WO2019174597A1 - 一种过滤材料 - Google Patents

一种过滤材料 Download PDF

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Publication number
WO2019174597A1
WO2019174597A1 PCT/CN2019/077975 CN2019077975W WO2019174597A1 WO 2019174597 A1 WO2019174597 A1 WO 2019174597A1 CN 2019077975 W CN2019077975 W CN 2019077975W WO 2019174597 A1 WO2019174597 A1 WO 2019174597A1
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WIPO (PCT)
Prior art keywords
filter material
carbon black
nonwoven fabric
layer
polyester
Prior art date
Application number
PCT/CN2019/077975
Other languages
English (en)
French (fr)
Inventor
张磊
常敬颖
周豪亮
Original Assignee
东丽纤维研究所（中国）有限公司
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Application filed by 东丽纤维研究所（中国）有限公司 filed Critical 东丽纤维研究所（中国）有限公司
Priority to JP2020544636A priority Critical patent/JP2021511208A/ja
Priority to US16/975,285 priority patent/US20210362101A1/en
Priority to CN201980014320.3A priority patent/CN111741802A/zh
Priority to EP19768322.0A priority patent/EP3766565A4/en
Publication of WO2019174597A1 publication Critical patent/WO2019174597A1/zh

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D71/00—Semi-permeable membranes for separation processes or apparatus characterised by the material; Manufacturing processes specially adapted therefor
    • B01D71/06—Organic material
    • B01D71/30—Polyalkenyl halides
    • B01D71/32—Polyalkenyl halides containing fluorine atoms
    • B01D71/36—Polytetrafluoroethene
    • 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
    • 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
    • B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
    • B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
    • 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
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • 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
    • B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
    • B01D39/1692—Other shaped material, e.g. perforated or porous sheets
    • 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
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2055—Carbonaceous material
    • B01D39/2058—Carbonaceous material the material being particulate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D53/00—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols
    • B01D53/22—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion
    • B01D53/228—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by diffusion characterised by specific membranes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D69/00—Semi-permeable membranes for separation processes or apparatus characterised by their form, structure or properties; Manufacturing processes specially adapted therefor
    • B01D69/10—Supported membranes; Membrane supports
    • B01D69/107—Organic support material
    • B01D69/1071—Woven, non-woven or net mesh
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0216—Bicomponent or multicomponent fibres
    • B01D2239/0233—Island-in-sea
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0241—Types of fibres, filaments or particles, self-supporting or supported materials comprising electrically conductive fibres or particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0618—Non-woven
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0627—Spun-bonded
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0654—Support layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/065—More than one layer present in the filtering material
    • B01D2239/0668—The layers being joined by heat or melt-bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/08—Special characteristics of binders
    • B01D2239/086—Binders between particles or fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1258—Permeability
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1275—Stiffness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1291—Other parameters

Definitions

  • the invention relates to a filter material.
  • a combination of a nonwoven fabric support layer and a porous polytetrafluoroethylene membrane is used as a filter element for air filtration, and the filter element is used in an air filtration environment.
  • the air filter materials in this field are generally pleated.
  • the non-woven support material must have a certain degree of stiffness and the pleats will not be brittle, ensuring the pleat shape. And the location is unchanged.
  • the load capacity of the filter material increases, and the shape variable also increases, eventually forming an “ ⁇ ” type deformation, which leads to an increase in airflow resistance and dust holding.
  • Chinese Patent Publication No. CN101956296A discloses an aramid spunlace nonwoven filter material and a manufacturing method thereof, which are characterized in that a polytetrafluoroethylene porous film and a spunlace nonwoven fabric are hot-pressed, and the method is performed by multiple times of spunlacing.
  • a polytetrafluoroethylene porous film and a spunlace nonwoven fabric are hot-pressed, and the method is performed by multiple times of spunlacing.
  • the obtained filter material has high shape retention, it has high energy consumption and high cost.
  • An object of the present invention is to provide a filter material which has high bending strength, high gas permeability and high collection efficiency.
  • the filter material of the present invention contains a nonwoven fabric, and when the amount of deformation of the filter material is 10 mm, the bending strength is 2.0 MPa or more.
  • the bending strength is preferably 0.8 MPa or more.
  • the filter material of the present invention preferably has a structure of two or more layers.
  • the filter material of the present invention preferably comprises a polyester spunbonded nonwoven fabric support layer, a conductive carbon black layer, and a polytetrafluoroethylene porous film layer, and the polyester spunbonded nonwoven fabric support layer contains conductive carbon on at least one side thereof.
  • the black layer and the air inflow surface layer are polytetrafluoroethylene porous film layers, and the filter material has a basis weight of 130 to 250 g/m 2 .
  • the amount of carbon black particles adhered to the conductive carbon black layer is preferably 4 to 8 g/m 2 .
  • the basis weight of the polyester spunbonded nonwoven fabric support layer is preferably from 120 to 248 g/m 2 .
  • the air permeability of the polyester spunbonded nonwoven fabric support layer is preferably from 30.00 to 50.00 cm 3 /cm 2 /s at a pressure of 125 Pa.
  • the gas permeability of the above polytetrafluoroethylene porous film is preferably 8.00 to 23.00 cm 3 /cm 2 /s at a pressure of 125 Pa.
  • the gas permeability of the filter material of the present invention is preferably 4.50 to 15.00 cm 3 /cm 2 /s at a pressure of 125 Pa.
  • the thickness CV value of the filter material of the present invention is preferably 25% or less.
  • the difference in thickness between the highest point and the lowest point of the spunbonded nonwoven fabric support layer is preferably 30 ⁇ m or less.
  • the invention has the beneficial effects that the filter material of the invention solves the problem that the conventional film filter material has low bending strength, and the filter material has high bending strength and air permeability due to high temperature heat setting and cooling treatment of the filter material. High and high collection efficiency.
  • the filter material of the present invention can be applied to the fields of indoor, automotive air filters, vacuum cleaners, and coating line filtration.
  • the filter material of the present invention contains a nonwoven fabric, and when the amount of deformation of the filter material is 10 mm, the bending strength is 2.0 MPa or more.
  • the filter material may be a layer structure or a structure of two or more layers.
  • the filter material may be a polyester spunbonded nonwoven fabric, and may be a wet-laid nonwoven fabric or a hot-rolled nonwoven fabric.
  • Polyester spunbonded non-woven fabrics are made of polyester because of their high softening temperature and melting point, good heat resistance, high strength and modulus, good elasticity, abrasion resistance and impact resistance. Good creep resistance under load and anti-aging.
  • the above non-woven fabric adopts a spunbonding process, in which the polymer is extruded and stretched to form a continuous filament, and the filament is laid into a net, and the fiber web is subjected to self-bonding, thermal bonding, chemical bonding or mechanical
  • the reinforcing method is used to obtain a spunbonded nonwoven fabric. Since the spunbonded nonwoven fabric is composed of continuous filaments, the filaments are drawn and cooled by a high-speed air stream to form a fiber web, and the fiber web has a high degree of orientation and crystallinity, so the spunbonded nonwoven fabric has a high Breaking strength and low elongation at break, while also having high bending strength.
  • the wet-laid nonwoven fabric is a fiber web made by dehydrating water, fibers and chemical auxiliaries in a special shaper, and the formed fiber web is chemically reinforced with a binder.
  • the fibers in the wet-fabricated fiber web are arranged in a disorderly manner, and the material is almost isotropic, and the chemically reinforced fiber web has good uniformity, high strength and low production cost.
  • Hot-rolled non-woven fabrics use a pair of or two pairs of steel rolls or steel rolls coated with other materials to heat and press the fiber web, while applying hot melt glue inside the fiber web, causing some of the fibers in the fiber web to melt and stick.
  • the non-woven fabric obtained by cooling after cooling.
  • the filter material of the present invention preferably contains a polyester spunbonded nonwoven fabric in view of higher breaking strength and bending strength of the filter material.
