CN112252085A - 耐高温的阻燃汽车空气滤纸及其制备方法和应用 - Google Patents

耐高温的阻燃汽车空气滤纸及其制备方法和应用 Download PDF

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CN112252085A
CN112252085A CN202011049911.5A CN202011049911A CN112252085A CN 112252085 A CN112252085 A CN 112252085A CN 202011049911 A CN202011049911 A CN 202011049911A CN 112252085 A CN112252085 A CN 112252085A
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刘忠
马松松
惠岚峰
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Tianjin University of Science and Technology
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Abstract

本发明属于滤纸领域，尤其是涉及一种耐高温的阻燃汽车空气滤纸及其制备方法和应用。空气滤纸包括下述重量份组分：针叶木浆30‑40份、丝光浆8‑10份、甘蔗渣浆10‑20份，维纶纤维5‑12份、聚乙烯醇纤维8‑10份、玻璃纤维8‑12份、聚丙烯腈纤维6‑10份、硼硅酸盐玻璃纤维3‑5份，纳米滑石粉1‑2份、莫来石粉2‑3份、二氧化硅1‑3份，复配苯丙乳液2‑4份，改性丙烯酸乳液2‑3份，二乙醇酰胺0.5‑0.8份、月桂醇硫酸钠0.1‑0.3份，助剂3‑5份。本发明制备的阻燃性空气滤纸透水性好，过滤强度大，孔径小，过滤精度高，耐磨性和耐高温阻燃等效果优异。

Description

耐高温的阻燃汽车空气滤纸及其制备方法和应用
技术领域
本发明属于滤纸领域，尤其是涉及一种耐高温的阻燃汽车空气滤纸及其制备方法和应用。
背景技术
发动机被称为汽车的“心脏”，滤清器扮演着汽车的“肺”的作用，能够有效过滤吸入空气中的杂质，从而降低汽车“心脏病”的发作概率，延长发动机的使用寿命。车用空气滤纸是制备空气滤清器的主要材料之一，位于发动机的进气***中，由于发动机工作时需要释放大量的热量、气缸的回火或滤清器中吸入带火星或明火的可燃物等，导致频频发生汽车发动机自燃的事故，因此要求用于空气滤清器生产的空气滤纸需要具有一定的阻燃性能。市场上，空气滤纸的阻燃持久性差，甚至无阻燃效果，所以制备具有高效阻燃且持久性好的车用空气滤纸成为一个函需解决的问题。
汽车用滤纸是汽车工业重要的过滤材料，是一种很有发展潜力的特种纸品，具有广泛发展空间：随着中国汽车工业迅速发展，大力促进了汽车滤纸新品种的需求。目前，国内厂商生产的滤纸主要以木棉、废棉、少量木浆为原料，极少使用丝光浆，在胶乳的使用上也没有选择性能较好的苯丙乳液或者丙烯酸乳液，导致生产出来的滤纸过滤效率低、容尘量低，透气度低、强度弱，给汽车正常行驶带来严重的安全隐患和能源损耗。另外，由于发动机工作时释放大量的热量、气缸的回火等原因，导致频频发生汽车发动机自燃的事故。
