CN101098740A - 改进的高强度、高容量过滤介质及结构 - Google Patents
改进的高强度、高容量过滤介质及结构 Download PDFInfo
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Abstract
在流体材料的过滤中,从运动流中除去颗粒物需要相当的压力以保持流动和良好的除去颗粒物能力。本发明的过滤器是皱褶的、高湿强度的材料,其具有适于获得从液流中大幅降低颗粒物加载而又不会堵塞或机械损坏的基重,渗透率和效率。特别地,本发明的过滤器允许从非水流中除去大部分比例的颗粒物,所述非水流包括润滑油,液压流体和其它被污染的流。
Description
[0001]本申请是2005年11月4日提交的PCT国际专利申请,对于除美国之外的所有指定国以美国公司Donaldson Company,Inc.为申请人,对于美国以美国公民Keh B.Dema和Linda M.Olson为申请人,并且要求2004年11月5日提交的美国专利申请第10/982,538号的优先权。
技术领域
[0002]本发明涉及一种过滤介质和使用这种介质的过滤器。该介质对于从流中过滤颗粒物具有高强度,效率和高容量。该过滤介质包括无纺织物,适于从流动的流体例如水流或包括燃料,润滑油和液压流体在内的非水流中除去颗粒物。本发明涉及无纺介质层,该介质层获得足够的湿强度,颗粒过滤效率,渗透率和其它特性,以承受通常的工作条件,例如流量、温度、压力和颗粒加载的变化,同时从液流中除去绝大多数颗粒物载荷。本发明还涉及过滤器结构,它包括一个或多个除去颗粒介质层以及其它类似或不类似的介质层。这些层可被支撑在多孔或有孔支撑上,并且在过滤作业期间可提供机械稳定性。最后,本发明涉及一种过滤水和非水流体的方法。
背景技术
[0003]无纺织物已经为许多最终用途被制造了许多年,包括过滤介质。所述由双组分或皮芯材料制成的结构被公开于,例如,Wincklhofer等人,美国专利号3,616,160;Sanders,美国专利号3,639,195;Perrotta,美国专利号4,210,540;Gessner,美国专利号5,108,827;Nielsen等人,美国专利号5,167,764;Nielsen等人,美国专利号5,167,765;Powers等人,美国专利号5,580,459;Berger,美国专利号5,620,641;Berger,美国专利号6,174,603;Hollingsworth等人,美国专利号6,146,436;Dong,美国专利号6,251,224;Sovari等人,美国专利号6,355,079;Hunter,美国专利号6,419,721;Cox等人,美国专利号6,419,839;Stokes等人,美国专利号6,528,439;Amsler,美国专利号H2,086,和Amsler,美国专利号6,267,252。所述结构由干法成形和湿法成形处理技术制成,并已用于空气和液体过滤应用中并取得了一定程度的成功。在这方面,我们业已发现,前述用于从流动流体中除去颗粒物的无纺织物,当在过滤状态下被液体浸湿时,经常具有缺少机械强度和使用寿命短的缺点。流体压力经常超过介质的湿破裂强度。介质还可能迅速被堵并且渗透率降低,造成流动降低或阻碍流体运动。破裂或堵塞的介质很快就无法过滤颗粒物。破裂的介质无法保护其设计要保护的设备远离颗粒物。大幅上升或高压力降会限制流体流动,导致流体流动和动力的损失。
[0004]已经作了很多尝试,以获得具有适当穿孔或多孔支撑的无纺结构。已经尝试了熔吹材料和热层叠技术,不过,所得到的结构通常具有不合适的孔径大小,降低的效率,降低的渗透率,缺少强度或其他问题,致使所述介质或过滤结构不足以进行有用的过滤应用。
[0005]对过滤介质,过滤器结构和过滤方法存在基本需求,使得它们可被用于从液体成分中,例如水液,并且尤其是非水液体诸如燃料,润滑油和液压流中,除去颗粒物质。本发明提供了所述介质,过滤结构和方法,并且提供了一种独特的介质或介质层组合,其可实现相当好的渗透率,高湿强度,相当好的效率和过滤寿命长。
发明内容
[0006]我们已经发现一种过滤介质和独特的过滤结构,能够从液流中除去颗粒物。该介质包括热粘合片材,它通过将适当比例的无机玻璃纤维,不同纤维直径的纤维混合物,和双组分热塑性粘合纤维组合而制成。这种介质可与最佳次级纤维和其它添加材料一起制成。这些成分组合以形成具有相当好的流动性,渗透率和高强度的过滤介质或无纺材料。本发明的介质可在高压下在相当长的一段时间内保持完好的过滤能力。所述介质和过滤器在良好的流量,高容量和良好的效率下工作。
[0007]本发明的第一方面包括具有热粘合无纺结构的过滤介质。
[0008]本发明的第二方面包括双层过滤介质,该过滤介质包括至少一个加载层(1oading layer)和至少一个效率层(efficiency layer),使流动流体首先通过加载层。
[0009]本发明的第三方面包括过滤结构,该过滤结构包括本发明的过滤介质,本发明的加载层过滤介质,本发明的效率层过滤介质或其组合,还与其它过滤层,支撑结构和其它过滤部件组合。
[0010]本发明的第四方面包括深度加载层,它可用作单独层或与效率层结合使用。该深度层可负责所述介质的大部分高性能特征,其中该深度加载层在承受应用条件时不会压缩或撕裂。
[0011]最后,本发明的第五方面包括一种使用本发明的过滤方面过滤含有颗粒物载荷的流动液相的方法。
[0012]一般,该技术可应用于过滤液体系统。在液体过滤技术中,收集机构被认为是筛分。在一个单层中,其效率就是该层的效率。流体应用中的复合效率受到具有最高效率的单层的效率的限制。所述液体会被引导通过本发明的介质,液体中含有的颗粒物滞留在筛分机构中。在液体过滤系统中,即,其中要过滤的颗粒物质携带在液体中,所述应用包括水和非水液体以及混合的水/非水应用,例如水流,润滑油,液压流体,燃料过滤系统或集雾器。水流包括自然的或人造的流,例如,污水,冷却水,工艺用水等。非水流包括汽油,柴油,石油和合成润滑剂,液压流体,制动液和其它酯基工作流体,切削油,食物等级油等。混合流包括水在油中和油在水中组合物的分散液,以及包括水和非水成分的溶胶。
