CN111020876A - High-efficiency filtering material with gradient structure and production method thereof - Google Patents
High-efficiency filtering material with gradient structure and production method thereof Download PDFInfo
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
- B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
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- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4391—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece characterised by the shape of the fibres
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/542—Adhesive fibres
- D04H1/544—Olefin series
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/559—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving the fibres being within layered webs
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
- D04H1/728—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by electro-spinning
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
- B01D2239/065—More than one layer present in the filtering material
- B01D2239/0681—The layers being joined by gluing
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- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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Abstract
The invention discloses a high-efficiency filter material with a gradient structure, which is formed by compounding four filter layers with different gradients and different apertures, wherein the first filter layer is a coarse mixed needled felt layer, the second filter layer is a fine mixed needled felt layer, the third filter layer is a superfine non-woven fabric layer, and the fourth filter layer is a hollow electrostatic spinning superfine fiber layer; the pore diameters from the first filtering layer to the fourth filtering layer are gradually reduced in a gradient manner. The invention takes environmental protection as the invention principle, and aims to improve the efficiency and the strength of the filter material and enhance the connectivity of the composite material; by adopting the technical processes of non-woven needling, wet-laid web formation, hot air and hollow electrostatic spinning, the hollow superfine fiber layer is introduced while ensuring good mechanical strength, the prepared high-efficiency filtering material with the gradient structure has good filtering effect, low filtration resistance and excellent mechanical property, the materials are bonded and reinforced by self, the connectivity is good, and the high-efficiency filtering material can be recycled.
Description
The invention relates to a high-efficiency filter material with a gradient structure, in particular to a high-efficiency filter material with a gradient structure and a production method thereof.
Background
With the further attention paid to the problem of air pollution, the comprehensive index of the filter material is required to be higher. The traditional preparation of air filter material adopts the acupuncture non-woven fabrics mostly, coats a layer microporous membrane on its surface to have certain air filter effect, nevertheless the material connectivity between microporous membrane and acupuncture non-woven fabrics after repetitious usage is showing and is reducing, and the microporous membrane produces and breaks, and comprehensive properties is relatively poor. At present, the electrostatic spinning and melt-blown non-woven technology is mature, the superfine fiber reaches micron or even nanometer level, and can completely replace a microporous membrane, thereby having higher filtering efficiency. Patents have introduced electrospun high efficiency filter materials, but they have placed the electrospun layer between two layers of base fabric, without creating a gradient effect, and the electrospun layer is extremely vulnerable to damage. In recent years, although air filtration is studied in many ways, the air filtration is still not perfect, such as woven fabric, short fiber spunlace nonwoven fabric and impregnated composite filter material, the cost is higher, the whole pore size is reduced after resin impregnation, and the filtration efficiency is lower. In addition, sea-island fiber nets, common fiber nets, reinforced fabrics and gradient filtering materials of the common fiber nets are also available, and the whole body is compounded by adopting needling or spunlace, so that the materials are too compact and the gradient filtering effect is poor.
Disclosure of Invention
The purpose of the invention is as follows: aiming at the problems of the conventional air filtering material, the invention provides a high-efficiency filtering material with a gradient structure and a production method thereof, wherein the novel high-efficiency filtering material is prepared by compounding four gradient filtering layers with different apertures by comprehensively applying needling, wet-laid web, hot air and hollow electrostatic spinning processes, the layers are bonded by self materials, and a hollow superfine fiber layer is introduced, so that the novel high-efficiency filtering material has the advantages of small gram weight, good mechanical property, durability, safety, environmental protection, excellent filtering efficiency and air permeability, and the total filtering efficiency reaches more than 99.99 percent. .
The technical scheme is as follows: the high-efficiency filter material with the gradient structure is formed by compounding four filter layers with different gradients and different apertures, wherein the first filter layer is a coarse mixed needled felt layer, the second filter layer is a fine mixed needled felt layer, the third filter layer is a superfine non-woven fabric layer, and the fourth filter layer is a hollow electrostatic spinning superfine fiber layer; the pore diameters from the first filtering layer to the fourth filtering layer are gradually reduced in a gradient manner.
Preferably, the coarse mixed needled felt layer is a needled felt made of conventional coarse denier fibers and ES fibers, the thickness of the conventional coarse denier fibers is 2.5-3D, the length of the conventional coarse denier fibers is 51mm, and the needled felt has a grammage of 100 g/m and is formed by a primary needling process.
