CN113750648B - 一种用于立式压滤机的滤布及其制备方法 - Google Patents

一种用于立式压滤机的滤布及其制备方法 Download PDF

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CN113750648B
CN113750648B CN202010484011.7A CN202010484011A CN113750648B CN 113750648 B CN113750648 B CN 113750648B CN 202010484011 A CN202010484011 A CN 202010484011A CN 113750648 B CN113750648 B CN 113750648B
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毕蕾
王继光
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Liaoning Bolian Filter Co ltd
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Abstract

本发明涉及滤布制备工艺，具体的说是一种用于立式压滤机的滤布及其制备方法。滤布由经、纬线交织形成高强低伸基布；再经针刺方式，在基布表层植入至少一层的短纤维网，形成短纤维间隙过滤层；而后通过热压，使表层低熔点纤维熔融挤压，形成小孔径滤膜层的复合滤布。由经、纬向纱线交织形成机织高密基布；在基布表面，以短纤维为原料针刺至少一层的纤维网，进而作为短纤维过滤层，而后通过热压使短纤维间隙过滤层的表层形成滤膜，即形成小孔径滤膜层的复合滤布。本发明中机织高强低伸基布为由经、纬向纱线构成稳定的二维结构，使织物强力高，伸长率小，尺寸稳定性高，满足压滤机对滤布低伸长的要求，保证使用寿命长，过滤效果稳定。

