大于约500cfm/sf(例如,约500cfm/sf至约1200cfm/sf,约500cfm/sf至约900cfm/sf)。在一些实施方案中,渗透率可以大于600cfm/sf(例如,约600cfm/sf至约1200cfm/sf,约600cfm/sf至约900cfm/sf)。在一些实施方案中,渗透率可以大于700cfm/sf(例如,约700cfm/sf至约1200cfm/sf,约700cfm/sf至约900cfm/sf)。
纤维网的渗透率根据ASTM D737:“Standard Test Method for AirPermeability of Textile Fabrics”测得。纤维网的渗透率是流动阻力的反函数并可以用Frazier渗透率测试仪(例如,Frazier渗透率测试仪91A)测量。Frazier渗透率测试仪测量在样品两侧固定压差下每单位时间通过单位面积样品的空气体积。渗透率以在0.5英寸水压差下每分钟每平方英尺的立方英尺表示。
应理解,对于纤维网来说其它合适的渗透率范围是可能的。
如上所述,在一些实施方案中,对于纤维网来说有利的是具有低厚度。例如,厚度可以小于约25密耳(例如,约5密耳至25密耳,约12密耳至约25密耳,约15密耳至约20密耳)。在一些实施方案中,厚度可以小于约20密耳(例如,约5密耳至20密耳,约12密耳至约20密耳,约15密耳至约20密耳)。
如本文所用的,纤维网厚度采用基于ASTM D5729:“Test Method for Thicknessof Nonwoven Fabrics”的试验在直径为1.128”的压机脚(presser foot)上使用0.125磅/平方英寸的外加力来确定。
应理解,对于纤维网来说其它合适的厚度范围是可能的。
如上所述,纤维网可以具有高刚度。在一些实施方案中,纤维网的刚度大于约200mg。在一些实施方案中,刚度大于约400mg(例如,约400mg至1700mg,约400mg至约800mg)。在一些实施方案中,刚度大于500mg(例如,约500mg至1700mg,约500mg至约800mg)。
如本文所用的,刚度值为Gurley刚度值并采用WSP 90.2:“Standard Test Methodfor Stiffness of Nonwoven Fabrics Using the Gurley Tester”来测量。
应理解,对于纤维网来说其它合适的刚度范围是可能的。
一般地,纤维网可以具有任何合适的基重。例如,纤维网的基重可以为约40g/m2至约300g/m2;在一些情况下,或者约60g/m2至约150g/m2。其它基重也是可能的。纤维网的基重根据ASTM D6242:“Test Method for Mass Per Unit of Nonwoven Fabric”测量。
在一些实施方案中,纤维网的孔隙率大于约70%。例如,孔隙率可以为约70%至约99%,或者约80%至约95%。孔隙率可以按每平方米网的克数除以其纤维密度与厚度的乘积来计算。其它孔隙率也是可能的。
一般地,纤维网可以采用常规设备制造。多种加工技术可用于制造纤维网,包括干法成网工艺、湿法成网工艺、气流成网工艺、纺粘工艺和熔喷工艺。一种合适的干法成网工艺可以使用一个或多个梳理机。在一些实施方案中,(例如,当使用一个梳理机时),也可以使用交叉铺网机。在使用多个梳理机(例如,4或5个梳理机)的实施方案中,所述机器可以连续布置在梳理线中。一般地,梳理机被设计为将纤维与杂质分开、将它们排列并输送以铺陈为网。所述机器可以包括一系列辊和鼓,其用多个突出的丝线和/或齿覆盖。在这一系列梳理机中的每个梳理机都可以将经过梳理的网输送至横跨这一系列梳理机运行的传送带,以将来自连续机器的经过梳理的网叠加到彼此之上,从而形成纤维网。
