CN105568562A - 一种医用无纺布复合材料及其制备方法 - Google Patents

一种医用无纺布复合材料及其制备方法 Download PDF

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CN105568562A
CN105568562A CN201610162565.9A CN201610162565A CN105568562A CN 105568562 A CN105568562 A CN 105568562A CN 201610162565 A CN201610162565 A CN 201610162565A CN 105568562 A CN105568562 A CN 105568562A
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CN105568562B (zh
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万全军
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Hengtian nonwoven Co. Ltd. Ka Wah
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万全军
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Abstract

本发明提供了一种医用无纺布复合材料的制备方法，具体步骤如下：（1）按重量份分别称取聚己二酸/对苯二甲酸丁二酯30～50份、聚乳酸20～30份和聚丙烯30～40份进行充分混合，得混合物A；（2）将步骤（1）中的混合物与1-4份的抗静电剂、0.5-2份的抗菌剂进行共混，然后通过双螺杆挤出机挤出造粒，得到共混物；（3）将步骤（2）中共混物进行真空干燥，干燥后的共混物通过螺杆挤压机加热、熔融、挤出、拉伸、冷却、自粘合形成无纺布；（4）对步骤（3）得到的无纺布的一侧喷涂防辐射层，最后放入干燥箱内干燥定型；本发明制备的医用无纺布复合材料既有抗菌性，又能防辐射、抗静电性能，主要应用于医用口罩的制备。

Description

一种医用无纺布复合材料及其制备方法
技术领域
本发明属于无纺布领域，特别是涉及一种医用无纺布复合材料及其制备方法。
背景技术
无纺布(非织造布)是一种不需要纺纱织布而形成的织物，只是将纺织短纤维或者长丝进行定向或随机撑列，形成纤网结构，然后采用机械、热粘或化学等方法加固而成。简单的讲就是：它不是由一根一根的纱线交织、编结在一起的，而是将纤维直接通过物理的方法粘合在一起的，所以，当你拿到你衣服里的粘称时，就会发现，是抽不出一根根的线头的。非织造布突破了传统的纺织原理，并具有工艺流程短、生产速度快，产量高、成本低、用途广、原料来源多等特点，在日常生产和生活中有着广泛的应用。但是，随着人们健康意识的提高和对生活质量的重视，如何赋予己经广泛应用的无纺布材料的优良的性能，成为当前一个热门的课题。中国专利CN1970865A公开了一种将表面镀银的纤维添加进无纺布纤维中的技术，具有杀灭常见细菌的能力。中国专利CN201109221Y公开了一种抗菌复合无纺布材料，它由三层材料复合而成，外层为吸水无纺布制作的吸水层，中间层为PE，PU膜或防水透气膜制作的防水层，里层为抗菌无纺布制作的抗菌层，使之同时具备了吸水、防水、抗菌的功能。中国专利CN104695137A公开了一种抗静电无纺布，该无纺布由聚酯，聚酰胺类聚合物，抗静电剂制备得到，该发明制备的无纺布纤维直径较细，得到无纺布具有比表面积大、孔隙率高、过滤效率优、柔软性好、舒适感强等优点，可广泛应用于医用和工业用口罩、保暖材料、过滤材料、医疗卫生材料、吸油材料、擦拭布、电池隔板以及隔音材料等领域。中国专利CN204076983U公开了一种用于制作医用口罩的无纺布复合材料，包括亲肤层、吸水层、第一PE层、除菌层、第二PE层和亲水PP无纺布层，所述亲肤层上粘结有一层吸水层，所述吸水层上粘结有第一PE层，第一PE层上粘结有除菌层，所述除菌层的上部粘结有第二PE层，第二PE层上粘结有亲水PP无纺布层。
