CN109848408B - Ultrahigh-precision fiber felt and preparation method thereof - Google Patents
Ultrahigh-precision fiber felt and preparation method thereof Download PDFInfo
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Abstract
The invention discloses an ultrahigh-precision fiber felt and a preparation method thereof, wherein the preparation method comprises the following steps: step 1) stranding the superfine fibers; step 2), performing non-woven laying to form an ultrafine fiber web; step 3), carrying out uniformity inspection; step 4), manufacturing a fiber felt blank; step 5), rolling in a flattening machine; step 6), sending the mixture into a vacuum sintering furnace for diffusion welding; step 7), carrying out secondary sintering; step 8), leveling, and measuring the bubble point pressure and the air permeability by using a bubble point detector and a nondestructive detector; and 9) folding the fiber felt blank, welding the fiber felt blank into a filter tube, and carrying out bubble point detection on the fiber felt blank after folding to meet the requirement, namely the ultrahigh-precision fiber felt.
Description
Technical Field
The invention belongs to the technical field of filter element preparation, and particularly relates to an ultrahigh-precision fiber felt and a preparation method thereof.
Background
The metal fiber felt is usually used for preparing a filter for filtering chemical fibers, the filtering precision of the metal fiber felt is generally within the range of 10-40 mu m, the precision of the fiber felt for filtering aerospace hydraulic oil generally needs to reach 3-5 mu m, and at present, domestic fresh manufacturers can prepare the ultrahigh-precision fiber felt in batches, and no document discloses the technology of the ultrahigh-precision fiber felt.
Disclosure of Invention
The invention aims to overcome the defects of the prior art, provides an ultrahigh-precision fiber felt and a preparation method thereof, and solves the problems that the prior art is low in filtering precision, cannot realize batch production and the like.
In order to solve the technical problem, the technical scheme of the invention is as follows: a preparation method of an ultrahigh-precision fiber felt comprises the following steps:
step 1) stranding the superfine fiber with the diameter of 2 mu m and the core number of 15000 cores;
step 2) carrying out non-woven laying on the superfine fibers twisted in the step 1) by adopting an airflow felt laying device to form superfine fiber webs;
step 3) carrying out uniformity inspection on the superfine fiber web in the step 2);
step 4) manufacturing a fiber felt blank by using the superfine fiber webs and the coarse fiber webs which are qualified in the step 3), wherein the filtering precision of the coarse fiber webs is 40-100 mu m, and the total single weight of the fiber felt blank is 950-1000 g/m2；
Step 5) rolling the fiber felt blank obtained in the step 4) in a flattening machine;
step 6) separating the fiber felt blank rolled in the step 5) by using an isolation layer, and sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding;
step 7) roughly flattening the sintered fiber felt blank, and then sending the fiber felt blank into a vacuum sintering furnace for continuous secondary sintering;
step 8) flattening the fiber felt blank secondarily sintered in the step 7), wherein the thickness of the fiber felt blank is 0.4-0.5 mm, the specification of the fiber felt blank comprises a 3-micrometer fiber felt blank and a 5-micrometer fiber felt blank, and a bubble point detector and a nondestructive detector are used for measuring the bubble point pressure and the air permeability of the fiber felt blank;
and 9) folding the fiber felt blank obtained in the step 8), welding the fiber felt blank into a filter tube, and carrying out bubble point detection on the fiber felt blank after folding to meet the requirement, namely the ultrahigh-precision fiber felt.
Preferably, the number of the strands plied in the step 1) is 4-8, and the gram weight is 6-9 g/m2。
Preferably, the licker-in speed of the airflow felt paving equipment in the step 2) is 1200-1500 RPM, the feeding roller speed of the airflow felt paving equipment is 60-90 RPM, and the gram weight of the paved superfine fiber web is 50-100 g/m2。
Preferably, the uniformity test in step 3) comprises the following steps:
step 3-1), placing the paved superfine fiber net on a light inspection table, and judging the uniformity through light transmission;
and 3-2) respectively taking 6 wafers with the diameter phi of 60mm in the length direction and the width direction of the superfine fiber web, measuring the single weight, and comparing, wherein the single weight deviation is qualified within the range of +/-5%.
