CN111686517A - 一种长效高精度覆膜滤料及其制备方法 - Google Patents

一种长效高精度覆膜滤料及其制备方法 Download PDF

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CN111686517A
CN111686517A CN202010497779.8A CN202010497779A CN111686517A CN 111686517 A CN111686517 A CN 111686517A CN 202010497779 A CN202010497779 A CN 202010497779A CN 111686517 A CN111686517 A CN 111686517A
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ptfe
fiber layer
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徐玉康
吴飞
寇婉婷
杨旭红
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Suzhou Hailan Environmental Protection Technology Co ltd
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Abstract

本发明公开了一种长效高精度覆膜滤料及其制备方法，覆膜滤料结构自上而下依次为PTFE微孔膜、PTFE纤维层、PET纤维层、PTFE扁平长丝基布层和PET纤维层；其制备方法先将PET纤维层铺设于PTFE扁平长丝基布层两侧获得复合纤维层，再用预针刺工艺加固获得非织造预针刺毡；再将PTFE纤维层铺置于非织造预针刺毡表面、采用高压水射流冲击PTFE纤维使其缠结于非织造预针刺毡；接着针刺、超喂热定型工艺处理表面带有PTFE纤维层的非织造预针刺毡；最后热压覆合工艺将PTFE微孔膜粘附于PTFE纤维层以制备本发明覆膜滤料。整个覆膜滤料机械力学性能好、覆膜牢度高、过滤效率高、过滤精度高。

Description

一种长效高精度覆膜滤料及其制备方法
技术领域
本发明涉及一种长效高精度覆膜滤料及其制备方法，属于覆膜滤料生产技术领域。
背景技术
传统静电除尘***无法满足烟尘排放新标准，覆膜滤料因具有较高的过滤效率(≥98％)、良好的化学和热稳定性等特点而使其在工业烟尘过滤领域的使用量快速增加。覆膜滤料在燃煤电厂和钢铁行业的使用率分别超过40％、90％。
然而，在实际工程应用中，覆膜滤料的有效工作时长一般低于3年，滤料使用效率较低、资源浪费严重，提高覆膜滤料的使用寿命是工业除尘行业急需解决的问题。覆膜滤料表面的高聚物膜为PTFE微孔膜，PTFE 极好的化学和热稳定性使其在化学成分复杂、温度高、腐蚀性强的工业烟尘中保持结构和性能稳定。PTFE微孔膜中含有大量原纤，其在含尘气流的冲击作用下，原纤断裂、微孔膜表面形成宏观孔洞，致使滤料失效。增加PTFE微孔膜尺寸稳定性、降低含尘气流对PTFE微孔膜的冲击作用强度是提高覆膜滤料使用寿命的有效方法。目前用于覆膜滤料的PTFE微孔膜的厚度一般低于10μm，增加PTFE微孔膜厚度，在一定程度上能够改善PTFE微孔膜的刚性、提供PTFE微孔膜的尺寸稳定性，但厚型PTFE微孔膜透气性能差，无法满足实际工况要求。