无纺布用途广泛，其中医用无纺布方面，包括一次性口罩、防护服、手术衣、隔离衣、实验服，护士帽、手术帽、医生帽、手术包、产妇包、急救包、尿布、枕套、床单、被套、鞋套等一次性医用耗材系列。与传统的纯棉机织医用纺织品相比，医用非织造织物具有对细菌、尘埃过滤性高、手术感染率低、消毒灭菌方便、易于与其它材料复合等特点。医用非织造产品作为用即弃的一次性用品，不仅使用便利，安全卫生，还能有效地防止细菌感染和医原性交叉感染。我国每年消耗大量的医用无纺布，但目前市售的医用无纺布功能比较单一，缺少一种集抗菌性、防辐射、抗静电等多功能于一身的医用无纺布。
发明内容
本发明的目的是为了解决现有技术的不足，提供一种医用多功能无纺布，该无纺布既有抗菌性，又能防辐射、抗静电性能。
为解决上述问题，本发明采用的技术方案为：
一种医用无纺布复合材料的制备方法，包括如下步骤：
（1）按重量份分别称取聚己二酸/对苯二甲酸丁二酯30～50份、聚乳酸20～30份和聚丙烯30～40份进行充分混合，得混合物A；
（2）将步骤（1）中的混合物与1-4份的抗静电剂、0.5-2份的抗菌剂进行共混，然后通过双螺杆挤出机挤出造粒，得到共混物；
（3）将步骤（2）中共混物进行真空干燥，干燥后的共混物通过螺杆挤压机加热、熔融、挤出、拉伸、冷却、自粘合形成无纺布；
（4）对步骤（3）得到的无纺布的一侧喷涂防辐射层，最后放入干燥箱内干燥定型。
所述聚己二酸/对苯二甲酸丁二酯的结构式为：，其中，10≤x≤40，10≤y≤40。
所述的抗静电剂为阴离子抗静电剂，具体为含有有机磺酸盐类的抗静电剂，其通式为(R-SO3)nM，其中R为C6-C18的直链烷基或烷基苯基，M是碱金属或碱土金属离子，n为1或2。
所述的抗菌剂为载银纳米二氧化钛或生物多肽类抗菌剂，所述生物多肽类抗菌剂选自硫酸鱼精蛋白、ε-聚赖氨酸、硫酸多粘菌素或纳他霉素中的一种或多种组合。
另外，步骤(2)中的挤出温度为220-250℃；步骤(3)中的共混物的真空干燥温度为80-120℃，干燥时间24-48h；步骤(3)中的混合物在制备熔喷无纺布的过程中，熔融温度为230-290℃；滚筒与喷丝口的距离为5-30cm，滚筒转速为20-35r/min；喷丝孔两侧的热气流的流速为50-250m/sec,温度为210-320℃；步骤(4)中的干燥定型温度为80-110℃，定型时间为5-20h。
根据本发明制备方法制备得到的医用无纺布复合材料，其厚度为0.2-0.4mm，克重为20-40g/m2，并且其主要应用于医用口罩的制备。
本发明的技术效果为：
（1）本发明的无纺布集抗菌性、防辐射、抗静电等功能于一身，基本能解决医用各个方面的需求；
（2）本发明得到的无纺布具有很好的广谱抗菌性，对大肠杆菌、金黄色葡萄球菌、白色念珠菌4小时检测，抗菌率均达到99.9%，另外，其具有十分持久的抗静电性能以及防辐射效果；
（3）本发明使用聚己二酸/对苯二甲酸丁二酯、聚乳酸和聚丙烯三种原料复配，制得的无纺布材料比表面积大、拉力弹性好、延展性好不易折断的性能；
（4）本发明设备简单、工艺流程短、能耗低，采用熔喷方法制备无纺布，使其纤维直径较细。
具体实施方式
下面结合实施例对本发明的技术方案做进一步的阐述：
实施例1
一种医用无纺布复合材料的制备方法，包括如下步骤：
（1）按重量份分别称取聚己二酸/对苯二甲酸丁二酯30份、聚乳酸20份和聚丙烯30份进行充分混合，得混合物A；
（2）将步骤（1）中的混合物与2份的十二烷基苯磺酸钠、1份的载银二氧化钛进行共混，然后通过双螺杆挤出机挤出造粒，得到共混物，挤出温度为230℃；
