WO2021082090A1 - 带锚点耐反吹纳米纤维复合滤材 - Google Patents

带锚点耐反吹纳米纤维复合滤材 Download PDF

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Publication number
WO2021082090A1
WO2021082090A1 PCT/CN2019/118693 CN2019118693W WO2021082090A1 WO 2021082090 A1 WO2021082090 A1 WO 2021082090A1 CN 2019118693 W CN2019118693 W CN 2019118693W WO 2021082090 A1 WO2021082090 A1 WO 2021082090A1
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substrate
anchor points
filter material
backflush
composite filter
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PCT/CN2019/118693
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English (en)
French (fr)
Inventor
董祥
徐晓东
徐卫红
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博裕纤维科技（苏州）有限公司
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    • 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
    • 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
    • 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
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/10—Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/66—Regeneration of the filtering material or filter elements inside the filter
    • B01D46/70—Regeneration of the filtering material or filter elements inside the filter by acting counter-currently on the filtering surface, e.g. by flushing on the non-cake side of the filter
    • B01D46/72—Regeneration of the filtering material or filter elements inside the filter by acting counter-currently on the filtering surface, e.g. by flushing on the non-cake side of the filter with backwash arms, shoes or nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B82—NANOTECHNOLOGY
    • B82Y—SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES; MEASUREMENT OR ANALYSIS OF NANOSTRUCTURES; MANUFACTURE OR TREATMENT OF NANOSTRUCTURES
    • B82Y40/00—Manufacture or treatment of nanostructures
    • 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
    • B01D2239/10—Filtering material manufacturing
    • 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
    • B01D2239/1233—Fibre diameter
    • 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
    • B01D2239/1283—Stability index

Definitions

  • the invention relates to the technical field of filter materials, in particular to a method for increasing the adhesion between micro-nano fibers and a substrate, and a nano-fiber composite filter material with anchor points that is resistant to blowback.
  • the gas turbine air intake system and industrial dust removal system continue to put forward higher standards for the technical indicators of the filter substrate in terms of filtration efficiency, resistance pressure drop, dust holding capacity, and service life.
  • the nano-scale fiber web prepared by high-voltage electrospinning has the characteristics of high efficiency and low resistance, and is a good raw material for preparing air filter materials. Since the filtration mechanism of the nanofiber composite air filter material is mainly surface mechanical interception, most of the captured particles are accumulated on the surface of the filter material, so it can be recycled and used through dynamic pulse back-blowing purification. If it can meet the technical indicators of resistance to backflushing, it will have a higher dust holding capacity and a longer service life in actual use.
  • the current high-voltage electrospun nanofiber composite filter material is one of the best filter materials for the industrial dust removal air system of the gas turbine intake system.
  • Donanldson, Finetex Mats TM , AntimicrobeWeb TM , NanoFilter TM , and Fibra-Web TM have been industrialized and mass-produced in the world. And other brands.
  • the filter products of other brands have different degrees of nanofiber nets falling off the substrate during the full-life pulse backflushing airflow cleaning process, so that the filtration efficiency and dust retention after cyclic backflushing The amount is declining, the running time of the filter has been severely shortened, and the cost of use has therefore increased.
  • CN101940856A and CN102908829A patents did not consider the technical indicators of full-life pulse backflush cleaning in the preparation, which easily caused the destruction of the nanofiber mesh surface, and the product could not provide stable and high-quality air for the gas turbine under the condition of dynamic pulse backflush. .
  • the technical solution of using solvent vapor to cause adhesion between fibers in the CN104028047B patent has safety problems, and its method of realizing abrasion resistance and peeling resistance has great safety hazards.
  • the working voltage in the mass production process of high-voltage electrospinning is often as high as tens of thousands of volts. Controlling the concentration of solvent vapor in the high-voltage field strength is a prerequisite for safe mass production.
  • the above-mentioned existing technical patents have the characteristics of difficult industrial mass production, complicated production procedures, and high production costs.
  • the technical problem to be solved by the present invention is to provide a method for increasing the adhesion of micro-nano fibers to a substrate.
  • the method has simple process, low production cost, and can be molded at one time, and the substrate and the micro-nano fibers deposited on the substrate The adhesion between the fibers is good, and the method can be used to produce nano-fiber composite filter materials, so that it has excellent back blow resistance.
  • the present invention provides a method for increasing the adhesion of micro-nano fibers to a substrate.
  • the substrate is sprayed with micro-nano fibers with beads by an electrostatic spinning method, and the beads serve as anchors.
  • the dot anchors the micro-nano fibers on the substrate, thereby increasing the adhesion between the micro-nano fibers and the substrate.
  • Another aspect of the present invention provides a backflush-resistant nanofiber composite filter material with anchor points, the composite filter material comprising:
  • a fibrous filter substrate A fibrous filter substrate
  • the minimum filtration efficiency of the composite filter material is 60%.
  • the filter substrate is a filter paper substrate, a meltblown non-woven fabric substrate or a needle punched/spunlaced filter felt substrate.
  • the weight of the filter paper substrate is 20 to 140 gsm; further, the weight of the meltblown non-woven fabric substrate and the needle punch/spunlace filter felt substrate is 20 to 250 gsm.
