CN112813688A - 一种防爆滤料及其制备方法 - Google Patents

一种防爆滤料及其制备方法 Download PDF

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CN112813688A
CN112813688A CN202011633702.5A CN202011633702A CN112813688A CN 112813688 A CN112813688 A CN 112813688A CN 202011633702 A CN202011633702 A CN 202011633702A CN 112813688 A CN112813688 A CN 112813688A
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coating
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郭晓蓓
高政
费传军
高明伟
张振
成朋
余佳彬
周诚
徐涛
尹奕玲
李帅
匡新波
吴涛
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Sinoma Science and Technology Co Ltd
Nanjing Fiberglass Research and Design Institute Co Ltd
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Nanjing Fiberglass Research and Design Institute Co Ltd
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Abstract

本发明公开了一种防爆滤料及其制备方法，该滤料包括导电涂覆微孔层与基材，先对基材进行浸润表面处理，随后刮涂、烘干，形成高效除尘防爆滤料，本发明通过在涂覆层和浸渍溶液中添加自反应交联的有机物和抗静电剂的方式制备复合抗静电滤料，该滤料涂覆微孔层与基材结合强力高、过滤效率高，抗静电效果好，在保持滤料原有性能不变的情况下，节约了基布的成本，简化了生产工艺。

Description

一种防爆滤料及其制备方法
技术领域
本发明涉及一种除尘防爆滤料，属于工业除尘过滤材料生产技术领域。
背景技术
袋式除尘捕集效率高，且不受烟尘性质的影响，作为处理烟尘的首选技术被广泛应用于水泥、电力、冶金、食品等工业除尘领域。随着袋式除尘应用场合越来越多，在一些具有可燃可爆粉尘捕集工况，例如水泥煤磨、轻金属及其合金打磨加工、粮食加工、木工加工、烟草及饲料加工等场合对滤料的抗静电能力提出了更高要求，排除危险隐患，此外，随着环保政策加严，排放浓度限额越来越低，例如水泥行业出现5mg/m3的颗粒物超低排放标准，因此攻克高效除尘防爆滤料技术迫在眉睫。
目前市场上高效除尘滤料主要为PTFE膜覆膜滤料，即在基材上覆合一层PTFE膜，为了实现抗静电性能，通常在PTFE膜及基材制备过程中加入金属纤维、碳纤维、有机高分子基络合导电纤维、碳粉、金属粉等导电材料，由于PTFE膜为高分子材料，加入金属等导电材料后会影响PTFE膜的成膜性能，易造成漏点，影响过滤效率，也有文献对PTFE膜进行电极化处理，该方法成本较高不利于产业化，此外抗静电性能不稳定，针对基材，加入导电材料后增加了基材制备难度，且很难保证基材质量的一致性。
发明内容
本发明的目的是提供一种高效除尘防爆滤料及其制备方法。
