CN112921500B - Method for manufacturing superfine fiber spunlace non-woven fabric filter material - Google Patents
Method for manufacturing superfine fiber spunlace non-woven fabric filter material Download PDFInfo
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- CN112921500B CN112921500B CN202110071955.6A CN202110071955A CN112921500B CN 112921500 B CN112921500 B CN 112921500B CN 202110071955 A CN202110071955 A CN 202110071955A CN 112921500 B CN112921500 B CN 112921500B
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4382—Stretched reticular film fibres; Composite fibres; Mixed fibres; Ultrafine fibres; Fibres for artificial leather
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M10/00—Physical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. ultrasonic, corona discharge, irradiation, electric currents, or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements
- D06M10/02—Physical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. ultrasonic, corona discharge, irradiation, electric currents, or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements ultrasonic or sonic; Corona discharge
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- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/16—Synthetic fibres, other than mineral fibres
- D06M2101/30—Synthetic polymers consisting of macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
- D06M2101/32—Polyesters
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- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2505/00—Industrial
- D10B2505/04—Filters
Abstract
The invention provides a method for manufacturing a superfine fiber spunlace non-woven fabric filter material, which comprises the following steps: (1) preparing raw materials; (2) melt spinning; (3) processing fibers; (4) carding to form a net; (5) carrying out spunlace reinforcement; (6) rolling by using a smooth roller; (7) heating and drying; (8) performing electret treatment; (9) and (6) coiling the finished product. The nano electret powder and resin are uniformly mixed and spun to prepare short fibers, and the short fibers are subjected to spunlace reinforcement and electret processes, so that the obtained superfine fiber spunlace non-woven fabric filter material has good filtering efficiency, lower gas resistance and higher mechanical tensile strength, the filtering performance of the filter material cannot be attenuated due to the change of the external environment, and the filter material is suitable for manufacturing various filter materials for industrial dust removal, protective clothing and protective masks and meets the requirement of efficiently purifying air.
Description
Technical Field
The invention relates to the technical field of non-woven fabrics, in particular to a manufacturing method of a superfine fiber spunlace non-woven fabric filter material.
Background
With the rapid development of social economy, the industrialization scale is continuously enlarged, and meanwhile, the problem of increasingly worsened air pollution is brought. Among them, fine particulate matters (PM2.5, PM1.0, etc.) are not only the most complicated air pollutants, but also the most harmful particulate pollutants to the human body, and have seriously affected the physical and mental health of people. Nonwoven filter materials have been widely used in the air filtration industry due to their short processing flow and low cost. Nonwoven materials currently used in air filtration are primarily spunbond materials, needle punched materials, through air blown materials, meltblown materials, electrospun materials, and combinations thereof.
The traditional air filtering material is mainly made of terylene or polypropylene staple fiber insulating materials which are easy to accumulate static electricity, and in order to ensure the fiber spinnability requirement in the carding process, a certain amount of oil is added in the production process of staple fibers to ensure the cohesive force and charge neutralization among the fibers. The fineness of the fiber is generally micron-sized, the diameter of the fiber is large, and the pore diameter between the fibers is large, so the filtering efficiency is low. And before electret treatment, the oil agent needs to be removed, otherwise, the stability of the charge is not facilitated.
The superfine fiber has larger specific surface area and proper pores, can adsorb, capture and obstruct solid particles in the air, and becomes an excellent filtering material. At present, the superfine fiber non-woven fabrics which are applied in the field of air filtration are melt-blown non-woven fabrics and electrostatic spinning materials. The electrostatic spinning material has very thin fibers, the diameter of the fibers reaches the nanometer level, but the technology cannot meet the requirement of commercial application due to low production efficiency, and the material strength is low, so that base cloth which can provide necessary mechanical strength for the material is required to be used in a composite way; the special high-melt-index polypropylene resin for the melt-blown non-woven fabric is subjected to high-speed high-temperature hot air stretching to obtain superfine fibers with the diameter of 1-10 mu m, and the superfine fibers have the characteristics of small fiber diameter, large specific surface area, high porosity, small filtration resistance and the like.