  • the filter paper substrate is a filter paper substrate prepared by papermaking of wood pulp fibers by wet papermaking technology.
  • the raw material of the filter paper substrate further includes 10 to 19.5% by weight of reinforcing fibers.
  • the reinforcing fibers are PET fibers and/or PP fibers, and the diameter is preferably 50-70 ⁇ m, and the length is preferably 5-10 cm. Reinforcing fibers can increase the stiffness, rupture strength and weather resistance of fiber-based substrates.
  • the filter paper substrate is a commercially available flat air filter paper or corrugated air filter paper.
  • the raw material of the meltblown non-woven fabric substrate is selected from at least one of polyester fiber (PET), polypropylene, polyvinylidene fluoride, PA6, and PA66.
  • the polymer configuring the spinning solution is selected from at least one of the following materials: polyvinylidene fluoride, polyurethane, polyacrylonitrile, polymethylmethacrylate, polylactic acid, polyamide, polyimide, Polyaramide, polybenzimidazole, polyethylene terephthalate, polypropylene, polyaniline, polyethylene oxide, polyethylene naphthalate, polybutylene terephthalate, styrene- Butadiene rubber, polystyrene, polyvinyl chloride, polyvinyl alcohol, polyvinyl butene, and their copolymers or derivatives.
  • the spinning solution is obtained by dissolving polyurethane in a mixed solvent, and the mixed solvent includes a solvent A and a solvent B in a mass ratio of 9:1 to 5:5, and the solvent A is N, N- Dimethylformamide or N,N-dimethylacetamide, and the solvent B is acetone or methyl ethyl ketone.
  • the spinning solution also contains 0.01% to 1% by weight of a conductive auxiliary agent to increase the conductivity of the polymer spinning solution.
  • the conductive auxiliary agent is preferably tetrabutylammonium perchlorate.
  • the spinning solution also contains polytetrafluoroethylene (PTFE) ultra-fine powder with a purity of 100%, a molecular weight of 10,000 or less, and a particle size of 0.5-2.5 ⁇ m.
  • PTFE polytetrafluoroethylene
  • the ultra-fine powder has good compatibility and Dispersibility.
  • the mass ratio of the polytetrafluoroethylene ultrafine powder to the spinning solution is 1: (4 to 99).
  • the principle of the present invention is:
  • the viscous force of the high polymer solution in the high-voltage electrospinning process is less than the drawing force of the electric field force and the repulsive force of the Coulomb force.
  • the jet remains in Rayleigh unstable motion.
  • continuous beads are formed between the nanofibers due to the interaction of the electric field force, the Coulomb force and the surface tension of the polymer solution, forming a nanofiber network with beads, and its single bead Stick to the substrate or nanofibers as a single bead anchor point (see Figure 10).
  • the diameter of the anchor point and the number of anchor points on the nanofiber can be controlled by adjusting the polymer solution viscosity and supply amount, spinning height, voltage and other spinning parameters; in addition, by adding in the spinning solution PTFE ultra-fine powder, the ultra-fine powder is uniformly dispersed in the polymer solution, and the polymer solution leaves the end face of the spinneret to form a charged jet under the electric field force drafting force, which overcomes the surface tension of the polymer solution , Part of the solution forms nano-scale fibers, and other parts of the polymer solution wrap the PTFE ultrafine powder to move upwards.
  • the electric field force drafting force and the Coulomb force repulsive force continue to decrease, which is smaller than that between the polymer solution and the PTFE ultrafine powder.
  • the adhesion force of the nanofibers continuously appears in the middle of the nanofibers with 2 ⁇ 3.5 ⁇ m wrapping points, that is, the nanofiber web with spider-like anchor points.
  • By adding PTFE ultrafine powder to the solution it is easier to control the number of anchor points per unit area.
  • the spinning distance of the jet flying to the receiving plate is reduced, that is, the solvent volatilization time is reduced, and the proper spinning distance is that the solvent in the nanofiber section is completely volatilized.
  • the diameter of the spider anchor point is a thousand times that of the nanofiber section.
  • the spider anchor point has a large amount of solvent and is not easy to volatilize.
  • the short volatilization time of the solvent is not completely volatilized due to the short ascending distance.
  • the solvent is processed in the oven before the winding, and the spider anchor point and the substrate have better adhesion.
  • bead-type and spider-type anchor points are prepared in nanofibers, which are concentrated on the fibers of the substrate (202 in Figure 10) to strengthen the overall strength of the nanofiber web, Since the diameter of the anchor point is 2 to 3 ⁇ m, which is much smaller than the diameter of the substrate fiber, the contact area between the nanofiber and the substrate fiber is increased without significantly increasing the resistance pressure drop, thereby strengthening the nanofiber and the substrate.
  • the adhesiveness of the material improves the backflush resistance; it also significantly increases the dust holding capacity and prolongs the service life of the device.
  • the nanofiber composite filter material produced by the present invention is formed at one time, has simple process, low production cost, and excellent product performance.
  • the filter efficiency can be stabilized to F9 (EN779-2012 standard) and above through electrostatic spraying of nanofibers. It has the characteristics of high efficiency and low resistance, and the performance of backflush resistance is perfect.
  • the filtration effect, resistance, dust holding capacity, and pulse backflush resistance performance of the EN779-2012 standard have reached the technical indicators of international high-end air filter materials.
