CN115382301A - 一种耐高温玻纤复合基布水刺滤料及其制备方法 - Google Patents

一种耐高温玻纤复合基布水刺滤料及其制备方法 Download PDF

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CN115382301A
CN115382301A CN202211019168.8A CN202211019168A CN115382301A CN 115382301 A CN115382301 A CN 115382301A CN 202211019168 A CN202211019168 A CN 202211019168A CN 115382301 A CN115382301 A CN 115382301A
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filter material
speed
glass fiber
temperature
spunlace
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CN115382301B (zh
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蒋湘粤
徐新杰
阳建军
徐卉
于淼涵
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Nanjing Jihua 3521 Environmental Protection Technology Co ltd
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Nanjing Jihua 3521 Environmental Protection Technology Co ltd
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    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B01D39/2017—Glass or glassy material the material being filamentary or fibrous
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  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geology (AREA)
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  • Filtering Materials (AREA)

Abstract

本发明涉及袋式除尘器的零部件技术领域，尤其涉及一种耐高温玻纤复合基布水刺滤料及其制备方法，包括如下步骤：S1.玻璃纤维复合基布的制备；S2.素毡的制备；S3.后处理。本发明将玻纤和芳纶纤维复合针刺单片毡材作为滤料的基布使用，可以满足滤料的强力、耐温性、耐腐蚀性等性能要求。本发明滤料的上下纤维层使用聚苯硫醚和聚四氟乙烯纤维混合，采用针刺预刺和水刺加工工艺，通过优化水刺压力等工艺参数，减小纤维损伤，提高滤料过滤精度。

Description

一种耐高温玻纤复合基布水刺滤料及其制备方法
技术领域
本发明涉及袋式除尘器的零部件技术领域，尤其涉及一种耐高温 玻纤复合基布水刺滤料及其制备方法。
背景技术
钢铁工业、水泥工业和燃煤电厂、垃圾焚烧等等所产生的烟尘不 仅温度高、浓度大，而且成分十分复杂，严重污染空气环境。随着经 济快速发展和人们环保意识不断增强，国家对环保问题日益重视，特 别在烟尘重污染领域，行业排放标准越来越严格，而袋式除尘器的应 用也越来越广泛。
目前，袋式除尘器核心部件是滤袋，滤袋一般使用非织造滤料， 为满足复杂工况条件，滤料通常采用基布作为加强中间层，上下面为 无纺纤维层。基布一般使用机织产品，而要满足耐高温、耐腐蚀性、 强力高等条件，基布常使用PTFE基布、PPS基布等，价格都较高。
