Long-acting charged dual-component polyphenylene sulfide filter material, manufacturing method and application thereof

Abstract

The application discloses a manufacturing method of long-acting charged double-component polyphenylene sulfide filter material, which comprises three layers of filter material, a base cloth layer as a middle layer, a long-acting charged fiber layer as an inner layer, and a magnetic adsorption layer as an outer layer; the long-acting charged double-component polyphenylene sulfide filter material is obtained by performing calendering and singeing on the three layers of filter material; the long-acting charged fiber layer is a double-component PbTiO3 / BaTiO3-PPS fiber filter material; and the magnetic adsorption layer is a double-component FeSiAl / PPS fiber filter material. The long-acting charged double-component polyphenylene sulfide filter material has the outer layer of the double-component FeSiAl / PPS fiber filter material, can perform magnetic adsorption filtration on metal dust in working condition dust in advance, thereby avoiding the problem that the metal dust enters the inner layer, causes the electrostatic charge to be conducted through the metal dust and lose the charge, and causes the electrostatic adsorption effect to be invalid; and since the charged material components PbTiO3 or BaTiO3 are mixed in the PPS fiber, the problem that the charged material components are lost under the scouring action of dust after long-term use is also avoided.

Description

Technical Field

[0001] This invention relates to the field of dust removal filter media technology, specifically to a long-lasting charged two-component polyphenylene sulfide filter media, its manufacturing method, and its application. Background Technology

[0002] Currently, baghouse dust collection technology is the most effective technical approach to control industrial particulate matter emissions. The performance and usage requirements of filter bags—characterized by "high efficiency, low resistance, and long lifespan"—have always been a focus of exploration for technical personnel in the industry. In particular, the control of PM10 and PM2.5 emissions has received significant attention from the national government and the public. When filter media capture particulate matter, the smaller the particle size, the lower the filtration efficiency and the higher the escape rate of fine particles. Therefore, how to effectively improve the efficiency of filter media for fine particles has always been a major challenge in this field and a focus of industry attention.

[0003] Currently, the industry uses electret meltblown fiber technology to improve the electrostatic adsorption effect of nonwoven fabrics, thereby enhancing the collection effect of fine dust. However, this method is subject to strict environmental conditions and will fail quickly. Under the influence of environmental factors such as humidity or temperature, the amount of charge on it will gradually decrease or even disappear, thus losing its adsorption effect on fine particles.

[0004] Existing technology CN111939648A discloses a method for manufacturing a piezoelectric and / or thermoelectric enhanced long-lasting dual-effect filter media. This method involves attaching piezoelectric and / or thermoelectric powder materials to the fiber surface using a coating process. Due to their spontaneous electrostatic generation, the filter media becomes a permanently charged material, thus enabling long-term use and permanent self-generating electrostatic power under harsh industrial flue gas conditions such as humidity, heat, and corrosion. However, under high-velocity dust erosion, the charged material on the fiber surface may be carried away by this coating technology, reducing the electrostatic adsorption effect during later use.

[0005] In addition, in some working conditions, industrial dust is mixed with metal dust. Under such conditions, the existing technology uses a coating method to attach piezoelectric and / or thermoelectric powder materials to the fiber surface. When the amount of metal dust on the filter bag surface reaches a certain level, it will make the filter bag surface conductive. The static charge on the fibers, which are inherently electrostatic, will be lost through the conduction of the metal dust, causing the electrostatic adsorption effect of the filter bag to fail. Summary of the Invention

[0006] The technical problem to be solved by this invention is how to manufacture a long-lasting charged two-component polyphenylene sulfide filter material that is not easily carried away by the charge and does not easily lose the charged material.

[0007] The present invention solves the above-mentioned technical problems through the following technical means:

[0008] The first aspect of this invention provides a method for manufacturing a long-lasting charged bicomponent polyphenylene sulfide (PPS) filter media. The long-lasting charged bicomponent PPS filter media comprises three layers: a middle layer is a base fabric layer, an inner layer is a long-lasting charged fiber layer, and an outer layer is a magnetic adsorption layer. The three layers are subjected to calendering and singeing processes to obtain the long-lasting charged bicomponent PPS filter media. The long-lasting charged fiber layer is a bicomponent PbTiO3 / BaTiO3-PPS fiber filter media, and the magnetic adsorption layer is a bicomponent FeSiAl / PPS fiber filter media.

[0009] Beneficial effects: The long-lasting charged bicomponent polyphenylene sulfide filter material of this invention has an outer layer of bicomponent FeSiAl / PPS fiber filter material. It can first use magnetic adsorption to filter metal dust in the working dust, thereby preventing metal dust from entering the inner layer and causing electrostatic charge to be lost through the conduction of metal dust, resulting in the failure of electrostatic adsorption effect. After filtering out the metal dust, the remaining non-metallic dust with smaller particle size then passes through the inner layer of bicomponent PbTiO3 / BaTiO3-PPS fiber. Under the fiber filtration and electrostatic adsorption of the bicomponent PbTiO3 / BaTiO3-PPS fiber (long-lasting charged fiber layer), the fine dust particles are captured and filtered, thereby achieving fine filtration and preventing fine dust from escaping. At the same time, since the charged material component PbTiO3 or BaTiO3 is mixed in PPS fiber, it also avoids the problem of the charged material component being lost under the scouring action of dust after long-term use.

