CN112192915A - 一种医用抗菌复合无纺布的制备方法 - Google Patents
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Abstract
本发明公开了一种医用抗菌复合无纺布的制备方法，所述复合无纺布包括防水层、吸水层和接触层；所述防水层为经过抗菌、疏水整理后的无纺布，所述吸水层为聚丙烯纤维与高吸水树脂经水刺工艺而成的无纺布，所述接触层为抗菌、柔软的无纺布；所述防水层、吸水层和接触层通过热压粘合。本发明提供的医用无纺布具有柔软亲肤、抗菌吸水、防水防渗、使用舒适等优势。
Description
技术领域
本发明涉及一种无纺布的制备方法，具体而言涉及一种医用抗菌复合无纺布的制备方法。
背景技术
医用材料主要有合成纤维无纺布和全棉无纺布，合成纤维无纺布的成份一般为70％粘胶、30涤纶(含石油合成原料)，其原料资源具有不可再生性，生产成本造价高，使用后销毁成本高，且不环保，同时在使用过程中，部分使用者会对其材料过敏，所以合成纤维无纺布医用材料应用并不广泛。而医疗卫生用全棉水刺无纺布因其原料是天然棉花，原料充足、处理简单，且医疗、卫生用全棉水刺无纺布具有柔软、环保、吸水性好，无毒无刺激无致敏性，使用方便舒适，避免了合成纤维无纺布因其化学成分对人体的损害，因而得到广泛使用。
目前抗菌非织造布主要由两种方法制得：一种是直接采用抗菌纤维通过水刺、针刺等非织造布工艺制备抗菌非织造布，另一种是将非织造布通过抗菌整理剂整理而获得抗菌性能。比较而言，前者抗菌效果较持久，耐洗性好，技术含量高，生产成本大。而后者加工处理比较简单，其耐洗性及抗菌效果持久性一般较差。
根据抗菌整理剂和非织造布的结合以及抗菌作用的形式，抗菌整理剂可以分为溶出型和非溶出型两大类。溶出型抗菌整理剂不与纤维发生化学结合，在使用过程中可以向周围扩散并形成抑菌环，在抑菌环内的微生物均被杀灭并不生长，达到抗菌效果。非溶出型抗菌整理剂能与纤维以化学键结合，这种效果较持久，它主要靠抗菌整理剂直接与微生物接触，使微生物无法存活、繁殖，也称吸附抗菌。
为了保证日用产品吸水性能，用于抗菌整理剂的多为溶出型抗菌剂，如银离子抗菌剂，植物抗菌精油或提取物等。溶出型抗菌剂虽然可以杀死微生物，但其与无纺布的结合不够牢固，影响抗菌效果。
此外，很多医用无纺布需要直接与使用者的皮肤接触，皮肤上通常会有创口，创口会有血液、黏液等渗出，因此，对于医用无纺布的要求除了抗菌之外，还需要柔软亲肤、吸水快、不反渗，能与外界环境之间形成隔离屏障，防止外界细菌侵入等。
发明内容
针对现有技术的不足，本发明的目的在于提供一种柔软亲肤、抗菌吸水、防水防渗、使用舒适的医用无纺布。
本发明解决技术问题所采用的技术方案是：一种医用抗菌复合无纺布的制备方法，所述复合无纺布包括防水层、吸水层和接触层；所述防水层为经过抗菌、疏水整理后的无纺布，所述吸水层为聚丙烯纤维与高吸水树脂经水刺工艺而成的无纺布，所述接触层为抗菌、柔软的无纺布；所述防水层、吸水层和接触层通过热压粘合。
进一步地，所述防水层的制备方法如下：S1，将无纺布先在抗菌整理剂中进行抗菌整理，烘干；S2，将S1中经过抗菌整理的无纺布用疏水整理液进行疏水整理，烘干；S3，将S2中经过疏水整理的无纺布多层复合，水刺处理后得到防水层。
进一步地，所述的抗菌整理剂包括浓度为0.1～30g/L的有机硅季铵盐、浓度为0.1～10g/L的聚乙二醇醚衍生物。
