High-temperature-resistant fireproof filter material base cloth and preparation method thereof

Abstract

The invention discloses a high-temperature-resistant fireproof filter material base cloth and a preparation method, and relates to the technical field of filter material base clothes.The high-temperature-resistant fireproof filter material base cloth comprises a base layer, a reinforcing layer and a protective layer, the base layer serves as a basic support and comprises a polyimide fiber woven layer, a twill weaving method is adopted, the fiber monofilament diameter is 8-12 micrometers, and the fiber monofilament diameter is 8-12 micrometers; the weaving density is 120-180 pieces per square centimeter; the reinforcing layer is positioned on the base layer and comprises basalt fiber gridding cloth, the gridding size of the gridding cloth is 3mm * 3mm-4mm * 4mm, and the fiber diameter is 12-18 microns; and the protective layer is the outermost layer and is made of intumescent fireproof paint, and a coating with the thickness of 0.5-0.8 mm is formed on the outer surface of the enhancement layer by adopting a blade coating process. The polyimide fiber woven layer and the basalt fiber gridding cloth are combined, so that the filter material base cloth can bear a high-temperature environment without the problems of deformation, softening and the like. The high temperature resistance of the polyimide fiber is combined with the high strength and high modulus of the basalt fiber, so that the stability of the base cloth at high temperature is improved.

Description

Technical Field

[0001] This invention relates to the field of filter media base fabric technology, specifically to a high-temperature resistant and fireproof filter media base fabric and its preparation method. Background Technology

[0002] There is a wide and stringent demand for high-temperature resistant fireproof filter media in numerous fields, including industrial production and building fire protection. Traditional filter media often fail to function stably in high-temperature environments. Some ordinary fiber-based base fabrics are prone to softening, deformation, or even combustion at high temperatures, compromising their structural integrity, rendering them ineffective at filtration, and consequently affecting the normal operation of production processes and potentially posing safety hazards. For example, in industrial settings with high-temperature flue gas emissions, ordinary filter media exhibit a significant decrease in filtration performance after prolonged exposure to high-temperature flue gas and are easily damaged by high temperatures, requiring frequent replacement and increasing production costs and maintenance workload. Furthermore, some existing so-called high-temperature resistant filter media also lack sufficient fire resistance; they fail to form an effective fire barrier when exposed to open flames or high-temperature flames, failing to provide reliable protection for equipment and personnel. Therefore, developing a high-performance high-temperature resistant fireproof filter media is of significant practical importance. Summary of the Invention

[0003] To address the problems existing in the prior art, the present invention provides a high-temperature resistant and fireproof filter material base fabric and its preparation method, so as to solve the problems mentioned in the background art.

[0004] This invention is achieved as follows: a high-temperature resistant fireproof filter material base fabric includes a base layer, a reinforcing layer, and a protective layer. The base layer serves as the basic support and includes a polyimide fiber woven layer using a twill weave method. The fiber monofilament diameter is 8-12 micrometers, and the weave density is 120-180 fibers per square centimeter. The reinforcing layer is located above the base layer and includes a basalt fiber mesh fabric with a mesh size of 3mm×3mm-4mm×4mm and a fiber diameter of 12-18 micrometers. The protective layer is the outermost layer and is composed of an intumescent fireproof coating. A coating with a thickness of 0.5-0.8mm is formed on the outer surface of the reinforcing layer using a scraping process.

[0005] In a preferred embodiment of the present invention, the base layer and the reinforcing layer are firmly bonded together by a high-temperature cured epoxy resin adhesive, and the film-forming substance in the fireproof coating and the surface of the basalt fiber mesh cloth permeate and combine between the reinforcing layer and the protective layer.

[0006] As a preferred embodiment of the present invention, the polyimide fibers in the polyimide fiber braided layer are modified with nano-titanium dioxide, and the loading of nano-titanium dioxide is 3%-5% of the fiber weight.

[0007] As a preferred embodiment of the present invention, the polyimide fiber braided layer is made of high-strength polyimide fiber, which has a tensile strength that is 20%-30% higher than that of ordinary polyimide fiber.

[0008] As a preferred embodiment of the present invention, the basalt fiber mesh is treated with organosilicon for waterproofing, and the waterproof rating reaches IPX5 or higher.

[0009] As a preferred embodiment of the present invention, the intumescent fire retardant coating further contains 3%-5% by mass of nano-montmorillonite, which is uniformly dispersed in the fire retardant coating.