在梳理线之后,将树脂添加到纤维网上。在一些实施方案中,使网通过饱和器,其将树脂施加到网上。饱和器可以为泡沫库,其施加发泡树脂分散体形式的树脂。在一些情况下,可以将表面活性剂(例如,十二烷基硫酸铵)添加到分散体中。应理解,可以采用其它施加树脂的技术,包括饱和结合、泡沫结合、喷射、印刷、粉末涂布或其它合适的方法。
在将树脂添加到纤维网上之后,然后对网施加加热步骤。加热步骤可以通过除去树脂的液相起到干燥作用。在一些工艺中,加热步骤通过软化粘结剂使得它可以变为可流动的并可以起到其粘结作用也作为粘结步骤。也就是说,在这些实施方案过程中,纤维网被干燥并且粘结剂在同一步骤过程中被软化。
在一些实施方案中,在加热步骤过程中,粘结纤维(或者,使用多组分纤维时,粘结纤维的组分例如鞘)可以随着树脂的液相蒸发并且树脂颗粒团聚和/或在纤维上形成涂层而软化。粘结剂和树脂材料可以共混合。也就是说,聚合物粘结剂和树脂可以完全共混。这样的共混合可以进一步提高所得网的刚度,可以提高褶皱率。当树脂和粘结剂具有如上所述的类似组成时,共混合可能是特别有效的。
在一些实施方案中,使用一些列蒸汽加热的烘缸进行加热步骤。然而,应理解,其它加热方法也是可能的,包括例如IR加热器、超声、微波辐射、烘箱和穿流式粘结机(through air bonder)。合适的干燥温度可以为约80℃至约200℃(例如,约110℃至约180℃)。合适的加热时间可以为约5秒至约50秒(例如,约10至约30秒)。其它加热温度和时间也是可能的。
在加热步骤之后,收集纤维网并根据需要进一步加工。进一步加工可以包括将网与一个或多个另外的纤维网结合以形成过滤介质。在一些实施方案中,对过滤介质实施打褶步骤以引入褶皱。打褶步骤一般包括:将网划线,然后施加压力。
应理解,在与任何其它网或其它组件结合之前,可以将纤维网自身打褶。可以进一步加工过滤介质以形成不同的过滤元件。
图2示出了根据一些实施方案的过滤介质20。该过滤介质包括如上所述且在图1中示出的纤维网10。网10在低厚度下可以具有本文所述的所希望的特征,包括高渗透率和刚度。在该实施方案中,网10可以用作背衬,其为介质提供机械整体性但在过滤污染物中不起显著作用。过滤介质包括第二纤维网22。如所示的,网10和网22包括褶皱12。所述第二纤维网可以被设计为具有与第一纤维网不同的作用。例如,可能要求第二纤维网过滤污染物。第二网可以具有多种不同的构造,一般地过滤介质在这方面是不受限制的。一种合适的构造是熔喷纤维网,例如如共有美国专利申请公开2009/0120048(其通过引用整体并入本文)中所描述的。如下面进一步描述的,过滤介质可以引入合适的过滤元件中。
应理解,合适的过滤介质可以包括任何另外的纤维网并且可以引入其它部件。
本文所述的网和介质可以被引入多种合适的过滤元件中。应理解,过滤元件可以具有多种不同的构造,特定构造取决于过滤元件所用于的应用。
在一些情况下,过滤元件包括可以围绕过滤介质布置的外壳。外壳可以具有不同的构造,所述构造根据预期应用而变化。在一些实施方案中,外壳可由围绕过滤介质外周布置的框形成。例如,框可以是围绕外周热密封的。在一些情况下,框可以被构造为适合板式过滤器用途。在一些情况下,框可以被构造为适合筒式过滤元件或者沟流(channel flow)应用。框可以由多种材料,包括例如纸板、金属、聚合物或任何合适材料的组合形成。过滤元件还可以包括本领域已知的多种其它部件,例如用于使过滤介质相对于框稳定的稳定部件、隔离物或任何其它合适的部件。
过滤元件一般可以用于多种过滤应用,特别是期望打褶介质的那些。合适的应用尤其是房间空气清洁、发动机/舱空气清洁、燃气轮机过滤、灰尘收集、液体过滤以及HVAC和HEPA用途的领域。
以下非限制性实施例描述根据本文所讨论的方面制得的纤维网。实施例
一般按照上述干法成网工艺制造纤维网。
对于实验1-3(见下表),用于形成网的纤维组分为100重量%粘结纤维。所用的粘结纤维为同心鞘/芯双组分纤维,包含熔点为110℃的共聚酯鞘和熔点为255-260℃的PET芯。对于实验1-3,以如下表所示不同比例将旦尼尔为4d和15d的纤维共混在一起,纤维直径为20~40微米。
