CN109572123A - 一种机织针织复合结构基耐高温环保滤料及其制备方法 - Google Patents

一种机织针织复合结构基耐高温环保滤料及其制备方法 Download PDF

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CN109572123A
CN109572123A CN201811367124.8A CN201811367124A CN109572123A CN 109572123 A CN109572123 A CN 109572123A CN 201811367124 A CN201811367124 A CN 201811367124A CN 109572123 A CN109572123 A CN 109572123A
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composite construction
temp
environmental protection
base fabric
woven
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顾珂里
杨正香
顾钰良
章军
王海艳
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Jiangsu Hengsheng Environmental Protection Science And Technology Co Ltd
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Jiangsu Hengsheng Environmental Protection Science And Technology Co Ltd
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Priority to PCT/CN2018/119191 priority patent/WO2020098015A1/zh
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    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
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    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
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    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
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    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
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    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
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    • B32—LAYERED PRODUCTS
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Abstract

本发明公开了一种机织针织复合结构基耐高温环保滤料及其制备方法，该滤料是将纤维纺成纱线后，织造成机织针织复合结构基布；将纤维经混合、梳理、铺网形成的混合纤维网分别铺设在复合结构基布的上下表面，用椭圆形刺针对基布和纤维网进行加固再进行整理制备得到。本发明利用机织针织复合基布的结构稳定性和适型性，以及椭圆形刺针对基布的损伤较小的特性而制备高强力、耐高温滤料，使滤料结构紧密、强力高，节约原材料，延长滤料的使用寿命。