[0013]制造本发明的介质使用了适当比例的玻璃纤维。玻璃纤维提供孔径尺寸控制,并与介质中的其它纤维结合以获得具有良好流量,高容量和良好效率的介质。术语玻璃纤维“源”表示玻璃纤维组合物,表征为作为独特的原材料可用的平均直径和长宽比。从不同直径的所述源获得的纤维混合物不读自单一源。
[0014]其他被称作“次级纤维”的纤维也可用于制造本发明的介质。次级纤维是单成分纤维,其向所述介质添加一些层构成或过滤特性。所述次级纤维可增加本发明的过滤特性,但是它也可以作为“粘合纤维”将纤维垫粘合成有用的介质网。这些纤维可增加所述介质的过滤特性,或可增加双组分纤维的粘合特性。术语“次级纤维”可包括来自天然合成或特定来源的多种不同的纤维。次级纤维通常是单组分纤维,其直径在约0.1至约100微米的范围内,并且可由多种材料制成,所述材料包括:天然棉绒织物,各种纤维素和蛋白质天然纤维,合成纤维包括人造纤维,丙烯酸,芳族聚酸胺,尼龙(包括尼龙6,尼龙6,6,尼龙6,12等),聚烯烃(包括聚乙烯,聚丙烯),聚酯纤维(包括聚对苯二甲酸乙二醇酯,聚对苯二甲酸丁二酯,PCT等)。此外,粘合纤维包括由比如聚氯乙烯,聚乙烯醇这样的聚合物制成的纤维。次级纤维还可包括无机纤维,例如碳/石墨纤维,金属纤维,陶瓷纤维及其组合。
[0015]本发明的优选过滤结构包括至少一个本发明的过滤介质层支撑在机械稳定的穿孔支撑结构上。所述过滤层可包括两个介质层,具有配合功能的本发明的加载层和效率层,以实现高效极佳的颗粒移除效果。当以连续方式制作时,加载层和效率层之间的差别可能难于区分,我们相信所述层具有下述一般和优选的特征。
表1
一般特征
说明 | 重量Lbs/3000 ft2 | 渗透率Ft-min-1 | 厚度英寸 | 载荷gms/ft2 | βx=75μm |
效率层 | 15-50 | 5-50 | 0.01-0.02 | 12 | 9 |
加载层 | 25-50 | 40-200 | 0.015-0.025 | 23 | 12 |
层叠成分 | 50-150 | 5-50 | 0.04-0.05 | 17 | 9 |
新加载层 | 25-50 | 50-125 | 0.01-0.02 | - | - |
新效率层 | 50-75 | 10-45 | 0.02-0.04 | 13 | 10 |
新成分 | 50-150 | 10-50 | 0.025-0.055 | 19 | 11 |
表2
优选特征
说明 | 重量Lbs/3000ft2 | 渗透率Ft-min-1 | 厚度英寸 | 载荷gms/ft2 | βx=75μm |
效率层 | 40-50 | 20-40 | 0.01-0.02 | 12 | 9 |
加载层 | 35-45 | 120-140 | 0.015-0.025 | 23 | 12 |
层叠成分 | 100-125 | 15-35 | 0.04-0.05 | 17 | 9 |
新加载层 | 30-40 | 100-140 | 0.01-0.02 | - | - |
新效率层 | 50-75 | 20-40 | 0.02-0.04 | 13 | 10 |
新成分 | 75-127 | 15-40 | 0.025-0.055 | 19 | 11 |
表3
特定特征
说明 | 重量Lbs/3000 ft2 | 渗透率Ft-min-1 | 厚度英寸 | 载荷gms/ft2 | βx=75μm |
效率层 | 42 | 28 | 0.018 | 12 | 9 |
加载层 | 40 | 135 | 0.022 | 23 | 12 |
层叠成分 | 110 | 21 | 0.045-0.050 | 17 | 9 |
新加载层 | 35 | 115 | 0.015-0.020 | - | - |
新效率层 | 65 | 30 | 0.03 | 13 | 10 |
新成分 | 100 | 22 | 0.05 | 19 | 11 |
[0016]穿孔结构支撑介质,所述介质受流体在压力作用下通过介质的影响。本发明的过滤结构还可与穿孔支撑的其它层,高渗透率、机械稳定的粗布和其他过滤层如加载层组合。这种多层介质通常被装在通常用于过滤非水液体的过滤器滤芯中。
[0017]“双组分纤维”是指热塑性材料,它具有至少一个纤维部分具有一熔点和第二热塑性材料部分具有一较低的熔点。这些纤维的物理构造通常是“并排”或“皮芯”结构。在并排结构中,两种树脂通常以相连的方式在并排结构中伸出。在皮芯结构中,低熔点(约100至120℃)的热塑性材料通常围绕较高熔点(通常超过240℃)的纤维材料挤出。较低熔点的聚合物用作热塑性粘合剂,熔融的聚合物粘接组分,而较高熔点的热塑性材料用作结构材料。在使用中,该双组分纤维通常具有约10至20微米的纤维尺寸或直径,并且通常以纤维形式具有约6至约12mm的长度,优选为约6mm。如上所述,这种纤维的截面结构可以是“并排”或“皮芯”结构或其它提供相同热粘合功能的结构。双组分纤维的价值在于:相对较低分子量的树脂可在片材成型条件下熔化以粘合所述双组分纤维,而片材中存在的其它纤维将材料制成机械稳定的片材。通常,双组分(皮芯和并排)纤维的聚合物由不同的热塑性材料制成,例如,聚烯烃/聚酯(皮-芯)双组分纤维,其中聚烯烃,例如聚乙烯外皮在低于核芯,例如聚酯的温度下熔化。通常,热塑性聚合物包括聚烯烃,例如聚乙烯,聚丙烯,聚丁烯,及其共聚物,聚四氟乙烯,聚酯,例如聚对苯二甲酸乙二醇酯,聚乙酸乙烯酯,聚氯乙烯-乙酸乙烯酯,聚乙烯醇缩丁醛,丙烯酸树脂,例如聚丙烯酸酯,和聚甲基丙烯酸酯,聚甲基丙烯酸甲酯,聚酰胺,即尼龙,聚氯乙烯,聚偏二氯乙烯,聚苯乙烯,聚乙烯醇,聚氨酯,纤维素树脂,即硝酸纤维素,醋酸纤维素,醋酸丁酸纤维素,乙基纤维素,等等,上述任意材料的共聚物,例如,乙烯-乙酸乙烯共聚物,乙烯-丙烯酸共聚物,苯乙烯-丁二烯嵌段共聚物,Kraton橡胶和类似物。本发明中特别优选的是可购自DuPont被称作271P的双组分纤维。其它纤维包括FIT 201,Kuraray N720和Niehimen 4080。所有这些显示,在第一次熔化结束时多壳交联的特征。这对于液体应用是重要的,其中适用温度通常高于外皮熔化温度。如果外皮不是完全结晶,则外皮聚合物会在应用中再熔化,并且覆盖或损坏下游设备和部件。