进一步地，所述疏水整理液的制备过程为：将正硅酸四乙酯加入水和乙醇的混合溶液中，搅拌下加入3-氨基丙基三甲氧基硅烷，搅拌均匀后加入氨水，反应4-5h后滴加十六烷基三甲氧基硅烷，继续反应4-5h，乙醇与水的重量比是 10：(1-1.2)，氨水与水的重量比为(1.3～1.5)：1；正硅酸四乙酯的添加量为混合溶液的3～3.5％，3-氨基丙基三甲氧基硅烷和十六烷基三甲氧基硅烷的添加量为混合溶液的1.5～1.8％。
进一步地，所述吸水层的制备方法如下：S1，将聚丙烯纤维除杂、梳理、铺网，加工得到聚丙烯无纺布基层；S2，取若干上述S1得到的聚丙烯无纺布基层，在任意两层之间均匀铺设高吸水树脂，得到吸水层复合结构；S3，通过水刺处理S2中得到的复合结构，各基层之间相互交联缠绕，得到含有高吸水树脂的聚丙烯无纺布作为吸水层。
进一步地，所述吸水层中，聚丙烯无纺布基层的数量为2～6层。
进一步地，所述接触层的制备方法如下：S1，将亲水纤维进行除杂、梳理、除去纤维表面的油溶性物质，烘干；S2，将S1处理后的亲水纤维加热搓洗、高速搅拌，清洗烘干；S3，将S2处理后的亲水纤维冷冻、干燥；S4，用抗菌整理液浸轧S3处理后的亲水纤维，烘干；S5，将S4处理后的抗菌亲水纤维梳理、铺网、水刺，得到水刺抗菌亲水无纺布作为接触层。
进一步地，所述亲水纤维为棉纤维、粘胶纤维、蚕丝纤维、丝光羊毛纤维中的一种或者两种以上的组合。
进一步地，所述抗菌整理液为含有质量百分数为0.1％～15％银离子抗菌剂的水溶液；按质量百分比计，所述银离子抗菌剂包括：银离子氨水溶液50％～ 70％、乙二胺四乙酸钠10％～20％、壳聚糖10％～40％。
进一步地，所述S3中，冷冻的温度为-70～-80℃，冷冻处理的时间为24～ 48h。
本发明的有益效果是：与现有技术中相比，本发明制备的医用抗菌无纺布包括了防水层、吸水层和接触层。
(1)防水层采用了抗菌疏水处理，为无纺布提供一道屏障，可防止外界病菌侵入，防水层采用先抗菌整理后疏水整理，采用的抗菌剂为有机硅季铵盐，采用聚乙二醇醚衍生物作为渗透剂，经过抗菌整理后的无纺布与疏水整理液之间有更好的结合效果，使得整理后的防水层无纺布具有非常好的抗菌、防水效果，同时又不会影响无纺布的透气性。
(2)吸水层中采用了聚丙烯纤维与高吸水树脂，高吸水树脂设于任意两层聚丙烯无纺布之间，通过水刺工艺复合，使得高吸水树脂在吸水层中分布更加均匀，且水刺工艺使得到的吸水层较为蓬松，聚丙烯纤维在各层之间穿插缠绕，形成无数个小蓬松空间，在这些小蓬松空间内均分布有高吸水树脂，这些高吸水树脂在吸水后膨胀，但由于高吸水树脂分布在各个小蓬松空间内，可防止高吸水树脂之间吸水后发生粘连结块，影响使用。
(3)接触层采用的亲水纤维，经过除油、搓洗或搅拌后，会加剧纤维垂直于纤维轴向的断裂，产生较多的纤维截断和不完全断口，冷冻处理引入的水结晶会将不完全断口撑开，导致纤维截断进一步增多，处理后的纤维具有更强的吸附能力；处理后的亲水纤维再用银离子抗菌剂进行抗菌整理，此时由于处理后的中空纤维的毛细管作用，更有利于对银离子抗菌剂的吸附，使得接触层的抗菌效果比较理想。此外，经过处理后的亲水纤维还具有很好的柔软度和亲肤性，当接触层直接与皮肤和创口接触时，会非常舒适，当创口有渗液时，会迅速被接触层吸收，在接触层内杀菌后进入吸水层内，被吸水层内的高吸水树脂锁定，使皮肤和创口保持无菌干燥，有利于恢复。
具体实施方式
下面通过具体实施例来进一步说明本发明。但这些实例仅用于说明本发明而不用于限制本发明的范围。
实施例1
