CN112221257A - 一种无缝圆筒过滤袋及其制造方法 - Google Patents

一种无缝圆筒过滤袋及其制造方法 Download PDF

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CN112221257A
CN112221257A CN202011054663.3A CN202011054663A CN112221257A CN 112221257 A CN112221257 A CN 112221257A CN 202011054663 A CN202011054663 A CN 202011054663A CN 112221257 A CN112221257 A CN 112221257A
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fiber
fabric
filter bag
woven fabric
woven
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CN112221257B (zh
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顾珂里
杨正香
龚震宇
曹青青
吴济宏
王海艳
顾钰良
王震声
章军
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Jiangsu Hengsheng Environmental Protection Science And Technology Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/0001—Making filtering elements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D29/00—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor
    • B01D29/11—Filters with filtering elements stationary during filtration, e.g. pressure or suction filters, not covered by groups B01D24/00 - B01D27/00; Filtering elements therefor with bag, cage, hose, tube, sleeve or like filtering elements
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • 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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Abstract

本发明公开了一种无缝圆筒过滤袋及其制备方法，该无缝圆筒过滤袋由内向外依次由第一非织造布、圆筒布、第二非织造布和聚四氟乙烯微孔膜复合而成；其中，圆筒布的织造是在圆织机上采用机织方法织造或者在电脑横机上用针织的方法编织而成。所述的复合是将滤袋两端用超声波焊接机通过热能粘结成一体，或用超声波焊接机通过热能粘结两端袋口，同时袋身的多层材料焊接机通过点状粘接在一起。按本发明制造工艺所制得的滤袋避免因滤袋缝线原因所造成的破损，撕裂现象的发生，彻底解决了因水刺和针刺所造成的对滤袋纤维和基布的损伤致使滤料强力下降的困扰，提高了环保滤料的产品质量和使用寿命。

Description

一种无缝圆筒过滤袋及其制造方法
技术领域
