CN102227247A - 具有纳米纤维网层的过滤介质 - Google Patents

具有纳米纤维网层的过滤介质 Download PDF

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CN102227247A
CN102227247A CN2009801481716A CN200980148171A CN102227247A CN 102227247 A CN102227247 A CN 102227247A CN 2009801481716 A CN2009801481716 A CN 2009801481716A CN 200980148171 A CN200980148171 A CN 200980148171A CN 102227247 A CN102227247 A CN 102227247A
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layer
filter
film
medium
fiber net
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CN102227247B (zh
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H·S·林
C-H·池
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DuPont Safety and Construction Inc
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EI Du Pont de Nemours and Co
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    • B01D39/1623Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
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Abstract

本发明公开了一种用于从空气或其他气体中过滤颗粒的过滤介质,所述过滤介质包括膜和位于所述膜上游并与所述膜流体接触的深层过滤层。所述深层过滤层包括纳米纤维网层和位于所述纳米纤维网层上游并与所述纳米纤维网层流体连通的预过滤层。所述预过滤层可以是非织造材料,并且在一个实施方案中,具体地讲还可以使熔喷非织造材料带电。

Description

具有纳米纤维网层的过滤介质
发明领域
本发明涉及过滤,更具体地讲,涉及用于从空气或其他气体中过滤颗粒的包括纳米纤维网层的过滤介质。
背景技术
从气体流中去除颗粒是一项重要的工业单元操作。用于过滤气体流中的颗粒等的常规装置包括但不限于滤袋、滤管、滤板和滤筒。过滤器通常包括介质,气体通过该介质同时该介质将颗粒从气体流中滤除。
通常根据过滤元件接触的流体流、系统的工作条件和要过滤的颗粒的类型来选择过滤介质的类型。可以粗略地将过滤介质分为深层过滤介质或表面过滤介质。颗粒在某种程度上趋于渗透并在深层过滤介质内积聚。相比之下,大部分颗粒在表面过滤介质的表面上聚集。
已知许多材料可用作深层过滤介质,包括纺粘或熔喷纤维网、毡和由包括聚酯、聚丙烯、芳族聚酰胺、纤维素、玻璃和含氟聚合物的多种材料制成的织物。已知的熔喷过滤介质展示出高效率和低压降。
为深层过滤介质(如熔喷介质)提供静电荷可改善其过滤效率。静电过滤材料或驻极体具有静电增强的纤维,这些纤维通过将颗粒吸向纤维并留住颗粒来提高过滤器性能。静电过滤器依靠荷电颗粒来显著增大过滤器给定压降下的收集效率。另外,静电过滤器的压降的增加速率通常比相似效率的机械过滤器的要慢。
