CN1129963A - 使驻极体过滤介质充电的方法 - Google Patents

使驻极体过滤介质充电的方法 Download PDF

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CN1129963A
CN1129963A CN94193221A CN94193221A CN1129963A CN 1129963 A CN1129963 A CN 1129963A CN 94193221 A CN94193221 A CN 94193221A CN 94193221 A CN94193221 A CN 94193221A CN 1129963 A CN1129963 A CN 1129963A
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base material
water
microfiber
electric charge
pressure
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CN1052042C (zh
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S·A·安加吉旺达
M·E·琼斯
D·E·迈耶
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3M Co
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Abstract

一种向热塑性微纤维的非织造基材充电以制成驻极体过滤介质的方法，该方法是向一种能够具有大量俘获电荷的热塑性不导电微纤维的非织造基材，在一定压力下将水注或水滴流喷射上去，所用的喷射压力应足以使该基材具有提高过滤作用的驻极体电荷；然后对该基材进行干燥。

Description

使驻极体过滤介质充电的方法
发明领域
本发明涉及由纤维诸如熔喷法微纤维制成的驻极体增强的过滤介质(简称为“驻极体”过滤器)。本发明是涉及一种制造从空气中去除细粒物质用的驻极体纤维过滤器的改进方法。本发明具体是涉及防尘滤毒装置以及增加过滤介质上面的具有增强过滤作用的静电荷的方法。
相关技术
多年来，人们都使用1954年5月25日出版的Naval ResearchLaboratories的报告第4364号中，Van A.Wente等人发表的“Manufacture of Super Fine Organic Fibers(超细有机纤维的制造)”一文中所述的熔喷法设备来由聚丙烯制造非织造纤维过滤器的基材。这种熔喷法微纤维基材一直广泛地用于细粒污染物的过滤，如作面罩和滤水器，又由于其它用途，如从水中去油用的吸着剂基材、隔声和隔热等。
当熔喷法纤维从喷孔生成出来后，若受到带电质点如电子或离子的轰击，使得熔喷法细纤维基材成为驻极体，则该基材的过滤质量会提高一倍以上。同样，当微纤维基材收集以后使其受到电晕处理，也可使其成为驻极体。熔喷法微纤维中聚丙烯特别适用，但其它聚合物如聚碳酸酯和多卤烃也可使用，只要它们可以用熔喷法制造微纤维，并且在预期的环境条件下具有合适的体积电阻率。
从空气中去除细粒污染物的纤维过滤器也可以用原纤化聚丙烯薄膜制造。可以在其原纤化之前，对其用静电法充电以提高其驻极体过滤的作用。
通常的聚合物如聚酯、聚碳酸酯等可以经过处理产生高度带电的驻极体，但是这些电荷一般是寿命很短的，尤其在潮湿条件下。驻极体结构可以是薄膜或片材，用作传声器、头戴受话器、扬声器等电声装置中的静电元件，用于尘粒控制、高压静电发电机、静电记录器等用途。
本发明简要说明
在一个方面，这些提供了一种向热塑性微纤维的非织造基材充电，以制成驻极体过滤介质的方法，该方法是向一种能够带有大量俘获电荷的热塑性不导电微纤维的非织造基材，在一定压力下将水注或水滴流喷射上去，所用的喷射压力应足以使该基材具有提高过滤作用的电荷；然后对该基材进行干燥。令人惊异的是，已经发现，仅仅将水注或水滴流喷射到非织造微纤维基材上，该基材上就会产生具有提高过滤作用的驻极体电荷。在用水喷射之前，若让基材接受电晕放电处理，还可进一步促进充电过程。基材最好是用熔喷法聚丙烯微纤维、聚(4—甲基—1—戊烯)微纤维或它们的混合纤维制造的。在这里，使用“喷水充电”这一术语来指所述的这个方法。
基材在受到水注或水滴流的喷射以后，看来是充了电荷，因为基材在受到水喷射后若受到未过滤的X射线幅照，其过滤效率显著地降低。
用本发明方法生产的驻极体纤维过滤器特别适合于用作防尘滤毒装置如面罩的空气过滤元件，还可用于不少用途，如家用和工业用空气调节器、空气滤清器、真空吸尘器、医用空气线路过滤器、以及车辆和例如计算机、计算机磁盘驱动器、电子仪器等普通设备用的空气调节系统。用于除尘滤毒装置中时，驻极体过滤器的形式可为模制的或折叠的半面面罩、可为可替换的过滤盒或过滤罐、也可为预滤器。在这些用途中，本发明方法生产的空气过滤器对于去除悬浮尘粒异常有效。这种驻极体过滤器介质，当用作空气过滤器，例如用于除尘滤毒装置时，其过滤性能比用已知方法充电的类似驻极体过滤器好得多。
附图的简要说明
图1是可用于制造在本发明方法中使用的微纤维基材的一种设备的侧视图。
图2是可用于本发明的一种水注喷射装置的透视图。
图3是可用于本发明的一种喷雾器的透视图。
图4是可用于本发明的一种泵送喷射器的透视图。
本发明的详细叙述
