CN108381938B - 具有灭菌通道可自由弯曲成型的烧结过滤网及其制作方法 - Google Patents
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Abstract
本发明涉及一种具有灭菌通道可自由弯曲成型的烧结过滤网及其制作方法，烧结过滤网的主体材料聚苯硫醚颗粒料表面包覆纳米银离子粉末层，在该包覆层的外面布设活性炭粉末，形成具有纳米银离子粉末包覆层的全穿透微孔结构的灭菌通道构造，该多孔包覆层在受热的聚苯硫醚材料体积膨胀下，通过界面将应力传递到纳米银离子粉末，使内部结构得到支撑，并将纳米银离子和粉状活性炭镶嵌在聚苯硫醚的表面，形成具有灭菌通道和微孔结构的烧结过滤网。本发明的制作方法采用混炼、装填材料入模具、加温烧结、出模等工艺，制品成型后，在烧结过滤网中间形成具有微孔结构的全穿透灭菌通道，其过滤面积大、过滤精度高，用水清洗后可反复使用。
Description
技术领域
本发明涉及采用聚苯硫醚塑料制作的多孔过滤网，特别涉及一种由纳米银离子、粉状活性炭组成灭菌通道并具有穿透作用且可自由弯曲成型的烧结微孔过滤网及其制作方法。
背景技术
在加快推进生态文明建设战略的指引下，国家对生态环境和空气质量的关注力度在持续提高，新风系统、空气净化器是有效治理空气污染的主要设备，特别是拦截粒径在2.5微米至10微米之间的颗粒物，其中过滤网就是新风系统、空气净化器系统中最重要的过滤元件之一。
由于PM2.5来源十分复杂，对人体的危害很大，特别是粒径小于2.5微米以下的颗粒物被吸入人体后会进入支气管，干扰肺部的气体交换，引发包括哮喘、支气管炎和心血管病等方面的疾病。这些颗粒还能通过支气管和肺泡进入血液，其中的有害气体、重金属等物质溶解在血液中，对人体健康的伤害程度更大。因此要求使用的过滤网应具有拦截微粉的效率高且体积小，对常见的有害微生物如大肠杆菌、金黄色葡萄球菌、白色念珠菌、军团菌等要有很好的抗菌效果。具有灭菌通道可自由弯曲成型的烧结过滤网就是针对上述要求研制的新一代过滤网。
目前市场上销售的空气净化器、新风输送系统的滤材均是以HEPA为主。HEPA分PP滤纸、玻璃纤维、复合PPPET滤纸、熔喷涤纶无纺布和熔喷玻璃纤维五种材质，主要为平面有折叠的方形或长方形结构的网，空气经过网的表面微孔时，微粉被拦截在网的表面，以此实行粉气分离来进行过滤。
关于目前市场上广泛使用的空气净化器、新风输送系统，过滤网在空净、新风机中具有核心作用，滤网的形状大都为方形或长方形，材质大体上都用PP滤纸或无纺布（不具备灭菌、除甲醛功能），通过折叠方式增加过滤面积，由于材料单薄，容尘量很有限，且不能清洗，必须经常更换，使用寿命通常在半年左右。因此，过滤网作为易耗件需要经常更换，由此极易造成二次污染，从而影响生态环境。
有鉴于此，该领域科研人员致力于研发一种具有灭菌通道可自由弯曲成型的烧结过滤网以改进空气净化器、新风输送系统的过滤效率。
发明内容
本发明的任务是提供一种具有灭菌通道可自由弯曲成型的烧结过滤网及其制作方法，它解决了上述现有技术所存在的问题，将聚苯硫醚塑料粉末、纳米银离子粉末、活性炭粉末经过混炼，加入到模具内烧结成一种全穿透微孔结构的具有任意弯曲功能的过滤网，这种过滤网可根据净化箱内流体力学的轮廓线条任意弯曲，经定型后装入空气净化器、新风系统的净化箱内成为具有灭菌通道可自由弯曲的烧结过滤网。
本发明的技术解决方案如下：
一种具有灭菌通道可自由弯曲成型的烧结过滤网，所述烧结过滤网的主体材料聚苯硫醚颗粒料表面包覆纳米银离子粉末层，在纳米银离子粉末包覆层的外面布设有活性炭粉末，形成具有纳米银离子粉末包覆层的全穿透微孔结构的灭菌通道构造，该多孔包覆层在受热的聚苯硫醚材料体积膨胀下，通过界面将应力传递到纳米银离子粉末，使内部结构得到支撑，并将纳米银离子和粉状活性炭镶嵌在聚苯硫醚的表面，形成具有灭菌通道和微孔结构的烧结过滤网；