Preferably, the fiber felt blank in the step 4) is formed by overlapping a plurality of layers of superfine fiber nets and a plurality of layers of coarse fiber nets, wherein the plurality of layers of coarse fiber nets are arranged on the outer layers on two sides, the plurality of layers of superfine fiber nets are arranged on the inner layer, and the layer number ratio of the coarse fiber nets to the superfine fiber nets is 4: 6.
Preferably, the vacuum degree of the vacuum sintering furnace in the step 6) is 5.0 × 10-2Pa, the sintering temperature is 1020-1050 ℃, and after sintering, the temperature is reduced to 900 ℃ and nitrogen gas quenching is carried out.
Preferably, the vacuum degree of the vacuum sintering furnace in the step 7) is 5.0 × 10-2Pa, the sintering temperature is 1120-1150 ℃, and after sintering, the temperature is reduced to 900 ℃ and nitrogen gas quenching is carried out.
Preferably, when the bubble point pressure of the prepared 3-micron fiber felt blank in the step 8) is more than or equal to 10000Pa, the air permeability is more than or equal to 10L/min2The performance meets the requirements; when the bubble point pressure of the prepared 5-micron fiber felt blank is more than or equal to 7500Pa, the air permeability is more than or equal to 40L/min2The performance of the catalyst meets the requirements.
Preferably, the wave height of the wave folding in the step 9) is 8mm, the wave number is 45, the requirement is met when the bubble point pressure of the fiber felt blank with the diameter of 3 μm after wave folding is more than or equal to 8000Pa, and the requirement is met when the bubble point pressure of the fiber felt blank with the diameter of 5 μm after wave folding is more than or equal to 6000 Pa.
Preferably, the ultrahigh-precision fiber felt is prepared by the preparation method of any one of the above methods.
Compared with the prior art, the invention has the advantages that:
(1) the ultra-high precision fiber felt prepared by the invention can meet the requirements on air permeability and bubble point pressure, the uniformity of the superfine fiber web after the superfine fibers are paved by an airflow method is consistent, the product quality is controllable, the integral fastness of the fiber felt blank after high-temperature sintering is reliable, and the fiber felt blank can be folded and cannot be easily broken;
(2) the ultra-high precision fiber felt prepared by the invention is used for manufacturing a filter element for filtering a thin film material, the filtering precision can reach 3 mu m and 5 mu m, the pressure of a bubble point respectively reaches 10000Pa and 7500Pa, and the air permeability respectively reaches 10L/min2、40L/min.dm2The bubble point pressure after wave folding reaches 8000Pa and 6000Pa respectively, the pore diameter distribution is uniform, and the superfine fiber is solvedThe problems of paving and batch high-temperature sintering are solved;
(3) the preparation method has reasonable process, is simple and easy to operate, reduces the cost, improves the production efficiency and can be used for batch production.
Detailed Description
The following describes embodiments of the present invention with reference to examples:
it should be noted that the structures, proportions, sizes, and other elements shown in the specification are included for the purpose of understanding and reading only, and are not intended to limit the scope of the invention, which is defined by the claims, and any modifications of the structures, changes in the proportions and adjustments of the sizes, without affecting the efficacy and attainment of the same.
In addition, the terms "upper", "lower", "left", "right", "middle" and "one" used in the present specification are for clarity of description, and are not intended to limit the scope of the present invention, and the relative relationship between the terms and the terms is not to be construed as a scope of the present invention.
The airflow felt paving equipment, the leveling machine, the vacuum sintering furnace, the bubble point detector, the nondestructive detector and the lamp inspection table are all in the prior art.