专利CN103877789A公开了一种利用水刺加固技术制备玻纤PPS复合水刺毡覆膜滤料，该专利在PTFE微孔膜与主体滤料间嵌入一层PPS纤维附着层，采用水刺工艺将PPS纤维附着层与复合纤维层以及基布层同时加固。但是，相较于针刺加固，水刺加固作用强度较低，在这种情况下，滤料内纤维缠结度低、滤料机械力学性能较差。另外，在水针的冲击作用下，PPS纤维附着层中大量PPS纤维进入滤料内部，降低含尘气体对 PTFE微孔膜冲击作用的强度比较有限。
专利CN108057279A公开了一种聚四氟乙烯覆膜滤料及其制备方法，该专利采用在针刺毡表面涂覆一层含氟聚物的粘合剂以提高PTFE微孔膜与针刺毡的覆合牢度。然而，含氟聚合物水溶液粘合剂难以均匀涂覆于针刺毡表面，对于PTFE微孔膜的粘附牢度的提高程度有限。
因此，提高覆膜滤料中PTFE微孔膜尺寸稳定性、降低含尘气流对 PTFE微孔膜冲击作用强度，仍是目前提高覆膜滤料有效工作时长的途径。
发明内容
本发明所要解决的技术问题是：提供一种长效高精度覆膜滤料及其制备方法，该制备方法制作的覆膜滤料使用寿命长，覆膜牢度更强，过滤效率以及过滤精度更高。
为解决上述技术问题，本发明的技术方案是：一种长效高精度覆膜滤料，其自上而下依次包括PTFE微孔膜、PTFE纤维层、PET纤维层、 PTFE扁平长丝基布层和PET纤维层，所述PTFE微孔膜、PTFE纤维层、 PET纤维层、PTFE扁平长丝基布层和PET纤维层通过针刺加固成型。
其中优选的，PTFE纤维长度为50～80mm，PTFE纤维线密度为 1～20dtex，PTFE纤维层面密度为100～300g/m2。
其中优选的，PET纤维长度为50～70mm，PET纤维线密度为2～4dtex， PET纤维层面密度为100～300g/m2。
其中优选的，PTFE扁平长丝线密度为350～600dtex，PTFE扁平长丝基布层的面密度为100～200g/m2。
其中优选的，该长效高精度覆膜滤料的面密度为500～750g/m2。
另外，一种长效高精度覆膜滤料的制备方法，其步骤包括：
步骤一：制备PTFE纤维层，该纤维层采用长度和线密度分别为50～80mm、1～20dtex的PTFE纤维经梳理获得PTFE纤维层；
步骤二：制备PET纤维层，该纤维层采用长度和线密度分别为 50～70mm、2～4dtex的PET纤维经梳理交叉铺网获得PET纤维层；
步骤三：制备PTFE扁平长丝基布层，采用线密度为350～600dtex的 PTFE扁平长丝经编织加工获得平纹组织的PTFE扁平长丝基布层，面密度为100～200g/m2；
步骤四：预针刺缠结，将PET纤维层置于PTFE扁平长丝基布层两侧，形成结构为“PET纤维层-PTFE扁平长丝基布层-PET纤维层”复合纤维层，通过预针刺工艺缠结加固获得非织造预针刺毡；
步骤五：水刺缠结，将PTFE纤维层铺置于上述非织造针刺毡表面，通过高压水针冲击使PTFE纤维再次***、形成线密度更低的纤维，同时水针使PTFE纤维嵌入非织造预针刺毡；
步骤六：针刺加固，将上述表面带有PTFE纤维层的非织造预针刺毡喂入主针刺机构，通过主针刺工艺缠结加固而获得非织造滤毡；
步骤七：热定型，将上述非织造滤毡喂入超喂热定型机构，通过超量喂入、高温软化处理而获得致密性好的非织造滤毡；
步骤八：后处理，将上述经热定型后的非织造滤毡经烧毛、轧光；
步骤九：热粘合覆膜，将PTFE微孔膜铺置于带有PTFE纤维层的非织造滤毡表面，再经高温轧辊作用使得PTFE微孔膜覆于非织造滤毡表面，制成覆膜滤料。
