CN115445327A - 一种耐碱芳纶复合过滤袋及其制作工艺 - Google Patents

一种耐碱芳纶复合过滤袋及其制作工艺 Download PDF

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CN115445327A
CN115445327A CN202211027589.5A CN202211027589A CN115445327A CN 115445327 A CN115445327 A CN 115445327A CN 202211027589 A CN202211027589 A CN 202211027589A CN 115445327 A CN115445327 A CN 115445327A
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alkali
filter bag
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composite filter
fiber
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杨文军
李波
严义平
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Guangde Huilong Environmental Protection Technology Co ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Abstract

本发明涉及一种耐碱芳纶复合过滤袋及其制作工艺，属于过滤袋制造技术领域，所述耐碱芳纶复合过滤袋的制作工艺，包括以下步骤：将间位芳纶纤维、玻璃纤维和聚苯硫醚纤维进行开松混合、梳理铺网、针刺、烧毛处理，得针刺毡基材；再将耐碱乳液喷涂在针刺毡基材上，烘干后再将热压复合膨化聚四氟乙烯微孔膜，最后经冷却定型、剪裁和缝合得耐碱芳纶复合过滤袋。本发明综合了间位芳纶纤维的耐磨性能，玻璃纤维对水和弱碱溶液侵蚀的稳定性和聚苯硫醚纤维的耐碱腐蚀性能，增强了所制作的耐碱芳纶复合过滤袋的耐水性和耐碱腐蚀性；其中，耐碱乳液主要由硅烷偶联剂水解后在针刺毡基材上形成硅烷膜，进一步提高了耐碱芳纶复合过滤袋的耐碱腐蚀性。

