CN111038038B - 一种医用复合材料及其制造工艺 - Google Patents

一种医用复合材料及其制造工艺 Download PDF

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CN111038038B
CN111038038B CN201911305690.0A CN201911305690A CN111038038B CN 111038038 B CN111038038 B CN 111038038B CN 201911305690 A CN201911305690 A CN 201911305690A CN 111038038 B CN111038038 B CN 111038038B
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composite material
medical composite
parts
fiber
polyester filament
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CN111038038A (zh
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邢介虎
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Shandong Juntai Medical Protective Product Technology Co ltd
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Shandong Juntai Medical Protective Product Technology Co ltd
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Priority to EP20864322.1A priority patent/EP3858607A4/en
Priority to JP2022523389A priority patent/JP2022544869A/ja
Priority to PCT/CN2020/079456 priority patent/WO2021120426A1/zh
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Abstract

本发明涉及一种医用复合材料及其制造工艺，医用复合材料由聚对苯二甲酸乙二脂纤维、碳离子长丝纤维、聚氨基甲酸脂膜和辅料组成。制造工艺为，聚酯长丝纤维的制造；导电丝纤维制造；将聚酯长丝纤维与导电丝纤维织造成具备防静电功能的纺织材料；阻菌膜的制造；医用复合材料的制造。本发明制造的医用复合材料具有高度的防水、防渗透、阻菌功能，完全杜绝了病人血液、体液、冲洗液、其他污染物的渗透，实现了双向防护功能；同时具备良好的湿气透过功能。

