One-way filtering three-dimensional metal fabric and method for manufacturing the same

Abstract

The application provides a three-dimensional metal fabric for one-way filtration and a preparation method thereof, three metal drawing fibers with different diameters are made into metal yarns respectively, then the three metal yarns are woven into metal fabrics with different warp and weft densities respectively, and finally the three metal fabrics are sequentially stacked and sintered to obtain the three-dimensional metal fabric for one-way filtration. The application selects three metal fibers with different diameters for spinning, then weaves the three yarns with different specifications into plain weave structure woven fabrics with different warp and weft densities, the three fabrics have different porosity structures, different filtration precision, stronger durability, wear resistance, warp and weft bidirectional tensile breaking strength and excellent flame retardant performance; finally, the plain weave fabrics with different porosities are sequentially stacked and sintered to form the filtration fabric with a porosity gradient, which can realize the function of one-way liquid filtration and optimize the filtration effect.

Description

Technical Field

[0001] This invention belongs to the fields of textile design, metal filtration products, etc., and specifically relates to a three-dimensional metal fabric for unidirectional filtration and its preparation method. Background Technology

[0002] With the continuous development of industry, our air and freshwater environments have suffered enormous pollution. If left unchecked, we will inevitably face the consequences of nature's actions. Therefore, the invention and design of filtration products have become crucial. However, most metal filtration products currently on the market are designed using metal fibers through nonwoven technology. For example, Chinese patent publication CN107119386A discloses a metal fiber felt for filtration prepared by needle punching; Chinese patent publication CN103978216A discloses a metal fiber felt for filtration prepared by dry or wet methods. All these methods use short metal fibers to form a mesh felt. Such filtration products are difficult to use effectively for extended periods, have low strength and short lifespan, and are prone to damage and filtration inaccuracy.

[0003] Therefore, there is an urgent need for a product that is powerful, long-lasting, and capable of operating in high-temperature or corrosive gas environments for unidirectional filtration. Summary of the Invention

[0004] The purpose of this invention is to solve the problems existing in the prior art and provide a three-dimensional metal fabric for unidirectional filtration and its preparation method, which has the characteristics of high temperature resistance, corrosion resistance and high strength, and can work in high temperature environment or environment with corrosive gas.

[0005] This invention is achieved through the following technical solution:

[0006] The first aspect of the present invention provides a method for preparing a three-dimensional metal fabric for unidirectional filtration, wherein three metal drawn fibers of different diameters are respectively made into metal yarns, and then the three metal yarns are respectively woven into metal fabrics with different warp and weft densities. Finally, the three metal fabrics are sequentially stacked and sintered to obtain a three-dimensional metal fabric for unidirectional filtration.

[0007] Furthermore,

[0008] Metal yarn is made by sequentially drawing, combing, drawing, roving, spinning, and self-winding metal fibers.

[0009] Furthermore,

[0010] The diameters of the three different metal drawn fibers are 12-25μm, 8-16μm and 2-8μm, respectively.

[0011] Furthermore,

[0012] The metal drawn fibers are stainless steel fibers or iron-chromium-aluminum fibers.

[0013] Furthermore,

[0014] The specifications of the metal yarns made from three different diameter metal drawn fibers are 290-320tex, 180-240tex and 90-120tex, respectively.

[0015] Furthermore,

[0016] Three types of metal yarns were used to make metal fabrics with different warp and weft densities using a plain weave method.

[0017] The densities of the three types of metallic yarn plain weave are as follows:

[0018] Warp density: 5-10 threads / cm; Weft density: 5-10 threads / cm;

[0019] Warp density 7-12 threads / cm, weft density 7-12 threads / cm;

[0020] Warp density 10-15 threads / cm, weft density 10-15 threads / cm.

[0021] Furthermore,

[0022] The sintering process parameters are: temperature 980℃-1120℃, holding time 4-5h.

[0023] In a second aspect, the present invention provides a three-dimensional metal fabric for unidirectional filtration, which is prepared by the preparation method described above.

[0024] Compared with the prior art, the beneficial effects of the present invention are:

[0025] This invention first selects three metal fibers with different diameters for spinning based on the different diameters of the metal fibers, which can produce three yarns with good durability, abrasion resistance, excellent tensile breaking strength and good flame retardant properties.