[0010] Preferably, the preparation method of the bicomponent PbTiO3 / BaTiO3-PPS fiber is as follows:

[0011] (1) Granulation: PbTiO3 / BaTiO3 and coupling agent are added to PPS powder, mixed and dried to obtain a mixture. The mixture is fed into an extruder for melting, extrusion and granulation to obtain PbTiO3 / BaTiO3-PPS modified resin.

[0012] (2) Spinning: PbTiO3 / BaTiO3-PPS modified resin is placed in the outer layer as the skin layer and conventional PPS resin is placed in the inner layer as the core layer for bicomponent spinning. Before the fiber heat setting in the post-spinning stage, a hot tunnel oven with an electric field is added and the fiber is heat dried at a uniform speed to obtain bicomponent PbTiO3 / BaTiO3-PPS fiber.

[0013] Preferably, the preparation method of the bicomponent FeSiAl / PPS fiber is as follows: FeSiAl, silica and PPS resin are mixed and granulated to form magnetic PPS modified resin. The magnetic PPS modified resin is used as the core layer and PPS resin is used as the skin layer. The fibers are then spun in a bicomponent manner and then subjected to a stretching and setting stage and a drying and setting stage to obtain the bicomponent FeSiAl / PPS fiber.

[0014] Preferably, the bicomponent PbTiO3 / BaTiO3-PPS fiber filter media is obtained by opening, mixing, carding, web laying, needle punching, and then heat setting at high temperature using bicomponent PbTiO3 / BaTiO3-PPS fibers.

[0015] Preferably, the bicomponent FeSiAl / PPS fiber filter material is obtained by opening, mixing, carding, web laying, needle punching, and then heat setting at high temperature using bicomponent FeSiAl / PPS fibers.

[0016] Preferably, the PbTiO3 / BaTiO3, coupling agent, and PPS powder are added at 5-15%, 5-10%, and 75-90% of the total mass, respectively.

[0017] Preferably, the PbTiO3 / BaTiO3 has a particle size of 0.5-15 μm; the PPS powder has a particle size of 100-2000 μm; and the coupling agent is a silane coupling agent.

[0018] Preferably, the FeSiAl, silica and PPS resin are mixed in a mass ratio of 1-4:0.8-1.2:5-8.

[0019] Preferably, the base fabric is an insulating material of PPS or PTFE.

[0020] The second aspect of the present invention provides a long-lasting charged two-component polyphenylene sulfide filter material manufactured by the above-described manufacturing method.

[0021] Beneficial effects: The long-lasting charged two-component polyphenylene sulfide filter material of the present invention has a magnetic adsorption layer structure with magnetic PPS modified resin as the core layer and PPS resin as the skin layer. By using PPS resin to encapsulate the magnetic PPS modified resin, the magnetic material (FeSiAl) in the PPS can be protected, avoiding the problem of the modified PPS resin being washed away by metal dust during the filtration of metal dust, resulting in the loss of magnetic material. In addition, the outer PPS resin increases the toughness and strength of the magnetic adsorption layer. The long-lasting charged fiber layer structure has PbTiO3 / BaTiO3-PPS modified resin placed on the outer layer as the skin layer and conventional PPS resin placed on the inner layer as the core layer. The PbTiO3 / BaTiO3-PPS modified resin, as a charged fiber layer, can adsorb micro dust particles, and the PPS resin as the core layer enhances the strength of the long-lasting charged fiber layer.

[0022] The third aspect of this invention provides the application of long-lasting charged two-component polyphenylene sulfide filter media in dust collector filter bags.

[0023] The advantages of this invention are:

[0024] The long-lasting charged bicomponent polyphenylene sulfide filter media of this invention has an outer layer of bicomponent FeSiAl / PPS fiber filter media. This allows for the magnetic adsorption and filtration of metallic dust in the working environment, preventing metallic dust from entering the inner layer and causing electrostatic charge loss through conduction, thus preventing the electrostatic adsorption effect from failing. After filtering out the metallic dust, the remaining smaller non-metallic dust particles pass through the inner layer of bicomponent PbTiO3 / BaTiO3-PPS fibers. Under the filtration of the fibers and electrostatic adsorption of the bicomponent PbTiO3 / BaTiO3-PPS fiber layer (long-lasting charged fiber layer), the fine dust particles are captured and filtered, achieving fine filtration and preventing the escape of fine dust. Furthermore, since the charged material component PbTiO3 or BaTiO3 is mixed in the PPS fiber, the loss of the charged material component due to dust erosion after long-term use is also avoided.

[0025] The long-lasting charged two-component polyphenylene sulfide filter material of the present invention has a magnetic adsorption layer structure in which magnetic PPS modified resin is used as the core layer and PPS resin is used as the skin layer. By using PPS resin to encapsulate the magnetic PPS modified resin, the magnetic material (FeSiAl) in PPS can be protected, avoiding the problem of the modified PPS resin being washed away by metal dust during the filtration of metal dust, resulting in the loss of magnetic material. In addition, the outer PPS resin increases the toughness and strength of the magnetic adsorption layer. The long-lasting charged fiber layer structure is that PbTiO3 / BaTiO3-PPS modified resin is placed on the outer layer as the skin layer and conventional PPS resin is placed on the inner layer as the core layer. The PbTiO3 / BaTiO3-PPS modified resin, as a charged fiber layer, can adsorb micro dust particles, and the PPS resin as the core layer enhances the strength of the long-lasting charged fiber layer. Attached Figure Description

[0026] Figure 1 This is a cross-sectional view of the bicomponent PbTiO3 / BaTiO3-PPS fibers in the embodiment;