[0010] As a preferred embodiment of the present invention, an aramid fiber nonwoven fabric transition layer is provided between the basalt fiber mesh and the base layer, wherein the aramid fiber nonwoven fabric has a basis weight of 20-30 g / m².

[0011] As a preferred embodiment of the present invention, the intumescent fire-retardant coating contains 8%-12% by mass of expandable graphite micropowder.

[0012] A method for preparing a high-temperature resistant fireproof filter material base cloth includes the following steps:

[0013] Preparation of the base layer: Polyimide fibers are selected, with the diameter of the single fiber filament controlled at 8-12 micrometers. The polyimide fibers are woven into a polyimide fiber woven layer with a weave density of 120-180 fibers per square centimeter using a twill weave method, which serves as the base layer for basic support.

[0014] Preparation of the reinforcing layer: Basalt fiber mesh cloth with a mesh size of 3mm×3mm-4mm×4mm and a fiber diameter of 12-18 micrometers is selected; the prepared basalt fiber mesh is arranged on the base layer as the reinforcing layer;

[0015] Preparation of protective layer: Apply intumescent fire retardant coating to the outer surface of the reinforcing layer using a scraping process to form a coating with a thickness of 0.5-0.8 mm, which serves as the outermost protective layer;

[0016] The base layer and the reinforcing layer are firmly bonded together by a high-temperature cured epoxy resin adhesive. Between the reinforcing layer and the protective layer, the film-forming substance in the fireproof coating permeates and combines with the surface of the basalt fiber mesh.

[0017] The polyimide fibers in the polyimide fiber woven layer are modified with nano-titanium dioxide, and the loading of nano-titanium dioxide is 3%-5% of the fiber weight; the polyimide fiber woven layer uses high-strength polyimide fibers, whose tensile strength is 20%-30% higher than that of ordinary polyimide fibers; the basalt fiber mesh is treated with organosilicon for waterproofing, and the waterproof rating reaches IPX5 or higher; the intumescent fireproof coating also contains 3%-5% by mass of nano-montmorillonite, which is uniformly dispersed in the fireproof coating.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0019] 1. The combination of polyimide fiber woven layer and basalt fiber mesh fabric enables the filter media base fabric to withstand high-temperature environments without deformation or softening. The high-temperature resistance of polyimide fiber combined with the high strength and high modulus of basalt fiber greatly improves the stability of the base fabric at high temperatures, meeting the stringent requirements for high-temperature resistant materials in high-temperature industrial production, fire protection, and other fields, ensuring the normal operation of equipment in high-temperature environments.

[0020] 2. The protective layer formed by intumescent fire-retardant coatings expands rapidly when exposed to high temperatures, forming a heat-insulating and fire-resistant barrier that effectively prevents the transfer of flames and heat. This not only protects the internal base layer and reinforcing layer but also provides a certain degree of fire protection for the surrounding environment, reducing the risk of fire and improving the safety of personnel and equipment.

[0021] 3. The twill weave of the base layer, along with the appropriate fiber filament diameter and weave density, gives the filter media base cloth excellent filtration performance. It effectively filters dust, particles, and other impurities in high-temperature environments, meeting the filtration precision requirements of industrial production, ensuring smooth production processes, and improving product quality.

[0022] 4. The basalt fiber mesh reinforcement layer enhances the overall strength of the base fabric, disperses external forces and thermal stress, and reduces the possibility of damage to the base layer due to stress or thermal expansion and contraction. Simultaneously, the fire-resistant protection of the protective layer indirectly extends the service life of both the base layer and the reinforcement layer, resulting in a longer service life for the filter media base fabric, reducing replacement frequency, and lowering production costs. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of the high-temperature resistant fireproof filter material base cloth provided in the embodiment of the present invention;

[0024] Figure 2 This is a flowchart illustrating the preparation method of the high-temperature resistant fireproof filter material base fabric provided in this embodiment of the invention. Detailed Implementation

[0025] To further understand the invention's content, features, and effects, the following embodiments are provided, and detailed descriptions are given in conjunction with the accompanying drawings.

[0026] The structure of the present invention will now be described in detail with reference to the accompanying drawings.

[0027] like Figure 1 and Figure 2 As shown in the figure, the high-temperature resistant fireproof filter material base fabric provided by the embodiment of the present invention includes a base layer 1, a reinforcing layer 2, and a protective layer 3. The base layer 1 serves as a basic support and includes a polyimide fiber woven layer, which adopts a twill weave method. The diameter of the fiber monofilament is 8-12 micrometers, and the weave density is 120-180 fibers per square centimeter. The reinforcing layer 2 is located on the base layer 1 and includes a basalt fiber mesh cloth. The mesh size is 3mm×3mm-4mm×4mm, and the fiber diameter is 12-18 micrometers. The protective layer 3 is the outermost layer and is composed of an intumescent fireproof coating. A coating with a thickness of 0.5-0.8mm is formed on the outer surface of the reinforcing layer 2 by a scraping process.