本发明的上述目的通过独立权利要求的技术特征实现，从属权利要求以另选或有利的方式发展独立权利要求的技术特征。
实现本发明目的的技术解决方案是：一种高效除尘防爆滤料的制备方法，该滤料包括导电涂覆微孔层与基材，先对基材进行浸润表面处理，随后刮涂、烘干，形成高效除尘防爆滤料，具体包括以下步骤：
1)浸渍后处理
将素毡浸入处理剂中，通过调节浸渍设备的压辊压力调整液布比，使其质量比在3:1～1:1之间，使处理剂均匀渗透到素毡的内部，
其中，浸渍素毡所用的处理剂，以质量百分数计，包括：十二烷基苯磺酸钠0.5-1.7％、碳酸钙0.5-1.1％、离子液体抗静电剂2-6％、抗静电剂10-45％、聚四氟乙烯乳液6-15％、聚丙烯酸脂乳液5-10％、含氧官能团硅油4-8％，余量水；
2)刮涂
取出浸渍处理剂后的素毡，立刻在上表面刮涂浆料制备刮涂层；
其中，刮涂层所用的浆料，以质量百分数计，包括：相容剂0.4-0.7％、成膜剂3-7％、异氰酸酯基8-15％、季铵盐1-4％、抗静电剂8-25％、聚四氟乙烯乳液30-40％，余量水；
3)烘燥
经刮涂后的素毡进行预烘和焙烘，得到高效除尘防爆滤料，
其中，烘箱预烘温度为160～180℃，预烘时间为15～20min；焙烘温度为190～200℃，焙烘时间为15～20min。
较佳的，将耐高温纤维通过开松、混合、梳理、铺网、并网后加入基布，基布总克重为300-700g/m2，进行针刺，得到总克重为500～900g/m2素毡。
具体的，基布材质包括聚四氟乙烯纤维、聚酰亚胺纤维、聚苯硫醚纤维、玻璃纤维、芳纶纤维中的一种或多种。
较佳的，浸渍素毡所用的处理剂中，含氧官能团硅油为环氧基改性硅油；离子液体抗静电剂为十八烷基二甲基羟乙基季铵硝酸钠；抗静电剂由有机硅抗静电剂和羧酸盐类离子抗静电剂以质量比例1：5～1：10混合协同发挥耐温抗静电作用，其中，有机硅抗静电剂为二甲基硅油，羧酸盐类离子抗静电剂为丙烯酸共聚物。
较佳的，刮涂层所用的浆料中，相容剂为马来酸酐接枝聚乙烯；成膜剂为质量比为4:1～1:1的聚碳酸酯和聚氨酯的混合物；异氰酸酯基为二苯基甲烷二异氰酸酯；作为催化剂的季铵盐为四丁基氯化铵；抗静电剂由有机硅抗静电剂和羧酸盐类离子抗静电剂以质量比例1：5～1：10混合协同发挥耐温抗静电作用，其中，有机硅抗静电剂为二甲基硅油，羧酸盐类离子抗静电剂为丙烯酸共聚物。
与现有技术相比，本发明的有益的效果是：
按照本发明的高效除尘防爆玻璃纤维滤料的制备方法，通过在涂覆层和浸渍溶液中添加自反应交联的有机物和抗静电剂的方式制备复合抗静电滤料，该滤料涂覆微孔层与基材结合强力高、过滤效率高，抗静电效果好，在保持滤料原有性能不变的情况下，节约了基布的成本，简化了生产工艺。
应当理解，前述构思以及在下面更加详细地描述的额外构思的所有组合只要在这样的构思不相互矛盾的情况下都可以被视为本发明公开的发明主题的一部分。另外，所要求保护的主题的所有组合都被视为本发明公开的发明主题的一部分。
结合附图从下面的描述中可以更加全面地理解本发明教导的前述和其他方面、实施例和特征。本发明的其他附加方面例如示例性实施方式的特征和/或有益效果将在下面的描述中显见，或通过根据本发明教导的具体实施方式的实践中得知。
附图说明
图1为本发明所述高效除尘防爆滤料的结构示意图。
其中，附图标记含义为：1-涂覆微孔层；2-界面自反应层；3-基材。
具体实施方式
为了更好地理解本发明，下面结合实施例进一步阐明本发明的内容，但本发明的内容不仅仅局限于下面的实施例。
本发明的实施例不必定意在包括本发明的所有方面。应当理解，上面介绍的多种构思和实施例，以及下面更加详细地描述的那些构思和实施方式可以以很多方式中任意一种来实施，这是因为本发明所公开的构思和实施例并不限于任何实施方式。另外，本发明公开的一些方面可以单独使用，或者与本发明公开的其他方面的任何适当组合来使用。