[0018]“玻璃纤维”是由各种类型的玻璃制成的纤维。用于本发明纸中的玻璃纤维包括下述名称的玻璃类型:A,C,D,E,Zero Boron E,ECR,AR,R,S,S-2,N,和类似物,并且一般,可以是制成纤维的任何玻璃,所述玻璃或通过用于制造增强纤维的拉丝工艺,或通过用于制造绝热纤维的纺丝工艺制成。所述纤维通常以直径为约0.1至10微米和长宽比(长度除以直径)为约10至1,0000的纤维的集合来设置。
[0019]我们已经发现,通过混合不同纤维直径可以获得通过混合不同比例而显著改进的渗透率。通常,一种产品中制造的玻璃纤维的纤维直径在某个变化范围内。我们已经发现,混合不同尺寸的纤维(平均纤维直径),约0.1至1微米,约0.3至2微米,约0.5至3,约0.75至5或约3至10微米,可产生高渗透率和极佳的流动。本文中的术语混合是指,所述介质包含不同尺寸,通常是不同直径的至少两种不同纤维源的至少部分。
[0020]一定量的含树脂粘合组分对于本发明的无纺介质获得足够的强度是必要的。用作粘合剂的树脂可以是水溶性或可分散聚合物的形式,直接添加到造纸分散液中,或者是热塑性粘合纤维的形式,将树脂材料与芳族聚酸胺纤维和玻璃纤维混合,以在无纺织物形成之后通过加热来激活作为粘合剂。分散纤维并然后添加粘合剂材料或分散粘合剂材料并然后添加纤维包括分散体形成的两个过程。将纤维的分散体与粘合剂材料的分散体组合也可制成分散体。纤维在分散体中的浓度可根据分散体的总重量在0.01至1重量百分比的范围内。分散体中的粘合材料的浓度可根据纤维的重量在5至50重量百分比的范围内;并且,如果粘合材料是纤条体,则浓度可根据纸的总重量在15至35重量百分比的范围内。
[0021]可以采用湿法或干法工艺。在制造本发明的介质中,使用湿法或干法加工形成纤维垫。所述垫被加热,通过内部粘合纤维而形成介质。用于本发明介质的双组分纤维允许纤维融合在机械稳定块中。所述双组分纤维具有热粘合外皮,导致所述双组分纤维与介质层中的其它纤维粘合。所述双组分纤维与水树脂和其它纤维配合以形成介质。
[0022]这种介质通常包括具有良好过滤性能的薄层。在很多应用中,尤其是那些涉及高流量的应用中,可采用一种可替换类型的过滤介质,有时通称为“深度”介质。通常的深度介质包括比标准介质有相对更厚缠结的纤维材料。深度介质一般以孔隙,密度或百分比固体含量来定义。例如,2-3%固态介质是纤维如此布置的深度介质垫,其总体积的约2-3%包括纤维材料(固体),其余是空气或气体空间。另一个定义深度介质的有用参数是纤维直径。如果固态百分比保持不变,但是纤维直径(尺寸)降低,则孔径缩小;即,纤维变得更有效并且会更有效地滞留更小的颗粒。一种通常传统的深度介质过滤器是深的、相对恒定(或均匀)密度的介质,即一种系统,其中深度介质的固态贯穿其厚度保持基本恒定。本文中的“基本恒定”是指,贯穿介质的深度范围内只发现相当小的密度波动,如果有的话。所述波动,例如,可能由置有过滤介质的容器向其外接表面施加轻微的压力产生。一般,深度介质结构可被设计以基本上贯穿其体积或深度“加载”颗粒物质。因此,相对于表面加载的系统,当达到过滤器的使用寿命时,这种结构可被设计以加载更多量的颗粒物质。不过,一般这种结构交换的是效率,因为对于大量加载,相对低的固体介质是理想的。剃度密度系统,例如那些在前述专利中提到的,已经被设计以提供良好的效率和更长的寿命。在一些情况,表面加载介质在这种结构中用作“抛光(polish)”过滤器。在优选的湿法加工中,介质由水基配料制成,所述配料包括水介质中的纤维材料的分散体。所述分散体的水成液一般是水,但也可以包括各种其它材料,例如pH调节材料,表面活性剂,消泡剂,或其它加工助剂和类似物。该水成液通常通过将分散体引导到滞留所述分散固体的筛网或其它穿孔支撑上,并且让液体通过以产生湿纸组合物,从分散体排出。所述湿组合物一旦在支撑上形成,通常通过真空或其它压力进一步脱水并通过蒸发剩余液体进一步干燥。
[0023]本发明的介质可以在任何规模的设备上制成,从实验室筛网到工业规模的造纸机器,例如长网造纸机,斜网造纸机和圆网造纸机,及其组合。一般的工艺涉及:制造纤维,玻璃纤维,粘合材料在水成液中的分散体;将液体从分散体中排出以生成湿组合物;加热所述湿组合物以干燥和热粘合所述纤维成层,以形成可用的介质。这可一步完成,或者通过一系列步骤完成。
附图说明
[0024]图1以图表数据的形式示出了我们在过滤介质中使用双组分纤维的经验。使用双组分纤维(所有其它变量保持恒定)显著增加了本发明介质的过滤能力,所述介质保持良好的机械强度。
[0025]图2示出了通过使用双组分纤维而得到的有效颗粒加载的增加。
[0026]图3示出了通过在树脂浸透的介质中使用双组分纤维而得到的有效颗粒加载的增加。
[0027]图4示出了可以是浸透树脂或无树脂的类似手抄纸的多通结果。
[0028]图5是本发明自旋筒式过滤器的截面图,使用折叠介质层用于过滤液体。
[0029]图6是本发明的折叠介质由穿孔金属支撑支持的截面俯视图。该组合是本发明受支撑介质的一个方面。
[0030]图7示出了由筛网支撑支撑着的本发明折叠介质的下游侧的侧视图。
具体实施方式
[0031]本发明的介质涉及一种复合、无纺、空气成形或湿法成形的材料,其具有可成形性,硬度和刚度,和机械稳定的过滤特性;高的颗粒加载能力,在使用中的低压力降和适于用于过滤流体的孔径大小和效率。优选地,本发明的过滤介质通常是湿法成形,并且由随机定向排列的介质纤维和双组分纤维构成,所述纤维用本发明的双组分粘合纤维和粘合树脂粘合在一起。用加热激活粘合纤维和树脂中的热塑性粘合剂。可用于本发明的过滤器和方法中的纤维包含介质纤维,双组分粘合纤维,粘合剂和其它组分。所述介质可形成大致平面片材或形成为各种几何形状,通过在热粘合期间使用模板以容纳湿组合物。本发明的介质纤维包括玻璃,金属,硅石和其它相关的纤维。用于本发明的优选纤维是玻璃纤维,其长宽比为10至10,000,和直径在约0.1至约10微米的范围内,同时优选的材料是不同尺寸的玻璃纤维的混合物。