Preferably, the fine mixed needled felt layer is a needled felt made of conventional fine denier fibers and ES fibers in a mixed mode, the thickness of the conventional fine denier fibers is 1.5-2D, the length of the conventional fine denier fibers is 38mm, and the needled felt has the gram weight of 60-80g/m and is formed by a secondary needling process.
Preferably, the micro-fine non-woven fabric layer is a non-woven fabric layer made of conventional micro-fine denier fibers and ES fibers in a mixed mode, the conventional micro-fine denier fibers have the thickness of 0.8-1.2D and the length of 6-12mm, and the wet-process non-woven fabric has the gram weight of 30 g/m.
Preferably, the ES fibers in the coarse mixed needled felt layer, the fine mixed needled felt layer and the fine non-woven fabric layer are bicomponent low-melting-point hot-melt fibers, the core layer is polypropylene fibers with a melting point of 167 ℃, and the skin layer is polyethylene fibers with a melting point of 130 ℃.
Preferably, the 4 gram weight of the hollow electrospun superfine fiber layer is 5-20g/m, and the fiber raw material in the hollow electrospun superfine fiber layer is the same as the conventional superfine fiber in the conventional superfine non-woven fabric layer.
A preparation process of a high-efficiency filter material with a gradient structure comprises the following steps:
(1) preparing a coarse mixed needled felt layer: conventional coarse denier fibers with the thickness of 2.5-3D and the length of 51mm and ES fibers are mixed according to a ratio of 6:4 and are subjected to opening carding to form a uniform fiber web, the uniform fiber web is fed into a needle machine to be subjected to pre-needling and one-step needling, and a coarse mixed needle felt layer with the grammage of 100 and 150g/m is obtained;
(2) preparing a fine mixed needled felt layer: mixing conventional fine denier fibers with the thickness of 1.5-2D and the length of 38mm with ES fibers according to a ratio of 6:4, opening and carding to form a uniform fiber web, then entering a needling area through a net conveying curtain, keeping the fibers perpendicular to the needles, and obtaining a fine mixed needled felt layer with the gram weight of 60-80g/m after twice needling;
(3) preparing a superfine non-woven fabric layer: pretreating conventional microfine denier fiber with thickness of 0.8-1.2D and length of 6-12mm and ES fiber, mixing two kinds of fiber according to a ratio of 6:4, soaking in water, dispersing, mixing in a size mixing tank to obtain a homogeneous mixed solution, adding water at normal temperature, further diluting, mixing to obtain a mixed solution with a concentration of 0.1-0.15%, feeding into a non-woven wet-laid system to form a wet paper sheet, removing excessive water under the action of a mangle roller, and drying in a 70-90 deg.C oven to obtain a paper sheet with a grammage of 30g/m2The fine nonwoven fabric layer of (4);
(4) bonding: stacking the prepared coarse mixed needled felt layer, the fine mixed needled felt layer and the fine non-woven fabric layer in sequence, putting the stacked layers into an oven to be in a semi-molten state, bonding the three fiber webs together by utilizing the ES fiber hot-melt bonding performance in the coarse mixed needled felt layer, the fine mixed needled felt layer and the fine non-woven fabric layer, setting the temperature of a hot air oven to be 130 ℃, keeping the hot air time to be about 3min, and then entering a cold air area under the action of a net conveying curtain for quick shaping to obtain a fiber web complex;
(5) preparing a hollow electrostatic spinning superfine fiber layer: blending fiber materials, a dimethylacetamide solution and a spinning aid, stirring for 18h-48h under magnetic stirring at the rotating speed of 300r/min-400r/min to obtain a uniform spinning solution with the mass fraction of 5% -20%, assembling two metal capillary tubes with different inner and outer diameters into a hollow electrostatic spinning nozzle in a sleeve mode, injecting the spinning solution into an outer tube and injecting a hollow air flow into an inner tube under the conditions that the voltage is 16-20kV, the flow rate of the spinning solution is 0.3-1.0mL/h, the air flow rate of the hollow air flow is 0.2-0.8mL/h, the diameter of the inner tube is 0.3-1.0mm, the diameter of the outer tube is 1-1.8mm, and the receiving distance is 10-20cm, and directly and vertically spraying and loading the hollow electrostatic spinning superfine fiber layer with the gram weight of 5-20g/m on the fiber web prepared in the step (4), obtaining the high-efficiency filter material with the gradient structure.
