CN101670209A - 制造复合材料过滤介质的方法 - Google Patents
制造复合材料过滤介质的方法 Download PDFInfo
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- CN101670209A CN101670209A CN200910170624A CN200910170624A CN101670209A CN 101670209 A CN101670209 A CN 101670209A CN 200910170624 A CN200910170624 A CN 200910170624A CN 200910170624 A CN200910170624 A CN 200910170624A CN 101670209 A CN101670209 A CN 101670209A
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- China
- Prior art keywords
- filter media
- nonwoven fabric
- composite filter
- nanofibers
- media
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Abstract
制造复合材料过滤介质(10)的方法包括:用纺粘法形成包含很多双组分合成纤维(30)的非织造织物基材(12),用拷花轧辊压延该非织造织物基材,以形成包含粘结区(37)的很多基本平行的间断线(33)的粘结区图案(31),以将合成双组份纤维粘结在一起形成非织造织物。按ASHRAE 52.2-1999试验法测定,该非织造织物的过滤效率至少为约50%。该方法还包括通过电喷纺丝聚合物溶液以在非织造织物的至少一面上形成很多纳米纤维而涂覆上纳米纤维层,以形成复合材料过滤介质。按ASHRAE 52.2-1999试验法测定,该复合材料过滤介质的过滤效率至少为约75%。该方法还包括使用相对的波纹辊(40,50)在约90℃-约140℃的温度下将复合材料过滤介质波纹成形。
Description
相关申请交互参考
本申请是2008年8月1日提交的美国专利申请系列号12/184,634的部分延续,其是2007年8月22日提交的美国专利申请系列号11/843,228的部分延续,要求2007年3月5日提交的临时专利申请系列号60/893,008的优先权。
发明背景
本发明领域一般地涉及复合材料非织造过滤介质,更具体地,涉及波纹的或拷花的复合材料非织造过滤介质。
一些已知的过滤介质复合材料结构结合了产生基材的湿铺层(wet-laid)造纸工艺和在过滤介质基材的一面或两面上沉积轻质纳米纤维涂层的静电纺丝技术。一般,介质基材的基础重量是100~120g/m2,纳米纤维层的基础重量是0.5g/m2或更小。
已经知道,轻质纳米纤维层在高机械应力作用下易受损伤,尤其因为纳米纤维层是由直径小于500nm,更典型地,100nm的纤维形成的。已经知道,存在纳米纤维从过滤介质上脱落下来的“脱落”问题,因为对于依赖于极性引力的传统静电纺丝纤维,纳米纤维与基础介质之间的引力结合较弱。另外,已知的用静电纺丝法纺成的纳米纤维层在结构上是二维的或在厚度上是单纤维层,而且当纳米纤维层开裂或断裂时,尘埃能轻易地透过基础介质基材。纳米纤维层受损后,尘埃可透过基础介质并造成过滤器操作压降的升高。而且已知的介质基材也有机械应力限制且在高尘含量下易变形。