本发明涉及一种无缝圆筒过滤袋及其制造方法，属环境保护领域。该圆筒滤袋既适用于中低温液体的除杂过滤，也适用于高温工况条件下烟气的除尘及空气净化。
背景技术
滤袋是除尘技术中袋式除尘器的核心部件，其作用是捕集烟气中的灰尘，达到环保和控制污染的要求。现行用于钢铁、冶金、化工、水泥制造，垃圾焚烧等行业高温烟气除尘的滤袋装置，绝大多数采用高技术纤维如聚苯硫醚(PPS)、聚酰亚胺(P84)、芳纶、芳砜纶等纤维，以及无机纤维，如聚四氟乙烯(PTFE)、玄武岩、玻纤等纤维为原材料，其制作过程要经历下列几道工序：1、长丝或短纤经机织成基布；2、单一纤维短纤或多种纤维混合，梳理、铺网，经预针刺、主针刺制作成非织造布；3、基布和非织造布复合加固成纤维毡；4、纤维毡裁剪，缝制成滤袋。
在上述制造过程的散纤维梳理、铺网，经针刺成非织造布，及对基布和非织造布的复合加固两道工序中，刺针的针尖及针身上的倒勾会造成纤维损伤，严重时会使纤维断裂，使纤维毡强力造成10-30％的下降，为了达到滤料的产品要求，就必须通过增加纤网和基布的纤维使用量，来弥补针刺所带来的损伤，造成原材料的浪费。
其次，在上述加工过程中缝制滤袋所形成的缝口在长达2-3年的高温除尘过程中，会造成缝线开裂破损，使滤袋失效而影响过滤效率。
无损伤及低损伤加固技术已成为国内外滤料行业亟待解决的技术难题。美国专利(专利号5755962)公开了一种复合纤维毡连续缠绕在管状心轴上2至5个完整卷绕而形成的圆形管状，由预过滤袋及标准过滤袋组成的过滤组件。美国专利(专利号US2004/10013807A1)公开了一种在无缝过滤袋织物上为提高过滤性，进行涂层的处理方法。针对现有滤袋制造过程中存在的缺陷，本发明人曾发明了“一种泡沫涂层复合耐高温滤料及其制备方法”，专利号为CN107261643.B，专利公开了通过泡沫涂层的方法使组成滤料的微孔膜、非织造布、基布、非织造布等几层材料层与层之间用泡沫粘合剂相互粘合的复合加固技术，部分解决了低损伤加固技术的生产难题，但非织造布的形成仍是采用针刺或水刺，使纤维之间相互缠绕的方法，使无纺布具有一定的强力。
圆织机编织筒布有两种方式，一种是采用塑料编织机械，属机织设备。主要生产颗粒较小的粮食、化肥的“密不透风”的塑料编织袋，或装颗粒较大的，如土豆、西红柿、辣椒、青菜、罗卜用的网眼袋，编织材料是聚酯、聚丙烯的扁丝，由于使用材料很粗犷，圆织机的经纱架再大，也只有500个纱锭。另一种是近10年开始流行用于编织无缝内衣的电脑横机，属针织类设备。该圆织机是以生产女性贴身内衣裤为唯一产品，讲究贴身穿着的舒适、柔软，和与肌体紧密结合，因而所用材料为真丝、棉、仿棉细旦聚酯纤维等，该设备有提花、移圈、起圈、翻针等复杂系统。
用上述两种设备织造以高技术纤维、合成纤维及无机纤维为原材料的环保领域的滤料尚未见报道。
发明内容
本发明针对现有技术，提供一种无缝圆筒过滤袋及其制造方法，本发明所述的无缝圆筒滤袋是以一种或多种纤维材料织造的圆筒布为里层，相同或不同材质的非织造布、聚四氟乙烯微孔膜为外层的环形织物，制造工艺主要包括：圆筒布的织造；非织造布的制造；多层材料的复合加固。具体是在圆织机上用经、纬纱交织的机织方法，或用能织造无缝内衣的横机上用针织的织造方法织成圆筒布。本发明另一特征是：组成该无缝圆筒滤袋的多层材料复合是依靠滤袋两端用超声波焊接机通过热能相互粘成一体；或用同样的方法处理两端袋口，袋身的多层材料也用焊接机通过点状焊接在一起，使得滤袋更加牢固。
本发明的目的是通过以下方式实现的：
一种无缝圆筒过滤袋，该无缝圆筒过滤袋由内向外依次由第一非织造布、圆筒布、第二非织造布和聚四氟乙烯微孔膜复合而成；其中，圆筒布层的织造是在圆织机上采用机织方法织造或者在电脑横机上用针织的方法编织而成。
上述复合是将滤袋两端用超声波焊接机通过热能粘结成一体，或用超声波焊接机通过热能粘结两端袋口，袋身的多层材料也用焊接机通过点状粘接在一起。
