CN111409341B - 一种基于水刺无纺材料的医用口罩材料及其制备方法 - Google Patents
一种基于水刺无纺材料的医用口罩材料及其制备方法 Download PDFInfo
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- CN111409341B CN111409341B CN202010106138.5A CN202010106138A CN111409341B CN 111409341 B CN111409341 B CN 111409341B CN 202010106138 A CN202010106138 A CN 202010106138A CN 111409341 B CN111409341 B CN 111409341B
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- water
- solution
- spunlace
- adhesive
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- C—CHEMISTRY; METALLURGY
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Abstract
本发明公开了一种基于水刺无纺材料的医用口罩材料及其制备方法，包括依次贴合的外防护层、粘合剂层以及经过拒水、拒油、抗血液和抗酒精四抗整理的水刺无纺布层，所述外防护层为PTFE薄膜，所述水刺无纺布层由竹浆纤维和抗菌涤纶纤维制成。制备方法为：水刺无纺布层的制备：将竹浆纤维和涤纶纤维按比例混合后，经梳理、铺网、牵伸后进行高压水刺，然后经过四抗整理后高温烘干并杀菌、分切、收卷得到水刺无纺布层；外防护层覆合：将粘合剂涂覆在水刺无纺布层表面，再覆盖PTFE薄膜，经过加热辊加压复合后多级拉幅定型得最终材料。本发明中的医用口罩材料没有任何轧点，手感柔软且透气性好，佩戴舒适又同时具备良好的防护性。
Description
技术领域
本发明涉及医用材料技术领域，尤其是涉及一种基于水刺无纺材料的医用口罩材料及其制备方法。
背景技术
医用口罩是一种医疗防护用品，其作用是抵抗液体、过滤颗粒物和细菌等效用，保证人员的安全。目前的医用口罩大多采用SMS或SMMS纺粘加熔喷非织造材料复合PE膜等外防护层制成，或直接纺粘无纺布复合以PU膜或TPU膜等外防护层制成。例如，一种在中国专利文献上公开的“隔尘抗菌的医用口罩”，其公告号CN203152562U，外层为纺粘无纺布层、负离子纳米无纺布层或银离子纤维无纺布层。中间层是熔喷无纺布层或空气净化滤膜层。内层是竹纤维无纺布层或竹纤维纺织面料层。
但传统的医用口罩材料佩戴舒适性差，一是由于纺粘无纺布靠轧点做出来，手感比较硬，柔软度差；二是由于防护性和透气透湿性是相矛盾的，使用覆膜材料来达到好的防护效果时，就无法避免会使佩戴者感到闷热出汗，且佩戴者呼出的水分也不能有效排出，而具有良好透气透湿性的材料又不能很好的阻隔血液、酒精等，防护效果差。因此，找到合适的材料，使医用口罩可以达到防护性和舒适性并存，是亟需解决的问题。
发明内容
本发明是为了克服现有技术中的医用口罩材料手感比较硬，柔软度差；且防护性和透气透湿性难以并存，为了达到良好的防护效果只能使得佩戴舒适性差的问题，提供一种基于水刺无纺材料的医用口罩材料及其制备方法，使用四抗(拒水，拒油，抗血液，抗酒精)整理后且具有抗菌性能的水刺无纺布和与PTFE薄膜复合后的材料制作医用口罩，水刺无纺布没有任何轧点，手感柔软且透气性好，经过四抗整理后又具备良好的防护性，与同样具有良好防护性和透气性的PTFE薄膜复合后制作出的医用口罩可以兼具防护性和舒适性。
为了实现上述目的，本发明采用以下技术方案：