  • the filter material of the present invention has a mountain shape, and the bending strength is an initial bending strength of the filter material. If the bending strength of the filter material is less than 2.0 MPa, the rigidity of the filter material is small, and the pleat stability of the discounted article is lowered. It is easy to be deformed or even damaged during long-term use, resulting in poor filtration effect of the filter material and shortened life. Considering that the product use environment has high requirements on continuity, when it is replaced in the middle, it takes time and labor, and the product life expectancy is as long as possible. Therefore, when the deformation amount of the filter material of the present invention is 10 mm, the bending strength is preferably 2.5 MPa or more. It is preferably 2.5 to 4.0 MPa.
  • the bending strength is preferably 0.8 MPa or more.
  • the initial modulus of the filter material largely determines the service life of the final filter material.
  • the bending strength of the small deformation (5mm) is greater than 0.8MPa, it means that the initial modulus of the filter material is large, and the dust is allowed to be used at the beginning of use.
  • the amount is small, the ability to resist the influence of dust and airflow resistance is strong, it is not easy to be deformed, and the service life is long.
  • the bending strength of the filter material of the present invention is more preferably 1.5 MPa or more when the deformation amount is 5 mm.
  • the filter material of the present invention preferably has a structure of two or more layers.
  • the filter material comprises a polyester spunbonded nonwoven fabric and a polytetrafluoroethylene porous film layer.
  • the polyester in the polyester spunbonded nonwoven fabric has a core-sheath structure, that is, the core portion is a high melting point component, the melting point is 220 to 260 ° C, the sheath portion is a low melting point component, and the melting point is 180 to 220 ° C.
  • the core-sheath type polyester resin is subjected to processing steps such as extrusion, drawing, web forming, and reinforcement to form a polyester spunbonded nonwoven fabric.
  • the polytetrafluoroethylene porous film is a rod-shaped strip extruded from polytetrafluoroethylene, which is calendered into a semi-finished product of a film, and is stretched and heat-set at a temperature below the melting point to obtain a porous product.
  • the polytetrafluoroethylene microporous membrane is a flexible and elastic microporous material with smooth surface, high porosity, uniform pore size distribution and permeable and watertight properties.
  • the polyester spunbonded nonwoven fabric and the polytetrafluoroethylene porous film are composited by a hot pressing process to obtain the filter material of the present invention, and the temperature of the hot pressing process is 180 to 220 ° C, because the polyester nonwoven fabric sheath can be obtained
  • the molded portion is sufficiently melted and sufficiently combined with the porous polytetrafluoroethylene film under a certain pressure of the pressure roller while keeping the core portion unmelted.
  • the two-layer filter material obtained by such a composite method not only has high collection efficiency for particles, but also ensures a certain air permeability. When applied to an environment with high filtration performance requirements, the advantages of high efficiency and low resistance of the filter material can be fully utilized.
  • the filter material of the present invention has a two-layer structure
  • the other case is that the filter material comprises a polyester spunbonded nonwoven fabric and a conductive carbon black layer.
  • the conductive dispersion liquid is prepared by using a certain concentration of conductive carbon black particles, and then the conductive dispersion liquid is dispersed on one side of the polyester spunbonded nonwoven fabric by printing, spraying or dipping, and dried to prepare a conductive functional filter. material.
  • the advantage of the conductivity of the filter material can be fully utilized.
  • the filter material of the present invention preferably comprises a polyester spunbonded nonwoven fabric support layer, a conductive carbon black layer, and a polytetrafluoroethylene porous film layer, and the polyester spunbonded nonwoven fabric support layer contains conductive carbon on at least one side thereof.
  • the black layer and the air inflow surface layer are polytetrafluoroethylene porous film layers, and the filter material has a basis weight of 130 to 250 g/m 2 .
  • One layer of the filter material of the present invention is a spunbonded nonwoven fabric as a support material. The spunbonded nonwoven fabric is obtained by extruding, drawing, laminating, and reinforcing the polymer.
  • the spunbonded nonwoven fabric is composed of continuous long fibers, the fibers are drawn by a high-speed air stream, have a high degree of orientation and crystallinity, and the fibers are crisscrossed in the form of a web, so that the fibers have a high breaking strength and a low fracture. Elongation and high flexural strength.
  • the spunbonded non-woven fabric support material of the filter material of the invention is made of polyester as raw material, and the polyester fiber can maintain excellent physical properties in a wide temperature range, high impact strength, good friction resistance, good rigidity, large stiffness, and low moisture absorption. It has good dimensional stability and is resistant to most organic solvents and inorganic acids.
  • the polyester fiber in the present invention is a core-sheath structure polyester fiber.
  • the core layer fiber is a high melting point polyester component
  • the sheath layer polyester component has a low melting point.
  • the selection is for the hot melt compounding of the polytetrafluoroethylene porous film, and the low melting point sheath fiber is melted due to high temperature.
  • the polytetrafluoroethylene porous film can be more firmly bonded to the polyester spunbonded nonwoven fabric.
  • polyester spunbonded nonwoven fabric can ensure a certain degree of air permeability, it is far from meeting the filtration requirement, so in order to obtain a filter material with higher collection efficiency, a layer of hot-pressed polyester spunbonded nonwoven fabric is pressed.
  • PTFE has good chemical stability, low friction coefficient and high temperature resistance. It has a large number of micropores and a small pore size. It has high dust removal efficiency, is not affected by particle size distribution, is easy to clean by surface filtration, and has low dust removal resistance. It is stable, has good air permeability and long service life.
  • the conductive carbon black layer on at least one side of the spunbonded nonwoven fabric support layer means that a conductive carbon black layer is disposed on the upper surface and/or the lower surface of the spunbonded nonwoven fabric support layer, that is, the filter material of the present invention comprises two Species: (1) According to the order of contact with air, the first layer is a polytetrafluoroethylene porous membrane layer, the second layer is a conductive carbon black layer, and the third layer is a spunbonded nonwoven fabric support material layer, which is formed from top to bottom.
  • the first layer is a porous polytetrafluoroethylene film layer
  • the second layer is a conductive carbon black layer
  • the third layer is a spunbonded nonwoven fabric support layer
  • the fourth layer It is a conductive carbon black layer, and a four-layer structure is formed from top to bottom.
  • the grammage of the filter material of the present invention is preferably from 130 to 250 g/m 2 .
  • the weight of the filter material has a great relationship with the flexural strength. The thicker the weight, the thicker the material, the more fiber per unit area. After the fiber mesh is reinforced, the more fibers are used to resist deformation in the unit size. Therefore, the bending strength is also increased accordingly.
  • the grammage of the filter material is too small, the fiber content is small, the material as a whole is soft, and the conformal property after the folding process is poor, and it is easily deformed; if the grammage of the filter material is too large, although the bending strength is large, Improvement, but the material is thicker, the air permeability after bonding is lower, the pressure loss during filtration is high, and the cost of the product is higher.
  • the amount of the conductive carbon black particles adhered is preferably 4 to 8 g/m 2 . If the adhesion amount of the conductive carbon black particles is too high, the air permeability of the spunbonded nonwoven fabric support material itself is lowered, and the hardness is increased, the material becomes hard, which is inconvenient for the later discount processing; if the conductive carbon black particles are attached If too little, the electrical conductivity of the support material itself is not guaranteed, which limits its application range.
  • the basis weight of the polyester spunbonded nonwoven fabric support layer in the present invention is preferably from 120 to 248 g/m 2 . If the gram weight of the polyester spunbonded nonwoven fabric support layer is too small, the filter material is soft, the stability between the pleats after processing is poor, and the deformation is easy to be used during use, resulting in a decrease in the collection efficiency of the filter material; If the gram weight of the polyester spunbonded nonwoven fabric support layer is too large, the thickness of the substrate is increased, and the final filter material has a reduced gas permeability after hot pressing, and the substrate has a large rigidity, which is difficult to handle during the pleating process. The size of the pleats after pleats is also unstable.
  • the air permeability of the polyester spunbonded nonwoven fabric support layer is preferably from 30.00 to 50.00 cm 3 /cm 2 /s at a pressure of 125 Pa.
  • the size of the air permeability determines the filtration effect and service life of the final product. If the air permeability of the polyester spunbonded nonwoven fabric support layer is too small, the thickness thereof is large, which is disadvantageous for the subsequent pleating process, and the air permeability of the obtained filter material becomes small after the PTFE porous film is attached. In use, the pressure loss is high and the running power is large; if the air permeability of the polyester spunbonded nonwoven fabric support layer is too large, the support material itself has a low weight, and the stiffness requirement is not obtained after the pleating process. At the same time, after the porous film of polytetrafluoroethylene is attached, the collection efficiency of the filter material is lowered.
