CN112389050B - 一种夹碳布复合材料 - Google Patents

一种夹碳布复合材料 Download PDF

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CN112389050B
CN112389050B CN202011173368.XA CN202011173368A CN112389050B CN 112389050 B CN112389050 B CN 112389050B CN 202011173368 A CN202011173368 A CN 202011173368A CN 112389050 B CN112389050 B CN 112389050B
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activated carbon
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邵丹
柳海涛
孟彩霞
王桂霞
边军
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Railway police college
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B33/00—Layered products characterised by particular properties or particular surface features, e.g. particular surface coatings; Layered products designed for particular purposes not covered by another single class
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B9/00—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00
    • B32B9/04—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B9/047—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising such particular substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material made of fibres or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0253—Polyolefin fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B32B2264/107—Ceramic
    • B32B2264/108—Carbon, e.g. graphite particles

Abstract

本发明公开了一种夹碳布复合材料，包括上、下无纺布面层，在上、下无纺布面层之间依次设置有第一纤维胶丝层、第一活性碳颗粒层、第二纤维胶丝层、双组分复合纤维丝层、第三纤维胶丝层、第二活性碳颗粒层、第四纤维胶丝层；采用热辊轧机压制时，首先将活性碳颗粒预热到150~160℃再进行铺撒；加热辊和压制辊的温度要达到双组分复合纤维丝外层和纤维胶丝层的熔化温度；压制成型的成品夹碳布复合材料的厚度为5mm±0.5mm。与现有的夹碳布复合材料相比，本发明生产的夹碳布复合材料具有优异的过滤、防毒、防有害气体性能，适合作为空气过滤材料，尤其适用于制作过滤网和洁净室材料，具有重量轻、透气性好，防毒时间长等优点。

Description

一种夹碳布复合材料
技术领域
本发明涉及环保材料，尤其是涉及一种过滤性能优异的夹碳布复合材料。
背景技术
夹碳布复合材料作为一种安全环保的空滤材料，广泛应用于空调、汽车空调滤清器、空气净化器滤芯及工业设备的空气过滤器滤芯等领域。目前常见的夹碳布复合材料多是在两层热熔胶层之间设置一层活性炭，或者如专利文献《夹碳布复合材料》（CN200994436Y）中所述的两层纺织面料层中间设置一层活性炭热熔胶层，由于活性炭被紧紧包裹在热熔胶层之间，限制了活性炭的活性，而且这种夹碳布中的含炭量太小，仅能做到200g/m2，且胶水与表面层之间透气性差，严重影响了夹碳布的吸附净化功能。
发明内容
本发明的目的在于提供一种透气性好、过滤功能强的夹碳布复合材料。
为实现上述目的，本发明可采取下述技术方案：
本发明所述的夹碳布复合材料，包括上、下无纺布面层，在所述上、下无纺布面层之间依次设置有第一纤维胶丝层、第一活性碳颗粒层、第二纤维胶丝层、双组分复合纤维丝层、第三纤维胶丝层、第二活性碳颗粒层、第四纤维胶丝层；
采用热辊轧机压制时，首先将活性碳颗粒预热到150~160℃再进行铺撒；加热辊和压制辊的温度要达到双组分复合纤维丝外层和纤维胶丝层的熔化温度；压制成型的成品夹碳布复合材料的厚度为5mm±0.5mm。
所述双组分复合纤维丝由内芯和外皮组成，其中内芯为高熔点材料（如PP），外皮为低熔点材料（如PE）。
所述第一纤维胶丝层、第二纤维胶丝层、第三纤维胶丝层和第四纤维胶丝层的熔点与双组分复合纤维丝外皮的熔点相同。
为减少用胶量，避免碳颗粒被胶覆盖，所述第一纤维胶丝层、第二纤维胶丝层、第三纤维胶丝层和第四纤维胶丝层的纤维胶丝使用量为10~100g/m2。
所述活性碳颗粒的粒度为0.3mm~0.6mm。
所述第一活性碳颗粒层和第二活性碳颗粒层铺设的厚度为1~2mm。
本发明的优点在于创造性的利用了双组份复合纤维丝内芯和外皮熔点不同的特性，将其作为本申请夹碳布复合材料的中心骨架，在一定温度下，外皮熔化并和碳颗粒进行粘连，但是内芯仍然能起到很好的支撑作用，保证成品夹碳布复合材料的形状不会塌陷；同时，本申请采用纤维胶丝来替代常规夹碳布复合材料中的热熔胶层对碳颗粒进行粘固，减少了用胶量，大大提高了复合材料的滤效和透气性。
与现有的夹碳布复合材料相比，本发明生产的夹碳布复合材料具有优异的过滤、防毒、防有害气体性能，适合作为空气过滤材料，尤其适用于制作过滤网和洁净室材料，具有重量轻、透气性好，防毒时间长等优点。
附图说明
图1为本发明复合材料的断面结构示意图。
图2为图1中双组分复合纤维丝层中复合纤维的断面放大图。
具体实施方式
下面结合附图对本发明做更加详细的说明，以便于本领域技术人员的理解。
需要说明的是，在本发明的描述中，术语“上”、“下”等指示的方位或位置关系为基于附图所示的方位或位置关系，仅是为了便于描述，而不能理解为对本发明的限制。
如图1所示，本发明所述的夹碳布复合材料，是由热辊轧机压制而成的九层结构，该复合材料自下而上依次为下无纺布面层1，第一纤维胶丝层2，第一活性碳颗粒层3，第二纤维胶丝层4，双组分复合纤维丝层5，第三纤维胶丝层6，第二活性碳颗粒层7，第四纤维胶丝层8和上无纺布面层9；
实际制造时：
上无纺布面层9和下无纺布面层1优选PP材料织物，熔点为160℃；
双组分复合纤维丝层5的复合纤维丝由内芯501和外皮502组成，如图2所示；其中内芯为高熔点材料（如PP），熔点160℃；外皮为低熔点材料（如PE），熔点130℃；
第一纤维胶丝层2、第二纤维胶丝层4、第三纤维胶丝层6和第四纤维胶丝层8优选采用PE纤维胶丝，其熔点与双组分复合纤维丝外皮的熔点相同（130℃）。
为减少用胶量，避免碳颗粒被胶覆盖，第一纤维胶丝层2、第二纤维胶丝层4、第三纤维胶丝层6和第四纤维胶丝层8各层的纤维胶丝用量为10~100g/m2，使用时，可以根据具体情况在该范围内进行适当调整：如可以将靠近双组分复合纤维丝层5的第二纤维胶丝层4和第三纤维胶丝层6所用的纤维胶丝用量减少，在保证碳颗粒粘结牢固的前提下，减少了用胶量，降低了生产成本。
本发明第一活性碳颗粒层3和第二活性碳颗粒层7所用的碳颗粒的粒度为0.3mm~0.6mm，其铺撒厚度要小于两层碳颗粒的粒径（0.6~1.2mm），考虑到衬底材料的蓬松性，优选厚度为1~2mm；
本发明夹碳布复合材料采用热辊轧机压制成型。
为避免碳颗粒不能很好的和纤维胶丝进行粘合，需要将活性碳颗粒预热到150~160℃再进行铺撒；为提高工效和铺撒的均匀度，可采用两组雕刻辊转运撒碳，以满足大克重的要求。
轧制时，热辊轧机的加热辊和压制辊的温度要达到双组分复合纤维丝外层熔化温度（130℃），保证双组分复合纤维丝层的外层是熔化状态而内芯为非熔化状态，同时纤维胶丝的胶层也处于熔化状态；热辊轧机采用连续滚动模式，瞬时压制，使碳颗粒和纤维胶丝牢固的粘合在一起；压制成型的成品夹碳布复合材料的厚度为5mm左右。
本发明制备的成品夹碳布复合材料经测量，其性能参数如下：
含碳量960g-1000g/m2，风阻小于30Pa，碳颗粒表面被PE材料热熔堵塞率小于10%。采用微差压计测量风阻压损。
将现有奥迪汽车（A6L车型）空调滤芯用夹碳布复合材料作为对比，采用同样的测试方法，其含碳量为300g/ m2，风阻110Pa，碳颗粒表面被PE材料热熔堵塞率55%。
通过上述对比可以看出，本发明制造的九层夹碳布复合材料含碳量远高于现有产品，透气性好，吸附净化效果更为突出。

