CN110465134B - 一种新型的复合过滤材料及其制备方法 - Google Patents
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Abstract
本发明公开一种新型的复合过滤材料及其制备方法,新型的复合过滤材料至少包括支撑层、覆膜层和静电微过滤层;其中,覆膜层平均孔径主要分布在0.5~10μm之间,静电微过滤层孔径主要分布在10~50μm之间。本发明新型的复合过滤材料为微孔覆膜层和静电微过滤层复合构造,可进一步提高材料过滤效率;并且根据覆膜层集尘的可脱离性,产品使用过程中可将阻挡于覆膜层的灰尘清除,极大延长了产品的使用寿命。
Description
技术领域
本发明涉及一种新型的复合过滤材料及其制备方法,主要应用于空气净化器、汽车空调滤、新风净化机等空气净化领域。
背景技术
近年来,随着人们生活水平的提高,建筑物、汽车等数量急剧增多,同时工业污染日益严重,导致有害气体的排出量增加,对室内及车内空气质量都造成严重影响,而室内及车内空气品质对人体健康影响尤为关键,因此室内及车内空气品质成为全世界关注的焦点之一。
空气净化器及汽车空调滤主要作用是过滤掉室内及车内空气中的灰尘、有害气体及其他有害物质,而空气净化器及汽车空调过滤核心部件为过滤芯,过滤芯使用的过滤材料好坏直接影响到过滤网的效果和使用寿命。
目前,低阻力、高过滤效率的过滤材料以静电驻极材料最为常见,但是此类材料普遍存在使用寿命短、不可重复使用的问题。专利CN106823558A虽然提出一种防水防油可水洗空气净化滤芯,但是已经被静电熔喷过滤层吸附的颗粒物很难再脱离,而且经过水洗后静电效应会有所减弱。而专利CN101407976A提出应用于工业烟气的高过滤效率覆膜复合针刺毡过滤材料,虽然效率可达99.999%,但是依靠表面过滤的覆膜材料过滤效率越高,往往需要制备的孔径越小,最终导致材料压损急剧增加。此材料应用于空气净化器或汽车空调滤将造成风机负荷过大,耗电量增加。
发明内容
本发明的目的在于提供一种新型的复合过滤材料及其制备方法,以解决现有过滤材料在使用过程中存在的过滤效果不理想、使用寿命短的问题。
本发明的技术解决方案如下:一种新型的复合过滤材料,至少包括支撑层、覆膜层和静电微过滤层;其中,覆膜层位于支撑层和静电微过滤层之间,平均孔径主要分布在0.5~10μm之间,静电微过滤层平均孔径主要分布在10~50μm之间。
优选的,支撑层起到粗过滤和支撑骨架作用,支撑层主要构成为玻璃纤维、或聚合物纤维、或二者混合物纤维加工而成的无纺布,支撑层平均孔径主要分布在50~300μm之间,由于支撑层具有一定孔径,可以滤除空气中的毛发、纸屑等大颗粒灰尘,玻璃纤维或PET、维尼纶等聚合物纤维具有良好的韧性可用于制备支撑材无纺布,支撑材孔径分布优选100~200μm之间,既满足材料支撑所需的强度要求,覆膜层所阻挡的灰尘也容易清理出来。
优选的,覆膜层主要为聚合物材质覆膜层,聚合物材料覆膜成型性、柔韧性好,并且疏水性聚合物膜可有效防止灰尘结块,积尘清理时灰尘易脱落,在众多聚合物中,PTFE膜材疏水性好,覆膜孔径分布较均匀,并且具有一定阻燃性,因此,优选PTFE材质覆膜;覆膜层为表面过滤集尘,0.5~10μm的孔径可充分将空气中绝大部分颗粒物阻挡于覆膜层集尘侧;而部分透过膜孔的微尘可由致密的静电微过滤层吸附,覆膜层平均孔径低于0.5μm,虽然过滤效率有所增加,但是覆膜层压损急剧升高,最终导致整体过滤材料压损较大。大气中绝大部分污染物为PM10,所以孔径大于10μm导致大部分灰尘透过覆膜层,将导致材料过滤效率较低,并且静电微过滤层的负荷增大,当静电微过滤层大量集尘后压损升高,过滤材料使用寿命急剧缩短。为应对空气中主要污染物PM2.5,覆膜层平均孔径优选0.5~2.5μm之间。