Example 1
The invention discloses a preparation method of an ultrahigh-precision fiber felt, which comprises the following steps:
step 1) stranding the superfine fiber with the diameter of 2 mu m and the core number of 15000 cores;
step 2) carrying out non-woven laying on the superfine fibers twisted in the step 1) by adopting an airflow felt laying device to form superfine fiber webs;
step 3) carrying out uniformity inspection on the superfine fiber web in the step 2);
step 4) manufacturing a fiber felt blank by using the superfine fiber webs and the coarse fiber webs which are qualified in the step 3), wherein the filtering precision of the coarse fiber webs is 40-100 mu m, and the coarse fiber websThe total weight of the fiber felt blank is 950-1000 g/m2；
Step 5) rolling the fiber felt blank obtained in the step 4) in a flattening machine;
step 6) separating the fiber felt blank rolled in the step 5) by using an isolation layer, and sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding;
step 7) roughly flattening the sintered fiber felt blank, and then sending the fiber felt blank into a vacuum sintering furnace for continuous secondary sintering;
step 8) flattening the fiber felt blank secondarily sintered in the step 7), wherein the thickness of the fiber felt blank is 0.4-0.5 mm, the specification of the fiber felt blank comprises a 3-micrometer fiber felt blank and a 5-micrometer fiber felt blank, and a bubble point detector and a nondestructive detector are used for measuring the bubble point pressure and the air permeability of the fiber felt blank;
and 9) folding the fiber felt blank obtained in the step 8), welding the fiber felt blank into a filter tube, and carrying out bubble point detection on the fiber felt blank after folding to meet the requirement, namely the ultrahigh-precision fiber felt.
Example 2
The invention discloses a preparation method of an ultrahigh-precision fiber felt, which comprises the following steps:
step 1) stranding the superfine fiber with the diameter of 2 mu m and the core number of 15000 cores;
step 2) carrying out non-woven laying on the superfine fibers twisted in the step 1) by adopting an airflow felt laying device to form superfine fiber webs;
step 3) carrying out uniformity inspection on the superfine fiber web in the step 2);
step 4) manufacturing a fiber felt blank by using the superfine fiber webs and the coarse fiber webs which are qualified in the step 3), wherein the filtering precision of the coarse fiber webs is 40-100 mu m, and the total single weight of the fiber felt blank is 950-1000 g/m2；
Step 5) rolling the fiber felt blank obtained in the step 4) in a flattening machine;
step 6) separating the fiber felt blank rolled in the step 5) by using an isolation layer, and sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding;
step 7) roughly flattening the sintered fiber felt blank, and then sending the fiber felt blank into a vacuum sintering furnace for continuous secondary sintering;
step 8) flattening the fiber felt blank secondarily sintered in the step 7), wherein the thickness of the fiber felt blank is 0.4-0.5 mm, the specification of the fiber felt blank comprises a 3-micrometer fiber felt blank and a 5-micrometer fiber felt blank, and a bubble point detector and a nondestructive detector are used for measuring the bubble point pressure and the air permeability of the fiber felt blank;
and 9) folding the fiber felt blank obtained in the step 8), welding the fiber felt blank into a filter tube, and carrying out bubble point detection on the fiber felt blank after folding to meet the requirement, namely the ultrahigh-precision fiber felt.
Preferably, the number of the strands plied in the step 1) is 4-8, and the gram weight is 6-9 g/m2。
Preferably, the licker-in speed of the airflow felt paving equipment in the step 2) is 1200-1500 RPM, the feeding roller speed of the airflow felt paving equipment is 60-90 RPM, and the gram weight of the paved superfine fiber web is 50-100 g/m2。
Preferably, the uniformity test in step 3) comprises the following steps:
step 3-1), placing the paved superfine fiber net on a light inspection table, and judging the uniformity through light transmission; and 3-2) respectively taking 6 wafers with the diameter phi of 60mm in the length direction and the width direction of the superfine fiber web, measuring the single weight, and comparing, wherein the single weight deviation is qualified within the range of +/-5%.
