Fluid fabric based on photocatalysis-kinetic energy synergy as well as preparation method and application of fluid fabric

Abstract

The invention relates to the technical field of functional fabrics, in particular to a fluid fabric based on photocatalysis-kinetic energy synergy as well as a preparation method and application of the fluid fabric. According to the invention, active fibers are prepared from a polymer and a nano material, and then the fluid fabric based on photocatalysis-kinetic energy synergy is prepared from the active fibers. The fluid fabric comprises a surface layer, a middle layer and an inner layer which are sequentially arranged, at least one layer contains the active fibers, and the middle layer is a supporting layer and is connected with the surface layer and the inner layer in an upright or inclined mode to form a three-dimensional gap space. According to the invention, efficient and stable immobilization of the catalyst is realized, and loss and secondary pollution are avoided; the constructed three-dimensional fabric structure enhances mass transfer and light utilization, and the pollutant degradation efficiency is remarkably improved; the product has good catalytic activity, durability and engineering application prospects, and is suitable for efficient photocatalytic sewage treatment.

Description

Technical Field

[0001] This invention relates to the field of functional fabric technology, and in particular to a fluid fabric based on photocatalysis-kinetic energy synergy, its preparation method, and its application. Background Technology

[0002] With the continuous development of industrialization, the wastewater discharged from industries such as chemical, printing and dyeing, and pharmaceuticals is becoming increasingly complex, containing large amounts of high-concentration, non-biodegradable organic pollutants, posing a severe challenge to traditional water treatment technologies. Currently widely used methods such as physical adsorption, chemical oxidation, and biological treatment generally have limitations in treating this type of wastewater. Physical methods suffer from limited adsorption capacity and difficulties in material regeneration; chemical methods often require continuous addition of reagents, which is not only costly but may also generate additional chemical pollution; biological methods are sensitive to toxic substances, have long treatment cycles, and lack operational stability. Therefore, developing efficient, stable, and environmentally friendly advanced treatment technologies has become an urgent need for the industry.

[0003] Photocatalytic oxidation technology is considered a promising solution, but it still faces significant obstacles in practical engineering applications. On the one hand, highly active nanocatalysts are difficult to immobilize in flowing water, easily leaching and deactivating, causing secondary pollution, and their recovery and recycling are fraught with difficulties. On the other hand, catalytic materials themselves have inherent defects such as limited light absorption range, high carrier recombination rate, and susceptibility to poisoning or deactivation in complex wastewater environments. Simultaneously, traditional reactor designs often suffer from low light energy utilization and insufficient contact between reactants and catalysts, resulting in overall treatment efficiency far below theoretical expectations. These bottlenecks severely restrict the practical promotion and application of photocatalytic technology in industrial wastewater treatment. Summary of the Invention

[0004] To address the aforementioned problems, in a first aspect, the present invention provides an active fiber made of polymers and nanomaterials.

[0005] Furthermore, the mass content of nanomaterials in the active fiber is 1-5%.

[0006] Furthermore, the polymer is PET.

[0007] Furthermore, the nanomaterial includes MXENE (Ti3C2T) X ), g-C3N4, ZnO quantum dots.

[0008] Furthermore, the MXENE (Ti3C2T) X The diameter of the film is 2-5 μm.

[0009] Furthermore, the method for preparing the active fiber includes the following steps:

[0010] (1) The polymer and nanomaterials are melt-blended and dispersed evenly, filtered, and the core spinning solution is prepared and metered before entering the spinning box A;

[0011] (2) The soluble polymer is melted and filtered to prepare the skin spinning solution, which is then metered and fed into the spinning box B;

[0012] (3) Spinning: Two melts are spun out into core-sheath structure fibers through a composite spinneret, cooled and shaped, then oiled, then wound, stretched, crimped and shaped to form active fibers with core-sheath structure.

[0013] (4) Remove the sheath of the active fiber with a core-sheath structure to make the core layer exposure rate ≥90% and obtain the active fiber.

[0014] Furthermore, in step (1), the mass of the nanomaterial is 1-5% of the polymer mass.

[0015] Furthermore, the melting temperature in step (1) is 240-265℃.

[0016] Furthermore, the soluble polymer in step (2) is an alkali-soluble polyester.

[0017] Furthermore, the melting temperature in step (2) is 160~190°C.

