CN112791510A - 一种聚四氟乙烯覆膜高效滤料及其制备方法 - Google Patents

一种聚四氟乙烯覆膜高效滤料及其制备方法 Download PDF

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CN112791510A
CN112791510A CN202011464839.2A CN202011464839A CN112791510A CN 112791510 A CN112791510 A CN 112791510A CN 202011464839 A CN202011464839 A CN 202011464839A CN 112791510 A CN112791510 A CN 112791510A
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polytetrafluoroethylene
layer
filter material
membrane
fiber
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徐志梁
徐掌平
罗文春
施亦斐
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Zhejiang Saixun Environmental Protection Technology Co ltd
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Zhejiang Saixun Environmental Protection Technology Co ltd
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  • Physics & Mathematics (AREA)
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Abstract

本发明公开了一种聚四氟乙烯覆膜高效滤料，包括依次层合的聚四氟乙烯微孔膜层，复合附着层、聚四氟乙烯纤维膜层和抑菌层；所述的复合附着层包括乳液涂层和经涂层乳液浸渍后的基布层；所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维编织而成的；所述的抑菌层为掺杂有抑菌组分的改性聚四氟乙烯纤维膜层。本发明还公开了一种聚四氟乙烯覆膜高效滤料的制备方法。本发明所述的聚四氟乙烯覆膜高效滤料结构简单制备简便，具有低空气阻力，高空气过滤效率，易清灰，使用寿命长以及滤菌抑菌的特点。

Description

一种聚四氟乙烯覆膜高效滤料及其制备方法
技术领域
本发明涉及空气过滤材料领域，具体涉及一种聚四氟乙烯覆膜高效滤料及其制备方法。
背景技术
聚四氟乙烯覆膜滤料是将一层微孔发泡的聚四氟乙烯（PTFE）薄膜复合在滤料基体的表面后得到的，具有除尘效率显著、使用环境适用性广、透气性好、经济效益好等特点。现有技术中通常采用的方法有两种，一种是胶粘法，另一种是热压复合法。前者因胶黏剂的自身在使用过程中存在耐温性差和容易老化的缺陷，导致PTFE膜层脱落，影响空气过滤效果，已经逐渐的被摒弃；后者是在现有技术中应用最为广泛的方法，将PTFE通过高温热压于普通滤料表面。
