CN107443848A - 一种复合针刺毡及其制造方法 - Google Patents

一种复合针刺毡及其制造方法 Download PDF

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CN107443848A
CN107443848A CN201710788573.9A CN201710788573A CN107443848A CN 107443848 A CN107443848 A CN 107443848A CN 201710788573 A CN201710788573 A CN 201710788573A CN 107443848 A CN107443848 A CN 107443848A
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CN107443848B (zh
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崔渊文
崔渊明
钱立根
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JIANGSU BLUE SKY ENVIRONMENTAL PROTECTION GROUP CO Ltd
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Abstract

本发明公开了一种复合针刺毡，包括中碱玻璃纤维基布，铝硼硅酸盐无碱玻璃纤维和化学纤维制成的面纱，以及基布与面纱之间的复合中间层，面纱外热压覆合聚四氟乙烯微孔膜；所述复合针刺毡中含有金属纤维。通过加入金属纤维，能够将粉尘带有的静电传导出去，克服了静电吸尘现象，还能提高复合针刺毡整体强度延长使用寿命，而且还能将复合针刺毡工作温度提高到300~350℃，增加了使用范围。

Description

一种复合针刺毡及其制造方法
技术领域
本发明属于玻璃纤维过滤材料领域，具体涉及一种复合针刺毡及其制造方法。
背景技术
传统的针刺毡滤料采用非织造针刺工艺和复合技术，多呈三维交错结构，可充分发挥纤维的捕尘功能，捕尘效果稳定；针刺毡没有或只有少量(有基布者)加捻的经纬纱线，其孔隙小而孔隙率大，分布均匀，总孔隙率达70～80％，为一般织造滤料的1.6～2倍，因而自身的透气性好，阻力低。但是，普通针刺毡滤料对于超细粉尘的过滤效率往往不尽如人意。另外，由于过滤的粉尘带有静电，造成粉尘凝结于针刺毡表面而堵塞孔隙，影响了针刺毡的过滤效率。
发明内容
为了克服现有技术的不足，本发明的目的在于提供克服静电吸尘的一种复合针刺毡及其制造方法。
为达到上述目的，本发明是通过以下的技术方案来实现的。
一种复合针刺毡，包括中碱玻璃纤维基布，铝硼硅酸盐无碱玻璃纤维和化学纤维制成的面纱，以及基布与面纱之间的复合中间层，面纱外热压覆合聚四氟乙烯微孔膜；所述复合针刺毡中含有金属纤维。通过加入金属纤维，能够将粉尘带有的静电传导出去，克服了静电吸尘现象，还能提高复合针刺毡整体强度延长使用寿命，而且还能将复合针刺毡工作温度提高到300～350℃，增加了使用范围。
进一步地所述金属纤维为不锈钢纤维、碳钢纤维、铸铁纤维、铜纤维、铝纤维中的任意一种。
进一步地所述中碱玻璃纤维基布由中碱玻璃纤维纱与金属纤维按重量比20:1～2的比例并捻缠绕成的混纺纱织成的经纬为5X6根/cm2的含金属纤维中碱玻璃纤维基布。经过试验随着金属纤维量增加，基布整体的导电性呈线性快速上升，至中碱玻璃纤维与金属纤维为10:1后，导电性上升趋势趋于平稳，此后再增加金属纤维导电性也无明显上升，而且随金属纤维的增加，基布的断裂强度呈缓慢下降趋势，因此选取中碱玻璃纤维纱与金属纤维的比例为20:1～2。
进一步地所述面纱中铝硼硅酸盐无碱玻璃纤维、化学纤维与金属纤维的重量比为30:10:1～2；所述铝硼硅酸盐无碱玻璃纤维中含有重量百分比为0.1％～2％的氧化钠；所述化学纤维为聚酞亚胺纤维或聚苯硫醚纤维、三聚腈胺纤维、聚丙烯睛纤维、聚四氟乙烯纤维中的任意一种。经过大量试验，综合比较断裂强度、导电性、耐受温度、摩擦系数等因素，最终确定最优比例。