现有技术的缺陷和不足：
滤料通常采用基布作为加强中间层，上下面为无纺纤维层，基布 一般使用机织产品，而要满足耐高温、耐腐蚀性、强力高等条件，基 布常使用PTFE基布、PPS基布等，价格都较高。
滤料上下面无纺纤维层现在主要采用针刺加工工艺，对纤维损伤 程度较大，且过滤精度无法满足越来越严格的排放标准。
发明内容
针对上述不足，本发明的目的是提供一一种耐高温玻纤复合基布 水刺滤料及其制备方法。
本发明提供了如下的技术方案：
一种耐高温玻纤复合基布水刺滤料的制备工艺，包括如下步骤：
S1.玻璃纤维复合基布的制备：对玻璃纤维和芳纶纤维进行开松、 混合、梳理、铺网，得到纤网层，采用预针刺机对纤网进行预针刺处 理，然后采用主针刺机对纤网进行主针刺处理，得到玻纤单片基布； 其中，玻璃纤维和芳纶纤维之间的质量比为7:3；
S2.素毡的制备：对聚苯硫醚和聚四氟乙烯纤维纤维进行开松、 混合、梳理、铺网，并在两台铺网机中间通过放卷机铺设制备的玻纤 复合基布，形成复合纤网，采用预针刺机对复合纤网进行预针刺处理， 得到预针刺毡，对预针刺毡进行水刺加固处理，得到滤料素毡；其中， 聚苯硫醚和聚四氟乙烯纤维的质量配比为2:1；
S3.后处理：素毡放卷后进行下一道工序为烧毛，烧毛后毡材进 行放卷，经过浸渍槽，过一遍聚四氟乙烯乳液处理，再过轧辊轧干， 控制轧余量在115％—130％，将轧干后的滤料进行烘干定型，最后收 卷；其中，烧毛速度为10-10.5m/min。
作为一种耐高温玻纤复合基布水刺滤料的制备工艺的优选技术 方案，在所述步骤S1中用到梳棉机的工艺参数为：主锡林转速为 800-850r/min，出棉道夫速度为30m/min，杂乱辊一速度为 13.3-13.5m/min，杂乱辊二速度为8.9-9m/min；剥棉辊速度为9m/min；
在所述步骤S1中用到铺网机的工艺参数为：铺网层数为1-2层， 输送皮带拉伸率为102％，铺网车拉伸率为102％；
在所述步骤S1中用到针刺机的工艺参数为：针刺深度为8-8.5mm， 针刺密度400-450p/cm2，入网牵伸率为0-3％，出网牵伸率为0-3％。
作为一种耐高温玻纤复合基布水刺滤料的制备工艺的优选技术 方案，步骤S2中得到滤料素毡的主令速度为4～6m/min。
作为一种耐高温玻纤复合基布水刺滤料的制备工艺的优选技术 方案，在所述步骤S2中用到喂棉箱的工艺参数为：底部传送带速度 为3.5m/min；角钉帘输送速度为18.5m/min；均棉罗拉速度为 100m/min；剥取罗拉速度为100m/min；
在所述步骤S2中用到梳棉机的工艺参数为：出棉道夫速度为 10m/min；刺辊速度为300m/min；工作辊速度为20m/min；剥棉辊 速度为100m/min；
在所述步骤S2中用到梳棉机的工艺参数为：输送皮带拉伸率为 103％。
作为一种耐高温玻纤复合基布水刺滤料的制备工艺的优选技术 方案，步骤S2中所述的水刺加固中水刺的工艺参数具体为：水刺速 度4-6m/min，水刺压力200～360bar，烘燥温度为100-150℃。
作为一种耐高温玻纤复合基布水刺滤料的制备工艺的优选技术 方案，在步骤S3中工艺参数为：烘干定型次数为1次，烘干定型的 超喂率为2-6％，烘干定型温度为200-240℃，烘干定型速度为 5-6m/min。
利用上述制备工艺制备出的滤料，包括中间加强层和无纺纤维层， 所述中间加强层的上、下端面附着有所述无纺纤维层。
本发明的有益效果是：
1.玻璃纤维由于具有耐高温、高强力、优异的尺寸稳定性和良好 的耐酸碱腐蚀性，越来越受到环保行业的青睐，玻璃纤维过滤材料能 够在260℃高温下长期稳定使用，强力往往可达到2000N以上，尺 寸稳定性大于99％，耐酸碱性良好，本发明将质量比为7:3的玻璃纤 维和芳纶纤维针刺单片毡材作为滤料的基布使用，可以满足滤料的强 力、耐温性、耐腐蚀性等性能要求，同时芳纶纤维相对于玻璃纤维成 本低，配比高，可以相对降低成本；
2.本发明滤料的上下纤维层使用的聚苯硫醚和聚四氟乙烯纤维， 采用水刺加工工艺，通过优化水刺压力等工艺参数，减小纤维损伤， 提高滤料过滤精度；聚苯硫醚和聚四氟乙烯纤维的质量比为2:1，容 易梳理，静电少，且聚苯硫醚较聚四氟乙烯便宜，配比高，成本相对 较低；
