CN116651085A - 耐高温复合过滤材料及其制备方法 - Google Patents

耐高温复合过滤材料及其制备方法 Download PDF

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CN116651085A
CN116651085A CN202310479667.3A CN202310479667A CN116651085A CN 116651085 A CN116651085 A CN 116651085A CN 202310479667 A CN202310479667 A CN 202310479667A CN 116651085 A CN116651085 A CN 116651085A
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filter material
preparing
layer
composite filter
woven fabric
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张转春
吴龙涛
张小宇
邱驰
陈雷雷
王亚飞
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Yimao Environmental Technology Co ltd
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Yimao Environmental Technology Co ltd
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    • B32B5/22—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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
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  • Engineering & Computer Science (AREA)
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Abstract

本发明公开了一种耐高温复合过滤材料及其制备方法，通过采用基布层/精过滤层/粗过滤层的多层次设计，并结合离心纺丝和静电纺丝的方法，制备得到纤维直径呈不均匀分布的非织造布材料，随后将非织造布材料通过浸轧工艺处理，烘干后在非织造布材料两侧形成一层微孔透气膜，得到耐高温复合过滤材料。本发明制备的复合过滤材料，通过多层次设计及透气微孔膜的协同作用，在保证过滤材料透气性的同时改善其过滤性能、过滤精度及清灰性能，达到高效过滤且使用寿命长的效果，且微孔膜优异的化学稳定性可以对复合过滤材料起到保护作用。另外，非织造布材料与浸轧工艺的协同作用，在提高复合过滤材料强度的同时也使其具备良好的挺度及耐温耐腐蚀性能。

Description

耐高温复合过滤材料及其制备方法
技术领域
本发明涉及过滤材料技术领域，尤其涉及一种耐高温复合过滤材料及其制备方法。
背景技术
玻璃纤维具有高效过滤、耐高温、耐腐蚀、化学稳定性好等优点，广泛应用于耐高温工业废气和化工废气的处理，其最突出的特点是耐高温，尺寸稳定性好，拉伸断裂强度高，瞬时可抵抗住350℃高温，无碱工况条件下可在280℃环境中连续使用，同时玻璃纤维在耐化学侵蚀方面，除了氢氟酸、高温强碱外，对其他介质都很稳定。另外，玻璃纤维可以在较细直径下保持某种挺度，而现有技术制备的化纤很难做到这点。但是，玻璃纤维的耐折性和耐磨性较差，因此一般不在振荡或脉冲系统上使用，且阻力相对PP熔喷+基材的HEPA过滤网要高，另外，玻璃纤维延展性差，玻璃纤维过滤器安装时很容易破坏。此外，一些学者认为：用玻璃纤维制作滤网的空气过滤器在使用过程中会存在玻璃纤维脱落的风险，而玻璃纤维一旦脱落会对人体健康造成一定的伤害。现有的采用聚丙烯滤纸的过滤器比较便宜，滤纸也比较结实，但是容尘能力偏低，使用寿命仅为玻纤滤纸过滤器的一半。
