CN110499667A - 一种超疏水高效空气过滤材料及其制备方法 - Google Patents
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Abstract
本发明公开了一种超疏水高效空气过滤材料及其制备方法,属于过滤材料技术领域。该空气过滤材料是由以下按质量百分数计的组分组成:微玻璃纤维50~99.8%、合成化纤0~20%、粘结剂0.1~20%、防水剂0.1~10%。该空气过滤材料采用湿法微玻璃纤维浸胶方法制备,通过将防水剂与粘结剂分开施加,使得防水剂富集于过滤材料的进气侧,经干燥固化而在过滤材料内部形成有益的特殊分布,使得本发明的过滤材料具有较高的孔隙毛细管压差,能够防止过滤气流中的水蒸气或者微小水滴进入,大大提升了抗水性能和过滤效能,有效延长了使用寿命。
Description
技术领域
本发明涉及过滤材料技术领域,具体涉及一种超疏水高效空气过滤材料及其制备方法。
背景技术
空气中的小颗粒可在人体肺部甚至血液循环系统沉积,造成呼吸系统疾病或者血栓;此外由于小颗粒比表面积较大,其能够吸附大量有毒物质如有机气体、病毒、细菌等,进一步对人体健康构成威胁。随着社会的发展,健康知识普及,人们越来越重视空气中细小颗粒污染的危害问题,近年来空气过滤产品已逐渐成为生活的必需品,同时市场对高效去除亚微米级颗粒污染物的过滤材料要求也大大提高。过滤材料通常以植物纤维、合成纤维和无机纤维等为原料,添加一定的化学助剂,使用干法或湿法造纸工艺及设备抄造而成。目前市面上主要的过滤材料主要由以下几种:1.驻极静电聚合物干法无纺布过滤材料,其缺点是静电会随着过滤的进行而耗散,从而导致过滤效率逐步衰减。2.湿法无纺布过滤材料,其缺点是具有较高的过滤气阻,且难以达到H13及以上级别的超高效过滤。3.表面涂层纳米纤维过滤材料,其缺点是制备工艺复杂、设备昂贵、制备成本高且过滤效率不稳定,以达到超高效过滤的效果。4.表面涂层膜过滤材料,其缺点是制备工艺复杂,膜材料昂贵,制造成本高昂,且材料纳污量和使用寿命低。5.湿法微玻纤高效过滤材料,其缺点是纤维材料本身不具有抗水性,通常采用在粘结剂中添加防水剂以提供所需的耐水及水蒸气性能,但是防水剂容易被分散到纤维基材中,且有可能被粘结剂本身所包埋,从而大大降低了材料的抗水性能。
因此,研制同时具备高抗水性能、高过滤效能并延长使用寿命的玻璃纤维空气过滤纸具有重要意义。
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一种超疏水高效空气过滤材料,本发明的过滤材料具有较高的孔隙毛细管压差,能够防止过滤气流中的水蒸气或者微小水滴进入,大大提升了抗水性能和过滤效能,有效延长了使用寿命。
为解决上述问题,本发明所采用的技术方案如下:
一种超疏水高效空气过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维50~99.8%、合成化纤0~20%、粘结剂0.1~20%、防水剂0.1~10%。
作为本发明优选的实施方式,所述微玻璃纤维为玻璃纤维棉或玻璃纤维短切丝。
作为本发明优选的实施方式,所述微玻璃纤维的直径为0.1~20μm。
作为本发明优选的实施方式,所述粘结剂选自苯乙烯/丙烯酸共聚物乳液、丙烯酸聚合物树脂及其乳液、醋酸乙烯酯乳液、环氧树脂及其乳液、酚醛树脂及其乳液中的至少一种。
作为本发明优选的实施方式,所述防水剂选自硅油乳液、聚烯烃蜡乳液、氟碳乳液中的至少一种。
本发明还提供了一种如上所述的超疏水高效空气过滤材料的制备方法,其包括以下步骤:
1)取配方量的微玻璃纤维和合成化纤分散于pH为2~6的无机酸溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,除渣后送入成形器制成湿纸页,并真空脱水;
3)将配方量的防水剂通过涂布或喷涂的方式施加于成型微玻璃纤维的一侧(进气侧)上,于80~180℃下干燥0.1~600s;
4)将配方量的粘结剂施加于成型微玻璃纤维的两侧上;