[0032]本发明的过滤介质通常适于高效的过滤特性,以使液体,包括含水或非水燃料,润滑油,液压流体和其它这样的流体可被快速地过滤,以除去杂质颗粒物。
[0033]我们已经发现,本发明的两个过滤介质可以组合,加载层和效率层,每个所述层具有不同的结构和过滤特性,以形成复合层。所述层是具有不同过滤特性的不同结构,相互配合以获得过滤性能。在制造工艺中首先形成效率层,允许更多更细的玻璃纤维沉积在介质的功效面或反面。这有助于形成梯度结构,以改进加载性能。加载层然后形成在效率层上面。优选在效率层完全形成之前。这允许两层之间的纤维有某些混合,形成梯度结构并且增强层之间的强度和粘合。当添加加载层时,也允许更细的纤维更多地与效率层混合。当形成效率层时,一些最细的纤维通过成形筛网或网流失。当形成加载层时,损失的最细纤维极少,这是因为它们被捕获并与最初的效率层混合。形成在一起的片材的性能,包括过滤和物理特性,对比分别形成并置于彼此之上的片材的性能是不同的。效率层是高效率的层,其具有适当的孔隙,效率,渗透率和其它过滤特征,以在流体通过过滤结构时,从流体流中除去任何残余的有害颗粒。本发明的加载过滤介质具有约33至约65g-m-2的基重。效率层具有约65至约130g-m-2的基重。效率层具有平均流动孔径,小于加载层的孔径,所述加载层的平均流动孔径在约2至10微米的范围内。加载层的渗透率在约80至160ft-min-1的范围内。效率层的渗透率在约10至50ft-min-1的范围内。本发明的加载层或效率层具有的湿破裂强度大于约5psi,通常约10至约30psi。组合过滤层具有的渗透率为约15至40ft-min-1,湿破裂强度为10至30psi,和基重为130至200g-m-2。微玻璃纤维未覆盖或上胶。只有大块的碎玻璃被上胶。在本申请中使用了上述两种类型。这些可买到的纤维被特征化地涂敷或上一层胶料。该涂层使得否则离子化的中性玻璃纤维形成并保持成束。玻璃纤维的制造商通常采用例如这样的胶料。上胶组合物和阳离子抗静电剂消除纤维聚合并允许在容器中搅动分散体时,使玻璃纤维均匀分散。玻璃纤维的混合物可以显著帮助改进材料的渗透率。我们已经发现,将具有平均颗粒尺寸为约0.3至0.5微米的玻璃纤维,平均颗粒直径为约1至2微米的玻璃纤维,平均颗粒直径为约3至6微米的玻璃纤维,或颗粒直径为约6至10微米的玻璃纤维的两种或多种来源以不同比例组合,可以显著提高渗透率。我们相信,所述玻璃纤维混合物获得可控的孔径,从而在介质层中产生确定的渗透率。
[0034]粘合树脂通常可包括溶剂型,水溶性或水敏性的聚合物材料。水基乳胶作为浸透树脂。可以很容易地使用溶剂型树脂,例如苯酚和环氧酚醛混合物。聚合物材料通常以干的形式或水分散体的形式提供。所述可用的聚合物材料包括丙烯酸聚合物,乙烯-醋酸乙烯酯聚合物,乙烯-乙烯基聚乙烯醇,乙二醇聚合物,聚乙烯-吡咯烷酮聚合物,以及可用于水溶液的天然树胶和树脂。双组分纤维的各种聚合物组合可用于本发明中,但重要的是第一种聚合物成分的熔化温度低于第二种聚合物成分的熔化温度,并且通常低于300。此外,所述双组分纤维是一体混合,并且与纸浆纤维均匀分散。熔化双组分纤维的第一种聚合物成分是必要的,以允许所述双组分纤维形成粘接骨架结构,一旦冷却,捕获并粘合许多纸浆纤维,并且粘合到其它双组分纤维。用于本发明介质的双组分纤维一般具有0.1至10毫米的长度和10至20微米的直径。
[0035]水溶性或可分散粘合聚合物的优选材料是水溶性或水可分散热固性树脂,例如丙烯酸树脂,异丁烯酸树脂,聚酰胺树脂,环氧树脂,酚醛树脂,聚脲素,聚氨基甲酸酯,蜜胺甲醛树脂,聚酯和醇酸树脂,一般并具体地讲,在造纸工业中常用的水溶性丙烯酸树脂,异丁烯酸树脂,聚酰胺树脂。所述热塑性粘合树脂材料通常为乙烯基热塑性树脂的水分散体,包括乙酸乙烯酯材料,氯乙烯树脂,聚乙烯醇树脂,聚乙酸乙烯树脂,聚乙烯乙酰树脂,丙烯酸树脂,异丁烯酸树脂,聚酰胺树脂,聚乙烯-乙酸乙烯共聚物树脂,热固性树脂,例如尿素苯酚,尿素甲醛,蜜胺,环氧树脂,聚氨酯,可固化的不饱和聚酯树脂,聚芳香树脂,间苯二酚树脂和类似的弹性树脂。所述粘合树脂通常涂敷纤维,并在最终的无纺基质上将纤维和纤维粘合。添加足够的树脂到配料,以完全涂敷纤维,而又不会造成在片材上形成薄膜覆盖在孔上。可在造纸过程中将树脂添加入配料中,或者在成型后将树脂适用在介质上。
[0036]用于在每个无纺层将三维无纺纤维网粘接在一起或用作额外粘合剂的胶乳粘合剂,可从本领域已知的各种胶乳粘合剂中选择。本领域的技术人员可根据要粘合的纤维类型选择特定的胶乳粘合剂。可通过已知技术,例如喷雾,发泡,幕式涂层,凹板滚压,或胶压饱和技术,来应用胶乳粘合剂。胶乳粘合剂中所用的固体量尤其取决于每层的纤维重量。一般,使用具有15至25%固体的胶乳粘合剂。
[0037]本发明的无纺介质可包含由多种亲水和疏水纤维制成的纤维。这些纤维与玻璃纤维和双组分纤维配合,形成具有机械稳定、但坚固的、可穿透的过滤介质,其可承受流体材料穿过时的机械应力并且在使用中可保持颗粒的加装。纤维特征通常由丹尼尔(denier)表示,通常认为其表示9000米纤维以克计的重量。
[0038]次级热塑性纤维包括,但不限于:聚酯纤维,聚酰胺纤维,聚丙烯纤维,共聚多醚纤维,聚对苯二甲酸乙二醇酯纤维,聚对苯二甲酸丁二酯纤维,聚醚酮酮(PEKK)纤维,聚醚醚酮(PEEK)纤维,液晶聚合物(LCP)纤维,及其混合物。聚酰胺纤维包括但不限于:尼龙6,66,11,12,612,和高温“尼龙”(例如尼龙46),包括纤维素纤维,聚乙酸乙烯酯,聚乙烯醇纤维(包括各种水解的聚乙烯醇,例如88%水解的,95%水解的,98%水解的,和99.5%水解的聚合物),棉,粘胶人造纤维,热塑性材料如聚酯,聚丙烯,聚乙烯等,聚乙酸乙烯酯,聚乳酸,和其它常见纤维类型。热塑性纤维一般是细的(约0.5-20丹尼尔)、短的(约0.1-5cm)、人造短纤维,可能包含预先混合的常用添加剂,例如抗氧化剂,稳定剂,润滑剂,增韧剂等。此外,热塑性纤维可用分散助剂进行表面处理。优选的热塑性纤维是聚酰胺和聚对苯二甲酸乙二醇酯纤维,最优选的是聚对苯二甲酸乙二醇酯纤维。