In the prior art, a method for manufacturing a filter material by using a spunlace nonwoven production process is disclosed in patent CN201610020275.0, and specifically, any two of polyester, polyamide and polyethylene are used as raw materials for mechanical energy composite spinning, a spunbond web with a large linear density difference of two fibers is obtained by controlling the air flow drafting pressure, the two webs are lapped and subjected to multi-channel spunlace fiber opening and consolidation to form the final superfine fiber nonwoven filter material, the material only depends on compact pore size to intercept particulate matters, the filter efficiency is only about 30%, and the defect that the smaller the pore size is, the larger the filter resistance is, is not in accordance with the use requirement of high-efficiency filtration. Patent CN201520841416.6 provides a orange segment type split fiber surface course dacron water thorn filter felt, still is a combined material, is applied to flue gas waste gas and filters, through the mode of gradient filtration, can catch PM2.5 granule, nevertheless only relies on the filter media aperture size of simplicity to carry out physics interception and filters, and is general to particulate matter (like about 0.3M granule) filter effects such as tiny dust.
Therefore, in order to meet the requirement of fine particles in air filtration, the development of a non-woven fabric filter material which has high efficiency, low resistance, high strength and easy industrialization is urgently needed.
Disclosure of Invention
The present invention is directed to a spunlace nonwoven fabric for air filtration, which solves the above problems of the prior art.
In order to achieve the purpose, the technical scheme of the invention is as follows: a spunlace non-woven fabric for air filtration,
(1) preparing raw materials: two resin components of polypropylene (PP) and Polyester (PET) are selected, the nano tourmaline powder can be respectively added in an atomizing spraying mode by using an ultrasonic spraying machine, the nano tourmaline powder can be uniformly dispersed in the resin, the mixing distribution is more uniform, the adding amount of the nano tourmaline powder is less, the cost can be remarkably saved, and the pore plate is difficult to block in the later stage. Wherein, the PET resin needs to be dried before the nano tourmaline powder is added.
(2) Melt spinning: the two components respectively enter two sets of melting components, namely a screw extruder, and the two components are heated, softened, melted and then sent to a metering pump, two polymer melts extruded quantitatively are fed into the same spinneret orifice of an orange petal type spinneret plate and extruded to prepare orange petal type PP/PET composite fibers; the orange petal type composite fiber is easy to disperse when being subjected to external force, and superfine fiber is easy to obtain;
(3) fiber processing: sequentially cooling, oiling, drafting, curling, loosening and shaping the PP/PET composite fibers, and cutting the PP/PET composite fibers to obtain PP/PET composite short fibers;
(4) carding to form a net: the PP/PET composite short fibers are subjected to opening and loosening and carding by needle teeth of a carding machine to be in a single fiber parallel and straight state, and a fiber web output by the carding machine is perpendicular to a lapping machine to do reciprocating motion and is lapped in a cross lapping mode and then is drafted to form a fiber web with a certain thickness;
(5) and (3) spunlacing and reinforcing: the fiber web is pre-wetted and then enters a spunlace machine, PP/PET composite short fibers in the fiber web are split into superfine fibers under the impact of multiple high-pressure water jets and are intertwined with each other to form wet spunlace nonwoven fabric, and the wet spunlace nonwoven fabric is pre-dewatered through a suction cavity to realize first fiber opening;
(6) smooth rolling: the wet spunlace non-woven fabric is further dehydrated and opened through rolling and pressing by two rollers, so that second opening is realized;
(7) heating and drying: the rolled spunlaced nonwoven fabric enters a hot air penetrating type dryer to completely remove moisture;
(8) performing electret treatment: the dried spunlace nonwoven fabric is subjected to strong electric field action of a high-voltage electrostatic generator for 1-2 times to store electric charges ionized from air in the superfine fibers so as to generate an electret effect;
(9) and (3) coiling a finished product: and rolling at a set speed to obtain the finished product of the superfine fiber spunlace nonwoven fabric filter material.
Preferably, the mass percentage of the nano tourmaline powder in the step (1) in each resin component is 0.3-0.8%, the particle size of the nano tourmaline powder is 200-800 nm, which can be 200-450 nm, 460-550 nm, 560-700 nm, etc., and the nano tourmaline is easy to agglomerate into aggregates when the particle size is too small. The existence of agglomeration phenomenon enlarges the particle size of the tourmaline, has great influence on a melt-blown spinning web forming process after being blended with a polymer, and the adhesion pore plate is easy to block by the excessively small particle size.
Preferably, the drying treatment of the PET resin in the step (1) requires: drying the mixture for 7 to 10 hours in hot air at the temperature of 160 to 170 ℃ to reduce the water content of the mixture from 0.4 percent to below 0.01 percent.
