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CN111086299A - 一种耐高温导电针刺毡的加工方法 - Google Patents

一种耐高温导电针刺毡的加工方法 Download PDF

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CN111086299A
CN111086299A CN201911162082.9A CN201911162082A CN111086299A CN 111086299 A CN111086299 A CN 111086299A CN 201911162082 A CN201911162082 A CN 201911162082A CN 111086299 A CN111086299 A CN 111086299A
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fiber
aramid
fibers
conductive
needled felt
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范福中
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Anhui Litongda Fiber New Material Co ltd
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Abstract

本发明属于除尘针刺毡技术领域，具体涉及一种耐高温导电针刺毡的加工方法，包括基布层以及基布层表面的导电针刺毡层；所述基布为芳纶纤维基布，导电针刺毡层的制备方法包括纤维原料准备、浸渍液制备、纤维原料预处理、制备针刺毡以及覆膜。本发明相比现有技术具有以下优点：本申请中通过对芳纶纤维和不锈钢纤维分别用浸渍液处理，对工况烟气里的明火、静电火球现象有效控制；通过将芳纶1313纤维、芳纶1414纤维、不锈钢纤维合理配比，能够得到具有一定梯度的面层，配合聚四氟乙烯导电膜的合理制备，在实现耐高温的条件下能够捕捉粒径较小的粉尘，使排放控制的到5g/kwh内，达到排放标准。

Description

一种耐高温导电针刺毡的加工方法
技术领域
本发明属于除尘针刺毡技术领域，具体涉及一种耐高温导电针刺毡的加工方法。
背景技术
在工况过程中的工业粉尘在浓度达到一定程度，如遇静电放电火花或外界点火等因素，易导致爆炸和火灾，在除尘系统中，粉尘在管道内，滤袋上的粉尘之间发生相互摩擦、碰撞、剥离、破碎都会使粉尘和滤料表面产生静电，当滤料表面带有一定量电荷而不能及时释放，就会形成高压放电而产生电火花，极有可能导致粉尘爆炸，这就要求滤料具有防静电性能同时具有耐高温性能，现有的防静电过滤材料一般采用以下3种方法，1）化学纤维与不锈钢纤维混合针刺，2）化学纤维与导电纤维混合针刺，3）在过滤材料中添加防静电剂。而目前高温烟气过滤工程需要考虑针对大于250℃高温烟气进行研究，玻璃纤维耐高温性能突出，具有较强的耐腐蚀性及尺寸稳定性，但其耐折性和耐磨性较差，影响其使用效果，芳纶纤维由于综合性能较好，成为主要的耐高温过滤材料之一，具有优异的热稳定性、阻燃性、电绝缘性、化学稳定性、可纺性及在高温条件下不熔滴的性能，广泛应用于烟气治理系统，但当烟气温度达到250℃时，芳纶针刺毡孔径分布会明显增大，内部结构被破坏，进而影响过滤性能，因此，需要改进芳纶针刺毡以改善其耐高温性能。
发明内容