3.采用预针刺机对复合纤网进行预针刺处，可以初步得到强度较 高的预针刺毡，避免在后续的水刺加固工艺中水刺头的高压将产品破 坏，再进行水刺加固处理，得到的滤料孔径小、过滤效果好；
4.轧辊轧干的控制轧余量在115％至130％，通过余量的控制抵消 了后续的烘干过程中产品收缩，而且控制毡材中聚四氟乙烯乳液的含 量，从而制备出符合规定的产品；
5.通过浸渍提高毡材表面含聚四氟乙烯乳液的量，进一步的提高 毡材的强力、耐腐蚀以及耐温性能。
附图说明
附图用来提供对本发明的进一步理解，并且构成说明书的一部分， 与本发明的实施例一起用于解释本发明，并不构成对本发明的限制。 在附图中：
图1是滤料的立体结构示意图；
图中标记为：1、中间加强层；2、上层无纺纤维层；3、下层无 纺纤维层；
具体实施方式
以下结合实施例和附图对本发明的构思、具体结构及产生的技术 效果进行清楚、完整地描述，以充分理解本发明的目的、方案和效果。 需要说明的是，在不冲突的情况下本申请中的实施例及实施例中的特 征可以相互组合。需要说明的是，如无特殊说明，当某一特征被称为 “固定”、“连接”在另一个特征，它可以直接固定、连接在另一个特征 上，也可以间接地固定、连接在另一个特征上。此外，本发明中所使 用的上、下、左、右等描述仅仅是相对于附图中本发明各组成部分的 相互位置关系来说的。
本发明所制得的耐高温玻纤复合基布水刺滤料的性能测试方法 具体如下：
1、厚度测试按照FZ/T60004-1991《非织造布厚度的测定》。
2、透气性测试按照GBT5453-1997《纺织品织物透气性的测定》。
3、经纬向断裂强力按GB/T3923.1测定。
4、滤料耐温特性测试按GB/T6719-2009《袋式除尘器技术要求》 以热处理后滤料的强度保持率及热收缩率表示。
注：滤料经热处理后的强度保持率和伸长率的测试按下列步骤进 行:在滤料样品上随机剪取500mm×400mm滤料4块；取出其中一块 试样，分别测定其经纬向断裂强度及断裂伸长率；将其余三块分别测 量其经向、纬向长度，标记后平行悬挂于高温箱内；以2℃/min速 度升温至该滤料最高连续使用温度后恒温并开始计时；恒温24h后取 出滤料，滤料冷却后分别测定各块滤料经纬向长度L,经纬向断裂强 力。
5、耐碱性测试按照GB/T6719-2009《袋式除尘器技术要求》以 滤料经碱性物质溶液浸泡后的强度保持率表示。
注：将滤料浸于质量分数为40％的NaOH常温溶液中；24h后将 其取出，经过清水充分漂洗，并在通风橱中干燥；按GB/T3923.1测 定其经纬向断裂强力，计算其经纬向断裂强力保持率。
6、瞬时工作温度下的断裂强力保持率测试按GB/T6719-2009《袋 式除尘器技术要求》。
注：测其试样的瞬时工作温度下的断裂强力保持率以及其他各项 性能均按如下程序准备试样：先将试样在所选择瞬时温度下加热10 分钟，然后放置室温下冷却10分钟，按此加热、冷却循环重复10 次后，再对该试样进行上述各项性能测试。
7.滤料VDI实验测试按照GB T 6719-2009袋式除尘器技术要求测 试。
实施例一
一种耐高温玻纤复合基布水刺滤料的制备工艺，包括如下步骤：
S1.玻璃纤维复合基布的制备：对玻璃纤维和芳纶纤维进行开松、 混合、梳理、铺网，得到纤网层，采用预针刺机对纤网进行预针刺处 理，然后采用主针刺机对纤网进行主针刺处理，得到玻纤单片基布； 其中，玻璃纤维和芳纶纤维之间的质量比为7:3；
S2.素毡的制备：对聚苯硫醚和聚四氟乙烯纤维纤维进行开松、 混合、梳理、铺网，并在两台铺网机中间通过放卷机铺设制备的玻纤 复合基布，形成复合纤网，采用预针刺机对复合纤网进行预针刺处理， 得到预针刺毡，对预针刺毡进行水刺加固处理，得到滤料素毡；其中， 聚苯硫醚和聚四氟乙烯纤维的质量配比为2:1；
S3.后处理：素毡放卷后进行下一道工序为烧毛，烧毛后毡材进 行放卷，经过浸渍槽，过一遍聚四氟乙烯乳液处理，再过轧辊轧干， 控制轧余量在115％—130％，将轧干后的滤料进行烘干定型，最后收 卷；其中，烧毛速度为10-10.5m/min。
表1是实施例一中步骤S1的工艺参数
Figure BDA0003813298800000071
表2是实施例一种步骤S2中开松至预刺的工艺参数
Figure BDA0003813298800000072