申请号为201510355401.3的发明专利，公开了一种聚四氟乙烯覆膜过滤材料的制备方法，其包括如下步骤：分别对聚四氟乙烯膜和涤纶纺粘无纺布进行预处理；将预处理后的聚四氟乙烯膜和涤纶纺粘无纺布进行复合，得到聚四氟乙烯覆膜过滤材料前驱体；将所述聚四氟乙烯覆膜过滤材料前驱体进行热定型处理，得到聚四氟乙烯覆膜过滤材料；其中，所述聚四氟乙烯微孔膜的预处理方法为：将聚四氟乙烯微孔膜进行预热后去除聚四氟乙烯微孔膜表面的静电。该发明的优点在于：热压覆合制成的涤纶滤料实现了表面过滤，过滤效率提高了，动态可达99.9995％，接近零排放，使用热压覆合技术生产的覆膜滤料可以实现高效、低阻及长寿命的效果。但是，由于涤纶纤维和聚四氟乙烯膜的表面能差别大，使得两者在热压复合后的粘附牢度较低，PTFE膜仍然存在脱落的可能；在热压过程中PTFE膜容易受到损伤和孔堵塞，导致滤料的透气量降低，阻力较大，空气过滤效率降低。
发明内容
本发明的目的是解决上述问题，提供低空气阻力的、空气过滤效率高的、容易清灰的且制备方法简单的一种聚四氟乙烯覆膜高效滤料。
为实现上述目的，本发明采用的技术方案如下：
一种聚四氟乙烯覆膜高效滤料，包括依次层合的聚四氟乙烯微孔膜层，复合附着层、聚四氟乙烯纤维膜层和抑菌层；所述的复合附着层包括乳液涂层和经涂层乳液浸渍后的基布层；所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维编织而成的；所述的抑菌层为掺杂有抑菌组分的改性聚四氟乙烯纤维膜层。
为了解决上述背景技术中所述的问题，本发明提出了一种聚四氟乙烯覆膜高效滤料，所述的聚四氟乙烯覆膜高效滤料包括依次层合的聚四氟乙烯微孔膜层，复合附着层、聚四氟乙烯纤维膜层和抑菌层。所述的聚四氟乙烯微孔膜层，具有摩擦系数低的特点，使得在表面过滤阶段滤料表面不易粘尘、积尘容易剥离、便于清洗，并且所述的聚四氟乙烯微孔膜具有良好的滤菌性能，可以过滤掉空气中的大部分细菌；所述的复合附着层包括乳液涂层和经涂层乳液浸渍后的基布层，在热压复合过程中，所述的复合附着层中的聚四氟乙烯分散树脂发生聚合，在所述的基布层的内部和表层上重新形成具有孔结构的聚四氟乙烯膜层，这使得所述的复合附着层与聚四氟乙烯微孔膜层和聚四氟乙烯纤维膜热压复合时，既能够与二者紧密复合又避免了复合过程中造成的三者的孔结构的堵塞，保证了最终制得的滤料的透气性能和低空气阻力；所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维编织而成的，其内部含有大量的全孔结构，能够降低空气透过阻力，而且所述聚四氟乙烯纤维膜为有机驻极体，可以利用自身的性能吸附过滤空气中的粉尘，起到辅助过滤的作用；所述的抑菌层包括抑菌组分，避免了在长期使用的过程中，微生物在滤料中的定植、繁殖，从而阻止了细菌滋生造成的微生物污染的发生。
优选地，所述的聚四氟乙烯微孔膜层的平均孔径为1~4.5μm。
优选地，所述的基布层为玻璃纤维、石棉纤维、金属纤维、涤纶纤维或腈纶纤维。
优选地，所述的细旦聚四氟乙烯纤维的丝径为0.45~1dtex。
优选地，所述的涂层乳液包括聚四氟乙烯分散树脂和分散剂，所述的分散剂的含量为聚四氟乙烯分散树脂质量的15~35%，所述的分散剂为煤油。
优选地，所述的抑菌组分为氧化银、氧化铜、氧化锌、氧化银系列、氧化铜系列或氧化锌系列纳米复合抑菌剂中的一种或多种的组合。
优选地，所述的抑菌组为纳米AgO抑菌剂、纳米Cu/ZnO复合抑菌剂、纳米Ag/AgO复合抑菌剂或纳米AgO/ZnO/CuO复合抑菌剂的一种或多种的组合物。
优选地，所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维由全绞式纱罗组织编织而成的。
本发明的另一目的是，提供一种上述的聚四氟乙烯覆膜高效滤料的制备方法。
一种聚四氟乙烯覆膜高效滤料的制备方法，包括步骤：
S1复合附着层的制备：将基布层浸渍于所述的涂层乳液中；浸渍结束后对浸渍处理后的基布层进行乳液涂布，涂布次数为2~3次；而后进行压延，压延时压辊的温度为130~160℃；S2聚四氟乙烯纤维膜的制备：将细旦聚四氟乙烯纤维编织成多个薄网，将所述的薄网以交叉方式铺叠成PTFE原膜，并对所述的PTFE原膜进行针刺加固处理；