所述烧结过滤网材料包括聚苯硫醚、纳米银离子以及活性炭合成物，所述烧结过滤网的烧结、弯曲定型的制作方法按下列步骤进行：
（1）选用颗粒度70微米粒径的聚苯硫醚粉末、颗粒度3微米粒径的纳米银离子粉末、颗粒度140微米粒径的粉状活性炭，原料的体积配比为：聚苯硫醚85%、纳米银离子4%、活性炭11%；
（2）混炼过程让银离子粉末包覆聚苯硫醚和活性炭，将聚苯硫醚粉末、粉状活性炭置入高速混料机，混料时间为90分钟，加温至140℃，然后开启封盖倒入纳米银离子粉末，混料时间为40分钟，加温至165℃，冷却出料；
（3）装填材料，将混炼的聚苯硫醚原料投入模具，将模具竖在超声振动台上震荡，使基材在模腔内密实，超声振动时间为3分钟；
（4）加温时迫使聚苯硫醚膨胀，烧结过程中，将装上料的模具吊挂在环形步进装置上，进入回转炉窑分段升温加热进行烧结，炉窑温度按段设定，第一节温度控制在50℃-160℃，第一节加温时间为110分钟，第二节温度控制在160℃-270℃，第二节加温时间为135分钟，第三节温度控制在270℃-290℃，第三节加温时间为65分钟，整个加热时间为310分钟；
（5）出模，将模具从环形步进装置上取下进行冷却，冷却方式采用风冷，冷却至100℃，松开模具紧固件，冷却至50℃即行开模，取出过滤网即形成一种具有灭菌通道可自由弯曲成型的烧结过滤网；
所述烧结过滤网具有数个相互并列的折叠形状且可自由弯曲的摺构造，过滤网前后呈W形状的V型结构，左右侧端面可供涂胶粘接以延伸长度，增加过滤面积，成为烧结过滤网完整的本体部分；
所述烧结过滤网前后呈W形状的V型结构，可根据流线型布置任意弯曲以充分适应流体力学中的线条轮廓，降低气流阻力，其左右侧端面可供涂胶粘接以延伸长度，增加过滤面积，便于安装，便于根据净化箱内流体力学的轮廓线条任意弯曲与连接，上下端面通过涂胶粘接在弯曲轮廓的槽框内起到密封作用，烧结过滤网经定型后装入空气净化器、新风系统的净化箱内成为具有灭菌通道可自由弯曲的烧结过滤网。
本发明的一种具有灭菌通道可自由弯曲成型的烧结过滤网是由聚苯硫醚粉末、纳米银离子粉末、活性炭粉末经过混炼，加入到铝制成型模具内，模具吊挂在环形步进装置上，进入回转炉窑分段升温加热烧结成型成为制成品，由于过滤网前后呈W形状的V型结构和基材加入了杀菌的银离子粉末，因此被称为具有灭菌通道可自由弯曲成型的烧结过滤网。
由于聚苯硫醚、银离子、活性炭经混炼后在加热至熔融状态下也不流动，其熔融指数基本为零，作为加工微孔结构的过滤材料恰恰是一种较为理想的原料选择。
本发明的一种聚苯硫醚、银离子、活性炭合成材料微孔成型技术是选用颗粒度70微米粒径的聚苯硫醚粉末、颗粒度3微米粒径的纳米银离子粉末、颗粒度140微米粒径的粉状活性炭，根据配比、混炼，加入到铝制成型模具内，模具吊挂在环形步进装置上，进入回转炉窑分段升温加热，受热的聚苯硫醚材料体积膨胀，通过界面将应力传递到银离子粉末，使内部结构得到支撑，并将纳米银离子和粉状活性炭牢牢地镶嵌在聚苯硫醚的表面，形成具有微孔结构的灭菌通道，充分改善了复合材料的力学性能，使其具备反复清洗、反复使用功能，为空气净化器、新风输送系统选用无耗材的过滤网提供了选项，具有重大的应用价值。
附图说明
图1是本发明的一种具有灭菌通道的烧结过滤网的材料内部结构示意图。
图2是本发明的一种具有灭菌通道的烧结过滤网初始制品的主视结构示意图。
图3是按图2所示烧结过滤网的俯视结构示意图。
图4是本发明的一种具有灭菌通道可自由弯曲成型的烧结过滤网的主视结构示意图，显示了可自由弯曲连接状态。
图5是按图4所示可自由弯曲成型的烧结过滤网的俯视结构示意图。
附图标记：