  • the gas permeability of the above polytetrafluoroethylene porous film is preferably 8.00 to 23.00 cm 3 /cm 2 /s at a pressure of 125 Pa. If the gas permeability of the porous polytetrafluoroethylene membrane is too small, the pore size and porosity of the polytetrafluoroethylene porous membrane structure are small, and the collection efficiency of the filter material after the bonding is improved, but the pressure loss is large, and the equipment is large.
  • the gas permeability of the filter material of the present invention is preferably 4.50 to 15.00 cm 3 /cm 2 /s at a pressure of 125 Pa. If the permeability of the filter material is too small, the filter material has a large pressure loss, a high cleaning cost, and a short life; if the permeability of the filter material is too large, it means that the filter material has a large effective filtration size and is easy to be granulated. Through the filter material, the filtration effect is not up to standard.
  • the thickness CV value of the filter material of the present invention is preferably 25% or less.
  • the thickness CV value refers to the degree of dispersion of the thickness of the filter material, that is, the degree of uniformity of the thickness. The smaller the CV value of the filter material, the better. The smaller the thickness CV value, the more uniform the thickness of the filter material and the uniformity of the thickness, which is more conducive to subsequent discounting and use. If the thickness CV of the filter material is too large, the uniformity of the thickness of the filter material is deteriorated, and after the subsequent folding molding, the filter efficiency, pressure loss, and gas permeability are uneven, which affects the effect and life in the actual use process.
  • the difference in thickness between the highest point and the lowest point of the spunbonded nonwoven fabric support layer is preferably 30 ⁇ m or less.
  • the thickness of the highest point of the spunbonded nonwoven fabric support layer of the present invention means the value of the maximum thickness of the entire nonwoven fabric, and the thickness of the lowest point means the minimum thickness of the entire nonwoven fabric.
  • the difference between the thickness of the highest point of the spunbonded nonwoven fabric of the present invention and the lowest point must be within a certain range, that is, the surface of the spunbonded filament nonwoven fabric is flat, and there is no obvious unevenness.
  • the difference in thickness between the highest point and the lowest point of the surface of the spunbonded nonwoven fabric is more than 30 ⁇ m, in the subsequent compounding of the porous polytetrafluoroethylene film, on the one hand, due to the unevenness of the surface of the spunbonded nonwoven fabric, the polytetrafluoroethylene is caused.
  • the surface tension of the ethylene porous membrane is not uniform, and the yield of the porous membrane composite filter material is also lowered; on the other hand, the surface of the spunbonded nonwoven fabric is uneven, and the porous polytetrafluoroethylene membrane and the spunbonded nonwoven fabric are reduced.
  • the contact area between the layers, so that the polytetrafluoroethylene porous film is more easily detached from the surface of the spunbonded nonwoven support layer under the pulse cleaning, and the service life of the overall filter material is reduced.
  • the method for manufacturing the filter material of the present invention comprises the following steps:
  • a conductive support material dispersing the conductive carbon black particle dispersion liquid on at least one side of the polyester spunbonded nonwoven fabric by printing, spraying or dipping to obtain a conductive support material;
  • the conductive carbon black particle dispersion liquid described in the above step (1) needs to be added with a certain proportion of binder, in order to prevent the carbon black particles on the surface of the spunbonded nonwoven fabric from falling off, thereby failing to achieve the required conductivity.
  • the printing method here refers to gravure printing, in particular, the entire printing plate surface is coated with ink, and then the special ink scraping mechanism is used to remove the blank portion of the ink, so that the ink remains only in the mesh portion of the graphic portion.
  • the spraying method is to form a uniform and fine mist droplet of the conductive carbon black dispersion by means of a spray gun or an atomizer by means of compressed air, and is applied to the polyester spunbonded nonwoven fabric support material by spraying, and the method is simple and the cost is low. Low, but the nozzle is easy to block during the spraying process, and needs to be cleaned frequently; the impregnation method is not easy to control the adhesion amount, and the uniformity is not guaranteed, and the air permeability of the finished product is greatly affected, and the energy consumption in the adhesion process is high; Preferably, a printing process is employed.
  • the drying temperature in the above step (1) is between 120 and 160 ° C. If the drying temperature is lower than 120 ° C, the conductive carbon black layer cannot adhere to the surface of the support material sufficiently, resulting in insufficient fastness; if the drying temperature is Above 160 ° C, on the one hand, the core sheath structural fiber will partially melt to cause a strong decrease of the support material, and on the other hand, the melted fiber may wrap the conductive carbon black to cause a decrease in electrical conductivity.
  • step (2) heat setting processing is performed at a heat setting temperature of 110 to 200 °C. Because the filter material needs to be discounted, deformation will occur during long-term use, resulting in increased airflow resistance, reduced dust holding capacity, reduced filtration efficiency, and reduced filter life. Generally, the crystallinity of the polyester filament can reach about 45 to 60%, and the heat setting treatment of a certain condition can improve the crystallinity of the fiber. After the polyester fiber is heated, its molecular structure will undergo three stages of change.
  • the movement of the molecular segment begins, and then as the temperature gradually increases, The movement of the molecular chain is intensified, the adjustment is completed at the new position, and finally the position of the molecular segment below the glass transition temperature is fixed.
  • the heat setting temperature is less than 110 ° C, the molecule has just entered a high elastic state, the motion limitation of the macromolecular segment is eliminated, and the single bond rotation motion around the macromolecular spindle is started, but there is not enough energy to generate a large displacement, so The crystallinity of the fiber does not change much, and the elastic modulus also increases little.
  • the macromolecules in the fiber gradually obtain the energy of motion in the stage of 120 °C ⁇ 200 °C.
  • the intermolecular bondage is gradually reduced, the macromolecules can be dislocated and curled, the elastic modulus of the fiber decreases rapidly, the deformability increases, the shrinkage rate also increases significantly, the molecular structure of the macrofiber changes greatly, and the crystallinity of the molecule increases.
  • the degree of orientation is increased and the density is increased.
  • the heat setting temperature of the filter material is preferably from 120 to 160 °C.
  • the filter material was cut into a square of 200 mm ⁇ 200 mm, and the grammage of the filter material was calculated from the weight, and the average was measured three times, and the final result was taken as the average value of the three times.
  • the thickness of the filter material was measured using a thickness dial gauge (compression force 0.000245 Pa), and 10 points of the filter material having an area of 1 m ⁇ 1 m were measured in the lateral direction, and 10 points were measured vertically. A total of 100 points were selected for measurement, and the average was determined. value.
  • ⁇ represents the standard deviation of the thickness of the filter material
  • ⁇ represents the average thickness
  • Thickness difference maximum average thickness of the section - minimum average thickness of the section thickness.
  • the Frazier fabric air permeability test method was used, and 30 points were randomly selected to measure the air permeability of the filter material, and the average value was obtained.
  • the collection efficiency of the filter material is measured based on the filter material collection efficiency test method specified in JIS B 9908.
  • the two-stage free support, central loading test method (three-point loading test) is used to determine the bending strength of the filter material under the deformation variables of 5 mm and 10 mm, respectively.
  • d thickness of the sample (mm).
