CN1211935A - 带静电的纤维过滤网 - Google Patents

带静电的纤维过滤网 Download PDF

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CN1211935A
CN1211935A CN97192569A CN97192569A CN1211935A CN 1211935 A CN1211935 A CN 1211935A CN 97192569 A CN97192569 A CN 97192569A CN 97192569 A CN97192569 A CN 97192569A CN 1211935 A CN1211935 A CN 1211935A
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filter medium
sparse cloth
sparse
cloth
enhancing
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CN1077443C (zh
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T·E·哈斯克特
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3M Co
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Minnesota Mining and Manufacturing Co
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    • 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
    • B32B5/22—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
    • B32B5/24—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 one layer being a fibrous or filamentary layer
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
    • D04H3/04—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
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Abstract

本发明提供一种非织造驻极体纤维过滤介质,所述过滤介质由将一层驻极体纤维的非织造纤维网针刺、并合于一稀疏布支持层上制得。所述稀疏布支持层材料具有许多分散孔隙,所述孔隙的平面上的平均截面面积至少为0.25mm2,更好的是1.0mm2。所述增强用稀疏布具有在98.4米/分的迎面气流速度下的、小于1.5mm水柱的总压力降。生成的过滤介质的使用寿命长、压力降低且过渡效率高。

Description

带静电的纤维过滤网
发明领域及发明背景
本发明涉及一种非织造驻极体织物过滤介质的制造方法及由该方法制造的产品。
驻极体(electret)纤维的非织造纤维网通常由松散连接的充电驻极体的纤维组成。由该非织造纤维网组成的过滤介质可在非织造纤维网的形成过程之前、过程中、或在其形成的过程后充电。例如，在第4,588,537号美国专利上记载了一种在纤维网形成后充电的例子。在该例子中，可充电的蓬松非织造纤维网可用包括梳理及溶喷等多种方法形成后，加压下充电，然后，再恢复其原有的厚度。
另外，也可如第4,215,682号美国专利(Kubik等人)上所记载地，在纤维网形成之时对纤维进行充电。在该方法中，溶喷法纺制的纤维在其刚从溶喷孔中挤出之时，即受到离子辐射及电子轰击。该纤维在大气中以极快的速度固化，并被收集成为细纤维的互相缠结的半粘着体(semi-coherent mass)，即，纤维网。所述纤维网最好是稀疏型的，以便提供一个液体通过由该纤维网形成的过滤器所需的低压力降。