[0027] Figure 2 This is a cross-sectional view of the bicomponent FeSiAl / PPS fibers in the embodiment;

[0028] Figure 3 This is a side cross-sectional view of the long-lasting charged two-component polyphenylene sulfide filter material in the embodiment;

[0029] Figure 4 Front view of a dust collector filter bag made of long-lasting charged two-component polyphenylene sulfide filter media;

[0030] 1-Bicomponent PbTiO3 / BaTiO3-PPS fiber body, 2-PPS resin layer a, 3-PbTiO3 / BaTiO3-PPS modified resin layer; 4-Bicomponent FeSiAl / PPS fiber body, 5-FeSiAl / PPS modified resin layer, 6-PPS resin layer b; 7-Base fabric layer, 8-Bicomponent FeSiAl / PPS fiber filter media layer, 9-Bicomponent PbTiO3 / BaTiO3-PPS fiber filter media layer. Detailed Implementation

[0031] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below in conjunction with the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] Unless otherwise specified, all test materials and reagents used in the following examples are commercially available.

[0033] Unless otherwise specified in the embodiments, the techniques or conditions described in the literature in this field or in accordance with the product manual may be followed.

[0034] Example 1

[0035] A method for manufacturing a long-lasting charged two-component polyphenylene sulfide filter media, comprising the following specific steps:

[0036] S1: Preparation of bicomponent PbTiO3-PPS fibers

[0037] (1) Granulation: 500g of PbTiO3 with a particle size of 0.5μm and 500g of silane coupling agent were added to 9000g of PPS powder with a particle size of 100μm. The mixture was mixed and melted into filaments in a three-screw extruder granulator. After water cooling and molding, the filaments were cut. The cutting machine speed was 600-800r / min. The screw extrusion temperature was set at 280℃, 300℃, 305℃, 320℃, 330℃, 320℃, 325℃, 300℃, and 290℃. The PbTiO3-PPS modified resin with a diameter of 1-3cm was obtained by extrusion granulation.

[0038] (2) Spinning: PPS resin is placed in the core layer and PbTiO3-PPS modified resin is placed in the outer layer for bicomponent spinning. Core layer: PPS resin is dried, melt extruded, filtered, and melt metered before entering the composite spinning box; Process parameters: Drying temperature 200℃, drying time 12h; Screw temperature of melt extrusion: 290℃, 310℃, 320℃, 330℃, 335℃; Main and pre-screen pressure of filter: 0.1MPa; Side blowing speed, temperature and pressure: 0.6m / s, 22℃, 500KPa.

[0039] Skin layer: The granulated PbTiO3-PPS modified resin is dried, melt-extruded, filtered, and melt-metered before entering the composite spinning box. The specific process parameters are as follows: chip drying temperature 210℃, drying time 15h; screw temperature: 300℃, 310℃, 335℃, 330℃, 340℃; main and pre-web pressure: 0.1MPa; side blowing speed, temperature and pressure: 0.5m / s, 22℃, 500KPa.

[0040] In the spinning assembly, PPS resin and PbTiO3-PPS modified resin are extruded together at the inlet of the spinneret through their respective channels, forming a bicomponent PbTiO3-PPS filament with a clear interface. After passing through the stretching and setting stage, the bicomponent PbTiO3-PPS fiber is formed through drying and setting. The specific parameters of the stretching process are: first stretching ratio of 1.2 times, water bath heating temperature of 100℃; second stretching ratio of 0.8 times, superheated steam temperature of 180℃.

[0041] (3) Electret: Before the fiber heat setting in the post-spinning stage, a hot corridor oven with an electric field is added. The electric field strength in the oven is 25kv / mm~35kv / mm, and the temperature is 170℃~250℃. The filter material travels at a constant speed in the oven for 10min~20min. After passing through the heat drying at a constant speed, bicomponent PbTiO3-PPS fiber is obtained.

[0042] S2: Preparation of bicomponent FeSiAl / PPS fibers

[0043] (1) Granulation: 100g of FeSiAl, 80g of silica and 500g of PPS resin are mixed and melt-granulated in a three-screw extruder. The screw extrusion temperature is set to 290℃, 310℃, 305℃, 310℃, 330℃, 320℃, 320℃, 310℃ and 280℃. Magnetic FeSiAl / PPS modified resin is obtained by extrusion granulation.

[0044] (2) Spinning: The magnetic FeSiAl / PPS modified resin is made into bicomponent FeSiAl / PPS fibers through a composite spinning box. The drying temperature of the composite spinning box is 190℃ and the drying time is 10h. The screw temperature of melt extrusion is 290℃, 300℃, 310℃, 320℃, and 330℃. The pressure of the main and pre-screen filters is 0.15MPa. The side blowing speed, temperature, and pressure are 0.6m / s, 25℃, and 600KPa. The magnetic PPS modified resin and PPS resin are extruded together at the inlet of the spinneret through their respective channels. The magnetic FeSiAl / PPS modified resin is used as the core layer and the PPS resin is used as the skin layer. After stretching and drying, the bicomponent FeSiAl / PPS fibers are obtained.

[0045] S3: Preparation of Long-Lasting Charged Two-Component Polyphenylene Sulfide Filter Media

[0046] The prepared bicomponent PbTiO3-PPS fiber and bicomponent FeSiAl / PPS fiber were respectively opened, mixed, carded, laid, needle punched and heat-set at high temperature to obtain bicomponent PbTiO3-PPS fiber filter media and bicomponent FeSiAl / PPS fiber filter media. Then, the prepared filter media and the base cloth filter media were calendered and singed to obtain long-lasting charged bicomponent polyphenylene sulfide filter media.