本发明的目的是针对现有芳纶针刺毡在烟气温度达到250℃时，芳纶针刺毡孔径分布会明显增大，内部结构被破坏，进而影响过滤性能的问题，提供了一种耐高温导电针刺毡的加工方法。
本发明是通过以下技术方案实现的：一种耐高温导电针刺毡的加工方法，包括基布层以及基布层表面的导电针刺毡层；所述基布为芳纶纤维基布，导电针刺毡层的制备方法包括以下步骤：
（1）准备纤维原料：芳纶1313纤维，线纤维密度为2.2-2.6dtex，长度为50-54mm；芳纶1414纤维，线纤维密度为0.72-0.78dtex，长度为34-38mm；不锈钢纤维，线纤维密度为0.5dtex，长度为25-30mm；
（2）制备浸渍液，按重量份计，将含钴纳米粉6-10份、络合剂0.6-0.8份、活性剂0.2-0.3份、聚四氟乙烯20-30份、全氟环醚6-10份、去离子水60份搅拌均匀即得；
（3）对纤维原料预处理：分别将芳纶1313纤维、芳纶1414纤维、不锈钢纤维在浸渍液中浸没，浸渍时间为6-12小时，完成后在温度为80-100℃的条件下干燥3-7小时；
（4）将浸没处理后的芳纶1313纤维、芳纶1414纤维、不锈钢纤维按重量比5:3:2混合，利用开松机松解后充分混合，得到混合纤维导入气压棉箱，喂入梳理机，进入梳理机后对混合纤维进行梳理后纤维单网，将纤维单网在芳纶纤维基布表面重叠铺设，规格为700-800g/m²，进入针刺机，制成导电针刺毡，针刺密度为200刺/cm²；
（5）将导电针刺毡在850-950℃的条件下进行烧结，然后引入热覆膜机与聚四氟乙烯导电膜进行热压覆膜即可。
具体的，所述芳纶纤维基布的材质为芳纶纤维，芳纶纤维线密度为2dtex，长度为50-54mm，基布面密度为130g/m²。
具体的，所述含钴纳米粉的制备方法包括以下内容：按重量份计，将22-28份纳米钴粉、6-10份碳分子筛、3-5份甲基纤维素、1-2份γ-巯丙基三甲氧基硅烷、12-16份对叔丁基苯酚甲醛树酯、2-4份聚4-甲基-1-戊烯、6-10份含氟丙烯酸酯树脂混合均匀，然后投入混捏机中混碾2-4小时，完成后挤出得到条状材料，在温度为100℃的烘箱中干燥1小时后研磨成粉，得到含钴纳米粉；
纳米钴粉是通过气相蒸发冷凝法制备，纯度高、粒径小，球形度高，密度小且颗粒均匀，比表面积大，具有耐高温性能，可用于高强度合金或防腐合金，还能作为催化剂、干燥剂、粘结剂。
具体的，所述钴粉的粒径为50-100nm，密度为8.9g/cm³，产品纯度＞99.5%。
具体的，所述碳分子筛的颗粒直径为1.5mm，堆比重为630-650g/L，抗压强度为≥100N/颗，吸附压力为0.75-0.8MPa；其型号为YTCMS-200、YTCMS-220、YTCMS-240、YTCMS-260中的一种；
碳分子筛是一种非极性碳素材料，其结构中的打孔和中孔起到通道作用，微孔和亚微孔起到容纳作用。
所述对叔丁基苯酚甲醛树酯具有较强的耐热性，机械强度好，伸长率低，具有较好的耐化学腐蚀性和电绝缘性，通常用作胶黏剂、涂料、涤纶带和防腐胶等。
含钴纳米粉通过将纳米钴粉、碳分子筛与其他辅助材料有效组合，能够使所得含钴纳米粉为结构稳定，且具有导电性能的材质；通过与聚四氟乙烯、全氟环醚混合稳定附着于纤维表面，改善芳纶纤维的耐高温性能，使其能够长时间在250℃左右的工作环境使用，不会出现针刺毡孔径增大，保持对微小粉尘的有效捕捉。
具体的，所述络合剂为柠檬酸、氨基乙酸、二乙醇胺、三乙醇胺、乙二胺、乙二胺四乙酸中的一种或多种；所述活性剂为N,N-二甲基十二烷基二甲基叔胺。