S3抑菌层的制备：将所述的抑菌组分与聚四氟乙烯分散树脂均匀混合后，经过筛分、熟化、压延、拉伸和热定型处理后得到掺杂有抑菌组分的改性聚四氟乙烯纤维膜层，所述的抑菌组分的含量为所述的聚四氟乙烯分散树脂的质量的2~10%；
S4聚四氟乙烯覆膜高效滤料的制备：将聚四氟乙烯微孔膜层、步骤S1制得的复合附着层、S2制得的聚四氟乙烯纤维膜和S3制得的抑菌层依次层叠后进行热压复合，热压辊的转速为5~18m/min，热压温度为300~400℃。
本发明产生的有益效果包括：
1. 本发明所述的一种聚四氟乙烯覆膜高效滤料，包括依次层合的聚四氟乙烯微孔膜层，复合附着层、聚四氟乙烯纤维膜层和抑菌层，结构简单制备简便，具有低空气阻力，高空气过滤效率，易清灰，使用寿命长的特点。
2. 本发明所述的复合附着层中的基布层，可以对所述的聚四氟乙烯微孔膜层起到支撑的作用，避免其在热压复合过程中出现变形，进一步保证了所述聚四氟乙烯覆膜高效滤料的结构完整性。
3. 本发明所述的聚四氟乙烯覆膜高效滤料两面分别包括聚四氟乙烯微孔膜层和抑菌层，二者均属于聚四氟乙烯膜材料，其本身具有较强的疏水性能，可以防止滤料吸潮降低对空气的过滤效果，减少了滤料的更换次数，延长了滤料的使用寿命。
4. 本发明所述的聚四氟乙烯覆膜高效滤料，具有滤菌和抑菌效果，对过滤的空气中的细菌进行过滤的同时避免了细菌在滤料中的滋生及传播。
5. 本发明对制得的PTFE原膜进行针刺加固，一方面使其结构更加紧密，保证了所述的聚四氟乙烯纤维膜的强度和使用性能；另一方面针刺处理后，所述的聚四氟乙烯纤维膜的表面粗糙度增大，增强了其与所述的复合附着层之间接触面积，增加结合强度。
6. 本发明中采用的抑菌组分为具有耐高温性能的纳米抑菌剂，能够与聚四氟乙烯分散树脂充分混合，而且在高温热压复合后仍然可以保持较高的抑菌性能。
具体实施方式
下面结合具体实施例对本发明进行进一步地详细说明。
在本发明的描述中，“多个”的含义是两个或两个以上，除非另有明确具体的限定。
本发明实施例中使用的化学试剂，除特别说明外均为市售产品。
本发明实施例中透气性的测试方法参照GB/T36138-2018 《除菌用聚四氟乙烯平板式微滤膜》。
实施例1
一种聚四氟乙烯覆膜高效滤料，包括依次层合的聚四氟乙烯微孔膜层，复合附着层、聚四氟乙烯纤维膜层和抑菌层；所述的复合附着层包括乳液涂层和经涂层乳液浸渍后的基布层；所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维编织而成的；所述的抑菌层为掺杂有抑菌组分的改性聚四氟乙烯纤维膜层。所述的聚四氟乙烯微孔膜层的平均孔径为0.5~2.5μm，孔隙率大于等于90%。
所述的基布层为玻璃纤维、石棉纤维、金属纤维、涤纶纤维或腈纶纤维。
所述的细旦聚四氟乙烯纤维的丝径为0.45dtex。
所述的涂层乳液包括聚四氟乙烯分散树脂和分散剂，所述的分散剂的含量为聚四氟乙烯分散树脂质量的15%，所述的分散剂为煤油。
所述的抑菌组分为纳米氧化银和氧化锌的组合物。
一种聚四氟乙烯覆膜高效滤料的制备方法，包括步骤：
S1复合附着层的制备：将基布层浸渍于所述的涂层乳液中；浸渍结束后对浸渍处理后的基布层进行乳液涂布，涂布次数为2次；而后进行压延，压延时压辊的温度为130℃；S2聚四氟乙烯纤维膜的制备：将细旦聚四氟乙烯纤维编织成多个薄网，将所述的薄网以交叉方式铺叠成PTFE原膜，并对所述的PTFE原膜进行针刺加固处理；
S3抑菌层的制备：将所述的抑菌组分与聚四氟乙烯分散树脂均匀混合后，经过筛分、熟化、压延、拉伸和热定型处理后得到掺杂有抑菌组分的改性聚四氟乙烯纤维膜层，所述的抑菌组分的含量为所述的聚四氟乙烯分散树脂的质量的2%；
S4聚四氟乙烯覆膜高效滤料的制备：将聚四氟乙烯微孔膜层、步骤S1制得的复合附着层、S2制得的聚四氟乙烯纤维膜和S3制得的抑菌层依次层叠后进行热压复合，热压辊的转速为5m/min，热压温度为300℃。