Description

一种耐碱芳纶复合过滤袋及其制作工艺
技术领域
本发明属于过滤袋制造技术领域，具体地，涉及一种耐碱芳纶复合过滤袋及其制作工艺。
背景技术
芳纶是一种具有高强度、高模量、耐高温、质量轻等优良性能的高科技合成纤维，其强度是钢丝的5-6倍，模量为钢丝或玻璃纤维的2-3倍，韧性是钢丝的2倍，而密度仅为钢丝的1/5左右，在560℃的温度下，不分解、不熔化。因此，芳纶是制作布袋除尘器的滤袋的首选材料，布袋除尘前端常伴随有脱硫工艺，脱硫工艺是利用碱金属氧化物(氧化钙、氧化镁等)进行脱硫，未反应的过量的碱金属氧化物和烟气中的水分混合后会严重腐蚀过滤袋，过滤袋的更换成本占比除尘器的维护费用的60-80％，现有的过滤袋的使用寿命大致为2-2.5年，过滤袋的耐碱性有待进一步提升，进一步提高过滤袋的使用寿命，降低成本。
发明内容
为了解决背景技术中提到的技术问题，本发明的目的在于提供一种耐碱芳纶复合过滤袋及其制作工艺。
本发明的目的可以通过以下技术方案实现：
一种耐碱芳纶复合过滤袋的制作工艺，包括以下步骤：
S1、将间位芳纶纤维、玻璃纤维和聚苯硫醚纤维进行开松混合处理，混合均匀后，得混合纤维，将混合纤维进行梳理铺网，得基布层；
S2、对基布层进行针刺处理，其中，针刺深度5-10mm，针刺密度650针/cm2，针刺处理后进行烧毛处理，得针刺毡基材；
S3、通过喷涂烘干设备将耐碱乳液喷涂在针刺毡基材上，设定烘干段的温度依次为60-80℃、100-130℃和170-200℃，烘干后得增强基材；
S4、增强基材的一侧为迎尘层，增强基材的另一侧为内层，通过覆膜机将膨化聚四氟乙烯微孔膜与增强基材的内层高温热压复合，再经过冷却定型、剪裁和缝合得耐碱芳纶复合过滤袋。
在上述制作工艺过程中，基布层由间位芳纶纤维、玻璃纤维和聚苯硫醚纤维进行混合，三者均为高温纤维，使用温度均高于150℃，间位芳纶纤维为主要基布材料，间位芳纶纤维具有优异的耐磨性能，但是其耐水解性能和耐酸碱性能一般；玻璃纤维对水和弱碱溶液具有高度的稳定性；聚苯硫醚纤维具有优异的耐酸碱性能，但质脆、易产生应力脆裂。通过将玻璃纤维和聚苯硫醚纤维加入间位芳纶纤维中进行混合，可增强基布层的耐水性、耐碱腐蚀性，同时保证了基布层的强度和耐磨性。
同时，通过对基布层进行针刺、烧毛、喷涂和烘干处理，针刺、烧毛处理保证了基布层的过滤功能，喷涂耐碱乳液，强化基布层的耐碱性能，同时，耐碱乳液作为纤维外防层，提高了纤维的使用寿命。
最后，在耐碱芳纶复合过滤袋的内侧热压膨化聚四氟乙烯微孔膜，膨化聚四氟乙烯微孔膜的孔径为1-2μm，厚度为20-25mm，根据不同的工业要求可以选择不同孔径和厚度的膨化聚四氟乙烯微孔膜，膨化聚四氟乙烯微孔膜的作用为提高耐碱芳纶复合过滤袋的滤尘效果。
进一步地，步骤S1中所述间位芳纶纤维、玻璃纤维和聚苯硫醚纤维的质量比为5-7：1-2：1。
在上述制作工艺过程中，以间位芳纶纤维为主要材料，玻璃纤维和聚苯硫醚纤维作为辅助增强材料，控制玻璃纤维和聚苯硫醚纤维的用量，综合提升耐碱芳纶复合过滤袋的耐磨性能和耐碱腐蚀性能。
进一步地，步骤S1中开松混合处理过程为：将间位芳纶纤维、玻璃纤维和聚苯硫醚纤维输送至开松混合机中进行自由式开松混合。
进一步地，所述耐碱乳液由以下步骤制成：
A1、向去离子水中加入冰醋酸并搅拌均匀，向中加入硅烷偶联剂，搅拌水解30-60min，再加入成膜剂，搅拌10-20min，得混合液；
A2、向混合液中加入有机硅润滑剂和氯化铵，搅拌5-15min，再加入聚四氟乙烯分散液和氟化乙烯丙烯，继续搅拌40-60min，得耐碱乳液。
在上述制备过程中，冰醋酸作为水解催化剂，硅烷偶联剂在冰醋酸的催化作用下与发生水解反应，制备的耐碱乳液喷涂在针刺毡基材上后，会在针刺毡基材上形成硅烷膜，提高针刺毡基材的耐碱腐蚀性能，同时，加入了成膜剂、有机硅润滑剂和氯化铵，成膜剂有助于提升耐碱乳液的流平性；有机硅润滑剂和作为阳离子润滑剂的氯化铵辅助提高耐碱乳液的浸润效果。
进一步地，步骤A1中所述去离子水、冰醋酸、硅烷偶联剂、成膜剂的用量比为200-300mL：20-30mL：2-5mL：60-80mL。
进一步地，所述成膜剂为聚丙烯酸酯成膜剂、环氧树脂乳液成膜剂和水溶性环氧树脂成膜剂按照质量比为6-13：5-8：5-7复配而成。
进一步地，步骤A2中所述有机硅润滑剂、氯化铵、聚四氟乙烯分散液和氟化乙烯丙烯的用量比为3-10mL：5-15mL：80-100mL：45-60mL。
进一步地，一种耐碱芳纶复合过滤袋，由上述制作工艺制作而成。
本发明的有益效果：
本发明选用玻璃纤维和聚苯硫醚纤维作为间位芳纶纤维的补强纤维，综合了玻璃纤维对水和弱碱溶液侵蚀时的稳定性和聚苯硫醚纤维的耐碱腐蚀性能，过滤袋在使用时，烟气中的水和碱金属氧化物会附着在过滤袋外表面，形成的碱性湿润环境会造成过滤袋的腐蚀，利用玻璃纤维的防水性和聚苯硫醚纤维的耐碱腐蚀性能，增强了所制作的耐碱芳纶复合过滤袋的耐水性和耐碱腐蚀性，同时保证了基布层的强度。