在耐高温导电针刺毡加工方法过程中，步骤（5）所述聚四氟乙烯导电膜的制备方法为，所涉及原料按重量份计，将纳米氧化锆置于相当于其重量3倍且质量浓度为10%的盐酸溶液中，搅拌处理30-40分钟后，过滤，在温度80℃的条件下烘干，得到盐酸处理后的纳米氧化锆；然后将聚四氟乙烯乳液20-30份、盐酸处理后的纳米氧化锆2-6份、润滑剂0.2-0.8份、氟硅烷偶联剂的异丙醇稀释溶液12-18份、石墨粉1-2份搅拌混合，预压得到圆柱棒料，然后经挤压、压延得到厚度为0.12mm的片状膜材，再经脱脂、拉伸、固化后收卷得到。
具体的，所述纳米氧化锆的粒度为400目以上；石墨粉的粒度为400目以上；润滑剂为硬脂酸酰胺、油酸酰胺、硬脂酸正丁酯、甘油三烃硬脂酸酯、微晶石蜡、氧化聚乙烯蜡中的一种或几种混合。
具体的，所述质量浓度为10%的盐酸溶液的温度为80-90℃。
芳纶纤维耐高温、耐老化、耐酸碱、抗腐蚀、耐摩擦，具有较好的尺寸稳定性，芳纶1313纤维为间位芳纶，芳纶1414纤维为对位芳纶，芳纶1414纤维相比芳纶硬度大，强度高，其强度是优质钢材的5-6倍，模量是钢材或玻璃纤维的2-3倍，韧性是钢材的2倍，但其价格较贵。
聚四氟乙烯导电膜的制备过程中通过对纳米氧化锆用盐酸溶液处理，改变其表面性能，而纳米氧化锆在常温条件下是绝缘体，在高温条件下则具有较好的导电性，通过表面处理与其他基材有效结合，能够保证在高温使用环境中的导电性能，同时还具有较好的化学稳定性和材料复合性；与少量的石墨粉配合作用，能够保证聚四氟乙烯导电膜的导电性能。
本发明相比现有技术具有以下优点：本申请中通过对芳纶纤维和不锈钢纤维分别用浸渍液处理，对工况烟气里的明火、静电火球现象有效控制；通过将芳纶1313纤维、芳纶1414纤维、不锈钢纤维合理配比，能够得到具有一定梯度的面层，配合聚四氟乙烯导电膜的合理制备，在实现耐高温的条件下能够捕捉粒径较小的粉尘，使排放控制的到5g/kwh内，达到排放标准；长时间在250-280℃内工作，能够保证针刺毡内部结构的稳定性，进而保证过滤稳定性。
具体实施方式
实施例1
一种耐高温导电针刺毡的加工方法，包括基布层以及基布层表面的导电针刺毡层；所述基布为芳纶纤维基布，所述芳纶纤维基布的材质为芳纶纤维，芳纶纤维线密度为2dtex，长度为50-54mm，基布面密度为130g/m²；导电针刺毡层的制备方法包括以下步骤：
（1）准备纤维原料：芳纶1313纤维，线纤维密度为2.4dtex，长度为52mm；芳纶1414纤维，线纤维密度为0.75dtex，长度为36mm；不锈钢纤维，线纤维密度为0.5dtex，长度为28mm；
（2）制备浸渍液，按重量份计，将含钴纳米粉8份、氨基乙酸0.7份、N,N-二甲基十二烷基二甲基叔胺0.25份、聚四氟乙烯25份、全氟环醚8份、去离子水60份搅拌均匀即得；
所述含钴纳米粉的制备方法包括以下内容：按重量份计，将25份纳米钴粉、8份型号为YTCMS-200的碳分子筛、4份甲基纤维素、1.5份γ-巯丙基三甲氧基硅烷、14份对叔丁基苯酚甲醛树酯、3份聚4-甲基-1-戊烯、8份含氟丙烯酸酯树脂混合均匀，然后投入混捏机中混碾3小时，完成后挤出得到条状材料，在温度为100℃的烘箱中干燥1小时后研磨成粉，得到含钴纳米粉；
（3）对纤维原料预处理：分别将芳纶1313纤维、芳纶1414纤维、不锈钢纤维在浸渍液中浸没，浸渍时间为9小时，完成后在温度为90℃的条件下干燥5小时；
（4）将浸没处理后的芳纶1313纤维、芳纶1414纤维、不锈钢纤维按重量比5:3:2混合，利用开松机松解后充分混合，得到混合纤维导入气压棉箱，喂入梳理机，进入梳理机后对混合纤维进行梳理后纤维单网，将纤维单网在芳纶纤维基布表面重叠铺设，规格为750g/m²，进入针刺机，制成导电针刺毡，针刺密度为200刺/cm²；
