CN1729101A - 具有改进的静电消散的水力缠绕过滤介质及其制造方法 - Google Patents

具有改进的静电消散的水力缠绕过滤介质及其制造方法 Download PDF

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CN1729101A
CN1729101A CNA2003801072810A CN200380107281A CN1729101A CN 1729101 A CN1729101 A CN 1729101A CN A2003801072810 A CNA2003801072810 A CN A2003801072810A CN 200380107281 A CN200380107281 A CN 200380107281A CN 1729101 A CN1729101 A CN 1729101A
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fleece
scrim
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赫伯特·哈特格罗夫
辛西娅·道森·麦克诺尔
拉塞尔·廷德尔
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PARRIMOE GROUP CO Ltd
Avintiv Specialty Materials Inc
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Abstract

本发明涉及一种由导电稀松纱组成的过滤介质，以便改进静电消散时间。另外，本发明涉及一种制造这种过滤介质的方法，该过滤介质通过当毛网(P)停留在带有小孔的表面(18)上时利用来自歧管(22)的高压喷水口水力缠绕毛网(P)形成，这样，避免机械针刺法的不利影响，同时提供具有所要求强度特性的过滤介质，而在性能上没有限制因素。

Description

具有改进的静电消散的水力缠绕过滤介质及其制造方法
技术领域
本发明主要涉及用作过滤介质的无纺织物，特别是，包含由导电稀松纱(scrim)构成的水力缠绕无纺织物的过滤介质，以及通过使用带有小孔的表面制造该过滤介质的方法。
背景技术
为了限制杂质引入周围环境，或循环返回到相关加工过程，过滤诸如气体的流体通常需要去掉微粒或从气流分离杂质。通常希望最大化可获得的过滤表面面积，以便从流体流中去除掉大量的不希望有的污染物，同时保持由过滤器引起的运行压力差尽可能低，以便获得长的使用寿命和最小化表面应变。
过滤的一种形式通常被称为阻截，即，过滤介质起类似滤网的作用，机械地截住那些大于介质固有小孔尺寸的微粒。较大尺寸微粒被过滤介质中的孔隙从流体流中去除掉，微粒一个接一个堆积产生滤饼，滤饼继续去除掉更小的微粒。
特别是，在所谓的“袋滤室过滤器”中，当气体通过过滤介质时微粒材料被从气流中去除掉。在典型的应用中，过滤介质具有通常套筒状管状结构，气流被分配成以便将正被过滤的微粒沉积在套筒外部。在这类应用中，过滤介质通过使介质受到脉冲反向气流而定期被清理，该脉冲反向气流从套筒外部驱逐被过滤的微粒材料用于收集到袋滤室过滤器结构的下部。美国专利文件No.4,983,434，这里引入作为参考，显示了袋滤室过滤器结构和现有技术的过滤层压物。
迄今，无纺织物已经有利地用于制造过滤介质。通常，用于此类用途的无纺织物已被缠绕，且采用机械针刺法成为一体，机械针刺法有时被称为“织针毡合”，它需要从纤维网结构重复插入和抽出钩针。当这种加工工艺使纤维结构成为一体且有助于完整性时，钩针不可避免地剪切许多连续纤维，且在纤维结构上产生不希望的穿孔，这将损害过滤器的完整性且降低有效过滤。针刺法也对所产生的织物的强度有害，为了显示足够强度用于过滤的用途，需要相配的无纺织物具有较高的基础重量。
