CN112937030A - 一种可洗涤纳米纤维防螨家纺复合面料及其制备方法 - Google Patents
一种可洗涤纳米纤维防螨家纺复合面料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种可洗涤纳米纤维防螨复合家纺面料及其制备方法,该复合家纺面料包括层叠布置的第一功能布层、纳米纤维过滤层和第二功能布层;纳米纤维过滤层为以弹性体聚合物为原料采用溶液法气流纺丝工艺制备的高弹性无纺纳米纤维层,其通过胶粘剂与第一功能布层和第二功能布层压合为一体;弹性体聚合物采用高弹性的TPU、POE、SBS中的一种或几种。本发明提供的防螨复合家纺面料及其制备方法,中间纳米纤维过滤层直接采用以弹性体聚合物为原料的纳米纤维构成,弹性纳米纤维在外力拉扯下产生变形,外力停止后纤维会自行回弹到原始状态,可以有效避免洗涤后纤维结构遭到破坏而降低隔螨效果。
Description
技术领域
本发明涉及功能性家纺材料技术领域,尤其涉及一种可洗涤纳米纤维防螨复合家纺面料及其制备方法。
背景技术
据统计,即使是整洁的家,平均每张床上被褥螨虫和尘埃螨虫也至少有1500万只,螨虫能引起皮肤过敏,长痘痘、皮炎等。螨虫属于节肢动物门蛛形纲广腹亚纲的一类体型微小的动物,身体大小一般都在0.5毫米左右,有些小到0.1毫米。而棉纤维直径约为15~20微米,涤纶腈纶等熔喷纤维直径约100微米,纳米纤维直径只有0.1~1微米。纤维直径越细,过滤效果越好,相较与棉纤维和熔喷纤维,因此纳米纤维具有更好的过滤拦截效果,可以起到完全隔螨的效果。
传统的抗虫防螨面料通常是对纤维或织物制备前后进行抗菌除螨整理,如已公开专利CN111331948A披露了一种在熔融纺丝时加入纳米级抗菌防螨颗粒制得的吸湿快干的抗虫防螨面料;又如已公开专利CN210454037U也同样披露一种在制备涤纶纤维层和尼龙纤维层熔融纺丝时均加入纳米级抗菌防螨颗粒的抗菌防螨功能面料。这些经抗菌除螨整理的功能面料虽然具有抗菌除螨效果强、工艺简单的特点,但是生产出的布料在经过多次洗涤后,抗菌除螨效果将大大降低,无法实现布料的长时间抗菌除螨,导致后期处理较为繁琐,且浪费原材料。
目前将纳米纤维应用到家纺领域还是一个比较新的课题,虽然实验表明其隔螨效果很好,但是也面临着许多问题。如已公开专利CN111559129A披露了一种超细纤维内层采用10μm以下以阻止螨虫或螨虫病菌渗透到人体上的超细纤维纺织面料;又如已公开专利CN211074935U披露了一种采用弹性纤维层和纳米银抗菌层的沙发弹性竹纤维面料。通过采用纳米纤维提高织物密度虽然能够使螨虫无法通过织物,一定程度上实现了抗菌除螨的目的,但由于织物的高密度导致其手感较差,且在洗涤过程中强力拉扯会造成纤维网络变形、纤维断裂,从而破坏了纳米纤维的高效过滤结构,大大降低了纳米纤维的隔螨效果。
发明内容
本发明的目的是针对现有防螨家纺面料手感较差及洗涤后防螨效果降低的缺陷,提出一种可洗涤纳米纤维防螨复合家纺面料及其制备方法。
为实现上述目的,本发明采用以下技术方案:
本发明的第一个方面是提供一种可洗涤纳米纤维防螨复合家纺面料,包括层叠布置的第一功能布层、纳米纤维过滤层和第二功能布层;其中:
所述纳米纤维过滤层为以弹性体聚合物为原料采用溶液法气流纺丝工艺制备的高弹性无纺纳米纤维层,其通过胶粘剂与所述第一功能布层和第二功能布层压合为一体。
进一步地,在所述的可洗涤纳米纤维防螨复合家纺面料中,所述弹性体聚合物为TPU(热塑性聚氨酯)、POE(乙烯-辛烯共聚物)、SBS(苯乙烯类嵌段共聚物)中的一种或几种。
进一步地,在所述的可洗涤纳米纤维防螨复合家纺面料中,所述高弹性无纺纳米纤维层的面密度为2~10g/m2;所述纳米纤维直径为300~600nm。