也可如第4,798,850号美国专利所记载地，对纤维进行充电。该专利描述将不同的纤维混合一起的方法。所述方法在纤维选用适当时，将可减少纤维网形成之时纤维中的静电电荷。其它涉及带电纤维和纤维网充电的专利有第4,904,174号美国专利、第5,122,048号美国专利及第4,592,815号美国专利。
一种形成非织造驻极体纤维过滤网的特别有效的方法描述于第30,782号美国再颁专利(Van Turnout等人)。该专利中的驻极体纤维由一电晕放电薄膜形成，所述薄膜细纤化形成带电纤维，然后，由梳理或气流成网法等通常的方法将所述带电荷纤维形成非织造过滤纤维网。该充电方法提供了一种该纤维特别高的注入电荷的电荷密度。然而，由该预充电的纤维形成纤维网的方法也会碰到许多问题：这些纤维通常很大，无卷曲，且不易卷曲。部分地由于这些原因，上述纤维不易形成一均匀、粘结、特别是低基重的纤维网。第4,363,682号美国专利特别研究了这个问题后，提出将所述细纤化的纤维网用于面罩的方法。为提供一种更具粘结力的纤维网，以及为提供一种不易发生纤维脱落现象(resists shedding)的纤维，该专利建议进行一种后压花处理。该后压花处理将外侧表面的纤维连接一起，从而，可提供一种用于面罩的更具粘结力和更舒适的纤维网。上述处理也易形成一种更为紧缩的纤维网，结果，该纤维网将增加通过过滤网上的压力降，并会降低过滤器的使用寿命。
一种对上述压花处理所作的改进描述于第5,230,800号美国专利。该专利提出一种将上述细纤化的驻极体纤维过滤网(例如，以Van turnout等人所述的方法制得的纤维网)以针刺方式连接至一稀疏布(scrim)支持体上。其结果，生成一种其均匀性及过滤性能均改善的较为紧密、且内部连接良好的粘结纤维过滤器复合材料。
本发明的研究者意在提供一种使用寿命长、压力降小、且不会降低过滤器性能的非织造驻极体纤维过过滤介质。上述过滤材料可以经济、方便地制得，且易于安装为最终的过滤器形式。
发明简述
非织造驻极体纤维过滤介质及过滤器可由将驻极体纤维的非织造纤维网应用至一稀疏型稀疏布支持体(层)上，形成过滤介质而获得。一个未受支持的非织造纤维质过滤网置于一层稀疏、基本上不可拉伸的稀疏布支持体材料上。所述稀疏布支持体材料具有许多分散的孔隙及一横跨于该稀疏布支持体材料上(未附以所述过滤网时)、在98.4米/分的迎面速度(face velocity)下所测得的小于1.5mm水柱(H2O)高的压力降。所述孔隙在该过滤介质平面上的平均截面面积至少为0.25mm2，较好的是1.0mm2。所述纤维过滤网及稀疏布织物支持体材料藉由针刺，将该过滤网及稀疏布支持体材料连接，以形成一具有使用寿命长和过滤性能增强的高度均质的非织造纤维过滤介质。形成该非织造纤维过滤网的至少部分纤维被注以驻极体电荷。
附图说明
图1为根据本发明方法的一个优选的工序流程示意图。
优选实施方案简述
本发明涉及一个对描述于第5,230,800号美国专利上的发明方法的改进。该专利描述了一种方法：针刺结合一层由细纤化的驻极体纤维组成的纤维网和一层作为支持体的稀疏布织物，由此可以产生具有极为均匀的物理特性和操作性能的过滤介质。然而，本发明者的目的不光在于提供一种具有如第5,230,800号美国专利所述的各种性能的过滤介质，且也在于提供一种其使用寿命延长、在相对较高的迎面气流速度(face velocity)下，具有高的过滤效率的过滤介质。特别地，本发明者的目的在于提供一种高性能的炉用过滤器用的优质过滤介质；或者，在于提供一种通用的空气净化用过滤器；该空气净化用过滤器在其尽可能的使用寿命期间，可有效地过滤大量的空气。较好的是，所述过滤介质可以在高的迎面气流速度(例如，在大于250m/分的所述速度下)下使用，以使其即可以用作平板型过滤器，也可以用作增强功能型的褶皱型过滤器。令人意料不及的是：业以发现，藉由适当选择针刺连接纤维质过滤网层用的稀疏布支持层，非织造纤维质过滤介质和驻极体纤维将形成在高的迎面速度和延长的使用寿命下的优异的过滤性能。
