CN111671180A - 一种叠层复合功能性口罩滤芯、口罩及制备方法 - Google Patents
一种叠层复合功能性口罩滤芯、口罩及制备方法 Download PDFInfo
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Abstract
本发明公开了一种叠层复合功能性口罩滤芯、口罩及制备方法,口罩滤芯,由内到外依次设置亲肤吸湿层、过滤层、抑菌过滤层和防护层,这四层结构之间通过碳纤维短切针刺结构形成整体;亲肤吸湿层和防护层均为纺粘无纺布,抑菌过滤层为活性碳纤维层,过滤层为熔喷无纺布层。
Description
技术领域
本发明属于口罩技术领域,具体涉及一种叠层复合功能性口罩滤芯、口罩及制备方法,可实现对不同微颗粒和病菌的过滤和杀灭,同时具有除臭功能,保证口罩使用的舒适性。
背景技术
公开该背景技术部分的信息仅仅旨在增加对本发明的总体背景的理解,而不必然被视为承认或以任何形式暗示该信息构成已经成为本领域一般技术人员所公知的现有技术。
传统的医用一次性口罩均采用聚丙烯纤维的熔喷无纺布和纺粘无纺布叠层组合加工,利用超细纤维的多孔隙结构对粉尘、病菌或其它有毒害物质微粒起到过滤和阻隔作用。这种常用的叠层过滤材料采用的是层间的热贴合结构,各层之间的粘附力受到加工工艺的限制。此外,目前的无纺布材质主要为聚丙烯单一材料,无法做到对各种粒径的微颗粒的广泛吸附和过滤。
发明内容
为了解决现有技术中存在的技术问题,本发明的目的是提供一种叠层复合功能性口罩滤芯、口罩及制备方法。
为实现上述发明目的,本发明的一个或多个实施例公开了以下技术方案:
本发明一方面提供了一种叠层复合功能性口罩滤芯,由内到外依次设置亲肤吸湿层、过滤层、抑菌过滤层和防护层,这四层结构之间通过碳纤维短切针刺结构形成整体;
亲肤吸湿层和防护层均为纺粘无纺布,抑菌过滤层为活性碳纤维层,过滤层为熔喷无纺布层。
本发明的第二方面,提供一种口罩,包括所述叠层复合功能性口罩滤芯。
本发明的第三方面,提供上述叠层复合功能性口罩滤芯的制备方法,包括如下步骤:
对活性碳纤维层进行抑菌功能化处理,制得抑菌过滤层;
对纺粘无纺布的纤维单丝进行表面处理,得亲肤吸湿层;
将防护层、抑菌过滤层、过滤层和亲肤吸湿层依次叠加,然后通过碳纤维短切针刺形成整体。
与现有技术相比,本发明的以上一个或多个技术方案取得了以下有益效果:
活性碳纤维织物材料具有较发达的孔隙过滤结构,可以提高口罩滤芯的过滤吸附能力,扩大对各种粒径的微颗粒的吸附和过滤能力,同时可以改善口罩使用过程的舒适性。对活性碳纤维层进行抑菌功能化处理,可以提高其抑菌性能,以延长口罩的质量和使用寿命。
对纺粘无纺布的纤维单丝进行表面处理,可以提高该层的吸水性能,将该层作为内层使用时,进而提高口罩的使用舒适性。
附图说明
构成本发明的一部分的说明书附图用来提供对本发明的进一步理解,本发明的示意性实施例及其说明用于解释本发明,并不构成对本发明的不当限定。
图1为本发明实施例的一种叠层复合功能性口罩滤芯的叠层结构示意图。
其中,1、防护层,2、抑菌过滤层,3、过滤层,4、亲肤吸湿层。
具体实施方式
应该指出,以下详细说明都是示例性的,旨在对本发明提供进一步的说明。除非另有指明,本文使用的所有技术和科学术语具有与本发明所属技术领域的普通技术人员通常理解的相同含义。
需要注意的是,这里所使用的术语仅是为了描述具体实施方式,而非意图限制根据本发明的示例性实施方式。如在这里所使用的,除非上下文另外明确指出,否则单数形式也意图包括复数形式,此外,还应当理解的是,当在本说明书中使用术语“包含”和/或“包括”时,其指明存在特征、步骤、操作、器件、组件和/或它们的组合。
本发明一方面提供了一种叠层复合功能性口罩滤芯,由内到外依次设置亲肤吸湿层、过滤层、抑菌过滤层和防护层,这四层结构之间通过碳纤维短切针刺结构形成整体;