[0028] Base Layer 1: Base Layer 1 is made of polyimide fiber woven layer using a twill weave. Polyimide fibers themselves have excellent high-temperature resistance; their molecular structure is stable and can withstand high temperatures without significant physical changes. The fiber filament diameter is 8-12 micrometers, and this finer filament makes the woven layer more dense. The weave density is 120-180 fibers per square centimeter. This high-density weave enhances the overall strength and stability of Base Layer 1, providing a solid foundation for the entire filter media base fabric and ensuring that the base fabric will not easily deform or be damaged in high-temperature environments.

[0029] Reinforcing Layer 2: Basalt fiber mesh fabric, located above base layer 1, serves as reinforcing layer 2. Basalt fiber possesses high strength, high modulus, and excellent high-temperature resistance. The mesh fabric has a mesh size of 3mm×3mm-4mm×4mm, ensuring both flexibility and a tight fit with base layer 1. The fiber diameter is 12-18 micrometers, and this moderate fiber thickness further enhances the strength of the mesh fabric. When the filter media base fabric is subjected to external tensile forces or undergoes thermal expansion and contraction under high-temperature conditions, the basalt fiber mesh fabric can disperse stress, enhance the load-bearing capacity of base layer 1, and prevent cracking, thereby improving the overall durability and stability of the filter media base fabric.

[0030] Protective Layer 3: The outermost protective layer 3 is composed of an intumescent fire-retardant coating. Under normal temperatures, this coating remains stable, providing some protection to the internal structure. When exposed to high temperatures, the intumescent fire-retardant coating expands upon heating, rapidly forming a thick, foam-like insulating layer. This insulating layer effectively prevents heat transfer to the interior, slowing the temperature rise of the base layer 1 and reinforcing layer 2. Simultaneously, the increased volume after expansion fills any gaps, preventing the intrusion of flames and high-temperature gases, thus providing highly efficient fire protection for the entire filter media base.

[0031] Furthermore, the base layer 1 and the reinforcing layer 2 are firmly bonded together by a high-temperature cured epoxy resin adhesive, and the film-forming substances in the fireproof coating and the surface of the basalt fiber mesh cloth permeate and combine between the reinforcing layer 2 and the protective layer 3.

[0032] Furthermore, the polyimide fibers in the polyimide fiber woven layer are modified with nano-titanium dioxide, with the nano-titanium dioxide loading being 3%-5% of the fiber weight. This further enhances the high-temperature resistance and UV aging resistance of the base layer 1, improving the service life of the base fabric in complex environments. The polyimide fiber woven layer uses high-strength polyimide fibers, whose tensile strength is 20%-30% higher than that of ordinary polyimide fibers, further improving the mechanical properties of the base layer 1 and making the base fabric less prone to damage when subjected to large external forces. The basalt fiber mesh is treated with silicone waterproofing, achieving a waterproof rating of IPX5 or higher, effectively preventing moisture penetration into the base fabric and avoiding impact on its performance and service life due to dampness. The intumescent fire-retardant coating also contains 3%-5% nano-montmorillonite by mass. The nano-montmorillonite is uniformly dispersed in the fire-retardant coating, further optimizing the thermal stability and barrier properties of the protective layer 3, more effectively delaying heat transfer and protecting the internal structure during a fire.

[0033] Furthermore, an aramid fiber nonwoven fabric transition layer is provided between the basalt fiber mesh and the base layer 1. The aramid fiber nonwoven fabric has a basis weight of 20-30 g / m². This transition layer enhances the adhesion between the basalt fiber mesh and the base layer 1, making the reinforcing layer 2 more tightly bonded to the base layer 1, effectively improving the overall structural stability and mechanical properties of the base fabric. The intumescent fire-retardant coating contains 8%-12% expandable graphite powder by mass. At high temperatures, the expandable graphite powder expands rapidly, working synergistically with the foam-like heat insulation layer formed by the expansion of the fire-retardant coating to further improve the heat insulation performance and fire-retardant effect of the protective layer 3, enhancing its protective capability for the internal structure.