进一步地所述复合中间层含有按重量百分比计的下述纤维:玻璃纤维45～85％；聚酰亚胺纤维5～15％；聚酰胺——酰亚胺纤维0～35％，金属纤维5～10％。使中间层富有弹性，提高其耐折、耐磨性能，兼顾导电性。
进一步地所述聚四氟乙烯微孔膜由按重量百分比计的下述组分制成:平均粒径4～8微米的聚四氟乙烯粉50～95％、润滑剂4～45％、1～5％的石墨粉、乙炔黑、科琴黑中的一种。聚四氟乙烯本身是一种优良的绝缘体，为了保证生成的聚四氟乙烯微孔膜具有导电性，需要加入一种导电性极强的物质，通过实验和筛选发现加入适量的石墨粉或乙炔黑或科琴黑后明显的提高了聚四氟乙烯微孔膜导电性能。
进一步地还提供了一种复合针刺毡的制造方法，包括以下步骤：
(1)以中碱玻璃纤维与金属纤维纺成CC-2X3X2X180Z纱线织成经纬为5X6根/cm2的基布；
(2)以铝硼硅酸盐无碱玻璃纤维、化学纤维与金属纤维切割长3～4.9mm的短纤维，打松、混合均匀后梳理成厚薄均匀的面纱；
(3)将玻璃纤维、聚酰亚胺纤维、聚酰胺——酰亚胺纤维、金属纤维切割长3～4mm的短纤维并打松混合和梳理成复合中间层；
(4)将聚四氟乙烯粉、润滑剂、石墨粉、乙炔黑、科琴黑中的一种经过混料、制坯、挤出、压延、脱脂处理、拉伸后制成聚四氟乙烯微孔膜；
(5)将复合中间层铺设到基布两面，再在复合中间层外铺设面纱，送入予刺机针刺复合；
(6)将复合后的织物与聚四氟乙烯微孔膜热压复合；
(7)将热压后的针刺毡在表面处理剂中浸渍后，烘干即得复合针刺毡。
进一步地所述表面处理剂包括聚四氟乙烯乳液10-20％，聚丙烯酸酯乳液5-15％，偶联剂0.1～1.5％，防水剂1～5％，余量为水。所述偶联剂为钛酸酯偶联剂或是硅烷偶联剂。
进一步地所述步骤(6)中复合后的织物与聚四氟乙烯微孔膜于361～370℃和0.3～0.49MPa下热压复合。
进一步地所述步骤(7)中烘干步骤为先在100～130℃下预烘5～10min，再在180～190℃下焙烘8～15min。
有益效果：与现有技术相比，本发明的优点在于：
1)通过加入金属纤维，能够将粉尘带有的静电传导出去，克服了静电吸尘现象，还能提高复合针刺毡整体强度延长使用寿命，而且还能将复合针刺毡工作温度提高到300～350℃，增加了使用范围；
2)在聚四氟乙烯微孔膜加入石墨粉或乙炔黑或科琴黑进一步提高了复合针刺毡的导电性能。
具体实施方式
下面结合实例对本发明作进一步的详细说明。
实施例1
一种复合针刺毡的制造方法，包括以下步骤：
(1)按重量比20:1的比例将中碱玻璃纤维与不锈钢纤维纺成CC-2X3X2X180Z纱线织成经纬为5X6根/cm2的基布；
(2)按重量比30:10:2的比例将铝硼硅酸盐无碱玻璃纤维、化学纤维与不锈钢纤维切割长3mm的短纤维，打松、混合均匀后梳理成厚薄均匀的面纱；
(3)按重量百分比将玻璃纤维45％、聚酰亚胺纤维15％、聚酰胺——酰亚胺纤维35％、不锈钢纤维5％切割长3mm的短纤维并打松混合和梳理成复合中间层；
(4)按重量百分比将平均粒径4微米的聚四氟乙烯粉50％、润滑剂45％、石墨粉5％经过混料、制坯、挤出、压延、脱脂处理、拉伸后制成聚四氟乙烯微孔膜；
(5)将复合中间层铺设到基布两面，再在复合中间层外铺设面纱，送入予刺机针刺复合；
(6)将复合后的织物与聚四氟乙烯微孔膜于361-370℃和0.3MPa下热压复合；
(7)将热压后的针刺毡在表面处理剂中浸渍后，先在100℃下预烘10min，再在180℃下焙烘15min即得复合针刺毡；表面处理剂为按重量百分比聚四氟乙烯乳液10％，聚丙烯酸酯乳液5％，偶联剂0.1％，防水剂1％，余量为水，偶联剂为钛酸酯偶联剂。
实施例2
一种复合针刺毡的制造方法，包括以下步骤：
(1)按重量比20:2的比例将中碱玻璃纤维与碳钢纤维纺成CC-2X3X2X180Z纱线织成经纬为5X6根/cm2的基布；
(2)按重量比30:10:1的比例将铝硼硅酸盐无碱玻璃纤维、化学纤维与碳钢纤维切割长4.9mm的短纤维，打松、混合均匀后梳理成厚薄均匀的面纱；
(3)按重量百分比将玻璃纤维85％、聚酰亚胺纤维5％、碳钢纤维10％切割长4mm的短纤维并打松混合和梳理成复合中间层；
(4)按重量百分比将平均粒径5微米的聚四氟乙烯粉95％、润滑剂4％、乙炔黑1％经过混料、制坯、挤出、压延、脱脂处理、拉伸后制成聚四氟乙烯微孔膜；
(5)将复合中间层铺设到基布两面，再在复合中间层外铺设面纱，送入予刺机针刺复合；