[0018] Furthermore, in step (3), the spinning temperature is 265-285℃, the cooling wind speed is 1.0-1.5 m / s, the winding speed is 2400-2800 m / min, the stretching ratio is 1.5-3.0, the fiber crimp degree after crimping is ≥25%, and the setting temperature is 210-240℃.

[0019] Furthermore, in step (3), the fineness of the wound fiber is 150-300D.

[0020] Furthermore, in step (3), the mass ratio of the sheath to the core of the active fiber in the sheath-core structure is 7:2~5.

[0021] Further, the method for removing the outer layer of the active fiber with a core-sheath structure in step (4) is as follows: immerse the fiber in an alkaline solution at 95~120℃ for 15~45 minutes, then wash and dry it.

[0022] Furthermore, the fineness of the active fiber is 2-3D.

[0023] In a second aspect, the present invention provides a fluid fabric based on photocatalysis-kinetic energy synergy prepared from the above-mentioned active fibers, the fluid fabric comprising a surface layer, a middle layer and an inner layer arranged sequentially; wherein at least one of the surface layer, the middle layer and the inner layer contains active fibers.

[0024] Preferably, at least two layers of the fluid fabric contain active fibers.

[0025] Furthermore, the intermediate layer is a support layer, which mainly provides structural support and / or fluid channels; the support layer is made of yarns that connect the outer layer and the inner layer in an upright or inclined configuration, so that a three-dimensional gap space is formed between the outer layer and the inner layer.

[0026] In some embodiments of the present invention, the outer and inner layers of the fluid fabric contain active fibers.

[0027] The "photocatalysis-kinetic energy synergy" described in this invention refers to the continuous fluid kinetic energy generated by the flowing wastewater through the unique three-dimensional gap structure of the fabric. This kinetic energy works synergistically with the light energy provided by the light source above: the fluid kinetic energy enhances the mass transfer process of pollutants to the active sites on the fiber surface and promotes the departure of degradation products; the light energy excites the catalyst to generate active species such as free radicals, and the two work together to achieve efficient degradation of pollutants.

[0028] The beneficial effects of this invention are as follows:

[0029] (1) This invention utilizes an innovative melt spinning process to uniformly disperse and encapsulate the active components in the core structure of the fiber at a specific ratio, followed by an alkali-soluble outer layer for protection. This unique "core-skin" design not only ensures the stability of the active components during spinning and subsequent processing, but also allows for the controllable exposure of the active surface of the core layer by dissolving the outer layer through subsequent alkali treatment. This method immobilizes nanoscale active components within the fiber, avoiding the problems of loss, agglomeration, and difficult recovery associated with traditional powder catalysts, eliminating the risk of secondary pollution, and laying a solid foundation for the long-term recycling of the catalyst.

[0030] (2) This invention weaves active fibers into a fluid fabric with a clearly defined multi-level structure of "surface layer-support layer-inner layer". This design creates a three-dimensional network with high porosity, large specific surface area, and tortuous flow channels. When wastewater flows through the fabric, it is segmented, turbulent, and comes into full contact with the fiber surface, greatly enhancing the mass transfer process of pollutants to active sites. At the same time, the multi-layer parallel stacked structure of the fabric and the UV light source array above form an optimized light field distribution, ensuring that light can effectively penetrate and irradiate the internal fiber surface. The open structure of the fabric itself reduces light shading, allowing the loaded catalyst to be fully excited, thereby achieving a highly efficient synergy among "light-catalyst-pollutant" and significantly improving the pollutant degradation rate per unit time.

[0031] (3) In the test of continuous treatment of high-concentration chemical wastewater (COD=800 mg / L) for 24 hours, the fluid fabric based on photocatalysis-kinetic energy synergy prepared by the present invention showed that the reactor exhibited a consistently high removal efficiency, which proved that the active fiber fabric can not only effectively resist physical scouring and chemical poisoning in complex wastewater environments, but also has excellent durability of catalytic activity.