传统生产过滤袋的工艺流程如下：纤维A通过梭织机织造成基布，纤维B经混合、梳理、成单层纤维网，单层纤维网经交叉铺网成多层纤网；纤网经预针刺，主针刺成非织造布；纤维A织造的基布上、下层铺纤维B织造的非织造布，用针刺或水刺机进行复合加固成滤料；滤料经裁剪缝制成滤袋。
本发明生产圆筒滤袋的主要工艺流程如下：纤维A通过圆织机或电脑横机织造成圆筒布；纤维B采用纺粘的方法一次成型或经混合、梳理成单层纤维网，单层纤维网经交叉铺网成多层纤维网，多层纤网在复合机上进行粉点或浆点粘合成非织造布或者采用超声波焊接机通过热能使多层纤维网粘合成非织造布；将圆筒布和非织造布与聚四氟乙烯微孔膜复合成圆筒滤袋；其中，纤维A和纤维B相同或不同。
上述无缝圆筒过滤袋的制备方法可以具体包括以下步骤：
a、圆筒布的织造：将纤维在圆织机上采用经纱和纬纱相互交织的机织方法织造或者在电脑横机上用针织的方法编织而成；
b、非织造布的制造：采用纺粘的方法一次成型；或者采用短纤经混合、梳理、交叉铺网制成松散纤网，再将松散纤网在复合机上采用耐高温粘合剂，以粉点或浆点的方法使多层纤维网点式粘合成非织造布；或者采用超声波焊接机通过热能使多层纤维网粘合；
c、多层材料的复合加固：由内向外依次复合非织造布、圆筒布、非织造布和聚四氟乙烯微孔膜。
上述进行圆筒布的织造采用的纤维为高技术纤维、合成纤维或无机纤维中的一种或多种纤维混合、混织。优选高技术纤维、合成纤维或无机纤维采用纤度为150dtex-2500dtex的长丝或1.5Dtex—10Dtex的短纤维。
优选上述高技术纤维为聚苯硫醚长丝或短纤、聚酰亚胺长丝或短纤、芳纶长丝或短纤、石墨烯长丝或短纤；无机纤维为聚四氟乙烯长丝或短纤、无碱或有碱玻纤、玄武岩膨体纱或交拼纱线。本发明采用高技术纤维、合成纤维及无机纤维长丝或短纤为原材料织造滤袋，使粉尘、颗粒物、杂质和空气、液体等介质有效过滤或分离。
上述非织造布具体制备方法如下：切片通过熔融、纺丝、热粘合制成纺粘非织造布；或采用圆中空喷丝板纺制的海岛形超细纤维，经铺网、梳理成多层纤网；或用高技术纤维短纤单一品种或多品种纤维，经梳理、铺网成多层纤网，将上述纤网在复合机上采用耐高温粘合剂，用雕刻辊筒，以粉点式或浆点的方法，使粘合剂将多层纤维网粘合成非织造布，非织造布的重量范围在30g/㎡-450g/㎡。
所述的多层复合加固是将上述制成的圆筒布，非织造布等多层材料通过某种方式相互组合在一起，并进行加固的过程。圆筒过滤袋有最里层的非织造布、里层的圆筒布、次外层的非织造布和外层的聚四氟乙烯微孔膜组成，也可以是以圆筒布为基布层的1-3层材料组成，这由过滤介质、过滤时的工况条件及对过滤的不同要求来确定。一般情况下，以液体为过滤介质，常温及低温工况条件下的过滤及分离，可以以涤纶长丝为材料，一层涤纶圆筒布及以涤纶圆筒布为基布层复合非织造布的两层圆筒过滤袋。
上述复合过程具体如下：
a)将活动套筒调整到所需要的直径，将第一非织造布卷绕在活动套筒上，卷绕11/3圈，与活动套筒成30°角，从左到右剪成斜接口，采用超声波焊接将斜接口处上、下两层非织造布焊接在一起，形成非织造布圆筒；
b)将圆筒布套在非织造布筒的外层，非织造布筒的长度要比圆筒布长50-500mm，调整活动套筒到所需直径，使非织造布层和圆筒布紧绷在活动套筒上，非织造布筒的两端30-50mm翻盖在圆筒布两端外层，放平整后用超声波焊接机将非织造布和圆筒布焊接牢固；
c)将第二非织造布套在圆筒布外层，使第二非织造布两端分别比圆筒布长20-50mm，调大活动套筒直径到所需直径，卷绕11/3圈，与套筒成30°角，从左到右将非织造布裁剪成斜接口，采用超声波焊接机将斜接口处上、下两层非织造布焊接在一起，使布面平整；
d)聚四氟乙烯微孔膜卷绕在第二非织造布外层，卷绕11/3圈，在11/3圈处与活动套筒成30°角方向，从左将聚四氟乙烯微孔膜剪成斜接口，用超声波焊接斜接口处上、下两层聚四氟乙烯微孔膜；
e)将圆筒布从活动套筒上取下，将露在两端的聚四氟乙烯微孔膜及第二非织造布折叠到圆筒布的里层，整理平整，用超声波焊接机将圆筒布两端多层材料焊接牢固。
