CN114164561A - 一种芳砜纶驻极体高温过滤材料的制备方法 - Google Patents
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Abstract
本发明公开了先制备得到由预过滤层和主过滤层组成的双层复合纤维，其中预过滤层的纤维丝径分布在3‑10um；主过滤层的纤维丝径分布在1‑5um；再对双层复合纤维进行注极而得芳砜纶驻极体高温过滤材料产品，预过滤层和主过滤层采用双喷丝板熔喷工艺制得，预过滤层和主过滤层采用双喷丝板分别挤出，两喷丝板中挤出的超细纤维在凝网帘上成网具有一定的时间差，从而形成不同丝径分布的双层复合纤维。本发明的芳砜纶高温驻极体过滤材料具有极高的驻极体电荷稳定性、卓越的过滤效率、使用寿命长，应用广泛，适应性广。
Description
技术领域
本发明属于高分子滤材技术领域，特别涉及一种芳砜纶驻极体高温过滤材料的制备方法。
背景技术
随着现代工业的发展，工业生产过程中排放的高温烟气粉尘SOx、NOx等有害气体，对环境和人类身体健康造成危害，甚至危及生命。
目前，用于高温过滤的材料主要由于织物孔径大、结构疏松、对小粒径烟尘颗粒物过滤效果差、除尘效率低，并且在高温环境下的使用寿命较短，频繁更换滤袋等问题。
我国对耐高温纤维的需求量也逐年递增，，但是耐高温纤维在我国的生产尚处于起步阶段许多关键技术被国外公司垄断。当前我们的迫切需求，对耐高温过滤材料的研发尤为重要。
芳砜纶(PSA纤维)具有优良的耐热阻燃过滤性能、优异的物理机械性能和化学稳定性。PSA纤维长期使用温度为250℃，100h加热后强度保持率大于80％，极限氧指数(LOI)为33％，符合耐高温滤料用纤维原料的基本性能要求，芳砜纶在高温烟气净化领域的应用较少。
为了在芳砜纶过滤阻力不变的前提下提高过滤效率，可对芳砜纶熔喷过滤材料进行驻极处理，使其纤维带电，利用独特的静电过滤机制过滤空气中的微小颗粒。
发明内容
本发明针对上述现有技术的存在的问题，提供一种芳砜纶驻极体高温过滤材料的制备方法。
本发明通过以下技术手段实现解决上述技术问题的：
先制备得到由预过滤层和主过滤层组成的双层复合纤维，其中预过滤层的纤维丝径分布在3-10um；主过滤层的纤维丝径分布在1-5um；再对双层复合纤维进行注极而得芳砜纶驻极体高温过滤材料产品。
上述的预过滤层和主过滤层采用双喷丝板熔喷工艺制得，预过滤层和主过滤层采用双喷丝板分别挤出，两喷丝板中挤出的超细纤维在凝网帘上成网具有一定的时间差，从而形成不同丝径分布的双层复合纤维。
预过滤层的喷丝板孔径直径为0.4～0.6um，长径比为6～12；主过滤层的喷丝板孔径直径为0.1～0.4um，长径比为10～17，从而形成工艺控制条件下的预过滤层和主过滤层的纤维丝径尺寸要求。
对双层复合纤维进行注极采用电晕放电法或电击穿极化方法，其中采用电晕放电法进行驻极时，驻极电压正极为20～30KV，负极为10～30KV，驻极距离为2-5cm，驻极时间为1-4min。
所制得的芳砜纶双层复合纤维每平方米克重为50～200克，厚度为0.50～1.50毫米。
本发明的有益效果为：芳砜纶驻极体过滤机理是静电效应和非静电效应相结合，通过沉积在纤维上的电荷所形成的电场吸附微小颗粒物，实现静电过滤。同时纤维间的孔隙使材料通过直接捕获、惯性沉积、扩散效应和重力效应等实现机械过滤效果，是实现滤料高效低阻的有效方法。本发明的芳砜纶高温驻极体过滤材料具有极高的驻极体电荷稳定性、卓越的过滤效率、使用寿命长，应用广泛，适应性广。
附图说明
图1为电晕放电法的原理图。
具体实施方式