（3）将步骤（2）中共混物在100℃真空干燥32h，使得含水率小于120ppm，干燥后的共混物通过螺杆挤压机加热、在260℃下熔融、挤压成熔体，当熔体从模头的喷丝孔挤出时，受到喷丝孔两侧流速为90m/sec,温度为260℃的高压热气流喷吹，共混物熔体被拉伸成超细纤维，凝聚在离喷头距离10cm的滚筒式接收器上，接收器的滚筒转速为28r/min，自粘合成无纺布；
（4）对步骤（3）得到的无纺布的一侧喷涂防辐射层，最后放入干燥箱内干燥定型，干燥温度为100℃，干燥时间为12h。
实施例2
一种医用无纺布复合材料的制备方法，包括如下步骤：
（1）按重量份分别称取聚己二酸/对苯二甲酸丁二酯40份、聚乳酸30份和聚丙烯40份进行充分混合，得混合物A；
（2）将步骤（1）中的混合物与3份的十二烷基苯磺酸钠、1份的ε-聚赖氨酸进行共混，然后通过双螺杆挤出机挤出造粒，得到共混物，挤出温度为230℃；
（3）将步骤（2）中共混物在110℃真空干燥36h，使得含水率小于100ppm，干燥后的共混物通过螺杆挤压机加热、在280℃下熔融、挤压成熔体，当熔体从模头的喷丝孔挤出时，受到喷丝孔两侧流速为100m/sec,温度为280℃的高压热气流喷吹，共混物熔体被拉伸成超细纤维，凝聚在离喷头距离12cm的滚筒式接收器上，接收器的滚筒转速为30r/min，自粘合成无纺布；
（4）对步骤（3）得到的无纺布的一侧喷涂防辐射层，最后放入干燥箱内干燥定型，干燥温度为80℃，干燥时间为15h。
实施例3
一种医用无纺布复合材料的制备方法，包括如下步骤：
（1）按重量份分别称取聚己二酸/对苯二甲酸丁二酯50份、聚乳酸30份和聚丙烯40份进行充分混合，得混合物A；
（2）将步骤（1）中的混合物与4份的十二烷基苯磺酸钠、2份的载银二氧化钛进行共混，然后通过双螺杆挤出机挤出造粒，得到共混物，挤出温度为250℃；
（3）将步骤（2）中共混物在120℃真空干燥20h，使得含水率小于110ppm，干燥后的共混物通过螺杆挤压机加热、在250℃下熔融、挤压成熔体，当熔体从模头的喷丝孔挤出时，受到喷丝孔两侧流速为120m/sec,温度为270℃的高压热气流喷吹，共混物熔体被拉伸成超细纤维，凝聚在离喷头距离20cm的滚筒式接收器上，接收器的滚筒转速为25r/min，自粘合成无纺布；
（4）对步骤（3）得到的无纺布的一侧喷涂防辐射层，最后放入干燥箱内干燥定型，干燥温度为90℃，干燥时间为18h。
实施例4
一种医用无纺布复合材料的制备方法，包括如下步骤：
（1）按重量份分别称取聚己二酸/对苯二甲酸丁二酯30份、聚乳酸20份和聚丙烯30份进行充分混合，得混合物A；
（2）将步骤（1）中的混合物与2份的十二烷基苯磺酸钠、1份的硫酸鱼精蛋白进行共混，然后通过双螺杆挤出机挤出造粒，得到共混物，挤出温度为220℃；
（3）将步骤（2）中共混物在120℃真空干燥24h，使得含水率小于100ppm，干燥后的共混物通过螺杆挤压机加热、在280℃下熔融、挤压成熔体，当熔体从模头的喷丝孔挤出时，受到喷丝孔两侧流速为150m/sec,温度为240℃的高压热气流喷吹，共混物熔体被拉伸成超细纤维，凝聚在离喷头距离12cm的滚筒式接收器上，接收器的滚筒转速为26r/min，自粘合成无纺布；
（4）对步骤（3）得到的无纺布的一侧喷涂防辐射层，最后放入干燥箱内干燥定型，干燥温度为80℃，干燥时间为20h。
实施例5
一种医用无纺布复合材料的制备方法，包括如下步骤：
（1）按重量份分别称取聚己二酸/对苯二甲酸丁二酯38份、聚乳酸25份和聚丙烯35份进行充分混合，得混合物A；
（2）将步骤（1）中的混合物与1.8份的十二烷基苯磺酸钠、1.6份的硫酸多粘菌素进行共混，然后通过双螺杆挤出机挤出造粒，得到共混物，挤出温度为240℃；
