CN114159886A - 一种阻燃涤纶混纺滤料的制备方法 - Google Patents

一种阻燃涤纶混纺滤料的制备方法 Download PDF

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CN114159886A
CN114159886A CN202111323679.4A CN202111323679A CN114159886A CN 114159886 A CN114159886 A CN 114159886A CN 202111323679 A CN202111323679 A CN 202111323679A CN 114159886 A CN114159886 A CN 114159886A
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flame
retardant
filter material
layer
polyester blended
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杨东
周冠辰
徐辉
杨慧
付素雅
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Anhui Yuanchen Environmental Protection Science and Technology Co Ltd
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Anhui Yuanchen Environmental Protection Science and Technology Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
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  • Inorganic Chemistry (AREA)
  • Filtering Materials (AREA)

Abstract

本发明公开一种阻燃涤纶混纺滤料的制备方法，涉及滤料技术领域，本发明包括以下步骤：(1)阻燃涤纶混纺针刺毡的制备：阻燃涤纶混纺针刺毡包括依次连接的背尘层、支撑层、迎尘层和阻燃层，阻燃层主要由40‑50％涤纶阻燃纤维、40‑50％预氧丝、5‑10％普通涤纶纤维以及5‑10％玻璃纤维混纺制成；(2)将阻燃涤纶混纺针刺毡经烧毛、阻燃整理液浸渍、热定型、压光得到阻燃涤纶混纺滤料。本发明的有益效果在于：本发明的阻燃涤纶混纺滤料阻燃效果好，满足市场阻燃需求，且阻燃层在火焰灼烧时无熔滴物、无明显损毁变形，对针刺毡的过滤效率影响较小。