为使本发明实施例的目的、技术方案和优点更加清楚，下面将结合本发明实施例，对本发明的技术方案进行清楚、完整地描述，显然，所描述的实施例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他实施例，都属于本发明保护的范围。
本发明的芳砜纶驻极体高温过滤材料的制备方法具体包括：
步骤一：设置预过滤层的喷丝板孔径直径为0.4～0.6um，长径比为6～12；设置主过滤层的喷丝板孔径直径为0.1～0.4um，长径比为10～17；利用熔喷工艺控制两个喷丝板间隔性向凝网帘上挤出超细纤维，从而形成纤维丝径分布在3-10um的预过滤层以及纤维丝径分布在1-5um的主过滤层的，该预过滤层与主过滤层共同组成芳砜纶双层复合纤维；
步骤二：参见图1，采用电晕放电法对芳砜纶双层复合纤维驻极，驻极电压正极为20～30KV，负极为10～30KV，驻极距离为2-5cm，驻极时间为1-4min。
下面结合具体实施例进行说明。
实施例1
(1)采用熔喷工艺制备芳砜纶纤维预过滤层和主过滤层组成的双层复合纤维，其中预过滤层纤维丝径分布在3-10um；主过滤层纤维丝径分布在1-5um；预过滤层和主过滤层采用双喷丝板分别挤出，预过滤层的喷丝板孔径直径为0.4um，长径比为8；主过滤层的喷丝板孔径直径为0.2um，长径比为13。
(2)再对双层复合纤维进行注板而得产物；采用电晕驻极法，注板电压正极选择25KV，负极选择20KV，注板距离为2.5cm，驻极时间3min。
实施例2
(1)采用熔喷工艺制备芳砜纶纤维预过滤层和主过滤层组成的双层复合纤维，其中预过滤层纤维丝径分布在3-10um；主过滤层纤维丝径分布在1-5um；预过滤层和主过滤层采用双喷丝板分别挤出，预过滤层的喷丝板孔径直径为0.5um，长径比为7；主过滤层的喷丝板孔径直径为0.3um，长径比为13。
(2)再对双层复合纤维进行注极而得产物；采用电晕驻极法，注板电压正极选择30KV，负极选择25KV，注板距离为3.0cm，驻极时间1.5min。
实施例3
(1)采用熔喷工艺制备芳砜纶纤维预过滤层和主过滤层组成的双层复合纤维，其中预过滤层纤维丝径分布在3-10um；主过滤层纤维丝径分布在1-5um；预过滤层和主过滤层采用双喷丝板分别挤出，预过滤层的喷丝板孔径直径为0.5um，长径比为6；主过滤层的喷丝板孔径直径为0.3um，长径比为12。
(2)再对双层复合纤维进行注板而得产物；采用电晕驻极法，注板电压正极选择25KV，负极选择25KV，注板距离为2.0cm，驻极时间2min。
按照HCRJ 042—1999(附录E)中滤料耐热性能检测试验方法，对芳砜纶滤料的耐热性能进行检测。表1为芳砜纶滤料在250℃高温下的耐热性能试验结果及达标情况。
| 检验项目 | 实施例1 | 实施例2 | 实施例3 | 指标要求 |
| 250℃、24h加热后强度保持率/％ | 110.2 | 115.2 | 113.2 | ≥95 |
| 250℃、72h加热后强度保持率/％ | 106.0 | 109.0 | 107.0 | ≥90 |
| 250℃、100h加热后强度保持率/％ | 110.0 | 114.0 | 112.1 | ≥80 |
表1：芳砜纶驻极体高温过滤材料耐热性能试验结果及达标情况
表2为芳砜纶驻极体高温过滤材料过滤性能测试数据。采用大气尘作为实验尘源时，用大气尘埃计数器测定滤材过滤效率。上、下风侧计数浓度之差与上风侧浓度之比，为受试滤材的大气尘计数过滤效率，以百分数表示。
式中；Pi—粒径分组(≥0.5um,≥1.0um.≥2.0um，≥2.0um，≥5.0um)计数效率；
N1i—上风侧大于或等于某粒径粒子计数浓度的平均值(粒/L)；
N2i—下风侧大于或等于某粒径粒子计数浓度的平均值(粒/L)。
表2：芳砜纶驻极体高温过滤材料过滤性能测试数据
