Composite preparation apparatus and method for aerosol filtration material

Abstract

The application relates to the technical field of composite materials, in particular to a composite preparation device and method of aerosol filtering material; the device comprises a front unwinding roller and a rear unwinding roller, a rack is arranged between the front unwinding roller and the rear unwinding roller, a flattening roller, a glue gun, a heating roller, a pressing roller and a waste edge winding roller are sequentially arranged on the rack in a front-to-back sequence; a cooling roller is further arranged on the rack below the heating roller, an edge trimming device and a winding roller are sequentially arranged on the rack along the discharging direction of the cooling roller; a film unwinding roller is arranged on the rack at a position above the pressing roller and the waste edge winding roller; a plurality of guide rollers for guiding the material are arranged on the rack; in the preparation of the aerosol material, the original form and structure of each filter layer can be ensured, a suitable process can be selected according to the characteristics of the base material, the resistance increase is minimized, and the preparation of the high-efficiency, low-resistance, high-dust-containing aerosol material is realized.

Description

Technical Field

[0001] This invention relates to the field of composite materials technology, and specifically to a composite preparation apparatus and method for aerosol filter materials. Background Technology

[0002] With modernization, high-efficiency, low-resistance, cost-effective, safe, and environmentally friendly filter materials are becoming increasingly important. High-efficiency, low-resistance composite air filter materials can be manufactured using stacking, mixing, gradient, and multi-layer structures, allowing different fiber layers to filter particles of varying sizes and achieve excellent filtration performance.

[0003] Currently, aerosol multilayer composites use a single composite method. For example, the processes for compositing meltblown filter media, polytetrafluoroethylene filter media, and the skeleton are separate and require independent special equipment. This equipment occupies a large area, which limits the design of multi-level filter media structures and makes it impossible to integrate the functions of different filter media, thus failing to achieve performance optimization of composite filter media. Summary of the Invention

[0004] This invention overcomes the shortcomings of the prior art and provides a composite preparation device for aerosol filter materials.

[0005] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is as follows: a composite preparation device for aerosol filter materials, including a front unwinding roller and a rear unwinding roller, a frame is provided between the front unwinding roller and the rear unwinding roller, and a flattening roller, a glue gun, a heating roller, a pressing roller and a waste edge take-up roller are arranged sequentially above the frame from front to back; a cooling roller is also provided on the frame below the heating roller, and an edge trimming device and a take-up roller are arranged sequentially on the frame along the discharge direction of the cooling roller; a membrane unwinding roller is provided on the frame above the pressing roller and the waste edge take-up roller; multiple guide rollers for guiding the material are installed and distributed on the frame; a correction device is provided on the frame in the discharge direction of the rear unwinding roller; wherein the glue gun, the pressing roller and the heating roller together form a glue spraying composite unit; and the pressing roller, the cooling roller and the heating roller together form a hot pressing composite unit.

[0006] Furthermore, both the front unwinding roller and the rear unwinding roller are provided with two stations.

[0007] Furthermore, the take-up roller is equipped with a 6-inch bushing.

[0008] A method for preparing a composite aerosol filter material, using the aforementioned apparatus for preparing a composite aerosol filter material, includes the following steps:

[0009] (1) Place the skeleton layer material and the dust-collecting layer material on the front unwinding roller and the rear unwinding roller respectively, correct the deviation, enter the glue spraying and composite unit, composite flat pressing, water cooling, trimming, and tension winding to prepare the dust-collecting layer / skeleton layer coarse filter material, and then place it on another station of the front unwinding roller for later use.

[0010] (2) Place the skeleton layer material and membrane material on the front unwinding roller and membrane unwinding roller respectively, and after correction, enter the hot pressing composite unit, water cooling, trimming, cutting, and tension winding to prepare fiber membrane / skeleton layer fine filtration semi-finished filter material, and then place it on another station of the rear unwinding roller for later use.

[0011] (3) The coarse filter material and the fine filter material are unwound and stacked in the order of dust holding layer / skeleton layer / fiber membrane / skeleton layer. They are then bonded by the adhesive spraying unit, water-cooled, trimmed, and tension-wound to produce the finished multi-layer composite aerosol filter material.

[0012] This invention's preparation method includes two composite processes: hot pressing and adhesive spraying. Hot pressing is suitable for two substrates with significantly different melting points. By controlling temperature and pressure, the skeleton and outer layer fibers of the aerosol filter material are softened and melted, then bonded to a high-melting-point nanofiber filter membrane. Adhesive spraying involves bonding a filter layer with a complex stacking structure to the skeleton. This invention's composite preparation method and apparatus can achieve the composite preparation of multiple filter materials, minimizing the pressure drop of the composite filter material, optimizing filter material performance, and the process is green and environmentally friendly, producing no harmful waste gas. The aerosol filter material prepared by this invention using the two processes achieves an efficiency of 99.999%, with a 31% reduction in resistance compared to existing industrial filter materials. Evaluation in filter assembly applications shows that, while maintaining filtration accuracy, it improves dust holding capacity, extends the service life of the filter material, and the preparation process is mature and can meet the installation requirements of high-efficiency filters with different fold heights.