静电介质在使用过程中可能损失效率,尤其是当其在过滤元件接触水分或油性颗粒的环境中使用时。静电过滤器接触的许多颗粒和污染物会干扰其过滤功能。例如,液体气溶胶,尤其是油性气溶胶,趋于使驻极体过滤器损失其静电增强的过滤效率。
为了减少这些效应,可通过增加纤维网层或增大驻极体过滤器纤维网的厚度来增加驻极体过滤器中非织造聚合物纤维网的量。然而,增加的纤维网会增大驻极体过滤器两端的压降并增大重量和体积。
表面过滤器,例如膜,已经在某些应用中得到了普及,尤其是室外环境或待过滤流体包含液体气溶胶或粗糙化学物质的那些应用中。在其他应用中,膜过滤介质是有用的,因为其过滤效率比深层过滤介质的过滤效率更稳定。与深层过滤介质不同,膜具有稳定的过滤效率是因为膜过滤器的效率与灰尘颗粒积聚成块不相关。
聚四氟乙烯(PTFE)已经在许多领域展示出效用,例如粗糙化学物质环境,其通常会使许多常规金属和聚合材料降解。颗粒过滤领域的一个重大发展是采用膨胀聚四氟乙烯(ePTFE)膜过滤介质作为常规过滤元件上的表面层压体。此类过滤介质的例子描述于美国专利4,878,930和美国专利5,207,812中,这两个专利涉及用于从移动气体或空气流中去除灰尘颗粒的滤筒。由ePTFE制成的膜有利的一点是防水。然而,与深层过滤介质想比,膜可能显示出相对高的压降和相对低的灰尘容量。因此,在一些应用中,使用膜的过滤元件将需要频繁更换或清洁。
因此,需要这样一种过滤介质,其在清洁或更换前具有优异的使用寿命,并具有比过滤效率与之相当的介质更低的压降。
发明概述
本发明公开了用于从空气或其他气体中过滤颗粒的过滤介质,该过滤介质包括膜和位于膜上游并与膜流体接触的深层过滤层。深层过滤层包括纳米纤维网层和位于该纳米纤维网层上游并与之流体连通的预过滤层。
在本发明的一个实施方案中,纳米纤维网具有至少约2gsm的基重。在另一个实施方案中,预过滤层包括带电非织造材料。带电非织造材料还可包括熔喷纤维网。带电熔喷纤维网还可具有至少约30gsm的基重。
优选实施方案详述
如本文所用,术语“纳米纤维”是指具有小于约1000nm、甚至小于约800nm、甚至介于约50nm和500nm之间、并且甚至介于约100nm和400nm之间的数均直径或横截面的纤维。如本文所用,术语“直径”包括非圆形形状的最大横截面。
术语“非织造材料”是指包括多根无规分布的纤维的纤维网。纤维通常可以彼此结合,或者可以不结合。纤维可以是短纤维或连续纤维。纤维可包含一种材料或多种材料,也可以是不同纤维的组合,或者是分别包含不同材料的类似纤维的组合。“纳米纤维网”是包含纳米纤维的非织造纤维网。如本文所用,术语“纳米纤维网”与术语“纳米纤维网”同义。
术语“流体接触”涉及系统的两个组件,其中一个组件位于另一组件的上游,在系统常规操作期间,基本上流过系统的所有流体均首先通过上游组件,然后通过另外一个组件。如本文所用,术语“流体接触”和“流体连通”同义。
有关两个物品(如两个纤维网或一个纤维网与一个膜)的相对位置的术语“邻近”是指这两个物品彼此流体接触并且安装在相同过滤器主体上。它们可以彼此接触、彼此粘结,也可以在其中间具有间隙,在过滤系统正常运行期间,该间隙将填充液体或气体。
复合过滤介质包括至少一个与膜层流体连通的深层过滤介质层。深层过滤介质层包括与纳米纤维网层流体连通的预过滤层。预过滤层可以包括非织造材料,例如并且不意在限制,由聚丙烯或聚乙烯、非织造聚酯或聚酰胺织物、玻璃纤维、微玻璃纤维、纤维素和聚四氟乙烯组成的熔喷或纺粘纤维网。优选地,复合过滤器包括至少一个熔喷聚合物纤维网。深层过滤介质与纳米纤维网流体接触,纳米纤维网又与过滤膜接触。
通过用热空气的会聚流携带熔纺纤维来制备极精细长丝,从而制备熔喷纤维网。熔喷处理形成连续的亚旦尼尔纤维,其中直径相对小的纤维通常小于10微米。