具体地，本发明的支承过滤网的稀疏布支持体应该是一具有大量分散孔隙的、极为稀疏的稀疏型材料。所述孔隙从稀疏布的一侧表面贯通至其对侧表面。这些分散的孔隙平均截面面积至少为0.25mm2，最好的是1.0mm2。然而，各单个孔隙的面积可以是在0.1mm2至10mm2的、或更大的范围内。较好的是，所述孔隙具有贯通稀疏布的非曲折通道；更好的是，所述孔隙直接从稀疏布的一侧表面贯通至其对侧表面(例如，形成柱状通道)。通常，所述孔隙贯通稀疏布的平均通道长度对稀疏布厚度的比例为3比1，较好的为2比1，或更小。稀疏布的孔隙也可以一有效园直径(ECD)来描述。该直径表示可内接于各个孔隙截面的最大圆直径。ECD的平均值一般至少为300μm，较好的是，至少为500μm。尽管，稀疏布支持体材料孔隙是极为疏松的，但该孔隙应具有一定的强力，其抗拉强度至少为50kg/m，较好的是为100kg/m。比起该驻极体充电的过滤网材料(例如，其压力降小于过滤网压力降的50％，较好的是，小于其30％)来，稀疏布材料上的总压力降应较小，且，通常应具有在98.4米/分的迎面速度、环境温度下小于1.5mm水柱(H2O)、更好的是，小于0.5mm水柱(H2O)高的压力降。
上述稀疏布材料可以由任何合适的材料组成，例如，可由热塑性聚合物、韧性金属或诸如此类的材料组成。较好的是，所述稀疏布由例如稀疏布纤维的热塑性材料，或由例如交错层叠的、购自Amoco公司的商品名为ClafTM的聚乙烯纤维结网材料组成。也可以使用其它的交错层叠的纤维网，其层叠、叠压工序可由例如加热、声波或粘结等层压技术完成。如果，最终的过滤器须形成以褶皱，则所述的稀疏布最好也是可打摺的，这样，可不必使用附加的褶皱层。不过，如果希望的话，也可使用通常的可打褶皱的层。
上述纤维过滤网层为非织造纤维网。其中，至少一部分形成纤维网的纤维带了静电电荷。此处，该部分纤维通常指驻极体纤维。藉由已知的方法，例如，藉由电晕放电电极或高密度电场的使用，或者，藉由摩擦带电(如第4,798,850号美国专利所述)的方法，可以使得这些驻极体纤维充电。这些纤维可在其组合进过滤网之前、之中，或者，在形成过滤网之后进行充电。这些形成过滤网的纤维也可在将其掺入稀疏布支持体层之后再充以电荷。该非织造纤维过滤网可由通常的、包括溶喷法、梳理法、兰多粘合法及纺粘法等的非织造技术形成。较好的是，所述纤维网不经压实(例如，水流缠结法、加热或声波粘结法等)，但是，如果需要的话，也可以进行压实。
上述一层或多层纤维过滤网层的总基体重量可以在10-400g/m2的范围。较好的是，在用于炉用过滤网时，上述过滤网层的总基重为20-150g/m2的范围。一般来说，所述一层或多层过滤网层在98.4米/分的迎面速度下的总压力降小于10mm水柱(H2O)、更好的是，小于6mm水柱(H2O)。该过滤网层的压力降通常至少为1mm水柱以上。
图1所示为用于本发明的制造方法的设备装置1。卷筒2提供非织造的过滤网层10，该卷简也可以同时是所述纤维网的成形装置(例如，一种梳理机或其它的纤维网形成装置)。另外，可以从第二卷筒上剥离下第二层过滤网层，并将其并合入纤维网10。这使得纤维网基重的选择具有更大的余地。稀疏布支持体11从支持卷筒4喂至该纤维质过滤网层10上。然而，所述稀疏布支持体11也可喂至支持卷筒2的上游，这样，使得所述的纤维质过滤网层铺于稀疏布支持体11之上，或铺于二层稀疏布支持体层11之间。另外，也可以使用第二供给卷筒2’，这样，使得稀疏布支持体11成为夹于二层外层非织造过滤网层之间的中心层。这些状态示于图1，其中，第二供给卷简标以基本相同的标记(10’和2’)。另外，第二纤维质过滤网层可从相邻的供给卷筒退卷出，并合入纤维网10’，以便调节基重。上述二纤维质过滤网层10及10’的基重可以不同。
接着，一层或多层纤维过滤网层10，及稀疏布支持层11被喂至针刺部分5。这里，所述一层或多层纤维质过滤网层10藉由针刺，被并合入稀疏布支持层11，以形成过滤介质12。所述的针刺最好是在稀疏布支持体层之前穿透一顶层过滤纤维网层，以将其中的纤维横向推移，再牢固地向下挑入稀疏布支持层内，且，可能挑入上层稀疏布支持体中。因此，可促进该层的纤维与该稀疏布及底层过滤网层10’的纤维互相缠结、咬合。可以将许多根针进行这样的安装，使得穿透过滤介质12的复合物的密度约为10-300针孔/cm2。更高的针刺密度能使所述的过滤介质12变得更为紧密，同时，增加通过该过滤介质12的压力损耗。较好的是，所述针刺密度小于75针孔/cm2。将经针刺连接的复合材料过滤介质12再收集于卷筒6上，以便在下道工序中由通常的技术制成各个过滤器。