用于本发明的熔喷法微纤维可以按Van A.Wente，“超细热塑性纤维(Superfine Thermoplastic Fibers)”，Tndustrial EnginearingChemistry，Vol.，48，pp.1342-1346和Van A.Wente等人，“超细有机纤维的制造(Manufacture of Super Fine Organic Fibers)”，Re-port No.4364 of the Naval Research Laberatories，May25，1954中所述的方法来制造。
用于形成熔喷法微纤维的树脂是一种热塑性不导电的树脂，即该树脂具有的电阻率大于1014欧姆·厘米，它能够带有大量俘获电荷。为此适用的树脂包括聚丙烯、聚(4—甲基—1—戊烯)和它们的混合物。树脂应基本上不含有抗静电剂之类的材料，因为它们会增加电导率或者由于其它原因而影响纤维接受和保持静电荷的能力。熔喷法微纤维可以用一种树脂，用混合树脂例如聚丙烯和聚(4—甲基—1—戊烯)，或者用两种树脂呈层状的或皮芯的结构。当聚丙烯和聚(4—甲基—1—戊烯)用于层状或皮芯结构时，聚(4—甲基—1—戊烯)最好用在外表面上。
用于本发明驻极体纤维过滤器的熔喷法微纤维，其有效纤维直径一般约为3～30微米，最好约为7～15微米，其计算是按Davies，C.N.，”气载飘尘与颗粒的分离(The Separation of Airborne Dustand Particles”，Institution of Mechanical Engineers，London，Pro-ceedings 1B，1952中所提出的方法进行的。
在基材中也可以有短纤维存在。有了短纤维的基材比只含熔喷法微纤维的基材更为膨松。基材中短纤维的最多用量宜为90重量％，更宜为70重量％。含有短纤维的这类基材在美国专利4,118,531(Hauser)中有叙述。
基材中也可以含有吸着剂颗粒材料，如活性炭或氧化铝。这类颗粒在基材中的含量可达约80体积％。这类含有颗粒材料的基材在例如美国专利3,971,373(Braun)、4,100,324(Anderson)、4,429,001(Kolpin等人)中有叙述。
按本发明方法制备的驻极体过滤器介质，其织物单位重量宜为约10～500g/m2，10～100g/m2更宜。在制造熔喷法微纤维基材时，其织物单位重量可以例如藉改变集料器的速度或改变模具的通过量来调节。过滤器介质的厚度宜为0.25～20mm，0.5～2mm更宜。这种驻极体过滤器介质和其制造原料聚丙烯树脂不可经受那些会增加其导电率的不必要的处理，例如，接受γ射线和紫外射线的幅照、热解、氧化等。
适用于本发明的非织造微纤维基材可以用图1所示的设备制造。在这个设备中，有一个模具20，该模具有个挤压室21，其中推进着液态的纤维形成材料；有一些模孔22在模具的前端排成一线，纤维形成材料通过这些模孔挤压出来；还有一些相配合的气体孔23，气体通常是加热的空气以很高的速度通过这些气孔喷射出来。这高速的气流将挤出的纤维形成材料吸出并抽长拉细，使其在喷向集料器24的途径中固化成微纤维，并形成为基材。
当需要在基材中加入短纤维时，这些短纤维可以通过安装在微纤维喷制设备上方的磨刺辊32来引入(见图1)。一条短纤维的基材(一般是例如在回丝再生纤维的设备或RANDO-WEBBER设备上制造的膨松的非织造基材)在驱动辊29的作用下沿着平台28推进，基材的前端与磨刺辊32接触。磨刺辊32从基材27的前端将纤维不断地钩下使其互相分离。这些钩下的纤维随即由一股空气流沿着斜通道30输送到喷制的微纤维流中，与其混合。
若在基材中要加入颗粒材料，则可采用类似于斜通道30那样的加料装置引入。
对基材喷水充电，是以一定压力将水注或水滴流喷射在基材上，所用的压力应足以使基材具有提高过滤作用的驻极体电荷。获得最佳效果所需的压力取决于所用喷射器的类型、制造基材所用树脂的种类、基材的厚度和密度、以及在喷水充电前是否进行电晕充电之类的预处理。一般而言，适用的压力约为10～500psi(69～3450kPa)。产生水滴所用的水应该比较纯净，宜用蒸馏水或去离子水，而不直接用自来水。
可以用任何适合的喷射装置来产生水注或水滴流。用于对纤维进行喷水扭结的设备一般也适用于本发明的方法，但在喷水充电过程中所用的压力比一般用于喷水扭结的压力要低些。
图2表示一种适用的喷射装置的例子，在该装置中纤维基材在支托装置11上输送着。支托装置可以是一条带，最好是多孔的，例如是有网眼的筛带或织物带。水注12是用一个水泵(图中未示)提供的压力从水注头13中喷射出来的。水注12喷射在基材10的喷射点12′的位置上。最好还在多孔的支托带下面提供真空，目的是帮助喷射的水注通过基材以及减少干燥的能耗。
适用于本发明喷射装置的又一个例子包括图3所示的喷雾器，在其中，水由进水管14输入，压缩空气由进气管15输入，在喷嘴16形成水的喷雾撞击到基材10上面。还有一个喷射装置例示于图4，它是个泵送作用的喷射器，它有个泵送手柄17将水由供水装置18压送到喷嘴19形成喷雾。
在下述的一些实施例中，除非另有说明，一切百分数和份数均是按重量计。采用了下列一些试验方法来评价本发明的实施例。DOP穿透百分数与压力降
用一个具有4个喷口的TSI No.212喷射器，以30psi(207kPa)的洁净空气，产生了浓度为70～110mg/m3的直径为0.3微米的邻苯二甲酸二辛酯(DOP)颗粒的气溶胶。令含有这种颗粒的气溶胶以42.5L/min的流量即6.9cm/s的面速度流过直径为11.45cm的过滤介质样品，持续30秒钟。然后用Air Techmiques Inc.出品的TPA-8F型穿透百分数测量仪(它是一种光散射测量仪器)进行了穿透百分数的测量。穿透百分数最好是小于70％，小于40％更佳。压力降是用一电子测压计在流量为42.5L/min及面速度为6.9cm/s条件下测量的。压力降记为ΔP，以mm水柱为单位。对于单层的基材来说，压力降以小于4mm水柱为宜，小于3mm水柱更佳。
