CN112546735B - 一种梯度滤料用熔喷-针刺复合制备方法及制得的梯度针刺毡 - Google Patents

一种梯度滤料用熔喷-针刺复合制备方法及制得的梯度针刺毡 Download PDF

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CN112546735B
CN112546735B CN202011261822.7A CN202011261822A CN112546735B CN 112546735 B CN112546735 B CN 112546735B CN 202011261822 A CN202011261822 A CN 202011261822A CN 112546735 B CN112546735 B CN 112546735B
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杨东
胡呈杰
周冠辰
聂孙建
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Anhui Yuanchen Environmental Protection Science and Technology Co Ltd
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Abstract

本发明公开一种梯度滤料用熔喷‑针刺复合制备方法，涉及滤料加工技术领域，基于现有的超细梯度滤料性能较差，过滤精度不高的问题而提出的。本发明的梯度滤料包括依次连接的背尘层、支撑层、迎尘层和熔喷致密层，将熔喷纺丝成布的方法结合针刺成毡工艺，特别在针刺成毡的预刺机之后增加一套熔喷设备，以普通三层滤料为基材，熔喷一层的超细纤维均匀地喷洒在滤料表面，形成梯度滤料一次性成型工艺，同时经过复合针刺进行修面，最后经过烧毛、压光和热定型处理制得梯度针刺毡。本发明还提供上述制备方法制备的梯度梯度针刺毡。本发明制备的梯度滤料性能优异，外观平整，梯度结构明显，形成喇叭状通道，具有过滤精度优、产品质量稳定的特点。