一种基于水刺无纺材料的医用口罩材料，包括依次贴合的外防护层、粘合剂层以及经过拒水、拒油、抗血液和抗酒精四抗整理的水刺无纺布层，所述外防护层为PTFE薄膜，所述水刺无纺布层由质量比为1：(1～2)的竹浆纤维和抗菌涤纶纤维制成，面密度为150～250g/m2，所述外防护层的厚度为0.01～0.02mm；粘合剂层的厚度为0.01～0.03mm；水刺无纺布层的厚度为 0.25～0.55mm。
本发明采用竹浆纤维和抗菌涤纶纤维制成水刺无纺布后再与PTFE通过粘结剂复合，水刺过程中是利用水射流的冲击力使竹浆纤维和抗菌涤纶纤维互相缠结和穿插混合在一起，形成牢固的结构，水射流的作用力不会产生任何轧点，因此水刺无纺布层的手感柔软、悬垂性好；并且缠结后纤维之间的孔隙较多、透气性好，人体佩戴舒适。但单纯使用水刺无纺布层，无法起到有效的防护效果，因此本发明对水刺无纺布层进行了拒水、拒油、抗血液和抗酒精四抗整理，使得水刺无纺布层可以阻隔酒精、血液等液体的渗透，防止有机油类污染物对材料的润湿，并且防止材料在使用过程中由于摩擦引起静电从而对手术中精密仪器造成不良影响，并且水刺无纺布层材料中的抗菌涤纶纤维具有良好的抗菌性，可以防止细菌进入口鼻。然后将经四抗整理后的水刺无纺布层与外防护层PTFE薄膜复合，PTFE薄膜具有良好的抗水、抗油、抗酒精等防护作用，细菌在PTFE薄膜上也不易存活，因此与PTFE薄膜复合后，可以进一步提高材料的防护能力，达到医用防护要求；并且PTFE薄膜的孔径小、开孔率高，透气效果好，长时间佩戴不易闷热，佩戴舒适性好。
作为优选，抗菌涤纶纤维的制备方法为：将壳聚糖加入2～3％乙酸溶液中，磁力搅拌 20～30h后加入硝酸银，避光条件下磁力搅拌30～40min后将溶液经紫外线照射20～30min获得抗菌整理溶液；用抗菌整理溶液采用两浸两轧的方法对涤纶纤维进行抗菌整理后得到所述抗菌涤纶纤维。本发明采用壳聚糖基载银抗菌整理溶液对涤纶纤维进行抗菌整理得到抗菌涤纶纤维，纳米银可以使涤纶纤维具备良好的抗菌性能，从而使制得的医用口罩可以有效防护细菌。
作为优选，粘合剂层的粘合剂原料以重量份计包括：50～80份粘合剂基体，20～60份
纤维素基吸水保水剂，10～20份增粘树脂，5～20份矿物油，1～10份发泡剂。
水刺无纺布层经过四抗整理后获得良好防护性的同时，其拒水性也使得佩戴者呼出的水分和产生的汗液保留在贴身一侧，不易向外排出，长时间佩戴后内层很容易布满水分汗液，影响舒适性。因此本发明的粘合剂层中在粘合剂基体加入纤维素基吸水保水剂，由于纤维素具有优良的吸水性能，使得水刺无纺布层的两侧具有了不同的亲水性，可以实现材料的单向导湿功能，当人体产生的汗液与水刺无纺布层的内侧接触时，水分能在纤维素基吸水保水剂的吸水作用下自发地从贴身一侧连续不断的传输到粘合剂层，然后再经由粘合剂层慢慢蒸发通过PTFE薄膜上的空隙排入空气，使贴身一侧可以快速干燥，保持人体舒适。同时又由于纤维素吸水膨胀后不易溶解，因此纤维素基吸水保水剂还具有良好的保水性，吸收的水分可以有效保持在其内部，停留在粘合剂层中，也进一步提高了防护服的抗静电性能。纤维素基吸水保水剂镶嵌在粘合剂基体中，在周围粘合剂基体的制约作用下可以保证纤维素基吸水保水剂吸水膨胀后粘合剂层的整体结构不会发生改变，不影响粘合效果。
如果直接使粘合剂基体覆盖在PTFE薄膜和水刺无纺布之间，粘合剂基体内没有孔隙，会阻碍气体的排出，导致材料透气性降低。因此本发明在粘合剂材料中加入发泡剂，使粘合剂基体具有多孔结构，不但可以保证材料整体的透气性，而且粘合剂基体中的微孔可以机械地吸收液体，机械吸收速度比化学吸收更快，进一步提高了吸收汗液的速度，并且微孔结构也增大了汗液与粘合剂层的接触面积，提高了粘合剂层的吸水效果，保证了贴身侧的干燥，大大提高舒适性。
作为优选，纤维素基吸水保水剂的制备方法为：将竹浆纤维分散在浓度为6～8wt％的 NaOH溶液和浓度为10～12wt％的尿素溶液的混合液中，-20～-10℃冷冻1～3h，得纤维素溶液，竹浆纤维和混合液的质量比为1：(30～35)；搅拌下向纤维素溶液中加入浓度为2～4wt％的壳聚糖溶液，至壳聚糖与竹浆纤维的质量比为(1～2)：4；搅拌均匀后逐滴加入与纤维素溶液质量比为1：(30～50)的体积分数2～3％的戊二醛溶液，70～80℃下反应1～2h，将产物洗涤干燥后得到所述吸水保水剂。