  • Figure 1 is a schematic diagram of a single group of high-voltage electrospinning equipment used in an embodiment
  • Figure 2 is an electron microscope image of the composite filter material prepared in Example 1. Fiber metric system analysis, the system measured the fiber diameters to concentrate on 130nm-270nm, and most of the diameters are concentrated at 150nm;
  • Fig. 3 is an electron microscope image of the composite filter material prepared in Example 2. Fiber metric system analysis, the system measured the fiber diameter concentrated and then 170nm-255nm, most of the diameter concentrated in 180nm;
  • Figure 4 is an electron microscope image of the composite filter material prepared in Example 3. Fiber metric system analysis, the system measured the fiber diameters to concentrate on 250nm-300nm, most of the diameters are concentrated at 270nm;
  • Figure 5 is an electron microscope image of the composite filter material prepared in Example 4. Fiber metric system analysis, the system measured the fiber diameter to concentrate on 330nm-390nm, and most of the diameters are concentrated on 350nm;
  • Example 6 is an electron microscope diagram of the number and distribution of nanofiber anchor points in the composite filter material prepared in Example 5;
  • Figure 7 is an electron microscope diagram of the number and distribution of nanofiber anchor points in the composite filter material prepared in Example 6;
  • Example 8 is an electron microscope diagram of the number and distribution of nanofiber anchor points in the composite filter material prepared in Example 7;
  • Example 9 is an electron microscope diagram of the number and distribution of nanofiber anchor points in the composite filter material prepared in Example 8.
  • Example 10 is an electron micrograph of the composite filter material prepared in Example 7, in which 201 is the spider anchor point of the nanofiber web, and 202 is the substrate fiber;
  • Figure 11 shows the test report.
  • an industrialized assembly line is used to prepare 4 sets of spinneret systems (with the spinneret head facing upward) for high-voltage electrospinning.
  • the industrialized high-voltage electrospinning assembly line is shown in Figure 1, and at least the following equipment is required: unwinding Device 1, winding device 2, spinneret frame 3, receiving screen 4, high-voltage DC power supply 5, spinneret 6, spinneret 7, spinneret bracket 8, oven 9, conveyor belt 10, conveyor roller 11, supply ⁇ 12 ⁇ Liquid system 12.
  • the structure of the spinneret and the spinning unit is detailed in the CN201811180346.9 patent, and the industrial batching system and liquid supply system supporting the industrial high-voltage electrospinning assembly line are detailed in the CN105019042 B patent, which will not be repeated here.
  • the spinneret unit is a modular component, which can be assembled in multiples of 4 according to the production requirements, such as: 4 groups, 8 groups, 16 groups or more.
  • the instruments and software used in the present invention include: TEXTEST FX3300 air permeability tester, Phenom Pro electron microscope, Phenom fiber metric system, TSI 8130A filtration efficiency tester, Boyu 8100 pulse backflush test bench.
  • Hunan Zhengjia 115cw substrate substrate width 1.6 meters, filtration efficiency F7, mass 115gsm, thickness 0.3, air permeability 230L@200Pa l/m 2 /s, average pore size 45. ⁇ m, filtration efficiency 35 ⁇ 5%@0.3 ⁇ m DEHS@32L;
  • the raw materials for spinning dope are:
  • Solute Polyurethane, Lubrizol Estane TPU X595A-11;
  • Conductive aid 0.1% tetrabutylammonium perchlorate.
  • Production environment constant temperature and humidity workshop, temperature (30 ⁇ 2) °C, relative humidity (30 ⁇ 5)%, enthalpy value (50 ⁇ 5) kJ, fresh air volume of assembly line 9000m 3 /h, recovery air volume (exhaust air) 9050m 3 /h, the air pressure in the equipment is (2.5 ⁇ 0.5) Pa, and the solvent gas concentration is ⁇ (10 ⁇ 0.5) ppm.
  • nanofiber composite filter materials prepared in Examples 1 to 4 were tested using TIS81030A and the Phenom fiber metric system of the Phenom electron microscope, and the results are shown in Figures 2 to 5.
  • the strength of the nano fiber mesh and the filtration efficiency of the nano composite filter must be considered in the actual application process.
  • the diameter of the nano fiber determines the comprehensive performance of the nano composite material. .
  • the diameter of the nanofibers was concentrated within 200nm ( Figure 2 and Figure 3), and the resistance and filtration efficiency were good.
  • the strength of the nanofiber web was relatively low.
  • Example 4 when the diameter of the nanofibers is concentrated at 350 nm (as shown in Figure 5), the resistance increases significantly and the filtration efficiency decreases. In Example 3, the fiber diameter is concentrated at 250 nm (as shown in Figure 4), and the filtration efficiency and resistance parameters of the nanofiber composite filter material are good, so the solution preparation scheme of Example 3 is preferred.
  • the spinning solutions of Examples 5 to 8 were obtained by adding different contents of PTFE ultrafine powder.
  • the PTFE ultra-fine powder is 3M Dyneon, and the primary particle size reaches the nanometer level.