Description

一种梯度滤料用熔喷-针刺复合制备方法及制得的梯度针 刺毡
技术领域
本发明涉及滤料加工技术领域，具体涉及一种梯度滤料用熔喷-针刺复合制备方法制得的梯度针刺毡。
背景技术
目前，除尘滤料的加工方法主要分为机织法和针刺法两大类。机织法生产滤料主要是用各种纤维长丝或纱线，按照工艺设定的组织结构织成布料，其主要是平纹、斜纹和锻纹织物用于固液分离和气固分离，机织料大部分用在液固分离上，一少部分用于工业炉窑尾气治理；针刺法生产滤料主要是用平纹机织布做基布，将纤维用机械梳理成网，铺在基布两侧，通过针刺机刺针上下反复穿刺，使纤网和基布加固，牢固结合在一起再经过后处理，生产成针刺滤料，针刺滤料主要用于工业炉窑尾气排放治理
高密面层、超密面层、梯度滤料、非对称滤料等是目前市场上流行的滤料，其结构基本相似，即在滤料表面采用直径较细的纤维加工成相对致密的迎尘纤维层，滤料由于本身表面致密或粉尘积累后形成致密尘饼使得后续的粉尘难以进入内部，具有较好的清灰性能。产品检测发现，滤料企业或是为了降低成本、或设备不具备，实际上是把细纤维与粗纤维，简单在投料区混在一起进行铺网，并非由纯超细纤维加工而成的致密迎尘层，尚需再提高。CN105771420A公开了一种超细梯度滤料的生产方法，采用熔喷方式生产超细纤维将熔喷产出的超细纤维用纺丝直接成网法制成超细纤维网；将常规纤维采用机械成网方式梳理成纤维毛网；将机织基布放在中间，在基布下方铺设常规纤维毛网；在基布上方铺设常规纤维毛网，并在铺设时将超细纤维网嵌入其中；采用队列重叠方式将基布与各层纤维网加固形成超细梯度滤料。但是，该技术制备的梯度滤料的性能较差，过滤精度不高。
发明内容
本发明解决的技术问题在于提供一种产品性能优异、过滤精度高的梯度滤料用熔喷-针刺复合制备方法。
本发明是采用以下技术方案解决上述技术问题的：
本发明提供一种梯度滤料用熔喷-针刺复合制备方法，所述梯度滤料包括依次连接的背尘层、支撑层、迎尘层和熔喷致密层；
其通过以下方法制备，包括以下步骤：
(1)背尘层的制备：将背尘层原料进行开松后梳理铺网，通过气流成网的方式形成背尘层；
(2)支撑层的制备：将支撑层原料通过经纬向机织加工形成支撑层；
(3)迎尘层的制备：将迎尘层原料进行开松后梳理铺网，通过气流成网的方式形成迎尘层；
(4)采用机械成网方式将背尘层、支撑层、迎尘层三层通过预刺在一起勾连抱合，制得针刺毡基材；
(5)熔喷致密层：将熔喷致密层原料加入到螺杆挤出机挤出，形成熔体细流，熔体细流冷却固化形成初生纤维，再通过上油、牵伸、卷绕、定型、丝束切断形成超细纤维，所述螺杆挤出机有若干个温度不同的区，采用计量泵将熔融得到的熔体送至喷丝组件；依次打开主机、风机及接收网帘，风机的热风进行喷吹，直接将超细纤维均匀地喷洒在步骤(4)中预刺出来的针刺毡基材的表面，再经过主刺在一起勾连抱合，制得梯度滤料粗品；
(6)将步骤(5)中制得的梯度滤料粗品再经过烧毛、压光和热定型处理制得梯度针刺毡。
本发明将熔喷纺丝成布的方法结合针刺成毡工艺，特别在针刺成毡的预刺机之后增加一套熔喷设备，以普通三层滤料为基材，熔喷一层的超细纤维均匀地喷洒在滤料表面，形成梯度滤料一次性成型工艺，同时经过复合针刺进行修面，制得的梯度滤料具有优异的性能，且外观平整，梯度结构明显，形成喇叭状通道，具有过滤精度优，产品质量稳定。
优选地，所述步骤(1)中背尘层原料包括涤纶纤维、聚丙烯纤维、亚克力中的一种或者几种混合。
优选地，所述步骤(2)中支撑层原料为涤纶长丝基布。
优选地，所述步骤(2)中制得的支撑层的克重为66-87g/m2。
优选地，所述步骤(3)中迎尘层原料包括涤纶纤维、聚丙烯纤维、亚克力中的一种或者几种混合。
优选地，所述步骤(4)中熔喷致密层原料为热塑型纤维聚丙烯。
优选地，所述步骤(5)中喷洒在针刺毡基材的表面的超细纤维克重为25-50g/m2。
优选地，所述螺杆挤出机有4个温度呈递增趋势的区。
优选地，所述螺杆挤出机4个区的温度值分别为：一区温度为172℃，二区温度为180℃，三区温度为210℃，四区温度为216。
本发明还公开了上述制备方法制得的梯度针刺毡。
本发明的有益效果在于：
本发明将熔喷纺丝成布的方法结合针刺成毡工艺，特别在针刺成毡的预刺机之后增加一套熔喷设备，以普通三层滤料为基材，熔喷一层的超细纤维均匀地喷洒在滤料表面，形成梯度滤料一次性成型工艺，同时经过复合针刺进行修面，制得的梯度滤料具有优异的性能，且外观平整，梯度结构明显，形成喇叭状通道，具有过滤精度优，高达99.99％以上，经向强度1196N/5*20mm，纬向强度N/5*20mm，经向断裂伸长率17.2％，纬向断裂伸长率46.9％，产品质量稳定的特点。
附图说明
图1为本发明实施例的制得的梯度针刺毡的结构示意图；
图2为本发明实施例2制得的梯度针刺毡的SEM电镜检测结果图。
具体实施方式
以下将结合说明书附图和实施例对本发明做进一步详细说明。
下述实施例中所用的试验材料和试剂等，如无特殊说明，均可从商业途径获得。
实施例中未注明具体技术或条件者，均可以按照本领域内的文献所描述的技术或条件或者按照产品说明书进行。
实施例1
一种梯度滤料用熔喷-针刺复合制备方法，所述梯度滤料包括依次连接的背尘层、支撑层、迎尘层和熔喷致密层；
其通过以下方法制备，包括以下步骤：
(1)背尘层的制备：将涤纶纤维、聚丙烯纤维、亚克力中按照克重比为1:1:1进行开松后梳理铺网，通过气流成网的方式形成背尘层；
(2)支撑层的制备：采用涤纶纤维，通过经纬向机织加工形成支撑层，控制支撑层的克重为66g/m2；
(3)迎尘层的制备：将涤纶纤维、聚丙烯纤维、亚克力中按照克重比为1:1:1进行开松后梳理铺网，通过气流成网的方式形成迎尘层；