穿透百分数与压力降被用来计算一质量因子，被称为“QF值”，它由DOP穿透百分数的自然对数(Ln)和压力降计算的公式如下：初始的QF值高就表面初始的过滤性能好。QF值降低能与过滤性能的降低有效地相关。QF值一般宜最少约为0.25，至少约0.5更佳，至少约1最佳。香烟烟雾吸附试验
香烟烟雾吸附试验是在一容积为1m3的长方形试验室中进行，该试验室中有一个装有平板形过滤介质试样(14cm×14cm)的吸气装置(CAM770房间空气洁净器，Norlco Company)。有一个能抽吸一定数量香烟(1～10支)的吸烟装置，它能在一定的控制燃烧时间(4至5分钟)内藉抽吸香烟在试验室内发出香烟烟雾。有一风扇将在试验室中产生的香烟烟雾进行均匀的混和。有一个取样流量5ce/s，测量范围0.1～7.5微米粒度的激光颗粒计数器(Particle Mea-surement System的PMS LAS-X型)通过计数测量了试验室空气氛中的颗粒浓度。在吸附了香烟烟雾的前后，测量了过滤介质试样的颗粒俘获效率和压力降。
过滤介质试样的颗粒俘获效率的测量是用一个TSI AFT-8110(购自TSI，St.Paul，MN)自动过滤试验器进行的，用的是Nacl颗粒，通过试样空气的面速度为26.7cm/s。用TSI AFT-8110中的光度计分别测量在过滤介质试样上游位置和下游位置的Nacl颗粒浓度Cin和Cout，然后用下式计算过滤介质的颗粒俘获效率E：
          E＝(1－[Cout/Cin])×100％环境空气颗粒负载试验
对300mm×116mm的过滤介质试样，用环境空气以149ft3/min(250m3/hr)的流量通过若干个一定的时间，然后用粒度为0.3微米和1.0微米的颗粒进行检验。在此检验之前和经过指定的环境空气流过时间之后，都按香烟烟雾试验一节所述进行了颗粒俘获效率的测量。实施例1～7和对比实施例C1～C2
按Wente，Van A.，“超细热塑性纤维(Superfine Thermoplas-tic Fibers”，Industrial Engineering Chemistry，Vol.48，pp.1342～1346中所述，制备了聚丙烯(ESCORENE3505G，购自ExxonCorp.)微纤维的基材。该基材的织物单位重量为55g/m2，厚度为0.1cm。纤维的有效直径为7.6μm。基材试样用一台类似于图1所示的喷水扭结器(实验室型号，serial no.101，Honeycomb SystemsCorp.)产生的水注进行了喷射处理，该设备的喷射棒宽为24英寸(0.6米)，其上面每一英时(2.5厘米)宽度上有直径各为0.005英寸(0.13毫米)的喷射孔40个，采用的不同水压如表1所示。每个试样以3.5m/min的速度在喷射棒下通过，每一面进行喷水处理一次，真空抽吸、然后于70℃干燥一小时。经此处理的试样作了DOP穿透百分数和压力降的试验，算出质量因子QF的值。其结果列于表1。
                      表1
             压力           穿透率
 实施例     (kPa)            (％)          质量因子
   C1       34.5              78             0.09
   C2       69                72             0.11
   1        172               39             0.31
   2        345               32             0.37
   3        690               35             0.34
   4        1380              39             0.34
   5        2070              43             0.34
   6        2760              46             0.31
   7        3450              46             0.34
由表1数据可见，喷水充电(压力至少约170kPa)在这种基材中产生了有用的驻极体增强的过滤性能。实施例8～15和对比实施例C3～C4
如同实施例1～7那样，制备了基材，然后进行了电晕处理，其方法是将基材在与一块铝质接地板接触的情况下，在一个正的DC电晕源下面以1.2m/min的速度通过两次，电流维持在约0.01mA/cm电晕源，电晕源与接地板相距约4cm。然后将基材试样以表2所示的不同水压类似实施例1～7那样进行了水注喷射处理。经此处理的试样试验了DOP穿透百分数和压力降，算出质量因子，结果列于表2中。
                    表2
             压力          穿透率
 实施例     (kPa)           (％)        质量因子
   C3        0               27           0.38
   C4        69              21           0.46
   8         172             16           0.55
   9         345             15           0.57