上述已知的过滤介质复合材料结构,在用来过滤发电燃气轮机的入口空气时,在过滤器的整个操作寿命期间都允许细尘颗粒透过过滤器。一般而言,按ASHRAE52.2-1999试验法在已知操作流率下试验时,这类已知过滤介质在一般大于7.0mm H2O的压降下,都将提供捕获0.4μm颗粒的约55%的新型或清理操作效率。已经知道,由于这种低起始效率,在24,000h操作寿命期间,多达15~20lb的尘埃能透过已知过滤介质。涡轮蒸汽机叶片长期暴露在尘埃中会造成涡轮叶片严重和灾难性的结垢和腐蚀。清理涡轮叶片的现用方法需要定期从生产线上拆下涡轮,用水洗净叶片。涡轮停机时间很昂贵,因为涡轮不运转且因此停止发电了。理想的是提供在类似或更低压降下效率比已知过滤介质更高的过滤介质,以缩短或取消为清理涡轮叶片和/或更换已损叶片的涡轮停机时间。
发明概述
在一个方面,提供制造复合材料过滤介质的方法。该方法包括用纺粘法形成包括很多双组份合成纤维的非织造织物垫并用拷花轧辊压延该非织造织物基材,以形成具有很多基本平行的粘结区间断线的粘结区图案,以把合成纤维粘结在一起形成非织造织物,该非织造织物的最低过滤效率,按ASHRAE 52.2-1999试验法测定,为约50%。该方法还包括在非织造织物的至少一面上通过把聚合物溶液电喷纺成很多纳米纤维而敷涂上纳米纤维层,以形成复合材料过滤介质。该复合材料过滤介质的过滤效率,按ASHRE52.2-1999试验法测定,至少为约75%。该方法还包括使用相对的波纹辊在约90℃-约140℃的温度下将复合材料过滤介质波纹成形。
在另一个方面,提供制造复合材料过滤介质的方法。该方法包括用纺粘法形成包括很多双组份合成纤维的非织造织物垫并用拷花轧辊压延该非织造织物基材,以形成具有很多基本平行的粘结区间断线的粘结区图案,以把合成纤维粘结在一起形成非织造织物,该非织造织物的最低过滤效率,按ASHRAE 52.2-1999试验法测定,为约50%。该方法还包括在非织造织物的至少一面上通过把聚合物溶液电喷纺成很多纳米纤维而敷涂上纳米纤维层,以形成复合材料过滤介质。该复合材料过滤介质的过滤效率,按ASHRE52.2-1999试验法测定,至少为约75%。该方法还包括使用相对的拷花辊在约90℃-约140℃的温度下拷花复合材料过滤介质。
附图简述
图1是复合材料过滤介质的示例性方面的截面示意图。
图2是图1中所示用于过滤介质中的双组分纤维的光学显微镜照片。
图3是图1中所示基础介质基材的光学显微镜照片。
图4是图1中所示基础介质基材的粘结图案的顶视图。
图5是图1中所示的复合材料过滤介质在波纹成形后的示例性方面的截面示意图。
图6是根据示例性方面的波形辊的截面示意图。
图7是包括图4中所示的过滤介质的滤筒的侧视图。
图8是图7中所示滤筒的部分的放大的透视图。
图9是包括图7中所示滤筒的过滤装置的透视图。
图10是根据示例性方面的拷花辊的示意图。
图11是按照示例性方面的基础介质基材在不同基础重量下的分数效率(fractional efficiency)-粒度关系图。
图12是按照示例性方面的带有和不带有纳米纤维层的基础介质基材与带有和不带有纳米纤维层的对比基础介质基材的分数效率-粒度关系比较图。
图13是压降对按照示例性方面的带有和不带有纳米纤维层的基础介质基材与带有和不带有纳米纤维层的对比基础介质基材的比较条形图。
图14是按照示例性方面的带有纳米纤维层的基础介质基材与带有纳米纤维层的对比基础介质基材的压差对小时的比较图。
发明详述
下面详述用于过滤组件的复合材料过滤介质,和制备所述复合材料过滤介质的方法。复合材料过滤介质包括从双组分纤维用独特的纺粘工艺形成的合成非织造织物的介质基材。纳米纤维层通过电喷纺丝法被沉积在该介质基材的至少一面上。复合材料过滤介质是波纹形的或拷花的以提供有效的褶间的分离,所述褶对于在复合材料过滤介质的“干净”和“脏”的两面上的低限制气流提供了大的通道。在按美国加热、致冷和空调工程师协会(ASHRAE)52.2-1999试验法试验时,该复合材料介质提供约75%的保持的(retained)捕获0.4μm颗粒的起始过滤效率,这比已知过滤介质的性能提高了约20%。而且,该复合材料介质在压降比已知过滤介质低30%以上的条件下提供75%的效率。该复合材料过滤介质的质量因子(Qf)大于约450,而且在另一个实施方案中,大于约500。此外,该复合材料过滤介质的阻力(resistance)(或压降),按EN-1822(1998)测定,小于约4.0mm水,该基础介质基材的阻力,按照EN-1822(1998)测定,小于约2.5mm水。
