WO2021120484A1 - 一种复合纤维滤料及其制备方法 - Google Patents

一种复合纤维滤料及其制备方法 Download PDF

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WO2021120484A1
WO2021120484A1 PCT/CN2020/087322 CN2020087322W WO2021120484A1 WO 2021120484 A1 WO2021120484 A1 WO 2021120484A1 CN 2020087322 W CN2020087322 W CN 2020087322W WO 2021120484 A1 WO2021120484 A1 WO 2021120484A1
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woven fabric
fabric layer
fiber
layer
preparation
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PCT/CN2020/087322
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English (en)
French (fr)
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赵谦
费传军
高政
王屹
郭晓蓓
余佳彬
徐涛
尹奕玲
李帅
匡新波
张振
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南京玻璃纤维研究设计院有限公司
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Publication of WO2021120484A1 publication Critical patent/WO2021120484A1/zh

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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
    • 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
    • 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
    • B01D2239/10—Filtering material manufacturing

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  • the application belongs to the technical field of filter materials for industrial environmental protection and dust removal, and specifically relates to a composite fiber filter material and a preparation method thereof.
  • the bag filter has been used It is widely used in various industries. Filter material is the core of the bag filter, and its performance is directly related to the performance of the filter.
  • the service life of the dust collector is short and the filtering effect is not high.
  • the prior art discloses a basalt fiber coated filter material, which is made of basalt fiber. The bulked yarn is baked after surface treatment, and then laminated with PTFE film at high temperature.
  • the bag filter with this filter material is used to process dust-containing gas with high moisture content, the dust is easy to stick The filter material is attached, and it is not easy to remove, which causes the pores of the filter material to be blocked, resulting in a decrease in the filtering performance of the filter material, and shortening the service life of the bag filter.
  • the technical problem to be solved by this application is to overcome the defect that when the existing bag filter processes dusty gas with high moisture content, the dust easily adheres to the filter material, which causes the filter material pores to be blocked and affects the filtration performance, thereby providing A preparation method of composite fiber filter material which is not easy to accumulate dust and block and has high filtering efficiency.
  • this application also provides the composite fiber filter material prepared by the method.
  • the present application provides a method for preparing a composite fiber filter material.
  • the composite fiber felt is subjected to heat setting, surface treatment, and heat curing, and then heat-pressing with a breathable membrane.
  • the heating curing includes first heating curing and second heating curing; the first heating curing temperature is 190-300°C and the time is 5-10 min, and the second heating curing temperature is 300-360°C and the time is 1. ⁇ 5min; The second heating and curing temperature is higher than the first heating and curing temperature.
  • the breathable membrane is an expanded polytetrafluoroethylene microporous membrane.
  • the breathable membrane can also be a PTFE/PVDF composite breathable membrane (ie, a polytetrafluoroethylene/polyvinylidene fluoride composite breathable membrane) and a PTFE denitration functional breathable membrane.
  • a PTFE/PVDF composite breathable membrane ie, a polytetrafluoroethylene/polyvinylidene fluoride composite breathable membrane
  • a PTFE denitration functional breathable membrane ie, a polytetrafluoroethylene/polyvinylidene fluoride composite breathable membrane
  • the composite fiber felt uses a woven fabric layer as a reinforcing structure layer, and both sides of the woven fabric layer are respectively provided with a first nonwoven fabric layer and a second woven fabric layer; the first nonwoven fabric The pore diameters of the layer, the second woven fabric layer and the breathable membrane layer are reduced layer by layer; the breathable membrane layer serves as the dust facing surface of the composite fiber filter material.
  • the composite fiber felt further includes a third non-woven fabric layer, the third non-woven fabric layer is arranged above the second woven fabric layer and connected with the breathable film layer;
  • the pore diameter of the third nonwoven fabric layer is between the pore diameters of the second nonwoven fabric layer and the breathable membrane layer.
  • the pore size of the breathable membrane is 0.5-1 ⁇ m, the thickness is 3-15 ⁇ m, and the air permeability is 4-15 cm/s (127Pa);
  • the fiber fineness of the first non-woven fabric layer is 8-12 denier, and the grammage of the first non-woven fabric is 180-300 g/m 2 ;
  • the fiber fineness of the second non-woven fabric layer is 2 to 4 deniers, and the grammage of the second non-woven fabric is 100 to 200 g/m 2 ;
  • the fiber fineness of the woven fabric layer is 4.5-7.5 denier, and the grammage of the woven fabric layer is 80-150 g/cm 2 ;
  • the fiber fineness of the third non-woven fabric layer is 0.5 to 1.5 denier, and the grammage of the third non-woven fabric is 20 to 100 g/m 2 .
  • the vertical and horizontal strength of the woven fabric layer is not less than 750N/50cm.
