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CN108654211A - 一种除尘耐高温滤料及其制备方法 - Google Patents

一种除尘耐高温滤料及其制备方法 Download PDF

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Publication number
CN108654211A
CN108654211A CN201810427266.2A CN201810427266A CN108654211A CN 108654211 A CN108654211 A CN 108654211A CN 201810427266 A CN201810427266 A CN 201810427266A CN 108654211 A CN108654211 A CN 108654211A
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parts
base fabric
fibre
high temperature
layer
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CN108654211B (zh
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朱靓靓
朱彦加
张瑜
李素英
张伟
付译鋆
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Jiangsu Lingfulong Environmental Engineering Co Ltd
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Jiangsu Lingfulong Environmental Engineering Co Ltd
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Abstract

本发明公开一种除尘耐高温滤料及其制备方法，包括基布层以及分别设置在基布层两面的耐磨层和迎尘层，所述基布层由经线和纬线织网得到，经线由聚四氟乙烯纤维和氧化锆纤维加捻并股编织而成，纬线由聚酰亚胺纤维和石英纤维加捻并股编织而成，基布经浸液处理后表层喷涂有导电金属粉，然后经微波固化成型得到，耐磨层由无碱玻璃纤维制成，迎尘层由聚间苯二甲酰间苯二胺纤维制成，其迎尘面针刺一层宣武岩纤维网，背尘面经机械起绒处理。本发明制备的基布浸液处理后采用微波加热固化成型，能够由内而外加热固化树脂，使纤维表面成膜均匀，提高表面综合性能，通过设置耐磨层和迎尘层，起到支撑和保护基布的作用，进一步提升滤布的耐受温度。