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 4 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 140 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.61 mm and a basis weight of 208 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 1 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 4 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.61 mm and a basis weight of 208 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 1 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 4 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter was subjected to heat setting treatment at a temperature of 180 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.61 mm and a basis weight of 208 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 1 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is uniformly sprayed on one side of the polyester spunbonded nonwoven fabric support (gram weight 220 g/m 2 , air permeability 33.61 cm 3 /cm 2 /s) to make the carbon black particles in the polyester filament
  • the adhesion amount of one side of the nonwoven fabric was 6 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles was placed in an oven at 130 ° C for drying to obtain a conductive support material and crimped. ;
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter was subjected to heat setting treatment at a temperature of 160 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.65 mm and a basis weight of 230 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 1 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is uniformly sprayed on one side of the polyester spunbonded nonwoven fabric support (gram weight 220 g/m 2 , air permeability 33.61 cm 3 /cm 2 /s) to make the carbon black particles in the polyester filament
  • the adhesion amount of one side of the nonwoven fabric was 6 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles was placed in an oven at 130 ° C for drying to obtain a conductive support material and crimped. ;
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is thermocompression-composited with a porous polytetrafluoroethylene film having a gas permeability of 26.33 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.65 mm and a basis weight of 228 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 1 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 4 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 200 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.61 mm and a basis weight of 208 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 1 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is uniformly sprayed on one side of the polyester spunbonded nonwoven fabric support (gram weight 125 g/m 2 , air permeability 49.54 cm 3 /cm 2 /s) to make the carbon black particles in the polyester filament
  • the adhesion amount of one side of the nonwoven fabric was 6 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles was placed in an oven at 130 ° C for drying to obtain a conductive support material and crimped. ;
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film-coated filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting and setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.35 mm and a basis weight of 133 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 1 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 6 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter was subjected to heat setting treatment at a temperature of 160 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.61 mm and a basis weight of 210 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 1 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the amount of adhesion of one side of the filament nonwoven fabric was 4 g/m 2 , and then the polyester polyester nonwoven fabric with carbon black particles was placed in an oven at 130 ° C for drying to obtain a conductive support material, and curly;
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 180 ° C by a setting machine to obtain a filter material having a thickness of 0.61 mm and a basis weight of 208 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 2 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 240 g/m 2 , air permeability 30.26 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 8 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.72 mm and a basis weight of 250 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 2 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to the front and back sides of the polyester spunbonded nonwoven fabric support (gram weight 240 g/m 2 , gas permeability 30.26 cm 3 /cm 2 /s) by printing to make the carbon black particles gather.
  • the adhesion of the front and back sides of the ester filament nonwoven fabric was 8 g/m 2 , and then the polyester spunbonded polyester non-woven fabric with carbon black particles was placed in an oven at a temperature of 130 ° C for drying to obtain a conductive Supporting material and curling;
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the amount of adhesion of one side of the filament nonwoven fabric is 2 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter was subjected to heat setting treatment at a temperature of 160 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.60 mm and a basis weight of 206 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 2 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is uniformly sprayed on one side of the polyester spunbonded nonwoven fabric support (gram weight 150 g/m 2 , air permeability 39.73 cm 3 /cm 2 /s) to make the carbon black particles in the polyester filament
  • the adhesion amount of one side of the nonwoven fabric was 6 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles was placed in an oven at 130 ° C for drying to obtain a conductive support material and crimped. ;
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting and setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.45 mm and a basis weight of 158 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 2 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is uniformly sprayed on one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) to make the carbon black particles in the polyester filament
  • the adhesion amount of one side of the nonwoven fabric was 6 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles was placed in an oven at 130 ° C for drying to obtain a conductive support material and crimped. ;
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.61 mm and a basis weight of 208 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 2 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 150 g/m 2 , air permeability 39.73 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 4 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting and setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.45 mm and a basis weight of 158 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 2 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is uniformly sprayed on one side of the polyester spunbonded nonwoven fabric support (gram weight 150 g/m 2 , air permeability 39.73 cm 3 /cm 2 /s) to make the carbon black particles in the polyester filament
  • the adhesion amount of one side of the nonwoven fabric was 4 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles was placed in an oven at 130 ° C for drying to obtain a conductive support material and crimped. ;
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting and setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.45 mm and a basis weight of 158 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 2 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, and the polyester is spun
  • the non-woven fabric support material (gram weight 150g/m 2 , air permeability 39.73cm 3 /cm 2 /s) is immersed in the conductive carbon black dispersion to adhere the carbon black particles to the polyester filament nonwoven fabric 4g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at a temperature of 130 ° C for drying, and a conductive support material is prepared and crimped;
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained film filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting and setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.45 mm and a basis weight of 158 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 2 for the physical properties of the filter material of the present invention.
  • a polyester spunbonded nonwoven fabric support material having a basis weight of 240 g/m 2 and a gas permeability of 30.26 cm 3 /cm 2 /s was heat-set by a shrink setting machine at a temperature of 160 ° C, and finally cooled.
  • a filter material having a thickness of 0.69 mm and a basis weight of 240 g/m 2 was obtained. See Table 3 for the physical properties of the filter material.
  • Polyester spunbond nonwoven material supporting the grammage of 240g / m 2, air permeability of 30.26cm 3 / cm 2 / s and air permeability of side 16.14cm 3 / cm 2 / s porous polytetrafluoroethylene The film was hot pressed and composited, and then the prepared film filter material was subjected to heat setting treatment at a temperature of 160 ° C through a folding setting machine, and finally subjected to cooling treatment to obtain a thickness of 0.70 mm and a basis weight of 242 g/m 2 . filter material.
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 3 for the physical properties of the filter material.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 240 g/m 2 , air permeability 30.26 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 8 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the conductive support material prepared in the above step (1) was heat-set at a temperature of 160 ° C, and finally subjected to cooling treatment to obtain a thickness of 0.71 mm and a basis weight of 248 g/m. 2 filter materials.
  • the air inflow surface layer of the filter material is a conductive carbon black layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 3 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied by printing to one side of the polyester wet-laid nonwoven support (gram weight 200 g/m 2 , air permeability 31.56 cm 3 /cm 2 /s), so that the carbon black particles are in the polyester
  • the wet non-woven fabric has an adhesion amount of 4 g/m 2 , and then the polyester wet-laid nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting and setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.60 mm and a basis weight of 208 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester wet non-woven fabric support material layer. See Table 3 for the physical properties of the filter material of the present invention.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester hot-rolled non-woven support material (gram weight 200 g/m 2 , air permeability 30.24 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the amount of adhesion of the hot-rolled non-woven fabric to one side was 4 g/m 2 , and then the hot-rolled polyester non-woven fabric with carbon black particles was placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter material was subjected to heat setting treatment at a temperature of 160 ° C by a setting and setting machine, and finally subjected to cooling treatment to obtain a filter material having a thickness of 0.60 mm and a basis weight of 208 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester hot rolled non-woven fabric support material layer. See Table 3 for the physical properties of the filter material of the present invention.
  • the filter materials prepared in Examples 1 to 22 can be used for air filtration, such as indoors, automobile air filters, dust collectors, and also in the fields of automobile painting, building materials painting, and hardware fitting powder coating line filtration.
  • conductive support material 17 parts by weight of conductive carbon black particles having a particle size of 4 ⁇ m, 3 parts by weight of acrylic resin were added to 100 parts by weight of water, and sufficiently stirred to prepare a conductive carbon black dispersion, which was obtained.
  • the conductive carbon black dispersion is applied to one side of the polyester spunbonded nonwoven fabric support (gram weight 200 g/m 2 , gas permeability 36.97 cm 3 /cm 2 /s) by printing to make the carbon black particles in the polyester
  • the adhesion amount of one side of the filament nonwoven fabric is 4 g/m 2 , and then the polyester spunbonded nonwoven fabric with carbon black particles is placed in an oven at 130 ° C for drying to obtain a conductive support material, and Curing
  • the carbon black particle surface of the conductive support material obtained in the above step (1) is hot-compressed with a porous polytetrafluoroethylene film having a gas permeability of 16.14 cm 3 /cm 2 /s, and then The obtained membrane filter was passed through a folding setting machine to finally obtain a filter material having a thickness of 0.61 mm and a basis weight of 209 g/m 2 .
  • the air inflow surface layer of the filter material is a polytetrafluoroethylene porous film layer in the order of contact with air, and the air outflow surface layer is a polyester spunbonded nonwoven fabric support material layer. See Table 4 for the physical properties of the filter material.
  • a polyester woven fabric having a basis weight of 240 g/m 2 and a gas permeability of 54.35 cm 3 /cm 2 /s was heat-set by a setting machine at a temperature of 160 ° C, and finally cooled to obtain a thickness of 0.85. Mm, a filter material having a basis weight of 240 g/m 2 . See Table 4 for the physical properties of the filter material.
  • the polyester spunbonded nonwoven fabric support material of Example 4 has a large gram weight, and the obtained filter material has a large gram weight and a high bending strength.
  • the polyester spunbonded nonwoven fabric has a low gas permeability, so the collection efficiency of the filter material is high.