本发明在针刺毡基材上喷涂有耐碱乳液，耐碱乳液主要由硅烷偶联剂水解后形成硅醇，硅醇羟基与针刺毡基材的表面之间产生氢键，最终在针刺毡基材上形成硅烷膜，提高针刺毡基材的耐碱腐蚀性能，同时，加入了成膜剂、有机硅润滑剂和氯化铵，成膜剂有助于提升耐碱乳液的流平性，辅助在针刺毡基材表面形成连续均匀的硅烷膜，有机硅润滑剂和作为阳离子润滑剂的氯化铵辅助提高耐碱乳液的浸润效果。最后，加入聚四氟乙烯分散液和氟化乙烯丙烯用于提高耐碱乳液的热稳定性和化学惰性，提高耐碱乳液的寿命。
具体实施方式
下面将结合本发明实施例，对本发明实施例中的技术方案进行清楚、完整地描述，显然，所描述的实施例仅仅是本发明一部分实施例，而不是全部的实施例。基于本发明中的实施例，本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其它实施例，都属于本发明保护的范围。
实施例1
制备耐碱乳液：
A1、向200mL去离子水中加入20mL冰醋酸并搅拌均匀，向中加入2mL硅烷偶联剂，搅拌水解30min，再加入60mL成膜剂，搅拌10min，得混合液，其中，成膜剂为聚丙烯酸酯成膜剂、环氧树脂乳液成膜剂和水溶性环氧树脂成膜剂按照质量比为6：5：5复配而成；
A2、向混合液中加入3mL有机硅润滑剂和5mL氯化铵，搅拌5min，再加入80mL聚四氟乙烯分散液和45mL氟化乙烯丙烯，继续搅拌40min，得耐碱乳液。
实施例2
制备耐碱乳液：
A1、向300mL去离子水中加入30mL冰醋酸并搅拌均匀，向中加入5mL硅烷偶联剂，搅拌水解60min，再加入80mL成膜剂，搅拌20min，得混合液，其中，成膜剂为聚丙烯酸酯成膜剂、环氧树脂乳液成膜剂和水溶性环氧树脂成膜剂按照质量比为13：8：7复配而成；
A2、向混合液中加入10mL有机硅润滑剂和15mL氯化铵，搅拌15min，再加入100mL聚四氟乙烯分散液和60mL氟化乙烯丙烯，继续搅拌60min，得耐碱乳液。
实施例3
制作耐碱芳纶复合过滤袋：
S1、将500g间位芳纶纤维、100g玻璃纤维和100g聚苯硫醚纤维输送至开松混合机中进行自由式开松混合，混合均匀后，得混合纤维，将混合纤维进行梳理铺网，得基布层；
S2、对基布层进行针刺处理，其中，针刺深度5mm，针刺密度650针/cm2，针刺处理后进行烧毛处理，得针刺毡基材；
S3、通过喷涂烘干设备将实施例1制备的耐碱乳液喷涂在针刺毡基材上，设定烘干段的温度依次为60℃、100℃和170℃，烘干后得增强基材；
S4、增强基材的一侧为迎尘层，增强基材的另一侧为内层，通过覆膜机将孔径为1μm，厚度为20mm的膨化聚四氟乙烯微孔膜与增强基材的内层高温热压复合，再经过冷却定型、剪裁和缝合得耐碱芳纶复合过滤袋。
实施例4
制作耐碱芳纶复合过滤袋：
S1、将700g间位芳纶纤维、200g玻璃纤维和100g聚苯硫醚纤维输送至开松混合机中进行自由式开松混合，混合均匀后，得混合纤维，将混合纤维进行梳理铺网，得基布层；
S2、对基布层进行针刺处理，其中，针刺深度10mm，针刺密度650针/cm2，针刺处理后进行烧毛处理，得针刺毡基材；
S3、通过喷涂烘干设备将实施例2制备的耐碱乳液喷涂在针刺毡基材上，设定烘干段的温度依次为80℃、130℃和200℃，烘干后得增强基材；
S4、增强基材的一侧为迎尘层，增强基材的另一侧为内层，通过覆膜机将孔径为2μm，厚度为25mm的膨化聚四氟乙烯微孔膜与增强基材的内层高温热压复合，再经过冷却定型、剪裁和缝合得耐碱芳纶复合过滤袋。
对比例1
将实施例3的步骤S1中玻璃纤维和聚苯硫醚纤维去除，其余制作过程不变，得耐碱芳纶复合过滤袋。
对比例2
将实施例4的步骤S3中实施例2制备的耐碱乳液去除，其余制作过程不变，得耐碱芳纶复合过滤袋。
将实施例1-2和对比例1-2制得的耐碱芳纶复合过滤袋进行性能检测，检测标准如下：
根据国家标准GB12625-2007(袋式除尘器用滤料及滤袋技术条件)检测耐碱芳纶复合过滤袋的样品的强度指标，其中样品尺寸为径向5cm*纬向20cm；
耐碱性能：将各组耐碱芳纶复合过滤袋的样品置于饱和氢氧化钙溶液中，23℃下浸泡168h，测试其强力保留率。
测试结果如表1所示：
表1
Figure BDA0003816193010000061
对比实施例1和对比例1的各项数据可得：本发明中通过玻璃纤维和聚苯硫醚纤维增强间位芳纶纤维，有助于提高耐碱芳纶复合过滤袋的强度和耐碱性能。
对比实施例2和对比例2的各项数据可得：利用本发明制备的耐碱乳液喷涂在针刺毡基材上，显著提升了制作而成的耐碱芳纶复合过滤袋的耐碱性能。
在说明书的描述中，参考术语“一个实施例”、“示例”、“具体示例”等的描述意指结合该实施例或示例描述的具体特征、结构、材料或者特点包含于本发明的至少一个实施例或示例中。在本说明书中，对上述术语的示意性表述不一定指的是相同的实施例或示例。而且，描述的具体特征、结构、材料或者特点可以在任何的一个或多个实施例或示例中以合适的方式结合。
以上内容仅仅是对本发明所作的举例和说明，所属本技术领域的技术人员对所描述的具体实施例做各种各样的修改或补充或采用类似的方式替代，只要不偏离发明或者超越本权利要求书所定义的范围，均应属于本发明的保护范围。