5)将上述制得的材料置于80~180℃下干燥0.1~600s后,再在80~180℃下固化0.1~600s,即得所述空气过滤材料。
作为本发明优选的实施方式,步骤1)中所述的无机酸溶液选自硫酸水溶液、盐酸水溶液、硝酸水溶液、磷酸水溶液、柠檬酸水溶液、醋酸水溶液中的至少一种。
作为本发明优选的实施方式,所述步骤3)和步骤4)的顺序可互换。
作为本发明优选的实施方式,步骤4)中的粘结剂通过浸渍、涂布或喷涂的方式施加于成型微玻璃纤维的两侧上。
相比现有技术,本发明的有益效果在于:
本发明的空气过滤材料采用湿法微玻璃纤维浸胶方法制备,通过将防水剂与粘结剂分开施加、并均匀地喷洒或涂敷于纤维材料表面,使得防水剂富集于过滤材料的进气侧,经干燥固化而在过滤材料内部形成有益的特殊分布,使得本发明的过滤材料具有较高的孔隙毛细管压差,能够防止过滤气流中的水蒸气或者微小水滴进入过滤材料内部甚至下游,大大提升了抗水性能和过滤效能,有效延长了使用寿命,能够广泛应用于室内空气质量控制、芯片制造和显示器制造等的工业电子厂房空气过滤、GMP制药车间空气过滤以及空调暖通进气系统过滤等领域。
具体实施方式
下面结合具体实施方式对本发明作进一步详细说明。
一种超疏水高效空气过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维50~99.8%、合成化纤0~20%、粘结剂0.1~20%、防水剂0.1~10%。
其中,微玻璃纤维为玻璃纤维棉或玻璃纤维短切丝;所述微玻璃纤维的直径为0.1~20μm。优选地,粘结剂选自苯乙烯/丙烯酸共聚物乳液、丙烯酸聚合物树脂及其乳液、醋酸乙烯酯乳液、环氧树脂及其乳液、酚醛树脂及其乳液中的至少一种。防水剂选自硅油乳液、聚烯烃蜡乳液、氟碳乳液中的至少一种。
如上所述的超疏水高效空气过滤材料的制备方法包括以下步骤:
1)取配方量的微玻璃纤维和合成化纤分散于pH为2~6的无机酸溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,除渣后送入成形器制成湿纸页,并真空脱水;
3)将配方量的防水剂通过涂布或喷涂的方式施加于成型微玻璃纤维的一侧(进气侧)上,于80~180℃下干燥0.1~600s;
4)将配方量的粘结剂通过浸渍、涂布或喷涂的方式施加于成型微玻璃纤维的两侧上;
5)将上述制得的材料置于80~180℃下干燥0.1~600s后,再在80~180℃下固化0.1~600s,即得所述空气过滤材料。
其中,步骤1)中所述的无机酸溶液选自硫酸水溶液、盐酸水溶液、硝酸水溶液、磷酸水溶液、柠檬酸水溶液、醋酸水溶液中的至少一种。所述步骤3)和步骤4)的顺序可互换;当先施加粘结剂时,施加完毕后再进行二次真空脱水。
实施例1:
一种超疏水高效空气过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维94.5%、粘结剂5%、防水剂0.5%。
以上超疏水高效空气过滤材料是采用湿法微玻璃纤维浸胶方法制备而成的,主要是在施加粘结剂后高压喷射低浓度防水剂,使得在过滤材料表面一侧形成富集层,经干燥固化后制得超疏水空气过滤材料,具体包括以下步骤:
1)取配方量的微玻璃纤维分散于pH为3的硫酸水溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,经除渣器除渣后送入成形器制成湿纸页,并真空脱水;
3)将成型微玻璃纤维浸渍于浓度为3%的粘结剂丙烯酸乳液中
4)将浓度为0.3%的防水剂氟碳乳液通过喷涂于成型微玻璃纤维的进气侧上,于80℃下干燥120s;
5)将上述制得的材料在160℃下固化60s,即得所述空气过滤材料。
实施例2:
一种超疏水高效空气过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维79.5%、合成化纤10%、粘结剂10%、防水剂0.5%。
以上超疏水高效空气过滤材料是采用湿法微玻璃纤维浸胶方法制备而成的,主要是在先高压喷射低浓度防水剂,使得在过滤材料表面一侧形成富集层,经初步干燥固化后再施加粘结剂,经再次干燥固化后制得超疏水空气过滤材料,具体包括以下步骤:
1)取配方量的微玻璃纤维和合成化纤分散于pH为5的盐酸水溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,经除渣器除渣后送入成形器制成湿纸页,并真空脱水;
3)将浓度为0.3%的防水剂聚烯烃蜡乳液喷涂于成型微玻璃纤维的进气侧上,于80℃下烘箱干燥60s;
4)将成型微玻璃纤维浸渍于浓度为3%的粘结剂醋酸乙烯酯乳液中;
5)将上述制得的材料在160℃下固化120s,即得所述空气过滤材料。
实施例3:
一种超疏水高效空气过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维72.5%、合成化纤20%、粘结剂7%、防水剂0.5%。
以上超疏水高效空气过滤材料是采用湿法微玻璃纤维浸胶方法制备而成的,主要是在施加粘结剂后高压喷射低浓度防水剂,使得在过滤材料表面一侧形成富集层,经干燥固化后制得超疏水空气过滤材料,具体包括以下步骤:
1)取配方量的微玻璃纤维和合成化纤分散于pH为6的磷酸水溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,经除渣器除渣后送入成形器制成湿纸页,并真空脱水;
3)将成型微玻璃纤维浸渍于浓度为3%的粘结剂苯乙烯/丙烯酸共聚物乳液中
4)将浓度为0.3%的防水剂硅油乳液通过喷涂于成型微玻璃纤维的一侧上,于80℃下干燥120s;
5)将上述制得的材料在160℃下固化60s,即得所述空气过滤材料。
实施例4:
一种超疏水高效空气过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维94.5%、粘结剂5.4%、防水剂0.1%。
以上超疏水高效空气过滤材料是采用湿法微玻璃纤维浸胶方法制备而成的,主要是在施加粘结剂后高压喷射低浓度防水剂,使得在过滤材料表面一侧形成富集层,经干燥固化后制得超疏水空气过滤材料,具体包括以下步骤:
1)取配方量的微玻璃纤维和化纤分散于pH为3的硫酸水溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,经除渣器除渣后送入成形器制成湿纸页,并真空脱水;
3)将成型微玻璃纤维浸渍于浓度为3%的粘结剂丙烯酸乳液中
4)将浓度为0.1%的防水剂氟碳乳液通过喷涂于成型微玻璃纤维的进气侧上,于80℃下干燥120s;
5)将上述制得的材料在160℃下固化60s,即得所述空气过滤材料。
实施例5:
一种超疏水高效空气过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维80%、合成化纤10%,粘结剂5%、防水剂5%。
以上超疏水高效空气过滤材料是采用湿法微玻璃纤维浸胶方法制备而成的,主要是在施加粘结剂后高压喷射低浓度防水剂,使得在过滤材料表面一侧形成富集层,经干燥固化后制得超疏水空气过滤材料,具体包括以下步骤:
1)取配方量的微玻璃纤维和化纤分散于pH为3的硫酸水溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,经除渣器除渣后送入成形器制成湿纸页,并真空脱水;
3)将成型微玻璃纤维浸渍于浓度为3%的粘结剂丙烯酸乳液中
4)将浓度为3%的防水剂氟碳乳液通过喷涂于成型微玻璃纤维的进气侧上,于80℃下干燥120s;
5)将上述制得的材料在160℃下固化60s,即得所述空气过滤材料。
对比例1:
一种过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维84.5%、合成化纤10%,粘结剂5%、防水剂0.5%。其是采用常规的湿法微玻璃纤维浸胶方法制备,主要是将防水剂乳液和粘结剂混合后再进行浸渍,具体包括如下步骤:
1)取配方量的微玻璃纤维和合成化纤分散于水中,制成混合悬浮液,经除渣器除渣后送入成形器制成湿纸页,并真空脱水;
3)将配方量的粘结剂丙烯酸乳液和防水剂氟碳乳液混合均匀后,将微玻璃纤维浸渍于混合液中;
4)将浸渍后的微玻璃纤维置于80℃下干燥120s、在160℃下固化60s,即得过滤材料。