| 检验项目/250℃ | 透气率/m·s<sup>-1</sup> | 增加率/％ | 透气度/m<sup>3</sup>·m<sup>-2</sup>·min<sup>-1</sup> |
| 实施例1 | 0.400 | 2.60 | 24.64 |
| 实施例2 | 0.415 | 2.65 | 24.88 |
| 实施例3 | 0.425 | 2.77 | 25.06 |
表3：芳砜纶驻极体高温过滤材料透气性能测试数据
要说明的是，在本文中，如若存在第一和第二等之类的关系术语仅仅用来将一个实体或者操作与另一个实体或操作区分开来，而不一定要求或者暗示这些实体或操作之间存在任何这种实际的关系或者顺序。而且，术语“包括”、“包含”或者其任何其他变体意在涵盖非排他性的包含，从而使得包括一系列要素的过程、方法、物品或者设备不仅包括那些要素，而且还包括没有明确列出的其他要素，或者是还包括为这种过程、方法、物品或者设备所固有的要素。在没有更多限制的情况下，由语句“包括一个……”限定的要素，并不排除在包括所述要素的过程、方法、物品或者设备中还存在另外的相同要素。
以上实施例仅用以说明本发明的技术方案，而非对其限制；尽管参照前述实施例对本发明进行了详细的说明，本领域的普通技术人员应当理解：其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换；而这些修改或者替换，并不使相应技术方案的本质脱离本发明各实施例技术方案的精神和范围。
Claims (4)
1.一种芳砜纶驻极体高温过滤材料的制备方法，其特征在于，依次包括如下步骤：
S1滤材制备：采用具有喷丝孔径差异的双喷丝板间隔性在凝网帘上挤出成型包括预过滤层和主过滤层的芳砜纶双层复合纤维，所述预过滤层纤维丝径为3-10um，所述主过滤层纤维丝径为1-5um；
S2驻极：对芳砜纶双层复合纤维驻极。
2.根据权利要求1所述的一种芳砜纶驻极体高温过滤材料的制备方法，其特征在于，所述预过滤层的喷丝板孔径直径为0.4～0.6um，长径比为6～12，所述主过滤层的喷丝板孔径直径为0.1～0.4um，长径比为10～17。
3.根据权利要求1所述的一种芳砜纶驻极体高温过滤材料的制备方法，其特征在于，所述S2驻极采用电晕放电法，驻极电压正极为20～30KV，负极为10～30KV，驻极距离为2-5cm，驻极时间为1-4min。
4.根据权利要求1所述的一种芳砜纶驻极体高温过滤材料的制备方法，其特征在于，所述芳砜纶双层复合纤维的每平方米克重为50～200克，厚度为0.50～1.50毫米。
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| CN111235863A (zh) * | 2020-03-12 | 2020-06-05 | 上海市纺织科学研究院有限公司 | 一种芳砜纶驻极体过滤材料的制备方法 |
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| JP2008221074A (ja) * | 2007-03-09 | 2008-09-25 | Toyobo Co Ltd | エレクトレット濾材およびその製造方法 |
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| WO2015017795A2 (en) * | 2013-08-02 | 2015-02-05 | Cummins Filtration Ip, Inc. | Gradient nanofiber filter media |
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