[0032] (4) The entire technical route is based on mature textile engineering and material processing technologies (melt spinning, warp knitting), with readily available raw materials and controllable processes, making it easy to achieve large-scale continuous production from fiber to fabric. The resulting fluid fabric has good flexibility and high strength, and can be cut, stacked, or wound according to the shape of the reactor, allowing for flexible assembly. In the embodiment, a multi-layer parallel stacked modular design is adopted, which allows the reactor's processing capacity to be easily adjusted by increasing or decreasing the number of fabric layers to adapt to different water quality and quantity requirements. This modular and scalable design greatly facilitates the design, installation, and maintenance in practical engineering, providing a new and reliable technical solution for building a compact, efficient, large-scale photocatalytic water treatment system. Attached Figure Description

[0033] Figure 1 The image shown is a SEM image of the active fibers prepared in Example 1. Detailed Implementation

[0034] Example 1

[0035] S1: Preparation of active fibers:

[0036] S11: MXENE (Ti3C2T) x Vacuum drying of 2-5 μm diameter PET chips; melt-blending and dispersing of copolymer PET chips (Eastman TX1501HF) and dried MXENE (Ti3C2T) at 250-254℃, followed by filtration to prepare core spinning solution, which is then metered and fed into spinning box A; the mass of MXENE is 3% of the sum of the mass of copolymer PET chips and MXENE.

[0037] S12: The alkali-soluble polyester (Yichang Qingjiang Development Co., Ltd., molecular weight 10000-15000, alkali dissolution rate ≥5% / min) is melted at 160~190°C, filtered, and the resulting skin spinning solution is metered and then fed into spinning box B.

[0038] S13: Spinning: Two melts are spun into a core-sheath structure fiber through a composite spinneret. The spinning temperature is 265~271℃. After cooling and shaping, the fiber is oiled and then wound to obtain a 200D fiber. The fiber is then stretched, crimped, and set to form a core-sheath structure active fiber. The mass ratio of the sheath to the core of the core-sheath structure active fiber is 7:3. The cooling wind speed is 1.2 m / s, the winding speed is 2600 m / min, the stretching ratio is 3, the crimp of the fiber after crimping is 28%, and the setting temperature is 225℃.

[0039] S14: Immerse the fiber in an alkaline solution at 100~105℃ for 25 minutes, wash and dry to obtain 2.5D active fiber.

[0040] S2: 150D / 48F active yarn made from active fibers.

[0041] S3: Weaving of fluid fabric: High-speed warp knitting machine is used for weaving, with 4 guide bars. Two guide bars weave the outer and inner layers, both of which are chain braided structures with a mesh size of 800 μm, a warp density of 30 threads / cm, and a weft density of 20 threads / cm, using 150D / 48F active yarn. The remaining two guide bars are symmetrically chain braided synchronously to form a support layer between the outer and inner layers. The support layer is made of 50D polyester monofilament with a thickness of 2.5cm.

[0042] S4: Application in wastewater treatment: Under the illumination of a 365nm UV LED array light source with a power density of 0.1 W / cm², wastewater circulates through the reactor for 24 hours. The reactor is composed of 5 layers of fluid fabric (1m×1m in size) stacked in parallel. The 365nm UV LED array light source is located 5cm directly above the fabric. The water flow velocity is 0.5 m / s. The wastewater is comprehensive wastewater from a chemical industrial park (COD=800mg / L). The treatment effect is shown in Table 1.

[0043] Comparative Example 1 (Traditional Activated Sludge Process)

[0044] Treating the same wastewater (800 mg / L COD) requires 72 hours. To treat the wastewater of Example 1, the aeration tank takes 28 hours (1500 m³ volume), the secondary sedimentation tank takes 24 hours (500 m³ volume), and the aeration power is 80 kW. The treatment results are shown in Table 1.

[0045] Comparative Example 2

[0046] The difference between Comparative Example 2 and Example 1 is that MXENE was not added in step S11, but otherwise it is the same as Example 1.

[0047] Comparative Example 3

[0048] S1: Vacuum drying of MXENE; the copolymer PET chips and the dried MXENE (Ti3C2T) are melt-blended and dispersed evenly at 250~254℃, filtered, and the resulting core spinning solution is metered and then fed into spinning box A; the mass of the MXENE is 3% of the sum of the mass of the copolymer PET chips and the MXENE.

[0049] S2 spinning: The melt is spun into fibers through the spinneret assembly. The spinning temperature is 265~271℃. After cooling and shaping, the fibers are oiled and then wound to obtain 200D fibers. The fibers are stretched, crimped, and set. The cooling wind speed is 1.2 m / s, the winding speed is 2600 m / min, the stretching ratio is 3, the crimp of the fibers after crimping is 28%, and the setting temperature is 225℃.

[0050] S3: 150D / 48F active yarn made from active fibers.

[0051] S4: Same as S3-S4 in Example 1.