结合图1，本发明所述高效除尘防爆滤料从上至下包括依次连接的涂覆微孔层1；界面自反应层2；基材3。
本发明在基材的浸渍处理剂中添加含氧官能团硅油等，刮涂层所用的浆料含有异氰酸酯基、聚四氟乙烯乳液和抗静电剂等添加剂。聚四氟乙烯乳液在成膜剂的作用下形成涂覆微孔层；复配的抗静电剂能够有效降低滤料基材与涂覆微孔层的电阻；涂覆后基材中的含氧官能团硅油与涂覆层中的异氰酸酯基在四丁基氯化铵促进下在界面处原位发生有机自反应交联。因此在改善复合滤料抗静电性的同时，能有效提高过滤效率而运行阻力没有明显增加，同时提高了导电涂覆微孔层与基材结合强度。
实施例1
本发明所述的高效除尘防爆玻璃纤维机织布滤料，包括以下步骤：
1)素毡的制备
将玻璃长丝纤维经过纺织工艺制备，最终得到总克重为660g/m2玻璃纤维机织布。
2)处理剂的配置
处理剂质量百分比为：十二烷基苯磺酸钠(1％)、碳酸钙(0.8％)、十八烷基二甲基羟乙基季铵硝酸钠(3％)、抗静电剂(21％，二甲基硅油：丙烯酸共聚物＝1:10)、聚四氟乙烯乳液(8％，东岳集团)、丙烯酸酯乳液(8％，济南汇锦川化工有限公司)、环氧基改性硅油(6.2％，张家港市天瑞化工有限公司型号TR-8021)、水(52％)。将以上各种材料混合均匀后，加入容器中。处理剂配置完成后，将素毡浸入处理剂中。
3)涂层浆料配置
刮涂层所用处理剂为：马来酸酐接枝聚乙烯(0.6％)，成膜剂(5％，按聚碳酸酯和聚氨酯以质量比3:2混合，参考专利US8936836B2)，二苯基甲烷二异氰酸酯12％、四丁基氯化铵1.5％、抗静电剂(21％，二甲基硅油：丙烯酸共聚物＝1:10)、聚四氟乙烯乳液35％、水24.9％。
4)浸渍后处理
将浸渍好处理剂的素布，通过刮涂的方式，将浆料涂覆在滤料表面。
5)烘燥
刮涂后的复合毡在烘箱牵引力的作用下进入烘箱进行预烘和焙烘，预烘温度设为170℃，预烘时间为18min；焙烘温度为200℃，焙烘时间为15min。烘干滤毡表面及内部多余的水分，并使部分胶液得以挥发，最终完成滤毡的热定型。
检测的相关性能如下表1所示：
表1
电阻率(Ωcm) 半衰期(S) 平均阻力(Pa) 排放检测(mg/Nm<sup>3</sup>) 结合力(N) 使用温度(℃)
12 1.3 700 ≤5 14 ≤240
。
实施例2
一种玻璃纤维机织布滤料，包括以下步骤：
1)素毡的制备
将玻璃长丝纤维经过纺织工艺制备，最终得到总克重为660g/m2玻璃纤维机织布。
2)处理剂的配置
处理剂质量百分比配方为：十二烷基苯磺酸钠(1％)、碳酸钙(0.8％)、十八烷基二甲基羟乙基季铵硝酸钠(3％)、抗静电剂(21％，二甲基硅油∶丙烯酸共聚物＝1∶5)、聚四氟乙烯乳液(8％，东岳集团)、丙烯酸酯乳液(8％，济南汇锦川化工有限公司)、环氧基改性硅油(6.2％)、水(52％)。将以上各种材料混合均匀后，加入容器中。处理剂配置完成后，将素毡浸入处理剂中。
3)涂层浆料配置
刮涂层所用处理剂为：马来酸酐接枝聚乙烯(0.6％)，成膜剂(5％，按聚碳酸酯和聚氨酯以质量比3∶2混合，参考专利US8936836B2)，二苯基甲烷二异氰酸酯12％、四丁基氯化铵1.5％、抗静电剂(21％，二甲基硅油∶丙烯酸共聚物＝1∶5)、聚四氟乙烯乳液35％、水24.9％。
4)浸渍后处理
将浸渍好处理剂的素布，通过刮涂的方式，将浆料涂覆在滤料表面。
5)烘燥
刮涂后的复合毡在烘箱牵引力的作用下进入烘箱进行预烘和焙烘，预烘温度设为170℃，预烘时间为18min；焙烘温度为200℃，焙烘时间为15min。烘干滤毡表面及内部多余的水分，并使部分胶液得以挥发，最终完成滤毡的热定型。