  • first non-woven fabric layer, the second non-woven fabric layer, and the third non-woven fabric layer are made of at least one chopped fiber of aramid fiber, polyimide fiber or aramid fiber. It is processed by needle punching or spunlacing after uniform opening, carding and cross-laying; the length of the chopped fiber is 3-10cm;
  • the woven fabric layer is formed by weaving at least one fiber of polytetrafluoroethylene fiber, aramid fiber, polyimide fiber, and aramid fiber.
  • the temperature of the heat setting is 210 to 300° C., and the time is 4 to 10 minutes.
  • the surface treatment is to perform a surface treatment solution immersion treatment on the composite fiber felt after the heat setting, and the surface treatment solution includes the following components by weight:
  • the temperature of the hot-press lamination is 220-320°C, and the pressure is 0.1-1 MPa.
  • a laminating unit is used for the hot-pressing laminating; the speed of the laminating unit is 3-20 m/min.
  • the breathable membrane is prepared by the following method:
  • the air-permeable membrane is formed after the billeting, pushing, calendering, longitudinal drawing and transverse drawing are carried out in sequence.
  • the present application also provides a composite fiber filter material prepared according to the above preparation method.
  • the preparation method of the composite fiber filter material is that the composite fiber felt is subjected to heat setting, surface treatment, and heating and curing, and then heat-pressing and laminating with a breathable membrane; the heating and curing include the first Heating curing and second heating curing.
  • the second heating curing is heating at 300-360°C for 1 to 5 minutes.
  • a second heating curing stage is added to the surface-treated composite fiber in this application.
  • the felt is quickly sintered at high temperature to quickly agglomerate the effective ingredients in the treatment agent, and form mixed agglomerated particles with a secondary particle size of 3-8 ⁇ m, which are attached to the surface of the filter material. This particle size meets the requirements of structural hydrophobicity.
  • the surface treatment of the felt makes the surface of the filter material hydrophobic, and realizes that the filter material has the functions of chemical hydrophobicity and structural hydrophobicity at the same time. It is not easy to adhere to dust during use, and it will not block the pores. It is easy to remove dust and effectively improve filtration.
  • the filter performance of the material can prolong the service life of the bag filter.
  • the method for preparing the composite fiber filter material provided by the present application uses a breathable membrane as the dust-facing surface of the composite fiber filter material, and the breathable membrane has a puffed microporous, multi-node, multi-layer drawing mesh structure.
  • the multi-layer staggered spatial network structure effectively intercepts most of the dust and improves the dust filtration efficiency.
  • a third non-woven fabric layer is arranged below the breathable membrane layer, which is a superfine fiber layer formed by chopped fibers with a fiber fineness of 0.5 to 1.5 deniers, which enhances the secondary interception function of the filter material against dust, and
  • the combination of the expanded polytetrafluoroethylene film layer realizes the conversion from deep filtration to surface filtration, ensures the interception stability of the filter material to dust, and provides multiple guarantees for ultra-low dust emission.
  • the pore size of the composite fiber filter material provided by this application is enlarged layer by layer from the dust facing surface to the clean air surface, forming a bell-like channel, thereby further avoiding the accumulation and clogging of internal dust, and ensuring the emission requirements while also Extend the service life of the filter material.
  • the preparation method of the composite fiber filter material provided by this application is to perform the polytetrafluoroethylene emulsion immersion treatment on the composite fiber felt after the heat setting, which improves the hydrophobicity of the filter material surface and is not easy to adhere during use Dust improves the filtration efficiency; at the same time, the resulting filter material product has good heat resistance and corrosion resistance.
  • the composite fiber filter material provided by this application has excellent mechanical properties, the strength in the warp and weft directions are both greater than 1300N/50cm, and the elongation at break in the warp and weft directions are both lower than 30%. Moreover, the composite filter material of the present application can be used for a long time at a high temperature of 300°C, has strong air permeability and waterproof performance, and has a waterproof performance of level 5, and the filtration efficiency for ultrafine dust can reach 99.9995%, which ensures the low running resistance of the filter material. And long service life, it can be widely used in high temperature and high humidity environment that ordinary filter media cannot reach.
  • Fig. 1 is a schematic diagram of the structure of the composite fiber filter material of Example 1 of the application;
  • This embodiment provides a composite fiber filter material, the structure of which is shown in Figure 1.
  • the composite fiber filter material has a five-layer structure, including an expanded polytetrafluoroethylene microporous membrane layer 1 and a third layer that are sequentially stacked together.
  • the third non-woven fabric layer 2 is an ultrafine aramid non-woven fabric layer
  • the second non-woven fabric layer 3 is a conventional polyimide non-woven fabric layer
  • the woven fabric layer 4 is an aramid plain weave machine.
  • the woven fabric layer, the first non-woven fabric layer 5 is a conventional polyimide non-woven layer.