一种医用抗菌复合无纺布的制备方法，所述复合无纺布包括防水层、吸水层和接触层；所述防水层为经过抗菌、疏水整理后的无纺布，所述吸水层为聚丙烯纤维与高吸水树脂经水刺工艺而成的无纺布，所述接触层为抗菌、柔软的无纺布；所述防水层、吸水层和接触层通过热压粘合。
所述防水层的制备方法如下：S1，将无纺布先在抗菌整理剂中进行抗菌整理，烘干；S2，将S1中经过抗菌整理的无纺布用疏水整理液进行疏水整理，烘干；S3，将S2中经过疏水整理的无纺布多层复合，水刺处理后得到防水层。
所述的抗菌整理剂包括浓度为5g/L的有机硅季铵盐、浓度为2g/L的聚乙二醇醚衍生物。
所述疏水整理液的制备过程为：将正硅酸四乙酯加入水和乙醇的混合溶液中，搅拌下加入3-氨基丙基三甲氧基硅烷，搅拌均匀后加入氨水，反应4-5h后滴加十六烷基三甲氧基硅烷，继续反应4-5h，乙醇与水的重量比是10：1，氨水与水的重量比为1.3：1；正硅酸四乙酯的添加量为混合溶液的3％，3-氨基丙基三甲氧基硅烷和十六烷基三甲氧基硅烷的添加量为混合溶液的1.8％。
所述吸水层的制备方法如下：S1，将聚丙烯纤维除杂、梳理、铺网，加工得到聚丙烯无纺布基层；S2，取若干上述S1得到的聚丙烯无纺布基层，在任意两层之间均匀铺设高吸水树脂，得到吸水层复合结构；S3，通过水刺处理S2中得到的复合结构，各基层之间相互交联缠绕，得到含有高吸水树脂的聚丙烯无纺布作为吸水层。所述吸水层中，聚丙烯无纺布基层的数量为2层。
所述接触层的制备方法如下：S1，将棉纤维进行除杂、梳理、除去纤维表面的油溶性物质，烘干；S2，将S1处理后的亲水纤维加热搓洗、高速搅拌，清洗烘干；S3，将S2处理后的棉纤维在-70℃下冷冻处理的时间为48h，干燥；S4，用抗菌整理液浸轧S3处理后的棉纤维，烘干；S5，将S4处理后的抗菌棉纤维梳理、铺网、水刺，得到水刺抗菌亲水无纺布作为接触层。
所述抗菌整理液为含有质量百分数为1％银离子抗菌剂的水溶液；按质量百分比计，所述银离子抗菌剂包括：银离子氨水溶液70％、乙二胺四乙酸钠10％、壳聚糖20％。
实施例2
一种医用抗菌复合无纺布的制备方法，其余与实施例1相同。区别在于，防水层中采用的抗菌整理剂包括浓度为10g/L的有机硅季铵盐、浓度为4g/L的聚乙二醇醚衍生物。吸水层中，聚丙烯无纺布基层的数量为3层。接触层中，抗菌整理液的组成为：所述抗菌整理液为含有质量百分数为5％银离子抗菌剂的水溶液。
实施例3
一种医用抗菌复合无纺布的制备方法，其余与实施例1相同。区别在于，防水层中采用的抗菌整理剂包括浓度为15g/L的有机硅季铵盐、浓度为6g/L的聚乙二醇醚衍生物。吸水层中，聚丙烯无纺布基层的数量为4层。接触层中，抗菌整理液的组成为：所述抗菌整理液为含有质量百分数为8％银离子抗菌剂的水溶液；按质量百分比计，所述银离子抗菌剂包括：银离子氨水溶液75％、乙二胺四乙酸钠10％、壳聚糖15％。
实施例4
一种医用抗菌复合无纺布的制备方法，其余与实施例1相同。区别在于，防水层中采用的抗菌整理剂包括浓度为20g/L的有机硅季铵盐、浓度为8g/L的聚乙二醇醚衍生物。吸水层中，聚丙烯无纺布基层的数量为5层。接触层中，亲水纤维为蚕丝纤维；抗菌整理液的组成为：所述抗菌整理液为含有质量百分数为10％银离子抗菌剂的水溶液；按质量百分比计，所述银离子抗菌剂包括：银离子氨水溶液75％、乙二胺四乙酸钠12％、壳聚糖13％。
实施例5