[0039]本发明的片状介质通常用造纸工艺制成。介质可以是平面或可以制成各种几何形状。所述湿法工艺特别有用,并且多种纤维成分被设计用于水分散工艺。不过,本发明的介质可通过干法工艺制成,该工艺使用适于干法工艺的类似成分。用于湿法成形片材制作的机器包括手工成形片材设备,长网造纸机,圆柱形造纸机,倾斜造纸机,组合造纸机,和其它机器,所述机器可以采用适当混合的纸张配料,形成配料成分层,除去流体含水成分,以形成湿片。含有所述材料的纤维浆通常被混合,以形成均匀的纤维浆。然后对纤维浆进行湿法造纸加工。一旦纤维浆形成湿法成形片材,所述湿法成形片材随后被干燥,固化或以其它方式加工,以形成干的可渗透的但真实的片材或介质。一旦充分干燥并加工成过滤介质,所述片材通常的厚度为约0.01至0.1或0.02至0.08英寸,具有的基重为约30至250g-m-2。对于工业规模加工,本发明的双组分垫一般通过使用造纸类型的机器加工,例如可购买到的长网造纸机,圆网造纸机(wire cylinder),Stevens成型机(Stevens Former),Roto成型机(Roto Former),Inver成型机(Inver Former),Venti成型机(Venti Former),和倾斜的三角成形机(inclined DeltaFormer)。优选使用倾斜的三角成形机。例如,本发明的双组分垫可通过形成双组分纤维和介质或玻璃纤维浆,并在混合容器内混合所述浆体来制备。在所述工艺中使用的水量可以根据所用设备的尺寸而变化。配料可进入常规网前箱,在那里脱水并沉积到移动的金属丝筛网上,在这里通过抽吸或真空脱水,以形成无纺双组分网。然后可以通过常规方式用粘合剂对所述网进行涂层,例如通过浸萃方法或粘辊技术,并且通过干燥炉,所述干燥炉干燥垫子并固化粘合剂,并且热粘合所述片材或介质。所得到的垫子可以大卷的形式收集。
[0040]合成尤其是聚酯和玻璃纤维多层过滤介质可通过使用双组分PET/PET以及单体PVA粘合纤维和丙烯酸胶乳树脂制成。效率层和加载层在造纸机上几乎同时形成。过滤介质适于移动和近距离液压应用,以及移动设备润滑油应用。
实验
手抄纸制作工序的说明
[0041]使用表4中的配料配方并使用下述工序制成八个用于实验的12英寸乘以12英寸大小的手抄纸。
步骤:
[0042]选择材料并称重,将它们放入单独的容器中。例如,为了制造一批12英寸乘以12英寸大小的手抄纸,使用76克选定的纤维或纤维(取决于配料要求)。纤维在已知量的水中使用搅拌器分散。如果搅拌器的容量不足以一次性分散一批中的所有纤维,将该批纤维分为更多可管理的部分,具有足够的硫酸,以将pH值降至约2.5,以帮助分散并促进过滤介质的最终成型。在一个容器内混合纤维分散体的所有部分,然后添加额外的水,注意所用的水量,以达到最终片材成形的浓度(通常约0.05%),然后在手抄纸成型之前,充分搅动以获得均匀的分散体,15分钟应该足够。这种方法确保获得已知的浓度(材料中纤维重量对水的体积),并且对于每张手抄纸来说材料比例是相等的。造纸金属丝置于箱中的筛网上。封闭该箱子并加入水。加入2.5升的纤维分散体到箱中并搅动。排水以形成所述纸。干燥所述纸,使用真空除去过量的水分,允许风干或使用干相机,圆筒干燥器,热板机或其它设备加热。加热至双组分纤维的外皮聚合物的熔化温度之上。
[0043]使用树脂浸透步骤来用树脂浸透手抄纸,以获得强度和耐久度。将手抄纸放置在干燥炉的架子上并在300(150℃)下干燥10分钟,然后称重以获得初始基重。使用树脂公式,选择树脂成分并将它们分配入单独的容器中,然后将它们与水混合。使用胶压实验室浸透系统,将上辊压力调节至40psi。使浸透盘装满树脂溶液。将手抄纸浸入树脂盘中并将其正面和反面都浸透。用于反面或正面或两面的支撑粗布可被用于实验室浸透,以防止粘结并改进操作性。移除粗布,如果使用的话,并将湿手抄纸放置在干燥炉的架子上并在300(150℃)的温度下直至烘干,然后测量基重。使用下述公式计算树脂吸收量(pick up)(以百分比表示):
树脂吸收量=(浸透的重量-初始重量)·100/初始重量
如果树脂吸收量与目标吸收水平不同,则逐步调节树脂浓度,直到实现目标水平。用正确的树脂吸收水平,浸透一批手抄纸。移除粗布(如果使用了的话),将湿手抄纸放置在架子上,允许它们晾干一整夜。将干燥的纸在干燥炉的架子上在300(150℃)下放置干燥10分钟,测量重量并计算最终基重和树脂吸收量。
表4
配料特征
效率层(%基于干重)
干燥后层的基重 | 65-138g-m-2 |
乳胶树脂 | 高达25% |
PVA粘合纤维 | 0~2% |
PET/PET皮芯双组分粘合纤维 | 至少5% |
玻璃纤维 | 50~95% |
次级聚酯纤维 | 0~55% |
加载层
干燥后层的基重 | 33-65g-m-2 |
乳胶树脂 | 高达25% |
PVA粘合纤维 | 0~2% |
PET/PET皮芯双组分粘合纤维 | 高达15% |
玻璃纤维 | 70~90% |
次级聚酯纤维 | 0~25% |
[0044]使用公开的测试步骤制备第二组单层手抄纸。配料配方见下表5。聚乙烯醇(PVA)粘合树脂的用量为1%。
表5
配料信息
配料(干重%) | ||||
玻璃纤维(平均直径) | 配料A(93g-m-2) | 配料C(93g-m-2) | 配料D(93g-m-2) | 配料G(93g-m-2) |
玻璃纤维706(0.3微米) | 9% | 9% | 9% | 11% |
玻璃纤维110X(2微米) | 40% | 40% | 40% | 28% |