（3）将步骤（2）中共混物在100℃真空干燥28h，使得含水率小于120ppm，干燥后的共混物通过螺杆挤压机加热、在240℃下熔融、挤压成熔体，当熔体从模头的喷丝孔挤出时，受到喷丝孔两侧流速为100m/sec,温度为230℃的高压热气流喷吹，共混物熔体被拉伸成超细纤维，凝聚在离喷头距离18cm的滚筒式接收器上，接收器的滚筒转速为24r/min，自粘合成无纺布；
（4）对步骤（3）得到的无纺布的一侧喷涂防辐射层，最后放入干燥箱内干燥定型，干燥温度为110℃，干燥时间为15h。
性能测试
对本发明实施例1-5所得产品所得产品的性能进行测试，抗菌性：将产品碎片浸渍于菌液中，检测其表面受污染状况；防辐射：用辐射检测仪检测使用该产品后辐射剂量率的减少量，单位μSv/h；抗静电：用体积电阻，Ω.cm表示；测试结果见下表
实施例1 实施例2 实施例3 实施例4 实施例5 市售无纺布
抗菌性 99% 98% 100% 96% 97% 75%
防辐射 103 108 105 101 106 92
抗静电 108 108 108 108 108 108
从上表可知，实施例1-5的无纺布产品具有十分优异的抗菌、防辐射以及抗静电的性能。
最后应说明的是：以上所述仅为本发明的优选实施例而已，并不用于限制本发明，尽管参照前述实施例对本发明进行了详细的说明，对于本领域的技术人员来说，其依然可以对前述各实施例所记载的技术方案进行修改，或者对其中部分技术特征进行等同替换。凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (9)

1.一种医用无纺布复合材料的制备方法，其特征在于，包括如下步骤：
（1）按重量份分别称取聚己二酸/对苯二甲酸丁二酯30～50份、聚乳酸20～30份和聚丙烯30～40份进行充分混合，得混合物A；
（2）将步骤（1）中的混合物与1-4份的抗静电剂、0.5-2份的抗菌剂进行共混，然后通过双螺杆挤出机挤出造粒，得到共混物；
（3）将步骤（2）中共混物进行真空干燥，干燥后的共混物通过螺杆挤压机加热、熔融、挤出、拉伸、冷却、自粘合形成无纺布；
（4）对步骤（3）得到的无纺布的一侧喷涂防辐射层，最后放入干燥箱内干燥定型。
2.根据权利要求1所述的无纺布复合材料的制备方法，其特征在于，所述聚己二酸/对苯二甲酸丁二酯的结构式为：，其中，10≤x≤40，10≤y≤40。
3.根据权利要求1或2所述的无纺布复合材料的制备方法，其特征在于，所述的抗静电剂为阴离子抗静电剂。
4.根据权利要求3所述的无纺布复合材料的制备方法，其特征在于，所述的阴离子抗静电剂为含有有机磺酸盐类的抗静电剂，其通式为(R-SO3)nM，其中R为C6-C18的直链烷基或烷基苯基，M是碱金属或碱土金属离子，n为1或2。
5.根据权利要求4所述的无纺布复合材料的制备方法，其特征在于，所述的抗菌剂为载银纳米二氧化钛或生物多肽类抗菌剂。
6.根据权利要求4或5所述的无纺布复合材料的制备方法，其特征在于，所述生物多肽类抗菌剂选自硫酸鱼精蛋白、ε-聚赖氨酸、硫酸多粘菌素或纳他霉素中的一种或多种组合。
7.根据权利要求1所述的无纺布复合材料的制备方法，其特征在于，步骤(2)中的挤出温度为220-250℃；步骤(3)中的共混物的真空干燥温度为80-120℃，干燥时间24-48h；步骤(3)中的混合物在制备熔喷无纺布的过程中，熔融温度为230-290℃；滚筒与喷丝口的距离为5-30cm，滚筒转速为20-35r/min；喷丝孔两侧的热气流的流速为50-250m/sec,温度为210-320℃；步骤(4)中的干燥定型温度为80-110℃，定型时间为5-20h。
8.根据权利要求1-7任一项所述的制备方法制备得到的医用无纺布复合材料，其特征在于，所述无纺布厚度为0.2-0.4mm，克重为20-40g/m2。
9.根据权利要求8所述的医用无纺布复合材料的应用，其特征在于，所述无纺布复合材料用于制作医用口罩。
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