检测的相关性能如下表2所示：
表2
电阻率(Ωcm) 半衰期(S) 平均阻力(Pa) 排放检测(mg/Nm<sup>3</sup>) 结合力(N) 使用温度(℃)
12 1.3 700 ≤5 14 ≤220
。
对比例1
一种玻璃纤维机织布滤料，包括以下步骤：
1)素毡的制备
将玻璃长丝纤维经过纺织工艺制备，最终得到总克重为660g/m2玻璃纤维机织布。检测的相关性能如下表3所示：
表3
电阻率(Ωcm) 半衰期(S) 平均阻力(Pa) 排放检测(mgNm<sup>3</sup>) 结合力(N)
50 4.2 600 ≤25 /
对比例2
一种玻璃纤维机织布滤料，包括以下步骤：
1)素布的制备
将玻璃长丝纤维经过纺织工艺制备，最终得到总克重为660g/m2玻璃纤维机织布。
2)处理剂的配置
处理剂质量百分比配方为：十二烷基苯磺酸钠(1％)、碳酸钙(0.8％)、十八烷基二甲基羟乙基季铵硝酸钠(3％)、抗静电剂(21％，二甲基硅油∶丙烯酸共聚物＝1∶10)、聚四氟乙烯乳液(8％，东岳集团)、丙烯酸酯乳液(8％，济南汇锦川化工有限公司)、水(58.2％)。将以上各种材料混合均匀后，加入容器中。处理剂配置完成后，将素毡浸入处理剂中。
3)涂层浆料配置
刮涂层所用处理剂为：马来酸酐接枝聚乙烯(0.6％)，成膜剂(5％，按聚碳酸酯和聚氨酯以质量比3∶2混合，参考专利US8936836B2)，二苯基甲烷二异氰酸酯12％、四丁基氯化铵1.5％、环氧基改性硅油(6.2％)、抗静电剂(21％，二甲基硅油∶丙烯酸共聚物＝1∶10)、聚四氟乙烯乳液35％、水18.7％。
4)浸渍后处理
将浸渍好处理剂的素布，通过刮涂的方式，将浆料涂覆在滤料表面。
5)烘燥
刮涂后的复合毡在烘箱牵引力的作用下进入烘箱进行预烘和焙烘，预烘温度设为170℃，预烘时间为18min；焙烘温度为200℃，焙烘时间为15min。烘干滤毡表面及内部多余的水分，并使部分胶液得以挥发，最终完成滤毡的热定型。
测的相关性能如下表4所示：
表4
电阻率(Ωcm) 半衰期(S) 平均阻力(Pa) 排放检测(mgNm<sup>3</sup>) 结合力(N)
12 1.3 700 ≤5 6
对比例3
一种玻璃纤维机织布滤料，包括以下步骤：
1)素毡的制备
将玻璃长丝纤维经过纺织工艺制备，最终得到总克重为660g/m2玻璃纤维机织布。
2)处理剂的配置
处理剂质量百分比配方为：十二烷基苯磺酸钠(1％)、碳酸钙(0.8％)、十八烷基二甲基羟乙基季铵硝酸钠(3％)、抗静电剂(21％，二甲基硅油∶丙烯酸共聚物＝1∶10)、聚四氟乙烯乳液(8％，东岳集团)、丙烯酸酯乳液(8％，济南汇锦川化工有限公司)、二苯基甲烷二异氰酸酯12％、四丁基氯化铵1.5％、环氧基改性硅油(6.2％)、水(38.5％)。将以上各种材料混合均匀后，加入容器中。处理剂配置完成后，将素毡浸入处理剂中。
3)涂层浆料配置
刮涂层所用处理剂为：马来酸酐接枝聚乙烯(0.6％)，成膜剂(5％，按聚碳酸酯和聚氨酯以质量比3∶2混合，参考专利US8936836B2)，抗静电剂(21％，二甲基硅油∶丙烯酸共聚物＝1∶10)、聚四氟乙烯乳液35％、水38.4％。
4)浸渍后处理
将浸渍好处理剂的素布，通过刮涂的方式，将浆料涂覆在滤料表面。
5)烘燥
刮涂后的复合毡在烘箱牵引力的作用下进入烘箱进行预烘和焙烘，预烘温度设为170℃，预烘时间为18min；焙烘温度为200℃，焙烘时间为15min。烘干滤毡表面及内部多余的水分，并使部分胶液得以挥发，最终完成滤毡的热定型。
测的相关性能如下表5所示：
表5