(4)采用机械成网方式将背尘层、支撑层、迎尘层三层通过预刺在一起勾连抱合，制得针刺毡基材；
(5)熔喷致密层：将热塑型纤维聚丙烯加入到螺杆挤出机挤出，形成熔体细流，熔体细流冷却固化形成初生纤维，再通过上油、牵伸、卷绕、定型、丝束切断形成超细纤维，所述螺杆挤出机有若干个温度不同的区，采用计量泵将熔融得到的熔体送至喷丝组件；依次打开主机、风机及接收网帘，风机的热风进行喷吹，直接将超细纤维均匀地喷洒在步骤(4)中预刺出来的针刺毡基材的表面，再经过主刺在一起勾连抱合，制得梯度滤料粗品，控制喷洒在针刺毡基材的表面的超细纤维克重为25g/m2；
(6)将步骤(5)中制得的梯度滤料粗品再经过烧毛、压光和热定型处理制得梯度针刺毡，梯度针刺毡的结构如图1所示。
实施例2
一种梯度滤料用熔喷-针刺复合制备方法，所述梯度滤料包括依次连接的背尘层、支撑层、迎尘层和熔喷致密层；
其通过以下方法制备，包括以下步骤：
(1)背尘层的制备：将涤纶纤维、聚丙烯纤维、亚克力中按照克重比为1:1:1进行开松后梳理铺网，通过气流成网的方式形成背尘层；
(2)支撑层的制备：采用涤纶纤维，通过经纬向机织加工形成支撑层，控制支撑层的克重为66g/m2；
(3)迎尘层的制备：将涤纶纤维、聚丙烯纤维、亚克力中按照克重比为1:1:1进行开松后梳理铺网，通过气流成网的方式形成迎尘层；
(4)采用机械成网方式将背尘层、支撑层、迎尘层三层通过预刺在一起勾连抱合，制得针刺毡基材；
(5)熔喷致密层：将热塑型纤维聚丙烯加入到螺杆挤出机挤出，形成熔体细流，熔体细流冷却固化形成初生纤维，再通过上油、牵伸、卷绕、定型、丝束切断形成超细纤维，所述螺杆挤出机有若干个温度不同的区，采用计量泵将熔融得到的熔体送至喷丝组件；依次打开主机、风机及接收网帘，风机的热风进行喷吹，直接将超细纤维均匀地喷洒在步骤(4)中预刺出来的针刺毡基材的表面，再经过主刺在一起勾连抱合，制得梯度滤料粗品，控制喷洒在针刺毡基材的表面的超细纤维克重为40g/m2；
(6)将步骤(5)中制得的梯度滤料粗品再经过烧毛、压光和热定型处理制得梯度针刺毡。
实施例3
一种梯度滤料用熔喷-针刺复合制备方法，所述梯度滤料包括依次连接的背尘层、支撑层、迎尘层和熔喷致密层；
其通过以下方法制备，包括以下步骤：
(1)背尘层的制备：将涤纶纤维、聚丙烯纤维、亚克力中按照克重比为1:1:1进行开松后梳理铺网，通过气流成网的方式形成背尘层；
(2)支撑层的制备：采用涤纶纤维，通过经纬向机织加工形成支撑层，控制支撑层的克重为66g/m2；
(3)迎尘层的制备：将涤纶纤维、聚丙烯纤维、亚克力中按照克重比为1:1:1进行开松后梳理铺网，通过气流成网的方式形成迎尘层；
(4)采用机械成网方式将背尘层、支撑层、迎尘层三层通过预刺在一起勾连抱合，制得针刺毡基材；
(5)熔喷致密层：将热塑型纤维聚丙烯加入到螺杆挤出机挤出，形成熔体细流，熔体细流冷却固化形成初生纤维，再通过上油、牵伸、卷绕、定型、丝束切断形成超细纤维，所述螺杆挤出机有若干个温度不同的区，采用计量泵将熔融得到的熔体送至喷丝组件；依次打开主机、风机及接收网帘，风机的热风进行喷吹，直接将超细纤维均匀地喷洒在步骤(4)中预刺出来的针刺毡基材的表面，再经过主刺在一起勾连抱合，制得梯度滤料粗品，控制喷洒在针刺毡基材的表面的超细纤维克重为50g/m2；
(6)将步骤(5)中制得的梯度滤料粗品再经过烧毛、压光和热定型处理制得梯度针刺毡。
表1为实施例1-3的熔喷设备的相关参数
Figure BDA0002774886420000071
Figure BDA0002774886420000081
对比例1
本对比例通过购买市面上的国内外同类梯度滤料产品。
实施例4
分别对实施例1-3制备的梯度针刺毡与对比例1中购买的市面上的国内外同类梯度滤料产品的性能进行检测，检测结果如表2所示，可知本发明方法制备的梯度滤料的过滤性能与熔喷致密层的重量相关，初期随着致密层的克重增加，滤料的透气率下降，过滤效率增加幅度大；后期随着致密层的克重增加，滤料的透气率继续下降，但过滤效率增加幅度逐渐变缓并趋于稳定。
表2为实施例1-3和对比例1的梯度滤料产品的性能检测结果
产品 实施例1 实施例2 实施例3 对比例1
克重g/m<sup>2</sup> 543 558 568 542
厚度mm 1.79 1.82 1.83 1.90
经向强度N/5*20mm 1059 1187 1196 973
纬向强度N/5*20mm 2112 2209 2285 1930
经向断裂伸长率％ 17.2 16.4 16.8 17.2
纬向断裂伸长率％ 43.8 43.7 46.9 44.9
透气度m<sup>3</sup>/m<sup>2</sup>·min 11.3 9.6 8.2 14.9
过滤效率％ 99.9627 99.9958 99.9962 99.923
实施例5
将实施例2中制得的梯度针刺毡进行SEM电镜检测，检测结果如图2所示，本发明方法制得的梯度滤料外观平整，梯度结构明显，形成喇叭状通道。
综上所述，本发明将熔喷纺丝成布的方法结合针刺成毡工艺，特别在针刺成毡的预刺机之后增加一套熔喷设备，以普通三层滤料为基材，熔喷一层的超细纤维均匀地喷洒在滤料表面，形成梯度滤料一次性成型工艺，同时经过复合针刺进行修面，制得的梯度滤料具有优异的性能，且外观平整，梯度结构明显，形成喇叭状通道，具有过滤精度优，高达99.99％以上，经向强度1196N/5*20mm，纬向强度N/5*20mm，经向断裂伸长率17.2％，纬向断裂伸长率46.9％，产品质量稳定的特点。
以上仅是本发明的优选实施方式，本发明的保护范围并不仅局限于上述实施例，与本发明构思无实质性差异的各种工艺方案均在本发明的保护范围内。