Description

一种机织针织复合结构基耐高温环保滤料及其制备方法
技术领域
本发明属于过滤与分离材料领域，更具体地，涉及一种机织针织复合结构基耐高温环保滤料及其制备方法。
背景技术
袋式除尘器是一种干式滤尘装置，主要利用纤维织物的过滤作用对细微、干燥的粉尘进行捕捉，以达到过滤后空气能满足排放要求，对人体无害的作用。现有耐高温滤袋一般采用以P84、PPS、PTFE、芳纶、玄武岩、玻纤等纤维为原材料，采用非织造工艺，经针刺加工而成，刺针均采用三角形、三叶形截面。为了增强滤料的强力，滤料中间均有机织或针织的基布。滤料的强力由表层纤网和基布共同提供，强力的贡献率分别约为30％和70％。
滤料在针刺加固过程中，随着刺针的上下高速往复运动，针尖与倒钩冲击基布和纤网短纤，导致纤维断裂或损伤，滤料强力下降，使用寿命显著降低。
发明内容
本发明的目的是克服以上不足，提供一种机织针织复合结构基耐高温环保滤料及其制备方法，利用机织、针织复合基布的结构稳定性和适型性，以及椭圆形刺针对基布的损伤较小的特性而制备高强力、耐高温滤料，延长滤料的使用寿命。
为了实现上述目的，本发明提供一种机织针织复合结构基耐高温环保滤料，包括由针织结构和机织结构编织而成的机织针织复合结构基布，机织针织复合结构基布的上下表面均铺设混合纤维网，任意一面的混合纤维网的表面设有微孔过滤膜涂层。
本发明所述机织针织复合材料基布的针织结构为针织纱采用平针组织、双罗纹组织或罗纹组织；所述机织结构为经纱和纬纱交织而成。所述针织纱、经纱和纬纱为无机纤维或高性能纤维的单一纤维或二种纤维的混合纤维纱线。所述无机纤维优选玻纤或玄武岩纤维，高性能纤维优选P84、PPS、PTFE、芳纶纤维。
本发明所述机织针织复合结构基布密度为50-250g/m2，优选为100-250g/m2。
本发明所述混合纤维网是由单层纤维网通过交叉方式多层铺成，所述混合纤维网的密度为100-300g/m2，优选为100-250g/m2，所述单层纤维网密度为15-25g/m2。
本发明所述滤料厚度为1.5-3.0mm，密度为250-600g/m2，优选300-600g/m2。
本发明所述机织针织复合结构基耐高温环保滤料的制备方法，是将纤维纺成纱线后，织造成机织针织复合结构基布；将纤维经混合、梳理、铺网、预针刺形成的混合纤维网分别铺设在复合结构基布的上下表面，用椭圆形刺针对基布和纤维网进行针刺加固再进行整理制备得到。
上述方法所述机织针织复合结构基布由采用针织纱编织的平针组织、双罗纹组织或罗纹组织的针织结构和采用经纱和纬纱编织的平纹机织结构编织而成。采用的纱线是将纤维经梳棉、成条、粗纱、细纱工序制成。
上述方法所述纤维为无机纤维或高性能纤维短纤中的一种或两种纤维通过抓棉、开松、混合制成的纤维纱，或者玄武岩的膨体纱。所述纤维无机纤维或高性能纤维短纤，采用1.2-9D、长度为30-90.0mm的短纤，玄武岩纤维选用无捻纱、加捻纱或粗纱。其中，纤维纱线的线密度在3-10dtex，玄武岩纱线针织纱选用加捻纱，线密度为150-300dtex，捻度为35-50捻/50cm，玄武岩经、纬纱选用粗纱，线密度为600-2400dtex。
上述方法所述的预针刺条件为：植针密度：1250枚/m，针刺密度800-840刺/㎝2，针刺深度11mm，纤维网速度4m/min。
上述方法所述的针刺的条件为：针刺密度210-2000刺/cm2，针刺深度7-13mm，植针密度1000-3000枚/m，纤维网输出速度0.5-2.5m/min。所用刺针有两条棱，每条棱上有两个钩齿，钩齿与钩齿相间排列。
上述方法所述的整理为烧毛、定型和涂层；其中，烧毛是去除滤料表面的短小纤维，定型主要是提高滤料的热稳定性，涂层是在织物表面涂上微孔过滤膜涂层，增强滤料的过滤效率。所述涂层可以为PTFE超滤膜涂层(孔径为0.01～0.1μm)或陶瓷膜涂层(孔径为0.8nm～1μm)。
上述机织针织复合结构基耐高温环保滤料的制备方法具体包括以下步骤：
(1)将纤维经梳理、铺网和预针刺工序制成混合纤维网；
(2)将纤维经梳棉、成条、粗纱、细纱工序制成纱线；纱线作为针织纱采用平针组织、双罗纹组织或罗纹组织为针织结构，纱线作为经纱和纬纱采用平纹机织结构，编织成机织针织复合结构基布；
(3)机织针织复合结构基布上下表层分别平铺混合纤维网，输送到针刺设备，由植在针板上的椭圆形刺针高速上、下往复针刺加固制成滤料；
(4)滤料经过烧毛、定型和涂层得到最终产品。
上述方法制备的滤料厚度为1.5-3.0mm，重量250-600g/m2，纵横向断裂强力900-1600N/5cm，透气量100-200L/dm2·min。
与现有技术相比，本发明的有益效果为：
(1)机织针织复合基布是一种新型结构(CWK)织物，其中既有由经纱和纬纱相互交织形成的机织结构，又有由针织纱弯曲而成线圈，并相互穿套而形成的针织结构，是二种结构的复合。本发明所述基布同时融合了机织和针织技术，使基布具有结构稳定性和适型性。
