CN107326501A - 一种丝、纱包覆结构的复合材料缝纫线 - Google Patents
一种丝、纱包覆结构的复合材料缝纫线 Download PDFInfo
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Abstract
本发明涉及一种丝、纱包覆结构的复合材料缝纫线,该缝纫线是将聚四氟乙烯长丝作为包覆纱芯线,将具有与滤料面层纤维相同或具有相似或相补性能的纱线作为外包纱,通过包覆工艺形成包覆纱后,将包覆纱作为股线,再进行并捻合股而制成。由于外包纱线的毛羽,可以拦截更多透过针孔逃逸的粉尘,同时纱线层具有一定弹性,可以更密实地堵塞滤袋缝制针孔,从而提高滤袋除尘效率。并且由于纱线的包覆作用,保护了耐磨性能较差的聚四氟乙烯单丝,使缝纫线具有更好的耐磨性。
Description
技术领域
本发明涉及一种缝纫线,尤其是一种具有包覆结构的复合材料缝纫线。
背景技术
近年来,在大气污染治理形势日趋严峻的情况下,作为工业废气净化主要技术手段的袋式除尘技术,得到了国家环保政策的大力支持,而且不断提高的排放标准,也促使该技术得到了空前广泛的应用和发展。在燃煤电厂,在垃圾焚烧,在水泥窑炉以及钢铁、化工等领域的工业废气排放控制中,聚四氟乙烯(PTFE)、聚苯硫醚(PPS)、聚酰亚胺(PI)、芳纶以及玻纤等一些能够耐高温、耐腐蚀的滤料已经被广泛使用,正是这些材料生产的滤料,在袋式除尘技术和电袋一体复合除尘技术中承担了工业废气达标排放的主要任务。
为保证这些高性能滤料制成滤袋的使用安全和寿命,滤袋缝制一般都选择使用聚四氟乙烯缝纫线。聚四氟乙烯,简称PTFE ,我国俗称“塑料王”。材料具有良好耐温性能(-196℃~260℃)和优异的耐化学腐蚀、耐水解、抗氧化等性能,因此,聚四氟乙烯生产的缝纫线能够适应各种高温、腐蚀工况下的滤袋缝制使用。但是,在聚四氟乙烯缝纫线能够较好满足滤袋耐温和化学功能需要的同时,也因其材料特点,存在影响使用性能的缺点:
1.由于聚四氟乙烯缝纫线只有使用膜切单丝或挤出单丝生产,因此缝纫线的表面比较光滑且无摩擦力。滤料在缝制滤袋后,缝纫线与滤料(布)之间抱合力较低,从而导致缝纫线不能够很好地固化针孔阻拦的粉尘颗粒成为针孔阻塞体。所以,滤袋在除尘器工作时,由于排放引风压力的作用,粉尘仍然能够由针孔余隙中穿透,进入排放,而且会逐渐扩大,从而影响滤袋的过滤效率。为克服这一缺点,目前滤袋生产企业大部分是采用硅胶人工涂抹封堵针孔的办法封闭针孔,虽然也能取得较好的效果,但导致了大量的人工和材料浪费。
2.聚四氟乙烯缝纫线的耐磨性能差。由于聚四氟乙烯材料具有长链大分子结构,分子间互相引力小的特点,长丝纤维制作过程中,经过高倍牵伸后,分子链基本上是呈现在拉力方向和线性排列,这种线性排列的长链分子,在纤维内部以原纤形式存在,并呈现同向排列的结构,而较少有横向或斜向的交联。纤维的这种内部结构,在受到外力摩擦力后,原纤非常容易被剥离或撕裂,长时间重复摩擦或重摩擦力的破坏,会导致缝纫线残损或断裂失强。表现在滤袋上,由于滤袋不断的清灰运动,袋口部位会因粉尘颗粒侵入上下线锁扣部位,而导致磨损或磨断;在缝线部位有与异物碰撞时,缝纫线将被磨损或磨断。
3.如上述缺点1所述,聚四氟乙烯缝纫线目前没有使用纱线纺制,长丝(单丝)由于表面光滑,弹性小,在滤袋缝制时,线径只能小于针孔才能通过,从而在线与滤布之间会留有缝隙,这就导致滤袋在除尘工况中,在引风压力的作用下,有灰尘从针孔中逃逸,从而导致排放超标,而且滤袋使用时间越长,针孔透灰量越大。