  • Example 4 It is understood from Example 4 and Example 5 that under the same conditions, when the gas permeability of the polytetrafluoroethylene porous film of Example 4 is in a preferred range, the collection efficiency of the obtained filter material is slightly higher than that of Example 5.
  • Example 3 It is understood from Example 3 and Example 9 that under the same conditions, after the heat setting treatment in Example 9, the cooling treatment was not performed, and the bending strength of the obtained filter material at a deformation amount of 10 mm was slightly lower.
  • Example 10 From Examples 2, 8, 10, and 12, under the same conditions, the amount of the conductive carbon black particles adhered in Example 10 was large, and the surface resistance of the obtained filter material was smaller, and the conductivity was better.
  • Example 10 and Example 11 It can be seen from Example 10 and Example 11 that, under the same conditions, in the case where the filter material of Example 11 was subjected to the conductive processing on both sides, the collection efficiency and the deformation amount of the obtained filter material were 10 mm. Slightly high and good electrical conductivity.
  • Example 10 contains both a conductive carbon black layer and a polytetrafluoroethylene porous film layer, the deformation amount of the obtained filter material is 10 mm.
  • the bending strength is high at 5 mm, and the filtration material has high collection efficiency and good electrical conductivity.
  • the nonwoven fabric support material of the filter material of Example 2 is a preferred polyester spunbonded nonwoven fabric, and the deformation amount of the obtained filter material is 10 mm and The bending strength at 5 mm is high.

Abstract

一种含有无纺布的过滤材料，其变形量在10mm时，其抗弯曲强度为2.0MPa以上。

Description

一种过滤材料 技术领域
本发明涉及一种过滤材料。
背景技术
目前，在汽车建材等涂装领域，大多是采用无纺布支撑材层和聚四氟乙烯多孔膜的组合作为空气过滤用滤芯，该滤芯应用于空气过滤环境中。但是，该领域中的空气过滤材料一般都经过打褶加工，在褶裥加工过程中，无纺布支撑材料必须具有一定的硬挺度以及褶裥部位不会脆裂的性能，能保证褶裥形状及位置不变。同时，滤芯在长期使用过程中，随着积灰量的增大，滤材本身承重增大，形变量也增大，最终会形成“Ω”型变形，这样会导致气流阻力增大，容尘量减小，过滤效率降低，使用寿命缩短。因此为了改善上述缺陷，有采用多次针刺或水刺的方法来改善滤材的硬挺度，但是生产周期长，成本高；也有采用涂覆交联剂的方法使得滤材变硬，但是交联剂长期使用过程中可能会脱落，耐久性差，并且应为手感偏硬，不利于后道进一步加工。
如中国公开专利CN101956296A公开了一种芳纶水刺非织造布过滤材料及其制造方法，将聚四氟乙烯多孔膜与水刺非织造布热压复合，该方法中通过多次水刺的方式来改善滤材硬挺度，虽然制得的过滤材料具有高的保形性，但是能耗大，成本高。
发明内容
本发明的目的在于提供一种抗弯曲强度大、透气度高、捕集效率高的过滤材料。
本发明的解决技术方案是：本发明的过滤材料中含有无纺布，且该过滤材料的变形量在10mm时，其抗弯曲强度为2.0MPa以上。
本发明的过滤材料的变形量在5mm时，其抗弯曲强度优选为0.8MPa以上。
本发明的过滤材料优选为两层以上结构。
本发明的过滤材料优选包括聚酯纺粘无纺布支撑材层、导电炭黑层、聚四氟乙烯多孔膜层，所述聚酯纺粘无纺布支撑材层的至少一面上含有导电炭黑层，且空气流入面层为聚四氟乙烯多孔膜层，该过滤材料的克重为130～250g/m 2。
上述导电炭黑层的炭黑颗粒附着量优选4～8g/m 2。
上述聚酯纺粘无纺布支撑材层的克重优选120～248g/m 2。
在压力125Pa下，上述聚酯纺粘无纺布支撑材层的透气度优选30.00～50.00cm 3/cm 2/s。
在压力125Pa下，上述聚四氟乙烯多孔膜的透气度优选8.00～23.00cm 3/cm 2/s。
在压力125Pa下，本发明过滤材料的透气度优选4.50～15.00cm 3/cm 2/s。
本发明过滤材料的厚度CV值优选在25％以下。
上述纺粘无纺布支撑材层的最高点与最低点的厚度差优选在30μm以下。
本发明的有益效果是：本发明的过滤材料解决了以往覆膜过滤材料抗弯曲强度低的问 题，由于对过滤材料进行高温热定型及冷却处理，得到的过滤材料具有抗弯曲强度大、透气度高、捕集效率高的特点。本发明的过滤材料可应用于室内、汽车空气过滤器、吸尘器、涂装线过滤领域中。
具体实施方式
本发明的过滤材料中含有无纺布，且该过滤材料的变形量在10mm时，其抗弯曲强度为2.0MPa以上。该过滤材料可以为一层结构,也可以为两层以上结构。当本发明过滤材料为一层结构时，该过滤材料可以为聚酯纺粘无纺布，可以为湿法无纺布，也可以为热轧无纺布。聚酯纺粘无纺布采用聚酯为原料，因为聚酯软化温度和熔点较高、耐热性好、有较高的强度和模量、较好的弹性、耐磨性和耐冲击性，在载荷下的耐蠕变性好，抗老化。上述无纺布采用纺粘工艺，该工艺是将聚合物挤出、拉伸，形成连续长丝后，长丝铺设成网，纤维网再经过自身粘合、热粘合、化学粘合或机械加固方法，制得纺粘无纺布。由于纺粘无纺布由连续的长丝组成，长丝经过高速气流的牵伸、冷却后形成纤维网，纤维网有较高的取向度和结晶度，所以纺粘无纺布有较高的断裂强力和较低的断裂伸长率，同时还具有高抗弯曲强度。湿法无纺布是由水、纤维及化学助剂在专门的成形器中脱水而制成的纤维网，成形的纤维网采用粘合剂进行化学加固后得到的一种无纺布。湿法无纺布纤维网中纤维呈杂乱排列，材料几乎各向同性，经化学加固的纤网均匀性较好、强力较高、生产成本较低。热轧无纺布是利用一对或两对钢辊或包有其他材料的钢辊对纤维网进行加热加压，同时在纤维网内部施加热熔胶，导致纤维网中部分纤维熔融而产生粘结，冷却后加固得到的无纺布。由于热轧无纺布由是短纤维直接铺成网热粘结而成的，材料强度无方向性，纵横向强度相近，添加热熔胶后，材料表面光滑，透气性佳，防水性能好。考虑到过滤材料的更高的断裂强力以及抗弯曲强度，本发明的过滤材料优选含有聚酯纺粘无纺布。
本发明的过滤材料为山形状，该抗弯曲强度为过滤材料的初期抗弯曲强度，如果过滤材料的抗弯曲强度小于2.0MPa的话，表示滤材的刚性较小，打折品的褶间稳定性降低，长期使用过程中容易变形甚至破损，从而导致过滤材料的过滤效果变差，寿命缩短。考虑到产品使用环境对连续性要求高，中途更换时，耗时耗力，产品要求寿命尽可能长，因此本发明过滤材料的变形量在10mm时，其抗弯曲强度优选为2.5MPa以上，更优选为2.5～4.0MPa。
本发明过滤材料的变形量在5mm时，其抗弯曲强度优选为0.8MPa以上。滤材的初始模量很大程度上决定着最终滤材的使用寿命，当小变形处(5mm)的抗弯曲强度大于0.8MPa时，表示滤材的初始模量较大，在使用初期容尘量较少时抵抗粉尘及气流阻力影响的能力强，不容易变形，使用寿命长。考虑到产品使用初期抵抗变形的能力尽可能强，以及产品使用寿命的延长，因此本发明过滤材料的变形量在5mm时，其抗弯曲强度更优选1.5MPa以上。