  • the preparation method includes the following steps:
  • a polyimide fiber with a length of 10 cm and a fineness of 12 denier is uniformly opened and carded to form a single-layer fiber web, and then needled through multiple layers of the web. Puncture into a conventional polyimide fiber non-woven fabric with a grammage of 300g/m 2;
  • Preparation woven layer 4 the fineness of 7.5 denier aramid fiber forming the aramid fiber woven by plain woven grammage of 150g / cm 2;
  • the preparation of the second non-woven fabric layer 3 the polyimide fiber with a length of 5 cm and a fineness of 4 denier is uniformly opened and carded to form a single-layer fiber web, and then a multi-layer web is then needle punched to form a gram Conventional polyimide fiber non-woven fabric with a weight of 200g/m 2;
  • the composite fiber filter material is obtained by performing hot pressing and laminating under the following conditions.
  • This embodiment provides a composite fiber filter material, the structure of which is the same as that of the composite fiber filter material in Example 1.
  • the preparation method includes the following steps:
  • Preparation of the first non-woven fabric layer 5 Polyimide fibers with a length of 7 cm and a fineness of 10 deniers are uniformly opened and carded to form a single-layer fiber web, and then needled after multiple layers of the web.
  • the thorns form a conventional polyimide fiber non-woven fabric with a grammage of 240g/m 2;
  • Preparation woven layer 4 the fineness of 6 denier aramid fiber forming the aramid fiber woven by plain woven grammage of 120g / cm 2;
  • Preparation of the second non-woven fabric layer 3 Polyimide fibers with a length of 7 cm and a fineness of 3 deniers are uniformly opened and carded to form a single-layer fiber web, and then multi-layered and then needle punched to form a gram Conventional polyimide fiber non-woven fabric with a weight of 150g/m 2;
  • Preparation of the third non-woven fabric layer 2 The polyimide fiber with a length of 5 cm and a fineness of 1 denier is uniformly opened and carded to form a single-layer fiber web, and then multi-layered and then needle punched to form a gram Superfine aramid fiber non-woven fabric weighing 100g/m 2;
  • the composite fiber filter material is obtained by performing hot pressing and laminating under the conditions.
  • This embodiment provides a composite fiber filter material, the structure of which is the same as that of the composite fiber filter material in Example 1.
  • the preparation method includes the following steps:
  • Preparation of the first non-woven fabric layer 5 A polyimide fiber with a length of 10 cm and a fineness of 8 denier is uniformly opened and carded to form a single-layer fiber web, and then needled after multiple layers of the web.
  • the thorns form a conventional polyimide fiber non-woven fabric with a grammage of 180g/m 2;
  • Preparation woven layer 4 the fineness of 4.5 denier PSA fiber is formed by the textile grammage of 80g / cm PSA fiber plain woven fabric 2;
  • the aramid fibers with a length of 7 cm and a fineness of 2 deniers are uniformly opened and carded to form a single-layer fiber web, and then multiple layers of the web are then needle punched to form a grammage 100g/m 2 of conventional aramid fiber non-woven fabric;
  • the third non-woven fabric layer 2, the second non-woven fabric layer 3, the woven fabric layer 4, and the first non-woven fabric layer 5 are sequentially laminated and subjected to hydroentanglement to obtain a composite needle-punched fiber felt;
  • the composite fiber filter material is obtained by performing hot pressing and laminating under the following conditions.
  • This embodiment provides a composite fiber filter material, the structure of which is the same as that of the composite fiber filter material in Example 1.
  • the preparation method includes the following steps:
  • a polyimide fiber with a length of 10 cm and a fineness of 12 denier is uniformly opened and carded to form a single-layer fiber web, and then needled through multiple layers of the web. Puncture into a conventional polyimide fiber non-woven fabric with a grammage of 300g/m 2;
  • Preparation woven layer 4 the fineness of 7.5 denier PTFE fiber formed by the textile fiber grammage of plain woven fabric of polytetrafluoroethylene 150g / cm 2;
  • the preparation of the second non-woven fabric layer 3 the polyimide fiber with a length of 5 cm and a fineness of 4 denier is uniformly opened and carded to form a single-layer fiber web, and then a multi-layer web is then needle punched to form a gram Conventional polyimide fiber non-woven fabric with a weight of 200g/m 2;
  • the composite fiber filter material is obtained by performing hot pressing and laminating under the conditions.
  • This embodiment provides a composite fiber filter material.
  • the composite fiber filter material has a four-layer structure, including an expanded polytetrafluoroethylene microporous membrane layer 1, a second nonwoven fabric layer 3, and a woven fabric layer that are sequentially stacked together.
  • the preparation method is basically the same as in Example 2.
  • the composite fiber filter material has a five-layer structure, including a PTFE/PVDF composite breathable membrane, a third non-woven fabric layer, a second non-woven fabric layer, and a machine that are sequentially stacked together.
  • the woven fabric layer and the first non-woven fabric layer in which the PTFE/PVDF composite breathable film is a dust-facing surface layer, the third non-woven fabric layer is an ultrafine aramid non-woven fabric layer, and the second non-woven fabric layer is a conventional polyamide
  • the imine non-woven fabric layer, the woven fabric layer is an aramid plain weave fabric layer, and the first non-woven fabric layer is a conventional polyimide non-woven fabric layer.