虽然纤维素本身具有良好的吸水性能，但其吸水溶胀后不可逆，当吸收的水分较多时溶胀至一定程度后还是会发生溶解，限制了其吸水和保水量，并且会影响粘合剂层的粘合性能。因此本发明将从竹浆纤维中得到的竹浆纤维素与同样具有优良吸水性能的壳聚糖在交联剂的作用下制成了纤维素-壳聚糖水凝胶，由于存在交联网络，水凝胶可以溶胀和保有大量的水，并且其溶胀过程是可逆的，水分蒸发后又可恢复原来的结构，可以不断循环吸水，因此用其作为吸水保水剂时，吸水和保水能力都比单独使用纤维素和壳聚糖时有了显著提高，也可以提高粘合剂层的粘合稳定性。
并且将纤维素基吸水保水剂制成水凝胶结构，其三维网状结构中的孔洞也可以进一步提高水分的吸收速度，使水分可以更快的从水刺无纺布层的贴身一侧导入到粘合剂层中，提高人体佩戴的舒适性。
作为优选，粘合剂基体为改性聚氨酯弹性体，其制备方法为：
A)将活性炭在90～110℃下活化4～5h后分散于甲苯中得到分散液，活性炭和甲苯的比例为 1g：(50～100mL)；
B)向上述分散液中逐滴加入与活性炭的质量体积比为50g：(1～2mL)的2,4-甲苯二异氰酸酯和3～5滴二月桂酸二基丁锡，80～90℃下搅拌反应10～12h，过滤、洗涤、干燥后得到表面改性活性炭；
C)将质量比为1：(130～140)：(4～5)的表面改性活性炭、脱水后的四氢呋喃聚醚和4-4’二苯甲烷二异氰酸酯混合，75～85℃反应1.5～2.5h，得到预聚体；
D)将预聚体真空脱泡后加入与预聚体质量比为(5～6)：100的1,4-丁二醇，搅拌均匀后真空脱泡，浇入模具固化，100～110℃下熟化20～30h，研磨、造粒得到所述改性聚氨酯弹性体。
本发明中的粘合剂基体采用改性聚氨酯弹性体，聚氨酯弹性体形成的热熔胶具有优良的粘结性，具有无溶剂污染、初粘性高等优点。但用于医用口罩中时，人体呼出的大量水分和产生的汗液会对其不断进行腐蚀，影响其粘结性，并且纤维素基吸水保水剂吸水后会溶胀，而粘合剂基体需要在吸水保水剂的膨胀挤压下维持整体结构不发生改变，对其结构稳定性要求较高，因此本发明在聚氨酯弹性体中引入了活性炭，以提高其抗腐蚀能力和结构稳定性。
如果直接将活性炭加入聚氨酯弹性体中，活性炭的分散性差，容易团聚，因此本发明先通过步骤A)和B)，对活性炭表面进行改性，得到异氰酸酯化的改性活性炭，提高其分散性以及与聚氨酯弹性体的相容性，然后步骤C)和D)中采用原位聚合法制得填充有纳米填料的改性聚氨酯弹性体，用其作为粘合剂基体时，有效提高了粘合剂基体的抗腐蚀能力和结构稳定性。
作为优选，增粘树脂为石油树脂、松香甘油酯、脂松香、二萜烯聚合物中的一种或几种；所述发泡剂为摩尔比(1.5～2.5)：1的碳酸氢钠和柠檬酸。增粘树脂与粘合剂基体配合可以提高粘结性能，使水刺无纺布层和外部防护层更好的粘合。
本发明还提供一种上述医用口罩材料的制备方法，包括如下步骤：
(1)水刺无纺布层的制备：将竹浆纤维和抗菌涤纶纤维按比例混合后，经梳理、铺网、牵伸后进行高压水刺，然后经过四抗整理后高温烘干并杀菌、分切、收卷得到水刺无纺布层；
(2)粘合剂的制备：将粘合剂原料按比例混合后加入密炼机中，150～160℃下混炼1～2h，得到所述粘合剂；
(3)外防护层覆合：将上述制得的粘合剂涂覆在水刺无纺布层表面形成粘合剂层，再将PTFE 薄膜覆盖在粘合剂层上方，经过加热辊加压复合，然后进行多级拉幅定型，冷却后收卷得到所述医用口罩材料。
作为优选，步骤(1)中高压水刺工序采用多级水刺工艺：一级压力50～150bar，牵伸 90～200％；二级压力90～130bar，牵伸100～150％；三级压力100～180bar，牵伸100～150％；四级压力100～200bar，牵伸100～120％；五级压力80～150bar，牵伸90～120％。采用本发明中的多级高压水刺工艺及参数，可以保证竹浆纤维和涤纶纤维更好的缠结，并有良好的孔隙，使得制备出的水刺无纺布层具有足够的强度和良好的透气性。