Preferably, the extrusion temperature of the screw extruder in the step (2) is 250-260 ℃ for the PP component and 280-290 ℃ for the PET component respectively.
Preferably, the diameter of the spinneret orifice in the step (2) is 0.2-0.5 mm.
Preferably, in the orange petal type PP/PET composite fiber in the step (2), PP and PET resins are selected as two different components, and the interface between the two components is favorable for splitting the fiber under the action of mechanical external force such as spunlace and the like. Wherein the PP component accounts for 50-70% by mass, and the PET component accounts for 30-50% by mass.
Preferably, the orange-petal PP/PET composite fiber extruded from the spinneret plate in the step (3) has 16 petals or 32 petals.
Preferably, the oiling treatment in the step (3) is performed to increase cohesive force among fibers in the opening and carding process and reduce friction static, and the oiling rate is 0.5-1.0% of the weight of the fibers.
Preferably, the orange-peel PP/PET composite staple fibers processed in the step (3) have fineness of 2.0-2.5D and length of 38-51 mm.
Preferably, the spunlace machine in the step (5) consists of 5-7 spunlace heads, the distribution trend of spunlace pressure is low-high-low, the highest spunlace pressure is controlled at 15-18 MPa, and the lowest spunlace pressure is controlled at 4-5 MPa.
Preferably, the fiber web in the step (5) is formed by orange-peel PP/PET composite short fibers, comprises two mutually incompatible polymer components, has weak adhesion force, can be easily split under the impact of external forces such as water power and the like, requires the splitting rate to reach at least 70%, and ensures that the cloth surface is soft, fine, uniform and compact.
Preferably, the line pressure of the calendering roller in the step (6) is 120-300N/cm, preferably 150-230N/cm, the two fibers can be separated, the fiber opening effect is realized, and the spunlace pinholes can be modified.
Preferably, the temperature of the dryer in the step (7) is set to be 150-165 ℃.
Preferably, the high-voltage electrostatic generator in the step (8) has a strong electric field voltage of 10-60 kV.
Preferably, the winding speed in the step (9) is controlled to be 30-50 m/min.
Preferably, the basis weight of the non-woven fabric filter material in the step (9) is 50-100 g/m 2 。
The invention discloses a superfine fiber spunlace non-woven fabric filter material which is prepared by the method.
Compared with the prior art, the invention has the beneficial effects that:
(1) the superposition filtering is more efficient: the invention comprehensively utilizes the characteristics that PP and PET are non-water-absorbing insulating materials and are easy to accumulate charges, electret powder components capture and store the charges, superfine fibers have unique capillary structures and increase the number and the surface area of the fibers in unit area, and the like, and additive components are added into resin components and are subjected to electret treatment, so that the comprehensive filtration effect is greatly improved and can reach more than 90 percent after the electrostatic adsorption effect of a superimposed material is intercepted by considering the compact pore diameter of a nanometer, and the defect that the filtration effect of a pure physical interception filtration mode on fine particles is poor and is only 20 to 40 percent is overcome.
(2) The electret distribution is more uniform: the raw materials are added with the nano tourmaline powder in an ultrasonic atomization spraying mode, the powder is uniformly blown out and sprayed out by the air-entrapping air pressure of 0.1-0.3 mu pa and uniformly falls into the resin, the technical problems that the mixture is easy to agglomerate and sink when stirred and adheres to equipment pipelines and the like in the prior art are solved, and the electret effect is more stable.
(3) The invention adopts a mode of directly adding the nano tourmaline into the resin, the addition amount of the nano tourmaline is controllable, and the nano tourmaline can be dispersed in two resin components in a spraying mode, thereby avoiding the problems that the peel layer is damaged to generate dust and part of master batches are lost to cause uneven distribution after the fiber is subjected to mechanical striking treatment such as opening, carding and the like by directly adding the finished electret master batches into the peel layer in the prior art, the electret master batches are directly treated after lapping and hot air strengthening processes, and the oiling agent applied to the surface of the fiber causes the dissipation of the added charges, thereby ensuring the stability of the charges of the non-woven fabric, and the filtering efficiency reaches or even exceeds the use requirement.