Figure BDA0003813298800000081
表3是实施例一种步骤S2中水刺的工艺参数
Figure BDA0003813298800000082
表4是步骤S3后处理的工艺参数
烘干定型次数 1次
烘干定型率超喂 2％
烘干定型温度 200℃
烘干定型速度 5m/min
实施例二
一种耐高温玻纤复合基布水刺滤料的制备工艺，包括如下步骤：
S1.玻璃纤维复合基布的制备：对玻璃纤维和芳纶纤维进行开松、 混合、梳理、铺网，得到纤网层，采用预针刺机对纤网进行预针刺处 理，然后采用主针刺机对纤网进行主针刺处理，得到玻纤单片基布； 其中，玻璃纤维和芳纶纤维之间的质量比为7:3；
S2.素毡的制备：对聚苯硫醚和聚四氟乙烯纤维纤维进行开松、 混合、梳理、铺网，并在两台铺网机中间通过放卷机铺设制备的玻纤 复合基布，形成复合纤网，采用预针刺机对复合纤网进行预针刺处理， 得到预针刺毡，对预针刺毡进行水刺加固处理，得到滤料素毡；其中， 聚苯硫醚和聚四氟乙烯纤维的质量配比为2:1；
S3.后处理：素毡放卷后进行下一道工序为烧毛，烧毛后毡材进 行放卷，经过浸渍槽，过一遍聚四氟乙烯乳液处理，再过轧辊轧干， 控制轧余量在115％—130％，将轧干后的滤料进行烘干定型，最后收 卷；其中，烧毛速度为10-10.5m/min。
表5是实施例二中步骤S1的工艺参数
Figure BDA0003813298800000091
Figure BDA0003813298800000101
表6是实施例二中步骤S2中开松至预刺的工艺参数
Figure BDA0003813298800000102
Figure BDA0003813298800000111
表7是实施例二中步骤S2中水刺的工艺参数
Figure BDA0003813298800000112
表8是实施例二步骤S3后处理的工艺参数
烘干定型次数 1次
烘干定型率超喂 4％
烘干定型温度 220℃
烘干定型速度 5m/min
实施例三
一种耐高温玻纤复合基布水刺滤料的制备工艺，包括如下步骤：
S1.玻璃纤维复合基布的制备：对玻璃纤维和芳纶纤维进行开松、 混合、梳理、铺网，得到纤网层，采用预针刺机对纤网进行预针刺处 理，然后采用主针刺机对纤网进行主针刺处理，得到玻纤单片基布； 其中，玻璃纤维和芳纶纤维之间的质量比为7:3；
S2.素毡的制备：对聚苯硫醚和聚四氟乙烯纤维纤维进行开松、 混合、梳理、铺网，并在两台铺网机中间通过放卷机铺设制备的玻纤 复合基布，形成复合纤网，采用预针刺机对复合纤网进行预针刺处理， 得到预针刺毡，对预针刺毡进行水刺加固处理，得到滤料素毡；其中， 聚苯硫醚和聚四氟乙烯纤维的质量配比为2:1；
S3.后处理：素毡放卷后进行下一道工序为烧毛，烧毛后毡材进 行放卷，经过浸渍槽，过一遍聚四氟乙烯乳液处理，再过轧辊轧干， 控制轧余量在115％—130％，将轧干后的滤料进行烘干定型，最后收 卷；其中，烧毛速度为10-10.5m/min。
表9是实施例三中步骤S1的工艺参数
Figure BDA0003813298800000121
表10是实施例三中步骤S2中开松至预刺的工艺参数
Figure BDA0003813298800000122
Figure BDA0003813298800000131
表11是实施例三中步骤S2中水刺的工艺参数
Figure BDA0003813298800000132
表12是实施例三中步骤S3后处理的工艺参数
烘干定型次数 1次
烘干定型率超喂 6％
烘干定型温度 240℃
烘干定型速度 6m/min
对照实施例一
对聚苯硫醚和聚四氟乙烯纤维纤维进行开松、混合、梳理、铺网， 并在两台铺网机中间通过放卷机铺设制备的PTFE基布，形成复合纤 网，采用预针刺机对复合纤网进行预针刺处理，得到预针刺毡，对预 针刺毡进行水刺加固处理，得到滤料素毡，素毡放卷后进行下一道工 序为烧毛，烧毛后毡材进行放卷，经过浸渍槽，过一遍聚四氟乙烯乳 液处理，再过轧辊轧干，将轧干后的滤料进行烘干定型，最后收卷； 对照实施例基布采用PTFE基布，基布幅宽为2.3m，对照例与上述实 施例相比无S1步骤。
表13是对照实施例一中开松至预刺的工艺参数
Figure BDA0003813298800000141