现有技术中，公开号为CN 110711430 B的发明专利公开了一种复合过滤材料及其制备方法，该复合过滤材料由微米到亚微米再到纳米尺寸的纤维过滤层依次沉积复合制备得到，包括无纺布初效过滤层、多孔微纳米纤维中效过滤层、蛛网纳米纤维高效过滤层以及相邻设置的过滤层之间具有由相邻的过滤层中的纤维相互穿插形成的复合层。上述技术方案中，制备得到的过滤材料具备优异的空气过滤性能，然而其化学稳定性及挺度较玻璃纤维差，且使用寿命较短。
有鉴于此，有必要设计一种耐高温复合过滤材料及其制备方法，以解决上述问题。
发明内容
本发明的目的在于提供一种耐高温复合过滤材料及其制备方法。通过采用基布层/精过滤层/粗过滤层的多层次设计，同时结合离心纺丝和静电纺丝的方法，制备得到纤维直径呈不均匀分布的非织造布材料，并经过浸轧工艺处理，在非织造布材料表面形成一层透气微孔膜，得到具有较高过滤效率，同时具备良好挺度，且容尘量高、耐温性能良好的耐高温复合过滤材料。
为实现上述目的，本发明提供了一种耐高温复合过滤材料，其特征在于：包括非织造布材料以及设置于所述非织造布材料两侧的微孔透气膜，所述非织造布材料包括多层次设计的起支撑作用的基布层、纳米纤维精过滤层以及亚微米纤维粗过滤层。
为实现上述目的，本发明还提供了一种上述耐高温复合过滤材料的制备方法，包括如下步骤：
S1、配制预定量的第一纺丝液，通过离心纺丝制备得到一层无纺布A，作为基布层；
S2、配制预定量的第二纺丝液，在步骤S1得到的所述无纺布A上通过静电纺丝工艺，制备一层纳米纤维膜B，作为精过滤层；
S3、配制预定量的第三纺丝液，在步骤S2制备的所述纳米纤维膜B上通过离心纺丝工艺，制备一层亚微米级纤维层C，作为粗过滤层，得到非织造布材料；
S4、配制预定量的粘合剂，将所述粘合剂通过浸轧工艺对步骤S3制备得到的所述非织造布材料进行处理后烘干，使所述非织造布材料两侧形成一层微孔透气膜，得到耐高温复合过滤材料。
作为本发明的进一步改进，步骤S1～S3中，所述第一纺丝液、第二纺丝液和第三纺丝液配制使用的材料为聚酰亚胺、聚偏氟乙烯、聚丙烯腈或间位芳纶中的一种或几种，其中纺丝液配制所使用的溶剂为DMF、DMAC、丙酮、四氢呋喃中的任意一种或几种的混合物。
作为本发明的进一步改进，所述离心纺丝的纺丝液浓度为20wt％～35wt％，所述静电纺丝的纺丝液浓度为10wt％～20wt％。
作为本发明的进一步改进，步骤S1中，所述无纺布A的纤维直径为2～5μm，孔径为5～20μm，厚度为0.5～2mm，克重为20～200g/m2，孔隙率≥70％。
作为本发明的进一步改进，步骤S2中，所述纳米纤维膜B的纤维直径为0.05～2μm，孔径为3～10μm，厚度为0.1～1mm，克重为2～10g/m2，孔隙率≥85％。
作为本发明的进一步改进，步骤S3中，所述亚微米级纤维层C的纤维直径为1～3μm，孔径为5～15μm，厚度为0.2～2mm，克重为10～50g/m2，孔隙率≥80％。
作为本发明的进一步改进，步骤S4中，所述粘合剂为聚四氟乙烯乳液、聚丙烯酸酯、环氧树脂、水溶性丙烯酸乳液、水溶性酚醛树脂乳液、聚氨酯和丙烯酸树脂中的一种或几种的混合物。
作为本发明的进一步改进，步骤S4中，所述粘合剂的质量浓度为2wt％-10wt％，所述浸轧工艺的浸轧时间为2-4min，形成的所述微孔透气膜的孔径为1-5μm。
作为本发明的进一步改进，步骤S4中，所述烘干的装置为烘缸，依次通过两组烘缸进行干燥，所述两组烘缸的蒸汽温度依次为90℃-110℃、120℃-140℃，使干燥后的过滤材料含水量小于5％。
本发明的有益效果是：
1.本发明采用基布层/精过滤层/粗过滤层的多层次设计，同时结合离心纺丝和静电纺丝的方法，制备得到纤维直径呈不均匀分布的非织造布材料，并经过浸轧工艺处理，在非织造布材料表面形成一层透气微孔膜，通过纤维直径的不均匀分布和非织造布材料表面的透气微孔膜以及填充于非织造布材料孔隙中的胶体颗粒的协同作用，在保证过滤材料的透气性的同时改善其过滤性能、过滤精度及清灰性能，达到高效过滤且使用寿命长的效果。