经测试，所述的聚四氟乙烯覆膜高效滤料的透气性为110m3/(m2·h)。
实施例2
一种聚四氟乙烯覆膜高效滤料，包括依次层合的聚四氟乙烯微孔膜层，复合附着层、聚四氟乙烯纤维膜层和抑菌层；所述的复合附着层包括乳液涂层和经涂层乳液浸渍后的基布层；所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维编织而成的；所述的抑菌层为掺杂有抑菌组分的改性聚四氟乙烯纤维膜层。
所述的聚四氟乙烯微孔膜层的平均孔径为2.5μm，孔隙率大于等于90%。
所述的基布层为玻璃纤维、石棉纤维、金属纤维、涤纶纤维或腈纶纤维，本发明实施例对采用的基布层不做限定，本领域的技术人员可以根据具体的使用情况进行选择。
所述的细旦聚四氟乙烯纤维的丝径为1dtex。
所述的涂层乳液包括聚四氟乙烯分散树脂和分散剂，所述的分散剂的含量为聚四氟乙烯分散树脂质量的35%，所述的分散剂为煤油。
所述的抑菌组分为纳米AgO抑菌剂。
所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维由全绞式纱罗组织编织而成的。
一种聚四氟乙烯覆膜高效滤料的制备方法，包括步骤：
S1复合附着层的制备：将基布层浸渍于所述的涂层乳液中；浸渍结束后对浸渍处理后的基布层进行乳液涂布，涂布次数为3次；而后进行压延，压延时压辊的温度为160℃；
S2聚四氟乙烯纤维膜的制备：将细旦聚四氟乙烯纤维编织成多个薄网，将所述的薄网以交叉方式铺叠成PTFE原膜，并对所述的PTFE原膜进行针刺加固处理；
S3抑菌层的制备：将所述的抑菌组分与聚四氟乙烯分散树脂均匀混合后，经过筛分、熟化、压延、拉伸和热定型处理后得到掺杂有抑菌组分的改性聚四氟乙烯纤维膜层，所述的抑菌组分的含量为所述的聚四氟乙烯分散树脂的质量的10%；
S4聚四氟乙烯覆膜高效滤料的制备：将聚四氟乙烯微孔膜层、步骤S1制得的复合附着层、S2制得的聚四氟乙烯纤维膜和S3制得的抑菌层依次层叠后进行热压复合，热压辊的转速为18m/min，热压温度为400℃。
经测试，所述的聚四氟乙烯覆膜高效滤料的透气性为140m3/(m2·h)。
实施例3
一种聚四氟乙烯覆膜高效滤料的制备方法，包括步骤：
S1复合附着层的制备：将基布层浸渍于所述的涂层乳液中；浸渍结束后对浸渍处理后的基布层进行乳液涂布，涂布次数为2次；而后进行压延，压延时压辊的温度150℃；所述的基布层石棉纤维。所述的涂层乳液包括聚四氟乙烯分散树脂和分散剂，所述的分散剂的含量为聚四氟乙烯分散树脂质量的25%，所述的分散剂为煤油。
S2聚四氟乙烯纤维膜的制备：将细旦聚四氟乙烯纤维编织成多个薄网，将所述的薄网以交叉方式铺叠成PTFE原膜，并对所述的PTFE原膜进行针刺加固处理；所述的细旦聚四氟乙烯纤维的丝径为0.55dtex。
S3抑菌层的制备：将所述的抑菌组分与聚四氟乙烯分散树脂均匀混合后，经过筛分、熟化、压延、拉伸和热定型处理后得到掺杂有抑菌组分的改性聚四氟乙烯纤维膜层，所述的抑菌组分的含量为所述的聚四氟乙烯分散树脂的质量的5%。
S4聚四氟乙烯覆膜高效滤料的制备：将聚四氟乙烯微孔膜层、步骤S1制得的复合附着层、S2制得的聚四氟乙烯纤维膜和S3制得的抑菌层依次层叠后进行热压复合，热压辊的转速为13m/min，热压温度为350℃；所述的聚四氟乙烯微孔膜层的平均孔径为1μm，孔隙率大于等于90%。
所述的抑菌组分为氧化银、氧化铜、氧化锌、氧化银系列、氧化铜系列或氧化锌系列纳米复合抑菌剂中的一种或多种的组合，本发明实施例对所述的抑菌组分的种类不做限定，本领域技术人员可根据实际生产情况自行选择。
经测试，所述的聚四氟乙烯覆膜高效滤料的透气性为90m3/(m2·h)。
对比实施例1
本发明对比实施例1，与实施例1所述步骤S3的制备方法的不同之处在于，所述的抑菌层中不包括抑菌组分。
抑菌性能的测试