   10        690             15           0.61
   11        1380            15           0.66
   12        2070            13           0.80
   13        2760            14           0.79
   14        3450            18           0.75
   15        4140            25           0.61
由表2数据可见，喷水充电(在大于约170kPa的压力下)增加了基材的驻极体过滤性能。实施例16～21和对比实施例C5
如同实施例1～7那样制备了基材，不同的是使用了聚—4—甲基—1—戊烯(TPX MX-007]，购自Mitsui Chemical Co.)。这种基材也象实施例8～15那样进行了电晕处理。在实施例16～21中，这样的基材然后如实施例1～7那样，在表3所列的不同压力下，进行了喷射水滴处理。经过处理的试样试验了DOP穿透百分数和压力降，算出质量因子，结果列于表3中。
                         表3
                  压力             穿透率
  实施例         (kPa)              (％)           质量因子
    C5            0                  19              0.85
    16            69                 11              1.31
    17            172                2.1             2.06
    18            345                2.0             2.06
    19            1035               2.9             1.97
    20            1380               3.1             1.75
    21            2760               11              1.12
由表3数据可见，对在约69kPa或更大的压力对聚—4—甲基—1—戊烯的基材进行喷水充电，产生了具有优异的驻极体增强的过滤性能的基材。实施例22～24和对比实施例C6～C8
在实施例22～24和对比实施例C6～C8中，按美国专利4,118,531(Hausor)所述制备了含有50重量％短纤维的聚丙烯(ES-CORENE3505G)微纤维基材。每个基材的织物单位重量约为50g/m2。在实施例22和对比实施例C6中，所用的短纤维是SynetheticIndustries供应的17旦尼尔，5.1cm长的聚丙烯原纱(17dpp)；在实施例23和对比实施例C7中，所用的短纤维是Eastman chemicalCo.供应的15旦尼尔，3.1cm长的聚酯短纤维KODEL K-431(15dPET)；在实施例24和对比实施例C8中，所用的短纤维是EastmanChemical Co.供应的6旦尼尔，5.1cm长的聚酯短纤维KODEL K-211(6d PET)。聚酯短纤维在使用前，先用2重量％LIQUINOX(Alconox，Inc.)在热水(约140°F，60℃)中的溶液搅拌清洗5分钟以除去面层，然后漂洗、干燥之。
每条基材试样均如实施例8～15那样进行了电晕处理。在实施例22～24中，这些基材然后如同实施例1～7那样，以3.5m/min的运行速度和690kPa的静水压力进行了水柱喷射处理。经过处理的试样试验3DOP穿透百分数和压力降，算出质量因子，结果列于表4。
                表4
      纤维型号    穿透率实施例                 (％)    质量因子22        17d pp        49       1.6723        15d PET       44       2.2424        6d PET        47       1.82C6        17d pp        68       0.95C7        15d PET       72       0.97C8        6d PET        76       0.82
由表4数据可见，与仅进行电晕处理的基材比较，对熔喷法微纤维和短纤维的混合物基材在作电晕处理后再进行喷水充电，其质量因子有了增加。其中含50％15旦尼尔聚酯短纤维的基材，质量因子的增加最为显著。实施例25～26和对比实施例C9
如同实施例1～7那样制备了聚丙烯基材。该基材的织物单位重量为54g/m2，厚度为1.04mm，有效纤维直径为7.5μm和在对比实施例C9中，是将基材试样如实施例8～15那样进行了电晕充电处理。在实施例25中，是将基材试样用一喷雾器(SCD 052H型，SonicDevelopment Corp.出品，其谐振器罩除去)，以380-414kPa的空气压力，以等于大气压力的水压，距基材的每一面约7～12cm进行了喷水充电处理。在实施例26中，则是将基材如对比实施例C9那样先进行了电晕充电处理后，再如实施例25那样进行了喷水充电处理。经处理的试样试验了DOP穿透百分数和压力降，算出质量因子，结果列于表5。