  • Production environment constant temperature and humidity workshop, temperature (30 ⁇ 2) °C, relative humidity (30 ⁇ 5)%, enthalpy value (50 ⁇ 5) kJ, fresh air volume of assembly line 9000m3/h, recovery air volume (exhaust) 9050m3/h ,
  • the air pressure in the equipment is (2.5 ⁇ 0.5) Pa, and the solvent gas concentration is ⁇ (10 ⁇ 0.5) ppm.
  • the repulsive force with the Coulomb force is continuously reduced, which is less than the adhesion force between the polymer solution and the PTFE ultrafine powder, and the wrapping points of 2 to 3.5 ⁇ m appear continuously among the nanofibers, that is, the nanofiber web with spider anchor points.
  • the spider anchors are cured in an oven, and finally looped through a winding device to obtain a composite filter material.
  • nanofiber composite filter materials prepared in Examples 5 to 8 were tested through the Phenom electron microscope Phenom fiber metric system and TIS81030A.
  • the number of anchor points on the filter material fibers of Example 5 and Example 6 is sparse, the number of anchor points on the filter material fibers of Example 8 is too much, and the filter material fibers of Example 7 have an appropriate number Anchor point.
  • the reason is: the solid content of the spinning solution in Example 7 is 9%, the viscosity of the TPU polymer solution is 220CP ⁇ 5, and PTFE ultrafine powder is added.
  • the polymer solution wraps the PTFE ultrafine powder, and high-pressure electrostatic spinning In the process, the viscous force of the high polymer solution is less than the drawing force of the electric field force and the repulsive force of the Coulomb force.
  • the preferred embodiment 7 and the diameter of the nanofibers in the composite filter material of the embodiment 7 are concentrated in the range of 250-350 nm.
  • Table 4 shows the filtration efficiency results of the filter media measured by TIS81030A. It can be seen from the table that the filter materials of Examples 5 to 8 have excellent filtration efficiency, but the filter material of Example 8 has too many anchor points, resulting in a large resistance of the nanocomposite material and a decrease in air permeability.
  • the Boyu 8100 pulse backflushing test bench was used to test the backflush resistance of the composite filter materials prepared in Example 3 and Example 7.
  • the backflush air pressure was 3-6kg, the backflush area was 50.24cm 2 , and the number of backflushes was 1000 The results are shown in Table 5.