[0026] This invention uses a plain weave process to weave three different specifications of yarn into plain weave woven fabrics with different warp and weft densities. These three fabrics have different porosity structures and different filtration precisions, while also possessing stronger durability, abrasion resistance, biaxial tensile breaking strength, and excellent flame retardant properties.

[0027] This invention uses a stacking method to sequentially layer plain weave fabrics with different porosities to form a filter fabric with a pore gradient, which can achieve unidirectional liquid filtration function and optimize the filtration effect.

[0028] The yarn preparation and fabric weaving processes involved in this invention have mature industrial lines and can be mass-produced. The stacking and sintering method is simple and solves the problems of low strength, short life, easy damage and failure of filtration accuracy in existing filter products. Detailed Implementation

[0029] The present invention will now be described in further detail:

[0030] This invention provides a method for preparing a three-dimensional metallic fabric for unidirectional filtration, the method comprising the following steps:

[0031] Step 1: Select a metal drawn fiber, and process it by cutting, combing, drawing, roving, spinning, and self-winding to produce the first metal yarn; the metal drawn fiber is stainless steel fiber or iron-chromium-aluminum fiber.

[0032] Preferably, in step 1, the metal drawn fiber is a 12-25μm drawn fiber;

[0033] Preferably, in step 1, the specification of the first metal yarn is 290-320 tex;

[0034] Step 2: Select a metal drawn fiber, and process it by cutting, combing, drawing, roving, spinning, and self-winding to produce a second metal yarn; the metal drawn fiber is stainless steel fiber or iron-chromium-aluminum fiber.

[0035] Preferably, in step 2, the metal drawn fiber is an 8-16 μm drawn fiber;

[0036] Preferably, in step 2, the specification of the second metal yarn is 180-240 tex;

[0037] Step 3: Select a metal drawn fiber, and process it by cutting, combing, drawing, roving, spinning, and self-winding to produce a third metal yarn; the metal drawn fiber is stainless steel fiber or iron-chromium-aluminum fiber.

[0038] Preferably, in step 3, the metal drawn fiber is a 2-8 μm drawn fiber;

[0039] Preferably, in step 3, the specification of the third metal yarn is 90-120 tex;

[0040] This invention first selects three metal fibers with different diameters for spinning based on the different diameters of the metal fibers, which can produce three yarns with good durability, abrasion resistance, excellent tensile breaking strength and good flame retardant properties.

[0041] Step 4: Prepare the first metal fabric by plain weaving the first metal yarn;

[0042] Preferably, in step 4, the plain weave process of the fabric is: warp density 5-10 ends / cm, weft density 5-10 ends / cm;

[0043] Step 5: Prepare the second metal fabric by plain weaving the second metal yarn;

[0044] Preferably, in step 5, the plain weave process of the fabric is: warp density 7-12 ends / cm, weft density 7-12 ends / cm;

[0045] Step 6: Prepare the third metal yarn into a third metal fabric using a plain weave method;

[0046] Preferably, in step 6, the plain weave process of the fabric is: warp density 10-15 threads / cm, weft density 10-15 threads / cm;

[0047] This invention uses a plain weave process to weave three different specifications of yarn into plain weave woven fabrics with different warp and weft densities. These three fabrics have different porosity structures and different filtration precisions, while also possessing stronger durability, abrasion resistance, biaxial tensile breaking strength, and excellent flame retardant properties.

[0048] Step 7: Combine three different specifications of plain metal fabrics into a three-dimensional metal woven fabric by sequentially stacking them. Then, sinter the fabric using a high-temperature sintering process to obtain a three-dimensional metal fabric for unidirectional filtration with resistance to acid and alkali environments, high-temperature environments, and high mechanical properties.

[0049] Sequential layering specifically refers to the order of warp and weft density gradients. For example, the top layer transitions from the smallest warp and weft density fabric (such as the first metal fabric) to the medium warp and weft density fabric (such as the second metal fabric), and the bottom layer is the largest warp and weft density fabric (such as the third metal fabric).