而且,该复合材料过滤介质比已知过滤介质更耐久并提供更低的压降形成,因为在过滤和反向清理操作期间由施加在过滤介质上的力所形成的过滤介质的形变较小。而且,在相同或较低压降下,该纺粘波纹形介质基材比已知过滤介质基材更有效。用来形成介质基材的所述双组分纤维比用来形成已知过滤介质的纤维更细。此外,纳米纤维膜层的基础重量比已知过滤介质的高,这就允许所述过滤介质在反向脉冲清理下比已知过滤介质更有效地清理下来。纳米纤维层的高基础重量提供耐久的三维表面过滤层,它含有更长的曲折路径,允许高效和细颗粒捕获而不会明显限制空气流动或增加压降。此外,由于在波纹成形或拷花操作中附加的热加工,在基础介质基材和纳米纤维层之间的粘合连接改进了。
所谓“质量因子(Qf)”是指由以下方程定义的参数:
Qf=-25000·log(P/100)/ΔP
其中,“P”=过滤介质厚度的颗粒透过率(%);ΔP=横穿过介质的压降(Pa)。
所谓“阻力”是指用EN 1822(1998)所述的试验法测定的阻力(压降)。
参考附图。图1是过滤介质10的典型实施方案的截面图。过滤介质10包括具有第一面14和第二面16的基础介质基材12。在一个方面,纳米纤维层20被沉积在介质基材12的第一面14上。在另一个实施方案中,纳米纤维层20被沉积在第二面16上,以及在又一个实施方案中,纳米纤维层20被沉积在第一和第二面14和16的每一面上。在又一个方面,基础介质基材12不包括纳米纤维层。在又一个方面,在过滤介质10中形成很多个波形18(示于图5)。
介质基材12是由合成双组分纤维用纺粘法形成的非织造织物。适用的双组分纤维是具有芯-鞘结构、海岛结构或并列型结构的纤维。再参考图2,在该实施方案中,双组分纤维30包括芯32和环绕芯32的鞘34。双组分纤维30通过喷嘴被熔纺成很多连续纤维,均匀地沉积成无规三维纤网。然后对该纤网加热并拷花轧光(embossed calendered),使该纤网热粘结成图3所示的凝固纺粘织物36。来自接触拷花图案的轧辊的热量软化或熔化双组分纤维30的热塑性鞘34,使非织造纤维仅在与拷花图案的轧辊的接触点上粘结在一起。温度的选择要使双组分纤维30中熔点较低的鞘部分34发生至少软化或熔化。在一个实施方案中,温度为约90℃~约240℃。纤维的理想连接靠鞘部分34的熔化和冷却后的再凝固造成。
双组分纤维30的直径为约12μm~约18μm,比传统和普通纺粘产品中所用的已知纤维细。基础介质基材12的特点是用来凝固纺粘基础介质12的粘结图案。粘结图案取决于轧辊的拷花图案。介质12内纺粘双组分纤维的粘结区占织物总面积的约10%~约14%,而用于过滤的传统纺粘介质的粘结区约为29%~24%。粘结区使介质具有耐久性和功能,同时粘结点产生具有零空气流的熔化聚合物区域。
再参考图4,在基础介质12上的粘结图案31使基础介质12获得合格的耐久性,同时允许更多的纤维可用于过滤,从而提高过滤效率。粘结图案31包括很多平行的横跨基础介质12延伸的粘结区间断线33。该粘结区的平行间断线33上彼此错开,使间断线33上的非粘结区35的位置与相邻的间断线33上的粘结区37对准。介质12内纺粘双组分纤维30的粘结区37占织物总面积的约10%~约16%,而已知纺粘织物的粘结区为约19%~24%。较小的粘结面积允许基础介质12在以给定空气流试验时有更高的空气渗透率或,相反,更低压降。在典型实施方案中,基础介质12的基础重量为约100g/m2~约330g/m2,在另一个实施方案中,约100g/m2~约220g/m2。