（5）将导电针刺毡在900℃的条件下进行烧结，然后引入热覆膜机与聚四氟乙烯导电膜进行热压覆膜即可；
所述聚四氟乙烯导电膜的制备方法为，所涉及原料按重量份计，将纳米氧化锆置于相当于其重量3倍且质量浓度为10%、温度为85℃的盐酸溶液中，搅拌处理35分钟后，过滤，在温度80℃的条件下烘干，得到盐酸处理后的纳米氧化锆；然后将聚四氟乙烯乳液25份、盐酸处理后的纳米氧化锆4份、硬脂酸正丁酯0.5份、氟硅烷偶联剂的异丙醇稀释溶液15份、石墨粉1.5份搅拌混合，预压得到圆柱棒料，然后经挤压、压延得到厚度为0.12mm的片状膜材，再经脱脂、拉伸、固化后收卷得到。
实施例2
一种耐高温导电针刺毡的加工方法，包括基布层以及基布层表面的导电针刺毡层；所述基布为芳纶纤维基布，所述芳纶纤维基布的材质为芳纶纤维，芳纶纤维线密度为2dtex，长度为50mm，基布面密度为130g/m²；导电针刺毡层的制备方法包括以下步骤：
（1）准备纤维原料：芳纶1313纤维，线纤维密度为2.6dtex，长度为54mm；芳纶1414纤维，线纤维密度为0.78dtex，长度为38mm；不锈钢纤维，线纤维密度为0.5dtex，长度为25mm；
（2）制备浸渍液，按重量份计，将含钴纳米粉10份、三乙醇胺0.8份、N,N-二甲基十二烷基二甲基叔胺0.2份、聚四氟乙烯30份、全氟环醚10份、去离子水60份搅拌均匀即得；
所述含钴纳米粉的制备方法包括以下内容：按重量份计，将28份纳米钴粉、10份型号为YTCMS-220的碳分子筛、5份甲基纤维素、2份γ-巯丙基三甲氧基硅烷、12份对叔丁基苯酚甲醛树酯、4份聚4-甲基-1-戊烯、10份含氟丙烯酸酯树脂混合均匀，然后投入混捏机中混碾4小时，完成后挤出得到条状材料，在温度为100℃的烘箱中干燥1小时后研磨成粉，得到含钴纳米粉；
（3）对纤维原料预处理：分别将芳纶1313纤维、芳纶1414纤维、不锈钢纤维在浸渍液中浸没，浸渍时间为12小时，完成后在温度为100℃的条件下干燥7小时；
（4）将浸没处理后的芳纶1313纤维、芳纶1414纤维、不锈钢纤维按重量比5:3:2混合，利用开松机松解后充分混合，得到混合纤维导入气压棉箱，喂入梳理机，进入梳理机后对混合纤维进行梳理后纤维单网，将纤维单网在芳纶纤维基布表面重叠铺设，规格为800g/m²，进入针刺机，制成导电针刺毡，针刺密度为200刺/cm²；
（5）将导电针刺毡在850℃的条件下进行烧结，然后引入热覆膜机与聚四氟乙烯导电膜进行热压覆膜即可；
所述聚四氟乙烯导电膜的制备方法为，所涉及原料按重量份计，将纳米氧化锆置于相当于其重量3倍且质量浓度为10%、温度为90℃的盐酸溶液中，搅拌处理30分钟后，过滤，在温度80℃的条件下烘干，得到盐酸处理后的纳米氧化锆；然后将聚四氟乙烯乳液20份、盐酸处理后的纳米氧化锆6份、甘油三烃硬脂酸酯0.2份、氟硅烷偶联剂的异丙醇稀释溶液18份、石墨粉2份搅拌混合，预压得到圆柱棒料，然后经挤压、压延得到厚度为0.12mm的片状膜材，再经脱脂、拉伸、固化后收卷得到。
实施例3
一种耐高温导电针刺毡的加工方法，包括基布层以及基布层表面的导电针刺毡层；所述基布为芳纶纤维基布，所述芳纶纤维基布的材质为芳纶纤维，芳纶纤维线密度为2dtex，长度为54mm，基布面密度为130g/m²；导电针刺毡层的制备方法包括以下步骤：
（1）准备纤维原料：芳纶1313纤维，线纤维密度为2.2dtex，长度为54mm；芳纶1414纤维，线纤维密度为0.72dtex，长度为34mm；不锈钢纤维，线纤维密度为0.5dtex，长度为30mm；
（2）制备浸渍液，按重量份计，将含钴纳米粉6份、乙二胺四乙酸0.6份、N,N-二甲基十二烷基二甲基叔胺0.3份、聚四氟乙烯20份、全氟环醚6份、去离子水60份搅拌均匀即得；