在一个优选的实施方案中，可以按如第30,782号及31,285美国再颁专利所述的方法，对过滤器纤维网进行充电。形成该过滤网的驻极体纤维藉由从一带有静电电荷的薄膜(例如，用一电晕放电电极充电的)形成，所述静电带电薄膜被细纤化，以提供其截面基本上为矩形的驻极体纤维。然而，形成过滤网的纤维也可由任何已知的、如那些在前面发明背景部分所述的带电方法进行充电。
驻极体纤维最好是从可充电的介电材料的热塑性聚合物制得。其合适的材料包括：如聚丙烯、线型低密度聚乙烯、聚-1-丁烯、聚四氟乙烯、聚三氟氯乙烯、局(4-甲基-1-戊烯)、或聚氯乙烯等的聚烯烃；如聚苯乙烯等的芳香族聚芳烃；聚碳酸酯；聚酯；及其共聚物及混合物。其中，较好的是不带分支烷基游离基的聚烯烃及其共聚物。特别好的是，聚丙烯及聚丙烯共聚物。如第4,874,399号美国专利所教导地，也可与如聚(4-甲基-1-戊烯)等的介电质聚合物和共聚物混合加入本领域熟知的各种官能添加剂。也可如第4,789,504号美国专利，或者，特别是，如第4,456,648号美国专利所描述地，加入一脂肪酸金属盐，及加入通常的稳定剂(例如，加热，或U.V稳定剂)、填料、交联剂或诸如此类的添加剂。只要这些添加剂对薄膜及纤维形式的聚合物的充电能力的不利影响为最小。
对本发明的过滤介质还可另外加上其它的多孔层，例如，织造织物和非织造织物层，具体使用的如增强的支承稀疏布层(例如，纺粘层)、预过滤层、可褶皱层、覆盖纤维网等等。不过，这些附加层应足够稀疏，这样，对整个过滤器的压力降不会产生相反的影响。这些附加层可由通常的手段，例如，粘结、点粘结等等的方法被层压至过滤介质上。
本发明的过滤介质可用于任何通常的空气过滤器中，但，特别是可用于须用于过滤大量空气的炉用过滤器、汽车车厢过滤器及室内空气清净化用等的过滤器中。本发明的过滤介质可装入任何通常形式的、平板型或褶皱型的过滤器中。
实施例
用于本发明实施例中的各种支持层稀疏布的物理性能详述于表1中，其孔隙特性详述于表2中。在这些表中，试样A为ClafTM HS-9107，试样B为ClafTM2S-1501，试样C为ClafTM HS-701，而试样D为LutrasilTM 10gm/m2。LutrasilTM稀疏布可从Firma Karl Freudenberg,Kaiserbautern,Germany购得。ClafTM织物可从Amoco/Nisseke公司购得，而所有的织物皆可镀敷以金属铝。所述的ClafTM织物比较LutrasilTM稀疏布具有更低的起始压力降，既使前者具有更大的基重。
表1中给出的基重为5个试样的平均值。稀疏布的厚度是将5块试样层叠后给出。厚度的测量使用“平行板厚度测试仪”，测试厚度时施加0.1g/cm的压力，测得的值用5除，即得到所需的值。压力降的测量系在通过9.65cm2试样区的体积流量速率为100立升/分钟，产生98.4米/分钟的迎面速度时，在AFT 8110(购自TSI Inc.,Kinneapolis,MN)型自动过滤器测试仪上测试5块试样而得。抗拉强度系将2.54cm×17.8cm的试样，在288cm/分的十字头速度下，在Instron 1122型测试仪上测得。
然后，用一Leica Quantanet Q-570图象分析仪的低倍照相镜头(macro lens)图象分析稀疏布(A至C)纤维网。用一Q-370图象分析仪及一投影显微镜和一定角度的入射光分析稀疏布D。对稀疏布试样(A至C)，使用透射光照射其上的稀疏区域。在ClafTM稀疏布上扫描出一198.6mm2的试样区域，在LutrasilTM稀疏布上则对一29.24mm2的试样区域进行观察。分别扫描或观察各个试样的四个区域，并对每种支持体稀疏布的三块试样进行测试。所述的Q-570摄影机仅测得那些位于焦面的稀疏区域，即，位于同一测试平面的区域。对各个试样(A至D)来说，Q-570直接测得各个稀疏区域中的孔隙数目、孔隙的长度、宽度、周长及孔隙的面积。从所测的数值，可以算出孔隙的平均面积、平均纵横比及有效圆直径。表2报导了各种稀疏布A至E的各自孔隙面积及单个孔隙的平均面积(计算值)、及其孔隙平均长度、平均宽度、平均周长、平均纵横比(计算值)及孔隙的平均有效圆直径(ECD)(计算值)。