亲肤吸湿层和防护层均为纺粘无纺布,抑菌过滤层为活性碳纤维层,过滤层为熔喷无纺布层。
在一些实施例中,防护层的原料选自涤纶、丙纶、锦纶、氨纶或腈纶纤维。
进一步的,防护层的克重为20-30g/m2。单片克重控制在0.6-0.9克范围内。
在一些实施例中,所述抑菌过滤层中碳纤维的比表面积为1500-2500m2/g。
进一步的,抑菌过滤层的碳纤维单丝表面的平均孔径为1-4nm。
进一步的,所述抑菌过滤层的克重为20-30g/m2。单片克重控制在0.4-0.8 克范围内。
在一些实施例中,所述抑菌过滤层中的碳纤维选自T300、T700、T800、 T1000或黏胶基碳纤维。
在一些实施例中,所述过滤层的纤维选自涤纶、丙纶、锦纶、氨纶或腈纶纤维,或选自聚苯硫醚、聚醚醚酮、对苯二甲酸乙二醇酯或对苯二甲酸丁二醇酯制备的纤维。
在一些实施例中,所述过滤层为网状层叠结构。
进一步的,所述过滤层的单层网状过滤层的厚度为0.5-1mm。
更进一步的,所述过滤层的体密度为0.05-0.1g/cm3。熔喷无纺布过滤层的克重控制在20-30g/m2,单片克重控制在0.4-0.8克范围内。
在一些实施例中,所述亲肤吸湿层的材质选自涤纶、丙纶、锦纶、氨纶或腈纶纤维。
进一步的,亲肤吸湿层的克重为20-30g/m2,单片克重控制在0.6-0.9克范围内。
在一些实施例中,碳纤维短切针刺结构的密度为5-10针/cm2。
本发明的第二方面,提供一种口罩,包括所述叠层复合功能性口罩滤芯。
本发明的第三方面,提供上述叠层复合功能性口罩滤芯的制备方法,包括如下步骤:
对活性碳纤维层进行抑菌功能化处理,制得抑菌过滤层;
对纺粘无纺布的纤维单丝进行表面处理,得亲肤吸湿层;
将防护层、抑菌过滤层、过滤层和亲肤吸湿层依次叠加,然后通过碳纤维短切针刺形成整体。
在一些实施例中,对活性碳纤维层进行抑菌功能化处理的方法,包括如下步骤:
将活性碳纤维层在120-140℃真空脱气1-3小时;抽真空处理,将内部空气抽出。
将脱气后的活性碳纤维层浸渍在纳米二氧化钛或纳米银的水溶液中设定时间,干燥后即可。
进一步的,所述水溶液中纳米二氧化钛或纳米银的质量百分数为1.5-2.5%。
更进一步的,所述水溶液中纳米二氧化钛或纳米银的质量百分数为2-2.5%。
进一步的,干燥的温度为75-85℃,优选为80℃。干燥的温度过高会导致纤维损伤。
在一些实施例中,对纺粘无纺布的纤维单丝进行表面处理的方法,包括如下步骤:
向去离子水中加入有机酸,调节pH值为3-7;
向其中加入偶联剂,混合均匀,得处理液;
将防粘无纺布浸渍于处理液中,超声处理5-10min,干燥,即可。
进一步的,所述有机酸选自甲酸、乙酸或草酸中的一种或多种。采用弱酸进行处理,便于控制处理效果。
进一步的,所述偶联剂为硅烷偶联剂。
更进一步的,处理液中,偶联剂的浓度为0.1-1.0%。
进一步的,干燥的温度为60-80℃,干燥的时间为20-50min。
实施例1
本发明一种叠层组合设计的功能性口罩滤芯结构,具体的采用20g/m2克重的涤纶纤维制备单片克重为0.6克的纺粘无纺布防护层。
采用T300碳纤维长丝为原材料制备比表面积在500m2/g的单丝表面平均孔径1.0nm的、克重20g/m2的活性碳纤维抑菌过滤层,单片克重控制在0.4克。活性碳纤维的抑菌功能化处理,首先将活性碳纤维进行真空在130℃脱气处理 1小时,之后采用纳米二氧化钛的1.5%浓度的水溶液进行浸渍,80℃干燥2小时。
选用涤纶纤维制备纤维比表面积在0.01m2/g、体密度0.05g/cm3的熔喷无纺布过滤层,熔喷无纺布过滤层单层网状过滤层厚度在0.5mm,克重控制在20 g/m2,单片克重控制在0.4克。