Claims (4)

1.一种夹碳布复合材料，包括上、下无纺布面层，其特征在于：在所述上、下无纺布面层之间依次设置有第一纤维胶丝层、第一活性碳颗粒层、第二纤维胶丝层、双组分复合纤维丝层、第三纤维胶丝层、第二活性碳颗粒层、第四纤维胶丝层；
所述双组分复合纤维丝由内芯和外皮组成，内芯为高熔点材料，外皮为低熔点材料；
所述第一纤维胶丝层、第二纤维胶丝层、第三纤维胶丝层和第四纤维胶丝层的熔点与双组分复合纤维丝外皮的熔点相同；
采用热辊轧机压制时，首先将活性碳颗粒预热到150～160℃再进行铺撒；加热辊和压制辊的温度要达到双组分复合纤维丝外层和纤维胶丝层的熔化温度；压制成型的成品夹碳布复合材料的厚度为5mm±0.5mm。
2.根据权利要求1所述的夹碳布复合材料，其特征在于：所述第一纤维胶丝层、第二纤维胶丝层、第三纤维胶丝层和第四纤维胶丝层的纤维胶丝使用量为10～100g/ m2。
3.根据权利要求1所述的夹碳布复合材料，其特征在于：所述活性碳颗粒的粒度为0.3mm～0.6mm。
4.根据权利要求1所述的夹碳布复合材料，其特征在于：所述第一活性碳颗粒层和第二活性碳颗粒层铺设的厚度为1～2mm。
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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1943841A (zh) * 2006-09-23 2007-04-11 张连墩 夹炭无纺布过滤材料
CN106048777A (zh) * 2016-07-18 2016-10-26 无锡盛纤特邦工业材料有限公司 一种多用途皮芯复合单丝及其生产方法、应用
CN106794403A (zh) * 2014-07-21 2017-05-31 韩国生产技术研究院 除臭用过滤材料及利用其的除臭防尘复合过滤器

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN1943841A (zh) * 2006-09-23 2007-04-11 张连墩 夹炭无纺布过滤材料
CN106794403A (zh) * 2014-07-21 2017-05-31 韩国生产技术研究院 除臭用过滤材料及利用其的除臭防尘复合过滤器
CN106048777A (zh) * 2016-07-18 2016-10-26 无锡盛纤特邦工业材料有限公司 一种多用途皮芯复合单丝及其生产方法、应用

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