  • the composite filter material prepared in Example 3 has a significant drop in filtration efficiency when the pulse backflush air pressure is 5kg; when the backflush air pressure increases to 6kg, the filtration efficiency drops It’s about 30%.
  • the composite filter material prepared in Example 7 has excellent backflush resistance.
  • the backflush air pressure is 3 to 5 kg, the filtration efficiency does not decrease.
  • the backflush air pressure increases to 6 kg, the filtration efficiency still does not decrease significantly.
  • the composite filter material of Example 7 achieves the F9 (EN779-2012 standard) filter efficiency, but there is no obvious resistance pressure drop. This is because the composite filter material of Example 7 forms spider nanofiber anchor points during the production process, which increases the contact area between the nanofibers and the substrate, and enhances the adhesion between the nanofiber web and the substrate, thereby achieving It has excellent back blow resistance, obviously increases the dust holding capacity, and prolongs the service life of the device.

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Abstract

提供了一种增加微纳米纤维与基材粘合性的方法，通过静电纺丝的方法在基材上喷涂带有珠粒的微纳米纤维，所述珠粒作为锚固点将微纳米纤维锚固于基材上，从而增加了微纳米纤维与基材间的粘合性。另一方面提供了一种带锚点耐反吹纳米纤维复合滤材，包括一纤维类过滤基材以及通过静电纺丝的方法沉积在所述过滤基材至少一面上的纳米纤维层；所述纳米纤维层中的纳米纤维上形成有珠粒，所述珠粒将多根纳米纤维粘合在一起并粘接在过滤基材的纤维上。该方法工艺简单，生产成本低，能够一次性成型，且基材与沉积在基材上的微纳米纤维之间粘合性好，该方法能够用于生产纳米纤维复合滤材，使其具有优异的耐反吹性能。

Description

带锚点耐反吹纳米纤维复合滤材 技术领域
本发明涉及过滤材料技术领域，具体涉及一种增加微纳米纤维与基材粘合性的方法以及一种带锚点耐反吹纳米纤维复合滤材。
背景技术
当今空气污染问题备受关注，社会上普遍倡导高效环保地利用能源。燃气轮机进气系统和工业除尘系统对过滤基材技术指标从过滤效率、阻力压降、容尘量、使用寿命几项不断提出更高的标准要求。高压静电纺所制备的纳米级纤维网具有高效、低阻的特征，是制备空气滤材的良好的原材料。由于纳米纤维复合空气滤材的过滤机理是以表面机械拦截为主，捕获的颗粒绝大多数堆积在滤材表面，因此可以通过动态脉冲反吹净化而循环使用。如果其能达到耐反吹的技术指标，在实际使用中就具有更高的容尘量以及更长使用寿命。
当前高压静电纺纳米纤维复合滤料是燃气轮机进气系统工业除尘空气系统最好滤料之一，目前国际上实现工业化量产的有Donanldson，Finetex Mats TM，AntimicrobeWeb TM，NanoFilter TM，Fibra-Web TM等品牌商。经过调研，除Donanldson外，其他品牌商的滤料产品在全寿命脉冲反吹气流清洗过程中都出现不同程度的纳米纤维网从基材上脱落的现象，从而循环反吹后过滤效率和容尘量不断下降，过滤器运行时间严重缩短，使用成本因此增加。
国内的滤材技术相对落后，从军用(052系列舰、055系列舰)到民用电厂燃气轮机进气系统高端滤芯滤材(F9级别标准EN779-2012)市场被国外(Donanldson)垄断。据调研，国内企事业和技术院校对高压静电纺纳米纤维技术多数停留在实验室阶段，从设备到工艺量产纳米纤维复合滤材还有很多技 术性问题需要突破。如：CN101940856A和CN102908829A专利由于在制备中没有考虑到全寿命脉冲反吹清洗的技术指标，易造成纳米纤维网面的破环，产品无法在动态脉冲反吹的情况下为燃气轮机提供稳定优质的空气。CN104028047B专利中利用溶剂蒸汽使纤维间产生粘连的技术方案存在安全问题，其实现耐磨、抗剥离的方法具有很大的安全隐患。众所周知高压静电纺丝量产化过程中工作电压常高达数万伏，控制高压场强中溶剂蒸汽浓度是安全量产的先决条件。上述现有的技术专利同时都出现工业量产难度大，生产工序繁杂，生产成本高的特点。
发明内容
本发明要解决的技术问题是提供一种增加微纳米纤维与基材粘合性的方法，该方法工艺简单，生产成本低，能够一次性成型，且基材与沉积在基材上的微纳米纤维之间粘合性好，该方法能够用于生产纳米纤维复合滤材，使其具有优异的耐反吹性能。