制备纺粘无纺布亲肤吸湿层的纤维单丝进行表面特性处理,采用甲酸调节去离子水的pH值为3,之后选用KH550偶联剂与酸化的去离子水溶液在50℃下磁力搅拌下配成浓度为0.1%的处理液,之后将碳纤维超声处理浸渍5min于该溶液中,取出后60℃干燥20min。
最终将上述纺粘无纺布防护层、活性碳纤维抑菌过滤层、熔喷无纺布过滤层、纺粘无纺布亲肤吸湿层之间通过碳纤维短切针刺形成整体,针刺密度控制 5针/cm2形成口罩滤芯材料。
实施例2
本发明一种叠层组合设计的功能性口罩滤芯结构,具体的采用30g/m2克重的腈纶纤维制备单片克重为0.9克的纺粘无纺布防护层。
采用T1000碳纤维长丝为原材料制备比表面积在2500m2/g的单丝表面平均孔径4.0nm的、克重30g/m2的活性碳纤维抑菌过滤层,单片克重控制在0.8 克。活性碳纤维的抑菌功能化处理,首先将活性碳纤维进行真空在130℃脱气处理3小时,之后采用纳米银的2.5%浓度的水溶液进行浸渍,在80℃干燥4 小时。
选用聚苯硫醚热塑性纤维制备纤维比表面积0.1m2/g、体密度0.1g/cm3的熔喷无纺布过滤层,熔喷无纺布过滤层单层网状过滤层厚度在1mm,克重30 g/m2,单片克重控制在0.8克。
制备纺粘无纺布亲肤吸湿层的纤维单丝进行表面特性处理,采用乙酸调节去离子水的pH值在4,之后选用KH560偶联剂与酸化的去离子水溶液在60℃下磁力搅拌下配成浓度为1.0%的处理液,之后将碳纤维超声处理浸渍10min 该溶液,取出后80℃干燥50min。
最终将上述纺粘无纺布防护层、活性碳纤维抑菌过滤层、熔喷无纺布过滤层、纺粘无纺布亲肤吸湿层之间通过碳纤维短切针刺形成整体,针刺密度控制 10针/cm2形成口罩滤芯材料。
实施例3
本发明一种叠层组合设计的功能性口罩滤芯结构,具体的采用20-30g/m2克重的锦纶纤维制备单片克重为0.9克的纺粘无纺布防护层。
采用T700碳纤维长丝为原材料制备比表面积在2500m2/g的单丝表面平均孔径3.0nm的、克重30g/m2的活性碳纤维抑菌过滤层,单片克重在0.5克。活性碳纤维的抑菌功能化处理,首先将活性碳纤维进行真空在130℃脱气处理2 小时,之后采用纳米银的1%浓度的水溶液进行浸渍,在80℃干燥3小时。
选用对苯二甲酸乙二醇酯热塑性纤维制备纤维比表面积在0.1m2/g、体密度0.06g/cm3的熔喷无纺布过滤层,熔喷无纺布过滤层单层网状过滤层厚度在 0.7mm,克重控制在25g/m2,单片克重控制在0.7克。
制备纺粘无纺布亲肤吸湿层的纤维单丝进行表面特性处理,采用乙酸调节去离子水的PH值在6,之后选用KH570偶联剂与酸化的去离子水溶液在55℃下磁力搅拌下配成浓度为0.6%的处理液,之后将碳纤维超声处理浸渍7min该溶液,取出后65℃干燥25min。
最终将上述纺粘无纺布防护层、活性碳纤维抑菌过滤层、熔喷无纺布过滤层、纺粘无纺布亲肤吸湿层之间通过碳纤维短切针刺形成整体,针刺密度控制 6针/cm2形成口罩滤芯材料。
实施例4
本发明一种叠层组合设计的功能性口罩滤芯结构,具体的采用28g/m2克重的氨纶纤维制备单片克重为0.7克的纺粘无纺布防护层。
采用黏胶基碳纤维长丝为原材料制备比表面积在2400m2/g的单丝表面平均孔径2.0nm的、克重22g/m2的活性碳纤维抑菌过滤层,单片克重控制在0.5克。活性碳纤维的抑菌功能化处理,首先将活性碳纤维进行真空在130℃脱气处理 2小时,之后采用纳米二氧化钛的1.7%浓度的水溶液进行浸渍,在80℃干燥 2.5小时。
选用氨纶纤维制备纤维比表面积在0.09m2/g、体密度0.09g/cm3的熔喷无纺布过滤层,熔喷无纺布过滤层单层网状过滤层厚度在0.8mm,克重控制在27 g/m2,单片克重控制在0.7克。
制备纺粘无纺布亲肤吸湿层的纤维单丝进行表面特性处理,采用草酸调节去离子水的pH值在6,之后选用A-186偶联剂与酸化的去离子水溶液在50℃下磁力搅拌下配成浓度为1.0%的处理液,之后将碳纤维超声处理浸渍10min 该溶液,取出后80℃干燥50min。