Kirayoglu的美国专利文件No.4,556,601公布了一种水力缠绕的无纺织物，它可以被用作加强型气体过滤器。然而这种过滤材料不能承受收缩操作。所述织物受到收缩操作时，被认为对过滤材料的物理性能具有负面影响。
另外，一些过滤装置使用在过滤结构内部或直接接触过滤结构的丝栅或网格，这导致过滤装置非常易于带有静电。在不利环境，诸如木炭微粒的过滤中使用由金属丝组成的过滤装置，在挥发性条件下更易于被点燃。
发明内容
本发明涉及一种由导电稀松纱组成以便改进静电消散时间的过滤介质。另外，本发明涉及一种制造这种过滤介质的方法，该过滤介质通过水力缠绕形成，因而避免机械针刺法的不利影响，同时提供具有所要求强度特性而且性能上没有限制因素的过滤介质。本发明的过滤介质也显示出高的所希望的均匀性，以用于节省成本的利用。
根据本发明形成的过滤介质包含具有不超过大约6盎司/平方码的基本重量的水力缠绕的、主要是聚酯短纤维长度的纤维。过滤介质显示出马伦顶破强度至少大约198psi，加工方向(machine-direction)和横向收缩小于大约3％，优选地小于大约2％。过滤介质显示出加工方向抗张强度至少大约52lb/in(磅/英寸)，横向抗张强度至少大约55lb/in(磅/英寸)。
通过提供主要包含短纤维长度的聚酯织物的毛网(precursor web)且把毛网附着到导电稀松纱上形成本过滤介质。毛网连同导电稀松纱一起被并置在带有小孔的表面上，且水力缠绕以形成无纺层压织物形式的过滤介质。本方法还包括提供带有小孔的表面，它用于将重复图案施加到正形成的过滤介质上，以便提高过滤介质的过滤能力。
在本发明范围内还有：在水力缠绕后过滤介质被热定形。通过在毛网中包含可熔纤维，过滤介质的热定形能使得介质热粘合，因而增强材料的强度特性。
附图说明
通过下面的详细描述、附图和附加权利要求，本发明的其他特征和优点将会非常明了。
图1是实现本发明方法以形成无纺织物的装置的示意图；和
图2时显示袋滤室过滤器应用的示意图。
具体实施方式
本公布被认为是本发明的范例而且这并不是要将本发明局限于所示的特定实施例，基于这个理解，本发明允许有不同形式的实施例，附图中和下文中要描述的是本发明目前的优选实施例。
这里所描述的本发明包括水力缠绕无纺织物的使用，如下所述它可在目前针织毡所使用的所有场合中直接替代针织毡使用。这些应用包括：用在空气处理的管状或薄板形式的空气过滤，以及液体过滤系统，如袋滤室工段所示，和自动传输流体过滤以及其他使用针织毡的特殊用途。另外，本发明的水力缠绕的过滤介质包括导电稀松纱，以便协助可能积聚在过滤装置上的静电消散。
特别参照图1，其中显示了用于实现本发明方法以形成无纺织物的装置。织物由纤维基体形成，该纤维基体包含所挑选的能促进经济生产的纤维。纤维基体优选地被梳理，然后交叉互搭以形成毛网，用P表示。
图1显示了根据本发明用于形成无纺织物的装置。该装置包括平板式缠绕器12形式的带有小孔的成形表面，毛网P被放置在其上用于预缠绕。毛网P然后顺序地从缠绕歧管14下面通过，借此毛网受到高压喷水器16作用，这一过程为本领域普通技术人员所公知，且在Evans的美国专利文件No.3,485,706中有说明，这里引入作为参考。
图1的缠绕装置还包括成像和形成图案的鼓轮18，该鼓轮包括带有小孔的表面，用于完成现已缠绕的毛网的成像和形成图案。在预缠绕后，毛网由导辊20引导且进入图像转印装置18，在这，图像和/或图案被施加到位于装置的带有小孔的成形表面上的纤维上。纤维网并置到带有小孔的表面18，来自歧管22的高压水从与带有小孔的表面18径向向外间隔布置的喷嘴喷到向外面对的表面上。带有小孔表面18和歧管22也可根据共同转让的美国专利文件No.5,089,764、No.5,244,711、No.5,822,823和No.5,827,597中的说明来制造和运行，这些公布的专利这里引入作为参考。目前，优选地印有图像和/或图案的毛网P适用于提供流体管理，以及将要在下面描述的促进本无纺织物在过滤介质中使用。