(6)将复合后的织物与聚四氟乙烯微孔膜于361-370℃和0.49MPa下热压复合；
(7)将热压后的针刺毡在表面处理剂中浸渍后，先在130℃下预烘5min，再在190℃下焙烘8min即得复合针刺毡；表面处理剂为按重量百分比聚四氟乙烯乳液15％，聚丙烯酸酯乳液10％，偶联剂1.5％，防水剂5％，余量为水，偶联剂为硅烷偶联剂。
实施例3
一种复合针刺毡的制造方法，包括以下步骤：
(1)按重量比20:1的比例将中碱玻璃纤维与铸铁纤维纺成CC-2X3X2X180Z纱线织成经纬为5X6根/cm2的基布；
(2)按重量比30:10:2的比例将铝硼硅酸盐无碱玻璃纤维、化学纤维与铸铁纤维切割长4mm的短纤维，打松、混合均匀后梳理成厚薄均匀的面纱；
(3)按重量百分比将玻璃纤维50％、聚酰亚胺纤维10％、聚酰胺——酰亚胺纤维30％、铸铁纤维10％切割长3mm的短纤维并打松混合和梳理成复合中间层；
(4)按重量百分比将平均粒径6微米的聚四氟乙烯粉60％、润滑剂38％、科琴黑2％经过混料、制坯、挤出、压延、脱脂处理、拉伸后制成聚四氟乙烯微孔膜；
(5)将复合中间层铺设到基布两面，再在复合中间层外铺设面纱，送入予刺机针刺复合；
(6)将复合后的织物与聚四氟乙烯微孔膜于361-370℃和0.35MPa下热压复合；
(7)将热压后的针刺毡在表面处理剂中浸渍后，先在11℃下预烘9min，再在185℃下焙烘10min即得复合针刺毡；表面处理剂为按重量百分比聚四氟乙烯乳液20％，聚丙烯酸酯乳液15％，偶联剂0.8％，防水剂2％，余量为水，偶联剂为钛酸酯偶联剂。
实施例4
一种复合针刺毡的制造方法，包括以下步骤：
(1)按重量比20:2的比例将中碱玻璃纤维与铜纤维纺成CC-2X3X2X180Z纱线织成经纬为5X6根/cm2的基布；
(2)按重量比30:10:1的比例将铝硼硅酸盐无碱玻璃纤维、化学纤维与铜纤维切割长3mm的短纤维，打松、混合均匀后梳理成厚薄均匀的面纱；
(3)按重量百分比将玻璃纤维65％、聚酰亚胺纤维5％、聚酰胺——酰亚胺纤维25％、铜纤维5％切割长4mm的短纤维并打松混合和梳理成复合中间层；
(4)按重量百分比将平均粒径7微米的聚四氟乙烯粉72％、润滑剂25％、石墨粉3％经过混料、制坯、挤出、压延、脱脂处理、拉伸后制成聚四氟乙烯微孔膜；
(5)将复合中间层铺设到基布两面，再在复合中间层外铺设面纱，送入予刺机针刺复合；
(6)将复合后的织物与聚四氟乙烯微孔膜于361-370℃和0.4MPa下热压复合；
(7)将热压后的针刺毡在表面处理剂中浸渍后，先在120℃下预烘8min，再在180℃下焙烘15min即得复合针刺毡；表面处理剂为按重量百分比聚四氟乙烯乳液12％，聚丙烯酸酯乳液12％，偶联剂0.5％，防水剂2％，余量为水，偶联剂为硅烷偶联剂。
实施例5
一种复合针刺毡的制造方法，包括以下步骤：
(1)按重量比20:1的比例将中碱玻璃纤维与铝纤维纺成CC-2X3X2X180Z纱线织成经纬为5X6根/cm2的基布；
(2)按重量比30:10:2的比例将铝硼硅酸盐无碱玻璃纤维、化学纤维与铝纤维切割长4mm的短纤维，打松、混合均匀后梳理成厚薄均匀的面纱；
(3)按重量百分比将玻璃纤维70％、聚酰亚胺纤维5％、聚酰胺——酰亚胺纤维15％、铝纤维10％切割长3mm的短纤维并打松混合和梳理成复合中间层；
(4)按重量百分比将平均粒径8微米的聚四氟乙烯粉81％、润滑剂15％、石墨粉4％经过混料、制坯、挤出、压延、脱脂处理、拉伸后制成聚四氟乙烯微孔膜；
(5)将复合中间层铺设到基布两面，再在复合中间层外铺设面纱，送入予刺机针刺复合；
(6)将复合后的织物与聚四氟乙烯微孔膜于361-370℃和0.45MPa下热压复合；
(7)将热压后的针刺毡在表面处理剂中浸渍后，先在125℃下预烘6min，再在190℃下焙烘8min即得复合针刺毡；表面处理剂为按重量百分比聚四氟乙烯乳液18％，聚丙烯酸酯乳液8％，偶联剂1％，防水剂4％，余量为水，偶联剂为钛酸酯偶联剂。
对实施例1～5的复合针刺毡和普通市售针刺毡进行对比检测，检测数据如下：
数据表明本发明的复合针刺毡导电性、强度、工作温度都大大优于现有的针刺毡产品。
本发明按照上述实施例进行了说明，应当理解，上述实施例不以任何形式限定本发明，凡采用等同替换或等效变换方式所获得的技术方案，均落在本发明的保护范围之内。