Description

一种除尘耐高温滤料及其制备方法
技术领域
本发明涉及一种除尘耐高温滤料及其制备方法，属于工业除尘过滤材料领域。
背景技术
在水泥、钢铁、石油化工等领域，生产过程中需要对粉尘或者烟雾进行过滤处理，由于含尘气体往往温度较高，这就对布袋滤料提出了较高的要求，现有的过滤用布袋往往在基布的表面涂覆厚厚的耐火涂层，这样不利于气体的流通，导致布袋的过滤效率降低。
发明内容
发明目的：本发明所要解决的技术问题是针对现有技术的不足，提供一种机构简单，便于工业化连续生产的除尘耐高温滤料及其制备方法。
为了解决上述技术问题，本发明公开了一种除尘耐高温滤料，包括基布层以及分别设置在基布层两面的耐磨层和迎尘层，所述基布层由经线和纬线织网得到，经线由聚四氟乙烯纤维和氧化锆纤维加捻并股编织而成，纬线由聚酰亚胺纤维和石英纤维加捻并股编织而成，基布经浸液处理后表层喷涂有导电金属粉，然后经微波固化成型得到；所述耐磨层由无碱玻璃纤维制成，厚度为1～1.5mm，所述迎尘层由聚间苯二甲酰间苯二胺纤维制成，厚度为1～2mm，迎尘层的迎尘面针刺有一层宣武岩纤维网，背尘面经机械起绒处理；所述耐磨层和迎尘层分别通过针刺与基布层连接。
本发明基布中聚四氟乙烯纤维和聚酰亚胺纤维耐热、耐磨、耐腐蚀，同时搭配无机耐高温氧化锆纤维和石英纤维，能极大的提高基布在高温酸碱环境下的使用性能，无需增加专门的耐高温层，降低了滤布的厚度，便于除尘效率的提高；基布的上下表面通过设置耐磨层和迎尘层以延长滤料的使用寿命，聚间苯二甲酰间苯二胺纤维的连续工作温度能达到300℃左右，优于常规的合成纤维以及聚四氟乙烯纤维等，迎尘层的迎尘面针刺的宣武岩纤维网能够率先接触高温气体，起到支撑和保护基布的作用。基布表层预先喷涂有导电金属粉，其粘附在基布的表面，能够形成稳定的一次粉尘层，以克服新滤料前期除尘效率不高的弊病，另外迎尘层的背尘面经机械起绒处理，形成一层覆盖织物孔隙的短线，其能够在滤料进行反冲洗时，将基布表面冲洗下来的导电金属粉捕捉下来，避免导电金属粉随反冲洗的次数增加而失去作用。
其中，所述经线由体积比为6～7:3～4的聚四氟乙烯纤维和氧化锆纤维加捻并股编织而成。
所述纬线由体积比为6～7:3～4的聚酰亚胺纤维和石英纤维加捻并股编织而成。
所述经线线径为0.2～0.3mm，所述纬线线径为0.2～0.3mm，织网得到的基布经线密度为18～24根/cm，纬线密度为12～18根/cm。
所述浸液由以下按重量份计的组份组成：聚氨酯20～35份，有机硅树脂20～40份，全氟烷基乙基丙烯酸酯10～20份，活性炭5～7份，氢氧化镁3～5份，氧化锑2～4份，叔丁基对苯二酚衍生物(DTBHO)5～8份，硅油10～15份，聚氨酯和有机硅树脂能够在纤维表面成膜，以提高纤维表面的综合性能；全氟烷基乙基丙烯酸酯作为含氟表面活性剂，其分子疏水端吸附于纤维表面，亲水性基团指向空间，形成极性界面，吸附空气中的水分子，降低纤维或织物的表面比电阻，加速电荷逸散；活性炭的加入增加纤维表面的吸附粉尘能力；氢氧化镁和氧化锑作为阻燃剂；叔丁基对苯二酚衍生物(DTBHO)作为抗氧化剂；硅油则作为高效的交联剂。
优选地，所述宣武岩纤维预先浸渍聚四氟乙烯乳液处理，在宣武岩纤维表面形成聚四氟乙烯薄膜，以增加纤维表面性能。
所述宣武岩纤维网每平方米的重量为200～400g。
本发明还提供上述除尘耐高温滤料制备方法，包括如下步骤：
步骤一：将聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成经线，将聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布；
步骤三：将步骤二得到的基布进行浸液处理；
步骤四：取出浸液后的基布，至于微波中进行固化成型；
步骤五：在固化得到的基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层和由聚间苯二甲酰间苯二胺纤维制成的迎尘层即得。
步骤三中，所述浸液处理的温度为40～60℃，时间为3～6h，优选50℃保温5h，浸液处理以增加纤维表面的综合性能。
步骤四中，所述微波的加热功率为1～2KW，时间为30～50s，微波加热固化能够有效避免传统水蒸或烘干导致的纤维内外部固化成膜不均匀的现象，同时提高生产效率。
有益效果：
1、本发明滤料基布采用有机纤维和无机耐高温纤维加捻并股编织成网而成，具有良好的柔韧性和耐高温性能，无需额外的耐高温层既能满足高温腐蚀环境下的使用；
2、本发明滤料由基布层、耐磨层和迎尘层组成，基布上喷涂有导电金属粉，以增加基布的抗静电能力，迎尘层的背尘面经机械起绒处理，可以保证滤布随反冲洗的次数增加导电金属粉不会失效，迎尘面针刺有一层宣武岩纤维网，其能够率先接触高温气体，起到支撑和保护基布的作用，进一步提升滤布的耐受温度，延长使用寿命；
3、本发明滤料浸液处理后采用微波加热固化成型，能够由内而外加热固化树脂，使纤维表面成膜均匀，加速电荷逸散，提高表面综合性能。
具体实施方式
根据下述实施例，可以更好地理解本发明。
实施例1
步骤一：将体积比为7:3聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm经线，将体积比为7:3聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布，经线密度为18～24根/cm，纬线密度为12～18根/cm；
步骤三：将聚氨酯30份，有机硅树脂35份，全氟烷基乙基丙烯酸酯15份，活性炭6份，氢氧化镁4份，氧化锑3份，叔丁基对苯二酚衍生物(DTBHO)7份，硅油14份混合搅拌均匀，加热到50℃并保温，将步骤二得到的基布进行浸液处理5h；
步骤四：取出浸液后的基布，至于微波中于2KW进行加热40s固化成型；
步骤五：在固化得到的基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层(厚度为1～1.5mm)和由聚间苯二甲酰间苯二胺纤维制成的迎尘层(厚度为1～2mm，迎尘面针刺一层宣武岩纤维网，每平方米的重量为200～400g，背尘面经机械起绒处理)，即得。
实施例2
步骤一：将体积比为7:3聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm经线，将体积比为7:3聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布，经线密度为18～24根/cm，纬线密度为12～18根/cm；
步骤三：将聚氨酯35份，有机硅树脂40份，全氟烷基乙基丙烯酸酯20份，活性炭7份，氢氧化镁5份，氧化锑4份，叔丁基对苯二酚衍生物(DTBHO)8份，硅油15份混合搅拌均匀，加热到60℃并保温，将步骤二得到的滤布进行浸液处理3h；
步骤四：取出浸液后的基布，至于微波中于2KW进行加热30s固化成型；