Description

一种用于立式压滤机的滤布及其制备方法
技术领域：
本发明涉及滤布制备工艺，具体的说是一种用于立式压滤机的滤布及其制备方法。
背景技术
立式压滤机又称“滤布全行走式自动压滤机”，广泛应用于镍精矿、氧化锌浸出液、酵素、淀粉、碱渣、沸石、铜精矿等产品的过滤。立式压滤机通过挤压力，将滤布表层滤渣中的水份挤压出，以降低滤饼中的含水率。现阶段压滤机因为机上张力大，对滤布的强力及变形率有严格的要求。目前市面上用于压滤机的滤布多为机织滤布。
机织滤布是以经纬交织的形式形成交织点，交织点及纱线间隙是滤液渗透的主要途径。当交织孔隙小于滤料粒径时，固态颗粒被阻挡在滤布一侧，滤布过滤效果好；当交织孔隙大于滤料粒径时，固态颗粒穿过交织点，出现穿滤现象，或固态颗粒残留在滤布内部，出现堵塞现；当交织孔隙远远小于滤料粒径时，滤水效率低，固态滤料含水率高，不便于后续加工处理。由于上述问题，目前采用热定型等方式对机织物表面进行处理，但处理后依然保留有纱线交织的曲屈波度，并且在机械刮板的作用下表面伤害较大，表层清洁难度大。
无纺类过滤织物多应用于真空抽吸式滤机，是经短纤维网多层铺叠，形成纤维交错的层结构。过滤精度与纤维细度、纤维密度、纤网厚度、纤维排列、针刺工艺情况有关。过滤过程中实现多层过滤，截留粒径范围更广。无纺产品由于基布易变形，使无纺织物的机械性能差，过滤精度
不稳定。过滤过程中，固体物料易残留于纤维间，清洗难度大。且织物表层纤维易脱落，在机械外力作用下，易破损。
膜类织物多应用于气体、液体过滤中，过滤精度最高，产品表面光滑，极易清洗。但膜与基材复合时需要高温粘合，限制应用范围。膜类复合产品工艺路线长，制膜、覆膜成本高。膜制产品强度低，变形大，过滤面积和过滤压力受限，易破损、寿命短，无法应用于压滤机设备。
如何获得一种复合产品，能将三种滤材取长补短，既有机织的强力大、变形小，又有无纺织物的多层过滤效果，还兼俱膜类产品的过滤精度高、表面光洁易清理。综合以上功能的立式压滤布是本行业急需解决的问题。
发明内容
本发明目的在于提供一种用于立式压滤机的滤布及其制备方法。
为实现上述目的，本发明采用技术方案为：
一种用于立式压滤机的滤布，滤布由经、纬线交织形成高强低伸基布；再经针刺方式，在基布表层植入至少一层的短纤维网，形成短纤维间隙过滤层；而后通过热压，使表层低熔点纤维熔融挤压，形成小孔径滤膜层的复合滤布。
所述短纤维过滤层为从基布的两侧将短纤维针刺于其表面形成至少一层的纤维层网；其中，短纤维过滤层的最上层纤维层网由含低熔点的纤维针刺形成。
所述短纤维过滤层为两层以上的纤维层网；其中，所述与基布表面相邻的纤维层网由熔点高的中长纤维针刺形成；紧接着可以针刺高熔点纤维网做为过滤夹层；最后针刺低熔点棉型纤维网做为表层成膜。
所述高熔点为200℃以上；低熔点为110－150℃。
所述最上层纤维层网中低熔点纤维占20-100wt％，高熔点纤维占0-80wt％。
用于立式压滤机的滤布的制备方法，由经、纬向纱线交织形成机织高密基布；在基布表面，以短纤维为原料针刺至少一层的纤维网，进而作为短纤维过滤层，而后通过热压使短纤维间隙过滤层的表层形成滤膜，即形成小孔径滤膜层的复合滤布。
所述机织高强低伸基布为由经、纬线交织形成；其中，纱线为300－3000D合股，经密200－350根/10cm，纬密80－200根/10cm；
所述短纤维过滤层为从基布的两侧将短纤维针刺于其表面形成至少一层的纤维层网；其中，短纤维过滤层的最上层纤维层网由含低熔点的纤维针刺形成纤维层网；所述短纤维过滤层为两层以上的纤维层网；其中，所述与基布表面相邻的纤维层网由熔点高且较粗的中长纤维针刺形成，且至少一层；由熔点高且较粗的中长纤维针刺形成的纤维层网与由含低熔点的纤维针刺形成的纤维层网之间为至少一层的由熔点高且较细的棉型纤维形成的纤维层网。
所述滤布的高熔点中长纤维，粗壮的中长纤维提高短纤层的强力及牢度；滤布表层为低熔点纤维，较细的棉型纤维通过热压后，极易形成细腻、光滑的膜质滤层。
当上层纤维层网中低熔点纤维的含量为35wt％-100wt％时，形成不同厚度的滤膜；
当上层纤维层网中低熔点纤维的含量为20wt％－35wt％时，低熔点纤维起到粘合作用，使表层纤维牢度高，防止机械外力对表层纤维的损伤
所述热压温度为110－150℃，压力为7-8Pa；通过热压使短纤维过滤层表面形成具有均匀微小孔径过滤层。
一种用于立式压滤机的滤布的应用，所述滤布在用于立式压滤机在粒径为25－1μm精细物料过滤中的应用。
本发明所具有的优点：
本发明高性能立式机压滤布由机织成低伸型布为基布，再将短纤维针刺至少一层网，而后通过热压成膜或粘合，进而得到多层渗透式过滤布。结构上，规律的纱线交织点、随机分布的纤维间隙及细小的膜质微孔，形成多层的过滤结构。物理性能上，高强基布使产品实现低伸机械性能；光滑的表层。具体为：
1、本发明中机织高强低伸基布为由经、纬向纱线构成稳定的二维结构，使织物强力高，伸长率小，尺寸稳定性高，满足压滤机对滤布低伸长的要求，保证使用寿命长，过滤效果稳定。
2、本发明中的短纤维过滤层是以短纤维为原料，经初步梳理后，形成网纤维层，再以针刺方式，将纤维植绒在基布两侧形成至少一层纤维层网；短纤维过滤层中纵横分布的纤维层形成疏松的、多孔过的深层过滤、多层过滤，减少微小颗粒对滤布形成的伤害，提高过滤效果以及滤布使用寿命。基布表面的纤维层网为熔点高且较粗的中长纤维针刺形成，粗壮的中长纤维提高短纤层的强力及牢度。在第一层纤网上铺设低熔点棉型化纤网，并针刺。较细的棉型纤维提高成膜后表层的细腻及光滑程度。另一方面，弹性的纤网托载膜纤维层，形成缓冲，减少膜质表层的损伤。