所述含钴纳米粉的制备方法包括以下内容：按重量份计，将22份纳米钴粉、6份型号为YTCMS-240的碳分子筛、3份甲基纤维素、1份γ-巯丙基三甲氧基硅烷、16份对叔丁基苯酚甲醛树酯、2份聚4-甲基-1-戊烯、6份含氟丙烯酸酯树脂混合均匀，然后投入混捏机中混碾2小时，完成后挤出得到条状材料，在温度为100℃的烘箱中干燥1小时后研磨成粉，得到含钴纳米粉；
（3）对纤维原料预处理：分别将芳纶1313纤维、芳纶1414纤维、不锈钢纤维在浸渍液中浸没，浸渍时间为6小时，完成后在温度为80℃的条件下干燥3小时；
（4）将浸没处理后的芳纶1313纤维、芳纶1414纤维、不锈钢纤维按重量比5:3:2混合，利用开松机松解后充分混合，得到混合纤维导入气压棉箱，喂入梳理机，进入梳理机后对混合纤维进行梳理后纤维单网，将纤维单网在芳纶纤维基布表面重叠铺设，规格为700g/m²，进入针刺机，制成导电针刺毡，针刺密度为200刺/cm²；
（5）将导电针刺毡在950℃的条件下进行烧结，然后引入热覆膜机与聚四氟乙烯导电膜进行热压覆膜即可；
所述聚四氟乙烯导电膜的制备方法为，所涉及原料按重量份计，将纳米氧化锆置于相当于其重量3倍且质量浓度为10%、温度为80℃的盐酸溶液中，搅拌处理40分钟后，过滤，在温度80℃的条件下烘干，得到盐酸处理后的纳米氧化锆；然后将聚四氟乙烯乳液30份、盐酸处理后的纳米氧化锆2份、氧化聚乙烯蜡0.8份、氟硅烷偶联剂的异丙醇稀释溶液12份、石墨粉1份搅拌混合，预压得到圆柱棒料，然后经挤压、压延得到厚度为0.12mm的片状膜材，再经脱脂、拉伸、固化后收卷得到。
按各组方法制备所得试样规格为250mm×250mm，根据GB/T 24218.3-2010方法检测断裂强力和断裂伸长率，利用YG（B）026D-500型电子织物强力机对试样测试力学性能，纵横各测10次，拉伸速度为100mm/min，利用GB/T5453-1997对透气性进行检测；并检测其电导率；在温度为250℃的KSW型电炉温度控制器中热处理30分钟，完成后对尺寸稳定性进行检测，具体的为在热处理前后对纵、横尺寸进行标记和计算，得到热收缩率；并检测其电导率。
经过设置实验验证，单独使用芳纶1313纤维或与芳纶1414纤维不锈钢纤维组合时，会影响针刺毡的过滤效果，同时单独使用芳纶1313纤维与不锈钢纤维组合，其力学性能相对较差，而单独使用芳纶1414纤维又会增加制作成本，因此，需要对不同规格不同性质的纤维原料合理组合后使用。
设置对照组1，对浸渍液的原料进行调整，将含钴纳米粉替换为纳米钴粉，其余内容与实施例1中相同；设置对照组2，将实施例1浸渍液中碳分子筛去掉，其余内容不变；设置对照组3，将实施例1中纳米氧化锆去掉，其余内容不变；
在数据检测时，每组数据检测重复3-5次，最后求平均值得到以下内容：
表1
Figure 263149DEST_PATH_IMAGE002
通过表1中数据可以看出，本申请中所得针刺毡的电导率和平均透气性能达到使用要求，含钴纳米粉替换为纳米钴粉会影响针刺毡的力学性能，但对导电性以及透气性影响不大。
在热处理后对以上数据进行检测，得到以下结果：
表2
Figure 865776DEST_PATH_IMAGE004
通过表2中数据可以看出，本发明中对照组1中透气率增加，会在一定程度上影响过滤效果；而去掉纳米氧化锆会影响针刺毡的导电性能。

Claims (9)

1.一种耐高温导电针刺毡的加工方法，包括基布层以及基布层表面的导电针刺毡层；其特征在于，所述基布为芳纶纤维基布，导电针刺毡层的制备方法包括以下步骤：