袋身的多层材料也可以用焊接机通过点状粘接在一起。
优选当非织造布在活动套筒上卷绕11/3圈时，不是在与轴平行的方向从左到右剪断，而是在与主轴呈一个锐角的方向从左到右进行裁剪，并用超声波焊接机将上、下两层材料焊接粘牢。此方式使得滤袋强度明显增加。
上述采用的用于多层复合加固无缝圆筒过滤袋的活动套筒，包括主轴、固定在主轴上的伸缩曲杆，以及与多根伸缩曲杆连接的弧形活动板；所述同轴度方向上的伸缩曲杆连接同一块弧形活动板；所述主轴两端设有支架，主轴与支架之间设有滑轮；所述主轴还与马达相连接。
优选主轴上设有限位开关，主轴可在限位开关和滑轮的带动下沿轴向移动。
优选若干弧形活动板通过伸缩曲杆环绕在主轴的同一切面上。伸缩曲杆为折叠伸缩结构。环绕主轴的切面设置曲杆，每个切面均匀设有曲杆8-12根。沿主轴方向均匀设置3-6个切面的曲杆。弧形活动板板厚10-30mm，宽30-60mm。
工作过程如下：伸缩曲杆、弧形活动板、主轴、支架以及马达进行配合，完成活动套筒对圆筒布及非织造布层紧绷贴合工作。弧形活动板通过伸缩曲杆环绕连接在主轴切面一圈，在马达的驱动下，主轴沿轴向进行来回移动，从而带动伸缩曲杆以及弧形活动板的运动，使活动套筒的直径产生大小变化。圆筒布在活动套筒直径变化动作中，实现紧绷贴合工作。主轴上设有限位开关，主轴可在限位开关和滑轮的带动下进行轴向运动。马达与主轴一端相连接，驱动主轴在限位开关、支架以及滑轮的支持下进行移动。在主轴移动过程中，与主轴相连接的伸缩曲杆能进行可控的来回折叠动作，带动弧形活动板组成的套筒直径增大或缩小。伸缩曲杆为折叠伸缩结构。若干弧形活动板通过伸缩曲杆环绕在主轴的同一切面上。环绕主轴的切面均匀设有伸缩曲杆，且沿着主轴方向均匀设置3-6个切面的曲杆。在弧形活动板上套有圆筒布，圆筒布在弧形活动板的运动下与多层非织造布层紧绷贴合。
最优选活动套筒结构如下：活动套筒由中心轴、固定在中心轴上的伸缩曲杆，以及多根曲杆连接的活动板，及调节伸缩的限位开关等组成。中心轴的中间位置有3组曲杆，每组曲杆均匀分布在中心轴圆周方向的10根伸缩曲杆，同一方位的三个位置的伸缩曲杆的另一端固定有一块狭长的弧形板，10块弧形板通过轴的水平方向位置的变化形成直径大小不一的圆周状，以方便多层复合材料的复合加固操作。弧形板材质可以为氟树脂，板厚15mm，宽45mm。根据用户对圆筒滤袋直径、长度的要求可以有3500mm、4500mm、5000mm、6000mm、8000mm等系列长度活动套筒，可任意收放的直径范围为150mm-350mm。采用本活动套筒能避免因滤袋缝线原因所造成的破损，撕裂现象的发生，彻底解决了因水刺和针刺所造成的对滤袋纤维和基布的损伤致使滤料强力下降的困扰，尤其是对纬向纤维的破坏。对滤袋横向强力的损失率减少30％以上。
与现有技术比较本发明的有益效果：本发明以高技术纤维、合成纤维及无机纤维为原材料织成圆筒布，使粉尘、颗粒物、杂质和空气、液体等介质有效过滤或分离。以圆筒布作为滤袋里层制作的过滤袋是无缝的，可防止滤袋开裂，延长其使用寿命；本发明采用了适合用于复合加固的可收放系列活动套筒，使得圆筒布和非织造布、聚四氟乙烯微孔膜等几层材料的复合加固过程采用对纤维和织物无损伤的加工工艺，对滤袋强力无影响，显著节约材料成本。
按本发明制造工艺所制得的滤袋克服了按照现有技术制得滤袋的缺陷，避免因滤袋缝线原因所造成的破损，撕裂现象的发生，彻底解决了因水刺和针刺所造成的对滤袋纤维和基布的损伤致使滤料强力下降的困扰，尤其是对纬向纤维的破坏，特别是减少了对滤袋横向强力的损失在30％以上。提高了环保滤料的产品质量和使用寿命，本发明的产业化将彻底改变现有滤料行业的生产方式。
附图说明
以下结合附图对本发明的具体实施例作详细说明。
图1是本发明圆筒滤袋的结构示意图。
图中：9、第一非织造布，10、圆筒布，11、第二非织造布、12、聚四氟乙烯微孔膜。
图2示出了活动套筒结构示意图。