The invention discloses a high-efficiency filter material with a gradient structure based on the principle of optimized utilization of resources, which has the following effects:
(1) the gradient filter material prepared by compounding the coarse fibers and the fine fibers in a multi-layer manner has small gram weight, good filtering efficiency and air permeability, and the total filtering efficiency reaches more than 99.99 percent;
(2) according to the invention, a chemical auxiliary agent is not needed in a composite mode, the coarse mixed needled felt layer, the fine mixed needled felt layer and the fine non-woven fabric layer are subjected to hot melt self-adhesion, the hollow electrostatic spinning superfine fiber layer and the fine non-woven fabric layer use the same type of conventional fibers, the fiber layers are good in connectivity, durable, safe and environment-friendly;
(3) the filter material of the invention contains two layers of needled felts, and has excellent mechanical properties;
(4) according to the hollow electrostatic spinning superfine fiber layer, compared with a solid superfine fiber layer, the superfine fiber layer formed by the hollow electrostatic spinning superfine fiber layer is more uniform, the fiber cross gap is thinner, and the filtering effect is better;
(5) the chemical fibers in the invention can be recycled, the cost is reduced, and the sustainable development is realized;
(6) the preparation process adopted by the invention is easy to operate and can be used for mass production.
Drawings
FIG. 1 is a structural cross-sectional view of the present invention;
1. coarsely mixing the needled felt layer; 2. finely mixing the needled felt layer; 3. a microfine non-woven fabric layer; 4. and (3) hollow electrostatic spinning superfine fiber layers.
Detailed Description
As shown in fig. 1, the high-efficiency filter material with a gradient structure is formed by compounding four filter layers with different gradients and different pore diameters, wherein the first filter layer is a coarse mixed needled felt layer 1 with a larger pore diameter; the second filtering layer is a fine mixed needled felt layer 2 with smaller aperture; the third filtering layer is a micro non-woven fabric layer 3 with a micro pore size; the fourth filtering layer is a hollow electrostatic spinning superfine fiber layer 4 with extremely small aperture; the pore diameters from the first filtering layer to the fourth filtering layer are gradually reduced in a gradient manner; the coarse mixed needled felt layer 1 is a needled felt prepared by mixing conventional coarse denier fibers and ES fibers, the thickness of the conventional coarse denier fibers is 2.5-3D, the length of the conventional coarse denier fibers is 51mm, the gram weight of the needled felt is 100-150g/m, and the needled felt layer is formed by a one-time needling process; the fine mixed needled felt layer 2 is a needled felt made of conventional fine denier fibers and ES fibers in a mixing mode, the thickness of the conventional fine denier fibers is 1.5-2D, the length of the conventional fine denier fibers is 38mm, the gram weight of the needled felt is 60-80g/m, and the needled felt layer is formed through a secondary needling process; the micro-fine non-woven fabric layer 3 is a non-woven fabric layer made of conventional micro-fine denier fibers and ES fibers in a mixed mode, the conventional micro-fine denier fibers have the thickness of 0.8-1.2D and the length of 6-12mm, and the wet-process non-woven fabric has the gram weight of 30 g/m; the ES fibers in the coarse mixed needled felt layer 1, the fine mixed needled felt layer 2 and the fine non-woven fabric layer 3 are double-component low-melting-point hot-melt fibers, the core layer of the ES fibers is polypropylene fibers with a melting point of 167 ℃, and the skin layer of the ES fibers is polyethylene fibers with a melting point of 130 ℃; the grammage of the hollow electrospun superfine fiber layer 44 is 5-20g/m, the fiber raw material in the hollow electrospun superfine fiber layer 4 is the same as the conventional superfine denier fiber in the conventional superfine nonwoven fabric layer 3, and the conventional denier fiber mentioned in the coarse hybrid needled felt layer 1, the fine hybrid needled felt layer 2, the superfine nonwoven fabric layer 3 and the hollow electrospun superfine fiber layer 4 is any one of the fibers in the prior art, but the definition of the different layers on the conventional fiber is satisfied.