  • the preparation method is basically the same as in Example 1, except that in step (4) the cured composite needle-punched fiber felt is combined with a PTFE/PVDF composite breathable membrane with a pore size of 0.9 ⁇ m and a thickness of 11 ⁇ m through a laminating unit at 310°C. ,
  • the pressure is 0.2MPa, and the vehicle speed is 10m/min.
  • the composite fiber filter material is obtained by performing hot-pressing laminating.
  • the composite fiber filter material has a five-layer structure, including a PTFE denitration function breathable membrane, a third nonwoven fabric layer, a second nonwoven fabric layer, and a woven fabric layer that are sequentially stacked together.
  • the amine non-woven fabric layer, the woven fabric layer is an aramid plain weave fabric layer, and the first non-woven fabric layer is a conventional polyimide non-woven fabric layer.
  • the preparation method is basically the same as in Example 1, except that in step (4) the cured composite needle-punched fiber felt and the PTFE denitration function breathable membrane with a pore diameter of 0.75 ⁇ m and a thickness of 10 ⁇ m are heated at 300°C through a laminating unit.
  • the pressure is 0.6 MPa, and the vehicle speed is 12 m/min.
  • the composite fiber filter material is obtained by hot-pressing laminating.
  • This comparative example provides a composite fiber filter material, the structure of which is the same as that of the composite fiber material in Example 1, and the preparation method is basically the same as that of Example 2. The difference is that in this comparative example, the impregnated composite needle After being baked at 230° C. for 5 minutes, the barbed fiber felt is hot-pressed and laminated with the expanded polytetrafluoroethylene microporous membrane.

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Abstract

一种复合纤维滤料及其制备方法，该方法为将复合纤维毡经热定型、表面处理及加热固化后，再与膨化聚四氟乙烯微孔膜进行热压覆合；所述加热固化包括第一加热固化和第二加热固化，在第一加热固化后还增设第二加热固化，对经表面处理后的纤维毡进行快速高温烧结，使处理液中的有效成分迅速团聚，并形成二次粒径为3～8μm的混合团聚颗粒附着在滤料表面，该粒径满足结构式疏水的要求，同时，对纤维毡进行表面处理，使滤料表面具有憎水的性能，实现了滤料同时具有化学疏水与结构疏水的功能，在使用中不易粘附粉尘，而不至于堵塞孔隙，有效提高滤料的过滤性能，延长除尘器的使用寿命。

Description

一种复合纤维滤料及其制备方法
交叉引用