本发明的过滤介质由导电稀松纱组成，以便在静电消散期间起辅助作用。适合的稀松纱包括：各种各样的导电材料，例如薄膜材料或纺丝粘合材料。纺丝粘合材料包含连续单纤维，该连续单纤维主要通过喷丝头组件挤压热塑性树脂形成，生产出大量连续的热塑性单纤维。该单纤维然后被淬火和拉拔，并且被收集形成无纺纤维网。水力缠绕过滤介质的导电稀松纱提供的静电消散时间比不使用这种稀松纱层的过滤器少15％。
袋滤室过滤器结构主要用于需要从流体中过滤微粒材料的工业用途。流体进入过滤室，在过滤室中，安排有一个或多个通常为管状的、套筒过滤袋。借助过滤介质两侧的产生的压力差气体流过过滤袋的外表面，当材料卡在过滤介质时，颗粒材料从气流中去除。在气流引起袋滤室过滤器产生静电的情况下，导电稀松纱迅速消除静电的积聚。通常，通过每一个过滤袋定期的承受脉冲反向液体流，微粒物质从过滤袋的外部被去除，借此被特称为“滤饼”的微粒物质被迫从每一个过滤袋的外部沉积在袋滤室过滤器结构的下部。
体现本发明原理的袋滤室过滤介质也可以配置为如图2所示的过滤袋。对于这种应用，过滤介质也可做成平板状，相对边结合在一起形成末端开口的管子。管子然后一端被关闭形成套筒状袋子，如图2所示。对于其他应用，过滤介质也可以采用平板的形式，或采用末端开口的管子的形式。
除了袋滤室过滤外，其他可能的过滤应用包括供暖通风和空调(HVAC)过滤，在其中具有过滤介质的框架被放置到空气气流的通道中，在空气循环进入工作室之前从空气中去除诸如灰尘等微粒。食品和饮料过滤是另一个应用，在其中，过滤器可以放置在流体接触饮料制造物质之前或之后，以便从流体中去除掉污染物。凝结过滤也是另一个应用，例如用在柴油发动机和海上应用中。凝结过滤介质通常使用在位于液烃泵的上游或下游的框架和壳体中。其他可能的过滤应用包括真空过滤装置、去除雾气、涡轮入口过滤、汽车和卡车传动装置和空气进入过滤、冷却剂过滤、包括医用和药物过滤的化学过滤、发电过滤、办公设备过滤、造纸机毡封和排水层过滤，以及其它过滤应用。
体现本发明原理的过滤介质通过在带有小孔的表面上水力缠绕形成，如Drelich等人的美国专利文件No.5,244,711所公布的那样，这里引入作为参考。根据带有小孔表面的特定结构，纤维材料可以在织物平面上印有的重复的图案或重复图案可以凸出织物平面。用于实现本发明的带有小孔的表面通常包括诸如筛网的有网眼表面，或具有明显三维外形的图像转印装置，籍此，用于水力缠绕的喷到纤维材料的高压液体(水)流能通过带有小孔的表面。
根据本发明形成过滤介质是通过提供主要采用短纤维长度的聚酯纤维的毛网来实现，所选择的毛网具有与正形成的过滤介质的基本重量相对应的基本重量。毛网被定位成与导电稀松纱面对面布置，且水力缠绕以便形成无纺过滤介质。另外，前述水力缠绕过滤介质能被前移到三维图像转印装置上，以将图案或图像施加到织物上。同时希望导电纺丝粘合稀松纱能直接挤压到毛网上，轻微预缠绕，且随后在三维图像转印装置上缠绕。根据本发明，本过滤介质优选地具有不超过大约6盎司/平方码的基础重量，这样可通过缠绕促进有效制造，和形成该介质的节省成本的纤维材料。
根据用于制造本过滤介质的毛网的成分，材料强度和完整性能被提高。通过结合可熔纤维，例如旋覆纤维，或包括聚酯、聚酰胺和/或聚烯烃的两种成分的热塑材料，在水力缠绕后，能够在材料热固期间实现纤维结构的热粘合。另外，已经发现如果没有特定的可熔纤维，材料的热固能增强无纺织物强度和多孔性，提高过滤特性。
