CN107034686A - 耐腐蚀耐高压的环保过滤材料及其制备方法 - Google Patents

耐腐蚀耐高压的环保过滤材料及其制备方法 Download PDF

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CN107034686A
CN107034686A CN201710384403.4A CN201710384403A CN107034686A CN 107034686 A CN107034686 A CN 107034686A CN 201710384403 A CN201710384403 A CN 201710384403A CN 107034686 A CN107034686 A CN 107034686A
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parts
corrosion
silk
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filtering material
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CN107034686B (zh
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单素梅
朱彦加
朱靓靓
吴健健
张瑜
李素英
付译鋆
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JIANGSU SANYUAN ENVIRONMENTAL PROTECTION TECHNOLOGY CO.,LTD.
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Abstract

本发明公开了一种耐腐蚀耐高压的环保过滤材料及其制备方法，它包括由玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝混纺得到的纺织布，针刺在纺织布上下表面的氟美斯针刺毡，覆在氟美斯针刺毡表面的化学薄膜；纳米玄武岩纤维丝、纳米碳纤维丝和纳米玻璃纤维丝表面经过聚氨酯溶液浸渍处理；纳米芳纶纤维丝表面经过有机硅树脂浸渍处理。本发明提供的环保滤材结构设计合理，过滤性能好，具有优异的耐腐蚀、耐高温、抗拉力性强等综合性能，使用寿命长，可广泛应用于钢铁、水泥、石油化工、垃圾焚烧和电石厂等不同的行业，应用前景广泛。本发明提供的制备方法，工艺设计合理，可操作性强，能耗低，环保性强，且生产工作效率高，可实现工业化生产。

Description

耐腐蚀耐高压的环保过滤材料及其制备方法
技术领域
本发明涉及一种环保滤材，具体涉及一种环保性强，过滤性能好，耐腐蚀，耐高温，抗拉力性强的耐腐蚀耐高压的环保过滤材料及其制备方法，属于环保技术领域。
背景技术
在钢铁、水泥、石油化工、垃圾焚烧、电石厂等行业，生产过程中易产生大量的粉尘或烟雾等，需要过滤除尘处理，但是现有技术的过滤材料，耐腐蚀，耐高温，抗拉力性能弱，过滤效果差，易出现堵袋等问题，使用寿命较短，耐用性能差。
另外现有技术在单种纤维的纺织布性能并不全面，如在保持良好抗拉力和耐磨性同时，弹性模量较低，另外单个纤维纺织布在抗氧化、耐腐蚀，耐酸碱、拒油性防水等综合性能不全，因此，如何创造出耐腐蚀、耐高温、防油污、耐酸碱、抗拉力性等综合性能全面的过滤纺织布具有重要意义。
发明内容
发明目的：本发明的目的是为了解决现有技术的不足，提供一种结构设计合理，过滤性能好，耐腐蚀、耐高温、抗拉力性强，力学性能优，使用寿命长，应用范围广泛的环保过滤材料；本发明另外一个目的是提供该环保过滤材料的制备方法。
技术方案：为了实现以上目的，本发明采取的技术方案为：
一种耐腐蚀耐高压的环保过滤材料，它包括由玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝混纺得到的纺织布，针刺在纺织布上下表面的氟美斯针刺毡，覆在氟美斯针刺毡表面的化学薄膜；