本发明的过滤材料优选为两层以上结构，当本发明过滤材料为两层结构时，一种情况是该过滤材料包括聚酯纺粘无纺布和聚四氟乙烯多孔膜层。聚酯纺粘无纺布中的聚酯为芯鞘型结构，即芯型部分为高熔点成分，熔点为220～260℃，鞘型部分为低熔点成分，熔点为180～ 220℃。芯鞘型聚酯树脂经挤出、牵伸、成网、加固等加工步骤，形成聚酯纺粘无纺布。聚四氟乙烯多孔膜是由聚四氟乙烯挤出成型的棒带，经压延成薄膜的半成品，在熔点以下的温度进行拉伸、热定型后，制得多孔制品。聚四氟乙烯微孔膜是一种柔韧而富有弹性的微孔材料，表面平滑、孔隙率高、孔径分布均匀，具有透气不透水的特性。聚酯纺粘无纺布和聚四氟乙烯多孔膜采用热压工艺进行复合，制得本发明的过滤材料，热压工艺的温度为180～220℃，因为这样可以使聚酯无纺布鞘型部分充分熔融，并且在压辊的一定压力作用下，与聚四氟乙烯多孔膜充分复合，同时保持芯型部分未被熔融。采用这样的方式复合而得的两层结构的过滤材料，不仅对粒子的捕集效率高，而且保证了一定的透气度。当应用于对过滤性能要求较高的环境下时，可以充分发挥该过滤材料高效低阻的优势。当本发明过滤材料为两层结构时，另一种情况是该过滤材料包括聚酯纺粘无纺布和导电炭黑层。采用一定浓度的导电炭黑颗粒制备导电分散液，然后通过印刷、喷涂或浸渍的方式，将导电分散液分散于聚酯纺粘无纺布的一面，烘干后，制成具有导电功能的过滤材料。当应用于有抗静电要求的环境下时，可以充分发挥该过滤材料导电性能佳的优势。
本发明的过滤材料优选包括聚酯纺粘无纺布支撑材层、导电炭黑层、聚四氟乙烯多孔膜层，所述聚酯纺粘无纺布支撑材层的至少一面上含有导电炭黑层，且空气流入面层为聚四氟乙烯多孔膜层，该过滤材料的克重为130～250g/m 2。本发明的过滤材料一层为纺粘无纺布作为支撑材。纺粘无纺布是将聚合物挤出、牵伸、铺叠成网，然后经加固后制成。由于纺粘无纺布由连续的长纤维组成，纤维经过高速气流的牵伸，有较高的取向度和结晶度，纤维成网时纵横交错，所以有较高的断裂强力和较低的断裂伸长率，同时抗弯曲强度高。本发明过滤材料中纺粘无纺布支撑材选用聚酯为原料，聚酯纤维在较宽的温度范围内能保持优良的物理性能，抗击强度高、耐摩擦、刚性好、硬挺大、吸湿小、尺寸稳定性好、能耐绝大多数有机溶剂和无机酸的腐蚀。本发明中聚酯纤维是芯鞘结构聚酯纤维。其中，芯层纤维为高熔点聚酯成分，而鞘层聚酯成分熔点低，这样的选择是为了与聚四氟乙烯多孔膜进行热压复合时，低熔点的鞘层纤维会因高温而熔融，使得聚四氟乙烯多孔膜可与聚酯纺粘无纺布更牢固地贴合在一起。
上述聚酯纺粘无纺布虽然可以保证一定程度的透气度，但是远远不能达到过滤要求，因此为了得到更高捕集效率的过滤材料，在聚酯纺粘无纺布上热压一层聚四氟乙烯多孔膜。聚四氟乙烯的化学稳定性好，摩擦系数小，耐高温，制成的薄膜微孔数目多且孔径小，具有除尘效率高、不受粒径分布影响、表面过滤易于清灰，除尘阻力低且稳定、透气性能好、使用寿命长的特点。
这里纺粘无纺布支撑材层的至少一面含有导电炭黑层是指纺粘无纺布支撑材层上表面和/或下表面设置一层导电炭黑层，即本发明的过滤材料包括两种：(1)按照接触空气的顺序，第一层为聚四氟乙烯多孔膜层、第二层是导电炭黑层、第三层是纺粘无纺布支撑材层，自上而下形成三层结构；(2)按照接触空气的顺序，第一层为聚四氟乙烯多孔膜层、第二 层是导电炭黑层、第三层是纺粘无纺布支撑材层、第四层为导电炭黑层，自上而下形成四层结构。
本发明过滤材料的克重优选为130～250g/m 2。滤材的克重与抗弯曲强度有很大关系，克重越大，材料越厚，单位面积内纤维量越多，经过纤网加固后，单位尺寸内用来抵抗变形的纤维也越多，所以抗弯曲强度也相应增大。因此如果过滤材料的克重过小的话，纤维含量较少，材料整体偏软，经打折加工后保形性差，很容易变形；如果过滤材料的克重过大的话，虽然抗弯曲强度有很大改善，但是材料偏厚，贴合后透气度较低，过滤时压损高，另外产品的成本较高。
本发明中导电炭黑颗粒附着量优选4～8g/m 2。如果导电炭黑颗粒附着量过高的话，纺粘无纺布支撑材本身的透气度降低，并且使得硬度增大，材质变得板硬，对后期打折加工造成不便；如果导电炭黑颗粒附着量过少的话，支撑材本身的导电性能得不到保证，限制了其应用范围。
本发明中的聚酯纺粘无纺布支撑材层的克重优选120～248g/m 2。如果聚酯纺粘无纺布支撑材层的克重过小的话，滤材材质偏软，加工处理后褶间稳定性较差，使用中很容易变形，导致过滤材料的捕集效率降低；如果聚酯纺粘无纺布支撑材层的克重过大的话，基材厚度增大，经热压复合后最终滤材透气度降低，而且基材刚性大，打褶过程中不易操作，经过打褶后褶间尺寸也不稳定。
在压力125Pa下，上述聚酯纺粘无纺布支撑材层的透气度优选30.00～50.00cm 3/cm 2/s。透气度的大小决定着最终产品的过滤效果及使用寿命。如果聚酯纺粘无纺布支撑材层的透气度过小的话，其厚度较大，不利于后续打褶加工，而且贴合聚四氟乙烯多孔膜后，所得过滤材料的透气度会变小，在使用中压损较高，运行功率大；如果聚酯纺粘无纺布支撑材层的透气度过大的话，支撑材本身克重较低，打褶加工后达不到硬挺度要求，同时贴合聚四氟乙烯多孔膜后，过滤材料的捕集效率降低。
在压力125Pa下，上述聚四氟乙烯多孔膜的透气度优选8.00～23.00cm 3/cm 2/s。如果聚四氟乙烯多孔膜的透气度过小的话，说明聚四氟乙烯多孔膜结构中的孔径和孔隙率较小，贴合后滤材的捕集效率虽然提高，但是压损较大，设备运行成本高，使用寿命短；如果聚四氟乙烯多孔膜的透气度过大的话，贴合后滤材的透气度高于15cm 3/cm 2/s，过滤效果满足不了要求，而且因为膜体本身较薄，长时间使用中容易磨损。
在压力125Pa下，本发明过滤材料的透气度优选4.50～15.00cm 3/cm 2/s。如果过滤材料的透气度过小的话，滤材使用时压损大，清灰成本高，并且寿命缩短；如果过滤材料的透气度过大的话，表示过滤材料的有效滤过尺寸较大，颗粒物容易通过滤材，其过滤效果达不到要求。
本发明过滤材料的厚度CV值优选在25％以下。厚度CV值是指过滤材料厚度的离散程度，即厚度的均匀程度。过滤材料厚度CV值越小越好，厚度CV值越小代表过滤材料厚度越均匀， 厚度均匀性好，就更利于后续的打折及使用。如果过滤材料的厚度CV值过大的话，则过滤材料厚度均一性变差，在后续打折成型后，容易造成过滤效率、压损及透气性的不均一，影响实际使用过程中的效果及寿命。
上述纺粘无纺布支撑材层的最高点与最低点的厚度差优选在30μm以下。本发明的纺粘无纺布支撑材层最高点的厚度是指整体无纺布中断面厚度最大的值，最低点的厚度是指整体无纺布中断面厚度最小的值。本发明纺粘无纺布最高点的厚度与最低点的厚度差必须在一定的范围内，即纺粘长丝无纺布表面呈现平整状态，且没有明显的凹凸点。如果纺粘无纺布表面最高点和最低点的厚度差大于30μm的话，在后续的聚四氟乙烯多孔膜的复合中，一方面，由于纺粘无纺布表面的凹凸不平，使得聚四氟乙烯多孔膜表面张力不均匀，而且还会降低多孔膜复合过滤材料的成品率；另一方面，纺粘无纺布表面的凹凸不平，减少了聚四氟乙烯多孔膜与纺粘无纺布支撑层之间接触面积，从而使得聚四氟乙烯多孔膜在实际使用时在不断地脉冲清灰作用下，更容易从纺粘无纺布支撑层表面脱落下来，降低整体滤材的使用寿命。
本发明过滤材料的制造方法包括如下步骤：
(1)导电支撑材的制备：将导电炭黑颗粒分散液通过印刷、喷涂或浸渍的方式，分散于聚酯纺粘无纺布的至少一面，制得导电支撑材；
(2)过滤材料的制备：将导电支撑材中附有导电炭黑颗粒的其中一面与聚四氟乙烯多孔膜经过热压复合，然后在热定型温度为110～200℃下进行热定型加工，最终制得成品。
上述步骤(1)中所述的导电炭黑颗粒分散液中需要加入一定配比的粘合剂，目的是为了防止纺粘无纺布表面的炭黑颗粒脱落，从而达不到所需要的导电要求。这里的印刷法是指凹版印刷，具体是使整个印版表面涂满油墨，然后用特制的刮墨机构，把空白部分的油墨去除干净，使油墨只存留在图文部分的网穴之中，再在较大的压力作用下，将油墨转移到承印物表面，获得印刷品的方法。具有附着量能够实现精确控制，对基材透气度影响小，而且可以快速生产的特点。喷涂法是通过喷枪或雾化器借助压缩空气将导电炭黑分散液形成均匀而细微的雾滴，施涂于聚酯纺粘无纺布支撑材上，采用喷涂的方式，其方法简单，成本低，但在喷涂过程中喷头容易堵塞，需要经常清洗；浸渍法不易控制附着量，且均匀性得不到保证，对成品透气度影响较大，另外附着过程中能耗高；综上所述，优选采用印刷的加工方式。
上述步骤(1)中所述烘干温度为120～160℃之间，如果烘干温度低于120℃的话，导电炭黑层无法充分附着在支撑材表面,导致牢度不够；如果烘干温度大于160℃的话，一方面芯鞘结构纤维会部分熔融导致支撑材强力降低，另一方面熔融的纤维可能包裹导电炭黑致使导电性能下降。
上述步骤(2)中在热定型温度为110～200℃下进行热定型加工。因为过滤材料需要进行打折处理，长期使用中会发生变形，导致气流阻力增大，容尘量减小，过滤效率降低，过滤器使用寿命缩短。一般聚酯长丝结晶度能达到45～60％左右，而一定条件的热定型处理能提高纤维结晶度。涤纶纤维受热后，其分子结构将发生三个阶段的变化，首先当温度在玻璃 化转变温度(80℃～90℃)以上时开始发生分子链段的运动，然后随着温度的逐渐升高，分子链的运动加剧，在新的位置上完成调整，最后在玻璃化温度以下分子链段的位置固定下来。当热定型温度小于110℃时，分子刚刚进入高弹态，大分子链段的运动限制被消除，开始绕大分子主轴的单键旋转运动，但还没有足够的能量产生较大的位移，因此纤维结晶度变化不大，弹性模量也提高不大，随温度的升高，在120℃～200℃阶段，纤维中的大分子逐渐获得运动的能量。分子间的束缚逐渐减少，大分子可以滑移错位和卷曲，纤维的弹性模量迅速下降，变形能力增加，收缩率也明显增加，大纤维的分子结构发生较大的变化，分子的结晶度增加，取向度提高，密度加大。但如果热定型温度高于200℃的话，纤维接近粘流态，结晶度会显著下降，弹性模量也下降很多，强力和硬挺度也显著减小，尺寸稳定性不好；如果热定型温度低于110℃的话，纤维获得不了足够的能量完成分子内及分子间的重新排列，结晶度和取向度变化很少。综上所述，过滤材料的热定型温度优选120～160℃。
上述热定型加工后，还经过冷却处理。因为经过热定型处理后，材料中分子链段在新的位置进行调整，结晶度增大，需要迅速均匀的使滤材降到玻璃化温度以下，以使分子链段在新的位置稳定下来从而达到高抗弯曲强度的要求。如果冷却温度较长，滤材物理性能不均一，使用过程中尺寸稳定性较差，容易变形。
下面通过实施例更加详细地说明本发明，但本发明的保护范围不受这些实施例的限制，本发明过滤材料各物性的测定方法如下。