任何合适的合成双组分纤维30都可用来制造介质基材12的非织造织物。适用于双组分纤维30中芯32和鞘34的材料包括,但不限于,聚酯、聚酰胺、聚烯烃、热塑性聚氨酯、聚醚酰亚胺、聚苯醚、聚苯硫醚、聚砜、芳族聚酰胺和它们的混合物。适用于双组分纤维中鞘的材料包括熔点低于双组分纤维中芯材的热塑性材料,如聚酯、聚酰胺、聚烯烃、热塑性聚氨酯、聚醚酰亚胺、聚苯醚、聚苯硫醚、聚砜、芳族聚酰胺和它们的混合物。
纳米纤维层20用电喷纺丝法(electro-blown spinning)形成,该方法包括把聚合物溶液送进纺丝头,对纺丝头施以高电压并通过纺丝头排出聚合物溶液,同时在纺丝头下端注射进压缩空气。所施的高电压为约1kV~约300kV。形成纳米纤维的电喷纺丝法和所用的独特设备已详述在U.S.专利申请出版物2005/00677332中。电喷纺丝法提供耐久的纳米纤维的三维过滤层,比已知过滤介质上的已知纳米纤维过滤层厚。在典型实施方案中,纳米纤维膜层20的基础重量是约0.6g/m2~约20g/m2,在另一个实施方案中,约5g/m2~约10g/m2。纳米纤维层20内纳米纤维的平均直径为约500nm或更细。
如下所述,与已知过滤介质相比,介质基材12具有高空气渗透率,这就使纳米纤维与介质基材12有改善的机械粘结性。由于纳米纤维层20被涂覆在介质基材12的第一面14上,所以在电喷纺丝期间可以从介质基材的第二面16施加真空,以将纳米纤维固定在基材上。结合涂覆纳米纤维层20中所用的干燥温度,双组分纤维30的鞘部分34发生软化以及纳米纤维层20被进一步致密化并粘结到纺粘基础介质基材12上。结合介质基材12的高空气渗透率,真空作用就变得更有效,这使纳米纤维与介质基材12的双组分纤维具有强机械结合。
适合于用电喷纺丝法形成纳米纤维的聚合物不限于热塑性聚合物,还可包括热固性聚合物。适用的聚合物包括,但不限于,聚酰亚胺类、聚酰胺(尼龙)类、聚芳酰胺类、聚苯并咪唑类、聚醚酰亚胺类、聚丙烯腈类、聚对苯二甲酸乙二酯、聚丙烯、聚苯胺类、聚环氧乙烷类、聚萘二酸乙二酯类、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、聚偏氯乙烯、聚乙烯基丁烯和它们的共聚物或衍生化合物。聚合物溶液通过选择溶解所选聚合物的溶剂而制成。聚合物溶液可以与添加剂混合,例如,增塑剂、紫外光稳定剂、交联剂、固化剂、反应引发剂等。虽然溶解聚合物可不需要任何特定温度范围,但是,为促进溶解反应,可能需加热。
为降低纤维聚合物的Tg,在上述各聚合物中加入增塑剂会有利。适用的增塑剂将依赖于聚合物和纳米纤维层的具体最终应用。例如,尼龙聚合物可以用水或甚至来自静电纺丝或电喷纺丝工艺的残余溶剂进行增塑。适用于降低聚合物Tg的其它增塑剂包括,但不限于,脂族二元醇,芳族磺酰胺(aromatic sulphanomide),邻苯二甲酸酯类,包括,但不限于,邻苯二甲酸二丁酯、邻苯二甲酸二己酯、邻苯二甲酸二环己酯、邻苯二甲酸二辛酯、邻苯二甲酸二异癸酯、邻苯二甲酸二(十一烷)酯、邻苯二甲酸二(十二烷)酯和邻苯二甲酸二苯酯等。
再参考图5,在该典型实施方案中,波形18作为在复合材料过滤介质10中的交替上升和下降的基本上V形波浪形成。通过成形设备,波浪的最高点22和最低点24在基材的纤网的移动方向上延伸。最低点24具有至少约0.02英寸(0.5mm)的有效深度D,以允许过滤介质10在高尘埃负载下的透气性保持在低压差,低于约4英寸水柱(wc)。在典型实施方案中的波形间距(pitch)C是约3-约10个波形每英寸(约1.2-约3.9个波形每厘米),且在另一个实施方案中为约3-约6个波形每英寸(约1.2-约2.4个波形每厘米)。有效深度D和波形间距C的结合允许接触点的优化,其防止褶层在来自高空气速度和尘埃负载的高静态压力下崩塌。