3、本发明短纤维间隙过滤层中纤维层网当上层低熔点纤维重量百分比为35％-100％时，形成不同厚度的滤膜；当上层低熔点纤维重量百分比为20－35％时，低熔点纤维起到粘合、加固作用，使表层纤维牢度高，防止机械外力对表层纤维的损伤。
4.本发明中的热压滤膜小孔径过滤层，通过定型及压光的热处理方法得到。由于使低熔点纤维先熔化，外加压力后，在表层形成厚度一致、结构致密、孔隙均匀的膜，以实现表层精细过滤。
膜质光滑的表层短纤维层不受外部压力及滤料污染，保持持久的清洁及弹性，保证纤维层实现多层过滤效果。光滑的表层使滤饼易脱落，减少滤料对织物表面的磨损，使滤布易清洗、延长织物使用周期。
附图说明
图1为本发明是实例2提供的经向切面图。
图2A为本发明是实例1提供的成膜图；其中，膜质表层×150。
图2B为本发明是实例1提供的未成膜图；其中，未处理的短纤表层×150。
具体说明
以下通过具体实施例的形式，对本发明的上述内容再做进一步的详细说明。但不应将此理解为本发明上述主题的范围仅限于以下的实施例。凡基于本发明上述内容所实现的技术均属于本发明的范围。
实施例1
用于立式压滤机的滤布的制备：
A机织
以经纬密280*80根/10cm的复丝纱线交织形成坯布，再通过定型处理获得高强低伸稳定的基布。定型处理方式按照专利号为201220039536.0，发明名称为一种热辊式多辊牵拉定型机的文献中记载的方式进行。
B针刺
针刺三种细度、熔点不同的纤维。上层为成膜的主要原料，下层纤维植入基布，具体为：
第一层纤维网以高熔点毛型涤纶短纤为原料，纤维长度76MM，细度3.8dtex，长而粗壮的毛型纤维形成弹性的多维过滤层，在基布表面以针刺方式植入基布内。
第二层纤网以高熔点棉型涤纶短纤为原料，长度38MM，细度1.96dtex。在第一层纤网基础上，以针刺方式植入第一纤维层网内；
第三层纤维网以100wt％低熔点棉型丙纶短纤为原料，长度38MM，细度1.96dtex。在第二层纤网基础上，以针刺方式植入第二纤维层网内。
C成膜
所述针刺后滤布通过150℃热定型及压光，使第三层纤维网的丙纶纤维热压成膜，即形成小孔径滤膜层的复合滤布。如图2A中膜质表层，其在控制压力及速度条件下，可保证成膜均匀、厚度一致；同时以未经过热压成膜作为对照(参见图2B)；由图2可见，成膜后表层无枝状突起，滤饼更易脱落。
将所得滤布通过透气量测试仪进行检测，其压滤布透气量<1L/M2/S。
D本产品应用于锂盐的洗涤、过滤环节；将步骤C获得滤布应用于锂电池行业用BLZG9㎡全自动立式压滤机中进行过滤，压滤机进料含水率50-80％，过滤后滤饼含水率10-20％，经过滤可见其可过滤粒径为1－10um及以上的滤料。
实施例2
用于立式压滤机的滤布的制备：
A机织：
以经纬密270×88根/10cm的复丝纱线交织形成坯布，再通过定型处理获得高强低伸稳定的基布；定型处理方式按照专利号为201220039536.0，发明名称为一种热辊式多辊牵拉定型机的文献中记载的方式进行。
以经纬密280*80根/10cm的复丝经交织形成坯布，再通过定型处理获得高强低伸稳定的基布。定型处理方式按照专利号为201220039536.0，发明名称为一种热辊式多辊牵拉定型机的文献中记载的方式进行。
B针刺
针刺二种细度、熔点不同的纤维，上层为成膜的主要原料，下层纤维植入基布，形成交错层叠的纤维孔隙。具体为：
第一层纤维网以高熔点毛型涤纶短纤为原料，纤维长度76MM，细度3.8dtex，长而粗壮的毛型纤维形成弹性的多维过滤层，在基布表面以针刺方式植入基布内。
第二层纤维网以100wt％低熔点棉型丙纶短纤，长度38MM，细度1.96dtex。在第二层纤网基础上，以针刺方式植入第一纤维层网内。
C成膜
所述针刺后滤布通过150℃热定型及压光，使第二层纤维网的丙纶纤维热压成膜，即形成小孔径滤膜层的复合滤布。如图1中膜质表层，在控制压力及速度条件下，可保证成膜均匀、厚度一致。
将所得滤布通过透气量测试仪进行检测，压滤布透气量5－2L/M2/S。
同时将其用于过滤变性淀粉，经过滤后可见，该滤布可过滤粒径20－10um的滤料。
实施例3
用于立式压滤机的滤布的制备：
A机织：
以经纬密290×90根/10cm的复丝纱线交织形成坯布，再通过定型处理获得高强低伸稳定的基布。定型处理方式按照专利号为201220039536.0，发明名称为一种热辊式多辊牵拉定型机的文献中记载的方式进行。
B针刺
针刺二种细度、熔点不同的纤维，上下层起到过滤作用，下层纤维植入基布，具体为：
第一层纤维网以高熔点毛型涤纶短纤为原料，纤维长度76MM，细度3.8dtex，长而粗壮的毛型纤维形成弹性的多维过滤层，在基布表面以针刺方式植入基布内。
第二层纤维网以35wt％低熔点棉型丙纶短纤及65wt％高熔点涤纶纤维为原料，长度38MM，细度1.96dtex。在第二层纤网基础上，以针刺方式植入第一纤维层网内。
C成膜
所述针刺后滤布通过150℃热定型及压光，使第二层纤维网的丙纶纤维受热熔融，经外边挤压后与其它高熔点纤维粘接，提高表层纤维牢度。
将所得滤布通过透气量测试仪进行检测，压滤布透气量10-8L/M2/S。
同时将其用于过滤化工精炼产品经过滤后可见，该滤布可过滤粒径为25um及以上滤料。