丝光浆是一种特殊的浆种，主要用于汽车三滤纸的生产，可大幅度的提高滤纸的透气度，提高滤纸的容尘量，但是丝光化浆的用量要求一般应占总用浆的50％，由于生产丝光化浆的成本较高，因此汽车滤清器的生产大多采用普通的木浆生产，从而导致汽车空气滤纸性能降低。
因此现有的阻燃性空气滤纸阻燃效果差，力学性能差，并且成本较高是急需解决的问题。
发明内容
本发明为了有效的解决上述背景技术中的问题，提出了一种耐高温的阻燃汽车空气滤纸及其制备方法和应用，具体技术方案如下；
一种耐高温的阻燃汽车空气滤纸，包括下述重量份组分：针叶木浆30-40份、丝光浆8-10份、甘蔗渣浆10-20份，维纶纤维5-12份、聚乙烯醇纤维8-10份、玻璃纤维8-12份、聚丙烯腈纤维6-10份、硼硅酸盐玻璃纤维3-5份，纳米滑石粉1-2份、莫来石粉2-3份、二氧化硅1-3份，复配苯丙乳液2-4份，改性丙烯酸乳液2-3份，二乙醇酰胺0.5-0.8份、月桂醇硫酸钠0.1-0.3份，助剂3-5份。
复配苯丙乳液为三聚氰胺甲醛树脂和苯丙乳液的混合物；三聚氰胺甲醛树脂与苯丙乳液的质量比为13-15:80-90。
所述改性丙烯酸乳液采用下述方式制备：在丙烯酸乳液中加入4-5wt.％磁粉、3-5wt.％氧化铝,混合加热至70-80℃，30-40分钟后冷却即得。
所述助剂为消泡剂、偶联剂、湿强剂和干强剂；所述消泡剂为丁醇或辛醇；所述湿强剂为聚酰胺-环氧氯丙烷。
本发明还包括所述的耐高温的阻燃汽车空气滤纸的制备方法，包括以下步骤：
(1)将组分量针叶木浆、丝光浆、甘蔗渣浆用瓦力打浆机打浆至20-50°SR，在打浆过程中加入组分量助剂中的消泡剂，然后再加入维纶纤维、聚乙烯醇纤维、玻璃纤维、聚丙烯腈纤维、硼硅酸盐玻璃纤维混合，打浆结束后用硫酸调节pH并加入滤水酶后制备得到混合浆料；
(2)将纳米滑石粉、莫来石粉、二氧化硅搅拌混合均匀，再加入助剂中的偶联剂，充分搅拌均匀后，静止，然后置于100-120℃条件下烘干水分，得到粉体材料；
(3)将步骤(2)制备得到的粉体材料加入步骤(1)制备的混合浆料中，在混合浆料中加入助剂中的湿强剂和干强剂，然后加入组分量二乙醇酰胺，月桂醇硫酸钠混合均匀后，加热至70-80℃，经疏解机疏解后，再磨浆，加水调节混合浆的固含量为2-3％，调好的浆料经过标准纸页成型器成型后，在0.05-0.08Mpa的真空条件下对成型后的湿纸进行抽吸脱水；
(4)将改性丙烯酸乳液和复配苯丙乳液混合后制成浸渍液，将步骤(3)制备得到的纸浸入步骤(4)制备的浸渍液中浸渍30s-1min，再用玻璃棒除去过量的浸渍液；
(5)将步骤(4)的得到的纸在150℃以上烘干，压光和整理即得本发明的耐高温的阻燃空气滤纸。
本发明还包括一种汽车滤清器，使用所述的耐高温阻燃汽车空气滤纸。
本发明还包括所述的耐高温阻燃汽车空气滤纸在汽车滤清器中的应用。
与现有技术相比，本发明的有益效果是：
(1)本发明使用磁粉和氧化铝来改性丙烯酸乳液，用三聚氰胺甲醛树脂与苯丙乳液复配后的混合液代替常规的苯丙乳液，可以大大降低阻燃剂的使用量，同时不会降低滤纸的力学性能和滤过性能。本发明将针叶木浆、丝光浆、甘蔗渣浆，维纶纤维、聚乙烯醇纤维、玻璃纤维、聚丙烯腈纤维、硼硅酸盐玻璃纤维搭配使用，将有机植物纤维和无机纤维合理的搭配，种类的增加有效的降低了整体纤维的总用量，特别是大大降低了丝光浆的用量，从而降低了阻燃空气滤纸的原料成本。