步骤五：在固化得到的基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层(厚度为1～1.5mm)和由聚间苯二甲酰间苯二胺纤维制成的迎尘层(厚度为1～2mm，迎尘面针刺一层宣武岩纤维网，每平方米的重量为200～400g，背尘面经机械起绒处理)，即得。
实施例3
步骤一：将体积比为6:4聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm经线，将体积比为6:4聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布，经线密度为18～24根/cm，纬线密度为12～18根/cm；
步骤三：将聚氨酯20份，有机硅树脂20份，全氟烷基乙基丙烯酸酯10份，活性炭5份，氢氧化镁3份，氧化锑2份，叔丁基对苯二酚衍生物(DTBHO)5份，硅油10份混合搅拌均匀，加热到40℃并保温，将步骤二得到的滤布进行浸液处理6h；
步骤四：取出浸液后的基布，至于微波中于1KW进行加热50s固化成型；
步骤五：在固化得到的基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层(厚度为1～1.5mm)和由聚间苯二甲酰间苯二胺纤维制成的迎尘层(厚度为1～2mm，迎尘面针刺一层宣武岩纤维网，每平方米的重量为200～400g，背尘面经机械起绒处理)，即得。
对比例1
步骤一：将体积比为7:3聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm经线，将体积比为7:3聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布，经线密度为18～24根/cm，纬线密度为12～18根/cm；
步骤三：在得到的基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层(厚度为1～1.5mm)和由聚间苯二甲酰间苯二胺纤维制成的迎尘层(厚度为1～2mm，迎尘面针刺一层宣武岩纤维网，每平方米的重量为200～400g，背尘面经机械起绒处理)，即得。
对比例2
步骤一：将体积比为7:3聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm经线，将体积比为7:3聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布，经线密度为18～24根/cm，纬线密度为12～18根/cm；
步骤三：将聚氨酯30份，有机硅树脂35份，全氟烷基乙基丙烯酸酯10～20份，活性炭6份，氢氧化镁4份，氧化锑3份，叔丁基对苯二酚衍生物(DTBHO)7份，硅油14份混合搅拌均匀，加热到50℃并保温，将步骤二得到的基布进行浸液处理5h；
步骤四：取出浸液后的基布，至于烘箱中进行加热30分钟，固化成型既得。
步骤五：在固化得到的基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层(厚度为1～1.5mm)和由聚间苯二甲酰间苯二胺纤维制成的迎尘层(厚度为1～2mm，迎尘面针刺一层宣武岩纤维网，每平方米的重量为200～400g，背尘面经机械起绒处理)，即得。
对比例3
步骤一：将体积比为7:3聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm经线，将体积比为7:3聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布，经线密度为18～24根/cm，纬线密度为12～18根/cm；
步骤三：将聚氨酯30份，有机硅树脂35份，活性炭6份，氢氧化镁4份，氧化锑3份，硅油14份混合搅拌均匀，加热到50℃并保温，将步骤二得到的基布进行浸液处理5h；
步骤四：取出浸液后的基布，至于微波中于2KW进行加热40s固化成型。
步骤五：在固化得到的基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层(厚度为1～1.5mm)和由聚间苯二甲酰间苯二胺纤维制成的迎尘层(厚度为1～2mm，迎尘面针刺一层宣武岩纤维网，每平方米的重量为200～400g，背尘面经机械起绒处理)，即得。
对比例4
步骤一：将体积比为7:3聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm经线，将体积比为7:3聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成线径为0.2～0.3mm纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布，经线密度为18～24根/cm，纬线密度为12～18根/cm；
步骤三：将聚氨酯30份，有机硅树脂35份，全氟烷基乙基丙烯酸酯15份，活性炭6份，氢氧化镁4份，氧化锑3份，叔丁基对苯二酚衍生物(DTBHO)7份，硅油14份混合搅拌均匀，加热到50℃并保温，将步骤二得到的基布进行浸液处理5h；
步骤四：取出浸液后的基布，至于微波中于2KW进行加热40s固化成型；
步骤五：在固化得到的基布迎尘面针刺一层宣武岩纤维网(每平方米的重量为200～400g)即得。
将实施例1～3以及对比例1～4制备得到的除尘滤料制成规格为Φ120mm的滤袋，分别测定性能参数，结果见表1，从中可以看出，采用本发明制备得到的基布能够在330℃以上连续使用，且抗静电性能、抗拉强度和耐磨耐酸碱性能良好，浸液处理后经微波加热固化，滤布的各项性能得到较大提升。
表1
以上对比实施例表明，本发明制备得到的基布进行浸液处理后可大大提升性能，尤其浸液中的全氟烷基乙基丙烯酸酯对基布防静电性能的提高具有显著效果，其表面活性作用利于浸液中抗氧化剂和阻燃剂的分散，从而均匀地附着在纤维的表面。另外本发明打破传统纤维浸液干燥处理方法优先采用微波快递干燥的方法，可大大提高加热固化干燥效率的同时，提高浸液在基布上形成浸膜后的各种性能，取得了明显预料不到的技术效果。在基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层和由聚间苯二甲酰间苯二胺纤维制成的迎尘层，显著提高了滤料的耐磨性能和工作温度，使用寿命至少延长了两倍，迎尘层背尘面经机械起绒处理后，滤袋随反冲洗的次数增加补尘率下降不明显。
本发明提供了一种除尘耐高温滤料及其制备方法的思路及方法，具体实现该技术方案的方法和途径很多，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本发明的保护范围。本实施例中未明确的各组成部分均可用现有技术加以实现。