(4) The double fiber opening is more sufficient: the diameter of a spunlace consolidation water spraying hole is 0.10-0.12 mm, a row of water needle holes with similar sizes are longitudinally formed on the surface of the spunlace nonwoven fabric to influence the intercepting and filtering effect of the spunlace nonwoven fabric on fine particles, the fiber opening rate is further improved by adding a smooth roll rolling treatment process and adjusting the pressure of a roller, so that the water needle holes on the surface of the spunlace nonwoven fabric are filled, and the pores among materials are smaller. Meanwhile, the rolling process also reduces the water content of the material, is beneficial to improving the drying efficiency, and saves energy and reduces consumption. The invention adds a smooth roll rolling process after the spunlace reinforcement, and realizes the second fiber opening by controlling the rolling pressure so as to reduce the material pores.
(4) The charge stability is better: because the residual oil agent in the short fiber production process influences the stability of the charge after electret treatment, the method can wash away the oil agent by using high-pressure water jet during spunlace reinforcement, does not need to additionally increase post-treatment procedures, and is time-saving and labor-saving.
(5) When the flow is 32L/min and the mass median diameter of the sodium chloride aerosol is 0.26 mu m, the filtering efficiency is 88.2-95.6% and the filtering resistance is 79.6-130.1 Pa by adopting a TSI8130 filter material comprehensive performance test bench. By adopting a YG026H electronic fabric strength machine test, when the product gram weight is 50gsm, the longitudinal breaking strength is more than 150N/5cm, the transverse breaking strength is more than 115N/5cm, and when the product gram weight is more than 50gsm, the longitudinal breaking strength and the transverse breaking strength are both improved.
The manufacturing method of the invention adopts the steps of adding the nano tourmaline powder, orange segment type melt spinning, carding to form a net, double fiber opening, drying and electret treatment to store the electric charge in the superfine fiber, thereby realizing the double filtering functions of physical interception and electrostatic adsorption, obviously improving the filtering performance and the material strength, being capable of being used as an independent filtering material and meeting the index requirements of filtering PM2.5 and PM 1.0.
The method for preparing the superfine fiber spunlace nonwoven fabric filter material disclosed by the invention overcomes various defects in the prior art, the material surface is fine and compact, the handfeel is soft, and the characteristics of high strength, good wear resistance and the like are also realized, the limitation of the conventional melt-blown nonwoven fabric on the application aspects of industrial dust removal, protective clothing and the like only by the strength data of about 10N/5cm is solved, the filter performance cannot be attenuated due to the change of the external environment, the energy consumption is conveniently saved, the service life is prolonged, the superfine fiber spunlace nonwoven fabric filter material can be used for preparing the filter material of various industrial dust removal, protective clothing and protective masks, the requirement of high-efficiency air purification is met, the superfine fiber spunlace nonwoven fabric filter material has important significance for developing air filter materials, and a new thought can be provided for the design and development of the filter material.
The filter material has higher strength, can be supported without depending on composite base cloth, does not need complex treatment process and production efficiency effect, has low cost, and increases the safety of products.
Drawings
FIG. 1 is a process scheme of the present invention.
FIG. 2 is a microscopic image of a 16-segment orange-peel polypropylene/polyester composite staple fiber of the present invention.
Detailed Description
The technical scheme of the invention is further explained by the specific embodiment and the attached drawings.