Example one
A preparation process of a high-efficiency filter material with a gradient structure comprises the following steps:
(1) preparation of coarse mixed needled felt layer 1: polyester fibers with the thickness of 2.5-3D and the length of 51mm and ES fibers are mixed according to the ratio of 6:4 and are subjected to opening carding to form a uniform fiber web, the uniform fiber web is fed into a needle machine to be subjected to pre-needling and one-step needling, and a coarse mixed needled felt layer 1 with the weight of 100-150g/m is obtained;
(2) preparation of fine hybrid needled felt layer 2: polyamide fibers with the thickness of 1.5-2D and the length of 38mm and ES fibers are mixed according to the ratio of 6:4 and then are opened and carded to form a uniform fiber web, then the uniform fiber web enters a needling area through a net conveying curtain, the fibers and needles are kept perpendicular, and a fine mixed needled felt layer 2 with the gram weight of 60-80g/m is prepared after two times of needling;
(3) preparing a superfine non-woven fabric layer 3: pretreating polypropylene fiber and ES fiber with thickness of 0.8-1.2D and length of 6-12mm, mixing the two fibers at a ratio of 6:4, soaking in water, dispersing, mixing in a size mixing tank to obtain a homogeneous mixed solution with concentration of 1-3%, mixing for 10-20min, adding water at room temperature, diluting, mixing to obtain a mixture with concentration of 0.1-0.15%, feeding into a nonwoven wet-laid system to form a wet paper sheet, removing excess water under the action of mangle roller, and oven drying at 70-90 deg.C to obtain a paper sheet with a grammage of 30g/m2The fine nonwoven fabric layer 3;
(4) bonding: stacking the prepared coarse mixed needled felt layer 1, the fine mixed needled felt layer 2 and the fine non-woven fabric layer 3 in sequence, putting the stacked layers into an oven to be in a semi-molten state, bonding three fiber webs together by utilizing the ES fiber hot-melt adhesive property in the coarse mixed needled felt layer 1, the fine mixed needled felt layer 2 and the fine non-woven fabric layer 3, setting the temperature of a hot air oven to be 130 ℃, keeping the hot air time to be about 3min, and then entering a cold air area under the action of a net conveying curtain for rapid shaping to obtain a fiber web complex;
(5) preparing a hollow electrostatic spinning superfine fiber layer 4: blending polypropylene fibers, a dimethylacetamide solution and a spinning aid, stirring for 18h-48h under magnetic stirring at the rotating speed of 300r/min-400r/min to obtain a uniform spinning solution with the mass fraction of 5% -20%, assembling two metal capillary tubes with different inner and outer diameters into a hollow electrostatic spinning nozzle in a sleeve mode, injecting the spinning solution into an outer tube and injecting a hollow air flow into an inner tube under the conditions that the voltage is 16-20kV, the flow rate of the spinning solution is 0.3-1.0mL/h, the air flow rate is 0.2-0.8mL/h, the diameter of the inner tube is 0.3-1.0mm, the diameter of the outer tube is 1-1.8mm and the receiving distance is 10-20cm, directly and vertically spraying and loading the hollow electrostatic spinning ultrafine fiber layer 4 with the gram weight of 5-20g/m on the fiber web composite body prepared in the step (4), obtaining the high-efficiency filter material with the gradient structure.
Example two
A preparation process of a high-efficiency filter material with a gradient structure comprises the following steps:
(1) preparation of coarse mixed needled felt layer 1: polyphenylene sulfide fibers with the thickness of 2.5-3D and the length of 51mm and ES fibers are mixed according to the ratio of 6:4 and are subjected to opening carding to form a uniform fiber web, the uniform fiber web is fed into a needle machine, and a coarse mixed needle felt layer 1 with the gram weight of 100-150g/m is obtained through pre-needling and one-step needling;
(2) preparation of fine hybrid needled felt layer 2: mixing polyacrylonitrile fibers with the thickness of 1.5-2D and the length of 38mm and ES fibers according to a ratio of 6:4, opening and carding to form a uniform fiber web, then entering a needling area through a net conveying curtain, keeping the fibers perpendicular to needles, and obtaining a fine mixed needled felt layer 2 with the gram weight of 60-80g/m after twice needling;
(3) preparing a superfine non-woven fabric layer 3: pre-treating polytetrafluoroethylene fiber and ES fiber with the thickness of 0.8-1.2D and the length of 6-12mm, mixing the two fibers according to the ratio of 6:4, soaking and dispersing, mixing in a size mixing tank to obtain a homogeneous mixed solution, wherein the concentration of the mixed solution is 1-3%, mixing for 10-20min, adding water at normal temperature for further dilution, mixing until the concentration is 0.1-0.15%, sending into a non-woven wet-laid system to form a wet paper sheet, preliminarily removing excess water under the action of a mangle roller, and drying in a drying oven at 70-90 ℃ to obtain the polytetrafluoroethylene fiber and ES fiber with the gram weight of 30g/m2The fine nonwoven fabric layer 3;