(2)本发明制备的阻燃性空气滤纸透水性好，过滤强度大，孔径小，过滤精度高，耐磨性和耐高温阻燃等效果优异。
(3)本发明通过调整原料配比和涂布两方面配合赋予空气滤纸不仅有较强的耐高温和阻燃性，还具有较高的强度和过滤精度。本滤纸制备方法省步骤少，过程简洁，容易操作，所得空气滤纸适合作为发动机的空气滤清器的滤芯使用。
具体实施方式
为了使本技术领域的人员更好地理解本发明方案，下面结合实施方式对本发明作进一步的详细说明；
实施例1、本实施例示例了一种耐高温的阻燃汽车空气滤纸，由以下重量份数的原料组成：针叶木浆35份、丝光浆9份、甘蔗渣浆18份，维纶纤维6份、聚乙烯醇纤维9份、玻璃纤维10份、聚丙烯腈纤维8份、硼硅酸盐玻璃纤维4份，纳米滑石粉1.5份、莫来石粉2.5份、二氧化硅2份，质量比为15:85的三聚氰胺甲醛树脂和苯丙乳液的混合物3份，改性丙烯酸乳液3份，二乙醇酰胺0.6份、月桂醇硫酸钠0.1份，助剂4份。
本实施例还示例了上述耐高温的阻燃汽车空气滤纸的制备方法，包括以下步骤：
(1)将针叶木浆、丝光浆、甘蔗渣浆用瓦力打浆机打浆至30°SR，在打浆过程中加入消泡剂，然后再加入组分量维纶纤维、聚乙烯醇纤维、玻璃纤维、聚丙烯腈纤维、硼硅酸盐玻璃纤维混合，打浆结束后用硫酸调节pH并加入滤水酶后制备得到混合浆料；
(2)将纳米滑石粉、莫来石粉、二氧化硅搅拌混合均匀，再加入偶联剂，充分搅拌均匀后，静止，然后置于110℃条件下烘干水分，得到粉体材料；
(3)将步骤(2)制备得到的粉体材料加入步骤(1)制备的混合浆料中，在混合浆料中加入湿强剂和干强剂，然后加入二乙醇酰胺，月桂醇硫酸钠混合均匀后，加热至75℃，经疏解机疏解后，再磨浆，加水调节混合浆的固含量为2-3％，调好的浆料经过标准纸页成型器成型后，在0.06Mpa的真空条件下对成型后的湿纸进行抽吸脱水；
(4)将改性丙烯酸乳液和质量比为15:85的三聚氰胺甲醛树脂和苯丙乳液的混合物混合后制成浸渍液，将步骤(3)制备得到的纸浸入步骤(4)制备的浸渍液中浸渍50s，再用玻璃棒除去过量的浸渍液；
(5)将步骤(4)的得到的纸在150℃以上烘干，压光和整理即得本发明的耐高温的阻燃空气滤纸。
其中，所述改性丙烯酸乳液为在丙烯酸乳液中加入4-5％磁粉、3-5％氧化铝，混合加热至70-80℃，30-40分钟后冷却即得。
所述助剂为消泡剂、偶联剂、湿强剂和干强剂的混合物，其质量比为：1.5:0.7:1.5：0.8(下同)。
所述消泡剂为丁醇；所述湿强剂为聚酰胺-环氧氯丙烷，所述偶联剂为硅烷偶联剂KH550，所述的干强剂为聚丙烯酰胺。
经检测，本实施例制得的滤纸的成纸透气度为293.5L/m2·s，最大孔径为48μm，平均孔径为28.5μm，湿伸长率为0.59％，耐破度386KPa，抗张强度为16.52kN/m，过滤精度为5.2μm，杂质去除率为99.99％。
实施例2、本实施例示例一种耐高温的阻燃汽车空气滤纸，由以下重量份数的原料组成：针叶木浆40份、丝光浆8份、甘蔗渣浆20份，维纶纤维12份、聚乙烯醇纤维8份、玻璃纤维12份、聚丙烯腈纤维6份、硼硅酸盐玻璃纤维5份，纳米滑石粉1份、莫来石粉3份、二氧化硅1份，质量比为15：85的三聚氰胺甲醛树脂和苯丙乳液的混合物3份，改性丙烯酸乳液3份，二乙醇酰胺0.5份、月桂醇硫酸钠0.3份，助剂4份。