本申请要求在2019年12月18日提交中国专利局、申请号为201911308624.9、发明名称为“一种复合纤维滤料及其制备方法”中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请属于工业环保除尘用过滤材料技术领域，具体涉及一种复合纤维滤料及其制备方法。
背景技术
能源是经济社会发展和提高人民生活水平的重要物质基础，随着经济的快速发展，我国对能源的需求急剧上升，污染严重的重工业，如冶炼行业和发电行业迅速发展，而这些行业大部分都以煤炭作为主要燃烧材料，由此导致了严重的煤烟污染，给人类的生命健康造成了极大威胁。我国对烟尘的排放有严格的限制，且标准越来越严格。袋式除尘具有超高的除尘效率，实际应用中除尘效率可达99.99％。粉尘排放浓度达到10mg/Nm 3以下，有的甚至达到1mg/Nm 3，基本上达到零排放。而且粉尘比电阻、烟气成分、烟气量等对除尘效率影响较大的因素对袋式除尘器的除尘效率影响甚微，因此，作为细微粉尘排放控制的有效手段，袋式除尘器已被广泛应用于各个行业。过滤材料作为袋式除尘器的核心，其性能优劣直接关系到除尘器性能。
为解决部分高温烟气过滤行业烟尘温度过高、成分复杂导致除尘器使用寿命短及过滤效果不高的问题，现有技术公开了一种玄武岩纤维覆膜滤料，该滤料是将玄武岩纤维膨体纱经表面处理后烘焙，再与聚四氟乙烯膜高温热压覆合而成，然而，在利用该滤料的袋式除尘器处理含湿量大的含尘气体时，粉尘易粘附滤料，且不易除去，导致滤料孔隙被堵塞，导致滤料过滤性能下降，缩短了袋式除尘器的使用寿命。
发明内容
因此，本申请要解决的技术问题在于克服现有的袋式除尘器处理含湿量大的含尘气体时，粉尘易粘附滤料导致滤料孔隙被堵塞进而影响过滤性能的缺陷，从而提供一种内部不易积尘和堵塞，过滤效率高的复合纤维滤料的制备方法。同时，本申请还提供了由该方法制备得到的复合纤维滤料。
为解决上述技术问题，根据本发明的一个方面，本申请提供了一种复合纤维滤料的制备方法，将复合纤维毡经热定型、表面处理及加热固化后，再与透气膜进行热压覆合；
所述加热固化包括第一加热固化和第二加热固化；所述第一加热固化温度为190～300℃，时间为5～10min，所述第二加热固化温度为300～360℃，时间为1～5min；所述第二加热固化温度高于所述第一加热固化温度。
进一步地，所述透气膜为膨化聚四氟乙烯微孔膜。
进一步地，所述透气膜还可以为PTFE/PVDF复合透气膜(即：聚四氟乙烯/聚偏氟乙烯复合透气膜)及PTFE脱硝功能透气膜。
进一步地，所述复合纤维毡以机织布层为增强结构层，所述机织布层的两侧分别设置有第一非织造布层和第二织造布层；所述第一非织造布层、 第二织造布层及所述透气膜层的孔径逐层减小；所述透气膜层作为所述复合纤维滤料的迎尘面。
进一步地，所述复合纤维毡还包括第三非织造布层，所述第三非织造布层设置在所述第二织造布层的上方，并与所述透气膜层相接；
所述第三非织造布层的孔径介于所述第二非织造布层与所述透气膜层的孔径之间。
更进一步地，所述透气膜的孔径为0.5～1μm，厚度为3～15μm，透气率为4～15cm/s(127Pa)；
所述第一非织造布层的纤维细度为8～12旦，所述第一非织造布的克重为180～300g/m 2；
所述第二非织造布层的纤维细度为2～4旦，所述第二非织造布的克重为100～200g/m 2；
所述机织布层的纤维细度为4.5～7.5旦，所述机织布层的克重为80～150g/cm 2；
所述第三非织造布层的纤维细度为0.5～1.5旦，所述第三非织造布的克重为20～100g/m 2。
进一步地，所述机织布层的纵横向强力不小于750N/50cm。
进一步地，所述第一非织造布层、第二非织造布层及第三非织造布层为将芳纶纤维、聚酰亚胺纤维或芳砜纶纤维中的至少一种短切纤维经均匀开松、梳理成网和交叉铺网后经针刺或水刺加工而成；所述短切纤维的长度为3～10cm；
所述机织布层为将聚四氟乙烯纤维、芳纶纤维、聚酰亚胺纤维、芳纶 纤维中的至少一种纤维经纺织而成。
进一步地，所述热定型的温度为210～300℃，时间为4～10min。
进一步地，所述表面处理为对经所述热定型后的复合纤维毡进行表面处理液浸渍处理，所述表面处理液包括如下重量份的组分：
聚四氟乙烯乳液5～30份；硅烷型偶联剂1～3份；氟化乙烯丙烯共聚物乳液0～30份；丙烯酸树脂乳液0～20份。
进一步地，所述热压覆合的温度为220～320℃，压强为0.1～1MPa。
更进一步地，采用覆膜机组进行所述热压覆合；所述覆膜机组的车速为3～20m/min。
本申请中，所述透气膜采用如下方法制备：
将聚四氟乙烯微细颗粒和润滑剂混合后，再依次经制坯、推挤、压延、纵拉及横拉后，形成透气膜。
根据本发明的另一方面，本申请还提供了一种根据上述制备方法制备得到的复合纤维滤料。
本申请的技术方案，具有如下优点：
1.本申请提供的复合纤维滤料的制备方法，所述方法为将复合纤维毡经热定型、表面处理及加热固化后，再与透气膜进行热压覆合；所述加热固化包括第一加热固化和第二加热固化，所述第二加热固化为在300～360℃下加热1～5min，本申请在第一加热固化阶段后还增设第二加热固化阶段，对表面处理后的复合纤维毡进行快速高温烧结，使处理剂中的有效成分迅速团聚，并形成二次粒径为3～8μm的混合团聚颗粒附着在滤料表面，该粒径满足结构式疏水的要求，同时，对复合纤维毡进行表面处理，使滤料表 面具有憎水的性能，实现了滤料同时具有化学疏水与结构疏水的功能，在使用中不易粘附粉尘，而不至于堵塞孔隙，容易清灰，有效提高滤料的过滤性能，延长袋式除尘器的使用寿命。