其中，其特征在于：所述步骤五的水刺缠结工艺，水射流的压力为60～250bar，水射流直径为0.08～0.12mm，水射流冲击道数为3～10道；所述步骤九的PTFE微孔膜的孔径分布为0.5～3.5μm，微孔膜厚度为 3.0～10.0μm；所述步骤九的覆膜温度为300～380℃。
采用了上述技术方案后，本发明的效果是：本发明利用PTFE纤维易***特点，结合水射流刚性冲击作用，PTFE纤维在水射流冲击作用下发生***形成线密度更低的PTFE纤维，同时，水射流的缠结作用使低线密度PTFE纤维刺入非织造预针刺毡，表面层带有PTFE纤维层的非织造预针刺毡再经主针刺加固而获得目标非织造滤毡；该非织造滤毡表面含低线密度PTFE纤维层，其再经超喂热定型工艺处理，PTFE纤维层致密性增加，进一步提高非织造滤毡对亚微米尺度固体颗粒的捕捉能力；在非织造滤毡的PTFE纤维层上覆合一层PTFE微孔膜，通过热粘合覆膜技术制备获得一种覆膜滤料，PTFE纤维层与PTFE微孔膜的粘结牢度高于其他纤维与PTFE微孔膜，该覆膜滤料具有机械力学性能好、覆膜牢度高、过滤效率高、过滤精度高、使用寿命长等特点。
附图说明
下面结合附图和实施例对本发明进一步说明。
图1为长效高精度覆膜滤料结构示意图；
图1中，1-PTFE微孔膜，2-PTFE纤维层，3-PET纤维层，4-PTFE 基布层，5-PET纤维层。
具体实施方式
下面通过具体实施例对本发明作进一步的详细描述。
实施例1
如图1所示，本发明公开了一种长效高精度覆膜滤料，其结构自上而下依次包括PTFE微孔膜1、PTFE纤维层2、PET纤维层3、PTFE扁平长丝基布层4和PET纤维层5；PTFE纤维长度为50～80mm，PTFE 纤维线密度为1～20dtex，PTFE纤维层1面密度为100～300g/m2；PET纤维长度为50～70mm，PET纤维线密度为2～4dtex，PET纤维层3和PET 纤维层5面密度为100～300g/m2；PTFE扁平长丝线密度为350～600dtex， PTFE扁平长丝基布层4的面密度为100～200g/m2；该长效高精度覆膜滤料最终产品的面密度为500～750g/m2。
实施例2
本实施例公开了长效高精度覆膜滤料的制备方法，具体步骤为：
步骤一：采用上述规格的PTFE纤维，并将其梳理获得PTFE纤维层2；
步骤二：采用上述规格的PET纤维，并将其梳理交叉铺网获得PET 纤维层3和PET纤维层5；
步骤三：采用上述规格的PTFE扁平长丝，其经编织加工获得平纹组织的PTFE扁平长丝基布层4；
步骤四：预针刺缠结，将PET纤维层3和PET纤维层5置于PTFE 扁平长丝基布层4两侧，形成结构为“PET纤维层-PTFE扁平长丝基布 -PET纤维层”复合纤维层，通过预针刺工艺缠结加固获得非织造预针刺毡；
步骤五：水刺缠结，将PTFE纤维层2铺置于上述非织造预针刺毡表面，通过高压水射流冲击PTFE纤维层3～10次以使低线密度PTFE纤维嵌入非织造预针刺毡；其中，水射流的压力为60～250bar，水射流直径为0.08～0.12mm；
步骤六：针刺加固，将上述表面带有PTFE纤维层2的非织造预针刺毡喂入主针刺机，通过主针刺工艺缠结加固而获得非织造滤毡；
步骤七：热定型，将上述非织造滤毡喂入超喂热定型机构，喂入和输出速度分别为8.2m/min和8.0m/min，热定型温度为150℃，通过超量喂入、高温软化处理而获得致密性好的非织造滤毡；
步骤八：后处理，将上述经热定型后的非织造滤毡经烧毛、轧光等后处理；