ClafTM稀疏布A至C及E(E为C的未镀敷金属织物)具有大至300多倍于LutrasilTM稀疏布(D)的孔隙面积。同样，其由单个孔隙尺寸计算得到的有效圆直径，也显示了ClafTM稀疏布具有14-19倍于LutrasilTM稀疏布的有效圆面积。
实施例1
根据描述于第5,230,800号美国专利的方法，制得一稀疏布为衬底的非织造驻极体充电的纤维过滤介质(比较例1D)。上述方法中使用10gm/m2的纺粘型稀疏布LutrasilTM(稀疏布D)(购自Karl Freudenberg,Kaiserlautern,Germany)。上述用于过滤介质的过滤网含有约为35gm/m2的、根据第30,782号及第31,285号美国再颁专利方法制得的薄膜细纤化的驻极体纤维。制得三种相同的过滤介质。其不同之处在于：这些过滤介质使用ClafTM稀疏布(Amoco/Nisseke制造，并镀敷以铝)(稀疏布A至C及实施例lA至1C)。这些稀疏布以上述的、用于以LutrasilTM稀疏布制得的过滤介质的、标称35gm/m2薄膜细纤化的驻极体纤维质过滤网针刺。所有试样批上卷出过滤介质作分析、比较。其结果列于表Ⅲ。
用一面积为100cm2的圆盘形过滤介质称重，测得各个试样过滤介质的总基重，并转换为gm/m2。
从所测得的过滤介质的总基重中减去该稀疏布的重量，计算得到试样过滤器纤维网部分的平均基重。压力降及渗透率在AFT 8110型测试仪上，取3.8cm直径的圆形区域作为测试区域测得。测试气体流量为100立升/分钟(由此产生的迎面速度相当于98.4米/分钟或300ft/分钟)。要求测试使用的空气含有NaCl气溶胶。其中所含固体NaCl的浓度经校正、测定为14.66mg/m3。“百分比渗透率”为在过滤器的下游及上游测得的NaCl的颗粒浓度之比乘上100的比例。各个测试或测试循环产生“压力降”及“初始百分比渗透率”的值。循环进行AFT 8110型测试仪上的测试(空气中使用同样的NaCl的颗粒浓度)，直至达到一个特定的压力降(12.5mmH2O)。达到所述特定压力降的“循环数”可直接用于表示该过滤器的使用寿命。该压力降被选作为过滤介质使用寿命的终结(即，寿命用“循环数”表示)。这是因为，大多数炉用过滤器制造商认为，如果所述的压力降在以59米/分钟的迎面速度通过一褶皱型过滤器，或以98.4米/分钟的迎面速度通过一平板型过滤器时，其压力降达到12.5mmH2O，则过滤器必须变换。
品质因素Q由下述数学式加以定义： Q = - ln ( % P / 100 ) ΔP 式中，％P为百分渗透率，△P为mmH2O压力降，ln表示自然对数。Q数值总是正的，且随渗透率的降低而增加。反之，压力降增加，则Q减少。Q通常与基重无关。这样，Q可以用来比较不同基重纤维网的过滤性能。所有的结果均为三个测试试样的平均值，而实施例1C为二个试样的平均值。
表Ⅲ显示，衬以ClafTM稀疏布的过滤介质与对照过介质(试样D)比较起来，具有相当大的初始压力降，而其初始百分渗透率则差不多。然而，该衬以ClafTM稀疏布的过滤介质的使用寿命却双倍于那些其达到寿命终结的压力降，即12.5mmH2O的循环数所计算得到的过滤介质使用寿命。该衬以ClafTM稀疏布的过滤介质还具有较高的Q值。
                               表Ⅰ
稀疏布 稀疏布基重(g/m2) 稀疏布厚度(mm)     稀疏布：压力降(mm H2O) 稀疏布抗拉强度(kg/m)
    A     35.0     0.21     0.931     297.8
    B     23.1     0.15     0.507     196.2
    C     15.9     0.12     0.501     123.9