玻璃纤维112X(3微米) | 30% | 30% | 39% | 30% |
玻璃纤维Lauscha EC6-6SC(6微米) | 10% | 10% | - | - |
玻璃纤维Lauscha EC10-12SC(10微米) | 10% | - | - | - |
PVA(88%水解的)SPG 056-11 | 1% | 1% | 1% | 1% |
双组分纤维(DuPont 271P) | - | 10% | 20% | 30% |
表6
手抄纸数据表
配料 | 类型 | 粘合纤维 | 目标树脂吸收量 | 重量g-m-2 | 厚度英寸 | 渗透率ft-min-1 | 干抗拉强度lbs/(宽度) | 湿抗拉强度lbs/(宽度) | 干破裂强度psi | 加载gms | β@10μ | β@75μ |
A | 基本 | 0% | 0% | 109 | 0.031 | 27 | 2.2 | 0.9 | 8.6 | 8.5 | 4.15 | 6.98 |
C | 基本 | 10% | 0% | 101 | 0.030 | 29 | 2.4 | 1.3 | 8.4 | 8.7 | 4.66 | 7.76 |
D | 基本 | 20% | 0% | 103 | 0.052 | 31 | 1.4 | 0.8 | 8.5 | 10.6 | 5.17 | 8.95 |
G | 基本 | 30% | 0% | 101 | 0.035 | 32 | 1.6 | 0.8 | 10.3 | 12.8 | 6.15 | 10.76 |
A | 浸透 | 0% | 10% | 124 | 0.033 | 23 | 6.5 | 5.7 | 8.5 | 5.3 | 3.75 | 6.41 |
C | 浸透 | 10% | 10% | 111 | 0.031 | 28 | 4.1 | 7.4 | 8.3 | 8.8 | 4.57 | 7.54 |
D | 浸透 | 20% | 10% | 112 | 0.051 | 29 | 4.2 | 3.1 | 8.3 | 8.6 | 5.34 | 8.80 |
G | 浸透 | 30% | 10% | 111 | 0.035 | 31 | 10.9 | 10.6 | 15.2 | 9.9 | 5.93 | 9.77 |
[0045]表6示出,在本实验中,浸透的手抄纸(例如,配料D和G)相对于未浸透的类型具有相当的渗透率,β和加载过滤特性,但是具有改进的湿抗拉强度。
[0046]图2示出了使用根据ISO 16889测试标准的微流Bench对表6中的手抄纸(平板介质样本)进行的测试。基本结果显示,使用30%双组分纤维对比对照组(0%双组分)在加载量上有52%的增加。
[0047]图3示出,在表6的手抄纸中,浸透结果显示,使用30%双组分纤维对比浸透对照组(0%)在加载量上有55%的增加。
[0048]图4示出了使用无树脂的0%双组分作为对照的基本和浸透手抄纸的加载量数据。这也突出了使用双组分纤维的关键益处;添加浸透树脂减损了加载性能。如果将具有30%双组分纤维的基纸的干破裂强度(10.3psi)与具有双组分和浸透树脂的干破裂强度作比较,就会发现需要远大于10%的树脂吸收量来实现相同的强度。
[0049]图5是本发明自旋筒式过滤器的截面图。在图5中,示出了滤筒50具有外壳58,通常是塑料或金属。在滤筒结构的一端是接触表面端部密封59,自旋螺纹固定装置60包括出口环形空间52。接触表面具有入口孔51或液体入口51,允许具有潜在颗粒物载荷的液体进入滤筒50。该滤筒包括使用密封板56和55在两端密封的折叠介质54,以迫使液体使用液体流动通道53穿过折叠介质54。本发明的折叠介质材料54在没有某些形式的支撑时通常机械上不足以保持过滤特性。本发明的滤筒50使用支撑层57支撑折叠介质54,所述支撑层57防止折叠介质在液体通过滤筒的作用力下塌陷。
[0050]图6示出了本发明受支撑折叠介质的一个实施例。在图6中,示出了折叠介质54被支撑在穿孔的介质支撑61上。示出了液流63,其中流体穿过介质和穿孔支撑进入结构的内部。穿孔介质支撑包括支撑中的孔或孔隙62,以允许液流从介质外部进入过滤结构的内部。孔或孔隙62由金属61环绕,保持机械稳定的支撑,以防止折叠介质54坍塌。
[0051]图7是本发明筛网支撑介质的下游侧的侧视图。在图7中,示出了受支撑介质70,其中折叠介质54由筛网支撑71支撑。大致与图6类似,流体通过受支撑介质的介质侧经由介质的筛网支撑侧进入滤筒结构的内部。
[0052]使用测试方法ISO 16889“液压液力过滤器-用于评估过滤元件的过滤的多次通过方法(Hydraulic Fluid Power Filters-Multipass Method for Evaluating Filtrationof a Filter Element)”来获得加载量和β数据。在该测试方法中β结果在每段12.6有报道。β是液压工业使用的过滤器等级系统。βx=(颗粒数>过滤器上游的规定尺寸)/(颗粒数>过滤器下游的规定尺寸)。其中下标x表示颗粒的微米尺寸。例如,如果在过滤器上游计有1000个15微米或更大的颗粒,而在下游计有50个相同大小的颗粒,则β为20或β15=20。用另一种方式来说,该过滤器对于15微米或更大的颗粒具有95%的效率。使用根据ISO 16889测试标准的DCI Miniflow(微流)Bench对手抄纸(平板介质样本)进行测试。基本结果(见图2)显示,使用30%的双组分纤维对比对照组(0%双组分)在加载量上有52%的增加。渗透率涉及在0.5英寸水的压力降下流过过滤介质的空气量(ft3-min-1-ft-2或ft-min-1)。