本实施例还示例了上述耐高温的阻燃汽车空气滤纸的制备方法，包括以下步骤：
(1)将针叶木浆、丝光浆、甘蔗渣浆用瓦力打浆机打浆至20°SR，在打浆过程中加入消泡剂，然后再加入维纶纤维、聚乙烯醇纤维、玻璃纤维、聚丙烯腈纤维、硼硅酸盐玻璃纤维混合，打浆结束后用硫酸调节ph并加入滤水酶后制备得到混合浆料；
(2)将纳米滑石粉、莫来石粉、二氧化硅搅拌混合均匀，再加入偶联剂，充分搅拌均匀后，静止，然后置于110℃条件下烘干水分，得到粉体材料；
(3)将步骤(2)制备得到的粉体材料加入步骤(1)制备的混合浆料中，在混合浆料中加入湿强剂和干强剂，然后加入二乙醇酰胺，月桂醇硫酸钠混合均匀后，加热至80℃，经疏解机疏解后，再磨浆，加水调节混合浆的固含量为2-3％，调好的浆料经过标准纸页成型器成型后，在0.06Mpa的真空条件下对成型后的湿纸进行抽吸脱水；
(4)将改性丙烯酸乳液和质量比为15:85的三聚氰胺甲醛树脂和苯丙乳液的混合物混合后制成浸渍液，将步骤(3)制备得到的纸浸入步骤(4)制备的浸渍液中浸渍50s，再用玻璃棒除去过量的浸渍液；
(5)将步骤(4)的得到的纸在150℃以上烘干，压光和整理即得本发明的耐高温的阻燃空气滤纸。
经检测，本实施例制得的滤纸的成纸透气度为283L/m2·s，最大孔径为46μm，平均孔径为27.5μm，湿伸长率为0.56％，耐破度389KPa，抗张强度为15.52kN/m，过滤精度为5μm，杂质去除率为99.99％。
实施例3、本实施例示例一种耐高温的阻燃汽车空气滤纸，由以下重量份数的原料组成：针叶木浆40份、丝光浆9份、甘蔗渣浆15份，维纶纤维8份、聚乙烯醇纤维9份、玻璃纤维8-12份、聚丙烯腈纤维10份、硼硅酸盐玻璃纤维5份，纳米滑石粉1.5份、莫来石粉2.5份、二氧化硅1.5份，质量比为13：87的三聚氰胺甲醛树脂和苯丙乳液的混合物4份，改性丙烯酸乳液3份，二乙醇酰胺0.6份、月桂醇硫酸钠0.2份，助剂4份。
本实施例还示例了上述耐高温的阻燃汽车空气滤纸的制备方法，包括以下步骤：
(1)将针叶木浆、丝光浆、甘蔗渣浆用瓦力打浆机打浆至50°SR，在打浆过程中加入消泡剂，然后再加入维纶纤维、聚乙烯醇纤维、玻璃纤维、聚丙烯腈纤维、硼硅酸盐玻璃纤维混合，打浆结束后用硫酸调节ph并加入滤水酶后制备得到混合浆料；
(2)将纳米滑石粉、莫来石粉、二氧化硅搅拌混合均匀，再加入偶联剂，充分搅拌均匀后，静止，然后置于120℃条件下烘干水分，得到粉体材料；
(3)将步骤(2)制备得到的粉体材料加入步骤(1)制备的混合浆料中，在混合浆料中加入湿强剂和干强剂，然后加入二乙醇酰胺，月桂醇硫酸钠混合均匀后，加热至80℃，经疏解机疏解后，再磨浆，加水调节混合浆的固含量为2-3％，调好的浆料经过标准纸页成型器成型后，在0.06Mpa的真空条件下对成型后的湿纸进行抽吸脱水；
(4)将改性改性丙烯酸乳液和质量比为13:87的三聚氰胺甲醛树脂和苯丙乳液的混合物混合后制成浸渍液，将步骤(3)制备得到的纸浸入步骤(4)制备的浸渍液中浸渍30s，再用玻璃棒除去过量的浸渍液；
(5)将步骤(4)的得到的纸在150℃以上烘干，压光和整理即得本发明的耐高温的阻燃空气滤纸。