比较例D     10.0     0.08     1.008     22.4
                                表Ⅱ
  稀疏布   孔隙面积(mm2)     长度(mm)     宽度(mm)     周长(mm)    纵横比     ECD(mm)    孔隙数
    A     1.4     1.8     0.98     4.8     2.2     1.2     629
    B     2.0     2.1     1.2     5.8     2.2     1.5     511
    C     2.0     2.1     1.1     5.8     2.2     1.5     517
    D   0.008    0.26   0.034    0.22     2.3   0.085     785
    E     2.4     2.3     1.3     6.3     2.2     4.6     405
                              表Ⅲ
实施例    到达12.5mmH2O的循环数 过滤网基重(g/m2) 品质因数 初始压力降(mm H2O) 初始渗透率(％)
    1A     23.3     30.92     0.076     4.2     73.1
    1B     27.0     31.96     0.083     3.6     74.7
    1C     30     31.3     0.081     3.5     76.6
比较例1D     15.7     31.90     0.060     4.8     75.2
实施例11
使用稀疏布A至D及相同类型的细薄膜纤化驻极体带电的纤维过滤网40gm/m2，以如同实施例Ⅰ中所述的相似方法，制得过滤介质，并测试。
其结果示于表Ⅳ，其中的各个测试结果为5个试样的平均值。
表Ⅳ再次显示，在使用具有较大单个孔隙面积的支持层稀疏布时，过滤器使用寿命可以得到显著的提高，同时，压力降低，而Q值提高。
                            表Ⅳ
实施例 至12.5mmH2O的循环数 过滤网基重(g/m2) 品质因数 初始压力降(mm H2O) 初始渗透率(％)
    1A     14.1     40.17     0.063     5.9     68.8
    1B     17.8     40.10     0.076     4.9     69.0
    1C     20.5     40.16     0.078     4.6     69.7
比较例1D     11.8     39.83     0.072     6.4     63.2
实施例Ⅲ
根据第4,798,850号美国专利所述的方法，制得一摩擦带电的驻极体过滤网。该过滤网使用下述纤维材料：
70％(重量)的4旦尼尔聚丙烯；及
30％(重量)的购自Hoechst Celanese Corporation的3旦尼尔聚酯，T-183。
按第4,798,850号美国专利所述的方法，根据下述，将上述纤维作无序排列、梳理成网，然后针刺粘连成稀疏布：
27.75gm/m2的摩擦充电的驻极体纤维网，衬以的稀疏布D(比较例3D)；
29.64gm/m2的摩擦充电的驻极体纤维网、衬以18gm/m2的稀疏布ClafTM 2S-1601(实施例3A)；及
29.64gm/m2的摩擦充电的驻极体纤维网、衬以其上涂覆以5gm/m2的金属铝的18gm/m2的稀疏布ClafTM2S-1601(实施例3B)。
如同实施例Ⅰ中所述的测试方法，测得所有上述形成的过滤介质的过滤性能。表Ⅴ详述了得自该实施例的测试结果。实施例的过介质(3A及3B)比较比较例过滤介质(3D)来，具有较低的初始压力降，基于终结寿命的压力降为12.5mmH2O的循环数的使用寿命较长，和较高的Q值。所述比较例的过滤介质(3D)使用了基重较低，但平均孔隙面积也较低的LutrasilTM稀疏布。所述压力降的改善及使用寿命的改善优于那些实施例Ⅰ的过滤介质性能的改善。这可能是因为，支持层稀疏布的基重和压力降在整个过滤介质基重及压力降中占有较高的比例。