进一步地,在所述的可洗涤纳米纤维防螨复合家纺面料中,所述第一功能布层和/或第二功能布层为纯棉布料、涤纶布料、棉-涤纶混合面料或丝棉面料。
进一步地,在所述的可洗涤纳米纤维防螨复合家纺面料中,所述胶粘剂为反应型聚氨酯热熔胶或热固化型聚氨酯热熔胶。
本发明的第二个方面是提供一种如所述可洗涤纳米纤维防螨复合家纺面料的制备方法,包括如下步骤:
(1)配置前置溶液:将聚合物TPU、POE、SBS颗粒中的一种或几种溶于溶剂中,于35~60℃搅拌2~4h,配置成前置溶液;
(2)溶液法气流纺丝:将步骤(1)配置的前置溶液采用溶液法气流纺丝工艺牵伸形成高长径比的纳米纤维,并定向或随机排布形成纤网结构的高弹性无纺纳米纤维层;
(3)层压复合:将步骤(2)制备的高弹性无纺纳米纤维层采用胶粘剂分别与第一功能布层和第二功能布层在一定压力下复合为一体。
进一步地,在所述的可洗涤纳米纤维防螨复合家纺面料的制备方法中,步骤(1)中,所述前置溶液中聚合物的质量百分比为5~25%。
进一步地,在所述的可洗涤纳米纤维防螨复合家纺面料的制备方法中,步骤(1)中,所述溶剂为二甲基亚砜(DMSO)、二甲基甲酰胺(DMF)、EAC乙酸乙酯(EAc)、丙酮中的一种或几种。
进一步优选地,在所述的可洗涤纳米纤维防螨复合家纺面料的制备方法中,步骤(1)中,先将至少两种所述溶剂混合并采用超声处理15~30min后,再加入所述聚合物。
进一步地,在所述的可洗涤纳米纤维防螨复合家纺面料的制备方法中,步骤(2)中,所述溶液法气流纺丝工艺为:
使用注射泵将所述前置溶液以恒定速度从针头压出,在针头处以平行方向施加高速气流,在气流场中溶剂挥发,高分子牵伸形成高长径比的纳米纤维;
其中,纳米纤维收集距离为10~35cm,风速50~500m/min,供液速度1~10ml/h,针头直径0.1~0.75mm。
进一步地,在所述的可洗涤纳米纤维防螨复合家纺面料的制备方法中,先将步骤(2)中制备的纳米纤维收集于无粘附作用的无纺布上,待步骤(3)中与第一功能布层和第二功能布层复合时再与无纺布分离。
本发明采用上述技术方案,与现有技术相比,具有如下技术效果:
(1)中间纳米纤维过滤层直接采用以弹性体聚合物为原料的纳米纤维构成,弹性纳米纤维在外力拉扯下产生变形,外力停止后纤维会自行回弹到原始状态,面料的防螨性不会随着洗涤次数的增加而减小,可以有效避免洗涤后纤维结构遭到破坏而降低隔螨效果;
(2)采用溶液法气流纺丝工艺直接制备高密度排布的高弹性无纺纳米纤维层,而无需对纳米纤维或织物制备前后进行抗菌除螨工艺整理,免除了整理工序需要的能耗,极大的节约了资源,同时具有更好的螨虫过滤拦截效果,可以起到完全隔螨的效果,提高面料使用寿命;
(3)通过粘合剂将纳米纤维过滤层压合在两功能布层之间,一方面对对中间的纳米纤维过滤层起到一定的保护作用,另一方面克服中间高密度排布的纳米纤维过滤层手感差的缺陷,使得家纺面料整体弹力轻松、持久,且具有良好的舒适感;
(4)第一功能布层、纳米纤维过滤层和第二功能布层之间直接采用反应型粘合剂在一定压力下复合,不需要对制备前后的纳米纤维或织物进行除螨工艺整理等工序,整体工艺流程短,生产成本低,具有非常好的市场应用前景。
附图说明
图1为本发明一种可洗涤纳米纤维防螨复合家纺面料的结构示意图;
图2为本发明一种可洗涤纳米纤维防螨复合家纺面料的制备工艺流程图。
具体实施方式