2.本发明采用离心纺丝制备的无纺布作为基布层，一方面可以过滤粒径较大的颗粒，另一方面，利用无纺布纤维直径较粗的特点，可以起到支撑的作用，提高纤维强度，方便后期打折加工处理，同时，通过无纺布、微孔膜和填充于非织造布材料孔隙中的胶体颗粒的协同作用，使过滤材料具备良好挺度。
3.本发明采用耐高温材料进行离心纺丝和静电纺丝制备，使得到的过滤材料具备耐高温的性能，满足特殊条件下的应用需求。通过微孔膜具备优异的化学稳定性的特点，达到保护过滤材料的作用，从而提高过滤材料的化学稳定性。另外，使用本发明的复合过滤材料作为空气过滤器的滤网时，延展性较好，安装方便，不存在纤维脱落的风险，能满足使用需求。
具体实施方式
为了使本发明的目的、技术方案和优点更加清楚，下面结合具体实施例对本发明进行详细描述。
需要说明的是，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。
本发明提供了一种耐高温复合过滤材料，包括非织造布材料以及设置于所述非织造布材料两侧的微孔透气膜，所述非织造布材料包括多层次设计的起支撑作用的基布层、纳米纤维精过滤层以及亚微米纤维粗过滤层。
本发明还提供了一种上述耐高温复合过滤材料的制备方法，包括如下步骤：
S1、配制预定量的第一纺丝液，通过离心纺丝制备得到一层无纺布A，作为基布层，所述离心纺丝条件为：纺丝针头0.21mm，纺丝转速3000-4000rpm，收集高度3-5cm，环境温度20-30℃，湿度≤30％HR；
S2、配制预定量的第二纺丝液，在步骤S1得到的所述无纺布A上通过静电纺丝工艺，制备一层纳米纤维膜B，作为精过滤层，所述静电纺丝条件为：纺丝针头0.4mm，高压电场13-15Kv，收集高度10-30cm；
S3、配制预定量的第三纺丝液，在步骤S2制备的所述纳米纤维膜B上通过离心纺丝工艺，制备一层亚微米级纤维层C，作为粗过滤层，得到非织造布材料，所述离心纺丝条件为：纺丝针头0.16mm，纺丝转速3000-4000rpm，收集高度3-5cm，环境温度20-30℃，湿度≤30％HR；
S4、配制预定量的粘合剂，通过浸轧工艺对步骤S3制备得到的所述非织造布材料进行处理后烘干，使非织造布材料两侧形成一层微孔透气膜，得到耐高温复合过滤材料；其中，所述浸轧工艺的浸轧时间为2-4min。
步骤S1～S3中，所述第一纺丝液、第二纺丝液和第三纺丝液配制使用的材料为聚酰亚胺、聚偏氟乙烯、聚丙烯腈或间位芳纶中的一种或几种，其中纺丝液配制所使用的溶剂为DMF、DMAC、丙酮、四氢呋喃中任意的一种或几种的混合物；所述离心纺丝的纺丝液浓度为20wt％～35wt％，所述静电纺丝的纺丝液浓度为10wt％～20wt％。
步骤S1中，所述无纺布A的纤维直径为2～5μm，孔径为5～20μm，厚度为0.5～2mm，克重为20～200g/m2，孔隙率≥70％。
步骤S2中，所述纳米纤维膜B的纤维直径为0.05～2μm，孔径为3～10μm，厚度为0.1～1mm，克重为2～10g/m2，孔隙率≥85％。
步骤S3中，所述亚微米级纤维层C的纤维直径为1～3μm，孔径为5～15μm，厚度为0.2～2mm，克重为10～50g/m2，孔隙率≥80％。
步骤S4中，所述粘合剂为聚四氟乙烯乳液、聚丙烯酸酯、环氧树脂、水溶性丙烯酸乳液、水溶性酚醛树脂乳液、聚氨酯和丙烯酸树脂中的一种或几种的混合物；所述粘合剂的质量浓度为2wt％-10wt％，形成的所述微孔透气膜的孔径为1-5μm。
步骤S4中，所述烘干的装置为烘缸，将涂布有粘合剂的过滤材料以40m/min的送纸速度依次通过两组烘缸进行干燥，所述两组烘缸的蒸汽温度依次为90℃-110℃、120℃-140℃，使干燥后的过滤材料含水量小于5％。
下面结合具体的实施例对本发明提供的耐高温复合过滤材料进行说明。
实施例1
本实施例提供了一种耐高温复合过滤材料的制备方法，包括如下步骤：
S1、配制浓度为20wt％的聚丙烯腈纺丝液A，通过离心纺丝制备得到一层厚度为2mm的无纺布A，作为基布层；