优选的,静电微过滤层主要为驻极聚合物经熔喷并带电加工的无纺布,其纤维径主要分布在0.5~6.0μm之间,静电微过滤层主要依靠静电吸附作用捕捉透过覆膜层的少量颗粒物,根据使用环境对阻力和过滤效率的要求,其孔径分布在10~50μm之间。静电过滤层平均孔径越小,其阻力越高,过滤效率也越高,反之阻力减小过滤效率也降低。因为覆膜层过滤掉了0.5μm以上的绝大部分灰尘,而0.5μm以下微细尘极易受到静电吸引,所以即使静电过滤层孔径分布在10~50μm之间也可过滤绝大部分0.5m以下微细尘,驻极熔喷无纺布可保持半永久带电,其带电性可保持3年以上基本不减弱,熔喷无纺布纤维径可以做到极细达到数百纳米,熔喷无纺布纤维径主要分布在0.5~6μm之间,配合静电微过滤层孔径,纤维径越小材料越致密,过滤效率越高,其阻力会随之上升;反之,纤维径越大,其阻力越小,过滤效率有所降低。本发明从室内及车内空气净化综合考虑,纤维径分布在0.5~6μm之间其阻力和过滤效率较适宜。本发明中驻极无纺布带电加工方式可以为水流带电或高压带电,其中水流摩擦带电的无纺布带电荷分布较均匀,但是生产加工速度较慢;而高压带电工艺简单,生产速度快,但是电荷分布不均匀。
优选的,中间覆膜层平均孔径较小,可将大部分灰尘阻挡于材料进风侧,而物理集尘覆膜层的好处是灰尘的可脱离性,这样就可定期将覆膜层表面的灰尘反向吹扫倾倒或使用吸尘器进行清除,极大延长了产品的使用寿命。
优选的,覆膜层和静电微过滤层之间含有气体吸附过滤层,吸附剂包括活性炭、沸石、多孔硅胶、触媒或特定气体去除药剂中的一种或几种组合,气体吸附剂在气体吸附过滤层中的含有量分布在50~150g/m2之间,当气体吸附含量低于50g/m2时,气体消除效果较差,当含量超过150g/m2时,材料厚度较大,后期材料加工折叠时容易造成覆膜层破裂,导致粉尘容易透过过滤效率下降。
本发明还提供了一种新型的复合过滤材料的制备方法,主要由两个阶段构成,第一阶段:将支撑层和覆膜层进行预热处理,覆膜层表面再进行除静电处理后,支撑层、覆膜层通过热压复合方式进行贴合、定型得到新型的复合过滤材料先驱体;第二阶段:先驱体与静电微过滤层之间通过热熔胶复合得到本发明新型的复合过滤材料。为消除后期静电对材料清灰的影响,覆膜层首先进行除静电处理;支撑材和覆膜层采用热压复合方式可减小材料阻力,并且材料使用后易于除尘。静电微过滤层一般耐热性较差,并且加热对材料表面的静电荷分布影响较大。新型过滤材料先驱体与静电微过滤层之间通过热熔胶复合可消除静电微过滤层经高温加热的影响。
优选的,第一阶段中支撑层和覆膜层预热温度为50~100℃,覆膜层通过吹离子风的方法进行除静电,所述离子风的风量为80~500m3/h。热压时控制热轧温度160~200℃,压强为0.5~2MPa,热定型温度为100~150℃;第二阶段中利用PE热熔胶通过喷胶法复合,含气体吸附剂层的材料,使用热熔胶粉法复合。热压复合过程中,热轧辊温度低于160℃,压强小于0.5MPa将导致支撑层和覆膜层粘合不牢固导致分层;而温度高于200℃,压强大于2MPa时,高温导致支撑层聚合物纤维易软化或融化变形,材料大幅度收缩,加之强压力后低熔点聚合物支撑材可能发生结块或破损。此外,对于含有气体吸附剂层的本发明复合过滤材料,气体吸附剂层应位于覆膜层和静电微过滤层之间,而气体吸附剂层位于支撑材和覆膜层之间将导致使用过程中覆膜层阻挡的灰尘很难清理。并且由于气体吸附剂一般为活性炭、功能催化剂、化学反应剂等,喷胶法很难将其粘合牢固,所以气体吸附剂中需添加热熔胶粉,保证其不易掉粉脱落。
本发明的新型的复合过滤材料,其阻力分布在10~100Pa之间,过滤效率分布在75~99.999%之间。根据使用环境不同,其过滤效率要求不同。室内PM1.0颗粒物含量较多,因此本发明复合过滤材料覆膜层要求较小孔径,静电驻极熔喷无纺布也要求纤维径较细,以满足捕捉及微细尘的目的;而汽车用空调过滤器主要应对道路扬尘,主要为大量的PM10甚至更大颗粒的沙尘,所以本发明复合材料中覆膜层要求较大孔径,静电熔喷层纤维径也较大粗,以保证材料阻力较小并且不容易被大量沙尘堵塞。