(2)椭圆形刺针在相同针刺直径中横截面最大，刺针上下往复运动时，与基布的瞬间接触最温和，基布和非织造层短纤的损伤较少，强力可比同种纤维、同种规格滤料提高10％以上。可以延长使用寿命。
(3)本发明使用的纤维环保且能够耐磨耐高温，短纤也有利于避免被针刺损伤。
附图说明
图1为本发明所述的机织针织复合结构基耐高温环保滤料的结构示意图。
图2为本发明所述的机织针织复合结构基布的结构示意图。
图3为本发明所述的椭圆形刺针的结构示意图。
图4为本发明所述的椭圆形刺针的截面图。
图中：1-机织针织复合结构基布，2-混合纤维网，3-过滤膜涂层，4-针织纱，5-经纱，6-纬纱。
具体实施方式
下面将结合具体实施例更详细地描述本发明的优选实施方式。
根据图1和图2所示的一种机织针织复合结构基耐高温环保滤料，包括由针织结构和机织结构编织而成的机织针织复合结构基布1，所述机织针织复合结构基布1的上下两面均铺设混合纤维网2，任意一面的混合纤维网2表面设有过滤膜涂层3。
本发明所述机织针织复合材料基布1的针织结构为针织纱4采用平针组织、双罗纹组织或罗纹组织，所述机织结构为经纱5和纬纱6交织而成。所述混合纤维网2是由单层纤维网通过交叉方式多层铺成。
实施例1
将3.2D*51mm的PTFE短切纤维，经过开松、梳理、铺网和预针刺后形成混合纤维网2，其密度为100g/m2。
预针刺：植针密度：1250枚/m，针刺密度840刺/㎝2，针刺深度11mm，纤维网速度4m/min。
机织针织复合结构基布1采用3.2dtex*51mmPTFE短切纤维经梳棉、成条、粗纱、细纱工序制成的纱线，针织纱4形成1+1罗纹底组织，经纱5和纬纱6以平直的方式衬入地组织中，经纱5衬在地组织的线圈纵行内，纬纱6衬在地组织线圈和经纱之间，形成2层纬纱6和2层经纱5。单元结构中包括4个针织线圈，2根经纱5和4根纬纱6，2根经纱5分别衬在正面线圈纵行之内和反面线圈纵行之内，4根纬纱6衬入同一线圈横列中并由经纱分隔成2组，如图2所示。基布经密为62根/5cm，纬密为57根/5cm，基布密度为210g/m2，经向强力为1011.4N，断裂伸长率为13.7％，纬向强力为1081.7N，断裂伸长率为20.1％。
机织针织复合结构基布1的上下表层分别平铺混合纤维网2，输送到针刺设备，由植在针板上的椭圆形刺针高速上下进行往复针刺，形成滤料；滤料经过烧毛、定型、涂层工序，所述烧毛是去除滤料表面的短小纤维，涂层为在滤料一侧涂敷PTFE超滤膜涂层。
上述针刺步骤中针刺机(型号：SPN-250型，汕头三辉无纺机械厂有限公司生产)的针刺频率为430次/min，植针密度3000枚/m，幅宽为2500mm，纤维网输出速度1.5m/min，针刺密度1040刺/cm2，针刺深度9mm。
针刺机的刺针为椭圆形刺针(刺针型号为15*18*40*3DT，生产厂家德国格罗兹公司)。刺针有两条棱，每条棱上有两个钩齿，钩齿与钩齿相间排列，每两个钩齿之间的距离为3.18mm，如图3和图4所示。
经针刺加固后制成的高强耐高温滤料，密度为410g/m2，经向强力为990.3N，断裂伸长率为11.8％，纬向强力为972.1N，断裂伸长率为10.1％。
实施例2
将3.2D*51mm的PTFE短纤和1.6D*61mm的PPS短纤，经过开松、混合、梳理、交叉铺网和预针刺后，形成混合纤维网2，密度为120g/m2。
预针刺：植针密度：1250枚/m，针刺密度刺800刺/cm2，针刺深度11mm，纤维网速度4m/min。
机织针织复合结构基布1采用3.2dtex*51mmPTFE短切纤维经梳棉、成条、粗纱、细纱工序制成的纱线，针织纱4形成1+1罗纹底组织，经纱5和纬纱6以平直的方式衬入地组织中，经纱5衬在地组织的线圈纵行内，纬纱6衬在地组织线圈和经纱之间，形成2层纬纱6和2层经纱5。单元结构中包括4个针织线圈，2根经纱5和4根纬纱6，2根经纱5分别衬在正面线圈纵行之内和反面线圈纵行之内，4根纬纱6衬入同一线圈横列中并由经纱分隔成2组，如图2所示。经密为82根/5cm，纬密为76根/5cm，基布密度为200g/m2，经向强力为1011.4N，断裂伸长率为13.7％，纬向强力为1081.7N，断裂伸长率为20.1％。
机织针织复合结构基布1的上下表层分别平铺混合纤维网2，输送到针刺设备，由植在针板上的椭圆形刺针高速上下进行往复针刺，形成滤料；滤料经过烧毛、定型、涂层工序，所述烧毛是去除滤料表面的短小纤维，涂层是在滤料一面涂上陶瓷膜涂层。
上述针刺步骤中针刺机(型号：SPN-250型，汕头三辉无纺机械厂有限公司生产)的针刺频率为450次/min，植针密度3000枚/m，幅宽为2500mm，纤维网输出速度1.5m/min，针刺密度1040刺/cm2；针刺深度为9mm。
针刺机的刺针为椭圆形刺针(刺针型号为15*18*40*3DT，生产厂家德国格罗兹公司)。刺针有两条棱，每条棱上有两个钩齿，钩齿与钩齿相间排列，每两个钩齿之间的距离为3.18mm，如图3和图4所示。
经针刺加固后制成的高强耐高温滤料，密度为440g/m2，经向强力为983.1N，断裂伸长率为11.4％，纬向强力为977.3N，断裂伸长率为18.3％。