[0050] Preferably, in step 7, the sintering process of the fabric is 980℃-1120℃, and the holding time is 4-5h.

[0051] This invention uses a sequential stacking method to combine plain weave fabrics with different porosities to form a filter fabric with a pore gradient, which enables unidirectional liquid filtration and optimizes the filtration effect.

[0052] Example 1

[0053] Step 1: Select stainless steel drawn fibers with a diameter of 12μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce the first stainless steel yarn. The specification of the first stainless steel yarn is 290tex.

[0054] Step 2: Select stainless steel drawn fibers with a diameter of 8μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce a second stainless steel yarn. The specification of the second stainless steel yarn is 180ex.

[0055] Step 3: Select stainless steel drawn fibers with a diameter of 2μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce a third stainless steel yarn. The specification of the third stainless steel yarn is 90tex.

[0056] The tensile breaking strength test results of the three stainless steel yarns are shown in Table 1.

[0057] Table 1 Tensile breaking strength of three types of stainless steel yarns

[0058]

[0059]

[0060] Step 4: The first stainless steel yarn is prepared into the first stainless steel fabric by plain weaving. The weaving process of the first stainless steel fabric is: warp density 5 threads / cm, weft density 5 threads / cm.

[0061] Step 5: Prepare the second stainless steel fabric by plain weaving the second stainless steel yarn. The weaving process of the second stainless steel fabric is: warp density 7 threads / cm, weft density 7 threads / cm.

[0062] Step 6: The third stainless steel yarn is prepared into a third stainless steel fabric by plain weaving. The weaving process of the third stainless steel fabric is: warp density 10 threads / cm, weft density 10 threads / cm.

[0063] The performance test results of the three stainless steel fabrics are shown in Table 2.

[0064] Table 2 Properties of Three Stainless Steel Fabrics

[0065]

[0066] Step 7: Combine the three stainless steel plain weave fabrics into a three-dimensional stainless steel woven fabric by sequentially stacking them. Then, sinter the fabric using a high-temperature sintering process at a temperature of 980℃ and a holding time of 4 hours to obtain a three-dimensional stainless steel fabric for unidirectional filtration with high temperature resistance, acid and alkali resistance, and high mechanical properties.

[0067] The strength test results of the three-dimensional stainless steel fabric obtained in Example 1 are shown in Table 3.

[0068] Table 3 Tensile breaking strength of three-dimensional stainless steel fabric

[0069]

[0070] Example 2

[0071] Step 1: Select iron-chromium-aluminum drawn fibers with a diameter of 22μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce the first iron-chromium-aluminum yarn. The specification of the first iron-chromium-aluminum yarn is 230tex.

[0072] Step 2: Select iron-chromium-aluminum drawn fibers with a diameter of 16μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce a second iron-chromium-aluminum yarn. The specification of the second iron-chromium-aluminum yarn is 200tex.

[0073] Step 3: Select iron-chromium-aluminum drawn fibers with a diameter of 4μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce a third iron-chromium-aluminum yarn. The specification of the third iron-chromium-aluminum yarn is 130tex.

[0074] The tensile breaking strength test results of the three types of iron-chromium-aluminum yarns are shown in Table 4.

[0075] Table 4 Tensile breaking strength of three types of iron-chromium-aluminum yarns

[0076] Yarn categories Specification Tensile breaking strength test Elongation at break First iron-chromium-aluminum yarn 230tex 98cN 6％ Second iron-chromium-aluminum yarn 200ex 74cN 4.6％ Third iron-chromium aluminum yarn 100tex 55cN 3.3％

[0077] Step 4: The first iron-chromium-aluminum yarn is prepared into the first iron-chromium-aluminum fabric by plain weaving. The weaving process of the first iron-chromium-aluminum fabric is: warp density 7 threads / cm, weft density 7 threads / cm.

[0078] Step 5: Prepare the second iron-chromium-aluminum fabric by plain weaving the second iron-chromium-aluminum yarn. The weaving process of the second iron-chromium-aluminum fabric is: warp density 8 threads / cm, weft density 8 threads / cm.