本发明的有益效果是:与常规空气过滤材料相比,本发明产品在支撑层和静电微过滤层之间含有覆膜层,因此具有更高的过滤效率,并且中间覆膜层平均孔径较小,可将大部分灰尘阻挡于材料进风侧,而物理集尘性质的覆膜层的好处是灰尘的可脱离性,这样就可定期将覆膜层表面的灰尘反向吹扫倾倒或使用吸尘器进行清除,极大延长了产品的使用寿命。
附图说明
图1为本发明3层复合过滤材料截面图;
图2为本发明4层复合过滤材料截面图;
图3为本发明复合过滤材料的制备工艺流程图。
其中,1为支撑材;2为覆膜层;3为气体吸附层;4为静电驻极熔喷微过滤层。
具体实施方式
下面结合实施例对本发明进行更具体详细的说明,但本发明并不局限于实施例的范围。应当指出的是,对本领域技术来说,在不脱离本发明构思的前提下,还可以做出若干变形和改进,这些都属于本发明的保护范围。实施例中的各物性参数由下面方法测定。
【平均孔径】
使用多孔材料自动孔径测定装置Perm-Porometer(PMI),通过冒泡法算出平均孔径。测定过程中,在测定样品中任意5个地方取样得出的平均孔径均值即为材料的平均孔径。
【阻力】
参照GB6165-2008规定,在试验风速为5.33cm/s时,过滤材料前、后两侧的静压差。
【过滤效率】
参照GB6165-2008规定,在试验风速为5.33cm/s时,过滤材料对0.3μm以上聚苯乙烯乳胶球(PSL)的除去效率。即过滤材料过滤掉的PSL浓度与过滤前PSL浓度之比,单位以百分数%表示。
E=(1-A2/RA1)×100%
式中
A1—上游侧PSL浓度;
A2—下游侧PSL浓度;
R—相关系数;
E—过滤材料的过滤效率
【循环使用次数】
参照ISO-11155规定,使用人工粉尘A2粉尘进行发尘,当过滤材料终阻力达到初始阻力2倍时,停止发尘。将堆积与过滤材料覆膜层表面的粉尘抖落后,继续进行粉尘过滤试验,然后再次抖落;反复操作直到抖落粉尘后的过滤材料阻力达到初始阻力的1.5倍停止测试,累计进行试验的次数即为循环使用次数。
实施例1
首先将平均孔径为0.5μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为10μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
实施例2
首先将平均孔径为5μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为10μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
实施例3
首先将平均孔径为10μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为10μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
实施例4
首先将平均孔径为0.5μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为30μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
实施例5
首先将平均孔径为0.5μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为50μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
实施例6
首先将平均孔径为10μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为50μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
实施例7
首先将平均孔径为0.5μm的PTFE膜层和平均孔径为290μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为10μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