为了解决上述技术问题，本发明提供了一种增加微纳米纤维与基材粘合性的方法，通过静电纺丝的方法在基材上喷涂带有珠粒的微纳米纤维，所述珠粒作为锚固点将微纳米纤维锚固于基材上，从而增加了微纳米纤维与基材间的粘合性。
本发明另一方面提供了一种带锚点耐反吹纳米纤维复合滤材，所述复合滤材包括：
一纤维类过滤基材；以及
通过静电纺丝的方法沉积在所述过滤基材至少一面上的纳米纤维层；所述纳米纤维层中的纳米纤维上形成有珠粒，所述珠粒将邻近的纳米纤维粘合在一起并粘接在过滤基材的纤维上。
进一步地，所述复合滤材的最低过滤效率为60％。
进一步地，所述过滤基材为滤纸基材、熔喷无纺布基材或针刺/水刺过滤毡基材。
进一步地，所述滤纸基材的重量为20～140gsm；进一步地，所述熔喷无纺布基材、针刺/水刺过滤毡基材的重量为20～250gsm。
进一步地，所述滤纸基材为木浆纤维通过湿法抄纸技术抄造制备出的滤纸基材。
进一步地，所述滤纸基材的原料中还包括10～19.5wt％的增强纤维。进一步地，所述增强纤维为PET纤维和/或PP纤维，其直径优选为50～70μm，长度优选为5～10cm。增强纤维能够增加纤维类基材的挺度、耐破裂强度和耐候性。
进一步地，所述滤纸基材为市售平板空气滤纸或带瓦楞空气滤纸。
进一步地，所述熔喷无纺布基材的原料选自聚酯纤维(PET)、聚丙烯、聚偏氟乙烯、PA6、PA66中的至少一种。
进一步地，配置纺丝液的聚合物选自下述材料中的至少一种：聚偏氟乙烯、聚氨酯、聚丙烯腈、聚甲基丙烯酸甲酯、聚乳酸、聚酰胺、聚酰亚胺、聚芳酰胺、聚苯并咪唑、聚对苯二甲酸乙二酯、聚丙烯、聚苯胺、聚环氧乙烷、聚萘二酸乙二酯、聚对苯二甲酸丁二酯、苯乙烯-丁二烯橡胶、聚苯乙烯、聚氯乙烯、聚乙烯醇、聚乙烯基丁烯，以及它们的共聚物或衍生物。
进一步地，所述纺丝液是由聚氨酯溶于混合溶剂中得到的，所述混合溶剂包括质量比为9:1～5:5的溶剂A和溶剂B，所述溶剂A为N，N-二甲基甲酰胺或N，N-二甲基乙酰胺，所述溶剂B为丙酮或丁酮。
进一步地，纺丝液中还包含0.01％～1wt％的导电助剂，以增加聚合物纺丝液的导电性。所述导电助剂优选为四丁基高氯酸铵。
进一步地，纺丝液中还包含聚四氟乙烯(PTFE)超细粉，其纯度为100％，分子量为10000以下，粒径为0.5～2.5μm，该超细粉具有良好的相容性和分散性。进一步地，所述聚四氟乙烯超细粉与纺丝液的质量比为1:(4～99)。
本发明的原理为：
聚合物溶液粘度低到一定的情况下，高压静电纺丝过程中高聚合物溶液的粘滞力小于电场力的牵伸力和库仑力的排斥力射流保持做瑞利(Rayleigh)不稳定性运动，在往上牵伸的带电射流上行中由于电场力、库仑力和聚合物溶液表面张力相互作用下纳米纤维中间而产生了连续的珠粒，形成了带珠粒的纳米纤维网，其单个珠粒粘在基材或纳米纤维上成为单个珠粒式锚固点(见图10)。
本发明中，可以通过对聚合物溶液粘度和供应量、纺丝高度、电压等纺丝参数的调整，来控制纳米纤维上锚固定点的直径、锚固点的数量；另外通过在纺丝液中加入PTFE超细粉，超细粉均匀的分散在聚合物溶液中，在电场力牵伸下聚合物溶液离开喷丝头端面上形成为带电射流，电场力牵伸力克服了聚合物溶液的表面张力，部分溶液形成纳米级纤维，其他部分聚合物溶液包裹着PTFE超细粉体上行，过程中电场力牵伸力和库仑力排斥力不断减小，小于聚合物溶液和PTFE超细粉体之间的黏合力，在纳米纤维中间连续出现2～3.5μm的包裹点，即带蜘蛛式锚固点纳米纤维网。通过在溶液中加入PTFE超细粉体，更容易控制单位面积锚点数量。通过对纺丝距离的适当调整使射流飞向接收极板的距离减少，即溶剂挥发时间减少，适当纺丝距离即纳米纤维段的溶剂完全挥发，蜘蛛式锚固点直径是纳米纤维段千倍，蜘蛛式锚固点溶剂量多且不易挥发，由于上行距离近致使挥发时间短溶剂未完全挥发，收卷前进烘箱处理溶剂，蜘蛛式锚固点和基材之间具有更好的黏合性。
本发明的有益效果：
1.本发明通过在纳米纤维中制备珠粒式和蜘蛛式锚固点(图10中201)，集中落在基材的纤维上(图10中202)加强了纳米纤维网的整体强度的同时， 由于锚固点的直径在2～3μm，远远小于基材纤维的直径，在没有明显增大阻力压降的同时，增大了纳米纤维和基材纤维的接触面积，从而增强了纳米纤维和基材的粘合性，提高了耐反吹性能；且明显增大了容尘量，延长了器件的使用寿命。
2.本发明生产的纳米纤维复合滤材一次性成型，工艺简单，生产成本低，产品性能优秀。在由木浆纤维与化纤合成制备的M6-F8级别(EN779-2012标准)滤纸或无纺布上，通过静电喷涂纳米纤维使过滤效率稳定达到F9(EN779-2012标准)及以上级别。具有高效低阻特性同时耐反吹性能表现完美，经EN779-2012标准测试过滤效果、阻力、容尘量、耐脉冲反吹性能达到国际高端空气滤材的技术指标。
附图说明
图1为实施例中所使用的高压静电纺丝设备单组的示意图；
图2为实施例1制备的复合滤材的电镜图Fiber metric系统分析，系统测得纤维直径集中再130nm-270nm，多数直径集中在150nm；
图3为实施例2制备的复合滤材的电镜图Fiber metric系统分析，系统测得纤维直径集中再170nm-255nm，多数直径集中在180nm；
图4为实施例3制备的复合滤材的电镜图Fiber metric系统分析，系统测得纤维直径集中再250nm-300nm，多数直径集中在270nm；
图5为实施例4制备的复合滤材的电镜图Fiber metric系统分析，系统测得纤维直径集中再330nm-390nm，多数直径集中在350nm；
图6为实施例5制备的复合滤材中纳米纤维锚固点数量及分布电镜图；
图7为实施例6制备的复合滤材中纳米纤维锚固点数量及分布电镜图；
图8为实施例7制备的复合滤材中纳米纤维锚固点数量及分布电镜图；
图9为实施例8制备的复合滤材中纳米纤维锚固点数量及分布电镜图；
图10为实施例7制备的复合滤材的电镜图，其中201为纳米纤维网蜘蛛式锚固点，202为基材纤维；
图11为测试报告。
具体实施方式