作为优选，步骤(1)中四抗整理的方法为：将水刺无纺布层在三防整理剂中充分浸润，轧出多余水分后经过三道烘箱进行烘干及定型，所述三道烘干温度分别为：第一道烘箱温度115～125℃，第二道烘箱温度145～155℃，第三道烘箱温度175～185℃。
作为优选，步骤(3)中加压复合时的温度为150～250℃，压力为0.5～8公斤；多级拉幅定型时进行五级拉伸，每级拉伸率3～5％。由于覆膜加工的张力比较大，水刺无纺布难免有幅宽收缩的情况，因此本发明采用该多级拉幅工艺，可以确保成品的幅宽要求，同时不对成品的性能产生影响。
因此，本发明具有如下有益效果：
(1)基于竹浆纤维和抗菌涤纶纤维的水刺无纺布制成的医用口罩材料手感柔软、悬垂性好；孔隙较多、透气性好，人体佩戴舒适；涤纶纤维经抗菌整理、水刺无纺布层经四抗整理并与 PTFE薄膜复合后防护性能佳；
(2)粘合剂层使用粘合剂基体和纤维素基吸水保水剂制成，在保证粘合性的同时使粘合剂层具有吸水性保水性，使水刺无纺布层两侧具有不同的亲水性，从而实现单向导湿，使人体呼出的水分和产生的汗液能快速的传输至粘合剂层，保证贴身一侧的干燥舒适，并且粘合剂层吸水后也可以提高材料的抗静电性能；
(3)纤维素基吸水保水剂采用纤维素-壳聚糖水凝胶结构，提高了其吸水和保水能力，保证了粘合剂层的粘合稳定性，并且可以加速汗液向粘合剂层的传导速度，提高穿着的舒适性；
(4)粘合剂基体使用填充有纳米填料的改性聚氨酯弹性体，用其作为粘合剂基体时，有效提高了粘合剂基体的抗腐蚀能力和结构稳定性。
具体实施方式
下面结合具体实施方式对本发明做进一步的描述。
实施例1：
一种基于水刺无纺材料的医用口罩材料，包括依次贴合的0.01mm外防护层、0.02mm粘合剂层以及经过拒水、拒油、抗血液和抗酒精四抗整理的0.40mm水刺无纺布层，外防护层为PTFE 薄膜，粘合剂层为市售聚氨酯粘合剂，水刺无纺布层由质量比为1：1的竹浆纤维和抗菌涤纶纤维制成，面密度为：200g/m2。
抗菌涤纶纤维的制备方法为：将壳聚糖加入2％乙酸溶液中，磁力搅拌24h后加入硝酸银，避光条件下磁力搅拌35min后将溶液经紫外线照射25min获得抗菌整理溶液，抗菌溶液中壳聚糖的质量分数为3％，硝酸银的质量分数为0.7％；用抗菌整理溶液采用两浸两轧的方法对涤纶纤维进行抗菌整理后得到所述抗菌涤纶纤维。
上述医用口罩材料的制备方法，包括如下步骤：
(1)水刺无纺布层的制备：将竹浆纤维和涤纶纤维按比例混合后，经梳理、铺网、牵伸后进行多级高压水刺(一级压力100bar，牵伸100％；二级压力110bar，牵伸120％；三级压力150bar，牵伸120％；四级压力150bar，牵伸110％；五级压力100bar，牵伸100％)；然后进行四抗整理(将水刺无纺布层在三防整理剂中充分浸润，轧出多余水分后经过三道烘箱进行烘干及定型；三防整理剂由大金TG5243和TG5671按照质量比为1：2混配而成；三道烘干温度为：第一道烘箱温度120℃，第二道烘箱温度150℃，第三道烘箱温度180℃)；杀菌、分切、收卷得到水刺无纺布层；
(2)外防护层覆合：将市售聚氨酯粘合剂涂覆在水刺无纺布层表面形成粘合剂层，再将PTFE 薄膜覆盖在粘合剂层上方，经过加热辊加压复合(温度200℃，压力5公斤)；然后进行五级拉幅定型，每级拉伸率4％，冷却后收卷得到所述防护服材料。
实施例2：
一种基于水刺无纺材料的医用口罩材料，包括依次贴合的0.01mm外防护层、0.02mm粘合剂层以及经过拒水、拒油、抗血液和抗酒精四抗整理的0.40mm水刺无纺布层，外防护层为PTFE 薄膜；水刺无纺布层由质量比为1：1的竹浆纤维和抗菌涤纶纤维制成，面密度为：200g/m2，粘合剂层的粘合剂原料以重量份计包括：70份改性聚氨酯弹性体，50份纤维素基吸水保水剂， 15份松香甘油酯，10份医用级矿物油白油，4份碳酸氢钠和2份柠檬酸。