一般,渗透率,作为使用的术语,由根据ASTM D737的弗雷泽渗透率试验(Frazier Permeability Test)使用弗雷泽渗透率试验装置(Frazier Permeability Tester)来评定,该试验装置可购于美国马里兰州盖瑟斯堡的Frazier Precision Instrument公司(Frazier Precision Instrument Co.Inc.,Gaithersburg,Maryland),或者通过TexTest 3300或TexTest 3310来评估,该装置购自Advanced Testing Instruments Corp(ATI),243 East Black Stock Rd.Suite 2,Spartanburg,So.Carolina 29301,(864)989-0566,www.aticorporation.com。本发明涉及的孔径尺寸表示流动孔径的平均值,通过使用毛细流动气孔计装置确定,例如由Porus Materials,Inc.,Comell University Research Park,Bldg.4.83 Brown Road,Ithaca,New York 14850-1298,1-800-825-5764,www.pmiapp.com出售的Model APP 1200 AEXSC。
[0053]Kahlbaugh等人的美国专利第5,082,476号公开了一种使用深度介质的过滤器设计,其包括具有折叠部件的泡沫底层与本发明的微纤维材料组合。Stifelman等人的美国专利第5,104,537号涉及一种可用于过滤液体介质的过滤器结构。液体被夹带入过滤器外壳,通过过滤器的外部进入内部环形核芯,并随后在结构中返回积极使用。
[0054]Gillingham等人的美国专利第5,820,646号公开了一种波纹或Z过滤器结构,其使用特定的折叠过滤器设计,涉及塞紧的通道,要求流体流沿“Z”形通道通过至少一层过滤介质,以获得适当的过滤性能。形成折叠Z形形式的过滤介质可包含本发明的细纤维介质。
[0055]虽然本发明是结合其特定实施例加以描述的,但本发明可进一步地加以改进,并且本申请应当涵盖所有根据本发明的描述和本发明所属领域的已知或惯例的实践而对本发明作出的变化,使用或修改,其适用于前文中定义的必要特征和下文所附权利要求的范围。
Claims (12)
1、一种包括层的过滤介质,所述层包括约5%至50重量百分比的双组分粘合纤维,约50至95重量百分比的介质纤维,约0.5至25重量百分比的粘合树脂,所述层具有约30至250g-m-2的基重;其中所述层提供10至40ft-min-1的渗透率,和约高达50lb-in-2的湿破裂强度。
2、一种包括层的过滤器效率介质,所述层包括约5至25重量百分比的双组分粘合纤维,约50至95重量百分比的玻璃纤维,约0.5至25重量百分比的胶乳树脂,所述介质层具有约30至150g-m-2的基重;其中所述层提供10至40ft-min-1的渗透率,和约高达50lb-in-2的湿破裂强度。
3、一种包括层的过滤器加载介质,所述层包括约1至15重量百分比的双组分粘合纤维,约50至90重量百分比的玻璃纤维,约0.5至25重量百分比的胶乳树脂,所述介质层具有约25至75g-m-2的基重;其中所述层提供90至160ft-min-1的渗透率,和约高达50lb-in-2的湿破裂强度。
4、一种适于从流体中过滤颗粒物的过滤器滤筒,所述过滤器包括:
(a)外壳,具有入口和出口,与所述外壳的内部流体相通;
(b)在入口和出口之间用于过滤的过滤介质,所述介质包括层,所述层包括约至少5%至50重量百分比的双组分粘合纤维,约50至95重量百分比的介质纤维,约0.5至25重量百分比的粘合树脂,所述层具有约30至250g-m-2的基重;10至40ft-min-1的渗透率和约高达30lb-in-2的湿破裂强度;和
(c)穿孔的机械介质支撑。
5、根据权利要求1-4中任一权利要求所述的介质,其中所述介质包括约高达30lb-in-2的湿破裂强度,并且平均流动孔径在约2至约10微米的范围内。
6、根据权利要求1-4中任一权利要求所述的介质,其中所述介质包括具有约25至75g-m-2基重的加载层和具有50至150g-m-2基重的效率层,所述加载层包括约1至25重量百分比的双组分粘合纤维,约70至90重量百分比的玻璃纤维,所述效率层包括约5至25重量百分比的双组分粘合纤维,约50至95重量百分比的玻璃纤维;其中所述层提供10至40ft-min-1的渗透率,和约高达30lb-in-2的湿破裂强度。
7、根据权利要求1-4中任一权利要求所述的介质,包括加载层和效率层。
8、根据权利要求1-4中任一权利要求所述的介质,其中所述加载层具有约25至75g-m-2的基重。
9、根据权利要求1-4中任一权利要求所述的介质,其中所述效率层具有约50至150g-m-2的基重。
10、根据权利要求1-4中任一权利要求所述的介质,其中所述加载层包括约1至25重量百分比的双组分粘合纤维,约70至90重量百分比的玻璃纤维。
11、根据权利要求1-4中任一权利要求所述的介质,其中所述效率层包括约5至25重量百分比的双组分粘合纤维,约50至95重量百分比的玻璃纤维。
12、根据权利要求1-4中任一权利要求所述的介质,其中所述介质包括约4至约8微米的平均流动孔径。
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JP2010529902A (ja) | 2007-02-22 | 2010-09-02 | ドナルドソン カンパニー インコーポレイテッド | フイルタ要素及び方法 |
WO2008103821A2 (en) | 2007-02-23 | 2008-08-28 | Donaldson Company, Inc. | Formed filter element |
BRPI0821499A2 (pt) | 2007-12-31 | 2015-06-16 | 3M Innovative Properties Co | Artigos de filtração de fluído e métodos de preparo e uso dos mesmos |