Figure BDA0003813298800000151
表14是对照实施例一中针刺主刺的工艺参数
Figure BDA0003813298800000152
表15是对照实施例一中步骤S3后处理的工艺参数
烘干定型次数 1次
烘干定型率超喂 6％
烘干定型温度 240℃
烘干定型速度 6m/min
实验结果与检测
表16是实施例二与对照例一制备出的产品的物理检测数据
Figure BDA0003813298800000161
表16实施例二与对照例一制备出的滤料VDI实验数据
Figure BDA0003813298800000171
以上所述仅为本发明的优选实施例而已，并不用于限制本发明， 尽管参照前述实施例对本发明进行了详细的说明，对于本领域的技术 人员来说，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。凡在本发明的精神和原则之 内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护 范围之内。

Claims (7)

1.一种耐高温玻纤复合基布水刺滤料的制备工艺，其特征在于，包括如下步骤：
S1.玻璃纤维复合基布的制备：对玻璃纤维和芳纶纤维进行开松、混合、梳理、铺网，得到纤网层，采用预针刺机对纤网进行预针刺处理，然后采用主针刺机对纤网进行主针刺处理，得到玻纤单片基布；其中，玻璃纤维和芳纶纤维之间的质量比为7:3；
S2.素毡的制备：对聚苯硫醚和聚四氟乙烯纤维纤维进行开松、混合、梳理、铺网，并在两台铺网机中间通过放卷机铺设制备的玻纤复合基布，形成复合纤网，采用预针刺机对复合纤网进行预针刺处理，得到预针刺毡，对预针刺毡进行水刺加固处理，得到滤料素毡；其中，聚苯硫醚和聚四氟乙烯纤维的质量配比为2:1；
S3.后处理：素毡放卷后进行下一道工序为烧毛，烧毛后毡材进行放卷，经过浸渍槽，过一遍聚四氟乙烯乳液处理，再过轧辊轧干，控制轧余量在115％—130％，将轧干后的滤料进行烘干定型，最后收卷；其中，烧毛速度为10-10.5m/min。
2.根据权利要求1所述的耐高温玻纤复合基布水刺滤料的制备工艺，其特征在于，在所述步骤S1中用到梳棉机的工艺参数为：主锡林转速为800-850r/min，出棉道夫速度为30m/min，杂乱辊一速度为13.3-13.5m/min，杂乱辊二速度为8.9-9m/min；剥棉辊速度为9m/min；
在所述步骤S1中用到铺网机的工艺参数为：铺网层数为1-2层，输送皮带拉伸率为102％，铺网车拉伸率为102％；
在所述步骤S1中用到针刺机的工艺参数为：针刺深度为8-8.5mm，针刺密度400-450p/cm2，入网牵伸率为0-3％，出网牵伸率为0-3％。
3.根据权利要求1所述的耐高温玻纤复合基布水刺滤料的制备工艺，其特征在于，步骤S2中得到滤料素毡的主令速度为4～6m/min。
4.根据权利要求1所述的耐高温玻纤复合基布水刺滤料的制备工艺，其特征在于，在所述步骤S2中用到喂棉箱的工艺参数为：底部传送带速度为3.5m/min；角钉帘输送速度为18.5m/min；均棉罗拉速度为100m/min；剥取罗拉速度为100m/min；
在所述步骤S2中用到梳棉机的工艺参数为：出棉道夫速度为10m/min；刺辊速度为300m/min；工作辊速度为20m/min；剥棉辊速度为100m/min；
在所述步骤S2中用到梳棉机的工艺参数为：输送皮带拉伸率为103％。
5.根据权利要求1所述的耐高温玻纤复合基布水刺滤料的制备工艺，其特征在于，步骤S2中所述的水刺加固中水刺的工艺参数具体为：水刺速度4-6m/min，水刺压力200～360bar，烘燥温度为100-150℃。
6.根据权利要求1所述的耐高温玻纤复合基布水刺滤料，其特征在于，在步骤S3中工艺参数为：烘干定型次数为1次，烘干定型的超喂率为2-6％，烘干定型温度为200-240℃，烘干定型速度为5-6m/min。
7.基于权利要求1至6任一所述制备工艺制备出的滤料，其特征在于，包括中间加强层和无纺纤维层，所述中间加强层的上、下端面附着有所述无纺纤维层。
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