Description

一种阻燃涤纶混纺滤料的制备方法
技术领域
本发明涉及滤料技术领域，具体涉及一种阻燃涤纶混纺滤料的制备方法。
背景技术
随着环境标准的升级，国内对于大气颗粒物排放的标准日趋严格，袋式除尘器成为控制烟气粉尘排放的有效设备。但在高温烟气、燃爆性粉尘等除尘场所易发生滤袋烧毁甚至失火等事故，此时需要考虑除尘滤料的阻燃性能。目前涤纶纤维因其成本低、应用广特点，使涤纶滤料成为产量较多的滤料品种之一，但涤纶纤维的可燃性，使涤纶滤料产生燃烧熔滴物，在火灾中十分危险，且灼烧损毁会影响滤袋的过滤性能，可能导致粉尘排放超标，因此提高涤纶滤料的阻燃性能具有重要意义。
目前，提高涤纶滤料的阻燃性能主要有两种方法，一种是采用改性阻燃涤纶纤维与本质阻燃纤维进行混纺形成针刺毡，此类针刺毡阻燃性能好，但本质阻燃纤维价格高，混纺时使用比例高，影响在市场上的应用和推广；另一种是采用浸渍法对涤纶滤料进行后处理，使阻燃剂黏附在滤料表面来提高阻燃性，此方法成本较低，工艺简单，但基于涤纶纤维的可燃性，经过阻燃剂后处理的涤纶滤料遇高温明火仍然会熔融，产生灼烧破损，影响滤袋的过滤性能，如公开号为CN111893641A的专利申请公开一种阻燃环保混合毡的生产工艺，通过浸渍阻燃剂，使混合毡具有优良的阻燃性能。因此，从实用性和经济性出发，开发一种符合当前滤袋市场阻燃性能需求、价格需求的阻燃涤纶针刺毡，具有重要意义。
发明内容
本发明所要解决的技术问题在于提供一种阻燃性能良好、使用成本低的阻燃涤纶混纺滤料的制备方法。
本发明通过以下技术手段实现解决上述技术问题：
一种阻燃涤纶混纺滤料的制备方法，包括以下步骤：
(1)阻燃涤纶混纺针刺毡的制备：所述阻燃涤纶混纺针刺毡包括依次连接的背尘层、支撑层、迎尘层和阻燃层，所述阻燃层主要由40-50％涤纶阻燃纤维、40-50％预氧丝、5-10％普通涤纶纤维以及5-10％玻璃纤维混纺制成；
(2)将阻燃涤纶混纺针刺毡经烧毛、阻燃整理液浸渍、热定型、压光得到阻燃涤纶混纺滤料，所述阻燃整理液包括阻燃剂和水，所述阻燃剂和水的质量比为5:100，所述阻燃剂包括聚磷酸酯、磷酸铵、纳米二氧化硅和黏土粉末，所述纳米二氧化硅与黏土粉末的混合物、聚磷酸酯、磷酸铵的质量比为1:1:1，所述纳米二氧化硅与黏土粉末的质量比为1:1。
有益效果：本发明的阻燃涤纶混纺滤料阻燃效果好，满足市场阻燃需求，且阻燃层在火焰灼烧时无熔滴物、无明显损毁变形，对针刺毡的过滤效率影响较小。
本发明的阻燃涤纶混纺滤料降低了阻燃层的厚度，且阻燃层采用多种阻燃纤维混纺，从而降低了成本高的阻燃纤维的使用比例，在较少的用量下就能达到织物B1阻燃等级，且在火焰灼烧时无熔滴物、无明显损毁变形，对针刺毡的过滤效率影响较小降低了使用成本。
本发明中的阻燃涤纶混纺针刺毡阻燃层中纤维的种类和配比不在上述条件下时，滤料阻燃性能变差，续燃时间变长，灼烧时出现明显变形。
本发明中阻燃整理液的原料缺少其中一种或几种时，滤料在火焰灼烧时出现熔滴物和明显损毁变形。
优选地，所述阻燃涤纶混纺针刺毡的厚度为2-4mm。
优选地，所述背尘层和迎尘层均由普通涤纶纤维经开松、梳理、铺网制成。
优选地，所述支撑层为涤纶长丝基布。
优选地，所述阻燃层的厚度为0.5-1mm。
优选地，所述阻燃层主要由40-50％涤纶阻燃纤维、40-50％预氧丝、5-10％普通涤纶纤维以及5-10％玻璃纤维经混合、开松、梳理、机械铺网制成。
优选地，所述阻燃涤纶混纺针刺毡中背尘层、支撑层、迎尘层的总厚度为3-5mm。
优选地，所述步骤(2)中热定型温度为180-200℃，热定型时间为5-10min，热定型速度为7-11m/min。
优选地，所述步骤(2)中压光温度为130-170℃，压力为0.2-0.7MPa，速度为2.5-3.5m/min。
优选地，所述黏土粉末的粒径为1-10μm。
本发明的优点在于：本发明的阻燃涤纶混纺滤料阻燃效果好，满足市场阻燃需求，且阻燃层在火焰灼烧时无熔滴物、无明显损毁变形，对针刺毡的过滤效率影响较小。
本发明的阻燃涤纶混纺滤料降低了阻燃层的厚度，且阻燃层采用多种阻燃纤维混纺，从而降低了成本高的阻燃纤维的使用比例，在较少的用量下就能达到织物B1阻燃等级，且在火焰灼烧时无熔滴物、无明显损毁变形，对针刺毡的过滤效率影响较小降低了使用成本。
本发明中的阻燃涤纶混纺针刺毡阻燃层中纤维的种类和配比不在上述条件下时，滤料阻燃性能变差，续燃时间变短，灼烧时出现明显变形。
本发明中阻燃整理液的原料缺少其中一种或几种时，滤料在火焰灼烧时出现熔滴物和明显损毁变形。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本发明保护的范围。
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
阻燃涤纶混纺滤料的制备方法，具体包括以下步骤：
(1)阻燃涤纶混纺针刺毡的制备：
普通涤纶针刺毡：将普通涤纶纤维原料进行开松、梳理、铺网，通过气流成网的方式形成背尘层和迎尘层，涤纶长丝基布作为支撑层，采用机械铺网的方式将背尘层、支撑层和迎尘层通过针刺工艺使其相互抱合，形成普通涤纶针刺毡，厚度为3mm，待用；