2.本申请提供的复合纤维滤料的制备方法，将透气膜作为所述复合纤维滤料的迎尘面，所述透气膜具有膨化微孔、多节点、多层拉丝网状结构，这种多层交错的空间网状结构，有效拦截大部分粉尘，提高了粉尘的过滤效率。在所述透气膜层的下方设置第三非织造布层，其为纤维细度0.5～1.5旦的短切纤维形成的超细纤维层，增强了滤料对粉尘的二次拦截功能，与所述膨化聚四氟乙烯膜层相结合，实现了深层过滤向表面过滤的转化，保证了滤料对粉尘的拦截稳定性，为粉尘的超低排放提供了多重保障。另外，本申请提供的复合纤维滤料的孔径由迎尘面到净气面逐层放大，形成了类似喇叭口状的通道，从而进一步避免内部灰尘的集聚和堵塞，保证了排放要求的同时还延长了滤料的使用寿命。
3.本申请提供的复合纤维滤料的制备方法，对经所述热定型后的复合纤维毡进行聚四氟乙烯乳液浸渍处理，提高了滤料表面的憎水性能，在使用中不易粘附粉尘，提高了过滤效率；同时，也使所得的滤料产品具有良好的耐热防腐性能。
4.本申请提供的复合纤维滤料，力学性能优良，经纬向强力均大于1300N/50cm，经纬向断裂伸长率均低于30％。而且，本申请的复合滤料可在300℃高温下长期使用，透气性及防水性能强，防水性能达到5级，对超细粉尘过滤效率可达到99.9995％，保证了滤料较低的运行阻力及较长的使用寿命，可广泛适用于普通滤料不可企及的高温高湿环境。
附图说明
为了更清楚地说明本申请具体实施方式或现有技术中的技术方案，下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍，显而易见地，下面描述中的附图是本申请的一些实施方式，对于本领域普通技术人员来讲，在不付出创造性劳动的前提下，还可以根据这些附图获得其他的附图。
图1为本申请实施例1的复合纤维滤料的结构示意图；
附图标记说明：
1-聚四氟乙烯微孔膜层；2-第三非织造布层；3-第二非织造布层；4-机织布层；5-第一非织造布层。
具体实施方式
下面将对本申请的技术方案进行清楚、完整地描述，显然，所描述的实施例是本申请一部分实施例，而不是全部的实施例。基于本申请中的实施例，本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，都属于本申请保护的范围。此外，下面所描述的本申请不同实施方式中所涉及的技术特征只要彼此之间未构成冲突就可以相互结合。
实施例1
本实施例提供了一种复合纤维滤料，其结构如图1所示，该复合纤维滤料有五层结构，包括依次叠合在一起的膨化聚四氟乙烯微孔膜层1、第三非织造布层2、第二非织造布层3、机织布层4和第一非织造布层5，其中膨化聚四氟乙烯微孔膜层1为迎尘面层。
本实施例中，第三非织造布层2为超细芳纶非织造布层，第二非织造 布层3为常规聚酰亚胺非织造布层，机织布层4为芳纶平纹机织布层，第一非织造布层5为常规聚酰亚胺非织造层。其制备方法包括如下步骤：
(1)第一非织造布层5的制备：将长度为10cm、细度为12旦的聚酰亚胺纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为300g/m 2的常规聚酰亚胺纤维非织造布；
机织布层4的制备：将细度为7.5旦的芳纶纤维经纺织形成克重为150g/cm 2的芳纶纤维平纹机织布；
第二非织造布层3的制备：将长度为5cm、细度为4旦的聚酰亚胺纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为200g/m 2的常规聚酰亚胺纤维非织造布；
第三非织造布层2的制备：将长度为3cm、细度为1.5旦的芳纶纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为100g/m 2的超细芳纶纤维非织造布；
(2)将上述第三非织造布层2、第二非织造布层3、机织布层4及第一非织造布层5依次叠合后经针刺，得复合针刺纤维毡；
(3)将上述复合针刺纤维毡在220℃下热定型处理5min，再经由配比为聚四氟乙烯乳液30wt％，硅烷型偶联剂3wt％，氟化乙烯丙烯共聚物乳液30wt％，丙烯酸树脂乳液20％和余量的水所形成的表面处理液中浸渍，完成浸渍后，取出，在240℃下烘焙5min；然后在320℃下快速烧结2min；
(4)通过覆膜机组将上述固化后的复合针刺纤维毡与孔径为1μm，厚度为15μm的膨化聚四氟乙烯微孔膜在320℃，压强为0.2MPa，车速为8m/min的条件下进行热压覆合，即得所述复合纤维滤料。
实施例2
本实施例提供了一种复合纤维滤料，其结构同实施例1中的复合纤维率料结构。其制备方法包括如下步骤：
(1)第一非织造布层5的制备：将长度为7cm、细度为10旦的聚酰亚胺纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为240g/m 2的常规聚酰亚胺纤维非织造布；
机织布层4的制备：将细度为6旦的芳纶纤维经纺织形成克重为120g/cm 2的芳纶纤维平纹机织布；