【克重】
将过滤材料切成200mm×200mm的正方形，从重量计算出过滤材料的克重，平均测量3次，最终结果取该3次的平均值。
【厚度】
使用厚度千分表(挤压力0.000245Pa)测定过滤材料的厚度，测定面积大小为1m×1m的过滤材料的沿横向测定10点，纵向测定10点，共选择100点进行测定，求出平均值。
【厚度CV值】
厚度CV值是指过滤材料厚度的离散程度，即厚度的均匀程度，厚度CV值的计算公式如下：CV＝σ/μ×100％,
其中，σ表示过滤材料厚度的标准偏差；
μ表示厚度平均值。
【纺粘无纺布的厚度差】
取10枚长度为10mm，宽度为2mm的样品，对该10枚样品进行SEM断面分析，拍摄倍率为100倍，每枚样品各取20个点，分别测量该20个点的断面厚度，1枚样品的20个点中断面厚度最大的值记为h1，断面厚度最小的值记为h2，分别测试10枚样品，最后取10枚样品的断面厚度最大平均值以及断面厚度最小平均值。厚度差的计算公式如下：
厚度差＝断面厚度最大平均值-断面厚度最小平均值。
【透气度】
基于JIS L 1096标准，采用弗雷泽型织物透气度测试方法，随机选取30个点测定过滤材料的透气度，结果求取平均值。
【捕集效率】
基于JIS B 9908标准规定的滤材捕集效率测试方法，测定过滤材料的捕集效率。
【抗弯曲强度】
基于GB/T 9341—2008标准，采用两段自由支撑，中央加荷的试验方法(三点加荷试验)，测定过滤材料分别在5mm和10mm处形变量下的弯曲强度，三点弯曲强度计算公式如下：σ f＝3FL/2bd 2，
其中，σ f：弯曲强度(MPa)；
F：荷重(N)；
L：支点间距离(mm)；
b：样品的宽度(mm)；
d：样品的厚度(mm)。
【表面电阻】
根据DIN 54345标准，剪取120mm×120mm的样品各5枚，测定导电过滤材料的表面电阻，结果取平均值。
实施例1
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为140℃下进行热定型处理，最后给予冷却处理，制得厚度为0.61mm、克重为208g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表1。
实施例2
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.61mm、克重为208g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表1。
实施例3
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为180℃下进行热定型处理，最后给予冷却处理，制得厚度为0.61mm、克重为208g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表1。
实施例4
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液均匀地喷涂于聚酯纺粘无纺布支撑材(克重220g/m 2、透气度33.61cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为6g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.65mm、克重为230g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表1。
实施例5
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液均匀地喷涂于聚酯纺粘无纺布支撑材(克重220g/m 2、透气度33.61cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为6g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为 26.33cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.65mm、克重为228g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表1。
实施例6
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为200℃下进行热定型处理，最后给予冷却处理，制得厚度为0.61mm、克重为208g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表1。
实施例7
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液均匀地喷涂于聚酯纺粘无纺布支撑材(克重125g/m 2、透气度49.54cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为6g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.35mm、克重为133g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表1。
实施例8
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为6g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在 温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.61mm、克重为210g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表1。
实施例9
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯涤纶无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为180℃下进行热定型处理，制得厚度为0.61mm、克重为208g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表2。
实施例10
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重240g/m 2、透气度30.26cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为8g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.72mm、克重为250g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表2。
实施例11
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重240g/m 2、透气度30.26cm 3/cm 2/s)的正反两面，使炭黑颗粒在聚酯长丝无纺布正反两面的附着量为8g/m 2，然后将附有炭黑颗粒的聚酯纺粘涤纶无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的任意一炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.72mm、克重为250g/m 2 的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为导电炭黑层。本发明过滤材料的各物性参见表2。
实施例12
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为2g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.60mm、克重为206g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表2。
实施例13
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液均匀地喷涂于聚酯纺粘无纺布支撑材(克重150g/m 2、透气度39.73cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为6g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.45mm、克重为158g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表2。
实施例14
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液均匀地喷涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为6g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.61mm、克重为208g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空 气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表2。
实施例15
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重150g/m 2、透气度39.73cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.45mm、克重为158g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表2。