Claims (14)

1.一种机织针织复合结构基耐高温环保滤料，其特征在于包括由针织结构和机织结构编织而成的机织针织复合结构基布(1)，机织针织复合结构基布(1)的上下表面均铺设混合纤维网(2)，任意一面的混合纤维网(2)的表面设有微孔过滤膜涂层(3)。
2.根据权利要求1所述的机织针织复合结构基耐高温环保滤料，其特征在于所述机织针织复合结构基布(1)的针织结构为针织纱(4)采用平针组织、双罗纹组织或罗纹组织编织而成；所述机织结构由经纱(5)和纬纱(6)交织而成。
3.根据权利要求2所述的机织针织复合结构基耐高温环保滤料，其特征在于针织纱(4)、经纱(5)和纬纱(6)分别为无机纤维或高性能纤维的单一纤维或二种纤维的混合纤维纱线。
4.根据权利要求1所述的机织针织复合结构基耐高温环保滤料，其特征在于所述机织针织复合结构基布(1)密度为50-250g/m2。
5.根据权利要求1所述的机织针织复合结构基耐高温环保滤料，其特征在于所述混合纤维网(2)是由单层纤维网通过交叉方式多层铺成；所述混合纤维网(2)的密度为100-300g/m2，所述单层纤维网密度为15-25g/m2。
6.根据权利要求1所述的机织针织复合结构基耐高温环保滤料，其特征在于所述滤料厚度为1.5-3.0mm，密度为250-600g/m2。
7.一种权利要求1所述的机织针织复合结构基耐高温环保滤料的制备方法，其特征在于该方法是将纤维纺成纱线后，织造成机织针织复合结构基布；将纤维经混合、梳理、铺网、预针刺形成的混合纤维网分别铺设在复合结构基布的上下表面，用椭圆形刺针对基布和纤维网进行针刺加固再进行整理制备得到。
8.根据权利要求7所述的机织针织复合结构基耐高温环保滤料的制备方法，其特征在于所述的机织针织复合结构基布由采用针织纱编织的平针组织、双罗纹组织或罗纹组织的针织结构和采用经纱和纬纱编织的平纹机织结构编织而成。
9.根据权利要求8所述的机织针织复合结构基耐高温环保滤料的制备方法，其特征在于所述的纤维为无机纤维或高性能纤维短纤中的一种或两种纤维通过抓棉、开松、混合制成的纤维纱，或者玄武岩的膨体纱。
10.根据权利要求9所述的机织针织复合结构基耐高温环保滤料的制备方法，其特征在于所述纤维无机纤维或高性能纤维短纤，采用1.2-9D、长度为30-90.0mm的短纤，玄武岩纤维选用无捻纱、加捻纱或粗纱。
11.根据权利要求10所述的机织针织复合结构基耐高温环保滤料的制备方法，其特征在于所述纤维纱线的线密度在3-10dtex，玄武岩纱线针织纱选用加捻纱，线密度为150-300dtex，捻度为35-50捻/50㎝，玄武岩经、纬纱选用粗纱，线密度为600-2400dtex。
12.根据权利要求7所述的机织针织复合结构基耐高温环保滤料的制备方法，其特征在于所述的预针刺条件为：植针密度：1250枚/m，针刺密度800-840刺/㎝2，针刺深度11mm，纤维网速度4m/min。
13.根据权利要求7所述的机织针织复合结构基耐高温环保滤料的制备方法，其特征在于所述针刺的条件为：针刺密度210-2000刺/cm2，针刺深度7-13mm，植针密度1000-3000枚/m，纤维网输出速度0.5-2.5m/min；所用刺针有两条棱，每条棱上有两个钩齿，钩齿与钩齿相间排列。
14.根据权利要求7所述的机织针织复合结构基耐高温环保滤料的制备方法，其特征在于所述的整理为烧毛、定型和涂层；所述涂层是在织物表面涂上具有微细孔径的过滤膜。
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