抗菌涤纶纤维的制备方法为：将壳聚糖加入2％乙酸溶液中，磁力搅拌20h后加入硝酸银，避光条件下磁力搅拌30min后将溶液经紫外线照射20min获得抗菌整理溶液，抗菌溶液中壳聚糖的质量分数为2％，硝酸银的质量分数为0.6％；用抗菌整理溶液采用两浸两轧的方法对涤纶纤维进行抗菌整理后得到所述抗菌涤纶纤维。
纤维素基吸水保水剂的制备方法为：将竹浆纤维分散在浓度为7wt％的NaOH溶液和浓度为11wt％的尿素溶液的混合液中，-15℃冷冻2h，得纤维素溶液，竹浆纤维和混合液的质量比为1：32；搅拌下向纤维素溶液中加入浓度为3wt％的壳聚糖溶液，至壳聚糖与竹浆纤维的质量比为1：4；搅拌均匀后逐滴加入与纤维素溶液质量比为1：40的体积分数2％的戊二醛溶液，75℃下反应1.5h，将产物洗涤干燥后得到所述吸水保水剂。
改性聚氨酯弹性体制备方法为：A)将活性炭在100℃下活化4h后分散于甲苯中得到分散液，活性炭和甲苯的比例为1g：80mL；B)向上述分散液中逐滴加入与活性炭的质量体积比为50g：1mL的2,4-甲苯二异氰酸酯和4滴二月桂酸二基丁锡，85℃下搅拌反应11h，过滤、洗涤、干燥后得到表面改性活性炭；C)将质量比为1：135：4.5的表面改性活性炭、脱水后的四氢呋喃聚醚和4-4’二苯甲烷二异氰酸酯混合，80℃反应2h，得到预聚体；D)将预聚体真空脱泡后加入与预聚体质量比为5.5：100的1,4-丁二醇，搅拌均匀后真空脱泡，浇入模具固化，105℃下熟化24h，研磨、造粒得到所述改性聚氨酯弹性体。
上述护服材料的制备方法，包括如下步骤：
(1)水刺无纺布层的制备：将竹浆纤维和抗菌涤纶纤维按比例混合后，经梳理、铺网、牵伸后进行多级高压水刺(一级压力100bar，牵伸100％；二级压力110bar，牵伸120％；三级压力150bar，牵伸120％；四级压力150bar，牵伸110％；五级压力100bar，牵伸100％)；然后进行四抗整理(将水刺无纺布层在三防整理剂中充分浸润，轧出多余水分后经过三道烘箱进行烘干及定型；三防整理剂由大金TG5243和TG5671按照质量比为1：2混配而成；三道烘干温度为：第一道烘箱温度120℃，第二道烘箱温度150℃，第三道烘箱温度180℃)；杀菌、分切、收卷得到水刺无纺布层；
(2)粘合剂的制备：将粘合剂原料按比例混合后加入密炼机中，155℃下混炼1.5h，得到所述粘合剂；
(3)外防护层覆合：将粘合剂涂覆在水刺无纺布层表面形成粘合剂层，再将PTFE薄膜覆盖在粘合剂层上方，经过加热辊加压复合(温度200℃，压力5公斤)，然后进行五级拉幅定型，每级拉伸率4％，冷却后收卷得到所述防护服材料。
实施例3：
一种基于水刺无纺材料的医用口罩材料，包括依次贴合的0.02mm外防护层、0.01mm粘合剂层以及经过拒水、拒油、抗血液和抗酒精四抗整理的0.25mm水刺无纺布层，外防护层为PTFE 薄膜；水刺无纺布层由质量比为1：1.5的竹浆纤维和抗菌涤纶纤维制成，面密度为：250g/m2；粘合剂层的粘合剂原料以重量份计包括：50份改性聚氨酯弹性体，20份纤维素基吸水保水剂， 10份松香甘油酯，5份医用级矿物油白油，0.6份碳酸氢钠和0.4份柠檬酸。
抗菌涤纶纤维的制备方法为：将壳聚糖加入3％乙酸溶液中，磁力搅拌30h后加入硝酸银，避光条件下磁力搅拌40min后将溶液经紫外线照射30min获得抗菌整理溶液，抗菌溶液中壳聚糖的质量分数为4％，硝酸银的质量分数为0.8％；用抗菌整理溶液采用两浸两轧的方法对涤纶纤维进行抗菌整理后得到所述抗菌涤纶纤维。
纤维素基吸水保水剂的制备方法为：将竹浆纤维分散在浓度为6wt％的NaOH溶液和浓度为10wt％的尿素溶液的混合液中，-20℃冷冻1h，得纤维素溶液，竹浆纤维和混合液的质量比为1：30；搅拌下向纤维素溶液中加入浓度为2wt％的壳聚糖溶液，至壳聚糖与竹浆纤维的质量比为1：3；搅拌均匀后逐滴加入与纤维素溶液质量比为1：30的体积分数2％的戊二醛溶液，70℃下反应1h，将产物洗涤干燥后得到所述吸水保水剂。