最终将上述纺粘无纺布防护层、活性碳纤维抑菌过滤层、熔喷无纺布过滤层、纺粘无纺布亲肤吸湿层之间通过碳纤维短切针刺形成整体,针刺密度控制 9针/cm2形成口罩滤芯材料。
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,对于本领域的技术人员来说,本发明可以有各种更改和变化。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 (10)
1.一种叠层复合功能性口罩滤芯,其特征在于:由内到外依次设置亲肤吸湿层、过滤层、抑菌过滤层和防护层,这四层结构之间通过碳纤维短切针刺结构形成整体;
亲肤吸湿层和防护层均为纺粘无纺布,抑菌过滤层为活性碳纤维层,过滤层为熔喷无纺布层。
2.根据权利要求1所述的叠层复合功能性口罩滤芯,其特征在于:防护层的原料选自涤纶、丙纶、锦纶、氨纶或腈纶纤维;
进一步的,防护层的克重为20-30g/m2;
或,所述抑菌过滤层中碳纤维的比表面积为1500-2500m2/g;
进一步的,抑菌过滤层的碳纤维单丝表面的平均孔径为1-4nm;
进一步的,所述抑菌过滤层的克重为20-30g/m2;
进一步的,所述抑菌过滤层中的碳纤维选自T300、T700、T800、T1000或黏胶基碳纤维。
3.根据权利要求1所述的叠层复合功能性口罩滤芯,其特征在于:所述过滤层的纤维选自涤纶、丙纶、锦纶、氨纶或腈纶纤维,或选自聚苯硫醚、聚醚醚酮、对苯二甲酸乙二醇酯或对苯二甲酸丁二醇酯制备的纤维;
进一步的,所述过滤层为网状层叠结构;
进一步的,所述过滤层的单层网状过滤层的厚度为0.5-1mm;
更进一步的,所述过滤层的体密度为0.05-0.1g/cm3。
4.根据权利要求1所述的叠层复合功能性口罩滤芯,其特征在于:所述亲肤吸湿层的材质选自涤纶、丙纶、锦纶、氨纶或腈纶纤维;
进一步的,亲肤吸湿层的克重为20-30g/m2;
或,碳纤维短切针刺结构的密度为5-10针/cm2。
5.一种口罩,其特征在于:包括权利要求1-4任一所述叠层复合功能性口罩滤芯。
6.权利要求1-4任一所述叠层复合功能性口罩滤芯的制备方法,其特征在于:包括如下步骤:
对活性碳纤维层进行抑菌功能化处理,制得抑菌过滤层;
对纺粘无纺布的纤维单丝进行表面处理,得亲肤吸湿层;
将防护层、抑菌过滤层、过滤层和亲肤吸湿层依次叠加,然后通过碳纤维短切针刺形成整体。
7.根据权利要求6所述的制备方法,其特征在于:对活性碳纤维层进行抑菌功能化处理的方法,包括如下步骤:
将活性碳纤维层在120-140℃真空脱气1-3小时;
将脱气后的活性碳纤维层浸渍在纳米二氧化钛或纳米银的水溶液中设定时间,干燥后即可。
8.根据权利要求7所述的制备方法,其特征在于:所述水溶液中纳米二氧化钛或纳米银的质量百分数为1.5-2.5%;
更进一步的,所述水溶液中纳米二氧化钛或纳米银的质量百分数为2-2.5%。
进一步的,干燥的温度为75-85℃,优选为80℃。
9.根据权利要求6所述的制备方法,其特征在于:对纺粘无纺布的纤维单丝进行表面处理的方法,包括如下步骤:
向去离子水中加入有机酸,调节pH值为3-7;
向其中加入偶联剂,混合均匀,得处理液;
将防粘无纺布浸渍于处理液中,超声处理5-10min,干燥,即可。
10.根据权利要求9所述的制备方法,其特征在于:所述有机酸选自甲酸、乙酸或草酸中的一种或多种;
进一步的,所述偶联剂为硅烷偶联剂;
更进一步的,处理液中,偶联剂的浓度为0.1-1.0%;
进一步的,干燥的温度为60-80℃,干燥的时间为20-50min。
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