1为烧结过滤网的主体材料，聚苯硫醚颗粒料，为白色大颗粒。
2为过滤网的辅助材料，活性炭粉末，为灰色颗粒。
3为过滤网的包覆材料，纳米银离子粉末，为黑色包覆层。
具体实施方式
下面结合附图和实施例对本发明作详细说明。
参看图1，本发明提供一种具有灭菌通道可自由弯曲成型的烧结过滤网，烧结过滤网的主体材料聚苯硫醚颗粒料1表面包覆纳米银离子粉末层3，在纳米银离子粉末包覆层的外面布设活性炭粉末2，形成具有纳米银离子粉末包覆层的全穿透微孔结构的灭菌通道构造。该多孔包覆层在受热的聚苯硫醚材料体积膨胀下，通过界面将应力传递到纳米银离子粉末，使内部结构得到支撑，并将纳米银离子和粉状活性炭镶嵌在聚苯硫醚的表面，形成具有灭菌通道和微孔结构的烧结过滤网。
参看图2至图5，本发明的烧结过滤网前后呈W形状的V型结构，可根据流线型布置任意弯曲，以充分适应流体力学中的线条轮廓，降低气流阻力，其左右侧端面可供涂胶粘接以延伸长度，增加过滤面积，便于安装。
本发明还提供一种具有灭菌通道可自由弯曲成型的烧结过滤网的制作方法，烧结过滤网材料包括聚苯硫醚、纳米银离子以及活性炭合成物，烧结过滤网的烧结、弯曲定型的制作方法按下列步骤进行：
（1）优先选用70微米以上粒径的聚苯硫醚粉末、优先选用3微米以下粒径的纳米银离子粉末、优先选用140微米粒径的粉状活性炭，原料的体积配比为：聚苯硫醚85%、纳米银离子4%、活性炭11%。
聚苯硫醚粉料经过筛选，可采用小于70微米粒径的原料。纳米银离子粉末经过筛选，可采用小于3微米粒径的原料。粉状活性炭颗粒经过筛选，可采用小于140微米粒径的原料。
（2）混炼过程让银离子粉末包覆聚苯硫醚和活性炭，将聚苯硫醚粉末、粉状活性炭置入高速混料机，混料时间为90分钟，加温至140℃；然后开启封盖倒入纳米银离子粉末，混料时间为40分钟，加温至165℃，冷却出料。
（3）装填材料，将混炼的聚苯硫醚原料投入模具，将模具竖在超声振动台上震荡，使基材在模腔内密实。超声振动时间为3分钟。
（4）加温时迫使聚苯硫醚膨胀。烧结过程中，将装上料的模具吊挂在环形步进装置上，进入回转炉窑分段升温加热进行烧结，炉窑温度按段设定，第一节温度控制在50℃-160℃，第一节加温时间为110分钟；第二节温度控制在160℃-270℃，第二节加温时间为135分钟；第三节温度控制在270℃-290℃，第三节加温时间为65分钟。整个加热时间为310分钟。
（5）出模，将模具从环形步进装置上取下进行冷却，采用风冷，冷却至100℃，松开模具紧固件，冷却至50℃即行开模，取出过滤网即形成一种具有灭菌通道可自由弯曲成型的烧结过滤网，其中过滤网前后呈W形状的V型结构，左右侧端面可供涂胶粘接以延伸长度，增加过滤面积，成为烧结过滤网完整的本体部分。
（6）对成型后的烧结过滤网进行检验，合格后待用，根据检测设备情况可检验表面开孔率、风阻损失、净化效率和灭菌效果。
按本发明的一种具有灭菌通道可自由弯曲成型的烧结过滤网及其制作方法，选用颗粒度70微米的聚苯硫醚材料、颗粒度3微米的纳米银离子、颗粒度140微米的粉状活性炭，进行配比、混炼，加入到铝制成型模具内，模具吊挂在环形步进装置上，进入回转炉窑分段升温加热，受热的聚苯硫醚材料体积膨胀，相互挤压，将纳米银离子和粉状活性炭镶嵌在聚苯硫醚的表面，形成具有灭菌通道和微孔结构的烧结过滤网。其中过滤网前后呈W形状的V型结构，左右侧端面可供涂胶粘接以延伸长度，增加过滤面积，便于根据净化箱内流体力学的轮廓线条任意弯曲与连接，上下端面通过涂胶，粘接在弯曲轮廓的槽框内起到密封作用。
本发明的烧结过滤网制品成型后，在烧结过滤网中间形成具有微孔结构的全穿透灭菌通道，由于过滤网前后呈W形状的V型结构，过滤网可以作任意弯曲，以充分适应流体力学中的线条轮廓，降低气流阻力，提高过滤面积。