熔喷聚合物纤维网层可由多种聚合材料制成,包括聚丙烯、聚酯、聚酰胺、聚氯乙烯、聚甲基丙烯酸甲酯和聚乙烯。其中聚丙烯是更优选的聚合材料。通常,形成纤维网的聚合物纤维具有在约0.5微米至约10微米范围内的直径。优选地,纤维直径为约1微米至约5微米。
深层过滤层的厚度并不重要。例如,如果深层过滤介质是熔喷纤维网,则厚度可从约0.25mm至约3mm。更大的厚度导致更高的灰尘容量;然而,过厚的深层过滤介质层可能限制可在复合过滤介质中使用的层的总数。
本领域的技术人员还能够选择深层过滤介质的基重。例如,熔喷聚合物纤维网的重量可以在约1g/m2至约100g/m2范围内,优选地,熔喷纤维网的基重为约10g/m2至约50g/m2
在一个方面,深层过滤介质包括至少一个驻极体过滤介质层,该层包括具有静电荷的高效层。可使用多种已知技术将电荷赋予熔喷纤维网以改善纤维网的过滤性能。
例如,适合的纤维网为通过使纤维网经历一系列电场,使得相邻电场具有相对于彼此基本上相反的极性而方便地冷充电,其采用授予Tsai等人的美国专利5,401,446中提出的方法。如本文所述,纤维网的一面最初经历正电荷,而纤维网的另一面最初经历负电荷。然后使纤维网的第一面经历负电荷,而纤维网的另一面经历正电荷。然而,驻极体过滤材料也可通过多种其他已知技术制成。
深层过滤介质还可以包含添加剂以增强过滤性能,并且还可以具有低含量的可提取烃以改善性能。纤维可以包含某些可熔融加工的碳氟化合物,例如含氟化合物的唑烷酮和哌嗪,以及包含全氟化部分的化合物或低聚物。使用这些添加剂可尤其有利于带电纤维网过滤器的性能。
深层过滤层还包括纳米纤维网。初生纳米纤维网主要包含或仅包含纳米纤维,该纳米纤维有利地通过静电纺纱来制备,例如传统的静电纺纱或电吹法;还可通过熔喷法或其他此类合适的方法制备。传统的静电纺纱是在全文并入本文中的美国专利4,127,706中所述的技术,其中向聚合物溶液施加高电压以生成纳米纤维和非织造垫。然而,静电纺纱方法中的总生产能力太低,因此无法商业化生产基重较重的纤维网。
“电吹”方法在全文以引用方式并入本文中的世界专利公布WO 03/080905中公开。将包含聚合物和溶剂的聚合物溶液流从储罐送至喷丝头内的一系列纺丝喷嘴中,向喷丝头施加高电压,聚合物溶液经喷丝头排出。同时,任选地加热的压缩空气由空气喷嘴排出,该空气喷嘴设置在纺丝喷嘴的侧面或周边。通常向下引导空气以形成吹气流,吹气流包裹住新排出的聚合物溶液并使其向前,并且有助于形成纤维网,纤维网收集于真空室上方的接地多孔收集带上。电吹法使得可在相对短的时间周期内形成商用尺寸和数量的纳米纤维网,其基重超过约1gsm,甚至高达约40gsm或更高。
可将基底或稀松布布置在收集器上以便收集和组合在基底上纺成的纳米纤维网,使得将组合的纤维网用作高性能过滤器、擦拭物等。基底的实例可包括多种非织造布,例如熔喷非织造布、针刺或射流喷网非织造布、织造布、针织布、纸材等,对其使用并无限制,只要能将纳米纤维层添加到基底上。非织造布可包含纺粘纤维、干法成网或湿法成网纤维、纤维素纤维、熔喷纤维、玻璃纤维、或它们的共混物。
对可用于形成本发明的纳米纤维网的聚合物材料没有具体限制,所述聚合物材料包括加聚物和缩聚物材料,例如聚缩醛、聚酰胺、聚酯、聚烯烃、纤维素醚和酯、聚烯化硫、聚亚芳基氧化物、聚砜、改性的聚砜聚合物、以及它们的混合物。这些种类中优选的材料包括交联和非交联形式的不同水解程度(87%至99.5%)的聚(氯乙烯)、聚甲基丙烯酸甲酯(和其他丙烯酸类树脂)、聚苯乙烯、和它们的共聚物(包括ABA型嵌段共聚物)、聚(偏二氟乙烯)、聚(偏二氯乙烯)、聚乙烯醇。优选的加聚物往往是玻璃状的(Tg大于室温)。聚氯乙烯和聚甲基丙烯酸甲酯、聚苯乙烯聚合物的组合物或合金或低结晶度的聚偏氟乙烯和聚乙烯醇材料便是如此。一类优选的聚酰胺缩聚物为尼龙材料,例如尼龙-6、尼龙-6,6、尼龙6,6-6,10等。当通过熔喷法形成本发明的聚合物纳米纤维网时,可使用能够熔喷形成纳米纤维的任何热塑性聚合物,包括聚烯烃,例如聚乙烯、聚丙烯和聚丁烯;聚酯,例如聚(对苯二甲酸乙二酯);以及聚酰胺,例如上述尼龙聚合物。