电阻率(Ωcm) 半衰期(S) 平均阻力(Pa) 排放检测(mg/Nm<sup>3</sup>) 结合力(N)
12 1.3 700 ≤5 4
对比例4
一种玻璃纤维机织布滤料，包括以下步骤：
1)素毡的制备
将玻璃长丝纤维经过纺织工艺制备，最终得到总克重为660g/m2玻璃纤维机织布。
2)处理剂的配置
处理剂质量百分比配方为：十二烷基苯磺酸钠(1％)、碳酸钙(0.8％)、十八烷基二甲基羟乙基季铵硝酸钠(3％)、抗静电剂(21％，二甲基硅油∶丙烯酸共聚物＝1∶10)、聚四氟乙烯乳液(8％，东岳集团)、丙烯酸酯乳液(8％，济南汇锦川化工有限公司)、环氧基改性硅油(6.2％)、水(52％)。将以上各种材料混合均匀后，加入容器中。处理剂配置完成后，将素毡浸入处理剂中。
3)涂层浆料配置
刮涂层所用处理剂为：马来酸酐接枝聚乙烯(0.6％)，成膜剂(5％，按聚碳酸酯和聚氨酯以质量比3∶2混合，参考专利US8936836B2)，二苯基甲烷二异氰酸酯12％、抗静电剂(21％，二甲基硅油∶丙烯酸共聚物＝1∶10)、聚四氟乙烯乳液35％、水26.4％。
4)浸渍后处理
将浸渍好处理剂的素布，通过刮涂的方式，将浆料涂覆在滤料表面。
5)烘燥
刮涂后的复合毡在烘箱牵引力的作用下进入烘箱进行预烘和焙烘，预烘温度设为170℃，预烘时间为18min；焙烘温度为200℃，焙烘时间为15min。烘干滤毡表面及内部多余的水分，并使部分胶液得以挥发，最终完成滤毡的热定型。
检测的相关性能如下表6所示：
表6
电阻率(Ωcm) 半衰期(S) 平均阻力(Pa) 排放检测(mgNm<sup>2</sup>) 结合力(N)
12 1.3 700 ≤5 9
从上述实施例可知，本发明得到的抗静电滤料表面及基材电阻低，涂层与基材有机结合牢固，过滤效率高，耐高温，大幅度扩大了滤料的应用条件。
虽然本发明已以较佳实施例揭露如上，然其并非用以限定本发明。本发明所属技术领域中具有通常知识者，在不脱离本发明的精神和范围内，当可作各种的更动与润饰。因此，本发明的保护范围当视权利要求书所界定者为准。

Claims (9)

1.一种防爆滤料的制备方法，该滤料包括导电涂覆微孔层与基材，包括先对基材进行浸润处理，随后刮涂、烘干，形成所述的防爆滤料，其特征在于，
浸润处理采用的处理剂，以质量百分数计，包括：十二烷基苯磺酸钠0.5-1.7%、碳酸钙0.5-1.1%、离子液体抗静电剂2-6%、抗静电剂10-45%、聚四氟乙烯乳液6-15%、聚丙烯酸脂乳液5-10%、含氧官能团硅油4-8%，余量水；
刮涂处理采用的浆料，以质量百分数计，包括：相容剂0.4-0.7%、成膜剂3-7%、异氰酸酯基8-15%、季铵盐1-4%、抗静电剂8-25%、聚四氟乙烯乳液30-40%，余量水。
2.如权利要求1所述的方法，其特征在于，含氧官能团硅油为环氧基改性硅油。
3. 如权利要求1所述的方法，其特征在于， 离子液体抗静电剂为十八烷基二甲基羟乙基季铵硝酸钠。
4.如权利要求1所述的方法，其特征在于，抗静电剂由有机硅抗静电剂和羧酸盐类离子抗静电剂以质量比1：5~1：10组成，其中，有机硅抗静电剂为二甲基硅油，羧酸盐类离子抗静电剂为丙烯酸共聚物。
5.如权利要求1所述的方法，其特征在于，相容剂为马来酸酐接枝聚乙烯。
6.如权利要求1所述的方法，其特征在于，成膜剂为质量比为4:1~1:1的聚碳酸酯和聚氨酯的混合物。
7.如权利要求1所述的方法，其特征在于，异氰酸酯基为二苯基甲烷二异氰酸酯。
8.如权利要求1所述的方法，其特征在于，季铵盐为四丁基氯化铵。
9.如权利要求1-8任一项方法制备的防爆滤料。
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