对于本领域的技术人员来说，显见的是：在不背离本发明的范围及精神的情况下，本发明可以有多种修改和变化，而不应受到限制。
                                表Ⅴ
实施例     到达12.5mmH2O的循环数 纤维基重(g/m2)  稀疏布厚度(mm)  品质因数 初始压力降(mm H2O) 初始渗透率(％)
    3A     58.7  29.75     0.12  0.028     2.6     92.9
    3B     50.7  29.64     0.12  0.028     3.1     91.5
比较例3D     23.3  27.73     0.06  0.026     4.0     90.2

Claims (29)

1．一种空气过滤器，所述空气过滤器包括一框架及一非织造驻极体纤维过滤介质，所述非织造驻极体纤维过滤介质包括至少一层含有缠结纤维的非织造过滤网，所述非织造纤维中的至少一部分为充电的驻极体纤维，其中，所述过滤网藉由针刺并合于至少一层增强用稀疏布上，所述增强用稀疏布具有许多分散的孔隙，所述每个孔隙的平均截面面积至少为0.25mm2，所述增强用稀疏布具有在98.4米/分的迎面速度下测得的小于2.0mm水柱高的总压力降，其中，所述孔隙以非曲折的通道形式从所述稀疏布的一侧表面延伸至其对侧表面。
2．一种用于形成驻极体非织造过滤网的制造方法，其特征在于，所述方法包括下述步骤：
a)提供至少一层非织造过滤网；
b)将所述至少一层过滤网并合于一层增强用稀疏布上，所述增强稀疏布具有许多分散的孔隙，所述孔隙在过滤器平面上的平均截面面积至少为0.25mm2，所述增强用稀疏布具有在98.4米/分的迎面速度下所测得的小于1.5mm水柱高的总压力降；
c)针刺连接所述至少一层的过滤网和增强用稀疏布，以形成一过滤介质；
d)提供该过滤网的至少一部分纤维以驻极体电荷。
3．如权利要求2所述的方法，其特征在于，藉由将充电的薄膜细纤化，形成过滤网的驻极体充电纤维。
4．如权利要求2或3所述的方法，其特征在于，所述驻极体充电纤维藉由电晕放电完成充电。
5．如权利要求3所述的方法，其特征在于，所述驻极体充电纤维系在过滤网中充电。
6．如权利要求2或3所述的方法，其特征在于，所述驻极体充电纤维藉由摩擦充电完成充电。
7．如权利要求2-6之任一项所述的方法，其特征在于，所述增强用稀疏布为夹于二外层过滤网层之间的内层。
8．如权利要求2-7之任一项所述的方法，其特征在于，至少一层非织造过滤网由梳理法制成。
9．如权利要求2-8之任一项所述的方法，其特征在于，所述驻极体充电纤维为聚丙烯聚合物或共聚物纤维，所述稀疏布增强材料为纤维交叉层压的网状物。
10．一种非织造驻极体纤维过滤介质，所述非织造驻极体纤维过滤介质包括至少一层由缠结纤维形成的非织造过滤网，所述非织造过滤网中的至少一部分纤维为充电的驻极体纤维，其中，所述过滤网藉由针刺并合于至少一层增强用稀疏布上，所述增强用稀疏布具有许多分散的孔隙，所述孔隙的平均截面面积至少为0.25mm2，所述增强用稀疏布具有在98.4米/分的迎面速度下所测得的小于2.0mm水柱高的总压力降，其中，所述孔隙以非曲折的通道形式从所述稀疏布的一侧面延伸至其对侧面。
11．如权利要求10所述的非织造驻极体纤维过滤介质，其特征在于，所述的增强用稀疏布上的分散孔隙，其平均截面面积至少为0.5mm2。
12．如权利要求10所述的非织造驻极体纤维过滤介质，其特征在于，所述的增强用稀疏布上分散孔隙的平均截面面积至少为1.0mm2。
13．如权利要求10-12之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布上的分散孔隙具有的平均通道长度和所述稀疏布的平均厚度之比为3-1。
14．如权利要求10-13之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述的增强用稀疏布具有至少为50kg/m的抗拉强度。