Example 3
The invention discloses a preparation method of an ultrahigh-precision fiber felt, which comprises the following steps:
step 1) stranding the superfine fiber with the diameter of 2 mu m and the core number of 15000 cores;
step 2) carrying out non-woven laying on the superfine fibers twisted in the step 1) by adopting an airflow felt laying device to form superfine fiber webs;
step 3) carrying out uniformity inspection on the superfine fiber web in the step 2);
step 4) manufacturing a fiber felt blank by using the superfine fiber webs and the coarse fiber webs which are qualified in the step 3), wherein the filtering precision of the coarse fiber webs is 40-100 mu m, and the total single weight of the fiber felt blank is 950-1000 g/m2；
Step 5) rolling the fiber felt blank obtained in the step 4) in a flattening machine;
step 6) separating the fiber felt blank rolled in the step 5) by using an isolation layer, and sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding;
step 7) roughly flattening the sintered fiber felt blank, and then sending the fiber felt blank into a vacuum sintering furnace for continuous secondary sintering;
step 8) flattening the fiber felt blank secondarily sintered in the step 7), wherein the thickness of the fiber felt blank is 0.4-0.5 mm, the specification of the fiber felt blank comprises a 3-micrometer fiber felt blank and a 5-micrometer fiber felt blank, and a bubble point detector and a nondestructive detector are used for measuring the bubble point pressure and the air permeability of the fiber felt blank;
and 9) folding the fiber felt blank obtained in the step 8), welding the fiber felt blank into a filter tube, and carrying out bubble point detection on the fiber felt blank after folding to meet the requirement, namely the ultrahigh-precision fiber felt.
Preferably, the number of the strands plied in the step 1) is 4-8, and the gram weight is 6-9 g/m2。
Preferably, the licker-in speed of the airflow felt paving equipment in the step 2) is 1200-1500 RPM, the feeding roller speed of the airflow felt paving equipment is 60-90 RPM, and the gram weight of the paved superfine fiber web is 50-100 g/m2。
Preferably, the uniformity test in step 3) comprises the following steps:
step 3-1), placing the paved superfine fiber net on a light inspection table, and judging the uniformity through light transmission; and 3-2) respectively taking 6 wafers with the diameter phi of 60mm in the length direction and the width direction of the superfine fiber web, measuring the single weight, and comparing, wherein the single weight deviation is qualified within the range of +/-5%.
Preferably, the fiber felt blank in the step 4) is formed by overlapping a plurality of layers of superfine fiber nets and a plurality of layers of coarse fiber nets, wherein the plurality of layers of coarse fiber nets are arranged on the outer layers on two sides, the plurality of layers of superfine fiber nets are arranged on the inner layer, and the layer number ratio of the coarse fiber nets to the superfine fiber nets is 4: 6.
Preferably, the vacuum degree of the vacuum sintering furnace in the step 6) is 5.0 × 10-2Pa, the sintering temperature is 1020-1050 ℃, and after sintering, the temperature is reduced to 900 ℃ and nitrogen gas quenching is carried out.
Preferably, the vacuum degree of the vacuum sintering furnace in the step 7) is 5.0 × 10-2Pa, the sintering temperature is 1120-1150 ℃, and the sintering is finishedAfter the formation, the temperature is reduced to 900 ℃ and then the nitrogen is used for quenching.
Example 4
The invention discloses a preparation method of an ultrahigh-precision fiber felt, which comprises the following steps:
step 1) stranding the superfine fiber with the diameter of 2 mu m and the core number of 15000 cores;
step 2) carrying out non-woven laying on the superfine fibers twisted in the step 1) by adopting an airflow felt laying device to form superfine fiber webs;
step 3) carrying out uniformity inspection on the superfine fiber web in the step 2);
step 4) manufacturing a fiber felt blank by using the superfine fiber webs and the coarse fiber webs which are qualified in the step 3), wherein the filtering precision of the coarse fiber webs is 40-100 mu m, and the total single weight of the fiber felt blank is 950-1000 g/m2；
Step 5) rolling the fiber felt blank obtained in the step 4) in a flattening machine;
step 6) separating the fiber felt blank rolled in the step 5) by using an isolation layer, and sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding; the isolating layer enables the layers of the fiber felt blank to be in close contact with each other, and the number of lap joints among fibers is increased;
step 7) roughly flattening the sintered fiber felt blank, and then sending the fiber felt blank into a vacuum sintering furnace for continuous secondary sintering;
step 8) flattening the fiber felt blank secondarily sintered in the step 7), wherein the thickness of the fiber felt blank is 0.4-0.5 mm, the specification of the fiber felt blank comprises a 3-micrometer fiber felt blank and a 5-micrometer fiber felt blank, and a bubble point detector and a nondestructive detector are used for measuring the bubble point pressure and the air permeability of the fiber felt blank;
and 9) folding the fiber felt blank obtained in the step 8), welding the fiber felt blank into a filter tube, and carrying out bubble point detection on the fiber felt blank after folding to meet the requirement, namely the ultrahigh-precision fiber felt.