S2、配制浓度为10wt％的聚丙烯腈纺丝液B，在步骤S1得到的所述无纺布A上通过静电纺丝工艺，制备一层厚度为1mm纳米纤维膜B，作为精过滤层；
S3、配制浓度为20wt％的聚丙烯腈纺丝液C，在步骤S2制备的所述纳米纤维膜B上通过离心纺丝工艺，制备一层厚度为2mm的亚微米级纤维层C，作为粗过滤层，得到非织造布材料；
S4、配制质量浓度为6wt％的丙烯酸树脂液，通过浸轧工艺对步骤S3制备得到的所述过滤材料进行处理，所述浸轧工艺的浸轧时间为3min，使其两侧形成一层微孔透气膜，再以40m/min的送纸速度依次通过两组烘缸进行干燥，所述两组烘缸的蒸汽温度依次为100℃、130℃，使干燥后的过滤材料含水量小于5％，得到耐高温复合过滤材料。
实施例2～5
实施例2～5分别提供了一种耐高温复合过滤材料的制备方法，与实施例1相比，相关调整参数如表1所示，其余步骤均与实施例1一致，在此不再赘述。
表1实施例2～5中相关参数设置
对比例1-7
对比例1-7分别提供了一种耐高温复合过滤材料的制备方法，与实施例1相比，对比例1仅实施例步骤S1～S3；对比例2中将步骤S1-S3的制备顺序调整为S1，S3，S2；对比例3将浸轧工艺的浸轧时间调整为6min；对比例4-7分别将丙烯酸树脂液的浓度及浸轧时间调整为2wt％1min、1wt％2min、10wt％6min、12wt％4min，其余步骤与实施例1一致，在此不再赘述。
对实施例1～5及对比例1-7制备的耐高温复合过滤材料的性能进行检测，分别测定过滤效率、压降、透气性、挺度、容尘量、耐温性、耐折性、化学稳定性等参数，检测结果如表1所示。
表1实施例1～5及对比例1-7制备的耐高温复合过滤材料的相关性能检测结果
由表1可知，采用本方法制备的耐高温复合过滤材料，与现有技术中的玻璃纤维过滤材料相比，阻力由70Pa降低至22Pa以下，且本发明制备的复合过滤材料具有高过滤效率，对(0.3-10)μm的过滤效率均在99％以上，并具有良好的透气性能。与对比例1相比，实施例1-5制备的复合过滤材料的挺度明显提高，并可达到与现有玻璃纤维相近的水平(1.5mN.m左右)，表明通过无纺布、微孔膜和填充于非织造布材料孔隙中的胶体颗粒的协同作用，能使过滤材料具备良好挺度；同时，与对比例1相比，实施例1-5制备的复合过滤材料的过滤效率均明显提高，说明通过使用质量浓度为2-10wt％的丙烯酸树脂，浸轧时间为2-4min的浸轧工艺处理使过滤材料表面形成一层微孔透气膜，结合纤维直径的多层次分布和透气微孔膜以及填充于非织造布材料孔隙中的胶体颗粒的协同作用，能使过滤材料具备高过滤效率；与实施例1相比，当复合过滤材料的孔径呈梯度分布时(对比例2)，精过滤层直接与粘合剂接触，经浸轧处理后，由于精过滤层孔径较小，部分孔径因粘合剂的进入而堵塞，导致后续粘合剂无法进入内部，从而导致其过滤效率、透气性和容尘量较差，而本发明通过采用多层次设计结合粘合剂浓度及浸轧时间的控制，能在保证复合过滤材料具备良好过滤性的同时仍保持较好的透气性，避免粘合剂浓度过高使得纤维层孔隙堵塞导致阻力上升(对比例7)、粘合剂浓度过低导致的过滤效率、挺度及容尘量的降低(对比例5)，以及避免浸轧处理时间过短造成粘合剂分布不均匀导致过滤性能的降低(对比例4)和浸轧时间过长导致透气性降低(对比例3、6)。另外，与现有的直接将粘合剂通过涂胶的方式涂抹到过滤材料表面相比，本发明的制备方法能避免出现涂胶造成过滤材料透气性及过滤性差的问题。此外，本发明的复合过滤材料具有较高的容尘量、耐温性、耐折性及化学稳定性，可用于替代玻璃纤维，作为新型的空气过滤材料。