[0013] Furthermore, the skeleton layer is selected from a core-sheath bicomponent long-fiber nonwoven fabric, which is PE / PET nonwoven fabric, PP / PET nonwoven fabric, COPET / PET nonwoven fabric or PE / PP nonwoven fabric, preferably PE / PET nonwoven fabric.

[0014] Furthermore, the dust-collecting layer is selected as a coarse filter layer with a spatial pore structure, wherein the coarse filter layer with a spatial pore structure is melt-blown filter material, glass fiber filter material or electrospun filter material; preferably melt-blown filter material.

[0015] Furthermore, the membrane material is a polytetrafluoroethylene membrane, a polyvinylidene fluoride membrane, a polychlorotrifluoroethylene membrane, or a polytetrafluoroethylene / perfluoroalkyl ether copolymer; preferably a polytetrafluoroethylene membrane.

[0016] Preferably, the operating parameters of the adhesive spraying unit are: adhesive melting temperature controlled at 160-190℃; adhesive spraying amount 1-2g / m³. 2 Pressure is controlled at 0.15±0.03MPa; production speed is 10-15m / min.

[0017] Preferably, the operating parameters of the hot-pressing composite unit are: the temperature of the heating roller 8 is set at 120-160℃; the pressure is controlled at 0.15±0.03MPa; and the production speed is 10-15m / min.

[0018] Compared with the prior art, the present invention has the following beneficial effects:

[0019] (1) In the preparation of aerosol materials, this invention can ensure the original shape and structure of each filter layer, and select appropriate processes according to the characteristics of the substrate to minimize the increase in resistance, thereby achieving the preparation of high-efficiency, low-resistance, and high-dust-holding aerosol materials. (2) The composite device integrates hot pressing and spraying functions, and uses the two processes together to meet the needs of different filter material stacking, multi-layer, gradient, and mixed design preparation. (3) The composite device integrates hot pressing and spraying functions, has a compact design structure, occupies little space, and fully considers the composite characteristics of different filter materials. It is flexible in operation and highly efficient. Its application in the preparation of aerosol filter materials is unprecedented. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the composite preparation device for the aerosol filter material of the present invention.

[0021] Figure 2 This is a flowchart of the composite preparation method of the aerosol filter material of the present invention.

[0022] The markings in the image are as follows:

[0023] 1-Front unwinding roller, 2-Rear unwinding roller, 3-Pressure roller, 4-Film unwinding roller, 5-Correction device, 6-Flattening roller, 7-Cooling roller, 8-Heating roller, 9-Trimming device, 10-Take-up roller, 11-Waste edge take-up roller, 12-Guide roller, 13-Rear unwinding roller. Detailed Implementation

[0024] The present invention will be further described below with reference to specific embodiments.

[0025] Example

[0026] like Figure 1As shown, a composite preparation device for aerosol filter material includes a front unwinding roller 1 and a rear unwinding roller 13. A frame is provided between the front unwinding roller 1 and the rear unwinding roller 13. A flattening roller 6, a glue gun 2, a heating roller 8, a pressing roller 3, and a waste edge take-up roller 11 are arranged sequentially from front to back on the frame. The glue gun 2 is equipped with a melting cylinder. A cooling roller 7 is also provided on the frame below the heating roller 8. An edge trimming device 9 and a take-up roller are arranged sequentially on the frame along the discharge direction of the cooling roller 7. 10; A film unwinding roller 4 is installed on the frame above the pressing roller 3 and the waste edge take-up roller 11; multiple guide rollers 12 for guiding materials are installed on the frame; a correction device 5 is installed on the frame in the discharge direction of the rear unwinding roller 13; wherein the glue gun 2, pressing roller 3 and heating roller 8 together form a glue spraying and laminating unit, and the heating roller 8 does not need to be heated when it is used as a component of the glue spraying and laminating unit; the pressing roller 3, cooling roller 7 and heating roller 8 together form a hot pressing and laminating unit. The laminating preparation device is equipped with an electronic control system for parameter setting, output calculation, yield tracking, and daily work data storage and retrieval. The laminating preparation device fully considers the characteristics of the substrate, and can perform glue spraying and laminating or separate heating and laminating, with each mechanism independently adjustable.

[0027] Furthermore, both the front unwinding roller 1 and the rear unwinding roller 13 are provided with two stations. The dual-station unwinding design facilitates roll changing and preparatory operations; it is equipped with magnetic powder braking and an air shaft; and it uses a floating roller to detect tension, achieving high-precision closed-loop control of tension.