图3示出了活动套筒的截面方向结构示意图。
图4示出了非织造布裁剪成斜接口的示意图。
图中：1、伸缩曲杆；2、弧形活动板；3、主轴；4、限位开关；5、支架；6、马达；7、滑轮；8、裁剪成斜接口的非织造布。
具体实施方式
以下通过具体实施例对本发明进行作进一步的解释说明：
实施例1
本实施例所制备的圆筒滤袋适用于瞬时温度300℃，长时间过滤温度280℃左右的工况条件下使用。
采用浙江石金玄武岩纤维有限公司生产的1350D玄武岩纤维膨体纱，在德国STOLL公司生产的CMS530HP35.2横机上织造圆筒布，速度1.3m/min，该款机型是在CMS530HP35.1型电脑横机的基础上，将纱架的筒子架间距放大到350mm，以适应采用大卷装丝筒需要。
编织时，为减少玄武岩纱在经过沉降片和齿口片时，纱线因摩擦出现毛刺现象，预先在纱筒上喷洒硅油，并用塑料袋密封4-5小时，使硅油渗透到内层纤维表面，在纱线经过的通道预先进行打蜡处理。圆筒布直径150mm，重量100g/㎡，用2.5Dtex×28mm玄武岩短切纤维在郑州纺织机械有限公司生产的梳理机上进行梳理，交叉铺网成90g/㎡纤维网，在常规复合机上用雕花镀铬辊筒经浸轧粘合剂液，在压力下进行热粘合得到第一非织造布。镀铬辊筒上用激光雕刻而成的雨滴状图案，雨滴状激光点深2mm，直径2mm，间距3mm，采用由太尔胶粘剂(广东)有限公司生产的生物基胶粘剂，复合机温度85℃，车速35m/min。
同样用3.5tex×28mm的玄武岩短切纤维为材料，经梳理、交叉铺网成150g/㎡的纤维网，在复合机上进行浆点粘合得到第二非织造布，采用的雕花辊筒，雨滴状激光点深2.5mm，直径2mm，间距2.5mm，采用太尔胶粘剂(广东)有限公司生产的低甲醛耐高温粘合剂7841A，复合机温度85℃，车速30m/min。
选用长度为4500mm的活动套筒，限位开关将活动套筒直径设定为250mm，将克重为90g/㎡的第一非织造布绕在上述套筒上，卷绕11/3圈，第一非织造布与套筒成30°角，用德国KRETZER公司生产的特种纤维剪刀从左到右剪成一个斜接口，沿斜接口将两层非织造布用深圳恒力信超声波设备有限公司生产的超声波焊接机将斜接口处上、下两层非织造布焊接在一起，焊接成圆筒型非织造布，通过限位开关缩小活动套筒直径，取长度为4000mm的织造好的玄武岩圆筒布套在套筒非织造布外层，两端露出各250mm的非织造布。
套好圆筒布后使其布面平整，将活动套筒直径恢复到250mm，使非织造布层和圆筒布紧绷在活动套筒上，布面平整，非织造布筒的两端30-50mm翻盖在圆筒布两端外层，放平整后用超声波焊接机将非织造布和圆筒布焊接牢固。
将长度为4500mm，重量为150g/㎡的第二非织造布卷绕在活动套筒上的圆筒布外层，使较外层的非织造布两端分别比圆筒布长30mm，调大活动套筒直径到所需直径，使布面平整无绉痕；卷绕11/3圈后，从左到右，沿30°角剪成斜接口，沿斜接口将非织造布之间用超声波焊接机焊接粘牢。
根据同样的原理，将宽度为4500mm，孔径为70nm，厚度为0.03mm的聚四氟乙烯膜卷绕在非织造布的外层，卷绕11/3圈，在11/3圈处与套筒成30°角方向，从左将聚四氟乙烯微孔膜剪成斜接口，聚四氟乙烯微孔膜的宽度要较圆筒布层宽50-100mm。稍微缩小活动套筒直径，将圆筒布从活动套筒上取下，将露出在圆筒布两端的第二非织造布和聚四氟乙烯微孔膜折叠到圆筒内层，整理平整，使用超声波焊接机将多层材料焊接牢固。
圆筒滤袋规格及性能测试指标：
圆筒滤袋直径250mm，厚度2.1mm，长度4000mm，克重540g/㎡，断裂强度(N/5cm)经向1150，纬向900，断裂伸长率(％)经向8，纬向15，透气量(L/d㎡.min)68.1，过滤效率(％)99.9。
实施例2
本实施例所制成的圆筒滤袋适用于过滤温度230℃的工况条件下使用。