所述的玄武岩纤维丝、碳纤维丝和玻璃纤维丝表面经过聚氨酯溶液浸渍处理；
所述的芳纶纤维丝表面经过聚四氟乙烯浸渍处理；
作为优选方案，以上所述的玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝的体积比为1～3:2～6:3～9:1～4。
作为优选方案，玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝为纳米级纤维丝。
作为优选方案，以上所述的耐腐蚀耐高压的环保过滤材料，所述的环保过滤材料的厚度为2～6毫米，每平方米的重量为800～1200克。
本发明所述的耐腐蚀耐高压的环保过滤材料的制备方法，包括以下步骤：
(1)首先将玄武岩纤维丝、碳纤维丝和玻璃纤维丝分别经过梳理、分沙后浸入含有聚氨酯的胶槽中进行浸胶处理，然后在卷纱机牵引下穿过导纱孔板，然后在微波加热箱内固化成型，分别得到表面均匀浸渍有聚氨酯薄膜层的玄武岩纤维丝、碳纤维丝和玻璃纤维丝；
(2)然后将芳纶纤维丝经过梳理、分沙后浸入含有聚四氟乙烯的胶槽中进行浸胶处理，然后在卷纱机牵引下穿过导纱孔板，然后在微波加热箱内固化成型，得到表面均匀浸渍有聚四氟乙烯薄膜层的芳纶纤维丝；
(3)将表面均匀浸渍有聚氨酯薄膜层的玄武岩纤维丝、碳纤维丝和玻璃纤维丝与表面均匀浸渍有聚四氟乙烯薄膜层的芳纶纤维丝通过织布机纺织得到的纺织布或者通过针刺的方式得到针刺纺织布；
(4)取步骤(3)的纺织布浸入储有耐腐蚀耐高温化学处理液的浸渍槽中浸轧，出槽后再进行1～2次轧辊挤压，然后输送到微波加热箱中进行加热固化成型；
(5)将步骤(4)加热固化成型的环保过滤材料通过成卷机打卷，并用聚氯乙烯薄膜包裹。
作为优选方案，以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，所述的耐腐蚀耐高温化学处理液由下列重量份数的原料组成：
有机硅树脂10～15份、甲醚化氨基树脂5～15份、醇酸树脂8～16份、聚氨酯4～8份、氟碳树脂3～9份、热固性丙烯酸甲酯4～8份、三元醇15～30份、正硅酸乙酯5～15份、苯酐3～6份、醋酸丁酯3～6份、异氰酸酯2～6份、乙二醇单丁醚3～6份、二甲基乙醇胺3～9份、去离子水20～60份。
作为更加优选方案，以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，所述的耐腐蚀耐高温化学处理液由下列重量份数的原料组成：
有机硅树脂15份、甲醚化氨基树脂15份、醇酸树脂10份、聚氨酯6份、氟碳树脂6份、热固性丙烯酸甲酯6份、三元醇20份、正硅酸乙酯10份、苯酐5份、醋酸丁酯5份、异氰酸酯4份、乙二醇单丁醚6份、二甲基乙醇胺9份、去离子水40份。
本发明通过大量实验筛选表面化学处理液的组成，优选得到最佳的化学处理液，可以在纺织布表面浸渍得到耐腐蚀、耐高温、附着力强、抗拉力性好，耐候性佳的薄膜，可以明显提高纺织布的力学性能和理化性能，较单一的现有技术的聚四氟乙烯薄膜，性能更加优越。
作为优选方案，以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，所述三元醇为甘油、三羟甲基丙烷或三羟甲基乙烷中的一种或它们的混合物。
作为优选方案，以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，步骤(1)和步骤(2)微波加热箱内微波加热功率为1KW，加热时间为5～30秒。
作为优选方案，以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，步骤(4)微波加热箱中，先在1KW微波源功率下加热5～30秒，然后在5KW微波源功率下加热10～30秒。