改性聚氨酯弹性体制备方法为：A)将活性炭在90℃下活化4.5h后分散于甲苯中得到分散液，活性炭和甲苯的比例为1g：50mL；B)向上述分散液中逐滴加入与活性炭的质量体积比为50g：1.5mL的2,4-甲苯二异氰酸酯和3滴二月桂酸二基丁锡，80℃下搅拌反应10h，过滤、洗涤、干燥后得到表面改性活性炭；C)将质量比为1：130：4的表面改性活性炭、脱水后的四氢呋喃聚醚和4-4’二苯甲烷二异氰酸酯混合，75℃反应1.5h，得到预聚体；D) 将预聚体真空脱泡后加入与预聚体质量比为5：100的1,4-丁二醇，搅拌均匀后真空脱泡，浇入模具固化，100℃下熟化20h，研磨、造粒得到所述改性聚氨酯弹性体。
上述护服材料的制备方法，包括如下步骤：
(1)水刺无纺布层的制备：将竹浆纤维和抗菌涤纶纤维按比例混合后，经梳理、铺网、牵伸后进行多级高压水刺(一级压力50bar，牵伸200％；二级压力90bar，牵伸150％；三级压力 100bar，牵伸150％；四级压力100bar，牵伸120％；五级压力80bar，牵伸120％)，然后进行四抗整理(将水刺无纺布层在三防整理剂中充分浸润，轧出多余水分后经过三道烘箱进行烘干及定型；三防整理剂由大金TG5243和TG5671按照质量比为1：2混配而成；三道烘干温度为：第一道烘箱温度115℃，第二道烘箱温度145℃，第三道烘箱温度175℃)，杀菌、分切、收卷得到水刺无纺布层；
(2)粘合剂的制备：将粘合剂原料按比例混合后加入密炼机中，150℃下混炼1h，得到所述粘合剂；
(3)外防护层覆合：将粘合剂涂覆在水刺无纺布层表面形成粘合剂层，再将PTFE薄膜覆盖在粘合剂层上方，经过加热辊加压复合(温度250℃，压力0.5公斤)，然后进行五级拉幅定型，每级拉伸率3％，冷却后收卷得到所述防护服材料。
实施例4：
一种基于水刺无纺材料的医用口罩材料，包括依次贴合的0.01mm外防护层、0.03mm粘合剂层以及经过拒水、拒油、抗血液和抗酒精四抗整理的0.55mm水刺无纺布层，外防护层为PTFE 薄膜；水刺无纺布层由质量比为1：2的竹浆纤维和抗菌涤纶纤维制成，面密度为：150g/m2；粘合剂层的粘合剂原料以重量份计包括：80份改性聚氨酯弹性体，60份纤维素基吸水保水剂， 20份松香甘油酯，20份医用级矿物油白油，7份碳酸氢钠和3份柠檬酸。
抗菌涤纶纤维的制备方法为：将壳聚糖加入3％乙酸溶液中，磁力搅拌20h后加入硝酸银，避光条件下磁力搅拌30min后将溶液经紫外线照射20min获得抗菌整理溶液，抗菌溶液中壳聚糖的质量分数为2％，硝酸银的质量分数为0.6％；用抗菌整理溶液采用两浸两轧的方法对涤纶纤维进行抗菌整理后得到所述抗菌涤纶纤维。
纤维素基吸水保水剂的制备方法为：将竹浆纤维分散在浓度为6wt％的NaOH溶液和浓度为10wt％的尿素溶液的混合液中，-20℃冷冻1h，得纤维素溶液，竹浆纤维和混合液的质量比为1：30；搅拌下向纤维素溶液中加入浓度为2wt％的壳聚糖溶液，至壳聚糖与竹浆纤维的质量比为1：3；搅拌均匀后逐滴加入与纤维素溶液质量比为1：30的体积分数2％的戊二醛溶液，70℃下反应1h，将产物洗涤干燥后得到所述吸水保水剂。
改性聚氨酯弹性体制备方法为：A)将活性炭在110℃下活化5h后分散于甲苯中得到分散液，活性炭和甲苯的比例为1g：100mL；B)向上述分散液中逐滴加入与活性炭的质量体积比为50g：2mL的2,4-甲苯二异氰酸酯和5滴二月桂酸二基丁锡，90℃下搅拌反应12h，过滤、洗涤、干燥后得到表面改性活性炭；C)将质量比为1：140：5的表面改性活性炭、脱水后的四氢呋喃聚醚和4-4’二苯甲烷二异氰酸酯混合，85℃反应2.5h，得到预聚体；D) 将预聚体真空脱泡后加入与预聚体质量比为6：100的1,4-丁二醇，搅拌均匀后真空脱泡，浇入模具固化，110℃下熟化30h，研磨、造粒得到所述改性聚氨酯弹性体。
上述护服材料的制备方法，包括如下步骤：
(1)水刺无纺布层的制备：将竹浆纤维和抗菌涤纶纤维按比例混合后，经梳理、铺网、牵伸后进行多级高压水刺(一级压力150bar，牵伸90％；二级压力130bar，牵伸100％；三级压力180bar，牵伸100％；四级压力200bar，牵伸100％；五级压力150bar，牵伸90％)，然后进行四抗整理(将水刺无纺布层在三防整理剂中充分浸润，轧出多余水分后经过三道烘箱进行烘干及定型；三防整理剂由大金TG5243和TG5671按照质量比为1：2混配而成；三道烘干温度为：第一道烘箱温度125℃，第二道烘箱温度155℃，第三道烘箱温度185℃)，杀菌、分切、收卷得到水刺无纺布层；