[0079] Step 6: The third iron-chromium-aluminum yarn is prepared into a third iron-chromium-aluminum fabric by plain weaving. The weaving process of the third iron-chromium-aluminum fabric is: warp density 13 threads / cm, weft density 13 threads / cm.

[0080] The performance tests of the three iron-chromium-aluminum fabrics are shown in Table 5.

[0081] Table 5. Properties of three types of iron-chromium-aluminum fabrics

[0082]

[0083] Step 7: Combine the three types of iron-chromium-aluminum plain weave fabrics into a three-dimensional iron-chromium-aluminum woven fabric by sequentially stacking them. Then, sinter the fabric using a high-temperature sintering process at a temperature of 1050℃ and a holding time of 4.5h to obtain a three-dimensional iron-chromium-aluminum woven fabric for unidirectional filtration with high temperature resistance, acid and alkali resistance, and high mechanical properties.

[0084] The strength test results of the three-dimensional iron-chromium-aluminum fabric obtained in Example 2 are shown in Table 6.

[0085] Table 6 Tensile breaking strength of three-dimensional iron-chromium-aluminum fabrics

[0086]

[0087] Example 3

[0088] Step 1: Select stainless steel drawn fibers with a diameter of 22μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce the first stainless steel yarn. The specification of the first stainless steel yarn is 300tex.

[0089] Step 2: Select stainless steel drawn fibers with a diameter of 12μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce a second stainless steel yarn. The specification of the second stainless steel yarn is 220ex.

[0090] Step 3: Select stainless steel drawn fibers with a diameter of 6μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce a third stainless steel yarn. The specification of the third stainless steel yarn is 100tex.

[0091] The tensile breaking strength test results of the three stainless steel yarns are shown in Table 7.

[0092] Table 7 Tensile breaking strength of three types of stainless steel yarns

[0093] Yarn categories Specification Tensile breaking strength test Elongation at break First stainless steel yarn 300tex 168cN 9.5％ Second stainless steel yarn 220ex 116cN 6.9％ Third stainless steel yarn 100tex 94cN 5.2％

[0094] Step 4: The first stainless steel yarn is prepared into the first stainless steel fabric by plain weaving. The weaving process of the first stainless steel fabric is: warp density 8 threads / cm, weft density 8 threads / cm.

[0095] Step 5: Prepare the second stainless steel fabric by plain weaving the second stainless steel yarn. The weaving process of the second stainless steel fabric is: warp density 10 threads / cm, weft density 10 threads / cm.

[0096] Step 6: The third stainless steel yarn is prepared into a third stainless steel fabric by plain weaving. The weaving process of the third stainless steel fabric is: warp density 12 threads / cm, weft density 12 threads / cm.

[0097] The performance test results of the three stainless steel fabrics are shown in Table 8.

[0098] Table 8 Properties of Three Stainless Steel Fabrics

[0099]

[0100] Step 7: Combine the three stainless steel plain weave fabrics in a sequential stacking manner to form a three-dimensional stainless steel woven fabric. Then, sinter the fabric using a high-temperature sintering process at a temperature of 1050℃ and a holding time of 4.5h to obtain a three-dimensional stainless steel fabric for unidirectional filtration with high temperature resistance, acid and alkali resistance, and high mechanical properties.

[0101] The tensile breaking strength test results of the three-dimensional stainless steel fabric obtained in Example 3 are shown in Table 9.

[0102] Table 9 Tensile breaking strength of three-dimensional stainless steel fabric

[0103]

[0104] Example 4

[0105] Step 1: Select iron-chromium-aluminum drawn fibers with a diameter of 25μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce the first iron-chromium-aluminum yarn. The specification of the first iron-chromium-aluminum yarn is 320tex.

[0106] Step 2: Select iron-chromium-aluminum drawn fibers with a diameter of 16μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce a second iron-chromium-aluminum yarn. The specification of the second iron-chromium-aluminum yarn is 240tex.

[0107] Step 3: Select iron-chromium-aluminum drawn fibers with a diameter of 8μm, and process them by cutting, combing, drawing, roving, spinning, and self-winding to produce a third iron-chromium-aluminum yarn. The specification of the third iron-chromium-aluminum yarn is 120tex.

[0108] The tensile breaking strength test results of the three types of iron-chromium-aluminum yarns are shown in Table 10.