[0052] Table 1. Comparison of wastewater treatment effects between Example 1 and Comparative Examples 1-3

[0053] Performance indicators <![CDATA[Energy consumption (kW / m 3 )]]> COD removal rate (%) Sludge production (kg / ton) Membrane flux decay rate (%, 50 h) Example 1 0.08 92（24 h） 0.5 <5% Comparative Example 1 0.8 85（72 h） 5.0 blockage Comparative Example 2 0.07 35（24 h） 3 35 Comparative Example 3 / 48（24 h） 1.9 26

[0054] Example 2

[0055] The difference between Example 2 and Example 1 is that MXENE in step S11 is replaced with g-C3N4 (brand: XFNANO, model: XFI10), and everything else is the same as in Example 1.

[0056] Example 3

[0057] The difference between Example 3 and Example 1 is that in step S11, "the mass of MXENE is 3% of the sum of the mass of copolymer PET chips and MXENE" is changed to "the mass of MXENE is 1% of the sum of the mass of copolymer PET chips and MXENE". The rest is the same as in Example 1.

[0058] Example 4

[0059] The difference between Example 4 and Example 1 is that in step S11, "the mass of MXENE is 3% of the sum of the mass of copolymer PET chips and MXENE" is changed to "the mass of MXENE is 5% of the sum of the mass of copolymer PET chips and MXENE". The rest is the same as in Example 1.

[0060] Comparative Example 4

[0061] The difference between Comparative Example 4 and Example 1 is that the phrase "the mass of MXENE is 3% of the sum of the mass of copolymer PET chips and MXENE" in step S11 is changed to "the mass of MXENE is 6% of the sum of the mass of copolymer PET chips and MXENE". The rest is the same as in Example 1.

[0062] The treatment effects of the wastewater treatment applications in Examples 1-4 and Comparative Example 4 are shown in Table 2.

[0063] Table 2

[0064] COD removal rate (%) Example 1 92 Example 2 77 Example 3 72 Example 4 90 Comparative Example 4 75

[0065] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. An active fiber, characterized in that, The active fiber is made of polymer and nanomaterials; the mass content of nanomaterials in the active fiber is 1-5%; the nanomaterials include MXENE, g-C3N4, and ZnO quantum dots.

2. The active fiber as described in claim 1, characterized in that, The polymer is PET.

3. A method for preparing active fibers as described in any one of claims 1-2, characterized in that, Includes the following steps: (1) The polymer and nanomaterials are melt-blended and dispersed evenly, filtered, and the core spinning solution is prepared and metered before entering the spinning box A; (2) The soluble polymer is melted, filtered, and prepared into a skin spinning solution, which is then metered and fed into spinning box B; (3) Spinning: Two melts are spun out into core-sheath structure fibers through a composite spinneret, cooled and shaped, then oiled, then wound, stretched, crimped and shaped to form active fibers with core-sheath structure. (4) Remove the sheath of the active fiber with a core-sheath structure to make the core layer exposure rate ≥90% and obtain the active fiber.

4. The method for preparing active fibers as described in claim 3, characterized in that, The mass ratio of the sheath to the core of the active fiber with a sheath-core structure is 7:2~5.

5. The method for preparing active fibers as described in claim 3, characterized in that, The soluble polymer is an alkali-soluble polyester.

6. The method for preparing active fibers as described in claim 3, characterized in that, In step (3), the spinning temperature is 265-285℃, the cooling wind speed is 1.0-1.5 m / s, the winding speed is 2400-2800 m / min, the stretching ratio is 1.5-3.0, the fiber crimp degree after crimping is ≥25%, and the setting temperature is 210-240℃.

7. The method for preparing active fibers as described in claim 3, characterized in that, The method for removing the outer layer of the active fiber with a core-sheath structure in step (4) is as follows: immerse the fiber in an alkaline solution at 95~120℃ for 15~45 minutes, then wash and dry it.

8. A fluid fabric based on photocatalysis-kinetic energy synergy, characterized in that, The fabric contains the active fiber as described in claim 1.

9. The fluid fabric based on photocatalysis-kinetic energy synergy as described in claim 8, characterized in that, The fluid fabric comprises a top layer, a middle layer, and an inner layer arranged sequentially; wherein at least one of the top layer, the middle layer, and the inner layer contains active fibers; The intermediate layer is a support layer, which is made of yarns that connect the outer layer and the inner layer in an upright or inclined configuration, so that a three-dimensional gap space is formed between the outer layer and the inner layer.

10. The fluid fabric based on photocatalysis-kinetic energy synergy as described in claim 8, characterized in that, The outer and inner layers are made of braided chain structure.

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