下面结合附图和具体实施例对本发明作进一步说明，以使本领域的技术人员可以更好地理解本发明并能予以实施，但所举实施例不作为对本发明的限定。
1.原料
聚氨酯，路博润lubrizol Estane TPU X595A-11；
甲基甲酰胺，纯度>99.9％(GC)，市购；
丙酮，纯度>97.0％(GC)，市购；
PTFE超细粉，3M Dyneon，初级粒径达到纳米级。
2、生产设备
本发明各实施例中使用工业化流水线配制4组喷丝系统(喷丝针头朝上设置)进行高压电纺，其中工业化高压静电纺流水线如图1所示，其至少需要配置如下设备：退卷装置1，收卷装置2，喷丝室框架3，接收屏4，高压直流电源5，喷丝头6，喷丝组7，喷丝组支架8，烘箱9，传送带10，传送辊11，供液系统12。喷丝头和喷丝单元的结构详见CN201811180346.9专利，与该工业化高压静电纺流水线配套的工业化配料系统和供液系统详见CN 105019042 B专利，在此不再赘述。喷丝单元为模块化组件，可根据产量要求配制以4的倍数组装如：4组、8组、16组或更多。
3、检测仪器及设备
本发明使用到的仪器及软件有：TEXTEST FX3300透气性测试仪、Phenom Pro电镜、Phenom fiber metric系统、TSI 8130A过滤效率测试仪、博裕8100脉 冲反吹测试台。
实施例1～4
(1)滤纸基材
湖南正佳115cw基材：基材门幅1.6米，过滤效率F7，质量115gsm，厚度0.3，透气量230L@200Pa l/m 2/s，平均孔径45.μm，过滤效率35±5％@0.3μm DEHS@32L；
(2)配置电纺溶液
配置纺丝液的原料为：
溶质：聚氨酯，路博润lubrizol Estane TPU X595A-11；
溶剂：DMF/MEK 8:2；
导电助剂：0.1％的四丁基高氯酸铵。
表1 实施例1～4的纺丝液的配方
Figure PCTCN2019118693-appb-000001
(3)在滤纸基材上制备纳米纤维
生产环境：恒温恒湿车间，温度(30±2)℃，相对湿度(30±5)％，焓值(50±5)kJ，流水线新风风量9000m 3/h，回收风量(排风)9050m 3/h，设备内空压(2.5±0.5)Pa，溶剂气体浓度<(10±0.5)ppm。
生产参数：溶液量350g/h，纺丝高度120mm，喷丝组位移速度40mm/s，位移距离50mm，纺丝电压60kv，车速4.5m/min。
具体制备过程：
将湖南正佳115cw基材通过退卷装置1进入设置有4组喷丝组件的纺丝流水线中，按照表1的配方，通过工业化配料系统和供液系统进行配料和供液，在高压电场的作用下，位于数千个喷头顶端处的溶液富集了大量电荷形成静电排斥力，克服了聚合物溶液表面张力，溶液形成纳米级纤维，落在基材上，最后通过收卷装置进行打圈，得到纳米纤维复合滤材。
表2 实施例1～4制备的纳米纤维复合滤材的技术参数
Figure PCTCN2019118693-appb-000002
采用TIS81030A和Phenom电镜Phenom fiber metric系统测试实施例1～4制备的纳米纤维复合滤材，结果如图2～5所示。
由于纳米网层再基材表面喷涂只有0.02g/m 2左右，在实际应用过程中必须考虑到纳米纤维网的强度和纳米复合滤材的过滤效率，纳米纤维直径决定着纳米复合材料的综合性能。相同材料和工艺下制备的纳米纤维直径越粗纳米纤维网强度越好。纳米纤维直径越小滤材过滤效率越高。实施例1、实施例2中纳米纤维直径集中在200nm内(图2、图3)，阻力及过滤效率表现良好纳米纤维网面强度相对较低。实施例4，当纳米纤维直径集中在350nm(如图5)情 况，阻力明显增大且过滤效率下降。实施例3中纤维直径集中在250nm(如4图)，纳米纤维复合滤材过滤效率、阻力参数良好，所以优选实施例3溶液配制方案。
实施例5～8
(1)配置纺丝液
以实施例3的电纺溶液作为基础液，通过添加不同含量的PTFE超细粉，得实施例5～8的纺丝液。其中，PTFE超细粉为3M Dyneon，初级粒径达到纳米级。
表3 实施例5～8纺丝液的配方
  电纺溶液(wt％) PTFE(wt％)
实施例5 99 1
实施例6 97 3
实施例7 95 5
实施例8 93 7
(2)在滤纸基材上制备纳米纤维
生产环境：恒温恒湿车间，温度(30±2)℃，相对湿度(30±5)％，焓值(50±5)kJ，流水线新风风量9000m3/h，回收风量(排风)9050m3/h，设备内空压(2.5±0.5)Pa，溶剂气体浓度<(10±0.5)ppm。
生产参数：溶液量350g/h，纺丝高度120mm，喷丝组位移速度40mm/s，位移距离50mm，纺丝电压60kv，车速4.5m/min。
具体制备过程：
将湖南正佳115cw基材通过退卷装置进入设置有4组喷丝组件的纺丝流水 线中，通过工业化配料系统和供液系统进行配料和供液，在高压电场的作用下，位于数千个喷头顶端处的溶液富集了大量电荷形成静电排斥力，克服了聚合物溶液表面张力，部分溶液形成纳米级纤维，其他部分聚合物溶液包裹着PTFE超细粉体上行，过程中电场力牵伸力和库仑力排斥力不断减小，小于聚合物溶液和PTFE超细粉体之间的黏合力，在纳米纤维中间连续出现2～3.5μm的包裹点，即带蜘蛛式锚固点纳米纤维网。经过烘箱固化蜘蛛式锚点，最后通过收卷装置进行打圈，得到复合滤材。
性能测试
1.微观形貌及过滤参数测试
通过Phenom电镜Phenom fiber metric系统和TIS81030A测试实施例5～8制备的纳米纤维复合滤材。
参见图6～图10，实施例5和实施例6的滤材纤维上锚固点数量稀少，实施例8的滤材纤维上锚固点过多，而实施例7的的滤材纤维上具有合适数量的锚固点。其原因是：实施例7中纺丝溶液的固含量为9％，TPU聚合物溶液粘度为220CP±5，再加入PTFE超细粉，聚合物溶液包裹着PTFE超细粉体，高压静电纺丝过程中高聚合物溶液的粘滞力小于电场力的牵伸力和库仑力的排斥力射流保持做瑞利(Rayleigh)不稳定性运动，在往上牵伸的带电射流上行中由于电场力、库仑力和聚合物溶液表面张力及聚合物溶液和PTFE超细粉体之间的黏合力相互作用下纳米纤维中间更容易产生连续的珠粒，形成了带珠粒的纳米纤维网，其单个珠粒粘黏在基材或纳米纤维上成为单个蜘蛛式锚固点。