（1）准备纤维原料：芳纶1313纤维，线纤维密度为2.2-2.6dtex，长度为50-54mm；芳纶1414纤维，线纤维密度为0.72-0.78dtex，长度为34-38mm；不锈钢纤维，线纤维密度为0.5dtex，长度为25-30mm；
（2）制备浸渍液，按重量份计，将含钴纳米粉6-10份、络合剂0.6-0.8份、活性剂0.2-0.3份、聚四氟乙烯20-30份、全氟环醚6-10份、去离子水60份搅拌均匀即得；
（3）对纤维原料预处理：分别将芳纶1313纤维、芳纶1414纤维、不锈钢纤维在浸渍液中浸没，浸渍时间为6-12小时，完成后在温度为80-100℃的条件下干燥3-7小时；
（4）将浸没处理后的芳纶1313纤维、芳纶1414纤维、不锈钢纤维按重量比5:3:2混合，利用开松机松解后充分混合，得到混合纤维导入气压棉箱，喂入梳理机，进入梳理机后对混合纤维进行梳理后纤维单网，将纤维单网在芳纶纤维基布表面重叠铺设，规格为700-800g/m²，进入针刺机，制成导电针刺毡，针刺密度为200刺/cm²；
（5）将导电针刺毡在850-950℃的条件下进行烧结，然后引入热覆膜机与聚四氟乙烯导电膜进行热压覆膜即可。
2.如权利要求1所述一种耐高温导电针刺毡的加工方法，其特征在于，所述芳纶纤维基布的材质为芳纶纤维，芳纶纤维线密度为2dtex，长度为50-54mm，基布面密度为130g/m²。
3.如权利要求1所述一种耐高温导电针刺毡的加工方法，其特征在于，所述含钴纳米粉的制备方法包括以下内容：按重量份计，将22-28份纳米钴粉、6-10份碳分子筛、3-5份甲基纤维素、1-2份γ-巯丙基三甲氧基硅烷、12-16份对叔丁基苯酚甲醛树酯、2-4份聚4-甲基-1-戊烯、6-10份含氟丙烯酸酯树脂混合均匀，然后投入混捏机中混碾2-4小时，完成后挤出得到条状材料，在温度为100℃的烘箱中干燥1小时后研磨成粉，得到含钴纳米粉。
4.如权利要求3所述一种耐高温导电针刺毡的加工方法，其特征在于，所述钴粉的粒径为50-100nm，密度为8.9g/cm³，产品纯度＞99.5%。
5.如权利要求3所述一种耐高温导电针刺毡的加工方法，其特征在于，所述碳分子筛的颗粒直径为1.5mm，堆比重为630-650g/L，抗压强度为≥100N/颗，吸附压力为0.75-0.8MPa。
6.如权利要求1所述一种耐高温导电针刺毡的加工方法，其特征在于，所述络合剂为柠檬酸、氨基乙酸、二乙醇胺、三乙醇胺、乙二胺、乙二胺四乙酸中的一种或多种；所述活性剂为N,N-二甲基十二烷基二甲基叔胺。
7.如权利要求1所述一种耐高温导电针刺毡的加工方法，其特征在于，所述聚四氟乙烯导电膜的制备方法为，所涉及原料按重量份计，将纳米氧化锆置于相当于其重量3倍且质量浓度为10%的盐酸溶液中，搅拌处理30-40分钟后，过滤，在温度80℃的条件下烘干，得到盐酸处理后的纳米氧化锆；然后将聚四氟乙烯乳液20-30份、盐酸处理后的纳米氧化锆2-6份、润滑剂0.2-0.8份、氟硅烷偶联剂的异丙醇稀释溶液12-18份、石墨粉1-2份搅拌混合，预压得到圆柱棒料，然后经挤压、压延得到厚度为0.12mm的片状膜材，再经脱脂、拉伸、固化后收卷得到。
8.如权利要求7所述一种耐高温导电针刺毡的加工方法，其特征在于，所述纳米氧化锆的粒度为400目以上；石墨粉的粒度为400目以上；润滑剂为硬脂酸酰胺、油酸酰胺、硬脂酸正丁酯、甘油三烃硬脂酸酯、微晶石蜡、氧化聚乙烯蜡中的一种或几种混合。
9.如权利要求7所述一种耐高温导电针刺毡的加工方法，其特征在于，所述质量浓度为10%的盐酸溶液的温度为80-90℃。
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