本发明通过大量实验筛选，引进绿色环保的微波加热装置，打破现有技术依靠烘箱烘干的方式，现有的加热炉烘箱烘干，需要非常高的能耗，成本高，环保性低，且加热烘干温度需要阶梯升温烘干，操作复杂，生产效率低，且树脂浸入到空间极其细小的纤维纺织布内层，依靠烘箱外部烘干的方式，很难将其加热固化透，从而影响过滤材料的性能和成膜效果。本发明创造性的采用微波加热固化成膜的方式，微波可由内之外加热固化树脂，从而可以使树脂快速固化成膜，防止过滤纤维材料内部不能够彻底固化成膜的不足。并且采用微波加热，需要的功率低，加热固化时间短(一般只需要1到2分钟，而传统烘箱加热需要10～30分钟)，生产效率非常高，并且能耗非常低，加热成本是现有烘箱加热的十分之一，并且取得了非常好的技术效果。当然在选择微波加热功率和加热时间非常关键，过高的功率和过长的微波加热时间对纤维和薄膜具有一定的损伤，本发明通过大量实验选，先对单个纤维丝表面薄膜进行低功率1KW，5～30秒加热时间进行处理，先在单个纤维表面处理得到聚氨酯薄膜或有机硅树脂薄膜，这种处理方式可以最大程度的提高单个纤维的表面性能，相比现有技术先纺织得到织物再进行表面化学处理具有更加优越的理化性能，取得了非常好的技术效果。
纺织布在化学处理液浸胶后，本发明再经过优选的微波加热功率和加热时间，采用二个梯度进行微波辐射加热固化成膜，首先采用低功率1KW微波源功率下加热10～30秒，然后在高功率5KW微波源功率下加热10～30秒。这种分阶段、分功率的加热方式，可以使纺织布表面的形成致密附着力牢固的化学膜。本发明通过实验筛选，如果直接采用高功率的微波源加热，由于加热固化速度过快，成膜后附着力和致密性较差，耐用性较差。
作为优选方案，以上所述的纳米聚苯硫醚丝、纳米玄武岩纤维丝、纳米碳纤维丝和纳米芳纶纤维丝的体积比为1～3:2～6:3～9:1～4；
并且本发明通过大量实验筛选，在纺织布上下表面针刺有氟美斯针刺毡(氟美斯针刺毡以100％无碱玻璃纤维为原料，采用高支数玻璃纤维丝分丝成绒针刺而成，具有良好的耐热，阻燃，防腐效果、气体过滤阻力小、除尘效率超过机织滤料)，并且在有氟美斯针刺毡表面浸渍处理得到薄膜，可以在保证优异的机械力学性能的同时，最大程度的提高过滤性能。
有益效果：本发明提供的耐腐蚀耐高压的环保过滤材料及其制备方法和现有技术相比具有以下优点:
本发明提供的耐腐蚀耐高压的环保过滤材料，通过大量实验筛选得到最佳的纤维材料，制备得到的环保滤材结构设计合理，过滤性能好，并且具有优异的耐腐蚀、耐高温、抗拉力性强等综合性能，并且使用寿命长，可广泛应用于钢铁、水泥、石油化工、垃圾焚烧和电石厂等不同的行业，是一种新型的过滤材料，应用前景广泛。
本发明提供的耐腐蚀耐高压的环保过滤材料的制备方法，工艺设计合理，可操作性强，能耗低，环保性强，且生产工作效率高，可实现工业化生产。
具体实施方式
下面结合具体实施例，进一步阐明本发明，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，在阅读了本发明之后，本领域技术人员对本发明的各种等价形式的修改均落于本申请所附权利要求所限定的范围。
实施例1
1、一种耐腐蚀耐高压的环保过滤材料，它包括由玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝混纺得到的纺织布，针刺在纺织布上下表面的氟美斯针刺毡，覆在氟美斯针刺毡表面的化学薄膜；
所述的玄武岩纤维丝、碳纤维丝和玻璃纤维丝表面经过聚氨酯溶液浸渍处理；
所述的芳纶纤维丝表面经过聚四氟乙烯树脂浸渍处理；
所述的玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝的体积比为2:6:9:2。
以上所述的耐腐蚀耐高压的环保过滤材料，所述的环保过滤材料的厚度为2～6毫米，每平方米的重量为800～1200克。
2、耐腐蚀耐高压的环保过滤材料的制备方法，其包括以下步骤：
(1)首先将玄武岩纤维丝、碳纤维丝和玻璃纤维丝分别经过梳理、分沙后浸入含有聚氨酯的胶槽中进行浸胶处理，然后在卷纱机牵引下穿过导纱孔板，然后在微波加热箱内固化成型，分别得到表面均匀浸渍有聚氨酯薄膜层的玄武岩纤维丝、碳纤维丝和玻璃纤维丝；
(2)然后将芳纶纤维丝经过梳理、分沙后浸入含有聚四氟乙烯的胶槽中进行浸胶处理，然后在卷纱机牵引下穿过导纱孔板，然后在微波加热箱内固化成型，得到表面均匀浸渍有聚四氟乙烯树脂薄膜层的芳纶纤维丝；