Description

一种医用复合材料及其制造工艺
技术领域
本发明涉及一种医用复合材料及其制造工艺,具体涉及一种具备防水、防渗透、防污染、湿气透过、防静电、耐次氯酸盐漂洗、无脱絮功能的医用复合材料及其制造工艺,属于医用材料技术领域。
背景技术
现有技术中,医疗织物常用的材料为棉质材料和一次性无纺布材料。
棉质材料：没有基本的阻隔功能，病人血液、体液及其他污染物容易浸透棉质材料，导致医护人员、病人交叉感染；产生大量脱絮，脱絮会引起伤口感染及大面积医疗机构感染；没有阻菌功能，不能给予医护人员及病人最好的安全防护；棉质手术室医疗织物已经被欧美发达国家淘汰。
一次性无纺布材料：虽然有一定的阻隔功能，但是遇见大量的有压力的血液、体液、冲洗液时，做不到完全防护；湿气透过率太低，闷热，增加手术医护人员工作负担；单次使用成本高；产生大量医疗垃圾，焚烧处理会产生二噁英等有害物质，污染环境。
针对上述问题，发明人研发了一种新型医用复合材料，解决了棉质材料、一次性无纺布材料现存的问题；为医护人员及患者提供了更加安全的防护材料。
发明内容
本发明提供了一种医用复合材料及其制造工艺,具体涉及一种具备防水、防渗透、防湿气透过、防静电、耐次氯酸盐漂洗、阻菌、无脱絮功能的医用复合材料。本发明的技术方案如下：
一种医用复合材料由以下重量份数的组成：
聚对苯二甲酸乙二脂纤维55-65份、碳离子长丝纤维8-12份、聚氨基甲酸脂膜18-23份和辅料5-15份。
优选的，聚对苯二甲酸乙二脂纤维60份、碳离子长丝纤维10份、聚氨基甲酸脂膜20份和辅料10份；所述辅料为聚氨基甲酸脂胶。
本发明医用复合材料的制造工艺，具体步骤如下：
(1)制造聚酯长丝纤维，将聚酯长丝纤维做初步的改进，使用空气变形工艺使聚酯长丝纤维表面降低质地坚硬、光滑的程度；所述聚酯长丝纤维为聚对苯二甲酸乙二脂(PET)长丝纤维；
(2)制造导电丝纤维
使用纤维截面为圆形的涤纶长丝纤维，将碳离子充分渗透涤纶长丝纤维；然后采用镀膜工艺，将碳离子附着固定于纤维表面，厚度约1微米；
(3)将步骤(1)获得聚酯长丝纤维与步骤(2)获得的导电丝纤维织造成一种具备防静电功能的纺织材料，导电丝间隔距离1厘米；
(4)制造阻菌膜
利用聚氨基甲酸脂(PU)制作厚度为0.012-0.035mm厚度的薄膜，即得阻菌膜；
所述阻菌膜的结构：每平方厘米有13.95亿个微孔，每个微孔孔径280nm；本发明中微孔孔径小于液态水分子团直径0.1mm-7mm 2000倍，大于汽态水分子团直径3nm-4nm 70倍；
(5)医用复合材料制造：上下两层分别使用聚酯长丝纤维、导电丝纤维材料，中间层为阻菌膜，采用聚酯胶水滚涂复合工艺，将三层材料复合，即得医用复合材料。
本发明还包括，对医用复合材料的印染，使得印染后的医用复合材料达到4级标准要求(GB/T7069-1997)。具体印染步骤为：
(1)试样印染
采用40cm×100cm材料作为样品，采用玻璃或者釉瓷容器在印染剂中浸湿静置试样，再用次氯酸盐溶液浸泡60mi n，次氯酸盐溶液中有效氯含量2g/L，pH为11.0±0.2；
(2)材料印染
试验印染检验合格后，对医用复合材料批量印染。
本发明与现有技术相比具有以下优点：
本发明制造的医用复合材料具有高度的防水、防渗透、阻菌功能，完全杜绝了病人血液、体液、冲洗液、其他污染物的渗透，实现了双向防护功能，给予医护人员、病人最好的安全防护；同时具备良好的湿气透过功能，增加了医护人员、病人的舒适性；有利于手术衣、手术单、器械单的使用；防静电功能避免了因静电产生的手术风险；不产生脱絮，避免了脱絮带来的感染风险；耐次氯酸盐漂洗，增加了洗涤次数，降低了单次使用成本；本发明为可重复使用环保材料，处理过程中没有二噁英等致癌物的产生。本发明制造的医用复合材料除医疗领域之外，还可用于养老、婴幼儿等民用领域及部分军事领域。
具体实施方式
下面结合具体实施例来进一步描述本发明，本发明的优点和特点将会随着描述而更为清楚。但实施例仅是范例性的，并不对本发明的范围构成任何限制。本领域技术人员应该理解的是，在不偏离本发明的精神和范围下可以对本发明技术方案的细节和形式进行修改或替换，但这些修改和替换均落入本发明的保护范围内。
实例1：一种医用复合材料及其制造工艺
医用复合材料由以下重量份数的组成：
聚对苯二甲酸乙二脂纤维60份、碳离子长丝纤维10份、聚氨基甲酸脂膜20份和辅料10份；所述辅料为聚氨基甲酸脂胶。
上述医用复合材料的制造工艺，具体步骤如下：
(1)制造聚酯长丝纤维，将聚酯长丝纤维做初步的改进，使用空气变形工艺使聚酯长丝纤维表面降低质地坚硬、光滑的程度；所述聚酯长丝纤维为聚对苯二甲酸乙二脂(PET)长丝纤维；
(2)制造导电丝纤维
使用纤维截面为圆形的涤纶长丝纤维，将碳离子充分渗透涤纶长丝纤维；然后采用镀膜工艺，将碳离子附着固定于纤维表面，厚度约1微米；
(3)将步骤(1)获得聚酯长丝纤维与步骤(2)获得的导电丝纤维织造成一种具备防静电功能的纺织材料，导电丝间隔距离1厘米；
(4)制造阻菌膜
利用聚氨基甲酸脂(PU)制作厚度为0.015-0.025mm厚度的薄膜，即得阻菌膜；
所述阻菌膜的结构：每平方厘米有13.95亿个微孔，每个微孔孔径280nm；
(5)医用复合材料制造：上下两层分别使用聚酯长丝纤维、导电丝纤维材料，中间层为阻菌膜，采用聚酯胶水滚涂复合工艺，将三层材料复合，即得医用复合材料。
实例2：一种医用复合材料及其制造工艺
医用复合材料由以下重量份数的组成：
聚对苯二甲酸乙二脂纤维63份、碳离子长丝纤维12份、聚氨基甲酸脂膜22份和辅料13份；所述辅料为聚氨基甲酸脂胶。
上述医用复合材料的制造工艺，具体步骤如下：
(1)制造聚酯长丝纤维，将聚酯长丝纤维做初步的改进，使用空气变形工艺使聚酯长丝纤维表面降低质地坚硬、光滑的程度；所述聚酯长丝纤维为聚对苯二甲酸乙二脂(PET)长丝纤维；
(2)制造导电丝纤维
使用纤维截面为圆形的涤纶长丝纤维，将碳离子充分渗透涤纶长丝纤维；然后采用镀膜工艺，将碳离子附着固定于纤维表面，厚度约1微米；
(3)将步骤(1)获得聚酯长丝纤维与步骤(2)获得的导电丝纤维织造成一种具备防静电功能的纺织材料，导电丝间隔距离1厘米；
(4)制造阻菌膜
利用聚氨基甲酸脂(PU)制作厚度为0.012-0.035mm厚度的薄膜，即得阻菌膜；
所述阻菌膜的结构：每平方厘米有13.95亿个微孔，每个微孔孔径280nm；
(5)医用复合材料制造：上下两层分别使用聚酯长丝纤维、导电丝纤维材料，中间层为阻菌膜，采用聚酯胶水滚涂复合工艺，将三层材料复合，即得医用复合材料。
实例3：一种医用复合材料及其制造工艺
医用复合材料由以下重量份数的组成：
聚对苯二甲酸乙二脂纤维56份、碳离子长丝纤维9份、聚氨基甲酸脂膜18份和辅料8份；所述辅料为聚氨基甲酸脂胶。
上述医用复合材料的制造工艺，具体步骤如下：
(1)制造聚酯长丝纤维，将聚酯长丝纤维做初步的改进，使用空气变形工艺使聚酯长丝纤维表面降低质地坚硬、光滑的程度；所述聚酯长丝纤维为聚对苯二甲酸乙二脂(PET)长丝纤维；
(2)制造导电丝纤维
使用纤维截面为圆形的涤纶长丝纤维，将碳离子充分渗透涤纶长丝纤维；然后采用镀膜工艺，将碳离子附着固定于纤维表面，厚度约1微米；
(3)将步骤(1)获得聚酯长丝纤维与步骤(2)获得的导电丝纤维织造成一种具备防静电功能的纺织材料，导电丝间隔距离1厘米；
(4)制造阻菌膜
利用聚氨基甲酸脂(PU)制作厚度为0.025-0.035mm厚度的薄膜，即得阻菌膜；
所述阻菌膜的结构：每平方厘米有13.95亿个微孔，每个微孔孔径280nm；
(5)医用复合材料制造：上下两层分别使用聚酯长丝纤维、导电丝纤维材料，中间层为阻菌膜，采用聚酯胶水滚涂复合工艺，将三层材料复合，即得医用复合材料。
实施例4
本发明还包括，对医用复合材料的印染，使得印染后的医用复合材料达到4级标准要求(GB/T7069-1997)；具体印染步骤为：
(1)试样印染
采用40cm×100cm材料作为样品，采用玻璃或者釉瓷容器在印染剂中浸湿静置试样，再用次氯酸盐溶液浸泡60mi n，次氯酸盐溶液中有效氯含量2g/L，pH为11.0±0.2；
(2)材料印染
试验印染检验合格后，对医用复合材料批量印染。
试验例对本发明复合材料进行检测，检测结果如表1所示：
表1
Figure BDA0002323010760000061
此外，经检测，对照样品棉布在湿性条件下金黄色葡萄球菌透过，5个培养基平板上生长的菌落总数超过5个；在干性条件下，10个样片透过的菌落数之和为187cfu，远大于15cfu；而本发明医用复合材料在湿性条件下能有效阻隔金黄色葡萄球菌透过，在干燥条件下能有效阻隔枯草杆菌黑色变种芽孢透过；同时，经检测本发明医用复合材料洁净度-微生物≤300cfu/d㎡；洁净度-微粒物质≤3.5IPM；落絮≤4.0log10；干态、湿态涨破强度≥40KPa；干态、湿态断裂强度：≥20N。