Example 1:
the manufacturing method of the superfine fiber spunlace nonwoven fabric filter material shown in figure 1 comprises the following steps:
(1) preparing raw materials: selecting two resin components of polypropylene (PP) and Polyester (PET), and respectively adding the nano tourmaline powder in an ultrasonic spraying machine in an atomizing and spraying manner. The mass percentage of the nano tourmaline powder in each resin component is 0.4%. The grain size of the nano tourmaline powder is 200-450 nm, wherein the PET resin needs to be dried before use, and is dried for 8 hours in hot air at 170 ℃ to reduce the water content from 0.4% to below 0.01%;
(2) melt spinning: the two components respectively enter two sets of melting components according to the mass ratio of PP 70% and PET 30%, namely enter a screw extruder, are heated and softened, are melted, are sent to a metering pump, quantitatively extrude two polymer melts, and finally enter a spinneret orifice with the same aperture of 0.3mm of an orange petal type spinneret plate to be extruded to prepare orange petal type PP/PET composite fibers; the extrusion temperature of the screw extruder is 250 ℃ for polypropylene and 280 ℃ for polyester respectively;
(3) fiber processing: sequentially cooling, oiling, drafting, curling, loosening and shaping the PP/PET composite fiber, and cutting to obtain PP/PET composite short fiber with the fiber fineness of 2.5D and the length of 51 mm;
(4) carding to form a net: the PP/PET composite short fibers are subjected to opening and loosening and carding by needle teeth of a carding machine to be in a single fiber parallel and straight state, and a fiber web output by the carding machine is perpendicular to a lapping machine to do reciprocating motion and is lapped in a cross lapping mode and then is drafted to form a fiber web with a certain thickness;
(5) and (3) spunlacing and reinforcing: pre-wetting the fiber web, then feeding the fiber web into a spunlace machine, splitting PP/PET composite short fibers in the fiber web into superfine fibers under the impact of six high-pressure water needles with the spunlace pressure of 4Mpa, 7Mpa, 11Mpa, 13Mpa, 17Mpa and 14Mpa in sequence, mutually winding the superfine fibers into wet spunlace non-woven fabrics, and pre-dewatering the wet spunlace non-woven fabrics through a suction cavity;
(6) smooth rolling: and the wet spunlace non-woven fabric is further dehydrated and opened by rolling through two rollers under the linear pressure of 150N/cm.
(7) Heating and drying: the rolled spunlace nonwoven fabric enters a hot air penetrating type dryer with the temperature of 155 ℃ to thoroughly remove water;
(8) performing electret treatment: the dried spunlace nonwoven fabric is subjected to the action of a strong electric field of two 40KV high-voltage electrostatic generators to store electric charges ionized from the air in the superfine fibers so as to generate an electret effect;
(9) and (3) coiling a finished product: rolling at 45m/min to obtain 60g/m 2 And (5) a finished product of the superfine fiber spunlace non-woven fabric filter material.
When the flow is 32L/min and the mass median diameter of the sodium chloride aerosol is 0.26 mu m, the filtering efficiency is 90.3 percent and the filtering resistance is 100.1Pa by adopting a TSI8130 filter material comprehensive performance test bench for testing. When the gram weight of the product is 60gsm, the longitudinal breaking strength is 160N/5cm and the transverse breaking strength is 123N/5cm by adopting a YG026H electronic fabric strength machine test.
Example 2:
the method for manufacturing the superfine fiber spunlace nonwoven fabric filter material comprises the following steps:
(1) preparing raw materials: selecting two resin components of polypropylene (PP) and Polyester (PET), and respectively adding the nano tourmaline powder in an ultrasonic spraying machine in an atomizing and spraying manner. The grain diameter of the nano tourmaline powder is 300-400nm, and the mass percentage of the nano tourmaline powder in each resin component is 0.4%. Wherein, the PET resin needs to be dried before use, and is dried for 8 hours in hot air at 170 ℃ to reduce the water content from 0.4% to below 0.01%;
(2) melt spinning: the two components respectively enter two sets of melting components according to the mass ratio of PP 50% and PET 50%, namely enter a screw extruder, are heated and softened, are melted, are sent to a metering pump, quantitatively extrude two polymer melts, and finally enter a spinneret orifice with the same aperture of 0.3mm of an orange petal type spinneret plate to be extruded to prepare orange petal type PP/PET composite fibers; the extrusion temperature of the screw extruder is 250 ℃ for polypropylene and 280 ℃ for polyester respectively;
(3) fiber processing: sequentially cooling, oiling, drafting, curling, loosening and shaping the PP/PET composite fiber, and cutting to obtain PP/PET composite short fiber with the fiber fineness of 2.5D and the length of 51 mm;
(4) carding to form a net: the PP/PET composite short fibers are subjected to opening and loosening and carding by needle teeth of a carding machine to be in a single fiber parallel and straight state, and a fiber web output by the carding machine is perpendicular to a lapping machine to do reciprocating motion and is lapped in a cross lapping mode and then is drafted to form a fiber web with a certain thickness;
(5) and (3) spunlacing and reinforcing: pre-wetting the fiber web, then feeding the fiber web into a spunlace machine, splitting PP/PET composite short fibers in the fiber web into superfine fibers under the impact of six high-pressure water needles with the spunlace pressure of 4Mpa, 7Mpa, 11Mpa, 13Mpa, 17Mpa and 14Mpa in sequence, mutually winding the superfine fibers into wet spunlace non-woven fabrics, and pre-dewatering the wet spunlace non-woven fabrics through a suction cavity;
(6) smooth rolling: and the wet spunlace non-woven fabric is further dehydrated and opened by rolling through two rollers under the linear pressure of 220N/cm.