[0047] Example 2

[0048] S1: Preparation of bicomponent PbTiO3-PPS fibers

[0049] (1) Granulation: 1500g of PbTiO3 with a particle size of 15μm and 1000g of silane coupling agent were added to 7500g of PPS powder with a particle size of 2000μm. The mixture was mixed and melted into filaments in a three-screw extruder granulator. After water cooling and molding, the filaments were cut. The cutting machine speed was 600-800r / min. The screw extrusion temperature was set at 280℃, 300℃, 305℃, 320℃, 330℃, 320℃, 325℃, 300℃, and 290℃. The PbTiO3-PPS modified resin with a diameter of 1-3cm was obtained by extrusion granulation.

[0050] (2) Spinning: PPS resin is placed in the core layer and PbTiO3-PPS modified resin is placed in the outer layer for bicomponent spinning. Core layer: PPS resin is dried, melt extruded, filtered, and melt metered before entering the composite spinning box; Process parameters: Drying temperature 200℃, drying time 12h; Screw temperature of melt extrusion: 290℃, 310℃, 320℃, 330℃, 335℃; Main and pre-screen pressure of filter: 0.1MPa; Side blowing speed, temperature and pressure: 0.6m / s, 22℃, 500KPa.

[0051] Skin layer: The granulated PbTiO3-PPS modified resin is dried, melt-extruded, filtered, and melt-metered before entering the composite spinning box. The specific process parameters are as follows: chip drying temperature 210℃, drying time 15h; screw temperature: 300℃, 310℃, 335℃, 330℃, 340℃; main and pre-web pressure: 0.1MPa; side blowing speed, temperature and pressure: 0.5m / s, 22℃, 500KPa.

[0052] In the spinning assembly, PPS resin and PbTiO3-PPS modified resin are extruded together at the inlet of the spinneret through their respective channels, forming a bicomponent composite PbTiO3-PPS filament with a clear interface. After a stretching and setting stage, and finally drying and setting, bicomponent PbTiO3-PPS fibers are formed. Specific parameters for the stretching process are: first stretching ratio 1.2 times, water bath heating temperature 100℃; second stretching ratio 0.8 times, superheated steam 180℃.

[0053] (3) Electret: Before the fiber heat setting in the post-spinning stage, a hot corridor oven with an electric field is added. The electric field strength in the oven is 25kv / mm~35kv / mm, and the temperature is 170℃~250℃. The filter material travels at a constant speed in the oven for 10min~20min. After passing through the heat drying at a constant speed, bicomponent PbTiO3-PPS fiber is obtained.

[0054] S2: Preparation of composite FeSiAl / PPS fibers

[0055] (1) Granulation: 400g of FeSiAl, 120g of silica and 800g of PPS resin are mixed and melt-granulated in a three-screw extruder. The screw extrusion temperature is set to 290℃, 310℃, 305℃, 310℃, 330℃, 320℃, 320℃, 310℃ and 280℃. Magnetic FeSiAl / PPS modified resin is obtained by extrusion granulation.

[0056] (2) Spinning: Magnetic FeSiAl / PPS modified resin is made into bicomponent FeSiAl / PPS fiber through a composite spinning box. The drying temperature of the composite spinning box is 180℃ and the drying time is 13h. The screw temperature of melt extrusion is 290℃, 300℃, 310℃, 320℃ and 330℃. The pressure of the filter main and pre-screen is 0.2MPa. The side blowing speed, temperature and pressure are 0.8m / s, 30℃ and 800KPa. Magnetic PPS modified resin and PPS resin are extruded together at the inlet of the spinneret through their respective channels. Magnetic PPS modified resin is used as the core layer and PPS resin is used as the skin layer. After stretching and drying stages, bicomponent FeSiAl / PPS fiber is obtained.

[0057] S3: Preparation of Long-Lasting Charged Two-Component Polyphenylene Sulfide Filter Media

[0058] The prepared bicomponent PbTiO3-PPS fiber and bicomponent FeSiAl / PPS fiber were respectively opened, mixed, carded, laid, needle punched and heat-set at high temperature to obtain bicomponent PbTiO3-PPS fiber filter media and bicomponent FeSiAl / PPS fiber filter media. Then, the prepared filter media and the base cloth filter media were calendered and singed to obtain long-lasting charged bicomponent polyphenylene sulfide filter media.

[0059] Example 3

[0060] A method for manufacturing a long-lasting charged two-component polyphenylene sulfide filter media, comprising the following specific steps:

[0061] S1: Preparation of bicomponent BaTiO3-PPS fibers

[0062] (1) Granulation: 1000g of BaTiO3 with a particle size of 3μm and 800g of silane coupling agent were added to 8200g of PPS powder with a particle size of 800μm. The mixture was mixed and melted into filaments in a three-screw extruder granulator. After water cooling and molding, the filaments were cut. The cutting machine speed was 600-800r / min. The screw extrusion temperature was set at 280℃, 300℃, 305℃, 320℃, 330℃, 320℃, 325℃, 300℃, and 290℃. The extrusion granulation yielded BaTiO3-PPS modified resin with a diameter of 1-3cm.