本发明人有申请号为CN201610570877.3的在申请专利,在产品设计意图上,如封堵针孔,增加耐磨性等方面,均有与本发明相类似的地方,但该发明仅针对聚四氟乙烯(PTFE)与聚苯硫醚(PPS)复合滤料的缝制开发,使用范围有限制;其次,该发明使用的是聚四氟乙烯单丝和聚苯硫醚单纱或合股纱的多股并捻合股方式复合成线,实践中已经验证在低速缝制或非直线缝制时,由于PTFE单丝与PPS纱线在缝纫线中所呈现的拉伸张力和摩擦力都有差异(PTFE摩擦系数几乎为0),在缝制过程中,有会使通过针孔的PPS纱线受到较大的摩擦力而凸起,导致缝纫线受阻崩断的情况,从而影响缝制效率,该项在申请的专利产品,虽然可以较好地适用于高速直线三针机却存在低速、转折缝制使用容易断线的缺陷。而本发明正是基于申请号为CN201610570877.3的在申请发明专利的改进。
总之,作为袋式除尘器主要配件的滤袋的过滤性能,是保证除尘器排放达标的重要保证,提高滤袋过滤效率的每一项技术革新和改进,都具有十分重要的意义。因此,本发明从提高滤袋过滤效率角度出发,研究缝制后缝纫线针孔闭塞,降低粉尘穿透率,提高PTFE缝纫线的耐磨性,以及缝纫线与各种耐高温、耐腐蚀滤料缝制的缝制匹配性,力学性能的互补性。
发明内容
本发明的目的是提供一种丝/纱包覆结构的复合材料缝纫线,主要用于除尘过滤袋的缝制,可以有效地封堵滤袋缝制后针孔缝隙,提高滤料的过滤效率;还因为纱线的包覆作用,提高缝纫线的耐磨性,解决目前除尘过滤袋除尘效率低及缝纫线耐磨性差的问题;同时,还因为材料力学性能的互补,复合材料能够弥补在受热状态下聚四氟乙烯长丝因材料和热蠕变特性带来的强力衰减。
本发明缝纫线是使用聚四氟乙烯(PTFE)长丝与一种与滤料面层纤维性能相同、相近或相补的纤维材料纺制纱线复合而成。具体是:将聚四氟乙烯长丝作为包覆纱芯线,将具有与滤料面层纤维相同或具有相似或相补性能的纱线作为外包纱,通过包覆工艺形成包覆纱后,将包覆纱作为股线,再进行并捻合股而制成。
所述的聚四氟乙烯长丝为具有一定连续长度的,线密度在100~2000dtex的通过不同工艺生产的扁丝或圆丝,断裂强度≥3cN/dtex;这种长丝多以单丝形式呈现,须具有良好的性能稳定性、条干均匀,连续长度较大,热缩率、延伸率适中,线密度均匀度±10%,断裂延伸率4-10%,干热缩率≤3%。
所述的纱线应具备条干均匀,捻度适中的特点,纺纱用短纤维线密度在1~2dtex,单纱支数为10~60S,捻度300~600T/m,可以是单纱,也可以是两股以上合股纱。
所述的包覆纱进行并捻合股成缝纫线中的合股,可以是两股以上,并不限股数的多合股。
所述的包覆纱在进行并捻合股成缝纫线后,需要经过整烫式加热定型对缝纫线进行整理,定型温度在200℃~400℃。
所述的包覆纱成型后,应呈现为:外包纱缠绕密实、均匀,芯线不外漏;两根或两根以上包覆纱作为股线并捻合股成缝纫线后,股线表面基本上只有螺旋形式的纱线包覆层呈现。
作为优选的,聚四氟乙烯长丝应不限于膜切工艺制造的“膜切丝(扁丝)”和糊料挤出工艺制造的“挤出丝(圆丝),以及使用任何生产工艺制造的长丝类产品,包括单丝或复丝。
作为优选的,外包纱纱线是指聚四氟乙烯纤维之外的其它高性能纤维材料的短纤维,通过纺制而成。例如:聚苯硫醚(PPS)、聚酰亚胺、芳纶、亚克力、玻璃纤维及其对这些材料进行的改性材料等,但并不限于上述纤维材料。这些纤维具有一定的耐高温性、耐腐蚀性。
本发明的复合材料缝纫线的优点是:
(1)提高滤袋除尘效率。
①由于外包纱线的毛羽,可以拦截更多透过针孔逃逸的粉尘,同时纱线层具有一定弹性,可以更密实地堵塞滤袋缝制针孔。②除尘过程中,借助螺旋状缠绕纱线的摩擦力来增加与滤布的抱合力,线与滤布之间的固附,使针孔中被拦截下的粉尘也得到凝结固附,降低粉尘透过针孔逃逸数量。从而提高滤袋除尘效率。
(2)提高缝制效率。
因缝纫线以纱线包覆层为表层,缝纫线的表面拉伸张力和摩擦系数因一种材料而趋于一致,可减少断线率,增加缝纫线的适用性,提高缝制效率。
(3)提高使用寿命。