实施例8
首先将平均孔径为5μm的PTFE膜层和平均孔径为290μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧铺撒150g/m2的含胶粉活性炭过200℃烘箱,再与平均孔径为30μm的静电驻极PP熔喷无纺布通过热熔胶粉贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
实施例9
首先将平均孔径为0.5μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧铺撒100g/m2的含胶粉活性炭过180℃烘箱,再与平均孔径为10μm的静电驻极PP熔喷无纺布通过热熔胶粉贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
对比例1
将平均孔径为136μm的PET无纺布支撑材与平均孔径10μm的静电驻极PP熔喷无纺布复合,得到对比组过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
对比例2
首先将平均孔径为0.2μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为10μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
对比例3
首先将平均孔径为60μm的PTFE膜层和平均孔径为136μm的PET无纺布支撑材分别在90℃进行预热,然后使用300m3/h的离子风吹扫膜层表面除去静电。在热轧辊温度为180℃,压强为1MPa的条件下,将PTFE膜层通过热压法与无纺布支撑材覆合得到本发明新型的复合过滤材料先驱体;然后新型过滤材料先驱体的PTFE膜层一侧再与平均孔径为10μm的静电驻极PP熔喷无纺布通过喷胶贴合机进行复合,得到本发明新型多层复合过滤材料。测试过滤材料的阻力、过滤效率和循环使用次数。
由实施例1和实施例5,6可以看出,增加覆膜层或者静电熔喷无纺布孔径,材料阻力明显下降,并且循环使用次数增加,但是过滤效率有所下降。
由实施例1和对比例2,3可以看出,覆膜层孔径过小将影响过滤材料的阻力;而孔径过大,影响材料的循环使用次数。
由实施例8,9可知,本发明新型过滤材料可夹持少量气体吸附剂,可一定程度吸附空气中的有害气体。
Claims (1)
1.一种新型的复合过滤材料,其特征在于:至少包括支撑层、覆膜层和静电微过滤层;其中,覆膜层平均孔径主要分布在0.5~10μm之间,静电微过滤层孔径主要分布在10~50μm之间;其支撑层主要构成为玻璃纤维、或聚合物纤维、或二者混合物纤维加工而成的无纺布,支撑层平均孔径主要分布在50~300μm之间;其覆膜层主要为聚合物材质覆膜层,具体为PTFE覆膜;其静电微过滤层主要为驻极聚合物经熔喷并带电加工的无纺布,其纤维径主要分布在0.5~6.0μm之间,带电加工方式可以为水流带电或高压带电;其覆膜层和静电微过滤层之间含有气体吸附过滤层,气体吸附剂在气体吸附过滤层中的含有量分布在50~150g/m2之间;
所述的新型的复合过滤材料的制备方法,其特征在于:主要包含两个阶段:第一阶段:将支撑层和覆膜层进行预热处理,覆膜层表面再进行除静电处理后,支撑层、覆膜层通过热压复合方式进行贴合,定型得到新型的复合过滤材料先驱体;第二阶段:将先驱体与静电微过滤层之间通过热熔胶复合即可得到该复合过滤材料;
第一阶段中支撑层和覆膜层预热温度为50~100℃,控制热轧温度160~200℃,压强为0.5~2MPa,热定型温度为100~150℃;第二阶段中利用PE热熔胶通过喷胶法复合,含气体吸附剂层的材料,使用热熔胶粉法复合;
覆膜层除静电通过吹离子风的方法,所述离子风的风量为80~500m3/h。
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