(7) Heating and drying: the rolled spunlaced nonwoven fabric enters a hot air penetrating type dryer with the temperature of 160 ℃ to thoroughly remove water;
(8) performing electret treatment: the dried spunlace nonwoven fabric is subjected to the action of a strong electric field of two 50KV high-voltage electrostatic generators to store electric charges ionized from the air in the superfine fibers so as to generate an electret effect;
(9) and (3) coiling a finished product: rolling at 40m/min to obtain 80g/m 2 And (5) a finished product of the superfine fiber spunlace non-woven fabric filter material.
When the flow rate is 32L/min and the mass median diameter of sodium chloride aerosol is 0.26 mu m, the filtering efficiency is 93.1 percent and the filtering resistance is 110.3Pa by adopting a TSI8130 filter material comprehensive performance test bench. When the gram weight of the product is 80gsm, the longitudinal breaking strength is 170.6N/5cm and the transverse breaking strength is 131.2N/5cm by adopting a YG026H electronic fabric strength machine test.
Example 3
The spunlace nonwoven fabric for 50gsm air filtration is manufactured in the embodiment, the different steps are the same as the embodiment 1, the difference is that the amount of the added load short fibers is relatively small in the carding and web forming process, and the spunlace pressure in the spunlace reinforcement is divided into superfine fibers under the impact of six high-pressure water needles with the sequential water pressure of 3Mpa, 6Mpa, 10Mpa, 12Mpa, 16Mpa and 13Mpa, and the superfine fibers are mutually entangled to form the wet spunlace nonwoven fabric. The finished grammage is 50 gsm. The atomization spraying process comprises the following steps: the UAM4000L ultrasonic spraying machine provided by Hangzhou flying ultrasonic equipment, Inc. is used for atomizing the nano tourmaline powder into uniform particles by ultrasonic high-frequency oscillation, and then the particles are uniformly floated and attached in the resin after being sprayed out along with high-speed impact air jet flow. The ultrasonic frequency is 50KHz, the air-entrapping pressure is 0.1 mupa, and the particle size range of the nano tourmaline powder is 200-300 nm.
The filtration efficiency is 88.2 percent, and when the gram weight of the product is 50gsm, the longitudinal breaking strength is more than 150N/5cm, and the transverse breaking strength is more than 115N/5 cm.
The above-mentioned embodiments are merely illustrative of the inventive concept and are not intended to limit the scope of the invention, which is defined by the claims and the insubstantial modifications of the inventive concept can be made without departing from the scope of the invention.
Nothing in this specification is said to apply to the prior art.
Claims (8)
1. A manufacturing method of superfine fiber spunlace nonwoven fabric filter material is characterized by comprising the following steps:
(1) preparing raw materials: selecting two resin components of polypropylene PP and polyester PET, and respectively adding nano tourmaline powder in an atomizing and spraying manner, wherein the PET resin is dried before spraying the nano tourmaline powder; the atomization spraying process comprises the following steps: the nano tourmaline powder is atomized into uniform particles by utilizing ultrasonic high-frequency oscillation, and then the particles are uniformly floated and attached in resin after being sprayed out along with high-speed impact air jet; the ultrasonic air-entrapping pressure is 0.1-0.3 mu Pa;
(2) melt spinning: the two components respectively enter two sets of melting components, namely a screw extruder, and the two components are heated, softened, melted and then sent to a metering pump, two polymer melts extruded quantitatively are fed into the same spinneret orifice of an orange petal type spinneret plate and extruded to prepare orange petal type PP/PET composite fibers;
(3) preparing orange petal type PP/PET composite fibers into PP/PET composite short fibers;
(4) carding to form a net;
(5) carrying out spunlace reinforcement to obtain wet spunlace nonwoven fabric and realize first fiber opening;
(6) smooth rolling: the wet spunlace non-woven fabric is further dehydrated and opened through roller rolling to realize second opening; the line pressure of the calender roll in the smooth roll rolling is 120-300N/cm;
(7) heating and drying: the spunlace non-woven fabric after the second fiber splitting enters a hot air penetrating type dryer to thoroughly remove moisture;
(8) performing electret treatment: the dried spunlace nonwoven fabric is subjected to the action of a strong electric field of a high-voltage electrostatic generator to store electric charges ionized from the air in the superfine fibers so as to generate an electret effect;
(9) and (3) coiling a finished product: rolling at a set speed to obtain a finished product of the superfine fiber spunlace nonwoven fabric filter material;
the electric charge is stored in the superfine fiber by adding the nano tourmaline powder, orange segment type melt spinning, carding to form a net, double fiber opening, drying and electret treatment, so that the double filtering functions of physical interception and electrostatic adsorption are realized, the filtering performance and the material strength are obviously improved, the electric charge can be used as an independent filtering material, and the index requirements of filtering PM2.5 and PM1.0 can be met;
the superfine fiber spunlace non-woven fabric filter material is tested by a TSI8130 filter material comprehensive performance test bench, when the flow is 32L/min, the mass median diameter of sodium chloride aerosol is 0.26 mu m, the filtering efficiency is 88.2-95.6%, and the filtering resistance is 79.6-130.1 Pa; by adopting a YG026H electronic fabric strength machine test, when the product gram weight is 50gsm, the longitudinal breaking strength is more than 150N/5cm, the transverse breaking strength is more than 115N/5cm, and when the product gram weight is more than 50gsm, the longitudinal breaking strength and the transverse breaking strength are both improved.