对于实验4,使用粘结纤维和非粘结纤维。粘结纤维为用于实验1-3的粘结纤维并且占纤维总重量的80%。其余的20重量%纤维由旦尼尔为3d的人造纤维素纤维组成。
所有实验遵循类似工艺。该工艺采用四个连续布置的梳理机,每个梳理机制造经过梳理的网,所述网被收集在在梳理机之下运行的传送带上。来自连续机器的经过梳理的网叠加在彼此之上以形成纤维网。
在梳理线之后,向纤维网添加树脂。树脂基于网总重量的重量百分比如下表所示。该树脂是以发泡树脂分散体形式施加的共聚酯树脂。在该实施方案中,共聚酯树脂由间苯二甲酸、对苯二甲酸和磺基间苯二甲酸钠的共混合物构成。通过以0.15重量%(基于分散体)的含量引入十二烷基硫酸铵将聚酯树脂分散体制成泡沫。在将树脂添加到纤维网上之后,然后对该网实施加热步骤。该加热步骤包括一系列蒸汽加热的烘缸,其施加达到约154℃最高温度的热梯度。加热步骤使纤维网干燥并在同一步骤过程中使粘结剂活化。
收集纤维网并通过测量某些性质对其进行进一步评价。所测量的性质包括如下表所示的基重、厚度、渗透率、刚度和SFI。
表1
已经如此描述了本发明至少一个实施方案的几个方面,应理解本领域技术人员会容易地进行各种变更、改变和改进。这样的变更、改变和改进意在为本公开的一部分,并且意在本发明的精神和范围内。相应地,前述描述和图仅作为实例。
以下内容对应于母案申请的原始权利要求书:
1.一种纤维网,其渗透率大于约500cfm/sf,刚度大于约500mg,厚度小于约25密耳。
2.项1的纤维网,其中所述纤维网为非织造网。
3.项1的纤维网,其中所述纤维网包含合成纤维。
4.项1的纤维网,其中所述纤维网包含双组分纤维。
5.项4的纤维网,其中所述双组分纤维的重量百分比大于50重量%,基于所述纤维网中纤维的总重量百分比。
6.项1的纤维网,其中所述纤维网包含粘结纤维和非粘结纤维。
7.项1的纤维网,其中所述粘结纤维占所述纤维网中纤维总重量的大于50重量%。
8.项7的纤维网,其中所述粘结纤维是多组分纤维。
9.项1的纤维网,其中所述纤维网包含树脂。
10.项9的纤维网,其中所述树脂为胶乳形式。
11.项9的纤维网,其中所述纤维网包含含有与所述树脂相同种类的聚合物的粘结剂。
12.项11的纤维网,其中所述粘结剂和所述树脂为聚酯。
13.项1的纤维网,其中所述纤维网的渗透率为约500cfm/sf至约1200cfm/sf。
14.项1的纤维网,其中所述纤维网的刚度为约500mg至约1700mg。
15.项1的纤维网,其中所述纤维网的厚度为约12密耳至约25密耳。
16.项1的纤维网,其中所述纤维网的基重为约40g/m2至约300g/m2。
17.项1的纤维网,其中所述纤维网在5秒后的SFI小于约70°。
18.一种过滤介质,包括作为背衬的项1的纤维网和贴附到所述背衬上的第二纤维网。
19.一种过滤元件,包括项18的纤维网。
20.一种纤维网,其渗透率大于约500cfm/sf并且刚度大于约500mg,所述纤维网包含多组分纤维,其中所述多组分纤维占所述纤维网中纤维总重量的大于50重量%。
21.一种纤维网,其渗透率大于约500cfm/sf并且厚度小于约25密耳,其中所述纤维网包含粘结纤维和树脂,其中所述粘结纤维包含聚合物,所述树脂包含聚合物,并且所述粘结纤维的聚合物与所述树脂的聚合物的种类相同。
22.一种过滤流体的方法,所述方法包括:
用包含纤维网的过滤元件过滤流体,所述纤维网的渗透率大于约500cfm/sf,刚度大于约500mg,并且厚度小于约25密耳。
23.一种制造纤维网的方法,包括:
形成渗透率大于约500cfm/sf、刚度大于约500mg、厚度小于约25密耳的纤维网。
Claims (8)
1.一种纤维网,其渗透率大于约500cfm/sf,刚度大于约500mg,厚度小于约25密耳。
2.权利要求1的纤维网,其中所述纤维网为非织造网;和/或
其中所述纤维网包含合成纤维;和/或
其中所述纤维网包含双组分纤维;和/或