对比例2:
一种超疏水高效空气过滤材料,其是由以下按质量百分数计的组分组成:微玻璃纤维75%,粘结剂5%、防水剂20%。
以上超疏水高效空气过滤材料是采用湿法微玻璃纤维浸胶方法制备而成的,主要是在施加粘结剂后高压喷射低浓度防水剂,使得在过滤材料表面一侧形成富集层,经干燥固化后制得超疏水空气过滤材料,具体包括以下步骤:
1)取配方量的微玻璃纤维和化纤分散于pH为3的硫酸水溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,经除渣器除渣后送入成形器制成湿纸页,并真空脱水;
3)将成型微玻璃纤维浸渍于浓度为3%的粘结剂丙烯酸乳液中
4)将浓度为10%的防水剂氟碳乳液通过喷涂于成型微玻璃纤维的进气侧上,于80℃下干燥120s;
5)将上述制得的材料在160℃下固化60s,即得所述空气过滤材料。
性能验证:
将实施例1~3中所制得的超疏水高效空气过滤材料与对比例1中的过滤材料进行性能比较试验,分别测定滤纸定量、过滤效率、挺度、拉伸强度、过滤阻力、防水压力以及表面接触角等参数,结果见下表:
由上表可知,本发明实施例1~3中所制得的超疏水高效空气过滤材料与对比例1相比,在相同的过滤效率下,本发明的空气过滤材料具有较佳的防水压力,表面接触角也远优于对比例1,由此可见本发明的过滤材料具有超疏水性,能够有效防止过滤气流中的水蒸气或者微小水滴进入过滤材料内部甚至下游,大大提升了抗水性能和过滤效能,有效延长了使用寿命。进一步地,由实施例4和5可知,说明在本发明的防水剂用量下具有较低的过滤阻力和较佳的防水效果;由实施例1和对比例2可知,当防水剂用量较高时,会堵塞进气侧孔隙,从而造成滤材阻力急剧增加。
上述实施方式仅为本发明的优选实施方式,不能以此来限定本发明保护的范围,本领域的技术人员在本发明的基础上所做的任何非实质性的变化及替换均属于本发明所要求保护的范围。
Claims (9)
1.一种超疏水高效空气过滤材料,其特征在于:由以下按质量百分数计的组分组成:微玻璃纤维50~99.8%、合成化纤0~20%、粘结剂0.1~20%、防水剂0.1~10%。
2.根据权利要求1所述的超疏水高效空气过滤材料,其特征在于:所述微玻璃纤维为玻璃纤维棉或玻璃纤维短切丝。
3.根据权利要求1所述的超疏水高效空气过滤材料,其特征在于:所述微玻璃纤维的直径为0.1~20μm。
4.根据权利要求1所述的超疏水高效空气过滤材料,其特征在于:所述粘结剂选自苯乙烯/丙烯酸共聚物乳液、丙烯酸聚合物树脂及其乳液、醋酸乙烯酯乳液、环氧树脂及其乳液、酚醛树脂及其乳液中的至少一种。
5.根据权利要求1所述的超疏水高效空气过滤材料,其特征在于:所述防水剂选自硅油乳液、聚烯烃蜡乳液、氟碳乳液中的至少一种。
6.一种如权利要求1~5中任一项所述的超疏水高效空气过滤材料的制备方法,其特征在于:包括以下步骤:
1)取配方量的微玻璃纤维和合成化纤分散于pH为2~6的无机酸溶液中,制成浓度为5%的混合悬浮液;
2)将混合悬浮液稀释至浓度为0.5%,除渣后送入成形器制成湿纸页,并真空脱水;
3)将配方量的防水剂通过涂布或喷涂的方式施加于成型微玻璃纤维的一侧上,于80~180℃下干燥0.1~600s;
4)将配方量的粘结剂施加于成型微玻璃纤维的两侧上;
5)将上述制得的材料置于80~180℃下干燥0.1~600s后,再在80~180℃下固化0.1~600s,即得所述空气过滤材料。
7.根据权利要求6所述的超疏水高效空气过滤材料的制备方法,其特征在于:步骤1)中所述的无机酸溶液选自硫酸水溶液、盐酸水溶液、硝酸水溶液、磷酸水溶液、柠檬酸水溶液、醋酸水溶液中的至少一种。
8.根据权利要求6所述的超疏水高效空气过滤材料的制备方法,其特征在于:所述步骤3)和步骤4)的顺序可互换。
9.根据权利要求6所述的超疏水高效空气过滤材料的制备方法,其特征在于:步骤4)中的粘结剂通过浸渍、涂布或喷涂的方式施加于成型微玻璃纤维的两侧上。
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