可能有利的是,向上述多种聚合物中加入本领域已知的增塑剂以降低纤维聚合物的Tg。适合的增塑剂取决于将被静电纺纱或电吹的聚合物,并且取决于纳米纤维网具体的最终应用。例如,尼龙聚合物可用水或甚至用静电纺纱或电吹工艺中的残余溶剂来增塑。可用于降低聚合物Tg的本领域已知的其他增塑剂包括但不限于脂族二元醇类、芳族磺胺类、邻苯二甲酸酯类。邻苯二甲酸酯类包括但不限于选自下列的那些:邻苯二甲酸二丁酯、邻苯二甲酸二己酯、邻苯二甲酸二环己酯、邻苯二甲酸二辛酯、邻苯二甲酸二异癸酯、邻苯二甲酸双十一酯、邻苯二甲酸双十二酯、以及邻苯二甲酸二苯酯等。“Handbook of Plasticizers”(增塑剂手册)(George Wypych编辑,2004 Chemtec Publishing)公开了可用于本发明的其他聚合物/增塑剂组合,该文献以引用方式并入本文。
通过电吹法沉积的并且适用于本发明的纳米纤维的平均纤维直径小于约1000nm,或甚至小于约800nm,或甚至介于约50nm至约500nm之间,以及甚至介于约100nm至约400nm之间。各个纳米纤维层优选地具有至少约1g/m2,以及更优选地至少约2g/m2的基重。各个纳米纤维层还可以具有介于约6g/m2至约100g/m2,并且甚至介于约6g/m2至约60g/m2的基重,以及介于约20μm至约500μm,并且甚至介于约20μm至约300μm的厚度。
深层过滤层的下游是微孔聚合物膜过滤层。微孔聚合物膜旨在捕集通过可移除的深层过滤层的颗粒。微孔聚合物膜膜在从流体流除去颗粒和生物体方面具有经过证明的可信赖性和可靠性。膜的特征通常在于其聚合物组合物、透气率、水入侵压力和过滤效率。
多种微孔聚合物膜可用作膜过滤层,具体取决于应用的要求。膜过滤层可由以下示例性材料构建:硝化纤维、三乙酰纤维素、聚酰胺、聚碳酸酯、聚乙烯、聚丙烯、聚四氟乙烯、聚砜、聚氯乙烯、聚偏二氟乙烯、丙烯酸酯共聚物。
膜过滤层优选地由能够阻止液体通过的疏水材料构建。膜过滤层必须能够经受对过滤介质两端施加的压差,而不会有任何液体通过。优选的膜具有0.2巴至1.5巴的水入侵压力,以及约7弗雷泽至约100弗雷泽的平均透气率,并且更优选地约10弗雷泽至约40弗雷泽的平均透气率。
优选地,膜过滤层为微孔含氟聚合物,例如ePTFE、氟化乙丙烯(FEP)、全氟烷氧基聚合物(PFA)、聚丙烯(PU)、聚乙烯(PE)或超高分子量聚乙烯(uhmwPE)。
最优选地,膜过滤层包含ePTFE。适合的ePTFE膜描述于美国专利5,814,405中。该专利描述的膜具有良好的过滤效率、高气流和破裂强度。该专利充分描述了制备适合的ePTFE膜的方法,这些方法以引用方式并入本文。这些ePTFE膜得自W.L.Gore and Associates,Inc.of Newark,Del.或Donaldson Corporation of Minneapolis,MN。然而,也可以使用由其他方法构建的ePTFE膜。
膜过滤层可任选地包含填充材料以改善过滤器的某些特性。适合的填料,例如炭黑、或其他导电性填料、催化颗粒、热解法二氧化硅、胶态二氧化硅或吸附剂材料,例如活性炭或陶瓷填料,例如活性氧化铝和TiO2,以及可用于本发明的制备填充膜的方法充分描述于美国专利5,814,405中。
可提供支撑层以维持过滤层相对于流体流的正确取向。优选的支撑材料必须具有足够的刚性来支撑膜和可移除的层,但还必须足够柔软和灵活以避免损坏膜。支撑层可包含非织造织物或织造织物。适合的支撑层材料的其他例子可包括但不限于织造和非织造聚酯、聚丙烯、聚乙烯、玻璃纤维、微玻璃纤维和聚四氟乙烯。在褶皱取向,材料应在褶绉中提供气流通道同时保持褶绉分开(即,避免褶绉压扁)。例如纺粘非织造材料的材料尤其适用于本应用。