[0028] The film unwinding roller 4 is designed with independent unwinding to ensure that the film unwinding is not affected by shrinkage.

[0029] The glue gun 2 (equipped with a melting cylinder), pressure roller 3, and heating roller 8 together form a glue spraying and laminating unit. The glue gun 2 is equipped with a spray gun assembly fixing device and an up-and-down distance adjustment mechanism, which can adjust the different effects produced by the spraying distance. Each compressed air path is equipped with an independent heating system, which can preheat the atomized gas to avoid the spray gun temperature being affected by the low temperature of the physicochemical gas, thus avoiding the glue spraying effect. The melting cylinder adopts a segmented heating method to ensure that the heating speed is basically consistent. A precision metering pump and an independent glue dispensing pressure backflow control system are used to ensure more stable and smooth glue dispensing and reduce the increase in resistance during the laminating process.

[0030] The pressing roller 3, cooling roller 7 and heating roller 8 together form a hot-pressing composite unit. An independent pressure gauge is configured to adjust the bonding pressure and control the gap. By adjusting the temperature and pressure parameters of the heating roller, the increase in resistance during the composite process is reduced.

[0031] The aforementioned correction device 5, flattening roller 6, and several guide rollers 12 together constitute a feeding and winding transmission device. This ensures that the multi-layer composite aerosol filter material has a flat, uniform appearance, free of voids and wrinkles.

[0032] The trimming device 9 and waste edge winding 11 are used to cut and collect excess membrane material on both sides of the filter material to prevent the fiber membrane from sticking to the roller.

[0033] Furthermore, the take-up roller 10 is equipped with a 6-inch bushing. Increasing the diameter of the take-up roller ensures that the wound composite filter material is free of delamination and creases.

[0034] A method for preparing a composite aerosol filter material, comprising the above-mentioned apparatus for preparing the composite aerosol filter material, characterized by the following steps:

[0035] (1) Preparation of composite filter media for coarse filtration semi-finished products

[0036] The skeleton layer material and the dust-collecting layer material are placed on the front unwinding roller 1 and the rear unwinding roller 13 respectively. After correction, they enter the spray adhesive composite unit, where they are laminated, flattened, water-cooled, trimmed, and then tension-wound to prepare a semi-finished composite filter material of dust-collecting layer / skeleton layer. This material is then placed at another station on the front unwinding roller 1 for later use. The skeleton layer is made of PE / PET nonwoven fabric, and the dust-collecting layer is made of meltblown filter material. Meltblown filter material mainly captures particles through a combination of mechanical blocking and electrostatic adsorption. The fiber surface stores charge, which easily decays under high temperatures. Furthermore, the melting point of meltblown fibers is close to that of the skeleton fibers in the molten adhesive layer, making spray adhesive composite suitable. The unwound skeleton nonwoven fabric is sprayed with adhesive by the glue gun 2 and laminated with the meltblown filter material between the pressing roller 3 and the heating roller 8 (the heating roller 8 is not heated at this time). This compacts the two layers, ensuring a strong bond and preventing delamination. The laminated material is then wound up by the take-up roller 10 for later use. The spray adhesive composite process parameters are as follows:

[0037] The adhesive melting temperature should be controlled at (160-190)℃;

[0038] Adhesive application rate (1-2) g / m 2 ;

[0039] The pressure was controlled at (0.15±0.03) MPa;

[0040] Production speed (10-15) m / min

[0041] (2) Preparation of composite filter media for fine filtration semi-finished products

[0042] The skeleton layer material and membrane material are placed on the front unwinding roller 1 and membrane unwinding roller 4 respectively. After correction, they enter the hot-pressing composite unit, where they are compacted between the pressing roller 3 and the heating roller 8 (the heating roller 8 needs to be heated at this time), water-cooled, trimmed, cut, and then tension-wound to prepare a fiber membrane / skeleton layer fine filtration semi-finished composite filter material. This material is then placed at another station on the rear unwinding roller 13 for later use. The skeleton layer is preferably PE / PET nonwoven fabric, and the membrane material is polytetrafluoroethylene membrane. The skeleton layer and membrane material are placed on the front unwinding roller 1 and membrane unwinding roller 4 respectively for unwinding. The skeleton outer layer fibers soften and melt, bonding with the high-melting-point membrane material. The core layer fibers provide strong support and protection, and hot-pressing composite is preferred. The unwound skeleton nonwoven fabric and nanofiber membrane are hot-pressed together at the pressing roller 3. The hot-pressing composite process parameters are as follows:

[0043] The temperature of the hot press roller is set at (120-160)℃;

[0044] The pressure was controlled at (0.15±0.03) MPa;

[0045] Production speed (10-15) m / min.