Claims (8)

1.一种用于立式压滤机的滤布，其特征在于：滤布由经、纬线交织形成高强低伸基布；再经针刺方式，在基布表层植入短纤维，形成短纤维过滤层；而后通过热压，使表层低熔点纤维熔融挤压，形成小孔径滤膜层的复合滤布；
所述短纤维过滤层中，与基布表面相邻的纤维层网由熔点高且较粗的中长纤维针刺形成，且至少一层；由熔点高且较粗的中长纤维针刺形成的纤维层网与由含低熔点纤维针刺形成的纤维层网之间为至少一层的由熔点高且较细的棉型纤维形成的纤维层网。
2.根据权利要求1所述的用于立式压滤机的滤布，其特征在于：所述短纤维过滤层为从基布的两侧将短纤维针刺于其表面形成纤维层网。
3.根据权利要求2所述的用于立式压滤机的滤布，其特征在于：高熔点为200℃以上；所述低熔点为110－150℃。
4.根据权利要求2所述的用于立式压滤机的滤布，其特征在于：所述短纤维过滤层的表层纤维层中低熔点纤维占20-100wt%。
5.权利要求1所述的用于立式压滤机的滤布的制备方法，其特征在于：由经、纬向纱线交织形成机织高密基布；在基布表面，以短纤维为原料针刺纤维层网，进而作为短纤维过滤层，而后通过热压使短纤维过滤层的表层形成滤膜，即形成小孔径滤膜层的复合滤布。
6.根据权利要求5所述的用于立式压滤机的滤布的制备方法，其特征在于：机织高强低伸基布为由经、纬线交织形成；其中，纱线为300－3000D合股，经密200－350根/10cm，纬密80－200根/10cm；
所述短纤维过滤层为从基布的两侧将短纤维针刺于其表面形成纤维层网；其中，短纤维过滤层的表层纤维层网由含低熔点纤维针刺形成纤维层网；短纤维过滤层中，与基布表面相邻的纤维层网由熔点高且较粗的中长纤维针刺形成，且至少一层；由熔点高且较粗的中长纤维针刺形成的纤维层网与由含低熔点纤维针刺形成的纤维层网之间为至少一层的由熔点高且较细的棉型纤维形成的纤维层网。
7.根据权利要求5所述的用于立式压滤机的滤布的制备方法，其特征在于：所述热压温度为110－150℃，压力为7-8 Pa；通过热压使短纤维过滤层表面形成具有均匀微小孔径过滤层。
8.一种权利要求1-4任一项所述的用于立式压滤机的滤布的应用，其特征在于：所述滤布在用于立式压滤机在粒径为25－1μm精细物料过滤中的应用。
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