(2)粘合剂的制备：将粘合剂原料按比例混合后加入密炼机中，150℃下混炼1h，得到所述粘合剂；
(3)外防护层覆合：将粘合剂涂覆在水刺无纺布层表面形成粘合剂层，再将PTFE薄膜覆盖在粘合剂层上方，经过加热辊加压复合(温度150℃，压力8公斤)，然后进行五级拉幅定型，每级拉伸率5％，冷却后收卷得到所述防护服材料。
对比例1：
对比例1与实施例1的区别在于，对比例1中的无纺布层不经四抗整理，其余均与实施例1 中相同。
对比例2：
对比例2与实施例1的区别在于，对比例2中的外防护层使用PE膜，其余均与实施例1中相同。
对比例3：
对比例3与实施例1的区别在于，对比例3中步骤(2)中不采用多级拉幅定型，而是一次拉伸，其余均与实施例1中相同。
对比例4：
对比例4与实施例1的区别在于，对比例4中使用的涤纶纤维不经抗菌整理，其余均与实施例1中相同。
对上述实施例和对比例中制得的防护服材料的断裂强力(GB/T 24218.3)、抗渗水性 (GB/T 4744)、透湿量、贴身一侧的液体穿透时间进行测试(测试液体穿透时间时，用3mL滴管在贴身一侧距其表面2cm处，从5处不同位置分别滴1滴液滴，记录液滴从珠状到消失所需的时间，求平均值，作为贴身一侧的液体穿透时间)，结果如表1所示。
表1：医用口罩材料防护性测试结果。
| 编号 | 断裂强力(N) | 抗渗水性(cm H<sub>2</sub>O) | 透湿量(g/(m<sup>2</sup>·d)) | 液体穿透时间(s) |
| 实施例1 | 24 | 26 | 2994 | ＞120 |
| 实施例2 | 25 | 26 | 3033 | 53 |
| 实施例3 | 23 | 26 | 3054 | 48 |
| 实施例4 | 27 | 27 | 2984 | 62 |
| 对比例1 | 25 | 17 | 2989 | ＞120 |
| 对比例2 | 25 | 26 | 2352 | ＞120 |
| 对比例3 | 20 | 25 | 2478 | ＞120 |
| 对比例4 | 25 | 26 | 2968 | ＞120 |
采用琼脂平皿扩散法对上述实施例和对比例中制得的抗菌涤纶纤维进行抑菌性能测试，选用大肠杆菌和金黄色葡萄球菌作为试验菌种，结果如表2所示。
表2：抑菌圈直径(mm)。
从表1中可以看出，实施例1～4中采用本发明中的原料和方法制备出的医用口罩材料，断裂强力、抗渗水性及透湿量等性能均良好，满足防护和透气要求。而对比例1中的水刺无纺布层不经四抗整理，其防护性能达不到要求；对比例2中的外防护层采用PE薄膜代替本发明中的PTFE薄膜，其透湿量比实施例1中有显著降低，影响佩戴舒适性；对比例3中定型时没有采用多级拉伸定型工艺，材料的断裂强力和透湿量均有降低。而实施例2～4中的粘合剂层采用本发明中的方法制备的粘合剂，与实施例1中使用市售聚氨酯粘合剂相比，贴身一侧的液体穿透时间大大降低，证明使用本发明中的水胶体材料粘合剂可以实现单向导湿作用，有利于水分的导出，提高佩戴舒适性。
从表2中可以看出，使用本发明的抗菌整理溶液经抗菌整理后的涤纶纤维，具有良好的抑菌效果，可以对人体进行有效防护。
Claims (7)
1.一种基于水刺无纺材料的医用口罩材料，其特征是，包括依次贴合的外防护层、粘合剂层以及经过拒水、拒油、抗血液和抗酒精四抗整理的水刺无纺布层，所述外防护层为PTFE薄膜，所述水刺无纺布层由质量比为1：（1~2）的竹浆纤维和抗菌涤纶纤维制成，面密度为150~250g/m2，所述外防护层的厚度为0.01~0.02mm；粘合剂层的厚度为0.01~0.03mm；水刺无纺布层的厚度为0.25~0.55mm；