另外，毛网具有相同或不同组分的、有耐用的短纤维长度的纤维成分也属于本发明范围。耐用的短纤维长度的纤维从具有同一或混合纤维长度的天然或人造成分中选择，适合的天然纤维包括棉花、木质纸浆和粘胶人造丝、亚麻、大麻和洋麻，但不局限于这些。特别优选的天然纤维包括诸如玻璃的硅酸盐，以及聚乙腈和碳纤维。能被整体或部分混合的人造纤维包括热塑和热固聚合物，包括丙烯酸树脂以及聚碳酸酯。适用于与热塑树脂分散剂树脂混合的热塑聚合物包括聚烯烃、聚酰胺、聚酯。诸如α和对芳族聚酰胺等热塑芳族聚酰胺和蜜胺由于其高的热稳定性特别具有优势。热塑聚合物还可以从均聚物、共聚物、轭合物和其他衍生物包括那些具有复合的熔融添加剂或表面活性剂的热塑聚合物中选择。
另外，过滤介质包含附加织物层以形成分层过滤结构也属于本发明范围。附加层可以包括由天然、人造纤维或其组合组成的织物，但不局限于此。适合的天然纤维包括棉花、木质纸浆和粘胶人造丝，但不局限于这些。能被整体或部分混合的人造纤维包括热塑和热固聚合物。热塑聚合物还可以从均聚物、共聚物、轭合物和其他衍生物包括那些具有复合的熔融添加剂或表面活性剂的热塑聚合物中选择。
此外，能增加薄膜层以形成分层过滤结构。不同薄膜层可以包括铸造薄膜、挤压薄膜和网状薄膜。
挤压薄膜能按照下面代表性的直接挤压薄膜方法形成。包括至少两个料斗式装载机的混合和配料仓进给两种不同速度的推进加料器。不同速度的推进加料器将预定数量的聚合物碎片传递到混合料斗中，混合料斗装有混合螺旋桨以进一步使聚合物或聚合物的混合物均匀。聚合物碎片喂入到多区段挤压机中。在多区段挤压机中混合和挤压时，聚合物的混合物借助加热的聚合物管道通过过滤网转换器，其中，应用具有不同筛眼的碎料板以保留固体或半熔化的聚合物碎片以及其他大碎片。聚合物然后被喂入熔化泵，然后喂入合并组件(combining block)，合并组件允许挤压多个薄膜层，薄膜层可以是相同的成分或如上所述从不同系统喂入的。合并组件连接到挤压模，该挤压模放置在高处以便熔化的薄膜挤出后沉积在压送辊和铸造辊之间的缝隙中。
当本发明的过滤介质要接收薄膜层挤出物时，衬底材料以卷的形式提供给张力控制的退绕机。基底层退绕并在压送辊上面移动。从挤压模中挤出的熔化的薄膜挤出物沉积到在压送辊和铸造辊之间的间隙点的衬底材料上。新形成的基底层和薄膜成分然后通过脱模机被从铸造辊上移走，并卷到新的辊上。
诸如单片和多微孔薄膜等的透气薄膜或网状薄膜也能被用于分层过滤结构中。如美国专利文件No.6,191,211中所说明的单片薄膜和如美国专利文件No.6,264,864中所说明的多微孔薄膜，这里这两个专利都引入作为参考，阐明了这种透气阻挡薄膜的形成机理。诸如美国专利文件No.4,381,326和No.4,329,309中的那些网状薄膜代表了多孔薄膜。
可选择地，包括微-但尼尔织物和纳-但尼尔织物的连续单纤维织物可以合并到分层过滤结构。通常，连续单纤维无纺织物的形成包括纺丝粘合过程。纺丝粘合过程包括供应熔化的聚合物，熔化聚合物然后通过称为喷丝头或模的板上的大量孔在压力作用下被挤压。所产生的连续单纤维被淬火和采用若干方法中的任一种方法拉拔，诸如狭槽拉拔系统、衰减器枪或导丝辊。连续单纤维在诸如金属丝网输送带等移动的多孔表面上被收集成疏松网。当为了形成多层织物，多于一个喷丝头被顺序使用时，随后的网被收集在前面形成的网的最上表面上。网然后通常依靠热和压力，诸如热点粘结至少临时固化。使用这种方法，网或网的各层从两个热金属辊间通过，一个热金属辊具有浮雕印花图案，以施加并获得所需要的点粘结程度，通常整个表面面积的大约10％到40％被如此粘结。
适合的纳-但尼尔(micro-denier)的连续单纤维阻挡层能通过纳-但尼尔(nano-denier)单纤维直接纺纱制成，或者在沉积到基底层之前已经被分成纳-但尼尔单纤维的多成分单纤维制成。美国专利文件No.5,678,379和No.6,114,017，这里都引入作为参考，示例了可实施来支持本发明的直接纺纱方法。
在水力缠绕施加特别设计的图案到过滤介质上期间，使用三维图像转印装置也属于本发明的范围，籍此，介质的过滤特性能被进一步加强，包括有效表面面积的增加、过滤器清理效率的提高和深度过滤性能的改变。值得一提的是，与使用机械缠绕通常不能有目的地成像的常规针刺法织物相比，这是个独特的优点。