本发明首先提供了一种可洗涤纳米纤维防螨复合家纺面料,如图1所示,该复合家纺面料100包括层叠布置的第一功能布层101、纳米纤维过滤层102和第二功能布层103;其中:纳米纤维过滤层102为以弹性体聚合物为原料采用溶液法气流纺丝工艺制备的高弹性无纺纳米纤维层,其通过胶粘剂与第一功能布层101和第二功能布层103在一定压力和温度下压合为一体,胶粘剂为反应型聚氨酯热熔胶或热固化型聚氨酯热熔胶。中间纳米纤维过滤层102直接采用以弹性体聚合物为原料的纳米纤维构成,纳米纤维在外力拉扯下产生变形,外力停止后纤维会自行回弹到原始状态,面料的防螨性不会随着洗涤次数的增加而减小,可以有效避免洗涤后纤维结构遭到破坏而降低隔螨效果。
在一些实施例中,弹性体聚合物采用高弹性的TPU(热塑性聚氨酯,德国拜耳1185A)、POE(乙烯-辛烯共聚物,美国杜邦FusabondN416)、SBS(苯乙烯类嵌段共聚物,韩国LG化学411)中的一种或几种。
在一些实施例中,纳米纤维过滤层102中所采用的高弹性无纺纳米纤维层的面密度为2~10g/m2,优选为3~8g/m2,更优选为5~6g/m2。纳米纤维直径为300~600nm,优选为320~550nm,更优选为350~420nm。以保证纳米纤维过滤层102中分别的纳米纤维按照的密度排布,起到良好的防螨过滤效果。纳米纤维过滤层102两侧复合的第一功能布层101和/或第二功能布层103采用纯棉布料、涤纶布料、不同比例的棉-涤纶混合面料或不同比例的丝棉面料,一方面对对中间的纳米纤维过滤层102起到一定的保护作用,另一方面克服中间高密度排布的纳米纤维过滤层手感差的缺陷,使得家纺面料整体弹力轻松、持久,且具有良好的舒适感。
本发明还提供一种如可洗涤纳米纤维防螨复合家纺面料的制备方法,如图2所示,具体包括如下步骤:
(1)配置前置溶液:先将所需溶剂混合,超声处理20分钟后再加入适量聚合物颗粒,聚合物颗粒采用TPU(热塑性聚氨酯,德国拜耳1185A)、POE(乙烯-辛烯共聚物,美国杜邦FusabondN416)、SBS(苯乙烯类嵌段共聚物,韩国LG化学411)颗粒中的一种或几种,然后将混合液在35~60℃搅拌2~4h,配置成前置溶液;
(2)溶液法气流纺丝:将步骤(1)配置的前置溶液采用溶液法气流纺丝工艺牵伸形成高长径比的纳米纤维,并定向或随机排布形成纤网结构的高弹性无纺纳米纤维层;
(3)层压复合:将步骤(2)制备的高弹性无纺纳米纤维层采用胶粘剂分别与第一功能布层和第二功能布层在一定压力下复合为一体。
在一些实施例中,步骤(1)中,前置溶液中聚合物的质量百分比为5~25%;优选地,前置溶液中聚合物的质量百分比为6~22%;较为优选地,前置溶液中聚合物的质量百分比为8~20%;更为优选地,前置溶液中聚合物的质量百分比为12~16%。
在一些实施例中,步骤(1)中,溶剂为二甲基亚砜(DMSO)、二甲基甲酰胺(DMF)、乙酸乙酯(EAc)、丙酮中的一种或几种。优选地,步骤(1)中,先将至少两种溶剂混合并采用超声处理15~30min后,再加入聚合物。
在一些实施例中,步骤(2)中,溶液法气流纺丝工艺为:使用注射泵将前置溶液以恒定速度从针头压出,在针头处以平行方向施加高速气流,在气流场中溶剂挥发,高分子牵伸形成高长径比的纳米纤维;其中,纳米纤维收集距离为10~35cm,风速50~500m/min,供液速度1~10ml/h,针头直径0.1~0.75mm;
在一些实施例中,先将步骤(2)中制备的纳米纤维收集于无粘附作用的无纺布上,待步骤(3)中与第一功能布层和第二功能布层复合时再与无纺布分离。
下面通过具体实施例对本发明进行详细和具体的介绍,以使更好的理解本发明,但是下述实施例并不限制本发明范围。
实施例一
提供一种可洗涤纳米纤维防螨复合家纺面料,包括层叠布置的第一功能布层、纳米纤维过滤层和第二功能布层,其中,第一层功能布层为100g/m2的纯棉布,纳米过滤层为采用TPU颗粒为原料采用溶液法气流纺丝工艺制备的高弹性无纺纳米纤维层;第二层功能布层为100g/m2的纯棉布。