其中所述双组分纤维的重量百分比大于50重量%,基于所述纤维网中纤维的总重量百分比;和/或
其中所述纤维网包含粘结纤维和非粘结纤维;和/或
其中所述粘结纤维占所述纤维网中纤维总重量的大于50重量%;和/或
其中所述粘结纤维是多组分纤维;和/或
其中所述纤维网包含树脂;和/或
其中所述树脂为胶乳形式;和/或
其中所述纤维网包含含有与所述树脂相同种类的聚合物的粘结剂;和/或
其中所述粘结剂和所述树脂为聚酯;和/或
其中所述纤维网的渗透率为约500cfm/sf至约1200cfm/sf;和/或
其中所述纤维网的刚度为约500mg至约1700mg;和/或
其中所述纤维网的厚度为约12密耳至约25密耳;和/或
其中所述纤维网的基重为约40g/m2至约300g/m2;和/或
其中所述纤维网在5秒后的SFI小于约70°。
3.一种过滤介质,包括作为背衬的权利要求1的纤维网和贴附到所述背衬上的第二纤维网。
4.一种过滤元件,包括权利要求3的纤维网。
5.一种纤维网,其渗透率大于约500cfm/sf并且刚度大于约500mg,所述纤维网包含多组分纤维,其中所述多组分纤维占所述纤维网中纤维总重量的大于50重量%。
6.一种纤维网,其渗透率大于约500cfm/sf并且厚度小于约25密耳,其中所述纤维网包含粘结纤维和树脂,其中所述粘结纤维包含聚合物,所述树脂包含聚合物,并且所述粘结纤维的聚合物与所述树脂的聚合物的种类相同。
7.一种过滤流体的方法,所述方法包括:
用包含纤维网的过滤元件过滤流体,所述纤维网的渗透率大于约500cfm/sf,刚度大于约500mg,并且厚度小于约25密耳。
8.一种制造纤维网的方法,包括:
形成渗透率大于约500cfm/sf、刚度大于约500mg、厚度小于约25密耳的纤维网。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US12/488,334 | 2009-06-19 | ||
US12/488,334 US8083828B2 (en) | 2009-06-19 | 2009-06-19 | Fiber web having a high stiffness |
CN2010800265873A CN102458603A (zh) | 2009-06-19 | 2010-06-17 | 具有高刚度的纤维网 |
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CN201610548911.7A Pending CN106048899A (zh) | 2009-06-19 | 2010-06-17 | 具有高刚度的纤维网 |
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EP (1) | EP2442886A4 (zh) |
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Also Published As
Publication number | Publication date |
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CN102458603A (zh) | 2012-05-16 |
US8083828B2 (en) | 2011-12-27 |
EP2442886A4 (en) | 2013-02-13 |
US20120048797A1 (en) | 2012-03-01 |
EP2442886A1 (en) | 2012-04-25 |
WO2010148189A1 (en) | 2010-12-23 |
US20100319310A1 (en) | 2010-12-23 |
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