支撑层可以设置在膜过滤层的上游或下游。任选地,可将支撑材料层合到膜过滤层以形成基底层。在这个方面,基底层有利地提供对上方覆盖的熔喷介质层的支撑并充当最终的过滤表面。
在一个实施方案中,过滤系统可以包括纳米纤维网,该纳米纤维网具有一个或多个与微孔膜流体接触的纳米纤维层。在其他实施方案中,纳米纤维网可以具有根据ISO 534在施加的50kPa负载和200m2的砧面表面积下测定小于约300μm或甚至小于约150μm的厚度,该测定方法并入本文中。
纳米纤维网和膜可彼此相邻,并且可以任选地在表面的一部分或全部上彼此粘结。纳米纤维网和膜的结合可以通过以下方法来制备:将纳米纤维网粘结性地层压到膜上,或通过上述方法中将膜置于收集带上而直接在膜上形成纳米纤维层以形成膜/纳米纤维层结构,在这种情况下,纳米纤维层能够通过机械缠结粘附到膜上。膜的实例可包括多种微孔薄膜,例如拉伸的、填充的聚合物和膨胀的聚四氟乙烯(ePTFE),并且对膜的使用并无限制,只要膜具有所需的过滤性能。
在本发明的一个实施方案中,纳米纤维网和膜彼此流体接触,但不必彼此直接接触。它们可以保持在适当位置,中间有间隙,或它们可放在不同过滤器主体中并且通过流体运送通道或管连接。
膜可包含例如选自下列的聚合物:膨胀聚四氟乙烯、聚砜、聚醚砜、聚偏二氟乙烯、聚碳酸酯、聚酰胺、聚丙烯腈、聚乙烯、聚丙烯、聚酯、乙酸纤维素、硝酸纤维素、混合纤维素酯和它们的共混物和组合。
适合本发明的ePTFE膜可通过许多已知方法制备,但优选地通过将聚四氟乙烯膨胀来获得ePTFE,如美国专利4,187,390、4,110,239和3,953,566中所述,这些专利均以引用方式并入本文。所谓“多孔的”是指膜在20mm水标时具有至少0.05立方米/分钟/平方米(m/min)的透气率。可以使用在20mm水标或更高时具有200m/min透气率的膜。孔为ePTFE的节点和纤丝之间形成的微孔。
同样,可以使用以下专利中任何一项所述的膜:美国专利5,234,751、5,217,666、5,098,625、5,225,131、5,167,890、4,104,394、5,234,739、4,596,837、JPA 1078823和JPA 3-221541,其中对挤出的或成型的未膨胀PTFE进行加热以对制品进行烧结或半烧结。然后对烧结或半烧结的制品进行拉伸以形成所需的孔隙率和所需的特性。
就具体的应用而言,可向PTFE提供填充材料以便针对具体的应用来修改PTFE的特性。例如,从美国专利4,949,284可以了解到,可以将陶瓷过滤器(SiO2)和限量的微玻璃纤维掺入到PTFE材料中;并且在EP-B-0-463106中,提及了二氧化钛、玻璃纤维、炭黑、活性炭等作为填料。
由高度填充的聚合物通常是聚烯烃来制备微孔薄膜的技术是已知的。此类纤维网也适合用作本发明的膜。通常,聚烯烃(通常是聚乙烯)的组合与填充剂(通常是CaCO3)进行配混,然后挤出并拉伸成薄膜以形成微孔薄膜。
可用作本发明过滤膜的适合的微孔膜实例包括美国专利4,472,328、4,350,655和4,777,073中描述的那些,这些专利均以引用方式并入本文。
可将微孔膜和纳米纤维网保持为非粘结状态,或甚至将它们保持在不同过滤器主体中。微孔膜和纳米纤维网可以任选地相互粘结,诸如通过粘合剂粘结、热粘结和超声波粘结,但是也可以采用本领域技术人员已知的任何粘结方法。在一个优选的实施方案中,使用例如适用的层压技术将膜粘结到纳米纤维网上,例如在足以使涂覆到膜或纤维网上的粘合剂熔融的温度下使材料通过热辊隙。其中一个辊的表面可具有浮雕图案,以便在层压体中形成结合图案。
可任选地使用一种或多种粘合剂来将纳米纤维网和微孔膜或层压体粘结到内织物或外织物上。一种适用的粘合剂是热塑性粘合剂,在若干次加热和冷却循环中,该粘合剂在受热时会软化,然后在冷却时硬化。此类热塑性粘合剂的一个实例是“热融”粘合剂。