采用上海灵氟隆新材料科技有限公司生产的450D聚四氟乙烯长丝，在赛奥机械(广州)有限公司生产的WYZ-751×4圆织机上织造圆筒布，该款机型号是在WYZ-750×4型圆织机的基础上，筒子架纱锭扩容到800锭，筒间距增大到450mm，以适应采用大卷装丝筒，大容量织造的需要。织造前，先将长丝筒集中堆放，用浓度为10％硅油乳液喷洒，并用塑料布整体封盖，处理5hr，以利硅油渗透到内层纤维表面，防止长丝因摩擦出现起毛现象。圆筒布直径300mm，重量170g/㎡。编织时，在纱线经过的通道预先进行打蜡处理。
采用上海灵氟隆新材料科技有限公司生产的平均密度3.5Dtex×38mm聚四氟乙烯短纤在郑州纺织机械有限公司生产的梳理机上进行梳理，交叉铺网成多层纤维网，在常规复合机上用雕花镀铬辊筒经浸轧粘合剂液，在压力下进行热粘合，形成克重为90g/㎡的第一非织造布。镀铬辊筒上用激光雕刻而成的雨滴状图案，雨滴状激光点深2mm，直径2mm，间距3mm，粘合剂由太尔胶粘剂(广东)有限公司生产生物基胶粘剂，复合机温度85℃，车速35m/min。
同样采用3.5Dtex×38mm聚四氟乙烯短纤维为材料，经梳理、交叉铺网成150g/㎡的第二非织造布，在复合机上进行浆点粘合，采用的雕花辊筒，雨滴状激光点深2.5mm，直径2mm，间距2.5mm，采用太尔胶粘剂(广东)有限公司生产的低甲醛耐高温粘合剂7841A，复合机温度85℃，车速30m/min。
选用长度为4500mm的活动套筒，限位开关将活动套筒直径设定为300mm，将克重为90g/㎡的第一非织造布绕在上述套筒上，卷绕11/3圈，第一非织造布与套筒成30°角，用德国KRETZER特种纤维剪刀从左到右剪成一个斜接口。沿斜接口将两层非织造布用深圳恒力信超声波设备有限公司生产的超声波焊接机焊接成圆筒形非织造布，稍微缩小活动套筒直径，取长度为4000mm，直径为300mm已织造好的聚四氟乙烯圆筒布套在套筒非织造布中间位置，两端露出各250mm的非织造布。
套好圆筒布后，将活动套筒直径恢复到300mm，使非织造布层和圆筒布紧绷在活动套筒上，布面平整，将两端30-50mm的非织造布沿圆筒布端口翻到圆筒布上，放平整后用超声波焊接机将非织造布和圆筒布焊接牢固。
将长度为4500mm，150g/㎡的第二非织造布卷绕在活动套筒上的圆筒布外层，使较外层的非织造布两端分别比圆筒布长30mm，调大活动套筒直径到所需直径，使布面平整无绉痕；卷绕11/3圈后，从左到右，沿30°角剪成斜接口，沿斜接口将非织造布之间用超声波焊接机焊接粘牢。
将宽4500mm，孔径为70nm，厚度为0.03mm的聚四氟乙烯膜卷绕在非织造布的外层，卷绕11/3圈，在11/3圈处与套筒30°角方向，从左将聚四氟乙烯微孔膜剪成斜接口，用超声波焊接机将斜接口处两层聚四氟乙烯膜焊接牢固。稍微缩小活动套筒直径，将露出在圆筒布两端的第二非织造布和聚四氟乙烯微孔膜一起翻到圆筒的里面，铺平整后，从里面到外面将圆筒布两端的多层材料用超声波焊接机焊接牢固。
袋身的多层材料也用超声波焊接机通过点状粘接在一起。
圆筒滤袋规格及性能测试指标：
圆筒滤袋直径300mm，厚度2.6mm，长度4000mm，克重430g/㎡，断裂强度(N/5cm)经向1200，纬向950，断裂伸长率(％)经向11，纬向14，透气量(L/d㎡.min)78.3，过滤效率(％)99.9。
实施例3
本实施例所制成的圆筒滤袋适用于过滤温度230℃的工况条件下使用。
采用上海灵氟隆新材料科技有限公司生产的聚酰亚胺长丝1500D，在赛奥机械(广州)有限公司生产的WYZ-751×4圆织机上织造圆筒布，该款机型号是在WYZ-750×4型圆织机的基础上，筒子架纱锭扩容到800锭，筒间距增大到450mm，以适应采用大卷装丝筒，大容量织造的需要。织造前，先将长丝筒集中堆放，用浓度为10％硅油乳液喷洒，并用塑料布整体封盖，处理5hr，以利硅油渗透到内层纤维表面，防止长丝因摩擦出现起毛现象。圆筒布直径300mm，重量165g/㎡。编织时，在纱线经过的通道预先进行打蜡处理。