Claims (3)

1.一种医用复合材料，其特征在于，所述医用复合材料由以下重量份数的组成：
聚对苯二甲酸乙二酯 纤维55-65份、碳离子长丝纤维8-12份、聚氨基甲酸酯 膜18-23份和辅料5-15份；
所述医用复合材料的制造工艺，具体步骤如下：
（1）制造聚酯长丝纤维，将聚酯长丝纤维做初步的改进，使用空气变形工艺使聚酯长丝纤维表面降低质地坚硬、光滑的程度;所述聚酯长丝纤维为聚对苯二甲酸乙二酯 （PET）长丝纤维；
（2）制造导电丝纤维
使用纤维截面为圆形的涤纶长丝纤维，将碳离子充分渗透涤纶长丝纤维；然后采用镀膜工艺，将碳离子附着固定于纤维表面，厚度1微米；
（3）将步骤（1）获得聚酯长丝纤维与步骤（2）获得的导电丝纤维织造成一种具备防静电功能的纺织材料，导电丝间隔距离1厘米；
（4）制造阻菌膜
利用聚氨基甲酸酯 （PU）制作厚度为0.012-0.035mm厚度的薄膜，即得阻菌膜；
所述阻菌膜的结构：每平方厘米有13.95亿个微孔，每个微孔孔径280nm；
（5）医用复合材料制造：上下两层分别使用聚酯长丝纤维、导电丝纤维材料，中间层为阻菌膜，采用聚酯胶水滚涂复合工艺，将三层材料复合，即得医用复合材料。
2.根据权利要求1所述的医用复合材料，其特征在于，所述医用复合材料由以下重量份数的组成：
聚对苯二甲酸乙二酯 纤维60份、碳离子长丝纤维10份、聚氨基甲酸酯 膜20份和辅料10份；所述辅料为聚氨基甲酸酯 胶。
3.如权利要求1所述的医用复合材料，其特征在于，所述医用复合材料的制造工艺还包括对医用复合材料的印染，具体印染步骤为：
试样印染
采用40cm×100cm材料作为样品，采用玻璃或者釉瓷容器在印染剂中浸湿静置试样，再用次氯酸盐溶液浸泡60min，次氯酸盐溶液中有效氯含量2g/L，pH为11.0±0.2；
材料印染
试验印染检验合格后，对医用复合材料批量印染。
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