目前，希望使用100％聚酯短纤维长度的纤维，也希望使用90％聚酯纤维和10％可熔旋覆纤维的组合。织物重量选择为不超过大约6盎司/平方码。
尤其是，通过水力缠绕形成本发明的过滤介质已经发现能提供具有所需要的强度特征、抗收缩性和改进的静电消散时间的过滤介质。根据本发明形成的过滤介质适合用在诸如采矿、水泥、化学、钢铁、公用事业、和与炭黑一起起作用。本发明公布的过滤介质优选地显示出马伦顶破强度至少大约198psi(磅/平方英尺)，加工方向和横向收缩小于大约3％，更优选地小于大约2％。根据ASTM D461-93，第12部分，过滤介质优选地显示出加工方向抗张强度至少大约52lb/in(磅/英寸)，横向抗张强度至少大约55lb/in(磅/英寸)。
从前面所述可以看出，在不脱离本发明的真实精神和独创性概念的情况下可以实施大量更改和变化。应理解，并没有对这里所公布的特定实施例作任何限定。通过附加权利要求，本公告想要覆盖包含在权利要求范围内的所有类似更改。

Claims (13)

1、一种制造具有改进的静电消散的过滤介质的方法，包括以下步骤：
提供主要包含短纤维长度的纤维的毛网；
提供导电稀松纱；
提供带有小孔的表面；和
将所述毛网和导电稀松纱并置到所述带有小孔的表面上，并水力缠绕所述毛网和导电稀松纱以形成所述过滤介质，所述过滤介质具有不超过大约6盎司/平方码的基础重量，并具有至少大约198psi的马伦顶破强度、以及小于大约3％的加工方向和横向收缩。
2、如权利要求1所述的制造过滤介质的方法，其特征在于，包括：
提供三维图像转印装置，并将所述缠绕的毛网和导电稀松纱前移到所述三维图像转印装置上，以便施加三维图像。
3、如权利要求2所述的制造过滤介质的方法，其特征在于，包括：
提供三维图像转印装置，并将所述缠绕的毛网和导电稀松纱前移到所述三维图像转印装置上，以便施加三维图像。
4、一种制造具有改进的静电消散的过滤介质的方法，包括以下步骤：
提供主要包含短纤维长度的纤维的毛网；
提供由导电聚合熔融物构成的稀松纱；
提供带有小孔的表面；
提供三维图像转印装置；
将所述导电聚合熔融物直接挤压到所述毛网上，并水力缠绕所述毛网和导电稀松纱；将所述缠绕的毛网和导电稀松纱前移到所述三维图像转印装置上，以便施加三维图像；所述过滤介质具有不超过大约6盎司/平方码的基础重量，并具有至少大约198psi的马伦顶破强度、以及小于大约3％的加工方向和横向收缩。
5、如权利要求1所述的制造过滤介质的方法，其特征在于，包括在所述水力缠绕步骤之后热固所述过滤介质。
6、如权利要求2所述的制造过滤介质的方法，其特征在于，所述毛网包含可熔纤维，因而所述过滤介质在所述热固步骤中被热粘合。
7、一种过滤介质，包括已水力缠绕的、主要是短纤维长度的纤维和导电稀松纱，该介质具有不超过大约6盎司/平方码的基础重量，并具有至少大约198psi的马伦顶破强度、以及小于大约3％的加工方向和横向收缩。
8、一种分层过滤介质，包括已水力缠绕的、主要是短纤维长度的纤维和导电稀松纱，该介质具有不超过大约6盎司/平方码的基础重量，并具有至少大约198psi的马伦顶破强度、以及小于大约3％的加工方向和横向收缩。
9、如权利要求4所述的过滤介质，其特征在于，所述介质具有小于大约2％的加工方向和横向收缩。
10、如权利要求4所述的过滤介质，其特征在于，所述过滤介质具有至少大约52磅/英寸的加工方向抗张强度，和至少大约55磅/英寸的横向抗张强度。
11、如权利要求1所述的过滤介质，其特征在于，所述过滤介质是气体过滤器。
12、如权利要求1所述的过滤介质，其特征在于，所述过滤介质是空气过滤器。
13、如权利要求1所述的过滤介质，其特征在于，所述过滤介质是液体过滤器。
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