用于将多孔ePTFE膜层压到织物上的粘合剂也可以是多种含氟化合物分散体或合成胶乳中的一种,包括丁二烯丙烯腈共聚物、基于丙烯酸酯的共聚物、通过乳液聚合作用制备的氯乙烯和偏二氯乙烯聚合物和共聚物、苯乙烯-丁二烯共聚物、以及丁二烯、苯乙烯、和乙烯基吡啶的三聚物的含水阴离子分散体。
在进行层压之前,可使用不同的方法用粘合剂涂覆纳米纤维网或膜。例如,首先可以使用粘合剂涂覆纳米纤维网中需涂覆的区域,然后将ePTFE膜置于所涂覆织物的粘合剂侧上。向膜侧施加传导热和足够的压力,使粘合剂流入膜孔内。如果粘合剂为可交联的,则粘合剂会因为受热而交联,从而导致膜机械附着在基底上。
作为由含氟聚合物和非氟化聚合物的层压体制成的制品和层压方法的另一个例子,美国专利5,855,977公开了一种多层制品,该制品包括基本上非氟化的层和包含共聚化单体单元的含氟聚合物氟化层。该多层制品还包含脂族二胺或多胺。与不含脂族二胺或多胺的多层制品相比,脂族二胺或多胺可使得层之间的粘附性增加。
可使用多种其他方法来提高氟化聚合物层和聚酰胺之间的粘附性。例如,可在两个聚合物层之间加入粘合剂层。美国专利5,047,287公开了一种适用于机动车应用的隔膜,该隔膜包括基底织物,该基底织物具有通过粘合剂粘结到至少一个表面的氟橡胶层,该氟橡胶层包含具有氨基的丙烯腈-丁二烯或丙烯腈-异戊二烯橡胶。
有时也采用对一个或两个层进行表面处理来辅助粘结。例如,有些文献提出用带电气体气氛来处理含氟聚合物层(例如电晕处理),并且随后施加一层第二种材料,例如热塑性聚酰胺。例如,欧洲专利申请0185590(Ueno等人)和0551094(Krause等人)以及美国专利4,933,060(Prohaska等人)和5,170,011(Martucci)。
在某些情况下,将含氟聚合物的共混物和相异层自身用作中间层,以帮助将这两个层结合在一起。欧洲专利申请0523644(Kawashima等人)公开了一种塑性层压体,该塑性层压体具有聚酰胺树脂表面层和氟树脂表面层。
在将非含氟聚合物层粘结到含氟聚合物层的方法的另一个实例中,美国专利6,869,682描述了一种制品,该制品包括:a)包含含氟聚合物的第一层;和b)粘结到第一层上的第二层,第二层包含可熔融加工的基本上非氟化的聚合物、碱和冠醚的混合物。
在将非含氟聚合物层粘结到含氟聚合物层的方法的另一个实例中,美国专利6,962,754述了一种结构体,该结构体包括含氟聚合物层和直接粘附到其一侧的粘结层,该粘结层包含含有聚酰胺的粘结树脂,该聚酰胺来自单体的缩合,所述单体主要包含特定组成的至少一种二酸和至少一种二胺。
将各层结合到一起的方法(例如共挤或层压)中所采用的温度和压力可足以在层之间提供足够的结合力。然而,可能期望对所得的多层制品进行进一步的处理,例如使用附加的热量、压力或两者同时使用,以在各层之间提供更大的粘合剂结合强度。当通过挤出来制备多层制品时,一种提供附加热量的方法是延缓共挤后层压体的冷却。作为另外一种选择,可以通过在高于仅加工这几种组件所需的温度下将各层进行层压或共挤压,从而将附加热能加入到多层制品中。或者,作为另一种选择,可将成品层压体在高温下保持较长的一段时间。例如,可将成品多层制品置于单独的装置例如烤箱或加热的液体浴中以提高制品的温度。也可以使用此类方法的组合。
本发明的过滤器可包括稀松布层,其中稀松布仅邻近纳米纤维网、或仅邻近膜、或介于两者之间。如本文所用,“稀松布”为支撑层,并且可以是能够与纳米纤维网粘结、粘附或层压的任何平面结构。有利的是,可用于本发明的稀松布层为纺粘非织造层,但也可由非织造纤维的梳理纤维网等制成。可用于某些过滤应用的稀松布层需要足够的刚度来保持褶绉和死褶。
实施例
材料