(3)将表面均匀浸渍有聚氨酯薄膜层的玄武岩纤维丝、碳纤维丝和玻璃纤维丝与表面均匀浸渍有聚四氟乙烯薄膜层的芳纶纤维丝按体积比为2:6:9:2，通过织布机纺织得到的纺织布；
(4)取步骤(3)的纺织布浸入储有耐腐蚀耐高温化学处理液的浸渍槽中浸轧，出槽后再进行2次轧辊挤压，然后输送到微波加热箱中进行加热固化成型；
(5)将步骤(4)加热固化成型的环保过滤材料通过成卷机打卷，并用聚氯乙烯薄膜包裹。
所述的耐腐蚀耐高温化学处理液由下列重量份数的原料组成：
有机硅树脂15份、甲醚化氨基树脂15份、醇酸树脂10份、聚氨酯6份、氟碳树脂6份、热固性丙烯酸甲酯6份、甘油20份、正硅酸乙酯10份、苯酐5份、醋酸丁酯5份、异氰酸酯4份、乙二醇单丁醚6份、二甲基乙醇胺9份、去离子水40份。
以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，步骤(1)和步骤(2)微波加热箱内微波加热功率为1KW，加热时间为20秒。
以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，步骤(4)微波加热箱中，先在1KW微波源功率下加热20秒，然后在5KW微波源功率下加热20秒。
3、性能检测
取上述耐腐蚀耐高压的环保过滤材料进行基本力学和化学性能检测，检测结果如下：
由以上检测结果表明，本发明提供的耐腐蚀耐高压的环保过滤材料具有优异的过滤性能，并且具有优异的力学性能，是一种新型环保过滤材料，应用范围非常广泛。
实施例2
1、一种耐腐蚀耐高压的环保过滤材料，它包括由纳米玄武岩纤维丝、纳米碳纤维丝、纳米芳纶纤维丝和纳米玻璃纤维丝混纺得到的纺织布，针刺在纺织布上下表面的氟美斯针刺毡，覆在氟美斯针刺毡表面的化学薄膜；
所述的纳米纳米玄武岩纤维丝、纳米碳纤维丝和纳米玻璃纤维丝表面经过聚氨酯溶液浸渍处理；
所述的纳米芳纶纤维丝表面经过有机硅树脂浸渍处理；
所述的玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝的体积比为1:4:6:2。
以上所述的耐腐蚀耐高压的环保过滤材料，所述的环保过滤材料的厚度为2～6毫米，每平方米的重量为800～1200克。
2、耐腐蚀耐高压的环保过滤材料的制备方法，其包括以下步骤：
(1)首先将纳米玄武岩纤维丝、纳米碳纤维丝和纳米玻璃纤维丝分别经过梳理、分沙后浸入含有聚氨酯的胶槽中进行浸胶处理，然后在卷纱机牵引下穿过导纱孔板，然后在微波加热箱内固化成型，分别得到表面均匀浸渍有聚氨酯薄膜层的纳米玄武岩纤维丝、纳米碳纤维丝和纳米玻璃纤维丝；
(2)然后将纳米芳纶纤维丝经过梳理、分沙后浸入含有有机硅树脂的胶槽中进行浸胶处理，然后在卷纱机牵引下穿过导纱孔板，然后在微波加热箱内固化成型，得到表面均匀浸渍有有机硅树脂薄膜层的纳米芳纶纤维丝；
(3)将表面均匀浸渍有聚氨酯薄膜层的纳米级玄武岩纤维丝、纳米碳纤维丝和纳米玻璃纤维丝与表面均匀浸渍有有机硅树脂薄膜层的纳米级芳纶纤维丝按体积比为1:4:6:2，通过针刺的方式得到针刺纺织布；
(4)取步骤(3)的纺织布浸入储有耐腐蚀耐高温化学处理液的浸渍槽中浸轧，出槽后再进行2次轧辊挤压，然后输送到微波加热箱中进行加热固化成型；
(5)将步骤(4)加热固化成型的环保过滤材料通过成卷机打卷，并用聚氯乙烯薄膜包裹。
所述的耐腐蚀耐高温化学处理液由下列重量份数的原料组成：
有机硅树脂10份、甲醚化氨基树脂10份、醇酸树脂8份、聚氨酯8份、氟碳树脂3份、热固性丙烯酸甲酯8份、三羟甲基丙烷20份、正硅酸乙酯15份、苯酐6份、醋酸丁酯6份、异氰酸酯6份、乙二醇单丁醚6份、二甲基乙醇胺6份、去离子水60份。
以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，步骤(1)和步骤(2)微波加热箱内微波加热功率为1KW，加热时间为30秒。
以上所述的耐腐蚀耐高压的环保过滤材料的制备方法，步骤(4)微波加热箱中，先在1KW微波源功率下加热30秒，然后在5KW微波源功率下加热30秒。
3、性能检测