(4) bonding: stacking the prepared coarse mixed needled felt layer 1, the fine mixed needled felt layer 2 and the fine non-woven fabric layer 3 in sequence, putting the stacked layers into an oven to be in a semi-molten state, bonding three fiber webs together by utilizing the ES fiber hot-melt adhesive property in the coarse mixed needled felt layer 1, the fine mixed needled felt layer 2 and the fine non-woven fabric layer 3, setting the temperature of a hot air oven to be 130 ℃, keeping the hot air time to be about 3min, and then entering a cold air area under the action of a net conveying curtain for rapid shaping to obtain a fiber web complex;
(5) preparing a hollow electrostatic spinning superfine fiber layer 4: mixing polytetrafluoroethylene fiber material with dimethylacetamide solution and spinning aid, stirring for 18h-48h under magnetic stirring at the rotating speed of 300r/min-400r/min to obtain 5% -20% of uniform spinning solution, assembling two metal capillary tubes with different inner and outer diameters into a hollow electrostatic spinning nozzle in a sleeve mode, injecting spinning solution into an outer tube and injecting hollow air flow into an inner tube under the conditions that the voltage is 16-20kV, the flow rate of the spinning solution is 0.3-1.0mL/h, the flow rate of the hollow air flow is 0.2-0.8mL/h, the diameter of the inner tube is 0.3-1.0mm, the diameter of the outer tube is 1-1.8mm, and the receiving distance is 10-20cm, directly and vertically spraying and loading the mixture on the fiber web composite body prepared in the step (4) to finally prepare an electrostatic spinning superfine fiber layer 4 with the gram weight of 5-20g/m, obtaining the high-efficiency filter material with the gradient structure.
A high-efficiency filtering material with a gradient structure has the following advantages:
(1) the gradient filter material prepared by compounding the coarse fibers and the fine fibers in a multi-layer manner has small gram weight, good filtering efficiency and air permeability, and the total filtering efficiency reaches more than 99.99 percent;
(2) according to the invention, a chemical auxiliary agent is not needed in a composite mode, the coarse mixed needled felt layer 1, the fine mixed needled felt layer 2 and the fine non-woven fabric layer 3 are self-bonded by hot melt, the hollow electrostatic spinning superfine fiber layer 4 and the fine non-woven fabric layer 3 use the same type of conventional fibers, the fiber layers are good in connectivity, durable, safe and environment-friendly;
(3) the filter material of the invention contains two layers of needled felts, and has excellent mechanical properties;
(4) according to the hollow electrostatic spinning superfine fiber layer 4, compared with a solid superfine fiber layer, the formed superfine fiber layer is more uniform, the fiber cross gap is thinner, and the filtering effect is better;
(5) the chemical fibers in the invention can be recycled and reused, and can be developed sustainably;
(6) the preparation process adopted by the invention is easy to operate and can be used for mass production.
The invention takes environmental protection as the invention principle, and aims to improve the efficiency and the strength of the filter material and enhance the connectivity of the composite material; by adopting the technical processes of non-woven needling, wet-laid web formation, hot air and hollow electrostatic spinning, the hollow superfine fiber layer is introduced while ensuring good mechanical strength, so that the step-by-step gradient high-efficiency filtration is effectively realized, the filtration resistance is reduced, and the filtration effect is greatly improved.
Although the present invention has been described with reference to the preferred embodiments, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (7)
1. A high-efficiency filter material with a gradient structure is characterized in that: the high-efficiency filter material with the gradient structure is formed by compounding four filter layers with different gradients and different apertures, wherein the first filter layer is a coarse mixed needled felt layer, the second filter layer is a fine mixed needled felt layer, the third filter layer is a superfine non-woven fabric layer, and the fourth filter layer is a hollow electrostatic spinning superfine fiber layer; the pore diameters from the first filtering layer to the fourth filtering layer are gradually reduced in a gradient manner.
2. A high efficiency filter material having a gradient structure as set forth in claim 1, wherein: the coarse mixed needled felt layer is a needled felt made of conventional coarse denier fibers and ES fibers in a mixing mode, the thickness of the conventional coarse denier fibers is 2.5-3D, the length of the conventional coarse denier fibers is 51mm, and the needled felt has the grazing weight of 100-150g/m and is formed by a one-time needling process.
3. A high efficiency filter material having a gradient structure as set forth in claim 1, wherein: the fine mixed needled felt layer is a needled felt made of conventional fine denier fibers and ES fibers in a mixed mode, the thickness of the conventional fine denier fibers is 1.5-2D, the length of the conventional fine denier fibers is 38mm, the gram weight of the needled felt is 60-80g/m, and the needled felt layer is formed through a secondary needling process.