Claims (8)

1.一种耐碱芳纶复合过滤袋的制作工艺，其特征在于，包括以下步骤：
S1、将间位芳纶纤维、玻璃纤维和聚苯硫醚纤维进行开松混合处理，混合均匀后，得混合纤维，将混合纤维进行梳理铺网，得基布层；
S2、对基布层进行针刺处理，其中，针刺深度5-10mm，针刺密度650针/cm2，针刺处理后进行烧毛处理，得针刺毡基材；
S3、通过喷涂烘干设备将耐碱乳液喷涂在针刺毡基材上，设定烘干段的温度依次为60-80℃、100-130℃和170-200℃，烘干后得增强基材；
S4、增强基材的一侧为迎尘层，增强基材的另一侧为内层，通过覆膜机将膨化聚四氟乙烯微孔膜与增强基材的内层高温热压复合，再经过冷却定型、剪裁和缝合得耐碱芳纶复合过滤袋。
2.根据权利要求1所述的一种耐碱芳纶复合过滤袋的制作工艺，其特征在于，步骤S1中所述间位芳纶纤维、玻璃纤维和聚苯硫醚纤维的质量比为5-7：1-2：1。
3.根据权利要求1所述的一种耐碱芳纶复合过滤袋的制作工艺，其特征在于，步骤S1中开松混合处理过程为：将间位芳纶纤维、玻璃纤维和聚苯硫醚纤维输送至开松混合机中进行自由式开松混合。
4.根据权利要求1所述的一种耐碱芳纶复合过滤袋的制作工艺，其特征在于，所述耐碱乳液由以下步骤制成：
A1、向去离子水中加入冰醋酸并搅拌均匀，向中加入硅烷偶联剂，搅拌水解30-60min，再加入成膜剂，搅拌10-20min，得混合液；
A2、向混合液中加入有机硅润滑剂和氯化铵，搅拌5-15min，再加入聚四氟乙烯分散液和氟化乙烯丙烯，继续搅拌40-60min，得耐碱乳液。
5.根据权利要求4所述的一种耐碱芳纶复合过滤袋的制作工艺，其特征在于，步骤A1中所述去离子水、冰醋酸、硅烷偶联剂、成膜剂的用量比为200-300mL：20-30mL：2-5mL：60-80mL。
6.根据权利要求4所述的一种耐碱芳纶复合过滤袋的制作工艺，其特征在于，所述成膜剂为聚丙烯酸酯成膜剂、环氧树脂乳液成膜剂和水溶性环氧树脂成膜剂按照质量比为6-13：5-8：5-7复配而成。
7.根据权利要求4所述的一种耐碱芳纶复合过滤袋的制作工艺，其特征在于，步骤A2中所述有机硅润滑剂、氯化铵、聚四氟乙烯分散液和氟化乙烯丙烯的用量比为3-10mL：5-15mL：80-100mL：45-60mL。
8.一种耐碱芳纶复合过滤袋，其特征在于，由权利要求1-7任一项制作工艺制作而成。
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EP1862208A1 (de) * 2006-10-26 2007-12-05 A. Kayser GmbH u. Co.KG Textile Filtermedien Basaltfasern enthaltendes Filtermedium
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