取上述耐腐蚀耐高压的环保过滤材料进行基本力学和化学性能检测，检测结果如下：
由以上检测结果表明，本发明提供的耐腐蚀耐高压的环保过滤材料具有优异的过滤性能，并且具有优异的力学性能，是一种新型环保过滤材料，应用范围非常广泛。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。

Claims (9)

1.一种耐腐蚀耐高压的环保过滤材料，其特征在于：它包括由玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝混纺得到的纺织布，针刺在纺织布上下表面的氟美斯针刺毡，覆在氟美斯针刺毡表面的化学薄膜；
所述的纳米玄武岩纤维丝、纳米碳纤维丝和纳米玻璃纤维丝表面经过聚氨酯溶液浸渍处理；
所述的纳米芳纶纤维丝表面经过聚四氟乙烯浸渍处理；
所述的玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝的体积比为1～3:2～6:3～9:1～4。
2.根据权利要求1所述的耐腐蚀耐高压的环保过滤材料，其特征在于：所述的环保过滤材料的厚度为2～6毫米，每平方米的重量为800～1200克。
3.权利要求1或2所述的耐腐蚀耐高压的环保过滤材料的制备方法，其特征在于：包括以下步骤：
(1)首先将玄武岩纤维丝、碳纤维丝和玻璃纤维丝分别经过梳理、分沙后浸入含有聚氨酯的胶槽中进行浸胶处理，然后在卷纱机牵引下穿过导纱孔板，然后在微波加热箱内固化成型，分别得到表面均匀浸渍有聚氨酯薄膜层的玄武岩纤维丝、碳纤维丝和玻璃纤维丝；
(2)然后将芳纶纤维丝经过梳理、分沙后浸入含有聚四氟乙烯的胶槽中进行浸胶处理，然后在卷纱机牵引下穿过导纱孔板，然后在微波加热箱内固化成型，得到表面均匀浸渍有聚四氟乙烯薄膜层的芳纶纤维丝；
(3)将表面均匀浸渍有聚氨酯薄膜层的玄武岩纤维丝、碳纤维丝和玻璃纤维丝与表面均匀浸渍有聚四氟乙烯薄膜层的芳纶纤维丝通过织布机纺织得到的纺织布或者通过针刺的方式得到针刺纺织布；
(4)取步骤(3)的纺织布浸入储有耐腐蚀耐高温化学处理液的浸渍槽中浸轧，出槽后再进行1～2次轧辊挤压，然后输送到微波加热箱中进行加热固化成型；
(5)将步骤(4)加热固化成型的环保过滤材料通过成卷机打卷，并用聚氯乙烯薄膜包裹。
4.根据权利要求3所述的耐腐蚀耐高压的环保过滤材料的制备方法，其特征在于：所述的耐腐蚀耐高温化学处理液由下列重量份数的原料组成：
有机硅树脂10～15份、甲醚化氨基树脂5～15份、醇酸树脂8～16份、聚氨酯4～8份、氟碳树脂3～9份、热固性丙烯酸甲酯4～8份、三元醇15～30份、正硅酸乙酯5～15份、苯酐3～6份、醋酸丁酯3～6份、异氰酸酯2～6份、乙二醇单丁醚3～6份、二甲基乙醇胺3～9份、去离子水20～60份。
5.根据权利要求4所述的耐腐蚀耐高压的环保过滤材料的制备方法，其特征在于：所述的耐腐蚀耐高温化学处理液由下列重量份数的原料组成：
有机硅树脂15份、甲醚化氨基树脂15份、醇酸树脂10份、聚氨酯6份、氟碳树脂6份、热固性丙烯酸甲酯6份、三元醇20份、正硅酸乙酯10份、苯酐5份、醋酸丁酯5份、异氰酸酯4份、乙二醇单丁醚6份、二甲基乙醇胺9份、去离子水40份。
6.根据权利要求4或5所述的耐腐蚀耐高压的环保过滤材料的制备方法，其特征在于：所述三元醇为甘油、三羟甲基丙烷或三羟甲基乙烷中的一种或它们的混合物。
7.根据权利要求4所述的耐腐蚀耐高压的环保过滤材料的制备方法，其特征在于：步骤(1)和步骤(2)微波加热箱内微波加热功率为1KW，加热时间为10～30秒。
8.根据权利要求4所述的耐腐蚀耐高压的环保过滤材料的制备方法，其特征在于：步骤(4)微波加热箱中，先在1KW微波源功率下加热10～30秒，然后在5KW微波源功率下加热10～30秒。
9.根据权利要求4所述的耐腐蚀耐高压的环保过滤材料的制备方法，其特征在于：步骤(3)纺织或针刺时玄武岩纤维丝、碳纤维丝、芳纶纤维丝和玻璃纤维丝的体积比为1～3:2～6:3～9:1～4。
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