Preferably, the number of the strands plied in the step 1) is 4-8, and the gram weight is 6-9 g/m2。
Preferably, the licker-in speed of the airflow felt paving equipment in the step 2) is 1200-1500 RPM, the feeding roller speed of the airflow felt paving equipment is 60-90 RPM, and the gram weight of the paved superfine fiber web is 50-100g/m2。
Preferably, the uniformity test in step 3) comprises the following steps:
step 3-1), placing the paved superfine fiber net on a light inspection table, and judging the uniformity through light transmission; and 3-2) respectively taking 6 wafers with the diameter phi of 60mm in the length direction and the width direction of the superfine fiber web, measuring the single weight, and comparing, wherein the single weight deviation is qualified within the range of +/-5%.
Preferably, the fiber felt blank in the step 4) is formed by overlapping a plurality of layers of superfine fiber nets and a plurality of layers of coarse fiber nets, wherein the plurality of layers of coarse fiber nets are arranged on the outer layers on two sides, the plurality of layers of superfine fiber nets are arranged on the inner layer, and the layer number ratio of the coarse fiber nets to the superfine fiber nets is 4: 6.
Preferably, the vacuum degree of the vacuum sintering furnace in the step 6) is 5.0 × 10-2Pa, the sintering temperature is 1020-1050 ℃, and after sintering, the temperature is reduced to 900 ℃ and nitrogen gas quenching is carried out.
Preferably, the vacuum degree of the vacuum sintering furnace in the step 7) is 5.0 × 10-2Pa, the sintering temperature is 1120-1150 ℃, and after sintering, the temperature is reduced to 900 ℃ and nitrogen gas quenching is carried out.
Preferably, when the bubble point pressure of the prepared 3-micron fiber felt blank in the step 8) is more than or equal to 10000Pa, the air permeability is more than or equal to 10L/min2The performance meets the requirements; when the bubble point pressure of the prepared 5-micron fiber felt blank is more than or equal to 7500Pa, the air permeability is more than or equal to 40L/min2The performance of the catalyst meets the requirements.
Preferably, the wave height of the wave folding in the step 9) is 8mm, the wave number is 45, the requirement is met when the bubble point pressure of the fiber felt blank with the diameter of 3 μm after wave folding is more than or equal to 8000Pa, and the requirement is met when the bubble point pressure of the fiber felt blank with the diameter of 5 μm after wave folding is more than or equal to 6000 Pa.
Preferably, the ultrahigh-precision fiber felt is prepared by the preparation method of any one of the above methods.
Example 5
Step 1) plying the superfine fiber with the yarn diameter of 2 mu m and the core number of 15000, the ply number of 4 and the gram weight of 6g/m2；
Step 2) to the ultra-fine after the strandingThe fiber is non-woven spread by using an air flow felting device, wherein the speed of a licker-in is 1000RPM, the speed of a feeding roller is 60RPM, and the gram weight of the spread superfine fiber web is controlled to be 50g/m2；
Step 3) inspecting the paved superfine fiber web, judging the integral uniformity through a light inspection platform, then respectively weighing 6 wafers in the length and width directions of the superfine fiber web, wherein the single weight deviation is within the range of +/-5 percent and the wafers are qualified;
step 4) preparing a fiber felt blank, wherein the total single weight is controlled to be 950g/m2Overlapping a plurality of layers of superfine fiber nets and a plurality of layers of coarse fiber nets to prepare a fiber felt blank, wherein the plurality of layers of coarse fiber nets are arranged on the outer layers at two sides, the plurality of layers of superfine fiber nets are arranged on the inner layer, and the layer number ratio of the coarse fiber nets to the superfine fiber nets is 4: 6;
step 5), rolling the fiber felt blank by using a flattening machine;
step 6), separating the rolled fiber felt blank by an isolation layer, sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding, and performing primary sintering, wherein the vacuum degree is controlled to be 5.0 multiplied by 10-2Pa, the sintering temperature is controlled at 1020 ℃, and nitrogen gas quenching is carried out at 900 ℃;
step 7) rough flattening is carried out on the fiber felt blank sintered for the first time, then secondary vacuum sintering is carried out, and the vacuum degree is controlled to be 5.0 multiplied by 10-2Pa, controlling the sintering temperature at 1120 ℃, and quenching with nitrogen gas at 900 ℃;
step 8) flattening the fiber felt blank subjected to secondary vacuum sintering to 0.4mm, and detecting the bubble point pressure and the air permeability of the fiber felt blank, wherein the bubble point pressure is more than or equal to 10000Pa, and the air permeability is more than or equal to 10L/min.dm2Belongs to a 3 mu m fiber felt blank, and the performance index meets the requirement;
and 9) folding the fiber felt blank, welding the fiber felt blank into a filter tube, wherein the wave height of the folded wave is 8mm, the wave number is 45, carrying out bubble point detection on the fiber felt blank after folding, and the bubble point pressure of the fiber felt blank after folding is more than or equal to 8000Pa, so that the fiber felt blank meets the requirements.