Claims (10)

1.一种梯度滤料用熔喷-针刺复合制备方法，其特征在于，所述梯度滤料包括依次连接的背尘层、支撑层、迎尘层和熔喷致密层；
其通过以下方法制备，包括以下步骤：
(1)背尘层的制备：将背尘层原料进行开松后梳理铺网，通过气流成网的方式形成背尘层；
(2)支撑层的制备：将支撑层原料通过经纬向机织加工形成支撑层；
(3)迎尘层的制备：将迎尘层原料进行开松后梳理铺网，通过气流成网的方式形成迎尘层；
(4)采用机械成网方式将背尘层、支撑层、迎尘层三层通过预刺在一起勾连抱合，制得针刺毡基材；
(5)熔喷致密层：将熔喷致密层原料加入到螺杆挤出机挤出，形成熔体细流，熔体细流冷却固化形成初生纤维，再通过上油、牵伸、卷绕、定型、丝束切断形成超细纤维，所述螺杆挤出机有若干个温度不同的区，采用计量泵将熔融得到的熔体送至喷丝组件；依次打开主机、风机及接收网帘，风机的热风进行喷吹，直接将超细纤维均匀地喷洒在步骤(4)中预刺出来的针刺毡基材的表面，再经过主刺在一起勾连抱合，制得梯度滤料粗品；
(6)将步骤(5)中制得的梯度滤料粗品再经过烧毛、压光和热定型处理制得梯度针刺毡。
2.根据权利要求1所述的一种梯度滤料用熔喷-针刺复合制备方法，其特征在于：所述步骤(1)中背尘层原料包括涤纶纤维、聚丙烯纤维、亚克力中的一种或者几种混合。
3.根据权利要求1所述的一种梯度滤料用熔喷-针刺复合制备方法，其特征在于：所述步骤(2)中支撑层原料为涤纶长丝基布。
4.根据权利要求1所述的一种梯度滤料用熔喷-针刺复合制备方法，其特征在于：所述步骤(2)中制得的支撑层的克重为66-87g/m2。
5.根据权利要求1所述的一种梯度滤料用熔喷-针刺复合制备方法，其特征在于：所述步骤(3)中迎尘层原料包括涤纶纤维、聚丙烯纤维、亚克力中的一种或者几种混合。
6.根据权利要求1所述的一种梯度滤料用熔喷-针刺复合制备方法，其特征在于：所述步骤(4)中熔喷致密层原料为热塑型纤维聚丙烯。
7.根据权利要求1所述的一种梯度滤料用熔喷-针刺复合制备方法，其特征在于：所述步骤(5)中喷洒在针刺毡基材的表面的超细纤维克重为25-50g/m2。
8.根据权利要求1所述的一种梯度滤料用熔喷-针刺复合制备方法，其特征在于：所述螺杆挤出机有4个温度呈递增趋势的区。
9.根据权利要求8所述的一种梯度滤料用熔喷-针刺复合制备方法，其特征在于：所述螺杆挤出机4个区的温度值分别为：一区温度为172℃，二区温度为180℃，三区温度为210℃，四区温度为216℃。
10.采用权利要求1-9中任一项所述的梯度滤料用熔喷-针刺复合制备方法制得的梯度针刺毡。
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