步骤九：热粘合覆膜，将PTFE微孔膜1铺置于带有PTFE纤维层2 的非织造滤毡表面，再经高温轧辊作用使得PTFE微孔膜1覆于非织造滤毡表面，制成本发明产品；其中，PTFE微孔膜1的孔径分布为 0.5～3.5μm，PTFE微孔膜1厚度为3.0～10.0μm；覆膜温度为250～350℃。
实施例3
本实施例中，选取了不同参数的纤维和工艺参数按照实施例2的制作方法制备出实施例1中的覆膜滤料。
首先制备PTFE纤维层2、PET纤维层3和PET纤维层5，采用长度和线密度分别为80mm、20dtex的PTFE纤维经梳理获得PTFE纤维层 2，其面密度为300g/m2；采用长度和线密度分别为70mm、4dtex的PET 纤维经梳理交叉铺网获得PET纤维层3和PET纤维层5，PET纤维层3 和5的面密度均为300g/m2；再制备PTFE扁平长丝基布4，采用线密度为600dtex的PTFE扁平长丝经编织加工获得平纹组织的PTFE扁平长丝基布层4，面密度为150g/m2；
接着将PET纤维层3和PET纤维层5置于PTFE扁平长丝基布层4 两侧，形成结构为“PET纤维层-PTFE扁平长丝基布-PET纤维层”复合纤维层，并将其喂入预针刺机、获得非织造预针刺毡；再将PTFE纤维层 2铺置于该非织造预针刺毡表面，采用压力为250bar、直径为0.12mm 的高压水射流冲击PTFE纤维层2，冲击道数为5道；再将经水射流冲击、表面带有PTFE纤维层2的非织造预针刺毡喂入主针刺机，通过主针刺工艺缠结加固而获得非织造滤毡；
再接着将经主针刺加固的非织造滤毡喂入超喂热定型机，喂入和输出速度分别为8.2m/min和8.0m/min，热定型温度为150℃，通过超量喂入而获得致密性好的非织造滤毡；再对热定型后的非织造滤毡进行烧毛、轧光等后处理；
最后，将PTFE微孔膜1铺置于带有PTFE纤维层2、经热定型和后处理的非织造滤毡表面，温度为340℃压辊作用于平均孔径为3.5μm、厚度为4μm的PTFE微孔膜1使其与PTFE纤维层2粘合，进而获得机械力学性能好、覆膜牢度高、过滤效率高、过滤精度高、使用寿命长的覆膜滤料。
实施例4
本实施例中，选取了不同参数的纤维和工艺参数按照实施例2的制作方法制备出实施例1中的覆膜滤料。
首先制备PTFE纤维层2、PET纤维层3和PET纤维层5，采用长度和线密度分别为60mm、10dtex的PTFE纤维经梳理获得PTFE纤维层 2，其面密度为200g/m2；采用长度和线密度分别为65mm、2.7dtex的PET纤维经梳理交叉铺网获得PET纤维层3和PET纤维层5，PET纤维层3和5的面密度均为180g/m2；再制备PTFE扁平长丝基布4，采用线密度为450dtex的PTFE扁平长丝经编织加工获得平纹组织的PTFE扁平长丝基布层4，面密度为120g/m2；
接着将PET纤维层3和PET纤维层5置于PTFE扁平长丝基布层4 两侧，形成结构为“PET纤维层-PTFE扁平长丝基布-PET纤维层”复合纤维层，并将其喂入预针刺机、获得非织造预针刺毡；再将PTFE纤维层 2铺置于该非织造预针刺毡表面，采用压力为150bar、直径为0.1mm的高压水射流冲击PTFE纤维层2，冲击道数为4道；再将经水射流冲击、表面带有PTFE纤维层2的非织造预针刺毡喂入主针刺机，通过主针刺工艺缠结加固而获得非织造滤毡；
再接着将经主针刺加固的非织造滤毡喂入超喂热定型机，喂入和输出速度分别为8.2m/min和8.0m/min，热定型温度为150℃，通过超量喂入而获得致密性好的非织造滤毡；再对热定型后的非织造滤毡进行烧毛、轧光等后处理；