Claims (7)

1.一种复合针刺毡，其特征在于，包括中碱玻璃纤维基布，铝硼硅酸盐无碱玻璃纤维和化学纤维制成的面纱，以及基布与面纱之间的复合中间层，面纱外热压覆合聚四氟乙烯微孔膜；所述中碱玻璃纤维基布由中碱玻璃纤维纱与金属纤维按重量比20:1~2的比例并捻缠绕成的混纺纱织成的经纬为5X6根/cm2的含金属纤维中碱玻璃纤维基布；所述面纱中铝硼硅酸盐无碱玻璃纤维、化学纤维与金属纤维的重量比为30:10:1~2；所述铝硼硅酸盐无碱玻璃纤维中含有重量百分比为0.1%~2%的氧化钠；所述化学纤维为聚酞亚胺纤维或聚苯硫醚纤维、三聚腈胺纤维、聚丙烯睛纤维、聚四氟乙烯纤维中的任意一种；所述复合中间层含有按质量百分比计的下述纤维:玻璃纤维45~85%；聚酰亚胺纤维5~15%；聚酰胺——酰亚胺纤维0~35%，金属纤维5~10%；所述复合针刺毡中含有金属纤维。
2.根据权利要求1所述的一种复合针刺毡，其特征在于，所述金属纤维为不锈钢纤维、碳钢纤维、铸铁纤维、铜纤维、铝纤维中的任意一种。
3.根据权利要求1所述的一种复合针刺毡，其特征在于，所述聚四氟乙烯微孔膜由按质量百分比计的下述组分制成: 平均粒径4~8微米的聚四氟乙烯粉：50~95%、润滑剂：4~45%、1~5%的石墨粉、乙炔黑、科琴黑中的一种。
4.根据权利要求1-3任意一项权利要求所述的一种复合针刺毡的制造方法，其特征在于，包括以下步骤：
（1）以中碱玻璃纤维与金属纤维纺成CC-2X3X2X180Z纱线织成经纬为5X6根/cm2的基布；
（2）以铝硼硅酸盐无碱玻璃纤维、化学纤维与金属纤维切割长3~4.9mm的短纤维，打松、混合均匀后梳理成厚薄均匀的面纱；
（3）将玻璃纤维、聚酰亚胺纤维、聚酰胺——酰亚胺纤维、金属纤维切割长3~4mm的短纤维并打松混合和梳理成复合中间层；
（4）将聚四氟乙烯粉、润滑剂、石墨粉、乙炔黑、科琴黑中的一种经过混料、制坯、挤出、压延、脱脂处理、拉伸后制成聚四氟乙烯微孔膜；
（5）将复合中间层铺设到基布两面，再在复合中间层外铺设面纱，送入予刺机针刺复合；
（6）将复合后的织物与聚四氟乙烯微孔膜热压复合；
（7）将热压后的针刺毡在表面处理剂中浸渍后，烘干即得复合针刺毡。
5.根据权利要求4所述的一种复合针刺毡的制造方法，其特征在于，所述表面处理剂包括聚四氟乙烯乳液10-20%，聚丙烯酸酯乳液5-15%，偶联剂0.1~1.5%，防水剂1~5%，余量为水。
6.根据权利要求4所述的一种复合针刺毡的制造方法，其特征在于，所述步骤（6）中复合后的织物与聚四氟乙烯微孔膜于361~370℃和0.3~0.49MPa下热压复合。
7.根据权利要求4所述的一种复合针刺毡的制造方法，其特征在于，所述步骤（7）中烘干步骤为先在100~130℃下预烘5~10min，再在180~190℃下焙烘8~15 min。
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