US20090266759A1 (en) | 2008-04-24 | 2009-10-29 | Clarcor Inc. | Integrated nanofiber filter media |
-
2004
- 2004-11-05 US US10/982,538 patent/US8021457B2/en active Active
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- 2005-11-04 RU RU2007120884/15A patent/RU2007120884A/ru unknown
- 2005-11-04 JP JP2007540026A patent/JP2008518770A/ja not_active Withdrawn
- 2005-11-04 WO PCT/US2005/039793 patent/WO2006052656A1/en active Application Filing
- 2005-11-04 BR BRPI0517720-0A patent/BRPI0517720A/pt not_active IP Right Cessation
- 2005-11-04 KR KR1020077012742A patent/KR20070085813A/ko not_active Application Discontinuation
- 2005-11-04 EP EP05824837A patent/EP1812137A1/en not_active Withdrawn
- 2005-11-04 CN CNA2005800459990A patent/CN101098740A/zh active Pending
- 2005-11-04 MX MX2007005393A patent/MX2007005393A/es unknown
- 2005-11-04 AU AU2005304988A patent/AU2005304988A1/en not_active Abandoned
- 2005-11-04 CA CA002586658A patent/CA2586658A1/en not_active Abandoned
-
2007
- 2007-06-05 ZA ZA200704689A patent/ZA200704689B/xx unknown
- 2007-11-20 US US11/986,377 patent/US7985344B2/en active Active
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CN102575174A (zh) * | 2009-10-13 | 2012-07-11 | 埃克森美孚研究工程公司 | 用于基本油料的浊雾缓解和过滤性改善的方法 |
CN102085426A (zh) * | 2009-12-02 | 2011-06-08 | 现代自动车株式会社 | 柴油燃料过滤器 |
CN105828903A (zh) * | 2013-12-20 | 2016-08-03 | 霍林斯沃思和沃斯有限公司 | 具有细短纤维的过滤介质 |
CN105828903B (zh) * | 2013-12-20 | 2019-07-26 | 霍林斯沃思和沃斯有限公司 | 具有细短纤维的过滤介质 |
CN110314448A (zh) * | 2013-12-20 | 2019-10-11 | 霍林斯沃思和沃斯有限公司 | 具有细短纤维的过滤介质 |
CN106794405A (zh) * | 2014-09-08 | 2017-05-31 | 霍林斯沃思和沃斯有限公司 | 耐热油介质 |
CN111632434A (zh) * | 2014-12-19 | 2020-09-08 | 霍林斯沃思和沃斯有限公司 | 包括预过滤层的过滤介质 |
CN111632434B (zh) * | 2014-12-19 | 2022-04-15 | 霍林斯沃思和沃斯有限公司 | 包括预过滤层的过滤介质 |
CN110809492A (zh) * | 2017-04-13 | 2020-02-18 | 奥斯龙-明士克公司 | 过滤介质及其用途 |
CN111962328A (zh) * | 2020-08-25 | 2020-11-20 | 重庆再升科技股份有限公司 | 一种高效油气分离过滤材料及其制造方法 |
CN113262565A (zh) * | 2021-04-19 | 2021-08-17 | 陈志丽 | 一种高强度空气过滤器芯材料及其制备方法 |
Also Published As
Publication number | Publication date |
---|---|
AU2005304988A1 (en) | 2006-05-18 |
BRPI0517720A (pt) | 2008-10-21 |
MX2007005393A (es) | 2007-05-15 |
RU2007120884A (ru) | 2008-12-10 |
US8021457B2 (en) | 2011-09-20 |
CA2586658A1 (en) | 2006-05-18 |
ZA200704689B (en) | 2008-09-25 |
JP2008518770A (ja) | 2008-06-05 |
KR20070085813A (ko) | 2007-08-27 |
US20080073296A1 (en) | 2008-03-27 |
EP1812137A1 (en) | 2007-08-01 |
US7985344B2 (en) | 2011-07-26 |
US20060096932A1 (en) | 2006-05-11 |
WO2006052656A1 (en) | 2006-05-18 |
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