第二非织造布层3的制备：将长度为7cm、细度为3旦的聚酰亚胺纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为150g/m 2的常规聚酰亚胺纤维非织造布；
第三非织造布层2的制备：将长度为5cm、细度为1旦的聚酰亚胺纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为100g/m 2的超细芳纶纤维非织造布；
(2)将上述第三非织造布层2、第二非织造布层3、机织布层4及第一非织造布层5依次叠合后经针刺，得复合针刺纤维毡；
(3)将上述复合针刺纤维毡在230℃下热定型处理5min，再经由配比为聚四氟乙烯乳液20wt％，硅烷型偶联剂2wt％，氟化乙烯丙烯共聚物乳液15wt％，丙烯酸树脂乳液20％和余量的水所形成的表面处理液中浸渍，完成浸渍后，取出，在230℃下烘焙5min；然后在330℃下快速烧结3min；
(4)通过覆膜机组将上述固化后的复合针刺纤维毡与孔径为0.8μm，厚度为9μm的膨化聚四氟乙烯微孔膜在310℃，压强为0.25MPa，车速为 10m/min的条件下进行热压覆合，即得所述复合纤维滤料。
实施例3
本实施例提供了一种复合纤维滤料，其结构同实施例1中的复合纤维率料结构。其制备方法包括如下步骤：
(1)第一非织造布层5的制备：将长度为10cm、细度为8旦的聚酰亚胺纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为180g/m 2的常规聚酰亚胺纤维非织造布；
机织布层4的制备：将细度为4.5旦的芳砜纶纤维经纺织形成克重为80g/cm 2的芳砜纶纤维平纹机织布；
第二非织造布层3的制备：将长度为7cm、细度为2旦的芳砜纶纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为100g/m 2的常规芳砜纶纤维非织造布；
第三非织造布层2的制备：将长度为5cm、细度为0.5旦的芳纶纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为20g/m 2的超细芳纶纤维非织造布；
(2)将上述第三非织造布层2、第二非织造布层3、机织布层4及第一非织造布层5依次叠合后经水刺，得复合针刺纤维毡；
(3)将上述复合针刺纤维毡在210℃下热定型处理10min，再经由配比为聚四氟乙烯乳液5wt％，硅烷型偶联剂1wt％，氟化乙烯丙烯共聚物乳液10wt％，丙烯酸树脂乳液10％和余量的水所形成的表面处理液中浸渍，完成浸渍后，取出，在190℃下烘焙10min；然后在300℃下快速烧结5min；
(4)通过覆膜机组将上述固化后的复合针刺纤维毡与孔径为0.5μm， 厚度为3μm的膨化聚四氟乙烯微孔膜在220℃，压强为1MPa，车速为3m/min的条件下进行热压覆合，即得所述复合纤维滤料。
实施例4
本实施例提供了一种复合纤维滤料，其结构同实施例1中的复合纤维率料结构。其制备方法包括如下步骤：
(1)第一非织造布层5的制备：将长度为10cm、细度为12旦的聚酰亚胺纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为300g/m 2的常规聚酰亚胺纤维非织造布；
机织布层4的制备：将细度为7.5旦的聚四氟乙烯纤维经纺织形成克重为150g/cm 2的聚四氟乙烯纤维平纹机织布；
第二非织造布层3的制备：将长度为5cm、细度为4旦的聚酰亚胺纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为200g/m 2的常规聚酰亚胺纤维非织造布；
第三非织造布层2的制备：将长度为3cm、细度为1.5旦的芳纶纤维经均匀开松、梳理形成单层纤维网，再经多层铺网后经针刺形成克重为100g/m 2的超细芳纶纤维非织造布；
(2)将上述第三非织造布层2、第二非织造布层3、机织布层4及第一非织造布层5依次叠合后经针刺，得复合针刺纤维毡；
(3)将上述复合针刺纤维毡在300℃下热定型处理4min，再经由配比为聚四氟乙烯乳液5wt％，硅烷型偶联剂1wt％和余量的水所形成的表面处理液中浸渍，完成浸渍后，取出，在300℃下烘焙5min；然后在360℃下快速烧结1min；
(4)通过覆膜机组将上述固化后的复合针刺纤维毡与孔径为0.8μm，厚度为10μm的膨化聚四氟乙烯微孔膜在320℃，压强为0.1MPa，车速为20m/min的条件下进行热压覆合，即得所述复合纤维滤料。
实施例5
本实施例提供了一种复合纤维滤料，该复合纤维滤料有四层结构，包括依次叠合在一起的膨化聚四氟乙烯微孔膜层1、第二非织造布层3、机织布层4和第一非织造布层5，其中膨化聚四氟乙烯微孔膜层1为迎尘面层。其制备方法基本同实施例2。
实施例6
本实施例提供一种复合纤维滤料，该复合纤维滤料有五层结构，包括依次叠合在一起的PTFE/PVDF复合透气膜、第三非织造布层、第二非织造布层、机织布层和第一非织造布层，其中PTFE/PVDF复合透气膜为迎尘面层，第三非织造布层为超细芳纶非织造布层，第二非织造布层为常规聚酰亚胺非织造布层，机织布层为芳纶平纹机织布层，第一非织造布层为常规聚酰亚胺非织造层。其制备方法基本同实施例1，不同之处在于，步骤(4)通过覆膜机组将固化后的复合针刺纤维毡与孔径为0.9μm，厚度为11μm的PTFE/PVDF复合透气膜在310℃，压强为0.2MPa，车速为10m/min的条件下进行热压覆合，即得所述复合纤维滤料。