最后，将PTFE微孔膜1铺置于带有PTFE纤维层2、经热定型和后处理的非织造滤毡表面，温度为340℃压辊作用于平均孔径为2.0μm、厚度为4μm的PTFE微孔膜1使其与PTFE纤维层2粘合，进而获得机械力学性能好、覆膜牢度高、过滤效率高、过滤精度高、使用寿命长的覆膜滤料。
以上所述实施例仅是对本发明的优选实施方式的描述，不作为对本发明范围的限定，在不脱离本发明设计精神的基础上，对本发明技术方案作出的各种变形和改造，均应落入本发明的权利要求书确定的保护范围内。

Claims (7)

1.一种长效高精度覆膜滤料，其特征在于：其自上而下依次包括PTFE微孔膜、PTFE纤维层、PET纤维层、PTFE扁平长丝基布层和PET纤维层，所述PTFE微孔膜、PTFE纤维层、PET纤维层、PTFE扁平长丝基布层和PET纤维层通过针刺加固成型。
2.如权利要求1所述的长效高精度覆膜滤料，其特征在于：PTFE纤维长度为50～80mm，PTFE纤维线密度为1～20dtex，PTFE纤维层面密度为100～300g/m2。
3.如权利要求1所述的长效高精度覆膜滤料，其特征在于：PET纤维长度为50～70mm，PET纤维线密度为2～4dtex，PET纤维层面密度为100～300g/m2。
4.如权利要求1所述的长效高精度覆膜滤料，其特征在于：PTFE扁平长丝线密度为350～600dtex，PTFE扁平长丝基布层的面密度为100～200g/m2。
5.如权利要求1所述的一种长效高精度覆膜滤料，其特征在于：该长效高精度覆膜滤料的面密度为500～750g/m2。
6.一种长效高精度覆膜滤料的制备方法，其步骤包括：
步骤一：制备PTFE纤维层，该纤维层采用长度和线密度分别为50～80mm、1～20dtex的PTFE纤维经梳理获得PTFE纤维层；
步骤二：制备PET纤维层，该纤维层采用长度和线密度分别为50～70mm、2～4dtex的PET纤维经梳理交叉铺网获得PET纤维层；
步骤三：制备PTFE扁平长丝基布层，采用线密度为350～600dtex的PTFE扁平长丝经编织加工获得平纹组织的PTFE扁平长丝基布层，面密度为100～200g/m2；
步骤四：预针刺缠结，将PET纤维层置于PTFE扁平长丝基布层两侧，形成结构为“PET纤维层-PTFE扁平长丝基布层-PET纤维层”复合纤维层，通过预针刺工艺缠结加固获得非织造预针刺毡；
步骤五：水刺缠结，将PTFE纤维层铺置于上述非织造针刺毡表面，通过高压水针冲击使PTFE纤维再次***、形成线密度更低的纤维，同时水针使PTFE纤维嵌入非织造预针刺毡；
步骤六：针刺加固，将上述表面带有PTFE纤维层的非织造预针刺毡喂入主针刺机构，通过主针刺工艺缠结加固而获得非织造滤毡；
步骤七：热定型，将上述非织造滤毡喂入超喂热定型机构，通过超量喂入、高温软化处理而获得致密性好的非织造滤毡；
步骤八：后处理，将上述经热定型后的非织造滤毡经烧毛、轧光；
步骤九：热粘合覆膜，将PTFE微孔膜铺置于带有PTFE纤维层的非织造滤毡表面，再经高温轧辊作用使得PTFE微孔膜覆于非织造滤毡表面，制成覆膜滤料。
7.如权利要求6所述的一种长效高精度覆膜滤料的制备方法，其特征在于：所述步骤五的水刺缠结工艺，水射流的压力为60～250bar，水射流直径为0.08～0.12mm，水射流冲击道数为3～10道；所述步骤九的PTFE微孔膜的孔径分布为0.5～3.5μm，微孔膜厚度为3.0～10.0μm；所述步骤九的覆膜温度为300～380℃。
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