经检测，本实施例制得的滤纸的成纸透气度为274L/m2·s，最大孔径为47μm，平均孔径为28μm，湿伸长率为0.54％，耐破度379KPa，抗张强度为16kN/m，过滤精度为5.1μm，杂质去除率为99.99％。
实施例4、本实施例示例了一种耐高温的阻燃汽车空气滤纸，由以下重量份数的原料组成：针叶木浆38份、丝光浆10份、甘蔗渣浆19份，维纶纤维12份、聚乙烯醇纤维9份、玻璃纤维9份、聚丙烯腈纤维8份、硼硅酸盐玻璃纤维4份，纳米滑石粉1.5份、莫来石粉2.5份、二氧化硅2.5份，质量比为13：87的三聚氰胺甲醛树脂和苯丙乳液的混合物4份，改性丙烯酸乳液3份，二乙醇酰胺0.7份、月桂醇硫酸钠0.2份，助剂4份。
本实施例还示例了上述耐高温的阻燃汽车空气滤纸的制备方法，包括以下步骤：
(1)将针叶木浆、丝光浆、甘蔗渣浆用瓦力打浆机打浆至30°SR，在打浆过程中加入消泡剂，然后再加入维纶纤维、聚乙烯醇纤维、玻璃纤维、聚丙烯腈纤维、硼硅酸盐玻璃纤维混合，打浆结束后用硫酸调节ph并加入滤水酶后制备得到混合浆料；
(2)将纳米滑石粉、莫来石粉、二氧化硅搅拌混合均匀，再加入偶联剂，充分搅拌均匀后，静止，然后置于120℃条件下烘干水分，得到粉体材料；
(3)将步骤(2)制备得到的粉体材料加入步骤(1)制备的混合浆料中，在混合浆料中加入湿强剂和干强剂，然后加入二乙醇酰胺，月桂醇硫酸钠混合均匀后，加热至78℃，经疏解机疏解后，再磨浆，加水调节混合浆的固含量为2-3％，调好的浆料经过标准纸页成型器成型后，在0.06Mpa的真空条件下对成型后的湿纸进行抽吸脱水；
(4)将改性丙烯酸乳液和质量比为13:87的三聚氰胺甲醛树脂和苯丙乳液的混合物混合后制成浸渍液，将步骤(3)制备得到的纸浸入步骤(4)制备的浸渍液中浸渍30s，再用玻璃棒除去过量的浸渍液；
(5)将步骤(4)的得到的纸在150℃以上烘干，压光和整理即得本发明的耐高温的阻燃空气滤纸。
经检测，本实施例制得的滤纸的成纸透气度为291.6L/m2·s，最大孔径为49μm，平均孔径为27.6μm，湿伸长率为0.61％，耐破度390KPa，抗张强度为17.01kN/m，过滤精度为4.9μm，杂质去除率为99.99％。
实施例5、该实施例的原料与制备方法除了原料中将三聚氰胺甲醛树脂与苯丙乳液复配后的混合液替换为常规的苯丙乳液，其他与实施例1相同。经检测，本实施例制得的滤纸的成纸透气度为281.9L/m2·s，耐破度350KPa，抗张强度为13.08kN.m，过滤精度为3.7μm，杂质去除率为89.01％。
实施例6、该实施例的原料与制备方法除了原料中将使用磁粉和氧化铝来改性丙烯酸乳液替换为常规的丙烯酸乳液，其他与实施例1相同。经检测，本实施例制得的滤纸的成纸透气度为279.6L/m2·s，耐破度348KPa，抗张强度为14.01kN/m，过滤精度为2.9μm，杂质去除率为87.13％。
实施例7、该实施例的原料与制备方法除了原料中将使用磁粉和氧化铝来改性丙烯酸乳液替换为常规的丙烯酸乳液，将三聚氰胺甲醛树脂和苯丙乳液的混合物替换为常规的苯丙乳液，其他与实施例1相同。经检测，本实施例制得的滤纸的成纸透气度为269.9L/m2·s，耐破度339KPa，抗张强度为12.98kN/m，过滤精度为2.6μm，杂质去除率为86.52％。