再参考图6,相对的成型波形辊在过滤介质10的整个截面产生均匀的波形。下波形辊40包括具有很多基本V形的凸纹44的外表面42,所述V形凸纹44环绕下辊40延伸。凸纹44沿着下辊40的外表面42的宽度基本上均匀地间隔开,这样外表面42具有很多峰46和谷48。上波形辊50包括具有很多基本V形凸纹54的外表面52,所述V形凸纹54环绕上辊50延伸。凸纹54沿着上辊50的外表面52的宽度基本上均匀地间隔开,这样外表面52具有很多峰56和谷58。下辊40的凸纹44与上辊50的谷58对齐,和上辊50的凸纹54与下辊40的谷48对齐。凸纹44和54的宽度可以是达到下辊40和上辊50的相对的谷48和58的宽度的任何合适宽度。凸纹44和54分别与谷58和48之间的空间60分别限制下辊40和上辊50之间的辊隙。所述辊隙小于过滤介质10的厚度,其在当经过凸纹44和54分别与谷58和48之间时凝固过滤介质10。过滤介质10在辊隙处的固化将波形18定型为过滤介质10。在操作中,波形辊40和50的温度是约90℃-约140℃。
图7是由过滤介质10形成的过滤单元70的侧视图。在该典型实施方案中,过滤介质10包括很多褶层72,所述褶层被排列以使得波形18产生褶层72之间的隔离片的效果。过滤单元70包括第一端盖74和相对的第二端盖76,过滤介质10在端盖74与76之间延伸。过滤单元70具有带内管78的管形(示于图9)。过滤单元70呈圆柱形,但也可以是如图9所示的圆锥形。过滤单元70还可包括内和/或外支撑垫(supportlinder),以使过滤单元70具有结构整体性和/或支撑过滤介质10。如图8所示,在过滤单元70的相邻褶层(多个)72中的波形18确定了椭圆形管79(oval tube),其允许过滤的气体流过过滤单元70。在该典型实施方案中,波形18基本上垂直于褶层72的边缘延伸。
图9是过滤器组件80的透视图,它包括很多个以端对端关系成对安装在管板82上的过滤单元70。管板82分隔过滤器组件80的脏空气侧84与清洁空气侧86。以脉冲空气清理过滤单元70的清理体系88包括很多个安装在空气供应管道92上的空气喷嘴90。用引进过滤单元70的内管78的压缩空气的脉冲来清理收集脏物和尘埃的过滤单元70。
在另一个典型实施方案中,使用相对的拷花辊拷花过滤介质10。图10是下拷花辊100和上拷花辊102的示意图。在下拷花辊100和上拷花辊102的外表面108上设置了很多成对的凸纹104和沟槽106。每个凸纹104和每个沟槽106沿拷花辊100或102的部分圆周延伸。同样,在下拷花辊100上的每对的凸纹104和沟槽106与在上拷花辊102上相应对的凸纹104和沟槽106对齐,凸纹和沟槽的排布使得在下辊100上的每个凸纹104与在上辊102上的沟槽106对齐并啮合(mate),且在上辊102上的每个凸纹104与在下辊100上的沟槽106相对齐并啮合。很多成对的凸纹104和沟槽106贯穿拷花辊100和102以相错开的行的形式间隔开,所述错开的行限定了拷花图案。
复合材料过滤介质10通过纺粘法使用很多双组分合成纤维30制备非织造织物基础基材12而形成。然后以拷花轧光辊(embossing calenderroll)轧光基础基材12,以形成具有很多基本平行的粘结区间断线33的粘结区图案31,以将合成双组份纤维30粘合在一起来形成非织造织物基础基材12。按ASHRAE 52.2-1999试验法测量,所形成的基材12具有至少约50%的过滤效率。通过电喷纺丝聚合物溶液以在基础基材12的至少一个面上形成很多纳米纤维来施加纳米纤维层,从而形成复合材料过滤介质10。按ASHRAE 52.2-1999试验法测量,所得复合材料过滤介质具有至少约75%的过滤效率。然后使用相对的波纹辊40和50在约90℃-约140℃的温度下波纹成形复合材料过滤介质10。在另一个实施方案中,使用相对的拷花辊100和102在约90℃-约140℃的温度下拷花复合材料过滤介质10。