具体地,该可洗涤纳米纤维防螨复合家纺面料的制备方法,包括如下步骤:
(1)配置前置溶液:将适量TPU颗粒加入二甲基亚砜:乙酸乙酯=2:1的混合溶剂中,40℃加热条件下搅拌4h,最终获得质量分数16%TPU的纺丝溶液;
(2)溶液法气流纺丝:将纺丝溶液采用溶液法气流纺丝工艺牵伸形成高长径比的纳米纤维,将无纺布置于收集器上,设置收集距离为25cm,风力300m/min,单针供液速度5ml/h;并定向或随机排布形成纤网结构的高弹性无纺纳米纤维层;
(3)层压复合:将高弹性无纺纳米纤维层分别与第一功能布层和第二功能布层通过反应型聚氨酯热熔胶加压复合。
将本实施例值得的三层复合面料进行盐雾过滤测试,盐雾颗粒数量中值直径为75nm,过滤效率为98.2%,气阻130Pa。测试结果如下表1所示:
表1复合面料阻螨效果测试数据:
实施例二
提供一种可洗涤纳米纤维防螨复合家纺面料,包括层叠布置的第一功能布层、纳米纤维过滤层和第二功能布层,其中,第一层功能布层为100g/m2的纯棉布,纳米纤维过滤层为采用TPU颗粒为原料采用溶液法气流纺丝工艺制备的高弹性无纺纳米纤维层;第二层功能布层为200g/m2的纯棉磨毛布。
具体地,该可洗涤纳米纤维防螨复合家纺面料的制备方法,包括如下步骤:
(1)配置前置溶液:将适量POE颗粒加入乙酸乙酯溶剂中,40℃加热搅拌4h,最终获得质量分数12%TPU的纺丝溶液;
(2)溶液法气流纺丝:将纺丝溶液采用溶液法气流纺丝工艺牵伸形成高长径比的纳米纤维,将无纺布置于收集器上,设置收集距离为20cm,风力260m/min,单针供液速度4ml/h;并定向或随机排布形成纤网结构的高弹性无纺纳米纤维层;
(3)层压复合:将制备的高弹性无纺纳米纤维层分别与第一功能布层和第二功能布层通过反应型聚氨酯热熔胶加压复合。
将本实施例值得的三层复合面料进行盐雾过滤测试,盐雾颗粒数量中值直径为75nm,过滤效率为97.7%,气阻155Pa。其测试结果如下表2所示:
表2复合面料阻螨效果测试数据:
实施例三
提供一种可洗涤纳米纤维防螨复合家纺面料,包括层叠布置的第一功能布层、纳米纤维过滤层和第二功能布层,其中,第一层功能布层为200g/m2的羊羔绒涤纶布,纳米过滤层为采用TPU颗粒为原料采用溶液法气流纺丝工艺制备的高弹性无纺纳米纤维层;第二层功能布层为200g/m2的纯棉磨毛布。
具体地,该可洗涤纳米纤维防螨复合家纺面料的制备方法,包括如下步骤:
(1)配置前置溶液:将适量POE颗粒加入二甲基甲酰胺溶剂中,40℃加热条件下搅拌4h,最终获得质量分数20%SBS的纺丝溶液;
(2)溶液法气流纺丝:将纺丝溶液采用溶液法气流纺丝工艺牵伸形成高长径比的纳米纤维,将无纺布置于收集器上,设置收集距离为25cm,风力280m/min,单针供液速度3ml/h;并定向或随机排布形成纤网结构的高弹性无纺纳米纤维层;
(3)层压复合:将制备的高弹性无纺纳米纤维层分别与第一功能布层和第二功能布层通过反应型聚氨酯热熔胶加压复合。
将本实施例值得的三层复合面料进行盐雾过滤测试,盐雾颗粒数量中值直径为75nm,过滤效率为99.2%,气阻175Pa。其测试结果如下表3所示:
表3复合面料阻螨效果测试数据:
实施例四
提供一种可洗涤防螨复合家纺面料,包括层叠布置的第一功能布层和第二功能布层,其中,第一层功能布层为200g/m2的羊羔绒涤纶布,第二层功能布层为200g/m2的纯棉磨毛布,第一功能布层和第二功能布层通过反应型聚氨酯热熔胶加压复合。
将本对比例制得的两层复合面料进行盐雾过滤测试,盐雾颗粒数量中值直径为75nm,过滤效率为41.3%,气阻87Pa。其测试结果如下表4所示:
表4复合面料阻螨效果测试数据:
实施例五
提供一种可洗涤防螨复合家纺面料,包括层叠布置的第一功能布层和第二功能布层,其中,第一层功能布层为100g/m2的纯棉布,第二层第一层功能布层为50g/m2的纯棉布,第一功能布层和第二功能布层通过反应型聚氨酯热熔胶加压复合。
将本对比例制得的两层复合面料进行盐雾过滤测试,盐雾颗粒数量中值直径为75nm,过滤效率为24.7%,气阻55Pa。其测试结果如下表5所示:
表5复合面料阻螨效果测试数据:
以上对本发明的具体实施例进行了详细描述,但其只是作为范例,本发明并不限制于以上描述的具体实施例。对于本领域技术人员而言,任何对本发明进行的等同修改和替代也都在本发明的范畴之中。因此,在不脱离本发明的精神和范围下所作的均等变换和修改,都应涵盖在本发明的范围内。
Claims (10)
1.一种可洗涤纳米纤维防螨复合家纺面料,其特征在于,包括层叠布置的第一功能布层、纳米纤维过滤层和第二功能布层;其中:
所述纳米纤维过滤层为以弹性体聚合物为原料采用溶液法气流纺丝工艺制备的高弹性无纺纳米纤维层,其通过胶粘剂与第一功能布层和第二功能布层压合为一体。
2.根据权利要求1所述的可洗涤纳米纤维防螨复合家纺面料,其特征在于,所述弹性体聚合物为TPU(热塑性聚氨酯)、POE(乙烯-辛烯共聚物)、SBS(苯乙烯类嵌段共聚物)中的一种或几种。
3.根据权利要求1所述的可洗涤纳米纤维防螨复合家纺面料,其特征在于,所述高弹性无纺纳米纤维层的面密度为2~10g/m2;所述纳米纤维直径为300~600nm。
4.根据权利要求1所述的可洗涤纳米纤维防螨复合家纺面料,其特征在于,所述第一功能布层和/或第二功能布层为纯棉布料、涤纶布料、棉-涤纶混合面料或丝棉面料。
5.根据权利要求1所述的可洗涤纳米纤维防螨复合家纺面料,其特征在于,所述胶粘剂为反应型聚氨酯热熔胶或热固化型聚氨酯热熔胶。
6.一种如权利要求1~5任一项所述可洗涤纳米纤维防螨复合家纺面料的制备方法,其特征在于,包括如下步骤:
(1)配置前置溶液:将聚合物TPU、POE、SBS颗粒中的一种或几种溶于溶剂中,于35~60℃加热环境下搅拌2~4h,配置成前置溶液;
(2)溶液法气流纺丝:将步骤(1)配置的前置溶液采用溶液法气流纺丝工艺牵伸形成高长径比的纳米纤维,并定向或随机排布形成纤网结构的高弹性无纺纳米纤维层;
(3)层压复合:将步骤(2)制备的高弹性无纺纳米纤维层采用胶粘剂分别与第一功能布层和第二功能布层在一定压力下复合为一体。
7.根据权利要求6所述的可洗涤纳米纤维防螨复合家纺面料的制备方法,其特征在于,步骤(1)中,所述前置溶液中聚合物的质量百分比为5~25%。
8.根据权利要求6所述的可洗涤纳米纤维防螨复合家纺面料的制备方法,其特征在于,步骤(1)中,所述溶剂为二甲基亚砜(DMSO)、二甲基甲酰胺(DMF)、乙酸乙酯(EAc)、丙酮中的一种或几种。
9.根据权利要求6所述的可洗涤纳米纤维防螨复合家纺面料的制备方法,其特征在于,步骤(2)中,所述溶液法气流纺丝工艺为:
使用注射泵将所述前置溶液以恒定速度从针头压出,在针头处以平行方向施加高速气流,在气流场中溶剂挥发,高分子牵伸形成高长径比的纳米纤维;
其中,纳米纤维收集距离为10~35cm,风速50~500m/min,供液速度1~10ml/h,针头直径0.1~0.75mm。
10.根据权利要求6所述的可洗涤纳米纤维防螨复合家纺面料的制备方法,其特征在于,先将步骤(2)中制备的纳米纤维收集于无粘附作用的无纺布上,待步骤(3)中与第一功能布层和第二功能布层复合时再与无纺布分离。
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