Example 6
Step 1) plying the superfine fiber with the yarn diameter of 2 mu m and the core number of 15000, the ply number of 8 and the gram weight of 9g/m2；
Step 2) carrying out non-woven laying on the plied superfine fibers by using an airflow felt laying device, wherein the speed of a licker-in is 1500RPM, the speed of a feeding roller is 90RPM, and the gram weight of the laid superfine fiber web is controlled at 100g/m2；
Step 3) inspecting the paved superfine fiber web, judging the integral uniformity through a light inspection platform, then respectively weighing 6 wafers in the length and width directions of the superfine fiber web, wherein the single weight deviation is within the range of +/-5 percent and the wafers are qualified;
step 4) preparing a fiber felt blank, wherein the total single weight is controlled to be 1000g/m2Overlapping a plurality of layers of superfine fiber nets and a plurality of layers of coarse fiber nets to prepare a fiber felt blank, wherein the plurality of layers of coarse fiber nets are arranged on the outer layers at two sides, the plurality of layers of superfine fiber nets are arranged on the inner layer, and the layer number ratio of the coarse fiber nets to the superfine fiber nets is 4: 6;
step 5), rolling the fiber felt blank by using a flattening machine;
step 6), separating the rolled fiber felt blank by an isolation layer, sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding, and performing primary sintering, wherein the vacuum degree is controlled to be 5.0 multiplied by 10-2Pa, controlling the sintering temperature at 1050 ℃, and quenching with nitrogen gas at 900 ℃;
step 7) rough flattening is carried out on the fiber felt blank sintered for the first time, then secondary vacuum sintering is carried out, and the vacuum degree is controlled to be 5.0 multiplied by 10-2Pa, controlling the sintering temperature at 1150 ℃, and quenching with nitrogen gas at 900 ℃;
step 8) flattening the fiber felt blank subjected to secondary vacuum sintering to 0.5mm, and detecting the bubble point pressure and the air permeability of the fiber felt blank, wherein the bubble point pressure is more than or equal to 7500Pa, and the air permeability is more than or equal to 40L/min.dm2Belongs to a 5-micron fiber felt blank, and the performance index meets the requirement;
and 9) folding the fiber felt blank, welding the fiber felt blank into a filter tube, wherein the wave height of the folded wave is 8mm, the wave number is 45, carrying out bubble point detection on the fiber felt blank after folding, and the bubble point pressure of the fiber felt blank after folding is more than or equal to 6000Pa, so that the fiber felt blank meets the requirements.