实施例16
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液均匀地喷涂于聚酯纺粘无纺布支撑材(克重150g/m 2、透气度39.73cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.45mm、克重为158g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表2。
实施例17
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将聚酯纺粘无纺布支撑材(克重150g/m 2、透气度39.73cm 3/cm 2/s)浸渍于导电炭黑分散液中，使炭黑颗粒在聚酯长丝无纺布上的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.45mm、克重为158g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空 气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表2。
实施例18
将克重为240g/m 2、透气度为30.26cm 3/cm 2/s的聚酯纺粘无纺布支撑材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.69mm、克重为240g/m 2的过滤材料。该过滤材料的各物性参见表3。
实施例19
将克重为240g/m 2、透气度为30.26cm 3/cm 2/s的聚酯纺粘无纺布支撑材的一面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.70mm、克重为242g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。该过滤材料的各物性参见表3。
实施例20
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重240g/m 2、透气度30.26cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为8g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.71mm、克重为248g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为导电炭黑层，空气流出面层为聚酯纺粘无纺布支撑材层。本发明过滤材料的各物性参见表3。
实施例21
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯湿法无纺布支撑材(克重200g/m 2、透气度31.56cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯湿法无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯湿法无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.60mm、克重为208g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯湿法无纺布支撑材层。本发明过滤材料的各物性参见表3。
实施例22
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树 脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯热轧无纺布支撑材(克重200g/m 2、透气度30.24cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯热轧无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯热轧无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.60mm、克重为208g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯热轧无纺布支撑材层。本发明过滤材料的各物性参见表3。
实施例1～22制得的过滤材料可用于空气过滤，如室内、汽车空气过滤器、除尘器中，也可应用于汽车涂装、建材涂装、五金配件粉体涂装线过滤领域。
比较例1
(1)导电支撑材的制备：将粒径大小为4μm的导电炭黑颗粒17重量份，3重量份丙烯酸树脂加水到100重量份，进行充分搅拌制备成导电炭黑分散液，将制得的导电炭黑分散液通过印刷的方式涂于聚酯纺粘无纺布支撑材(克重200g/m 2、透气度36.97cm 3/cm 2/s)的其中一面，使炭黑颗粒在聚酯长丝无纺布一面的附着量为4g/m 2，然后将附有炭黑颗粒的聚酯纺粘无纺布置于温度为130℃的烘箱中进行烘干，制得导电支撑材，并进行卷曲；
(2)过滤材料的制备：将上述步骤(1)中制得的导电支撑材的炭黑颗粒面与透气度为16.14cm 3/cm 2/s的聚四氟乙烯多孔膜热压复合，然后将制得的覆膜滤材通过打折定型机，最后制得厚度为0.61mm、克重为209g/m 2的过滤材料。按照接触空气的顺序，该过滤材料的空气流入面层为聚四氟乙烯多孔膜层，空气流出面层为聚酯纺粘无纺布支撑材层。该过滤材料的各物性参见表4。
比较例2
将克重为240g/m 2、透气度为54.35cm 3/cm 2/s的涤纶机织物通过打折定型机并在温度为160℃下进行热定型处理，最后给予冷却处理，制得厚度为0.85mm、克重为240g/m 2的过滤材料。该过滤材料的各物性参见表4。
表1
Figure PCTCN2019077975-appb-000001
表2
Figure PCTCN2019077975-appb-000002
表3
Figure PCTCN2019077975-appb-000003
表4
Figure PCTCN2019077975-appb-000004
根据上述表
(1)由实施例1、2、3、6可知，同等条件下，实施例1与实施例2中过滤材料的热定型温度在优选范围中时，所得过滤材料的变形量在10mm时的抗弯曲强度高。
(2)由实施例4、7、13、14可知，同等条件下，实施例4中聚酯纺粘无纺布支撑材的克重大，所得过滤材料的克重就大、抗弯曲强度就高；聚酯纺粘无纺布支撑材的透气度低，所以过滤材料的捕集效率高。
(3)由实施例4和实施例5可知，同等条件下，实施例4中聚四氟乙烯多孔膜的透气度在优选范围时，所得过滤材料的捕集效率略高于实施例5。
(4)由实施例3和实施例9可知，同等条件下，实施例9中热定型处理后，未进行冷却处理，所得过滤材料的变形量在10mm时的抗弯曲强度略低。
(5)由实施例2、8、10、12可知，同等条件下，实施例10中导电炭黑颗粒附着量大，所得过滤材料的表面电阻越小，导电性能越好。
(6)由实施例10和实施例11可知，同等条件下，实施例11中过滤材料进行了正反两面的导电加工后，所得过滤材料的捕集效率及变形量在10mm时的抗弯曲强度略高，且导电性能好。
(7)由实施例15、16、17可知，同等条件下，实施例15中过滤材料导电炭黑层的加工方式在优选范围中时，所得过滤材料的变形量在10mm时和5mm时的抗弯曲强度高。
(8)由实施例10、18、19、20可知，同等条件下，实施例10中过滤材料同时含有导电炭黑层和聚四氟乙烯多孔膜层时，所得过滤材料的变形量在10mm时和5mm时的抗弯曲强度高，同时过滤材料的捕集效率高、导电性能好。
(9)由实施例2、21、22可知，同等条件下，实施例2中过滤材料的无纺布支撑材为优选的聚酯纺粘无纺布，所得过滤材料的变形量在10mm时和5mm时的抗弯曲强度高。
(10)由实施例1和比较例1可知，同等条件下，比较例1中未进行热定型处理，所得过滤材料的抗弯曲强度低。
(11)由实施例18和比较例2可知，同等条件下，比较例2中过滤材料为涤纶机织物，所得过滤材料的抗弯曲强度低。

Claims (11)

  1. 一种过滤材料，其特征在于：该过滤材料中含有无纺布，且该过滤材料的变形量在10mm时，其抗弯曲强度为2.0MPa以上。
  2. 根据权利要求1所述的过滤材料，其特征在于：该过滤材料的变形量在5mm时，其抗弯曲强度为0.8MPa以上。
  3. 根据权利要求1或2所述的过滤材料，其特征在于：该过滤材料为两层以上结构。
  4. 根据权利要求3所述的过滤材料，其特征在于：该过滤材料包括聚酯纺粘无纺布支撑材层、导电炭黑层、聚四氟乙烯多孔膜层，所述聚酯纺粘无纺布支撑材层的至少一面上含有导电炭黑层，且空气流入面层为聚四氟乙烯多孔膜层，该过滤材料的克重为130～250g/m 2。
  5. 根据权利要求4所述的过滤材料，其特征在于：所述导电炭黑层的炭黑颗粒附着量为4～8g/m 2。
  6. 根据权利要求4所述的过滤材料，其特征在于：所述聚酯纺粘无纺布支撑材层的克重为120～248g/m 2。
  7. 根据权利要求4所述的过滤材料，其特征在于：在压力125Pa下，所述聚酯纺粘无纺布支撑材层的透气度为30.00～50.00cm 3/cm 2/s。
  8. 根据权利要求4所述的过滤材料，其特征在于：在压力125Pa下，所述聚四氟乙烯多孔膜的透气度为8.00～23.00cm 3/cm 2/s。
  9. 根据权利要求4所述的过滤材料，其特征在于：在压力125Pa下，该过滤材料的透气度为4.50～15.00cm 3/cm 2/s。
  10. 根据权利要求1或2所述的过滤材料，其特征在于：该过滤材料的厚度CV值在25％以下。
  11. 根据权利要求4所述的过滤材料，其特征在于：所述纺粘无纺布支撑材层的最高点与最低点的厚度差在30μm以下。
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