[0034] A method for preparing a high-temperature resistant fireproof filter material base cloth includes the following steps:

[0035] Step S1: Preparation of base layer 1: Select polyimide fiber, with the diameter of the fiber monofilament controlled at 8-12 micrometers, and use twill weaving method to weave the polyimide fiber into a polyimide fiber braided layer with a weaving density of 120-180 strands per square centimeter, as the base layer 1 for basic support;

[0036] Step S2: Preparation of reinforcement layer 2: Basalt fiber mesh cloth with a mesh size of 3mm×3mm-4mm×4mm and a fiber diameter of 12-18 micrometers is made by selecting basalt fiber; the prepared basalt fiber mesh is arranged on the base layer 1 as reinforcement layer 2;

[0037] Step S3: Prepare protective layer 3: Apply intumescent fire retardant coating to the outer surface of reinforcing layer 2 using a scraping process to form a coating with a thickness of 0.5-0.8 mm, which serves as the outermost protective layer 3;

[0038] The base layer 1 and the reinforcing layer 2 are firmly bonded together by a high-temperature cured epoxy resin adhesive. Between the reinforcing layer 2 and the protective layer 3, the film-forming substances in the fireproof coating permeate and bond with the surface of the basalt fiber mesh.

[0039] Furthermore, the polyimide fibers in the polyimide fiber braided layer are modified with nano-titanium dioxide, and the loading of nano-titanium dioxide is 3%-5% of the fiber weight; this further enhances the high temperature resistance and UV aging resistance of the base layer 1, and improves the service life of the base fabric in complex environments.

[0040] The polyimide fiber woven layer uses high-strength polyimide fiber, whose tensile strength is 20%-30% higher than that of ordinary polyimide fiber; this further enhances the mechanical properties of the base layer 1, making the base fabric less prone to damage when subjected to greater external forces.

[0041] The basalt fiber mesh is treated with silicone for waterproofing, achieving a waterproof rating of IPX5 or higher; this effectively prevents moisture from penetrating into the base fabric, avoiding any impact on the base fabric's performance and service life due to dampness.

[0042] The intumescent fire-retardant coating also contains 3%-5% nano-montmorillonite by mass, which is uniformly dispersed in the fire-retardant coating.

[0043] Working principle of the invention:

[0044] Base Layer: Polyimide fibers with a single filament diameter controlled at 8-12 micrometers are selected and woven into a polyimide fiber woven layer with a weave density of 120-180 strands per square centimeter using a twill weave method. Polyimide fibers themselves possess certain high-temperature resistance. After modification with nano-titanium dioxide (3%-5% of fiber weight), the nano-titanium dioxide loading further enhances the base layer's high-temperature resistance and UV aging resistance. Nano-titanium dioxide can absorb UV energy and convert it into heat or harmless low-energy radiation, thus protecting the polyimide fibers from UV damage and extending the service life of the base fabric in complex environments. When high-strength polyimide fibers are selected, their tensile strength is 20%-30% higher than that of ordinary polyimide fibers, further improving the mechanical properties of the base layer and making it less prone to damage under greater external forces.

[0045] Reinforcing Layer: A basalt fiber mesh with a grid size of 3mm×3mm-4mm×4mm and a fiber diameter of 12-18 micrometers is placed on top of the base layer. Basalt fiber possesses high strength and high modulus, providing additional mechanical support to the base fabric. An aramid fiber nonwoven fabric transition layer with a basis weight of 20-30 g / m² is placed between the basalt fiber mesh and the base layer. The aramid fiber nonwoven fabric has excellent bonding properties, enhancing the adhesion between the basalt fiber mesh and the base layer, resulting in a tighter bond between the reinforcing layer and the base layer, effectively improving the overall structural stability and mechanical properties of the base fabric. Simultaneously, the basalt fiber mesh, treated with silicone for waterproofing and achieving a waterproof rating of IPX5 or higher, effectively prevents moisture penetration into the base fabric, avoiding impacts on its performance and service life due to dampness.

[0046] Protective Layer: An intumescent fire-retardant coating is applied to the outer surface of the reinforcing layer using a scraping process, forming a 0.5-0.8 mm thick coating as a protective layer. 8%-12% by mass of expandable graphite powder and 3%-5% by mass of nano-montmorillonite are added to the intumescent fire-retardant coating. Under high-temperature conditions, the expandable graphite powder expands rapidly, synergistically working with the foam-like insulation layer formed by the expansion of the fire-retardant coating to significantly improve the thermal insulation performance and fire-retardant effect of the protective layer, enhancing its protection of the internal structure. The nano-montmorillonite, uniformly dispersed in the fire-retardant coating, optimizes the thermal stability and barrier properties of the protective layer, more effectively delaying heat transfer during a fire, thereby protecting the internal structure.