一种医用抗菌复合无纺布的制备方法，其余与实施例1相同。区别在于，防水层中采用的抗菌整理剂包括浓度为30g/L的有机硅季铵盐、浓度为10g/L的聚乙二醇醚衍生物。吸水层中，聚丙烯无纺布基层的数量为6层。接触层中，亲水纤维为粘胶纤维；抗菌整理液的组成为：所述抗菌整理液为含有质量百分数为15％银离子抗菌剂的水溶液；按质量百分比计，所述银离子抗菌剂包括：银离子氨水溶液80％、乙二胺四乙酸钠10％、壳聚糖10％。
对比例1
与实施例1的区别在于，防水层在制备时，先进行疏水整理，后进行抗菌整理。
对比例2
与实施例1的区别在于，吸水层不是通过水刺工艺复合，而是通过普通的压合方式。
对比例3
与实施例1的区别在于，接触层在制备过程中，亲水纤维未进行S2和S3 处理，即亲水纤维进行除杂、梳理、除去纤维表面油溶性物质后，直接进行抗菌整理。
性能测试
1、将上述实施例1-5和对比例1-3中得到的各无纺布进行抗菌性能测试，结果如下表1所示。测试条件为：准备实施例1-5和对比例1-3中(厚度为40～ 46g/m2)样本，将样本裁剪出大小为20cm2的试样，将裁剪完成的试样放入臭氧灭菌柜中进行充分灭菌，灭菌时间60min。试样灭菌完成后放置到已接种检测菌培养皿中的培养基表面，将培养皿放置到恒温恒湿箱中培养。其中检测菌为大肠杆菌、大肠埃希菌、金黄色葡萄球菌、酵母菌和霉菌。在放置24h后，取出培养皿，检查培养皿中菌落总数，记录数据，并记入表1中。
表1
上述抗菌性能测试结果说明，本申请中得到的无纺布的抗菌性能随着抗菌整理剂浓度和用量的增加而增加；防水层中抗菌剂与疏水剂的整理顺序对无纺布的抗菌性能有影响，先进行疏水整理后，抗菌剂不易附着在防水层上，导致抗菌效果下降；接触层中，在抗菌整理之前对亲水纤维进行一系列前处理，使得亲水纤维截断断口增多，毛细管吸附能力很强，促使更多的银离子抗菌剂吸附在纤维上，增加了无纺布的抗菌效果。
2、将上述实施例1-5和对比例1-3中得到的各无纺布进行抗渗性能测试，结果如下表2所示。测试条件为：准备实施例1-5和对比例1-3中得到的无纺布 (厚度为40～46g/m2)样本，将各样本表面清理干净后分别裁剪出大小为20cm2的试样。实验采用杭州百铭仪器有限公司生产的812D型静水压试验机进行测试，测试采用GB/T24218《纺织品非织造布实验方法》第16部分：抗渗水性的测定(静水压法)中记载的实验方法进行，且实验水压从试样的上方施加，水压提升速度为(10±0.5)hPa/min；测试完成后观察测试仪上显示的实验结果，并将结果记入表2中。
表2
3、将上述实施例1-5和对比例1-3中得到的各无纺布进行吸水性能测试，结果如下表3所示。测试方法为：准备实施例1-5和对比例1-3中得到的无纺布 (厚度为40～46g/m2)样本，将各样本表面清理干净后分别裁剪出直径为10cm的圆形试样；将测试样品置于试验台上，接触层朝上，将测试漏斗的开口对准样品中心点，取30ml水注入测试漏斗中，使水渗入待测样品，并同步计时，当水完全穿透接触层被吸水层吸收，即接触层上的水消失时，计时结束，即为渗透时间。将标重统一为M的滤纸分别放置于各个吸水样品上，并在滤纸上放置2kg 的压块，5min后卸掉压块，并对各个样品上的滤纸进行称重，得到的重量分别为MS1、MS2、MS3、MS4、MS5、MD1、MD2、MD3，各个样品的回渗量计算方法即为MS1-M，MS2-M，MS3-M，MS4-M，MS5-M，MD1-M，MD2-M，MD3-M。
表3
上述吸水性能测试结果说明，吸水层经过水刺处理，层层交叉缠绕后，其高吸水树脂在吸水层中的分布更加均匀，吸水后不易结块，回渗量更低，保水效果更好。接触层中的亲水纤维经过系列前处理后，吸水速度更快、渗透时间更短，可以使与之接触的创口更好的保持干爽。