阻燃层：将阻燃涤纶纤维、普通涤纶纤维、预氧丝、玻璃纤维按照质量百分比分别为40％、40％、10％、10％混合、开松、梳理、铺网形成阻燃层，厚度为0.5mm；
将制得的阻燃层与制得的普通涤纶针刺毡通过机械铺网、再一次针刺工艺制得阻燃涤纶混纺针刺毡，厚度为3.3mm。
(2)将步骤(1)中的阻燃涤纶混纺针刺毡经烧毛、阻燃整理液浸渍、热定型、压光得到阻燃涤纶混纺滤料，厚度为2mm，其中阻燃整理液包括阻燃剂和水，阻燃剂和水的质量比为5:100，阻燃剂包括聚磷酸酯、磷酸铵、纳米二氧化硅和黏土粉末，纳米二氧化硅与黏土粉末的混合物、聚磷酸酯、磷酸铵的质量比为1:1:1，纳米二氧化硅与黏土粉末的质量比为1:1；热定型温度为200℃，热定型时间为5min，热定型速度为7m/min，压光压力为0.2MPa，压光温度为130℃，速度为2.5m/min。
实施例2
阻燃涤纶混纺滤料的制备方法，具体包括以下步骤：
(1)阻燃涤纶混纺针刺毡的制备：
普通涤纶针刺毡：将普通涤纶纤维原料进行开松、梳理、铺网，通过气流成网的方式形成背尘层和迎尘层，涤纶长丝基布作为支撑层，采用机械铺网的方式将背尘层、支撑层和迎尘层通过针刺工艺使其相互抱合，形成普通涤纶针刺毡，厚度为3mm，待用；
阻燃层：将阻燃涤纶纤维、普通涤纶纤维、预氧丝、玻璃纤维按照质量百分比分别为45％、45％、5％、5％混合、开松、梳理、铺网形成阻燃层，厚度为1mm；
将制得的阻燃层与制得的普通涤纶针刺毡通过机械铺网、再一次针刺工艺制得阻燃涤纶混纺针刺毡，厚度为3.7mm。
(2)将步骤(1)中的阻燃涤纶混纺针刺毡经烧毛、阻燃整理液浸渍、热定型、压光得到阻燃涤纶混纺滤料，厚度为3mm，其中阻燃整理液包括阻燃剂和水，阻燃剂和水的质量比为5:100，阻燃剂包括聚磷酸酯、磷酸铵、纳米二氧化硅和黏土粉末，纳米二氧化硅与黏土粉末的混合物、聚磷酸酯、磷酸铵的质量比为1:1:1，纳米二氧化硅与黏土粉末的质量比为1:1；热定型温度为180℃，热定型时间为10min，热定型速度为11m/min，压光压力为0.7MPa，压光温度为170℃，速度为3.5m/min。
实施例3
阻燃涤纶混纺滤料的制备方法，具体包括以下步骤：
(1)阻燃涤纶混纺针刺毡的制备：
普通涤纶针刺毡：将普通涤纶纤维原料进行开松、梳理、铺网，通过气流成网的方式形成背尘层和迎尘层，涤纶长丝基布作为支撑层，采用机械铺网的方式将背尘层、支撑层和迎尘层通过针刺工艺使其相互抱合，形成普通涤纶针刺毡，厚度为3mm，待用；
阻燃层：将阻燃涤纶纤维、普通涤纶纤维、预氧丝、玻璃纤维按照质量百分比分别为45％、45％、5％、5％混合、开松、梳理、铺网形成阻燃层，厚度为0.5mm；
将制得的阻燃层与制得的普通涤纶针刺毡通过机械铺网、再一次针刺工艺制得阻燃涤纶混纺针刺毡，厚度为3.2mm。
(2)将步骤(1)中的阻燃涤纶混纺针刺毡经烧毛、阻燃整理液浸渍、热定型、压光得到阻燃涤纶混纺滤料，厚度为2.5mm，其中阻燃整理液包括阻燃剂和水，阻燃剂和水的质量比为5:100，阻燃剂包括聚磷酸酯、磷酸铵、纳米二氧化硅和黏土粉末，纳米二氧化硅与黏土粉末的混合物、聚磷酸酯、磷酸铵的质量比为1:1:1，纳米二氧化硅与黏土粉末的质量比为1:1；热定型温度为190℃，热定型时间为8min，热定型速度为8m/min，压光压力为0.4MPa，压光温度为140℃，速度为3m/min。
对比例1
本对比例与实施例1的区别之处在于：阻燃层只包括普通涤纶纤维。
对比例2
本对比例与实施例1的区别之处在于：阻燃层由阻燃涤纶纤维、普通涤纶纤维、预氧丝、玻璃纤维按照质量百分比5：85：5：5经混合、开松、梳理、铺网形成阻燃层。
对比例3
本对比例与实施例1的区别之处在于：步骤(1)中阻燃层只包括普通涤纶纤维，步骤(2)中阻燃整理液包括阻燃剂和水，阻燃剂和水的质量比为5:100，阻燃剂为质量比为1:1的聚磷酸酯和纳米二氧化硅。
性能评估：极限氧指数和水平燃烧
对实施例1、对比例1-对比例3中阻燃涤纶混纺滤料的续燃时间、阴燃时间、损毁长度、熔滴物、极限氧指数指标进行测定，利用极限氧指数仪测定极限氧指数，利用水平燃烧仪器测定阻燃等级，织物燃烧性能评判标准：GB17591-2006《阻燃织物》，测定结果见表1。
表1为实施例和对比例中阻燃涤纶混纺滤料的测定结果
编号 续燃时间(s) 阴燃时间(s) 损毁长度mm) 熔滴物 极限氧指数
对比例1 25 0 250 有 ≤21％
实施例1 0 0 无 无 ＞31％
对比例2 5 0 80 无 ＞31％
对比例3 6 0 110 有 ＞31％
采用本发明方法制得的滤料极限氧指数大于31％，阻燃等级可达B1等级，且火焰灼烧时无熔滴物、无损毁面积，针刺毡阻燃层只发生部分炭化，对针刺毡的过滤效率影响较小。
对比例1中滤料的极限氧指数≤21％，易发生燃烧，对比例2和对比例3中滤料的极限氧指数虽然大于31％，但是出现明显损毁变形，对比例3出现熔滴物，对滤料的过滤效率影响较大。
以上实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。