本发明通过下面的实施例进一步描述,其仅是用于举例说明目的而提出,而并不意于限制本发明的范围。
按ASHRAE 52.2-1999试验法,以平板分数效率试验(flat sheetfractional efficiency test)来比较具有不同基础重量的基础介质基材12试样与对比基础介质基材的平板。以约10ft/min的流率引导含KCl颗粒的空气通过各试样。图11给出了对比试验的图示。线110代表基础重量为150g/m2的基础基材12,线112代表基础重量为200g/m2的基础基材12和线114代表基础重量为260g/m2的基础基材12。线116代表对比基础介质基材。这些基础介质基材不包括纳米纤维层。在KCl颗粒的整个粒度范围内,每一基础重量的基础介质基材12都具有比对比基础基材更高的效率。
按ASHRAE 52.2-1999试验法,以平板分数效率试验来比较基础介质基材12和包括纳米纤维20的基础介质基材12与带有和不带有纳米纤维层的对比基础介质基材的平板。以约10ft/min的流率引导含KCl颗粒的空气通过各试样。图12给出了对比试验的图示。线120代表150g/m2的基础介质基材12,线122代表包括纳米纤维层20的150g/m2基础介质基材12。线124代表对比基础介质基材和线126代表包括纳米纤维层的对比基础介质基材。在KCl颗粒的整个粒度范围内,带有和不带有纳米纤维层20的基础介质基材12都具有比带有和不带有纳米纤维层的对比基础基材更高的效率。
按ASHRAE 52.2-1999试验法,以平板压降试验(flat sheet pressuredrop test)来比较基础介质基材12和包括纳米纤维层20的基础介质基材12与带有或不带有纳米纤维层的对比基础介质基材的平板。以约10ft/min的流率引导含KCl颗粒的空气通过各试样。图13给出了比较试验的图示。条A代表对比基础介质基材和条B代表包括纳米纤维层的对比基础介质基材。条C代表150g/m2的基础介质基材12和条D代表包括纳米纤维层20的150g/m2基础介质基材。带有和不带有纳米纤维层20的基础介质基材12具有比带有和不带有纳米纤维层的对比基础基材更低的压降。
包括纳米纤维层20的复合材料过滤介质10的波形条被打摺,并通过使用改进的ASTM D6830-02试验法,与相当的具有纳米纤维层的已知过滤介质对比压差-时间关系。该试验方法在按原尺寸尘埃收集器建立的模拟条件下测试了过滤介质。标准化的尘埃由通过试验介质在控制的容积(空气对介质的常量比)下的滑流(slip stream)绘制(draw),并且记录了压降对时间的关系。反向脉冲喷射清洁以特定的间隔回冲过滤介质以净化收集到的尘埃。对ASTM D6830-02的改进如下。
尘埃输入设定在100克/小时,其导致大约0.5g/m3的过滤器尘埃负载。代替织物夹持环,带有测试盒的折叠过滤器盒的安装板(adapterplate)被安装在圆柱形抽提管(extraction tube)的过滤器夹持喷嘴组件(filter holding nozzle assembly)中的位置。原料气体空气流设定在10m3/hr。过滤器盒模流(module flow)设定在4.65m3/h。每个过滤器盒包含标称0.085m2(0.91ft2)的使用标准48毫米高的褶层的过滤器介质(除非相反指出)。暴露的褶层组由11个完整的3英寸长的褶层组成。该流设定导致3.0fpm的表观面速度(apparent facevelocity)。脉冲空气设定在0.5kPa(75psig)。脉冲清洁在试验启动后开始了15分钟。清洁间隔是基于900秒的时间间隔。试验尘埃是具有约1.5微米的平均粒径的氧化铝,Pural NF,购自Condea Chemie GmbH。总的共用时间是10小时。没有使用过滤器调节周期(filterconditioning period)。