Example 7
Step 1) plying the superfine fiber with the yarn diameter of 2 mu m and the core number of 15000, the ply number is 6 and the gram weight is8g/m2；
Step 2) carrying out non-woven laying on the plied superfine fibers by using an airflow felt laying device, wherein the speed of a licker-in roller is 1300RPM, the speed of a feeding roller is 80RPM, and the gram weight of the laid superfine fiber web is controlled to be 80g/m2；
Step 3) inspecting the paved superfine fiber web, judging the integral uniformity through a light inspection platform, then respectively weighing 6 wafers in the length and width directions of the superfine fiber web, wherein the single weight deviation is within the range of +/-5 percent and the wafers are qualified;
step 4) preparing a fiber felt blank, wherein the total single weight is controlled to be 980g/m2Overlapping a plurality of layers of superfine fiber nets and a plurality of layers of coarse fiber nets to prepare a fiber felt blank, wherein the plurality of layers of coarse fiber nets are arranged on the outer layers at two sides, the plurality of layers of superfine fiber nets are arranged on the inner layer, and the layer number ratio of the coarse fiber nets to the superfine fiber nets is 4: 6;
step 5), rolling the fiber felt blank by using a flattening machine;
step 6), separating the rolled fiber felt blank by an isolation layer, sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding, and performing primary sintering, wherein the vacuum degree is controlled to be 5.0 multiplied by 10-2Pa, controlling the sintering temperature at 1030 ℃, and quenching with nitrogen gas at 900 ℃;
step 7) rough flattening is carried out on the fiber felt blank sintered for the first time, then secondary vacuum sintering is carried out, and the vacuum degree is controlled to be 5.0 multiplied by 10-2Pa, controlling sintering temperature at 1130 deg.C, quenching with nitrogen gas at 900 deg.C;
step 8) flattening the fiber felt blank subjected to secondary vacuum sintering to 0.5mm, and detecting the bubble point pressure and the air permeability of the fiber felt blank, wherein the bubble point pressure is more than or equal to 10000Pa, and the air permeability is more than or equal to 10L/min.dm2Belongs to a 3 mu m fiber felt blank, and the performance index meets the requirement;
and 9) folding the fiber felt blank, welding the fiber felt blank into a filter tube, wherein the wave height of the folded wave is 8mm, the wave number is 45, carrying out bubble point detection on the fiber felt blank after folding, and the bubble point pressure of the fiber felt blank after folding is more than or equal to 8000Pa, so that the fiber felt blank meets the requirements.
The ultra-high precision fiber felt prepared by the invention can meet the requirements on air permeability and bubble point pressure, the uniformity of the superfine fiber web after the superfine fibers are paved by an air flow method is consistent, the product quality is controllable, the integral fastness of the fiber felt blank after high-temperature sintering is reliable, and the fiber felt blank can be folded and is not easy to break.
The ultra-high precision fiber felt prepared by the invention is used for manufacturing a filter element for filtering a thin film material, the filtering precision can reach 3 mu m and 5 mu m, the pressure of a bubble point respectively reaches 10000Pa and 7500Pa, and the air permeability respectively reaches 10L/min2、40L/min.dm2The bubble point pressure after wave folding reaches 8000Pa and 6000Pa, the pore diameter distribution is uniform, and the problems of paving and batch high-temperature sintering of superfine fibers are solved.
The preparation method has reasonable process, is simple and easy to operate, reduces the cost, improves the production efficiency and can be used for batch production.
While the preferred embodiments of the present invention have been described in detail, the present invention is not limited to the above embodiments, and various changes can be made without departing from the spirit of the present invention within the knowledge of those skilled in the art.
Many other changes and modifications can be made without departing from the spirit and scope of the invention. It is to be understood that the invention is not to be limited to the specific embodiments, but only by the scope of the appended claims.