[0063] (2) Spinning: PPS resin is placed in the core layer and BaTiO3-PPS modified resin is placed in the outer layer for bicomponent spinning. Core layer: PPS resin is dried, melt extruded, filtered, and melt metered before entering the composite spinning box; Process parameters: Drying temperature 200℃, drying time 12h; Screw temperature of melt extrusion: 290℃, 310℃, 320℃, 330℃, 335℃; Main and pre-screen pressure of filter: 0.1MPa; Side blowing speed, temperature and pressure: 0.6m / s, 22℃, 500KPa.

[0064] Skin layer: The granulated BaTiO3-PPS modified resin is dried, melt-extruded, filtered, and melt-metered before entering the composite spinning box; the specific process parameters are: chip drying temperature 210℃, drying time 15h; screw temperature: 300℃, 310℃, 335℃, 330℃, 340℃; main and pre-web pressure: 0.1MPa; side blowing speed, temperature and pressure: 0.5m / s, 22℃, 500KPa.

[0065] In the spinning assembly, PPS resin and BaTiO3-PPS modified resin are extruded together at the inlet of the spinneret through their respective channels, forming a bicomponent BaTiO3-PPS filament with a clear interface. After a stretching and setting stage, the filament is dried and set to form bicomponent BaTiO3-PPS fiber. The specific parameters of the stretching process are: first stretching ratio of 1.2 times, water bath heating temperature of 100℃; second stretching ratio of 0.8 times, superheated steam temperature of 180℃.

[0066] (3) Electret: Before the fiber heat setting in the post-spinning stage, a hot corridor oven with an electric field is added. The electric field strength in the oven is 25kv / mm~35kv / mm, and the temperature is 170℃~250℃. The filter material travels at a constant speed in the oven for 10min~20min. After passing through the heat drying at a constant speed, bicomponent BaTiO3-PPS fiber is obtained.

[0067] S2: Preparation of bicomponent FeSiAl / PPS fibers

[0068] (1) Granulation: 300g of FeSiAl, 100g of silica and 700g of PPS resin are mixed and melt-granulated in a three-screw extruder. The screw extrusion temperature is set to 290℃, 310℃, 305℃, 310℃, 330℃, 320℃, 320℃, 310℃ and 280℃. Magnetic FeSiAl / PPS modified resin is obtained by extrusion granulation.

[0069] (2) Spinning: The magnetic FeSiAl / PPS modified resin is made into bicomponent FeSiAl / PPS fibers through a composite spinning box. The drying temperature of the composite spinning box is 190℃ and the drying time is 10h. The screw temperature of melt extrusion is 290℃, 300℃, 310℃, 320℃, and 330℃. The pressure of the main and pre-screen filters is 0.15MPa. The side blowing speed, temperature, and pressure are 0.6m / s, 25℃, and 600KPa. The magnetic PPS modified resin and PPS resin are extruded together at the inlet of the spinneret through their respective channels. The magnetic FeSiAl / PPS modified resin is used as the core layer and the PPS resin is used as the skin layer. After stretching and drying, the bicomponent FeSiAl / PPS fibers are obtained.

[0070] S3: Preparation of Long-Lasting Charged Two-Component Polyphenylene Sulfide Filter Media

[0071] The prepared bicomponent BaTiO3-PPS fiber and bicomponent FeSiAl / PPS fiber were respectively opened, mixed, carded, laid, needle punched and heat-set at high temperature to obtain bicomponent BaTiO3-PPS fiber filter media and bicomponent FeSiAl / PPS fiber filter media. Then, the prepared filter media and the base cloth filter media were calendered and singed to obtain long-lasting charged bicomponent polyphenylene sulfide filter media.

[0072] Example 4

[0073] S1: Preparation of bicomponent PbTiO3-BaTiO3-PPS fibers

[0074] (1) Granulation: 800g of PbTiO3 with a particle size of 10μm, 700g of BaTiO3 with a particle size of 10μm, and 1000g of silane coupling agent were added to 7500g of PPS powder with a particle size of 1200μm. The mixture was mixed and melted into filaments in a three-screw extruder granulator. After water cooling and molding, the filaments were cut. The cutting speed was 600-800r / min. The screw extrusion temperature was set at 280℃, 300℃, 305℃, 320℃, 330℃, 320℃, 325℃, 300℃, and 290℃. The PbTiO3-BaTiO3-PPS modified resin with a diameter of 1-3cm was obtained by extrusion granulation.

[0075] (2) Spinning: PPS resin is placed in the core layer, and PbTiO3-BaTiO3-PPS modified resin is placed in the outer layer for bicomponent spinning. Core layer: PPS resin is dried, melt extruded, filtered, and melt metered before entering the composite spinning box; Process parameters: Drying temperature 200℃, drying time 12h; Screw temperature of melt extrusion: 290℃, 310℃, 320℃, 330℃, 335℃; Main and pre-screen pressure of filter: 0.1MPa; Side blowing speed, temperature and pressure: 0.6m / s, 22℃, 500KPa.

[0076] Skin layer: The granulated PbTiO3-BaTiO3-PPS modified resin is dried, melt-extruded, filtered, and melt-metered before entering the composite spinning box. The specific process parameters are as follows: chip drying temperature 210℃, drying time 15h; screw temperature: 300℃, 310℃, 335℃, 330℃, 340℃; main and pre-web pressure: 0.1MPa; side blowing speed, temperature and pressure: 0.5m / s, 22℃, 500KPa.