4. A high efficiency filter material having a gradient structure as set forth in claim 1, wherein: the superfine non-woven fabric layer is a non-woven fabric layer made of conventional superfine denier fibers and ES fibers in a mixed mode, the thickness of the conventional superfine denier fibers is 0.8-1.2D, the length of the conventional superfine denier fibers is 6-12mm, and the gram weight of the wet-process non-woven fabric is 30 g/m.
5. A high efficiency filter material having a gradient structure as set forth in claim 1, wherein: the ES fibers in the coarse mixed needled felt layer, the fine mixed needled felt layer and the fine non-woven fabric layer are double-component low-melting-point hot-melt fibers, the core layer of the ES fibers is polypropylene fibers with a melting point of 167 ℃, and the skin layer of the ES fibers is polyethylene fibers with a melting point of 130 ℃.
6. A high efficiency filter material having a gradient structure as set forth in claim 1, wherein: the 4 gram weight of the hollow electrostatic spinning superfine fiber layer is 5-20g/m, and the fiber raw materials in the hollow electrostatic spinning superfine fiber layer are the same as the conventional superfine fibers in the conventional superfine non-woven fabric layer.
7. A process for preparing a high efficiency filter material with a gradient structure according to any one of claims 1 to 6, wherein: the method comprises the following steps:
(1) preparing a coarse mixed needled felt layer: conventional coarse denier fibers with the thickness of 2.5-3D and the length of 51mm and ES fibers are mixed according to a ratio of 6:4 and are subjected to opening carding to form a uniform fiber web, the uniform fiber web is fed into a needle machine to be subjected to pre-needling and one-step needling, and a coarse mixed needle felt layer with the grammage of 100 and 150g/m is obtained;
(2) preparing a fine mixed needled felt layer: mixing conventional fine denier fibers with the thickness of 1.5-2D and the length of 38mm with ES fibers according to a ratio of 6:4, opening and carding to form a uniform fiber web, then entering a needling area through a net conveying curtain, keeping the fibers perpendicular to the needles, and obtaining a fine mixed needled felt layer with the gram weight of 60-80g/m after twice needling;
(3) preparing a superfine non-woven fabric layer: pretreating conventional microfine denier fiber with thickness of 0.8-1.2D and length of 6-12mm and ES fiber, mixing two kinds of fiber according to a ratio of 6:4, soaking in water, dispersing, mixing in a size mixing tank to obtain a homogeneous mixed solution, adding water at normal temperature, further diluting, mixing to obtain a mixed solution with a concentration of 0.1-0.15%, feeding into a non-woven wet-laid system to form a wet paper sheet, removing excessive water under the action of a mangle roller, and drying in a 70-90 deg.C oven to obtain a paper sheet with a grammage of 30g/m2The fine nonwoven fabric layer of (4);
(4) bonding: stacking the prepared coarse mixed needled felt layer, the fine mixed needled felt layer and the fine non-woven fabric layer in sequence, putting the stacked layers into an oven to be in a semi-molten state, bonding the three fiber webs together by utilizing the ES fiber hot-melt bonding performance in the coarse mixed needled felt layer, the fine mixed needled felt layer and the fine non-woven fabric layer, setting the temperature of a hot air oven to be 130 ℃, keeping the hot air time to be about 3min, and then entering a cold air area under the action of a net conveying curtain for quick shaping to obtain a fiber web complex;
(5) preparing a hollow electrostatic spinning superfine fiber layer: blending fiber materials, a dimethylacetamide solution and a spinning aid, stirring for 18h-48h under magnetic stirring at the rotating speed of 300r/min-400r/min to obtain a uniform spinning solution with the mass fraction of 5% -20%, assembling two metal capillary tubes with different inner and outer diameters into a hollow electrostatic spinning nozzle in a sleeve mode, injecting the spinning solution into an outer tube and injecting a hollow air flow into an inner tube under the conditions that the voltage is 16-20kV, the flow rate of the spinning solution is 0.3-1.0mL/h, the flow rate of the hollow air flow is 0.2-0.8mL/h, the diameter of the inner tube is 0.3-1.0mm, the diameter of the outer tube is 1-1.8mm, and the receiving distance is 10-20cm, directly and vertically spraying and loading the spinning solution on the fiber web prepared in the step (4), and finally preparing the electrostatic spinning superfine fiber layer with the gram weight of 5-20g/m, obtaining the high-efficiency filter material with the gradient structure.
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