本发明的烧结过滤网具有杀灭细菌和清除甲醛的功能，可自由弯曲，过滤面积大、过滤精度高。通过用水清洗后可反复使用，为新风系统、空气净化器采用无耗材增添了新材料选项。
在实际应用中，本发明的具有灭菌通道的烧结过滤网制品可应用于空气净化器、新风输送系统的尘气分离和灭菌，也可应用于空调系统的前置过滤网和通风设备上。
当然，本技术领域内的一般技术人员应当认识到，上述实施例仅是用来说明本发明，而并非用作对本发明的限定，只要在本发明的实质精神范围内，对上述实施例的变化、变型等都将落在本发明权利要求的范围内。
Claims (1)
1.一种具有灭菌通道可自由弯曲成型的烧结过滤网，其特征在于：所述烧结过滤网的主体材料聚苯硫醚颗粒料（1）表面包覆纳米银离子粉末层（3），在纳米银离子粉末包覆层的外面布设有活性炭粉末（2），形成具有纳米银离子粉末包覆层的全穿透微孔结构的灭菌通道构造，多孔包覆层在受热的聚苯硫醚材料体积膨胀下，通过界面将应力传递到纳米银离子粉末，使内部结构得到支撑，并将纳米银离子和粉状活性炭镶嵌在聚苯硫醚的表面，形成具有灭菌通道和微孔结构的烧结过滤网；
所述烧结过滤网材料包括聚苯硫醚、纳米银离子以及活性炭合成物，所述烧结过滤网的烧结、弯曲定型的制作方法按下列步骤进行：
（1）选用颗粒度70微米粒径的聚苯硫醚粉末、颗粒度3微米粒径的纳米银离子粉末、颗粒度140微米粒径的粉状活性炭，原料的体积配比为：聚苯硫醚85%、纳米银离子4%、活性炭11%；
（2）混炼过程让银离子粉末包覆聚苯硫醚和活性炭，将聚苯硫醚粉末、粉状活性炭置入高速混料机，混料时间为90分钟，加温至140℃，然后开启封盖倒入纳米银离子粉末，混料时间为40分钟，加温至165℃，冷却出料；
（3）装填材料，将混炼的聚苯硫醚原料投入模具，将模具竖在超声振动台上震荡，使基材在模腔内密实，超声振动时间为3分钟；
（4）加温时迫使聚苯硫醚膨胀，烧结过程中，将装上料的模具吊挂在环形步进装置上，进入回转炉窑分段升温加热进行烧结，炉窑温度按段设定，第一节温度控制在50℃-160℃，第一节加温时间为110分钟，第二节温度控制在160℃-270℃，第二节加温时间为135分钟，第三节温度控制在270℃-290℃，第三节加温时间为65分钟，整个加热时间为310分钟；
（5）出模，将模具从环形步进装置上取下进行冷却，冷却方式采用风冷，冷却至100℃，松开模具紧固件，冷却至50℃即行开模，取出过滤网即形成一种具有灭菌通道可自由弯曲成型的烧结过滤网；
所述烧结过滤网具有数个相互并列的折叠形状且可自由弯曲的摺构造，过滤网前后呈W形状的V型结构。
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| PE01 | Entry into force of the registration of the contract for pledge of patent right |
Denomination of invention: Sintered filter screen with sterilization channel that can be freely bent into shape and its production method Granted publication date: 20200616 Pledgee: The Bank of Shanghai branch Caohejing Limited by Share Ltd. Pledgor: SHANGHAI SUPERHIGH ENVIRONMENTAL PROTECTION TECHNOLOGY CO.,LTD. Registration number: Y2024980002068 |