所述粘合剂层的粘合剂原料以重量份计包括：50~80份粘合剂基体，20~60份纤维素基吸水保水剂，10~20份增粘树脂，5~20份矿物油，1~10份发泡剂；所述纤维素基吸水保水剂的制备方法为：将竹浆纤维分散在浓度为6~8wt%的NaOH溶液和浓度为10~12wt%的尿素溶液的混合液中，-20~-10℃冷冻1~3h，得纤维素溶液，竹浆纤维和混合液的质量比为1：（30~35）；搅拌下向纤维素溶液中加入浓度为2~4wt%的壳聚糖溶液，至壳聚糖与竹浆纤维的质量比为（1~2）：4；搅拌均匀后逐滴加入与纤维素溶液质量比为1：（30~50）的体积分数2~3%的戊二醛溶液，70~80℃下反应1~2h，将产物洗涤干燥后得到所述吸水保水剂；
所述粘合剂基体为改性聚氨酯弹性体，其制备方法为：
A）将活性炭在90~110℃下活化4~5h后分散于甲苯中得到分散液，活性炭和甲苯的比例为1g：（50~100mL）；
B）向上述分散液中逐滴加入与活性炭的质量体积比为50g：（1~2mL）的2,4-甲苯二异氰酸酯和3~5滴二月桂酸二基丁锡，80~90℃下搅拌反应10~12h，过滤、洗涤、干燥后得到表面改性活性炭；
C）将质量比为1：（130~140）：（4~5）的表面改性活性炭、脱水后的四氢呋喃聚醚和4-4’二苯甲烷二异氰酸酯混合，75~85℃反应1.5~2.5h，得到预聚体；
D）将预聚体真空脱泡后加入与预聚体质量比为（5~6）：100的1,4-丁二醇，搅拌均匀后真空脱泡，浇入模具固化，100~110℃下熟化20~30h，研磨、造粒得到所述改性聚氨酯弹性体。
2.根据权利要求1所述的一种基于水刺无纺材料的医用口罩材料，其特征是，所述抗菌涤纶纤维的制备方法为：将壳聚糖加入2~3%乙酸溶液中，磁力搅拌20~30h后加入硝酸银，避光条件下磁力搅拌30~40min后将溶液经紫外线照射20~30min获得抗菌整理溶液，抗菌溶液中壳聚糖的质量分数为2~4%，硝酸银的质量分数为0.6~0.8%；用抗菌整理溶液采用两浸两轧的方法对涤纶纤维进行抗菌整理后得到所述抗菌涤纶纤维。
3.根据权利要求1所述的一种基于水刺无纺材料的医用口罩材料，其特征是，所述增粘树脂为石油树脂、松香甘油酯、脂松香、二萜烯聚合物中的一种或几种；所述发泡剂为摩尔比（1.5~2.5）：1的碳酸氢钠和柠檬酸。
4.一种如权利要求1~3任一所述的医用口罩材料的制备方法，其特征是，包括如下步骤：
（1）水刺无纺布层的制备：将竹浆纤维和抗菌涤纶纤维按比例混合后，经梳理、铺网、牵伸后进行高压水刺，然后经过四抗整理后高温烘干并杀菌、分切、收卷得到水刺无纺布层；
（2）粘合剂的制备：将粘合剂原料按比例混合后加入密炼机中，150~160℃下混炼1~2h，得到所述粘合剂；
（3）外防护层覆合：将上述制得的粘合剂涂覆在水刺无纺布层表面形成粘合剂层，再将PTFE薄膜覆盖在粘合剂层上方，经过加热辊加压复合，然后进行多级拉幅定型，冷却后收卷得到所述医用口罩材料。
5.根据权利要求4所述的一种医用口罩材料制备方法，其特征是，步骤（1）中高压水刺工序采用多级水刺工艺：一级压力50~150bar，牵伸90~200%；二级压力90~130bar，牵伸100~150%；三级压力100~180bar，牵伸100~150%；四级压力100~200bar，牵伸100~120%；五级压力80~150bar，牵伸90~120%。
6.根据权利要求4或5所述的一种医用口罩材料制备方法，其特征是，步骤（1）中四抗整理的方法为：步骤（1）中四抗整理的方法为：将水刺无纺布层在三防整理剂中充分浸润，轧出多余水分后经过三道烘箱进行烘干及定型，所述三道烘箱 温度分别为：第一道烘箱温度115~125℃，第二道烘箱温度145~155℃，第三道烘箱温度175~185℃。
7.根据权利要求4所述的一种医用口罩材料制备方法，其特征是，步骤（3）中加压复合时的温度为150~250℃，压力为0.5~8公斤；多级拉幅定型时进行五级拉伸，每级拉伸率3~5%。
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