                     表5
                    穿透率
    实施例           (％)         质量因子
      C9              25            0.56
      25             45.5           0.36
      26              21            0.67
由表5数据可见，对这种基材用这种喷雾器进行喷水充电(实施例25)产生了较高的过滤性能，虽然其质量因子不如仅作电晕充电处理(对比实施例C9)的那么高。在电晕处理之后再用喷雾器进行喷水充电，在表5所示的实施例中给出的质量因子最高。实施例27和对比实施例C10
如同实施例1～7那样制备了基材，不同的是使用的聚合物是75％聚丙烯(FINA3860X，Fina Oil & Chemical Co.出品)和25％聚(4—甲基—1—戊烯)(TPX MX—007，Mitsui Chemical Co.出品)的粒料混合物。基材厚1.0mm，其织物单位重量为55g/m2，有效纤维直径为8.1μm。在实施例27中，象实施例8～15那样对基材进行了电晕处理，然后用水压345kPa进行了水注喷射处理。而在对比实施例C10中，仅对试样作了电晕处理。经处理的试样试验了DOP穿透百分数和压力降，算出质量因子，结果列于表6。
                     表6
                    穿透率
     实施例          (％)           质量因子
      27             6.8              1.16
      C10            29               0.51
由表6数据可见，对实施例27的基材在电晕处理之后还添加的喷水充电处理与仅受电晕充电处理的对比实施例C10相比，过滤性能有了显著提高。实施例28
象实施例1～7那样制备了聚丙烯/聚(4—甲基—1—戊烯)的多层微纤维，不同的是所用的设备中用了按美国专利5,207,970(Joseph等)所述的具有多层纤维的微纤维基材成形方法中所用的两个挤压器和一个三层进料器(分料组件)。第一个挤压器将熔体流动的指数为50的聚丙烯树脂(FINA Oil and Chemical Co.出品)的熔体流输送到进料器，在该进料器中树脂被加热至约320℃。第二个挤压器将聚(4—甲基—1—戊烯)树脂(TPX级别MX—007，MitsuiPetrochemical Industries，Ltd出品)加热到约343℃，将该树脂熔体流输送到进料器。该进料器将这两股聚合物熔体流再分成三股，使得出进料器时为交替的三层熔料流，其外面的两层是聚(4—甲基—1—戊烯)树脂。两个齿轮泵的流量调节到使得比例为75∶25的聚丙烯∶聚(4—甲基—1—戊烯)两股聚合物料流输送到进料器。纤维收集成基材时集料器与模具的距离为28cm(11英寸)。所得的三层微纤维基材的有效纤维直径小于约8微米，其织物单位重量为55g/m2。将基材如实施例8～15那样进行了电晕处理，然后如实施例1～7所述地用水压345kPa进行了喷水处理，之后再进行真空抽吸，70℃干燥1小时。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果示于表7。实施例29
如同实施例28那样制备了含有三层微纤维的基材，其织物单位重量为55g/m2，有效纤维直径小于约8微米，所不同的是在其制造过程中，输送到三层进料器中的聚丙烯对聚(4—甲基—1—戊烯)两股熔料流的比例为50∶50，集料器与模具的距离为23cm(9英寸)。这样制得的基材如实施例28那样进行了电晕处理、水注喷射处理和干燥。对可经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表7中。实施例30
如同实施例28那样制备了含有三层微纤维的基材，其织物单位重量为55g/m2，有效纤维直径小于约8微米，所不同的是在其制造过程中，输送到三层进料器中的聚丙烯对聚(4-甲基-1-戊烯)两股熔料流的比例为25∶75，集料器与模具的距离为19cm(7.5英寸)。这样制得的基材如实施例28那样进行了电晕处理、水注喷射处理和干燥。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表7中。买施例31
如同实施例28那样制备了聚(4-甲基-1-戊烯)的基材，所不同的是只用了一个挤压器，它将树脂加热至343℃。该挤压器通过一齿轮泵直接连接至模具。集料器与模具之间的距离为19cm(7.5英寸)。所得基材的有效纤维直径为8.5微米，织物单位重量为55g/m2。将基材如实施例28那样进行了电晕处理、水注喷射处理和干燥。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表7中。实施例32
如同实施例28那样制备了含有三层微纤维的基材，其织物单位重量为55g/m2，有效纤维直径小于约8微米，所不同的是在其制造过程中，第二个挤压器将熔体流动指数为50的聚丙烯树脂(FINACo.出品)和聚(4-甲基-1-戊烯)树脂(Mitsui Co.的“TPX”级别MX-007)的粒料混合物的熔体流输送到进料器中。出进料器的高聚物熔体流是交替的三层熔体流，其外面的两层是粒料混合物的熔体(聚丙烯对聚(4-甲基-1-戊烯)的重量比为75∶25)。两个齿轮泵的流量调节到使得重量比例为50∶50和聚丙烯熔体与粒料混合聚合物熔体输送到进料器。收集器与模具的距离为19cm(7.5英寸)。这样制得的基材如实施例28那样进行了电晕处理、水注喷射处理和干燥。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表7中。