Claims (10)

1.一种阻燃涤纶混纺滤料的制备方法，其特征在于：包括以下步骤：
(1)阻燃涤纶混纺针刺毡的制备：所述阻燃涤纶混纺针刺毡包括依次连接的背尘层、支撑层、迎尘层和阻燃层，所述阻燃层主要由40-50％涤纶阻燃纤维、40-50％预氧丝、5-10％普通涤纶纤维以及5-10％玻璃纤维混纺制成；
(2)将阻燃涤纶混纺针刺毡经烧毛、阻燃整理液浸渍、热定型、压光得到阻燃涤纶混纺滤料，所述阻燃整理液包括阻燃剂和水，所述阻燃剂和水的质量比为5:100，所述阻燃剂包括聚磷酸酯、磷酸铵、纳米二氧化硅和黏土粉末，所述纳米二氧化硅与黏土粉末的混合物、聚磷酸酯、磷酸铵的质量比为1:1:1，所述纳米二氧化硅与黏土粉末的质量比为1:1。
2.根据权利要求1所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述阻燃涤纶混纺针刺毡的厚度为2-4mm。
3.根据权利要求1所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述背尘层和迎尘层均由普通涤纶纤维经开松、梳理、铺网制成。
4.根据权利要求1所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述支撑层为涤纶长丝基布。
5.根据权利要求1所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述阻燃层的厚度为0.5-1mm。
6.根据权利要求1所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述阻燃层主要由40-50％涤纶阻燃纤维、40-50％预氧丝、5-10％普通涤纶纤维以及5-10％玻璃纤维经混合、开松、梳理、机械铺网制成。
7.根据权利要求1所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述阻燃涤纶混纺针刺毡中背尘层、支撑层、迎尘层的总厚度为3-5mm。
8.根据权利要求1所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述步骤(2)中热定型温度为180-200℃，热定型时间为5-10min，热定型速度为7-11m/min。
9.根据权利要求8所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述步骤(2)中压光温度为130-170℃，压力为0.2-0.7MPa，速度为2.5-3.5m/min。
10.根据权利要求1所述的阻燃涤纶混纺滤料的制备方法，其特征在于：所述黏土粉末的粒径为1-10μm。
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