Claims (10)

1.一种除尘耐高温滤料，其特征在于，包括基布层以及分别设置在基布层两面的耐磨层和迎尘层，所述基布层由经线和纬线织网得到，经线由聚四氟乙烯纤维和氧化锆纤维加捻并股编织而成，纬线由聚酰亚胺纤维和石英纤维加捻并股编织而成，基布经浸液处理后表层喷涂有导电金属粉，然后经微波固化成型得到；所述耐磨层由无碱玻璃纤维制成，厚度为1～1.5mm，所述迎尘层由聚间苯二甲酰间苯二胺纤维制成，厚度为1～2mm，迎尘层的迎尘面针刺有一层宣武岩纤维网，背尘面经机械起绒处理；所述耐磨层和迎尘层分别通过针刺与基布层连接。
2.根据权利要求1所述的一种除尘耐高温滤料，其特征在于，所述经线由体积比为6～7:3～4的聚四氟乙烯纤维和氧化锆纤维加捻并股编织而成。
3.根据权利要求1所述的一种除尘耐高温滤料，其特征在于，所述纬线由体积比为6～7:3～4的聚酰亚胺纤维和石英纤维加捻并股编织而成。
4.根据权利要求1所述的一种除尘耐高温滤料，其特征在于，所述经线线径为0.2～0.3mm，所述纬线线径为0.2～0.3mm，织网得到的基布经线密度为18～24根/cm，纬线密度为12～18根/cm。
5.根据权利要求1所述的一种除尘耐高温滤料，其特征在于，所述浸液由以下按重量份计的组份组成：聚氨酯20～35份，有机硅树脂20～40份，全氟烷基乙基丙烯酸酯10～20份，活性炭5～7份，氢氧化镁3～5份，氧化锑2～4份，叔丁基对苯二酚衍生物5～8份，硅油10～15份。
6.根据权利要求1至5所述的一种除尘耐高温滤料，其特征在于，所述宣武岩纤维预先浸渍聚四氟乙烯乳液处理。
7.根据权利要求6所述的一种除尘耐高温滤料，其特征在于，所述宣武岩纤维网每平方米的重量为200～400g。
8.权利要求1所述除尘耐高温滤料制备方法，其特征在于，包括如下步骤：
步骤一：将聚四氟乙烯纤维和氧化锆纤维分别经过梳理后加捻并股编织成经线，将聚酰亚胺纤维和石英纤维分别经过梳理后加捻并股编织成纬线；
步骤二：将步骤一得到的经线和纬线通过织布机织网得到基布；
步骤三：将步骤二得到的基布进行浸液处理。
步骤四：取出浸液后的基布，至于微波中进行固化成型；
步骤五：在固化得到的基布上下表面分别针刺由无碱玻璃纤维制成的耐磨层和由聚间苯二甲酰间苯二胺纤维制成的迎尘层即得。
9.根据权利要求8所述的除尘耐高温滤料制备方法，其特征在于，步骤三中，所述浸液处理的温度为40～60℃，时间为3～6h。
10.根据权利要求8所述的除尘耐高温滤料制备方法，其特征在于，步骤四中，所述微波的加热功率为1～2KW，时间为30～50s。
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