采用上海灵氟隆新材料科技有限公司生产的平均密度2.5Dtex×38mm聚酰亚胺短纤在郑州纺织机械有限公司生产的梳理机上进行梳理，交叉铺网成多层纤维网，在常规复合机上用雕花镀铬辊筒经浸轧粘合剂液，在压力下进行热粘合，形成克重为90g/㎡的第一非织造布。镀铬辊筒上用激光雕刻而成的雨滴状图案，雨滴状激光点深2mm，直径2mm，间距3mm，粘合剂由太尔胶粘剂(广东)有限公司生产生物基胶粘剂，复合机温度80℃，车速35m/min。
同样采用聚酰亚胺短纤2.5Dtex×38mm为材料，经梳理、交叉铺网成150g/㎡的第二非织造布，在复合机上进行浆点粘合，采用的雕花辊筒，雨滴状激光点深2.5mm，直径2mm，间距2.5mm，采用太尔胶粘剂(广东)有限公司生产的低甲醛耐高温粘合剂7841A，复合机温度80℃，车速30m/min。
选用长度为4500mm的活动套筒，限位开关将活动套筒直径设定为300mm，将克重为90g/㎡的第一非织造布绕在上述套筒上卷绕11/3圈，第一非织造布与套筒成30°角，，用德国KRETZER特种纤维剪刀从左到右剪成一个斜接口。沿斜接口将两层非织造布用深圳恒力信超声波设备有限公司生产的超声波焊接机焊接成圆筒形非织造布，稍微缩小活动套筒直径，取长度为4000mm，直径为300mm已织造好的圆筒布套在套筒非织造布中间位置，两端露出各250mm的非织造布。
套好圆筒布后，将活动套筒直径恢复到300mm，使非织造布层和圆筒布紧绷在活动套筒上，布面平整，将两端30-50mm的非织造布沿圆筒布端口翻到圆筒布上，放平整后用超声波焊接机将非织造布和圆筒布焊接牢固。
将长度为4500mm，150g/㎡的第二非织造布卷绕在活动套筒上的圆筒布外层，使较外层的非织造布两端分别比圆筒布长30mm，调大活动套筒直径到所需直径，使布面平整无绉痕；卷绕11/3圈后，从左到右，沿30°角剪成斜接口，沿斜接口将非织造布之间用超声波焊接机焊接粘牢。
将宽4500mm，孔径为70nm，厚度为0.03mm的聚四氟乙烯膜卷绕在非织造布的外层，卷绕11/3圈，在11/3圈处与套筒30°角方向，从左将聚四氟乙烯微孔膜剪成斜接口，用超声波焊接机将斜接口处两层聚四氟乙烯膜焊接牢固。稍微缩小活动套筒直径，将露出在圆筒布两端的第二非织造布和聚四氟乙烯微孔膜一起翻到圆筒的里面，铺平整后，从里面到外面将圆筒布两端的多层材料用超声波焊接机焊接牢固。
袋身的多层材料也用超声波焊接机通过点状粘接在一起。
圆筒滤袋规格及性能测试指标：
圆筒滤袋直径300mm，厚度2.5mm，长度4000mm，克重430g/㎡，断裂强度(N/5cm)经向1050，纬向850，断裂伸长率(％)经向10，纬向12，透气量(L/d㎡.min)79.2，过滤效率(％)99.9。
实施例4
实施例1-3使用的活动套筒结构如图2-3，包括主轴3、固定在主轴上的伸缩曲杆1，以及与多根伸缩曲杆1连接的弧形活动板2；所述同轴度方向上的伸缩曲杆1连接同一块弧形活动板2；所述主轴3两端设有支架5，主轴3与支架5之间设有滑轮7；所述主轴3还与马达6相连接。主轴3上设有限位开关4，主轴3可在限位开关4和滑轮7的带动下沿轴向移动。若干弧形活动板2通过伸缩曲杆1环绕在主轴的同一切面上。伸缩曲杆1为折叠伸缩结构。环绕主轴3的切面设置伸缩曲杆1，每个切面均匀设有伸缩曲杆8-12根。沿主轴方向均匀设置3-6个切面的伸缩曲杆1。弧形活动板2板厚10-30mm，宽30-60mm。
本活动套筒采用多块弧形活动板，活动板由伸缩曲杆带动，方便套在活动套筒上的圆筒形材料套上去或退出来。伸缩曲杆连接在主轴上，主轴由马达驱动，主轴上装有限位开关，主轴通过滑轮固定在支架上。随着主轴的左右移动，带动由活动板组成的套筒直径增大或缩小。

Claims (10)

1.一种无缝圆筒过滤袋，其特征在于该无缝圆筒过滤袋由内向外依次由第一非织造布(9)、圆筒布(10)、第二非织造布(11)和聚四氟乙烯微孔膜(12)复合而成；其中，圆筒布的织造是在圆织机上采用机织方法织造或者在电脑横机上用针织的方法编织而成。