由实施例5、6、7可以看出，虽然仅仅是将本发明的改性丙烯酸乳液替换为常规的丙烯酸乳液或/和将本发明的三聚氰胺甲醛树脂与苯丙乳液复配后的混合液代替常规的苯丙乳液，其他的组分以及制备方法不变，但是制备得到的滤纸的力学性能和滤过性能是远远不如本发明实施例1中的结果，由此看见，本发明的技术方案是非显而易见的，并且产生了意想不到的技术效果。
以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为发明的保护范围。

Claims (7)

1.一种耐高温的阻燃汽车空气滤纸，其特征在于，包括下述重量份组分：针叶木浆30-40份、丝光浆8-10份、甘蔗渣浆10-20份，维纶纤维5-12份、聚乙烯醇纤维8-10份、玻璃纤维8-12份、聚丙烯腈纤维6-10份、硼硅酸盐玻璃纤维3-5份，纳米滑石粉1-2份、莫来石粉2-3份、二氧化硅1-3份，复配苯丙乳液2-4份，改性丙烯酸乳液2-3份，二乙醇酰胺0.5-0.8份、月桂醇硫酸钠0.1-0.3份，助剂3-5份。
2.根据权利要求1所述的耐高温的阻燃汽车空气滤纸，其特征在于，复配苯丙乳液为三聚氰胺甲醛树脂和苯丙乳液的混合物；三聚氰胺甲醛树脂与苯丙乳液的质量比为13-15:80-90。
3.根据权利要求1所述的耐高温的阻燃汽车空气滤纸，其特征在于，所述改性丙烯酸乳液采用下述方式制备：在丙烯酸乳液中加入4-5wt.％磁粉、3-5wt.％氧化铝,混合加热至70-80℃，30-40分钟后冷却即得。
4.如权利要求1所述的耐高温的阻燃汽车空气滤纸，其特征是：所述助剂为消泡剂、偶联剂、湿强剂和干强剂；所述消泡剂为丁醇或辛醇；所述湿强剂为聚酰胺-环氧氯丙烷。
5.权利要求1-4任一所述的耐高温的阻燃汽车空气滤纸的制备方法，其特征是：包括以下步骤：
(1)将组分量针叶木浆、丝光浆、甘蔗渣浆用瓦力打浆机打浆至20-50°SR，在打浆过程中加入组分量助剂中的消泡剂，然后再加入维纶纤维、聚乙烯醇纤维、玻璃纤维、聚丙烯腈纤维、硼硅酸盐玻璃纤维混合，打浆结束后用硫酸调节pH并加入滤水酶后制备得到混合浆料；
(2)将纳米滑石粉、莫来石粉、二氧化硅搅拌混合均匀，再加入助剂中的偶联剂，充分搅拌均匀后，静止，然后置于100-120℃条件下烘干水分，得到粉体材料；
(3)将步骤(2)制备得到的粉体材料加入步骤(1)制备的混合浆料中，在混合浆料中加入助剂中的湿强剂和干强剂，然后加入组分量二乙醇酰胺，月桂醇硫酸钠混合均匀后，加热至70-80℃，经疏解机疏解后，再磨浆，加水调节混合浆的固含量为2-3％，调好的浆料经过标准纸页成型器成型后，在0.05-0.08Mpa的真空条件下对成型后的湿纸进行抽吸脱水；
(4)将改性丙烯酸乳液和复配苯丙乳液混合后制成浸渍液，将步骤(3)制备得到的纸浸入步骤(4)制备的浸渍液中浸渍30s-1min，再用玻璃棒除去过量的浸渍液；
(5)将步骤(4)的得到的纸在150℃以上烘干，压光和整理即得本发明的耐高温的阻燃空气滤纸。
6.一种汽车滤清器，其特征在于，使用权利要求1-4任一所述的耐高温阻燃汽车空气滤纸。
7.权利要求1-4任一所述的耐高温阻燃汽车空气滤纸在汽车滤清器中的应用。
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