Claims (10)
1. The preparation method of the ultrahigh-precision fiber felt is characterized by comprising the following steps of:
step 1) stranding the superfine fiber with the diameter of 2 mu m and the core number of 15000 cores;
step 2) carrying out non-woven laying on the superfine fibers twisted in the step 1) by adopting an airflow felt laying device to form superfine fiber webs;
step 3) carrying out uniformity inspection on the superfine fiber web in the step 2);
step 4) manufacturing a fiber felt blank by using the superfine fiber webs and the coarse fiber webs which are qualified in the step 3), wherein the filtering precision of the coarse fiber webs is 40-100 mu m, and the total single weight of the fiber felt blank is 950-1000 g/m2；
Step 5) rolling the fiber felt blank obtained in the step 4) in a flattening machine;
step 6) separating the fiber felt blank rolled in the step 5) by using an isolation layer, and sending the separated fiber felt blank into a vacuum sintering furnace for diffusion welding;
step 7) roughly flattening the sintered fiber felt blank, and then sending the fiber felt blank into a vacuum sintering furnace for continuous secondary sintering;
step 8) flattening the fiber felt blank secondarily sintered in the step 7), wherein the thickness of the fiber felt blank is 0.4-0.5 mm, the specification of the fiber felt blank comprises a 3-micrometer fiber felt blank and a 5-micrometer fiber felt blank, and a bubble point detector and a nondestructive detector are used for measuring the bubble point pressure and the air permeability of the fiber felt blank;
and 9) folding the fiber felt blank obtained in the step 8), welding the fiber felt blank into a filter tube, and carrying out bubble point detection on the fiber felt blank after folding to meet the requirement, namely the ultrahigh-precision fiber felt.
2. The method for preparing the ultra-high precision fiber mat according to claim 1, characterized in that: the number of the strands plied in the step 1) is 4-8 strands, and the gram weight is 6-9 g/m2。
3. The method for preparing the ultra-high precision fiber mat according to claim 1, characterized in that: in the step 2), the licker-in speed of the airflow felt paving equipment is 1200-1500 RPM, the feeding roller speed of the airflow felt paving equipment is 60-90 RPM, and the gram weight of the paved superfine fiber web is 50-100 g/m2。
4. The method for preparing the ultra-high precision fiber felt according to claim 1, wherein the uniformity inspection in the step 3) comprises the following steps: step 3-1), placing the paved superfine fiber net on a light inspection table, and judging the uniformity through light transmission; and 3-2) respectively taking 6 wafers with the diameter phi of 60mm in the length direction and the width direction of the superfine fiber web, measuring the single weight, and comparing, wherein the single weight deviation is qualified within the range of +/-5%.
5. The method for preparing the ultra-high precision fiber mat according to claim 1, characterized in that: the fiber felt blank in the step 4) is formed by overlapping a plurality of layers of superfine fiber nets and a plurality of layers of coarse fiber nets, wherein the plurality of layers of coarse fiber nets are arranged on the outer layers of two sides, the plurality of layers of superfine fiber nets are arranged on the inner layer, and the layer number ratio of the coarse fiber nets to the superfine fiber nets is 4: 6.
6. The method for preparing the ultra-high precision fiber mat according to claim 1, characterized in that: the vacuum degree of the vacuum sintering furnace in the step 6) is 5.0 multiplied by 10-2Pa, the sintering temperature is 1020-1050 ℃, and after sintering, the temperature is reduced to 900 ℃ and nitrogen gas quenching is carried out.
7. The method for preparing the ultra-high precision fiber mat according to claim 1, characterized in that: the vacuum degree of the vacuum sintering furnace in the step 7) is 5.0 multiplied by 10-2Pa, the sintering temperature is 1120-1150 ℃, and after sintering, the temperature is reduced to 900 ℃ and nitrogen gas quenching is carried out.
8. The method for preparing the ultra-high precision fiber mat according to claim 1, characterized in that: when the bubble point pressure of the prepared 3-micron fiber felt blank in the step 8) is more than or equal to 10000Pa, the air permeability is more than or equal to 10L/min2The performance meets the requirements; when the bubble point pressure of the prepared 5-micron fiber felt blank is more than or equal to 7500Pa, the air permeability is more than or equal to 40L/min2The performance of the catalyst meets the requirements.
9. The method for preparing the ultra-high precision fiber mat according to claim 1, characterized in that: the wave height of the wave folding in the step 9) is 8mm, the wave number is 45, the requirement is met when the bubble point pressure of the fiber felt blank with the diameter of 3 mu m after wave folding is more than or equal to 8000Pa, and the requirement is met when the bubble point pressure of the fiber felt blank with the diameter of 5 mu m after wave folding is more than or equal to 6000 Pa.
10. An ultra-high precision fiber felt is characterized in that: the ultra-high precision fiber felt is prepared by the preparation method of any one of claims 1 to 9.
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