[0047] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0048] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-temperature resistant fireproof filter material base fabric, comprising a base layer (1), a reinforcing layer (2), and a protective layer (3), characterized in that, The base layer (1) serves as the basic support, including a polyimide fiber braided layer, which is woven in a twill weave, with a fiber filament diameter of 8-12 micrometers and a weave density of 120-180 fibers per square centimeter; The reinforcing layer (2) is located above the base layer (1) and includes basalt fiber mesh cloth with a mesh size of 3mm×3mm-4mm×4mm and a fiber diameter of 12-18 micrometers. The protective layer (3) is the outermost layer, which is composed of an intumescent fire retardant coating. A coating with a thickness of 0.5-0.8 mm is formed on the outer surface of the reinforcing layer (2) by a scraping process.

2. The high-temperature resistant and fireproof filter material base fabric according to claim 1, characterized in that: The base layer (1) and the reinforcing layer (2) are firmly bonded together by a high-temperature cured epoxy resin adhesive. Between the reinforcing layer (2) and the protective layer (3), the film-forming substances in the fireproof coating and the surface of the basalt fiber mesh cloth permeate and combine with each other.

3. The high-temperature resistant fireproof filter material base fabric according to claim 1, characterized in that, The polyimide fibers in the polyimide fiber braided layer are modified with nano-titanium dioxide, and the loading of nano-titanium dioxide is 3%-5% of the fiber weight.

4. The high-temperature resistant fireproof filter material base fabric according to claim 3, characterized in that, The polyimide fiber braided layer is made of high-strength polyimide fiber, whose tensile strength is 20%-30% higher than that of ordinary polyimide fiber.

5. The high-temperature resistant fireproof filter material base fabric according to claim 4, characterized in that, The basalt fiber mesh is treated with silicone waterproofing, achieving a waterproof rating of IPX5 or higher.

6. The high-temperature resistant fireproof filter material base fabric according to claim 5, characterized in that, The intumescent fire-retardant coating also contains 3%-5% nano-montmorillonite by mass, which is uniformly dispersed in the fire-retardant coating.

7. The high-temperature resistant fireproof filter material base fabric according to claim 1, characterized in that, A layer of aramid fiber nonwoven fabric is provided between the basalt fiber mesh and the base layer (1), and the aramid fiber nonwoven fabric has a basis weight of 20-30 g / m².

8. The high-temperature resistant fireproof filter material base fabric according to claim 1, characterized in that, The intumescent fire-retardant coating contains 8%-12% expandable graphite powder by mass.

9. A method for preparing a high-temperature resistant fireproof filter material base cloth, characterized in that, Includes the following steps: Preparation of the base layer (1): Polyimide fiber is selected, with the diameter of the single fiber filament controlled at 8-12 micrometers. The polyimide fiber is woven into a polyimide fiber woven layer with a weaving density of 120-180 fibers per square centimeter using the twill weaving method, which serves as the base layer (1) for basic support. Preparation of reinforcing layer (2): Basalt fiber mesh cloth with a mesh size of 3mm×3mm-4mm×4mm and a fiber diameter of 12-18 micrometers is selected; the prepared basalt fiber mesh is arranged on the base layer (1) as the reinforcing layer (2); Preparation of protective layer (3): Apply intumescent fire retardant coating to the outer surface of reinforcing layer (2) using a scraping process to form a coating with a thickness of 0.5-0.8 mm, which serves as the outermost protective layer (3); The base layer (1) and the reinforcing layer (2) are firmly bonded together by a high-temperature cured epoxy resin adhesive. Between the reinforcing layer (2) and the protective layer (3), the film-forming substances in the fireproof coating and the surface of the basalt fiber mesh cloth permeate and combine with each other.

10. The high-temperature resistant fireproof filter material base fabric according to claim 9, characterized in that, The polyimide fibers in the polyimide fiber braided layer are modified with nano-titanium dioxide, and the loading of nano-titanium dioxide is 3%-5% of the fiber weight. The polyimide fiber braided layer is made of high-strength polyimide fiber, whose tensile strength is 20%-30% higher than that of ordinary polyimide fiber; The basalt fiber mesh is treated with silicone waterproofing, achieving a waterproof rating of IPX5 or higher. The intumescent fire-retardant coating also contains 3%-5% nano-montmorillonite by mass, which is uniformly dispersed in the fire-retardant coating.

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