以上实施方式仅用于说明本发明，而并非对本发明的限制，有关技术领域的普通技术人员，在不脱离本发明的精神和范围的情况下，还可以做出各种变化和变型，因此所有等同的技术方案也属于本发明的范畴，本发明的专利保护范围应由权利要求限定。
Claims (10)
1.一种医用抗菌复合无纺布的制备方法，其特征在于：所述复合无纺布包括防水层、吸水层和接触层；所述防水层为经过抗菌、疏水整理后的无纺布，所述吸水层为聚丙烯纤维与高吸水树脂经水刺工艺而成的无纺布，所述接触层为抗菌、柔软的无纺布；所述防水层、吸水层和接触层通过热压粘合。
2.如权利要求1所述的一种医用抗菌复合无纺布的制备方法，其特征在于，所述防水层的制备方法如下：S1，将无纺布先在抗菌整理剂中进行抗菌整理，烘干；S2，将S1中经过抗菌整理的无纺布用疏水整理液进行疏水整理，烘干；S3，将S2中经过疏水整理的无纺布多层复合，水刺处理后得到防水层。
3.如权利要求2所述的一种医用抗菌复合无纺布的制备方法，其特征在于，所述的抗菌整理剂包括浓度为0.1～30g/L的有机硅季铵盐、浓度为0.1～10g/L的聚乙二醇醚衍生物。
4.如权利要求2所述的一种医用抗菌复合无纺布的制备方法，其特征在于，所述疏水整理液的制备过程为：将正硅酸四乙酯加入水和乙醇的混合溶液中，搅拌下加入3-氨基丙基三甲氧基硅烷，搅拌均匀后加入氨水，反应4-5h后滴加十六烷基三甲氧基硅烷，继续反应4-5h，乙醇与水的重量比是10：(1-1.2)，氨水与水的重量比为(1.3～1.5)：1；正硅酸四乙酯的添加量为混合溶液的3～3.5％，3-氨基丙基三甲氧基硅烷和十六烷基三甲氧基硅烷的添加量为混合溶液的1.5～1.8％。
5.如权利要求1所述的一种医用抗菌复合无纺布的制备方法，其特征在于，所述吸水层的制备方法如下：S1，将聚丙烯纤维除杂、梳理、铺网，加工得到聚丙烯无纺布基层；S2，取若干上述S1得到的聚丙烯无纺布基层，在任意两层之间均匀铺设高吸水树脂，得到吸水层复合结构；S3，通过水刺处理S2中得到的复合结构，各基层之间相互交联缠绕，得到含有高吸水树脂的聚丙烯无纺布作为吸水层。
6.如权利要求5所述的一种医用抗菌复合无纺布的制备方法，其特征在于：所述吸水层中，聚丙烯无纺布基层的数量为2～6层。
7.如权利要求1所述的一种医用抗菌复合无纺布的制备方法，其特征在于，所述接触层的制备方法如下：S1，将亲水纤维进行除杂、梳理、除去纤维表面的油溶性物质，烘干；S2，将S1处理后的亲水纤维加热搓洗、高速搅拌，清洗烘干；S3，将S2处理后的亲水纤维冷冻、干燥；S4，用抗菌整理液浸轧S3处理后的亲水纤维，烘干；S5，将S4处理后的抗菌亲水纤维梳理、铺网、水刺，得到水刺抗菌亲水无纺布作为接触层。
8.如权利要求7所述的一种医用抗菌复合无纺布的制备方法，其特征在于：所述亲水纤维为棉纤维、粘胶纤维、蚕丝纤维、丝光羊毛纤维中的一种或者两种以上的组合。
9.如权利要求7所述的一种医用抗菌复合无纺布的制备方法，其特征在于： 所述抗菌整理液为含有质量百分数为0.1％～15％银离子抗菌剂的水溶液；按质量百分比计，所述银离子抗菌剂包括：银离子氨水溶液50％～70％、乙二胺四乙酸钠10％～20％、壳聚糖10％～40％。
10.如权利要求7所述的一种医用抗菌复合无纺布的制备方法，其特征在于：所述S3中，冷冻的温度为-70～-80℃，冷冻处理的时间为24～48h。
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