由于包覆结构,可以因材料异性、异形,从而弥补因热蠕变导致聚四氟乙烯缝纫线失强的材料缺陷,降低缝纫线在高温环境中因强力衰减或失强而带来的滤袋破裂风险,从而提高滤袋的使用寿合。
(4)提高耐磨性。
由于纱线的包覆作用,保护了耐磨性能较差的聚四氟乙烯单丝,使缝纫线具有更好的耐磨性,减少粉尘对聚四氟乙烯长丝的冲刷侵蚀,降低因粉尘侵入缝线锁扣而造成磨损断裂的风险和滤袋缝接部位与除尘器箱体、滤袋之间摩擦而造成的磨损断裂风险。
附图说明
以下结合附图及具体实施方式对本发明作进一步详细说明。
图1是包覆纱结构示意图。
图2是将包覆纱并捻合股制成的缝纫线结构示意图。
图中:1、芯线,2、外包纱,3、包覆纱,4、缝纫线。
具体实施方式
步骤一,使用一根用“糊料挤出”工艺生产的圆形440dtex聚四氟乙烯单丝作为芯线1,和一根20S聚苯硫醚单纱作为外包纱2,通过包覆纱机进行包覆形成包覆纱3。包覆捻向捻度520T/m,捻向为“S”;外包纱2单纱的捻度520T/m,使用线密度为1.8dtex、剪切长度为51mm的聚苯硫醚纤维梳理纺制。
步骤二,取经过上述工艺成型的包覆纱3两根,经过合股机进行并捻合股制成缝纫线4,并捻捻度480T/m,Z捻,。
步骤三,上述聚四氟乙烯单丝与聚苯硫醚包覆纱3并捻合股成线之后,需要再通过一加热板热烫定型装置进行定型,以消除余捻,并使芯线1和外包纱2进一步稳定缠绕与抱合。将合股线筒插入一被动放线轴放线,将线导入温度在200℃~220℃的定型装置内,以0.3~0.8m/min的速度,贴服于定型板全程通过,后端使用主动收线设备收线。
步骤四,将经过过热定型的缝纫线4,通过绕线装置,缠绕成轴后即为成品。
本实例产品检测结果为:线密度为1800dtex(1600den),断裂强力43N,断裂强力指标符合GB1996关于滤料缝纫线的要求。
本产品根据与聚四氟乙烯单丝复合的纱线材料和性能,可以用于缝制不同材料生产的针刺、水刺生产的耐高温、耐腐蚀等高性能除尘滤袋,因复合材料之间有多重的物理、化学性能的互补,可以有效降低缝纫线使用过程中强力失效的风险,同时在防止针孔粉尘逃逸,提高过滤效率,减少人工涂胶成本;其次包覆纱层,很好地提高了缝纫线的机械耐磨性能,降低聚四氟乙烯材料的应用风险。
以上所述,仅为本发明的具体实施方式,但本发明的保护范围并不局限于此,任何熟悉本领域的技术人员在本发明所揭露的技术范围内,可轻易想到的变化或替换,都应涵盖在本发明的保护范围之内。因此,本发明的保护范围应该以权利要求书所限定的保护范围为准。
Claims (3)
1.一种丝、纱包覆结构的复合材料缝纫线,其特征在于:由聚四氟乙烯长丝作为包覆纱芯线(1),由具有与滤料面层纤维相同或具有相似或相补性能的纱线作为外包纱(2),通过包覆工艺形成包覆纱(3)后,将包覆纱作为股线,再进行并捻合股而制成缝纫线(4);
所述的外包纱(2)为聚四氟乙烯纤维之外的其它高性能纤维材料的短纤维,通过纺制而成;所述的短纤维线密度在1~2dtex,单纱支数为10~60S,捻度300~500T/m,可以是单纱,也可以是两股以上合股纱;
所述的外包纱(2)包括聚苯硫醚、聚酰亚胺、芳纶、亚克力、玻璃纤维及其对这些材料进行的改性材料;
所述的包覆纱(3)进行并捻合股中的合股,可以是两股以上,并不限股数的多合股。
2.根据权利要求1所述的一种丝、纱包覆结构的复合材料缝纫线,其特征在于:所述的聚四氟乙烯长丝不限于膜切工艺制造的“膜切丝(扁丝)”和糊料挤出工艺制造的“挤出丝(圆丝)”,以及使用任何生产工艺制造的长丝类产品,包括单丝或复丝。
3.根据权利要求1所述的一种丝、纱包覆结构的复合材料缝纫线,其特征在于:所述的包覆纱(3)在进行并捻合股成缝纫线(4)后,经过整烫式加热定型对缝纫线进行整理,定型温度在200℃ ~400℃。
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