[0109] Table 10 Tensile breaking strength of three types of iron-chromium-aluminum yarns

[0110] Yarn categories Specification Tensile breaking strength test Elongation at break First iron-chromium-aluminum yarn 320tex 189cN 7.4％ Second iron-chromium-aluminum yarn 240ex 156cN 4.8％ Third iron-chromium aluminum yarn 120tex 120cN 3.7％

[0111] Step 4: The first iron-chromium-aluminum yarn is prepared into the first iron-chromium-aluminum fabric by plain weaving. The weaving process of the first iron-chromium-aluminum fabric is: warp density 10 threads / cm, weft density 10 threads / cm.

[0112] Step 5: Prepare the second iron-chromium-aluminum fabric by plain weaving the second iron-chromium-aluminum yarn. The weaving process of the second iron-chromium-aluminum fabric is: warp density 12 threads / cm, weft density 12 threads / cm.

[0113] Step 6: Prepare the third iron-chromium-aluminum fabric by plain weaving the third iron-chromium-aluminum yarn. The weaving process of the third iron-chromium-aluminum fabric is: warp density 15 threads / cm, weft density 15 threads / cm.

[0114] The performance test results of the three iron-chromium-aluminum fabrics are shown in Table 11.

[0115] Table 11 Properties of Three Types of Iron-Chromium-Aluminum Fabrics

[0116]

[0117] Step 7: Combine the three types of iron-chromium-aluminum plain weave fabrics into a three-dimensional iron-chromium-aluminum woven fabric by sequentially stacking them. Then, sinter the fabric using a high-temperature sintering process at a temperature of 1120℃ and a holding time of 5 hours to obtain a three-dimensional iron-chromium-aluminum woven fabric for unidirectional filtration with high temperature resistance, acid and alkali resistance, and high mechanical properties.

[0118] The tensile breaking strength test results of the three-dimensional iron-chromium-aluminum fabric obtained in Example 4 are shown in Table 12.

[0119] Table 12 Tensile breaking strength of three-dimensional iron-chromium-aluminum fabrics

[0120]

[0121]

[0122] The above technical solution is only one embodiment of the present invention. For those skilled in the art, based on the principles disclosed in the present invention, it is easy to make various types of improvements or modifications, and not limited to the technical solutions described in the specific embodiments of the present invention. Therefore, the foregoing description is only a preferred option and is not restrictive.

Claims

1. A method for preparing a three-dimensional metallic fabric for unidirectional filtration, characterized in that, Three different diameter metal drawn fibers are made into metal yarns, and then the three metal yarns are woven into metal fabrics with different warp and weft densities. Finally, the three metal fabrics are stacked in order of warp and weft density gradient and sintered to obtain a three-dimensional metal fabric for unidirectional filtration. Among them, the diameters of the three different metal drawn fibers are 12-25μm, 8-16μm and 2-8μm, respectively, and the metal drawn fibers are stainless steel fibers or iron-chromium-aluminum fibers. Three types of metal yarns were used to make metal fabrics with different warp and weft densities using a plain weave method. The densities of the three types of metallic yarn plain weave are as follows: Warp density: 5-10 threads / cm; Weft density: 5-10 threads / cm; Warp density 7-12 threads / cm, weft density 7-12 threads / cm; Warp density 10-15 threads / cm, weft density 10-15 threads / cm.

2. The method for preparing a three-dimensional metal fabric for unidirectional filtration according to claim 1, characterized in that, Metal yarn is made by sequentially drawing, combing, drawing, roving, spinning, and self-winding metal fibers.

3. The method for preparing a three-dimensional metal fabric for unidirectional filtration according to claim 1, characterized in that, The specifications of the metal yarns made from three different diameter metal drawn fibers are 290-320tex, 180-240tex and 90-120tex, respectively.

4. The method for preparing a three-dimensional metal fabric for unidirectional filtration according to claim 1, characterized in that, The sintering process parameters are: temperature 980℃-1120℃, holding time 4-5h.

5. A three-dimensional metallic fabric for unidirectional filtration, characterized in that, It is prepared by the preparation method as described in any one of claims 1-4.

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