15．如权利要求10-14之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布上的分散孔隙具有0.5-5的纵横比，所述增强用稀疏布上的分散孔隙具有平均通道长度和平均厚度之比为2-1。
16．如权利要求10-15之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布上的分散孔隙具有至少为300μm的平均ECD。
17．如权利要求15-16之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布具有至少为50kg/m的抗拉强度。
18．如权利要求10-17之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布具有至少为100kg/m的抗拉强度。
19．如权利要求10-18之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布上压力降小于1.5mm水柱(H2O)。
20．如权利要求10-19之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布上压力降小于1.0mm水柱。
21．如权利要求10-20之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布上的压力降小于过滤网压力降的50％。
22．如权利要求10-21之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布由热塑性聚合物纤维构成。
23．如权利要求10-22之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述驻极体纤维由一种形成薄膜聚合物的充蓄静电的薄膜经细化而形成。
24．如权利要求10-23之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述驻极体纤维为聚丙烯聚合物或共聚物。
25．如权利要求10-24之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述增强用稀疏布为夹于二非织造过滤网外层之间的中心层。
26．如权利要求10-25之任一项所述的非织造驻极体纤维过滤介质，其特征在于，至少一层非织造过滤网为梳理制成的纤维网。
27．如权利要求10-26之任一项所述的非织造驻极体纤维过滤介质，其特征在于，至少一层非织造过滤网为溶喷法形成的纤维网。
28．如权利要求10-27之任一项所述的非织造驻极体纤维过滤介质，其特征在于，至少一层非织造过滤网具有小于120gm/m2的总基重。
29．如权利要求10-28之任一项所述的非织造驻极体纤维过滤介质，其特征在于，所述过滤介质进一步包括一层层压至过滤介质外表面上的增强层。
CN97192569A 1996-02-26 1997-02-04 带静电的纤维过滤网 Expired - Fee Related CN1077443C (zh)

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EP0881931A1 (en) 1998-12-09
CN1077443C (zh) 2002-01-09
CA2245861A1 (en) 1997-08-28
US5800769A (en) 1998-09-01
JP2000504992A (ja) 2000-04-25
EP0881931B1 (en) 2007-12-05
DE69738347T2 (de) 2008-11-13
WO1997030771A1 (en) 1997-08-28
CA2245861C (en) 2005-01-04
DE69738347D1 (de) 2008-01-17
US5792242A (en) 1998-08-11
KR19990087272A (ko) 1999-12-15

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