图14显示了对比试验的示意图。线130表示具有48mm褶层高的复合材料过滤器介质10,线132表示具有42mm褶层高的复合材料过滤器介质10,和线134表示已知相当的过滤器介质。具有42mm或48mm褶层高的过滤器介质10试验样品经过10小时长的试验具有显著的较低压差。
在几乎所有的应用中,都能用上述由过滤介质10所形成的过滤单元70来过滤空气流,例如,过滤燃气轮机的入口空气。过滤介质10的独特结构比已知过滤介质更耐久,并由于波形构造因在过滤和反向清理操作期间由于施加在过滤介质上的力所引起的形变较小而产生较低的压降形成。过滤单元70能产生约75%以上的捕获透过最多(mostpenetrating)的粒度的浮质(aerosol)或尘埃(约0.3~约0.4μm)的平均效率,而已知过滤单元的效率是约50~55%。此外,纳米纤维层20的基础重量比已知过滤介质的重,这使过滤介质10在反向脉冲清理下比已知过滤介质更有效地清理干净。此外,纳米纤维层20较高的基础重量提供耐久的三维表面过滤层,它含有更长的曲折路径,允许高效率和细颗粒捕获而不限制空气流动或提高压降。
实施例1~2和对比实施例3~7的典型过滤介质说明过滤介质10的实施方案与已知过滤介质的对比。对于实施例1~2和对比实施例3~7的各过滤介质,都测定了效率、阻力和质量因子。效率按ASHRAE52.2-1999试验法测定,阻力按EN-1822(1998)测定,质量因子Qf按前述计算。
实施例1是纺粘聚酯双组分纤维基础介质基材和实施例2是实施例1的基础介质基材加上由电喷纺丝法形成的2g/m2纳米纤维层。对比实施例3是已知干法铺层聚酯基础介质基材和对比实施例4是实施例3的已知干法铺层聚酯基础介质基材加上2g/m2纳米纤维层。对比实施例5是湿法铺层合成纸加上<0.5g/m2纳米纤维层。对比实施例6是湿法铺层合成纸和对比实施例7是实施例6的湿法铺层合成纸加上20g/m2熔喷纤维层。实施例结果示于下表1中。在比较实施例2与对比实施例4、5和7的复合材料时,并不以牺牲效率作为减小阻力的代价,由此产生相关的高质量因子值。
表1
实施例 | 基础重量(g/m2) | 效率(%) | 阻力(mm H2O) | 质量因子 |
实施例1纺粘聚酯双组分纤维基 | 158.6 | 57.0 | 1.78 | 525 |
实施例2纺粘聚酯双组分纤维基+2g/m2纳米纤维层 | 154.6 | 80.2 | 3.43 | 534 |
对比实施例3干法铺层聚酯基 | 234.9 | 28.7 | 9.3 | 40 |
对比实施例4干法铺层聚酯基+2g/m2纳米纤维层 | 236.3 | 43.2 | 13.81 | 45 |
对比实施例5湿法铺层合成纸+<0.5g/m2纳米纤维层 | 121.2 | 40.5 | 9.77 | 59 |
对比实施例6湿法铺层合成纸 | 133.4 | 9.0 | 7.67 | 14 |
对比实施例7湿法铺层合成纸+20g/m2熔喷纤维层 | 150.2 | 86.4 | 8.79 | 251 |
效率在0.3μm,5.3cm/s面速度下测定(ASHRAE 52.2-1999)。
阻力按EN-1822(1998)测定。
质量因子由如下方程定义:Qf=-25000·log(P/100)/ΔP
本说明书已用实施例公开了本发明,包括最佳模式在内,而且也使本领域所有技术人员都能实践本发明,包括制造和应用任何设备或***并实施任何已引进的方法。本发明可取得专利的范围取决于权利要求,并可包括本领域技术人员能想到的其它实施例。这类其它实施例,如果它们的结构元素与权利要求中的字面语言并无差别,或如果它们包括与本权利要求中字面语言无本质差别的等代结构元素,则都要落在本权利要求范围之内。
制造复合材料过滤介质的方法
部件列表
10 | 复合材料过滤介质 |
12 | 基础介质基材 |
14 | 第一面 |
16 | 第二面 |
18 | 波形 |
20 | 纳米纤维层 |