综上所述，本发明公开的耐高温复合过滤材料，通过采用基布层/精过滤层/粗过滤层的多层次设计，同时结合离心纺丝和静电纺丝的方法，制备得到纤维直径呈不均匀分布的非织造布材料，并经过浸轧工艺处理，在非织造布材料表面形成一层透气微孔膜，通过纤维直径的不均匀分布和非织造布材料表面的透气微孔膜以及填充于非织造布材料孔隙中的胶体颗粒的协同作用，在保证过滤材料的透气性的同时改善其过滤性能、过滤精度及清灰性能，达到高效过滤且使用寿命长的效果。另外，利用无纺布纤维直径较粗的特点，可以起到支撑的作用，提高纤维强度，方便后期打折加工处理，同时，通过无纺布、微孔膜和填充于非织造布材料孔隙中的胶体颗粒的协同作用，使过滤材料具备良好挺度。此外，采用耐高温材料进行离心纺丝和静电纺丝制备，使得到的过滤材料具备耐高温的性能，满足特殊条件下的应用需求。通过微孔膜具备优异的化学稳定性的特点，达到保护过滤材料的作用，从而提高过滤材料的化学稳定性。另外，使用本发明的复合过滤材料作为空气过滤器的滤网时，安装方便，不存在纤维脱落的风险，能满足使用需求。
以上实施例仅用以说明本发明的技术方案而非限制，尽管参照较佳实施例对本发明进行了详细说明，本领域的普通技术人员应当理解，可以对本发明的技术方案进行修改或者等同替换，而不脱离本发明技术方案的精神和范围。

Claims (10)

1.一种耐高温复合过滤材料，其特征在于：包括非织造布材料以及设置于所述非织造布材料两侧的微孔透气膜，所述非织造布材料包括多层次设计的起支撑作用的基布层、纳米纤维精过滤层以及亚微米纤维粗过滤层。
2.一种权利要求1所述的耐高温复合过滤材料的制备方法，其特征在于，包括如下步骤：
S1、配制预定量的第一纺丝液，通过离心纺丝制备得到一层无纺布A，作为基布层；
S2、配制预定量的第二纺丝液，在步骤S1得到的所述无纺布A上通过静电纺丝工艺，制备一层纳米纤维膜B，作为精过滤层；
S3、配制预定量的第三纺丝液，在步骤S2制备的所述纳米纤维膜B上通过离心纺丝工艺，制备一层亚微米级纤维层C，作为粗过滤层，得到非织造布材料；
S4、配制预定量的粘合剂，将所述粘合剂通过浸轧工艺对步骤S3制备得到的所述非织造布材料进行处理后烘干，使所述非织造布材料两侧形成一层微孔透气膜，得到耐高温复合过滤材料。
3.根据权利要求2所述的耐高温复合过滤材料的制备方法，其特征在于：步骤S1～S3中，所述第一纺丝液、第二纺丝液和第三纺丝液配制使用的材料为聚酰亚胺、聚偏氟乙烯、聚丙烯腈或间位芳纶中的一种或几种，其中纺丝液配制所使用的溶剂为DMF、DMAC、丙酮、四氢呋喃中的任意一种或几种的混合物。
4.根据权利要求2所述的耐高温复合过滤材料的制备方法，其特征在于：所述离心纺丝的纺丝液浓度为20wt％～35wt％，所述静电纺丝的纺丝液浓度为10wt％～20wt％。
5.根据权利要求4所述的耐高温复合过滤材料的制备方法，其特征在于：步骤S1中，所述无纺布A的纤维直径为2～5μm，孔径为5～20μm，厚度为0.5～2mm，克重为20～200g/m2，孔隙率≥70％。
6.根据权利要求5所述的耐高温复合过滤材料的制备方法，其特征在于：步骤S2中，所述纳米纤维膜B的纤维直径为0.05～2μm，孔径为3～10μm，厚度为0.1～1mm，克重为2～10g/m2，孔隙率≥85％。
7.根据权利要求6所述的耐高温复合过滤材料的制备方法，其特征在于：步骤S3中，所述亚微米级纤维层C的纤维直径为1～3μm，孔径为5～15μm，厚度为0.2～2mm，克重为10～50g/m2，孔隙率≥80％。
8.根据权利要求2所述的耐高温复合过滤材料的制备方法，其特征在于：步骤S4中，所述粘合剂为聚四氟乙烯乳液、聚丙烯酸酯、环氧树脂、水溶性丙烯酸乳液、水溶性酚醛树脂乳液、聚氨酯和丙烯酸树脂中的一种或几种的混合物。
9.根据权利要求2所述的耐高温复合过滤材料的制备方法，其特征在于：步骤S4中，所述粘合剂的质量浓度为2wt％～10wt％，所述浸轧工艺的浸轧时间为2-4min，所述微孔透气膜的孔径为1～5μm。
10.根据权利要求2所述的耐高温复合过滤材料的制备方法，其特征在于：步骤S4中，所述烘干的装置为烘缸，依次通过两组烘缸进行干燥，所述两组烘缸的蒸汽温度依次为90℃-110℃、120℃-140℃，使干燥后的过滤材料含水量小于5％。
CN202310479667.3A 2023-04-28 2023-04-28 耐高温复合过滤材料及其制备方法 Pending CN116651085A (zh)

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