2. The manufacturing method according to claim 1, wherein the nano tourmaline powder accounts for 0.3-0.8% of each resin component by mass; the drying treatment requirements of the PET resin are as follows: drying the mixture for 7 to 10 hours in hot air at the temperature of 150 to 170 ℃ to reduce the water content of the mixture to be less than 0.01 percent.
3. The manufacturing method according to claim 1, wherein the step (3) of preparing the orange petal type PP/PET composite fiber into the PP/PET composite short fiber comprises the following steps: sequentially cooling, oiling, drafting, curling, loosening and shaping the orange petal type PP/PET composite fibers, and cutting to obtain PP/PET composite staple fibers, wherein the oiling rate is 0.5-1.0% of the weight of the fibers, the fineness of the PP/PET composite staple fibers is 2.0-2.5D, and the length of the PP/PET composite staple fibers is 38-51 mm;
the process of carding into web is: and (3) opening and loosening the PP/PET composite short fibers, carding the fibers by using the needle teeth of a carding machine to enable the fibers to be in a single fiber parallel and straight state, and paving the fiber webs output by the carding machine in a cross lapping mode to form the fiber webs with a certain thickness after being vertical to a lapping machine to do reciprocating motion.
4. The manufacturing method according to claim 1, wherein in the step (2), the extrusion temperature of the screw extruder is respectively 250-260 ℃ of PP and 280-290 ℃ of PET, the pore diameter of the spinneret plate is 0.2-0.5 mm, and the orange-peel PP/PET composite fiber prepared by extrusion is 16-petals or 32-petals, wherein the PP component accounts for 50-70% by mass, and the PET component accounts for 30-50% by mass;
the temperature of the dryer in the step (7) is set to be 150-165 ℃, and the voltage of a strong electric field of the high-voltage electrostatic generator in the step (8) is 10-60 kV;
the spunlace machine in the step (5) consists of 5-7 spunlace heads, the distribution trend of spunlace pressure is low-high-low, the highest spunlace pressure is controlled to be 15-18 MPa, the lowest spunlace pressure is controlled to be 4-5 MPa, the fiber opening rate of the superfine fibers in the step (5) is more than 70%, and the diameter of a spunlace consolidation water spraying hole is 0.10-0.12 mm;
and (4) controlling the winding speed in the step (9) to be 30-50 m/min.
5. The method according to claim 1, wherein the ultrasonic frequency is 50 to 120KHz, and the particle size of the tourmaline nanopowder is 200 to 800 nm.
6. The method of claim 5, wherein the nano tourmaline powder has a particle size in the range of 300 to 450 nm.
7. A hydroentangled nonwoven filter material of microfibres, characterized in that it is obtained by the process according to any one of claims 1 to 6.
8. The spunlace nonwoven filter material of claim 7, wherein the basis weight of the spunlace nonwoven filter material is 50-100 g/m 2 。
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| CN115262092A (en) * | 2022-07-27 | 2022-11-01 | 上海精发实业股份有限公司 | Orange petal cleavage type double-component filament needle-punched electrostatic cotton and preparation method thereof |
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