[0077] In the spinning assembly, PPS resin and PbTiO3-BaTiO3-PPS modified resin are extruded together at the inlet of the spinneret through their respective channels, forming a bicomponent composite PbTiO3-PPS filament with a clear interface. After a stretching and setting stage, and finally drying and setting, bicomponent PbTiO3-PPS fibers are formed. Specific parameters for the stretching process are: first stretching ratio 1.2 times, water bath heating temperature 100℃; second stretching ratio 0.8 times, superheated steam 180℃.

[0078] (3) Electret: Before the fiber heat setting in the post-spinning stage, a hot corridor oven with an electric field is added. The electric field strength in the oven is 25kv / mm~35kv / mm, and the temperature is 170℃~250℃. The filter material travels at a constant speed in the oven for 10min~20min. After passing through the heat drying at a constant speed, bicomponent PbTiO3-BaTiO3-PPS fiber is obtained.

[0079] S2: Preparation of composite FeSiAl / PPS fibers

[0080] (1) Granulation: 400g of FeSiAl, 120g of silica and 800g of PPS resin are mixed and melt-granulated in a three-screw extruder. The screw extrusion temperature is set to 290℃, 310℃, 305℃, 310℃, 330℃, 320℃, 320℃, 310℃ and 280℃. Magnetic FeSiAl / PPS modified resin is obtained by extrusion granulation.

[0081] (2) Spinning: Magnetic FeSiAl / PPS modified resin is made into bicomponent FeSiAl / PPS fiber through a composite spinning box. The drying temperature of the composite spinning box is 180℃ and the drying time is 13h. The screw temperature of melt extrusion is 290℃, 300℃, 310℃, 320℃ and 330℃. The pressure of the filter main and pre-screen is 0.2MPa. The side blowing speed, temperature and pressure are 0.8m / s, 30℃ and 800KPa. Magnetic PPS modified resin and PPS resin are extruded together at the inlet of the spinneret through their respective channels. Magnetic PPS modified resin is used as the core layer and PPS resin is used as the skin layer. After stretching and drying stages, bicomponent FeSiAl / PPS fiber is obtained.

[0082] S3: Preparation of Long-Lasting Charged Two-Component Polyphenylene Sulfide Filter Media

[0083] The prepared bicomponent PbTiO3-BaTiO3-PPS fibers and bicomponent FeSiAl / PPS fibers were respectively opened, mixed, carded, laid, needle-punched, and heat-set at high temperature to obtain bicomponent PbTiO3-PPS fiber filter media and bicomponent FeSiAl / PPS fiber filter media. Then, the prepared filter media and the base cloth filter media were calendered and singed to obtain long-lasting charged bicomponent polyphenylene sulfide filter media.

[0084] Comparative Example 1

[0085] S1: Production of bicomponent PbTiO3-PPS fibers:

[0086] (1) Granulation: 500g of PbTiO3 with a particle size of 0.5μm and 500g of silane coupling agent were added to 9000g of PPS powder with a particle size of 100μm. The mixture was mixed and melted into filaments in a three-screw extruder granulator. After water cooling and molding, the filaments were cut. The cutting machine speed was 600-800r / min. The screw extrusion temperature was set at 280℃, 300℃, 305℃, 320℃, 330℃, 320℃, 325℃, 300℃, and 290℃. The PbTiO3-PPS modified resin with a diameter of 1-3cm was obtained by extrusion granulation.

[0087] (2) Spinning: Conventional PPS resin is placed in the outer layer and PbTiO3-PPS modified resin is placed in the core layer for bicomponent spinning; Core layer: PPS resin is dried, melt extruded, filtered, and melt metered, and then enters the composite spinning box; Process parameters: Drying temperature 200℃, drying time 12h; Screw temperature of melt extrusion: 290℃, 310℃, 320℃, 330℃, 335℃; Main and pre-screen pressure of filter: 0.1MPa; Side blowing speed, temperature and pressure: 0.6m / s, 22℃, 500KPa.

[0088] Skin layer: The granulated PbTiO3-PPS modified resin is dried, melt-extruded, filtered, and melt-metered before entering the composite spinning box. The specific process parameters are as follows: chip drying temperature 210℃, drying time 15h; screw temperature: 300℃, 310℃, 335℃, 330℃, 340℃; main and pre-web pressure: 0.1MPa; side blowing speed, temperature and pressure: 0.5m / s, 22℃, 500KPa.

[0089] In the spinning assembly, PPS resin and PbTiO3-PPS modified resin are extruded together at the inlet of the spinneret through their respective channels, forming a bicomponent PbTiO3-PPS filament with a clear interface. After a stretching and setting stage, and finally drying and setting, bicomponent PbTiO3-PPS fibers are formed. Specific parameters for the stretching process are: first stretching ratio 1.2 times, water bath heating temperature 100℃; second stretching ratio 0.8 times, superheated steam 180℃.

[0090] (3) Electret: Before the fiber heat setting in the post-spinning stage, a hot corridor oven with an electric field is added. The electric field strength in the oven is 25kv / mm~35kv / mm, and the temperature is 170℃~250℃. The filter material travels at a constant speed in the oven for 10min~20min. After passing through the heat drying at a constant speed, bicomponent PbTiO3-PPS fiber is obtained.

[0091] S2: PPS fiber preparation

[0092] (1) Granulation: Mix 80g of silica with 600g of PPS resin and melt granulate in a three-screw extruder. The screw extrusion temperature is set to 290℃, 310℃, 305℃, 310℃, 330℃, 320℃, 320℃, 310℃, and 280℃. PPS modified resin is obtained by extrusion granulation.