                             表7
   实施例   穿透率％   质量因子   穿透率％     质量因子
             仅受电     仅受电    电晕处理＋   电晕处理＋
             晕处理     晕处理    喷水处理     喷水处理
     28       19.7       0.75       3.7          1.45
     29       15.4       0.8        6.3          1.30
     30       15.6       0.9        4.8          1.49
     31       19.4       0.73       2.5          1.52
     32       39.0       0.42       9.1          1.2
由表7数据可见，含有外层为聚(4-甲基-1-戊烯)的纤维的基材或者含聚(4-甲基-1-戊烯)的基材，受到电晕和水注喷射两种处理之后具有很优越的过滤性能。实施例33
如同实施例28那样制备了含有五层微纤维的基材，其织物单位重量为63g/m2，有效纤维直径小于约10微米，所不同的是在其制造过程中，是将聚丙烯对于聚(4-甲基-1-戊烯)的重量比为50∶50的两股熔料流输送到五层进料器中。出进料器的高聚物熔体流是交替的五层熔体流，其外面的两层是聚(4-甲基-1-戊烯)树脂。对所得的基材进行了电晕处理，其方法是将基材在与一块铝质接地板接触的情况下，以7m/min的速度依序在六个正的电晕源下面通过，此时电流维持在约0.05mA/cm，电晕源与接地板相距约7cm。经电晕处理的材料然后再如实施例28那样进行水注喷射处理，不同的是水压用690kPa。基材用真空抽吸，然后在一空气通过式干燥器中干燥约45秒钟。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表8中。实施例34
如同实施例28那样制备了含有五层微纤维的基材，其织物单位重量为62g/m2，有效纤维直径小于约10微米，所不同的是在其制造过程中，只用了一个挤压器，它将树脂加热到340℃。该挤压器将含有50重量％的聚丙烯树脂(其熔体流动指数为50)和50重量％聚(4-甲基-1-戊烯)(Mitsui公司，“TPX”级别MX-007)的粒料混合物的熔体流输送到进料器中。这样制得的基材如实施例33那样进行了电晕处理、水注喷射处理和干燥。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表8中。实施例35
如同实施例33那样制备了含有五层微纤维的基材，其织物单位重量为62g/m2，有效纤维直径小于约10微米，所不同的是在其制造过程中，第二个挤压器是将聚(4-甲基-1-戊烯)(Mitsui Petrochemi-cal Industries，Ltd的“TPX”级别DX820)的熔体流输送到进料器。出进料器的高聚物熔体流是交替的五层熔体流，其外面的两层是聚(4-甲基-1-戊烯)。两个齿轮泵的流量调节到使得重量比例为50∶50的聚丙烯与聚(4-甲基-1-戊烯)这两股熔体流输送到进料器。这样制得的基材如实施例33那样进行了电晕处理、水注喷射处理和干燥。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表8中。实施例36
如同实施例28那样制备了含有五层微纤维的基材，其织物单位重量为59g/m2，有效纤维直径小于约10微米，所不同的是在其制造过程中，第二个挤压器是将含有80重量％的聚丙烯树脂(其熔体流动指数为50)和20重量％的聚(4-甲基-1-戊烯)(Mitsui公司，“TPX”级别MX-007)的粒料混合物的熔体流输送到进料器中。出进料器的高聚物熔体流是交替的五层熔体流，其外面的两层是粒料混合物。两个齿轮泵的流量调节到使得重量比例为50∶50的聚丙烯与粒料混合物这两股聚合物熔体流输送到进料器。这样制得的基材如实施例33那样进行了电晕处理、水注喷射处理和干燥。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表8中。实施例37
用一股五层的熔体流，如同实施例28那样制备了聚(4-甲基-1-戊烯)(Mitsui公司，“TPX”级别MX-007)的基材，所不同的是只用了一个挤压器，它将树脂加热到343℃。该挤压器通过一齿轮泵直接连接至模具。所得的基材如实施例33那样经电晕处理、水注喷射处理和干燥。基材的织物单位为65g/m2，有效纤维直径小于约10微米。对于经电晕处理后(受水注喷射之前)的基材以及经电晕和喷水两种处理后的基材，均进行了压力降和穿透百分数的测量，算出质量因子。结果列于表8中。
                          表8
实施例    穿透率％    质量因子   穿透率％     质量因子
          仅受电       仅受电   电晕处理＋    晕处理＋
          晕处理       晕处理  水注喷水处理  水注喷水处理
  33       26.7         0.66       7.8          1.31
  34       28.7         0.49       11.8         0.94