因此优选实施例7，实施例7的复合滤材中纳米纤维的直径集中在250～350nm。
表4为通过TIS81030A测得的滤材过滤效率结果。从表中可以看出，实施例5～8的滤材均具有优异的过滤效率，但实施例8的滤材由于锚固点过多，造 成纳米复合材料阻力偏大，透气量下降。
表4 实施例5～8制备的复合滤材的过滤参数
Figure PCTCN2019118693-appb-000003
2.脉冲耐反吹测试
采用博裕8100脉冲反吹测试台分别测试实施例3与实施例7制备的复合滤材的耐反吹性能，反吹气压为3～6kg，反吹面积为50.24cm 2，反吹次数为1000次，所得结果如表5所示。
表5 实施例3与实施例7纳米纤维复合滤材(片材)的测试结果
Figure PCTCN2019118693-appb-000004
Figure PCTCN2019118693-appb-000005
根据表5的脉冲耐反吹数据可以发现，实施例3制备的复合滤材，在脉冲反吹气压为5kg的情况下，过滤效率出现了明显下降；当反吹气压增加至6kg时过滤效率下降了30％左右。
而实施例7制备的复合滤材的耐反吹性能优异，在反吹气压为3～5kg时过滤效率均没有出现下降，当反吹气压增加到6kg时，过滤效率仍然没有出现明显的下降。
参见图11的国家电网测试报告，实施例7的复合滤材，在达到F9(EN779-2012标准)过滤效率情况下，却没有出现明显的阻力压降。这是由于实施例7的复合滤材在生产过程中形成了蜘蛛式纳米纤维锚点，增大了纳米纤维和基材的接触面积，增强了纳米纤维网和基材的粘合性，从而实现了优良的耐反吹性能，明显增大了容尘量，而延长了器件的使用寿命。
以上所述实施例仅是为充分说明本发明而所举的较佳的实施例，本发明的保护范围不限于此。本技术领域的技术人员在本发明基础上所作的等同替代或变换，均在本发明的保护范围之内。本发明的保护范围以权利要求书为准。

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  1. 一种增加微纳米纤维与基材粘合性的方法，其特征在于，通过静电纺丝的方法在基材上喷涂带有珠粒的微纳米纤维，所述珠粒作为锚固点将微纳米纤维锚固于基材上，从而增加了微纳米纤维与基材间的粘合性。
  2. 一种带锚点耐反吹纳米纤维复合滤材，其特征在于，所述复合滤材包括：
    一纤维类过滤基材；以及
    通过静电纺丝的方法沉积在所述过滤基材至少一面上的纳米纤维层；所述纳米纤维层中的纳米纤维上形成有珠粒，所述珠粒将邻近的纳米纤维粘合在一起并粘接在过滤基材的纤维上。
  3. 如权利要求2所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述过滤基材为滤纸基材、熔喷无纺布基材或针刺/水刺过滤毡基材。
  4. 如权利要求3所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述滤纸基材的重量为20～140gsm，所述熔喷无纺布基材、针刺/水刺过滤毡基材的重量为20～250gsm。
  5. 如权利要求3所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述滤纸基材为木浆纤维通过湿法抄纸技术抄造制备出的滤纸基材。
  6. 如权利要求5所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述滤纸基材的原料中还包括10～19.5wt％的增强纤维。
  7. 如权利要求6所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述增强纤维为PET纤维和/或PP纤维；
    所述增强纤维的直径优选为50～70μm，长度优选为5～10cm。
  8. 如权利要求3所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述滤纸基材为市售平板空气滤纸或带瓦楞空气滤纸。
  9. 如权利要求3所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述熔喷无纺布基材的原料选自聚酯纤维、聚丙烯、聚偏氟乙烯、PA6、PA66中的至少一种。
  10. 如权利要求2所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，配置纺丝液的聚合物选自下述材料中的至少一种：聚偏氟乙烯、聚氨酯、聚丙烯腈、聚甲基丙烯酸甲酯、聚乳酸、聚酰胺、聚酰亚胺、聚芳酰胺、聚苯并咪唑、聚对苯二甲酸乙二酯、聚丙烯、聚苯胺、聚环氧乙烷、聚萘二酸乙二酯、聚对苯二甲酸丁二酯、苯乙烯-丁二烯橡胶、聚苯乙烯、聚氯乙烯、聚乙烯醇、聚乙烯基丁烯，以及它们的共聚物或衍生物。
  11. 如权利要求10所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述纺丝液中还包含0.01％～1wt％的导电助剂；
    所述导电助剂优选为四丁基高氯酸铵。
  12. 如权利要求10所述的带锚点耐反吹纳米纤维复合滤材，其特征在于，所述纺丝液中还包含聚四氟乙烯超细粉，其纯度为100％，分子量为10000以下，粒径为0.5～2.5μm；
    所述聚四氟乙烯超细粉与纺丝液的质量比优选为1:(4～99)。
PCT/CN2019/118693 2019-10-30 2019-11-15 带锚点耐反吹纳米纤维复合滤材 WO2021082090A1 (zh)

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