22 | 波浪最高点 |
24 | 最低点 |
30 | 双组份纤维 |
31 | 粘结区图案 |
32 | 芯 |
33 | 间断线 |
34 | 鞘 |
35 | 粘结区 |
36 | 固化的纺粘织物 |
37 | 粘结区 |
40 | 下成形辊 |
42 | 外表面 |
44 | V形凸纹 |
46 | 峰 |
48 | 谷 |
50 | 上成形辊 |
52 | 外表面 |
54 | V形凸纹 |
56 | 峰 |
58 | 谷 |
60 | 空间 |
70 | 过滤元件 |
72 | 褶层 |
74 | 第一端盖 |
76 | 第二端盖 |
78 | 内管 |
79 | 椭圆形管 |
80 | 过滤器组件 |
82 | 管板 |
84 | 脏空气侧 |
86 | 清洁空气侧 |
88 | 清洁*** |
92 | 空气供应管道 |
100 | 下拷花辊 |
102 | 上拷花辊 |
104 | 凸纹 |
106 | 沟槽 |
108 | 外表面 |
110 | 线 |
112 | 线 |
114 | 线 |
116 | 线 |
120 | 线 |
122 | 线 |
124 | 线 |
126 | 线 |
130 | 线 |
132 | 线 |
134 | 线 |
Claims (10)
1.制造复合材料过滤介质(10)的方法,所述方法包含:
用纺粘法形成包含很多双组分合成纤维(30)的非织造织物基材(12);
用拷花轧辊压延该非织造织物基材,以形成包含粘结区(37)的很多基本平行的间断线(33)的粘结区图案(31),以将合成双组份纤维粘结在一起形成非织造织物,按ASHRAE 52.2-1999试验法测定,该非织造织物的过滤效率至少为约50%;
通过电喷纺丝聚合物溶液以在非织造织物的至少一面上形成很多纳米纤维而涂覆上纳米纤维层(20),以形成复合材料过滤介质,按ASHRAE 52.2-1999试验法测定,该复合材料过滤介质的过滤效率至少为约75%;和
使用相对的波纹辊(40,50)在约90℃-约140℃的温度下将复合材料过滤介质波纹成形。
2.根据权利要求1的方法,其中很多双组分合成纤维(30)包括芯材(32)和鞘材(34),所述鞘材的熔点低于所述芯材。
3.根据权利要求1的方法,其中通过电喷纺丝聚合物溶液来涂覆纳米纤维层(20)包括在将纳米纤维层涂覆于非织造织物基材(12)上时对所述非织造织物基材施加真空。
4.根据权利要求1的方法,其中所述合成双组分纤维(30)的所述芯(32)包括聚酯纤维、聚酰胺纤维、聚烯烃纤维、热塑性聚氨酯纤维、聚醚酰亚胺纤维、聚苯醚纤维、聚苯硫醚纤维、聚砜纤维、芳族聚酰胺纤维中的至少一种。
5.根据权利要求1的方法,其中形成非织造织物基材(12)包括形成具有约100g/m2-约300g/m2的基础重量的非织造织物基材。
6.根据权利要求1的方法,其中形成非织造织物基材(12)包括形成双组份纤维(30)的粘结区(37)占所述非织造织物垫的面积约10%-约14%的非织造织物基材。
7.根据权利要求1的方法,其中形成非织造织物基材(12)包括形成具有平均直径为约12-约18微米的双组分纤维(30)的非织造织物基材。
8.根据权利要求1的方法,其中纳米纤维层(20)包含很多具有约500nm或更细的平均直径的纳米纤维,所述纳米纤维层具有约0.6g/m2-约20g/m2的基础重量。
9.根据权利要求1的方法,其中波纹成形复合材料过滤介质(10)包括波纹成形复合材料过滤介质,使得波纹(18)包括很多沿复合材料过滤介质的长度延伸的交替的峰和谷(46,48)。
10.根据权利要求1的方法,其中波纹成形复合材料过滤介质(10)包括波纹成形具有约3-约10个波形每英寸的波形间距和至少约0.02英寸的有效深度的复合材料过滤介质。
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