[0093] (2) Spinning: PPS modified resin is made into PPS fiber through a spinning box. The drying temperature of the spinning box is 190℃ and the drying time is 10h. The screw temperature of melt extrusion is 290℃, 300℃, 310℃, 320℃, and 330℃. The pressure of the main and pre-screen filters is 0.15MPa. The side blowing speed, temperature, and pressure are 0.6m / s, 25℃, and 600KPa. The PPS modified resin is extruded through the flow channel into the spinneret orifice, and then PPS fiber is obtained through the stretching and drying stages.

[0094] S3: Preparation of polyphenylene sulfide filter media

[0095] The two-component PbTiO3-PPS fiber and PPS fiber were respectively opened, mixed, carded, laid, needle punched and then heat-set at high temperature to obtain two-component PbTiO3-PPS fiber filter media and PPS fiber filter media. Then, the prepared filter media and the base cloth filter media were calendered and singed to obtain polyphenylene sulfide filter media.

[0096] Comparative Example 2

[0097] S1: PPS fiber preparation

[0098] (1) Granulation: 10,000g of PPS with a particle size of 100μm is mixed and melted into filaments in a screw extrusion granulator. After water cooling and molding, it is cut. The cutting speed is 600-800r / min. The screw extrusion temperature is set at 280℃, 300℃, 305℃, 320℃, 330℃, 320℃, 325℃, 300℃, and 290℃. PPS modified resin with a diameter of 1-3cm is obtained by extrusion granulation.

[0099] (2) Spinning: The PPS modified resin is dried, melt-extruded, filtered, and melt-metered before entering the spinning box; process parameters: drying temperature 200℃, drying time 12h; screw temperature of melt extrusion: 290℃, 310℃, 320℃, 330℃, 335℃; main and pre-screen pressure of filter: 0.1MPa; side blowing speed, temperature and pressure: 0.6m / s, 22℃, 500KPa. In the spinning assembly, the PPS modified resin is extruded through the flow channel into the spinneret orifice to form PPS filaments; then it goes through the stretching and setting stage. The specific parameters of the stretching process are: first stretching ratio 1.2 times, water bath heating temperature 100℃; second stretching 0.8 times, superheated steam 180℃; drying and setting to form PPS fibers.

[0100] S2: Fabrication of bicomponent FeSiAl / PPS fibers:

[0101] (1) Granulation: 100g of FeSiAl, 80g of silica and 500g of PPS resin are mixed and melt-granulated in a three-screw extruder. The screw extrusion temperature is set to 290℃, 310℃, 305℃, 310℃, 330℃, 320℃, 320℃, 310℃ and 280℃. Magnetic FeSiAl / PPS modified resin is obtained by extrusion granulation.

[0102] (2) Spinning: The magnetic FeSiAl / PPS modified resin is made into bicomponent FeSiAl / PPS fibers through a composite spinning box. The drying temperature of the composite spinning box is 190℃ and the drying time is 10h. The screw temperature of melt extrusion is 290℃, 300℃, 310℃, 320℃, and 330℃. The pressure of the main and pre-screen filters is 0.15MPa. The side blowing speed, temperature, and pressure are 0.6m / s, 25℃, and 600KPa. The magnetic PPS modified resin and PPS resin are extruded together at the inlet of the spinneret through their respective channels. The magnetic FeSiAl / PPS modified resin is used as the core layer and the PPS resin is used as the skin layer. After stretching and drying, the bicomponent FeSiAl / PPS fibers are obtained.

[0103] S3: Preparation of polyphenylene sulfide filter media

[0104] PPS fiber and bicomponent FeSiAl / PPS fiber were respectively opened, mixed, carded, laid, needle punched and then heat-set at high temperature to obtain PPS fiber filter media and bicomponent FeSiAl / PPS fiber filter media. Then, the prepared filter media and the base cloth filter media were calendered and singed to obtain polyphenylene sulfide filter media.

[0105] Performance testing methods:

[0106] 1. Filtration efficiency test of non-metallic dust: The filter media prepared in Examples 1-4 and Comparative Examples 1-2 were tested using a particulate matter filtration efficiency tester platform (the particulate matter filtration efficiency tester contains a sodium chloride aerosol generator, and the filtration performance is verified by the counting method, and the particulate matter is sodium chloride aerosol).

[0107] Test conditions: ambient temperature was (25±5)℃, relative humidity was (30±10)%, test flow rate was (85±4)L / min, and the test results are shown in Table 1.

[0108] Table 1. Filtration efficiency test results of non-metallic dust from the filter media prepared in Examples 1-4 and Comparative Examples 1-2.

[0109]

[0110]

[0111] The purpose of this test was to explore the collection efficiency of the examples and comparative examples for fine dust. The results showed that:

[0112] (1) In Examples 1 and 2, with the increase of PbTiO3 content, the long-term charging effect is better and the overall filtration accuracy of fine particles is improved. This is because the charging effect is increased and the electrostatic adsorption effect is better. However, the improvement effect is not obvious for particles larger than 5.0μm. This is because large particles are mainly filtered by the direct interception or sieving effect of the filter media.

[0113] (2) The overall particulate matter filtration efficiency of Comparative Example 1 and Example 1 is similar. This is because Comparative Example 1 also has a long-lasting charged fiber layer, so the charging effect is similar and the electrostatic adsorption effect is similar.

[0114] (3) Comparative Example 2 has a magnetic layer, but no long-term charged fiber layer. There is no metal dust in the test dust, so the charging effect is poor and the overall filtration accuracy is poor.