2.根据权利要求1所述的无缝圆筒过滤袋，其特征在于所述的复合是将滤袋两端用超声波焊接机通过热能粘结成一体，或用超声波焊接机通过热能粘结两端袋口，同时袋身的多层材料焊接机通过点状粘接在一起。
3.一种权利要求1或2所述的无缝圆筒过滤袋的制备方法，其特征在于该方法包括以下步骤：纤维A通过圆织机或电脑横机织造成圆筒布；纤维B采用纺粘的方法一次成型或经混合、梳理成单层纤维网，单层纤维网经交叉铺网成多层纤维网，多层纤网在复合机上进行粉点或浆点粘合成非织造布或者采用超声波焊接机通过热能使多层纤维网粘合成非织造布；将圆筒布和非织造布与聚四氟乙烯微孔膜复合成圆筒滤袋；其中，纤维A和纤维B相同或不同。
4.根据权利要求3所述的无缝圆筒过滤袋的制备方法，其特征在于进行圆筒布的织造采用的纤维为高技术纤维、合成纤维或无机纤维中的一种或多种纤维混合、混织。
5.根据权利要求4所述的无缝圆筒过滤袋的制备方法，其特征在于所述的高技术纤维、合成纤维或无机纤维采用纤度为150dtex-2500dtex的长丝或1.5Dtex—10Dtex的短纤维。
6.根据权利要求3或4所述的无缝圆筒过滤袋的制备方法，其特征在于所述的高技术纤维为聚苯硫醚长丝或短纤、聚酰亚胺长丝或短纤、芳纶长丝或短纤、石墨烯长丝或短纤；无机纤维为聚四氟乙烯长丝或短纤、无碱或有碱玻纤，玄武岩膨体纱或交拼纱线。
7.根据权利要求3所述的无缝圆筒过滤袋的制备方法，其特征在于所述的非织造布具体制备方法如下：切片通过熔融、纺丝、热粘合制成纺粘非织造布；或采用超细纤维经铺网、梳理成多层纤网；或用高技术纤维短纤单一品种或多品种纤维，经梳理、铺网成多层纤网，将上述纤网在复合机上采用耐高温粘合剂，用雕刻辊筒，以粉点式或浆点的方法，使粘合剂将多层纤维网粘合成非织造布，非织造布的重量范围在30g/㎡-450g/㎡。
8.根据权利要求3所述的无缝圆筒过滤袋的制备方法，其特征在于所述的复合过程具体如下：
a)将活动套筒调整到所需要的直径，将第一非织造布卷绕在活动套筒上，卷绕11/3圈，与套筒成30°角，从左到右剪成斜接口，采用超声波焊接将斜接口处上、下两层非织造布焊接在一起，形成非织造布圆筒；
b)将圆筒布套在非织造布筒的外层，非织造布筒的长度要比圆筒布长50-500mm，调整活动套筒到所需直径，使非织造布层和圆筒布紧绷在活动套筒上，非织造布筒的两端30-50mm翻盖在圆筒布两端外层，放平整后用超声波焊接机将非织造布和圆筒布焊接牢固；
c)将第二非织造布套在圆筒布外层，使第二非织造布两端分别比圆筒布长20-50mm，调大活动套筒直径到所需直径，卷绕11/3圈，与套筒成30°角，从左到右将非织造布裁剪成斜接口，采用超声波焊接机将斜接口处上、下两层非织造布焊接在一起；
d)聚四氟乙烯微孔膜卷绕在第二非织造布外层，卷绕11/3圈，在11/3圈处与套筒成300角方向，从左将聚四氟乙烯微孔膜剪成斜接口，用超声波焊接斜接口处上、下两层聚四氟乙烯微孔膜；
e)将圆筒布从活动套筒上取下，将露在两端的聚四氟乙烯微孔膜及第二非织造布折叠到圆筒布的里层，整理平整，用超声波焊接机将圆筒布两端多层材料焊接牢固。
9.根据权利要求8所述的无缝圆筒过滤袋的制备方法，其特征在于所述的活动套筒结构如下：包括主轴(3)、固定在主轴上的伸缩曲杆(1)，以及与多根伸缩曲杆(1)连接的弧形活动板(2)；所述同轴度方向上的伸缩曲杆(1)连接同一块弧形活动板(2)；所述主轴(3)两端设有支架(5)，主轴(3)与支架(5)之间设有滑轮(7)；所述主轴(3)还与马达(6)相连接。
10.根据权利要求9所述的无缝圆筒过滤袋的制备方法，其特征在于所述的主轴(3)上设有限位开关(4)，主轴(3)可在限位开关(4)和滑轮(7)的带动下沿轴向移动。
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