  35       25.8         0.55       9.3          1.01
  36       26.4         0.56       13.7         0.9
  37       25.2         0.51       7.1          1.24实施例38a—d，39a—d和40a—d
制造了直径10.16cm、厚1.3mm的圆形过滤层，实施例38a—d、39a—d、40a—d中用的分别是实施例35、36、37所述的基材材料。按美国专利4,886,058(Brostrom等)所述，装配了圆形过滤元件，对于该过滤元件的前壁和后壁所用的充电驻极体过滤介质层的层数列于表9。每一个装配好的过滤元件有一根内径1.91cm的圆形聚丙烯通气管。对过滤元件进行了DOP穿透百分数和压力降试验。结果列于表9。实施例41a—e
用熔体流动指数为50的聚丙烯树脂，如同实施例33那样制造了基材，不同的是只用了一个挤压器，它将树脂加热到320℃。该挤压器通过一齿轮泵直接连接至模具。所得基材的织物单位重量为55g/m2，有效纤维直径小于约8微米。该基材如实施例33那样经电晕处理、水注喷射处理和干燥。
如实施例38—40那样，装配了含有不同层数驻极体基材的过滤元件，并进行了试验。结果列于表9。对比实施例C11
用熔体流动指数为50的聚丙烯树脂；如同实施例41那样制造了基材，所不同的是所得的基材仅受电晕处理。如同实施例38—40那样，用六层驻极体过滤介质层装配了过滤元件，并进行了试验。结果列于表9。
                                  表9
         每个壁的过    初始穿透率    初始压力降    负荷穿透率    负荷压力降
实施例   滤介质层数       (％)         (mmH2O)      (％)         (mmH2O)
  38a        5            0.001         18.5         0.001          18.9
    b        4            0.001         15.4         0.003          15.9
    c        3            0.007         12.4         0.018          12.8
    d        2            0.161          9.6         0.529           9.8
  39a        5            0.002         17.6         0.006          18.0
    b        4            0.013         13.8         0.032          14.1
    c        3            0.114         11.9         0.294          12.4
    d        2            0.840          8.9         2.15            9.3
  40a        5            0.001         23.3         0.001          23.8
    b        4            0.001         18.4         0.001          18.9
    c        3            0.080         14.5         0.017          14.9
    d        2            0.167         10.8         0.311          11.1
  41a    6    0.001    21.4    0.001    21.8
    b    5    0.001    16.7    0.002    17.
    c    4    0.001    15.0    0.021    15.3
    d    3    0.007    12.0    0.237    12.4
    e    2    0.177    9.1     3.37     9.4
  C11    6    0.015    17.7    0.127    17.4
表9中的数据表明，与六层仅受电晕处理的聚丙烯微纤维结构相比，受了电晕处理后又受水注喷射处理的微纤维过滤介质，无论它是聚丙烯纤维的，聚丙烯与聚-4-甲基-1-戊烯多层纤维的，或者是聚-4-甲基-1-戊烯纤维的，其初始的DOP穿透百分数和最后负荷时的DOP穿透百分数均比较小。因此，若用喷水处理的微纤维介质来装配过滤元件，则所用的微纤维介质层数就可用得少些，结果该过滤元件两端的压力降也会较小些，而其过滤性能与使用较多层的电晕处理驻极体过滤介质相比仍可差不多，甚至更为优异。实施例42
如实施例31那样制备了过滤介质基材，不同的是集料器至模具的距离为40cm(16英寸)，树脂加热到372℃，有效纤维直径为14微米，织物单位重量为50g/m2，基材是在80℃干燥25分钟。测量了压力降。然后对此试样进行了香烟烟雾试验，测定了过滤器效率。结果列于表10。实施例43
如同实施例42那样制备了过滤介质基材，不同的是使用了TPXTM级别MX-002的聚(4-甲基-1-戊烯)。测量了压力降。然后对此试样进行了香烟烟雾试验，测定了过滤器效率。结果列于表10。