[0046] (3) Preparation of multi-layer composite finished filter media

[0047] The coarse and fine semi-finished filter media are unwound and layered in the order of dust-holding layer / skeleton layer / fiber membrane / skeleton layer, then bonded by a spray adhesive bonding unit, water-cooled, trimmed, and tension-wound to produce the finished multi-layer composite aerosol filter material. The process parameters for the spray adhesive bonding unit are as follows: adhesive melting temperature controlled at (160-190)℃;

[0048] Adhesive application rate (1-2) g / m 2 ;

[0049] The pressure was controlled at (0.15±0.03) MPa;

[0050] Production speed (10-15) m / min.

[0051] The properties of the multilayer composite aerosol filter material obtained using the above-described composite preparation apparatus and method are as follows:

[0052] Serial Number Testing items Test Results 1 Filtration efficiency 99.99978％ 2 resistance 239.0Pa 3 Dust holding capacity <![CDATA[74g / m 2 ]]>

Claims

1. A method for preparing a composite aerosol filter material, comprising using an apparatus for preparing a composite aerosol filter material, characterized in that, The composite preparation device for the aerosol filter material includes a front unwinding roller (1) and a rear unwinding roller (13). A frame is provided between the front unwinding roller (1) and the rear unwinding roller (13). A flattening roller (6), a glue gun (2), a heating roller (8), a pressing roller (3), and a waste edge take-up roller (11) are arranged sequentially from front to back on the frame. A cooling roller (7) is also provided on the frame below the heating roller (8). A trimming device (9) and a... are arranged sequentially on the frame along the discharge direction of the cooling roller (7). A take-up roller (10); a film unwinding roller (4) is provided on the frame above the pressing roller (3) and the waste edge take-up roller (11); multiple guide rollers (12) for guiding materials are installed on the frame; a correction device (5) is provided on the frame in the discharge direction of the rear unwinding roller (13); wherein the glue gun (2), the pressing roller (3) and the heating roller (8) together form a glue spraying composite unit; the pressing roller (3), the cooling roller (7) and the heating roller (8) together form a hot pressing composite unit; The preparation method includes the following steps: A. Place the skeleton layer material and the dust-collecting layer material on the front unwinding roller (1) and the rear unwinding roller (13) respectively. After correction, they enter the glue spraying composite unit, composite flat pressing, water cooling, trimming, and tension winding to prepare the dust-collecting layer / skeleton layer coarse filter material. Then place it on another station of the front unwinding roller (1) for later use. B. Place the skeleton layer material and the membrane material on the front unwinding roller (1) and the membrane unwinding roller (4) respectively. After correction, they enter the hot pressing composite unit, are water cooled, trimmed, cut, and then tensioned and wound to prepare the fiber membrane / skeleton layer fine filtration semi-finished filter material. Then place it on another station of the rear unwinding roller (13) for later use. C. The coarse filter material and the fine filter material are unwound and stacked in the order of dust holding layer / skeleton layer / fiber membrane / skeleton layer. They are then bonded by the adhesive spraying unit, water-cooled, trimmed, and tension-wound to produce the finished multi-layer composite aerosol filter material.

2. The composite preparation method of the aerosol filter material according to claim 1, characterized in that, The skeleton layer is selected from a core-sheath bicomponent long-fiber nonwoven fabric, which can be PE / PET nonwoven fabric, PP / PET nonwoven fabric, COPET / PET nonwoven fabric or PE / PP nonwoven fabric.

3. The composite preparation method of the aerosol filter material according to claim 1, characterized in that, The dust-collecting layer is selected as a coarse filter layer with a spatial pore structure, which is a melt-blown filter material, a glass fiber filter material, or an electrospun filter material.

4. The method for preparing a composite aerosol filter material according to claim 1, characterized in that, The membrane material is a polytetrafluoroethylene membrane, a polyvinylidene fluoride membrane, a polychlorotrifluoroethylene membrane, or a polytetrafluoroethylene / perfluoroalkyl ether copolymer.

5. The composite preparation method of the aerosol filter material according to claim 1, characterized in that, The operating parameters for the adhesive spraying unit are as follows: adhesive melting temperature controlled at 160-190℃; adhesive spraying amount 1-2g / m³. 2 Pressure is controlled at 0.15±0.03MPa; production speed is 10-15m / min.

6. The composite preparation method of the aerosol filter material according to claim 1, characterized in that, The operating parameters of the hot-pressing composite unit are as follows: the temperature of the heating roller 8 is set at 120-160℃; the pressure is controlled at 0.15±0.03MPa; and the production speed is 10-15m / min.

7. The composite preparation method of the aerosol filter material according to claim 1, characterized in that, Both the front unwinding roller (1) and the rear unwinding roller (13) are provided with two stations.

8. The composite preparation method of the aerosol filter material according to claim 1, characterized in that, The take-up roller (10) is equipped with a 6-inch bushing.

Images