实施例7
本实施例提供一种复合纤维滤料，该复合纤维滤料有五层结构，包括依次叠合在一起的PTFE脱硝功能透气膜、第三非织造布层、第二非织造布层、机织布层和第一非织造布层，其中PTFE/PVDF复合透气膜为迎尘面层， 第三非织造布层为超细芳纶非织造布层，第二非织造布层为常规聚酰亚胺非织造布层，机织布层为芳纶平纹机织布层，第一非织造布层为常规聚酰亚胺非织造层。其制备方法基本同实施例1，不同之处在于，步骤(4)通过覆膜机组将固化后的复合针刺纤维毡与孔径为0.75μm，厚度为10μm的PTFE脱硝功能透气膜在300℃，压强为0.6MPa，车速为12m/min的条件下进行热压覆合，即得所述复合纤维滤料。
对比例1
本对比例提供了一种复合纤维滤料，其结构同实施例1中的复合纤维率料结构，其制备方法基本同实施例2，不同之处在于，本对比例中，浸渍后的复合针刺纤维毡在230℃下烘焙5min后即与所述膨化聚四氟乙烯微孔膜进行热压覆合。
实验例1
按照GB/T6719-2009、HJ/T324-2006及GB/T 4745-2012的检测标准，对本申请实施例1-5及对比例1的复合纤维滤料进行性能检测，检测结果如下表所示。
表1不同复合纤维滤料性能测试结果
Figure PCTCN2020087322-appb-000001
Figure PCTCN2020087322-appb-000002
显然，上述实施例仅仅是为清楚地说明所作的举例，而并非对实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引伸出的显而易见的变化或变动仍处于本申请创造的保护范围之中。

Claims (10)

  1. 一种复合纤维滤料的制备方法，其特征在于，将复合纤维毡经热定型、表面处理及加热固化后，再与透气膜进行热压覆合；
    所述加热固化包括第一加热固化和第二加热固化；所述第一加热固化温度为190～300℃，时间为5～10min，所述第二加热固化温度为300～360℃，时间为1～5min；所述第二加热固化的温度高于所述第一加热固化的温度；优选地，所述透气膜为膨化聚四氟乙烯微孔膜。
  2. 根据权利要求1所述的制备方法，其特征在于，所述复合纤维毡以机织布层为增强结构层，所述机织布层的两侧分别设置有第一非织造布层和第二织造布层；所述第一非织造布层、第二织造布层及所述聚四氟乙烯微孔膜层的孔径逐层减小；所述透气膜层作为所述复合纤维滤料的迎尘面。
  3. 根据权利要求2所述的制备方法，其特征在于，所述复合纤维毡还包括第三非织造布层，所述第三非织造布层设置在所述第二织造布层的上方，并与所述透气膜层相接；
    所述第三非织造布层的孔径介于所述第二非织造布层与所述透气膜层的孔径之间。
  4. 根据权利要求3所述的制备方法，其特征在于，所述透气膜层的孔径为0.5～1μm，厚度为3～15μm；
    所述第一非织造布层的纤维细度为8～12旦，所述第一非织造布的克重为180～300g/m 2；
    所述第二非织造布层的纤维细度为2～4旦，所述第二非织造布的克重 为100～200g/m 2；
    所述机织布层的纤维细度为4.5～7.5旦，所述机织布层的克重为80～150g/cm 2；
    所述第三非织造布层的纤维细度为0.5～1.5旦，所述第三非织造布的克重为20～100g/m 2。
  5. 根据权利要求3或4所述的制备方法，其特征在于，所述第一非织造布层、第二非织造布层及第三非织造布层为将芳纶纤维、聚酰亚胺纤维或芳砜纶纤维中的至少一种短切纤维经均匀开松、梳理成网和交叉铺网后经针刺或水刺加工而成；所述短切纤维的长度为3～10cm；
    所述机织布层为将聚四氟乙烯纤维、芳纶纤维、聚酰亚胺纤维、芳纶纤维中的至少一种纤维经纺织而成。
  6. 根据权利要求1-5任一所述的制备方法，其特征在于，所述热定型的温度为210～300℃，时间为4～10min。
  7. 根据权利要求1-6任一所述的制备方法，其特征在于，所述表面处理为对经所述热定型后的复合纤维毡进行表面处理液浸渍处理，所述表面处理液包括如下重量份的组分：
    聚四氟乙烯乳液5～30份；硅烷型偶联剂1～3份；氟化乙烯丙烯共聚物乳液0～30份；丙烯酸树脂乳液0～20份。
  8. 据权利要求1-7任一所述的制备方法，其特征在于，所述热压覆合的温度为220～320℃，压强为0.1～1MPa。
  9. 权利要求1-8所述的制备方法，其特征在于，采用覆膜机组进行所述热压覆合；所述覆膜机组的车速为3～20m/min。
  10. 一种根据权利要求1-9任一所述的制备方法制备得到的复合纤维滤料。
PCT/CN2020/087322 2019-12-18 2020-04-27 一种复合纤维滤料及其制备方法 WO2021120484A1 (zh)

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