使用世界专利公布WO 03/080905中公开的上述电吹法从尼龙6,6,(Zytel xx,Du Pont,Wilmington,DE)的甲酸溶液制备纳米纤维网。从位于Middletown DE的DelStar Technologies获得32gsm或36gsm基重的带电熔喷物。不充电获得不带电的熔喷物。用来运行测试的PTFE膜是被评估为3微米过滤器的典型PTFE膜,测得其泡点和平均流孔隙分别为5.6和2.2微米。
测试
使用圆形开口直径为11.3cm(面积=100cm2)的自动过滤器测试仪(TSI型号No.8130)在平纸片介质上进行细小颗粒灰尘承载测试。使用2重量%氯化钠水溶液生成质量平均直径0.26微米的细小气溶胶,将其用在承载测试中。气流速率为40升/分钟,对应于6.67cm/s的面速率。根据设备制造商的规定,气溶胶浓度为约16mg/m3。在测试开始时测量过滤效率和初始压降,在测试结束时测量最终压降。通过用最终压降减去初始压降计算压降增长。
比较实施例1使用了相同的细小气溶胶承载步骤,介质由稀松布和PTFE膜制成。虽然细小气溶胶分布在稀松布一侧,但15.7分钟后气溶胶迅速加载到PTFE膜上并且水压降增大128.1mm。稀松布没有提供任何对细小气溶胶的预过滤。制备在稀松布和PTFE膜上具有带电熔喷层的介质。按照下述相同步骤执行承载测试。
表1示出了无纳米纤维网和具有四种不同基重的纳米纤维网的样本在约31分钟的过滤后的压力增加对比。因此编号为4A至4D的样本包括PTFE膜加稀松布、通过稀松布与PTFE流体接触的纳米纤维网、以及纳米纤维网上的带电熔喷材料。样本2A无纳米纤维网,只有带电熔喷纤维网。虽然初始阻力在存在纳米纤维网时稍高,但31分钟后的增加明显更低,证明了本发明在过滤期间保持低压力的效力。
表1
具有36gsm带电熔喷物的样本在31分钟后的压力增加。
Figure BPA00001378354400121
表2示出了对32gsm熔喷材料的类似比较。样本2B具有带电熔喷层,样本3具有不带电熔喷层。在存在带电熔喷纤维网的情况下,明显显示出相同的灰尘保持能力改善,同时也显示了让熔喷物带电的重要性。如果熔喷物上的电荷消散,则过滤器的灰尘保持能力会明显降低。对于实施例4F,存在纳米纤维网时的灰尘承载能力的进一步改善非常明显。
表2
具有32gsm熔喷物的样本
Figure BPA00001378354400122
表3示出了带电熔喷物和纳米纤维网组合在过滤介质中的效力。在表3中,样本5A至5D没有带电熔喷物。通过增大纳米纤维网的基重没有明显改善过滤介质的容量。然而当纳米纤维网的基重增大时,带电熔喷物介质的容量明显增大。
表3
纳米纤维网性能在有熔喷物和没有熔喷物情况下的对比
Figure BPA00001378354400131

Claims (6)

1.用于从空气或其他气体中过滤颗粒的过滤介质,所述过滤介质包括膜和位于所述膜上游并与所述膜流体接触的深层过滤层,其中所述深层过滤层包括纳米纤维网层和位于所述纳米纤维网层上游并与所述纳米纤维网层流体连通的预过滤层。
2.权利要求1的介质,其中所述纳米纤维网具有至少约2g/m2的基重。
3.权利要求1的介质,其中所述预过滤层包括带电非织造材料。
4.权利要求3的介质,其中所述带电非织造材料为熔喷纤维网。
5.权利要求4的介质,其中所述带电熔喷纤维网具有至少约30g/m2的基重。
6.一种包括权利要求1的过滤介质的过滤器。
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WO2010065949A1 (en) 2010-06-10
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KR20110103998A (ko) 2011-09-21
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