[0115] 2. Filtration efficiency test for metal dust: The above test method uses a particulate matter filtration efficiency tester containing a sodium chloride aerosol generator and employs a counting method to verify filtration performance. Since the particulate matter is sodium chloride aerosol, it cannot verify the influence of the magnetic layer on metal dust. Therefore, we changed the test method and used the German TOPAS-AFC-133VDI ​​dynamic filtration efficiency testing platform to test the performance of the filter media prepared in Examples 1-4 and Comparative Examples 1-2 (this method allows for the addition of metal dust).

[0116] The test dust consisted of 50% standard dust (alumina) and 50% metal dust (particle size ranging from 0.3 to 20 μm). The test method was based on Appendix B of GB / T6719-2009, and the test results are shown in Table 2.

[0117] Table 2. Filtration efficiency test results of non-metallic dust from the filter media prepared in Examples 1-4 and Comparative Examples 1-2.

[0118]

[0119] The results showed that when the metal dust particle sizes were 0.3 μm, 0.5 μm, 1.0 μm, and 2.5 μm, the filtration efficiency of Comparative Example 1 was lower than that of Example 1. This is because Comparative Example 1 did not have a magnetic adsorption layer. When filtering metal dust, the entire filter bag interlayer was filled with metal dust. After the metal dust entered the inner long-term charge layer, it acted as a conductive carrier, transferring the charge on the inner long-term charge layer to the metal bag cage, and then from the metal bag cage to the external device. This resulted in the loss of charge in the long-term charge layer, causing it to lose its ability to adsorb dust, thus reducing its filtration efficiency for fine dust. The filtration efficiency of Comparative Example 1 increased with the increase of the metal dust particle size because the fiber layer could filter larger particles.

[0120] When the metal dust particle sizes are 0.3μm, 0.5μm, 1.0μm, and 2.5μm, the metal dust filtration efficiency of Comparative Example 2 is lower than that of Example 1. This is because, although Comparative Example 2 has a magnetic adsorption layer, even if some metal dust is filtered, it does not have a long-lasting charged fiber layer. Due to the lack of charged adsorption, its filtration accuracy for non-metallic fine dust is not high.

[0121] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for manufacturing a long-lasting charged two-component polyphenylene sulfide filter material, characterized in that, The long-lasting charged bicomponent polyphenylene sulfide filter media comprises three layers: a middle layer is a base fabric layer, an inner layer is a long-lasting charged fiber layer, and an outer layer is a magnetic adsorption layer. The three layers are calendered and singed to obtain the long-lasting charged bicomponent polyphenylene sulfide filter media. The long-lasting charged fiber layer is a bicomponent PbTiO3 / BaTiO3-PPS fiber filter media, and the magnetic adsorption layer is a bicomponent FeSiAl / PPS fiber filter media.

2. The method for manufacturing the long-lasting charged two-component polyphenylene sulfide filter material according to claim 1, characterized in that, The preparation method of the bicomponent PbTiO3 / BaTiO3-PPS fiber is as follows: (1) Granulation: PbTiO3 / BaTiO3 and coupling agent are added to PPS powder, mixed and dried to obtain a mixture, and the mixture is fed into an extruder for melting, extrusion and granulation to obtain PbTiO3 / BaTiO3-PPS modified resin. (2) Spinning: PbTiO3 / BaTiO3-PPS modified resin is placed in the outer layer as the sheath layer and conventional PPS resin is placed in the inner layer as the core layer for bicomponent spinning. Before the fiber heat setting in the post-spinning stage, a hot tunnel oven with an electric field is added and the fiber is heat dried at a uniform speed to obtain bicomponent PbTiO3 / BaTiO3-PPS fiber.

3. The manufacturing method according to claim 1, characterized in that, The preparation method of the bicomponent FeSiAl / PPS fiber is as follows: FeSiAl, silica and PPS resin are mixed and granulated to prepare magnetic PPS modified resin. The magnetic PPS modified resin is used as the core layer and PPS resin is used as the skin layer. The fibers are then spun in a bicomponent manner and then subjected to a stretching and setting stage and a drying and setting stage to obtain the bicomponent FeSiAl / PPS fiber.

4. The manufacturing method according to claim 1, characterized in that, The bicomponent PbTiO3 / BaTiO3-PPS fiber filter media is obtained by opening, mixing, carding, web laying, needle punching, and then heat setting at high temperature; the bicomponent FeSiAl / PPS fiber filter media is obtained by opening, mixing, carding, web laying, needle punching, and then heat setting at high temperature.

5. The manufacturing method according to claim 2, characterized in that, The PbTiO3 / BaTiO3, coupling agent, and PPS powder are added at 5-15%, 5-10%, and 75-90% of the total mass, respectively.

6. The manufacturing method according to claim 2, characterized in that, The PbTiO3 / BaTiO3 has a particle size of 0.5-15 μm; the PPS powder has a particle size of 100-2000 μm; and the coupling agent is a silane coupling agent.

7. The manufacturing method according to claim 3, characterized in that, The FeSiAl, silica and PPS resin are mixed in a mass ratio of 1-4:0.8-1.2:5-8.

8. The manufacturing method according to claim 1, characterized in that, The base fabric is an insulating material made of PPS and PTFE.

9. Long-lasting charged bicomponent polyphenylene sulfide filter media manufactured by the manufacturing method according to any one of claims 1-8.

10. The application of the long-lasting charged two-component polyphenylene sulfide filter material as described in claim 9 in dust collector filter bags.

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