关于抑菌性能的测试参照国家标准GB/T 20944.3-2008《纺织品抗菌性能的评价第三部分：震荡法》进行，具体操作步骤如下：
将实施例1步骤S3制得的抑菌层和对比实施例1制得的未添加抑菌组分的聚四氟乙烯膜，制成相同面积的样品后，分别置于接种大肠杆菌的试管培养基中，在恒温振荡器中振荡培养18h后，分别测定对比实施例1和实施例1样品接种后培养基中最终得到的活菌数，并计算对应的抑菌率，所述的抑菌率=（原始活菌数-最终活菌数）/原始活菌数*100%。结果如下表所示：
Figure DEST_PATH_IMAGE002
注：CFU/mL为菌落形成单位，指单位体积中的活菌个数。
测试结果显示，虽然对比实施例1与实施例1制得的样品均具有抑菌性能，但是本发明实施例1制得的抑菌层的抑菌效果远大于对比实施例1制得的PTFE膜材料的抑菌性能。
以上所述仅为本发明的较佳实施例，并不用以限制本发明，凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明权利要求的保护范围之内。

Claims (9)

1.一种聚四氟乙烯覆膜高效滤料，其特征在于：包括依次层合的聚四氟乙烯微孔膜层，复合附着层、聚四氟乙烯纤维膜层和抑菌层；所述的复合附着层包括乳液涂层和经涂层乳液浸渍后的基布层；所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维编织而成的；所述的抑菌层为掺杂有抑菌组分的改性聚四氟乙烯纤维膜层。
2.根据权利要求1所述的一种聚四氟乙烯覆膜高效滤料，其特征在于：所述的聚四氟乙烯微孔膜层的平均孔径为0.5~2.5μm，孔隙率大于等于90%。
3.根据权利要求1所述的一种聚四氟乙烯覆膜高效滤料，其特征在于：所述的基布层为玻璃纤维、石棉纤维、金属纤维、涤纶纤维或腈纶纤维。
4.根据权利要求1所述的一种聚四氟乙烯覆膜高效滤料，其特征在于：所述的细旦聚四氟乙烯纤维的丝径为0.45~1dtex。
5.根据权利要求1所述的一种聚四氟乙烯覆膜高效滤料，其特征在于：所述的涂层乳液包括聚四氟乙烯分散树脂和分散剂，所述的分散剂的含量为聚四氟乙烯分散树脂质量的15~35%，所述的分散剂为煤油。
6.根据权利要求1所述的一种聚四氟乙烯覆膜高效滤料，其特征在于：所述的抑菌组分为氧化银、氧化铜、氧化锌、氧化银系列、氧化铜系列或氧化锌系列纳米复合抑菌剂中的一种或多种的组合。
7.根据权利要求1所述的一种聚四氟乙烯覆膜高效滤料，其特征在于：所述的抑菌组分为纳米AgO抑菌剂、纳米Cu/ZnO复合抑菌剂、纳米Ag/AgO复合抑菌剂或纳米AgO/ZnO/CuO复合抑菌剂的一种或多种的组合物。
8.根据权利要求1所述的一种聚四氟乙烯覆膜高效滤料，其特征在于：所述的聚四氟乙烯纤维膜层采用细旦聚四氟乙烯纤维由全绞式纱罗组织编织而成的。
9.如权利要求1所述的一种聚四氟乙烯覆膜高效滤料的制备方法，包括步骤：
S1复合附着层的制备：将基布层浸渍于所述的涂层乳液中；浸渍结束后对浸渍处理后的基布层进行乳液涂布，涂布次数为2~3次；而后进行压延，压延时压辊的温度为130~160℃；S2聚四氟乙烯纤维膜的制备：将细旦聚四氟乙烯纤维编织成多个薄网，将所述的薄网以交叉方式铺叠成PTFE原膜，并对所述的PTFE原膜进行针刺加固处理；
S3抑菌层的制备：将所述的抑菌组分与聚四氟乙烯分散树脂均匀混合后，经过筛分、熟化、压延、拉伸和热定型处理后得到掺杂有抑菌组分的改性聚四氟乙烯纤维膜层，所述的抑菌组分的含量为所述的聚四氟乙烯分散树脂的质量的2~10%；
S4聚四氟乙烯覆膜高效滤料的制备：将聚四氟乙烯微孔膜层、步骤S1制得的复合附着层、S2制得的聚四氟乙烯纤维膜和S3制得的抑菌层依次层叠后进行热压复合，热压辊的转速为5~18m/min，热压温度为300~400℃。
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