                                  表10实施例    压力降    未充电过    初始过滤    1根香烟后    5根香烟后    10根香烟
        (mmH2O)   滤器效率    器效率     的过滤器效   的过滤器效   后的过滤器
        在26.7      Euc(％)    Ei(％)     率Ef(％)     率Ef(％)     效率Ef(％)
        cm/sec
42       2.8         16.5      80.5         --            48.8         17.9
43       3.4         18.6      67.1        60.3           53.9         34.4
表10中的数据说明了由聚(4-甲基-1-戊烯)微纤维制成且经过电晕与喷水处理的过滤器，其过滤性能是很优越的。实施例44a和44b
如同实施例31制备了过滤介质基材，不同的是集料器与模具的距离是28cm(11英寸)，有效纤维直径是14微米。基材的织物单位重量为40g/m2，厚度为1.2mm(0.049英寸)。由此基材与一种科尔巴克稀布(80g/m2，BASF Corp.出品)制成了褶裥式过滤元件，该科尔巴克稀布是预先采用粘结剂用量约为1g/m2粘附到基材上的。制成的过滤元件长29cm，宽10cm，在其29cm全长上具有52个褶，褶的高度为28mm。对此过滤元件试验了初始效率和压力降，还试验了分别用含0.3微米粒度的颗粒(实施例44a)和1微米粒度的颗粒的环境空气负载通过后的过滤器效率。结果列于表11。
                              表11实施    颗粒粒度  初始效率  初始压力降  经133小时  经133小时后  经290小时  经290小时例      (um)       (％)     (mm H2O)   后的效率    的压力降    后的效率   后的压力降
                                        (％)      (mm H2O)     (％)      (mm H2O)44a     0.3        70.5       10.8        53.8        13.8         47         15.544b     1.0        86.8       10.8        79.0        13.8         75         15.5
表11中的数据说明，即使在连续地使用不同粒度范围的颗粒之后，本发明过滤介质基材的颗粒俘获效率仍可以长时期保持。
在不偏离本发明范围和精神的条件下，本领域的技术人员不难明白，对于本发明是可以进行各种修改和变换的，并且本发明并不限于这里所举的一些说明性实施例。

Claims (16)

1.一种向热塑性微纤维的非织造基材充电以制成驻极体过滤介质的方法，该方法包括向一种能够具有大量俘获电荷的热塑性不导电微纤维的非织造基材，在一定压力下将水注或水滴流喷射上去，所用的喷射压力应足以使该基材具有提高过滤作用的驻极体电荷；然后对该基材进行干燥。
2.如权利要求1所述的方法，其中所述的水注由一喷水扭结装置提供。
3.如权利要求1所述的方法，其中所述的水滴流由喷雾器提供。
4.如权利要求1所述的方法，其中所述的水注或水滴流的压力范围为69—3450kPa。
5.如权利要求1所述的方法，其中所述的基材在喷射水注或水滴流之前先经受电晕放电处理。
6.如权利要求1所述的方法，其中所述的基材还含有短纤维。
7.如权利要求6所述的方法，其中所述的短纤维占所述基材的90重量％。
8.如权利要求1所述的方法，其中所述的基材具有的织物单位重量为5—500g/m2。
9.如权利要求1所述的方法，其中所述的基材具有的厚度为0.25—20mm。
10.如权利要求1所述的方法，其中所述的微纤维的有效纤维直径为3—30μm。
11.如权利要求1所述的方法，其中所述的微纤维是聚丙烯、聚(4-甲基-1-戊烯)或它们的混合物。
12.如权利要求1所述的方法，其中所述的微纤维包含聚丙烯和聚(4-甲基-1-戊烯)。
13.如权利要求12所述的方法，其中的聚丙烯和聚(4-甲基-1-戊烯)在所述微纤维中是分层叠置的。
14.驻极体过滤介质，它是具有被俘获电荷的热塑性不导电微纤维的非织造基材，该电荷的提供是靠(1)在一定压力下将水注或水滴流喷射到基材上，所用的喷射压力足以使该基材具有提高过滤作用的驻极体电荷；(2)然后对基材进行干燥。
15.一种适于覆盖佩戴者鼻部和口部的有弹性的杯形过滤面罩，该面罩的材料是具有被俘获电荷的热塑性不导电微纤维的非织造基材，该电荷的提供是靠(1)在一定压力下将水注或水滴流喷射到基材上，所用的喷射压力足以使该基材具有提高过滤作用的驻极体电荷；(2)然后对基材进行干燥。
16.一个呼吸面罩组件，它包括一个面罩件，该面罩具有至少一个吸气口、吸气阀和吸气过滤器，还有至少一个呼气口、呼气阀、该面罩件所支撑的面垫圈和将面罩件挂在佩戴者头部用的吊带，其中的吸气过滤器包括具有被俘获电荷的热塑性不导电微纤维的非织造基材，该电荷的提供是靠(1)在一定压力下将水注或水滴流喷射到基材上，所用的喷射压力足以使该基材具有提高过滤作用的驻极体电荷；(2)然后对基材进行干燥。
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