CN114801393B - 一种多尺度纤维过滤层及其制备方法与应用 - Google Patents

一种多尺度纤维过滤层及其制备方法与应用 Download PDF

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CN114801393B
CN114801393B CN202210336031.9A CN202210336031A CN114801393B CN 114801393 B CN114801393 B CN 114801393B CN 202210336031 A CN202210336031 A CN 202210336031A CN 114801393 B CN114801393 B CN 114801393B
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CN114801393A (zh
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鲁明
陈平绪
叶南飚
周日敏
李成
丁超
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Kingfa Science and Technology Co Ltd
Guangdong Kingfa Science and Technology Co Ltd
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Guangdong Kingfa Science and Technology Co Ltd
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Abstract

本发明提供了一种多尺度纤维过滤层及其制备方法与应用。所述多尺度纤维过滤层，包括复合纤维层、设置在所述复合纤维层表面的静电纺丝纳米纤维；所述复合纤维层由可降解的熔喷纤维和短纤维复合而成，复合纤维层的面密度为20‑200g/m2，所述短纤维与熔喷纤维的质量比为0.05‑0.2；熔喷纤维的平均直径为1‑10微米，短纤维的平均直径为20‑150微米，平均长度为1‑50mm；所述静电纺丝纳米纤维的平均直径为10‑500纳米；静电纺丝纳米纤维的面密度为0.5‑2.0g/m2。本发明所述多尺度纤维过滤层，具有良好的防护效果，在贮存使用过程中不易衰减且透气性能好、不容易憋闷，可使用可降解生物材料制成。

Description

一种多尺度纤维过滤层及其制备方法与应用
技术领域
本发明涉及过滤材料领域，更具体地，涉及一种多尺度纤维过滤层及其制备方法与应用。
背景技术
目前一次性口罩主要是由聚丙烯、涤纶、氨纶等不可降解材料制备的，一旦流入生态环境，势必造成长久的污染。采用环境友好可降解材料制备的一次性口罩，可以在特定条件下快速降解为水和二氧化碳等小分子，避免对生态环境造成长久危害。
为了减少对生态环境的危害，现有技术也开发了一些可生物降解的口罩。现有技术公开了一种聚乳酸材料可生物降解环保型功能性防护口罩，其方案中仍使用了较多如PVDF、聚烯烃等不可降解材料，只实现了部分可降解，仍不能完全消除污染，并且当其中的可降解成分降解后，残余部分就变成了微塑料，更加难以从环境中回收，还可能造成更大的生态危害。此外，现有技术也公开了一种可降解的环保口罩，其公开了主体结构为天然纤维材料或可降解材料的方案，但是其过滤层主要为普通无纺布，对亚微米级微粒，细菌，飞沫的防护效果较差，无法有效阻隔尘埃，预防感染。还有的，现有技术公开了一种全生物降解口罩及制备方法，提出一种用高流动性可降解聚酯熔喷材料制备熔喷阻隔过滤层应用于口罩的方法，但聚酯是一种极性材料，介电常数小，且容易吸湿，本身静电驻极效果较差，且非常容易中和衰减，难有持久的防护效果。
因此，设计出一种具有防护效果，在贮存使用过程中不易衰减且透气性能好、不容易憋闷，能够应用于可降解生物材料制成的过滤层具有重要的意义。
发明内容
本发明的目的在于提供一种具有良好的防护效果，在贮存使用过程中不易衰减且透气性能好、不容易憋闷的多尺度纤维过滤层，可使用可降解生物材料制成。
本发明的另一个目的在于提供所述多尺度纤维过滤层的制备方法。
本发明的另一个目的在于提供多尺度纤维过滤层的应用。
为解决上述技术问题，本发明采用的技术方案是：
一种多尺度纤维过滤层，包括复合纤维层、设置在所述复合纤维层表面的静电纺丝纳米纤维；
所述复合纤维层由可降解的熔喷纤维和短纤维复合而成，复合纤维层的面密度为20-200g/m2，所述短纤维与熔喷纤维的质量比为0.05-0.2；熔喷纤维的平均直径为1-10微米，短纤维的平均直径为20-150微米，长度范围为1-50mm；
所述静电纺丝纳米纤维的平均直径为10-500纳米；静电纺丝纳米纤维的面密度为0.5-2.0g/m2。
本发明所述多尺度纤维过滤层，具有多级过滤效果：由熔喷纤维和短纤维构成的复合纤维网络能够过滤大部分直径10微米以上的颗粒物，而且由于粗短纤维的引入，使得纤维网络更加蓬松，使口罩的透气性和容尘量得以提高，佩戴舒适感提高，且不容易因颗粒物堵塞孔隙导致在佩戴过程中的透气性变差；纳米纤维网络则具有超细纤维孔隙，用以过滤亚微米级颗粒物、微生物等有害物质，起到更好的防护效果，对花粉、PM2.5、固体颗粒物、细菌、飞沫等污染物具有较高的过滤效果，可防止污染物进入佩戴者的呼吸系统，起到防护作用。
所述多尺度纤维过滤层的过滤效果主要是物理拦截作用，不同于驻极材料通过静电吸附拦截，在贮存使用过程中不易衰减，防护效果更为持久。
进一步说明，相比于熔喷布所采用的静电纺丝，本发明所述多尺度纤维过滤层中静电纺丝纳米纤维的纤维更细，纤维网络更致密，其主要起到物理过滤的作用而非静电吸附作用，和熔喷布是不同的原理。这种物理过滤，除非纤网结构发生破坏，不会随着静电衰减而出现滤效下降的问题。
另外，多尺度纤维结构的过滤层具有蓬松的纤维网络结构，更好地吸收呼吸出来的湿气，所制备的口罩在长时间佩戴过程中不易产生憋闷感。
优选地，所述熔喷纤维材料中聚乳酸含量≥80wt％，余量为聚丁二酸丁二醇酯、聚己二酸/对苯二甲酸丁二酯、聚己内酯中的一种或多种。
优选地，所述聚乳酸的重均分子量为50000-150000。
本发明所述多尺度纤维过滤层通过引入短纤维，引入短纤维后的复合纤维层更加蓬松，在进行堆肥降解测试时，与堆肥接种物的接触面更大，而且有更多氧气可以进入，所以降解效果会更好。
所述短纤维为胶粘纤维、棉纤维、竹纤维、聚乳酸短切纤维中的一种或多种。
所述静电纺丝纳米纤维的材料为聚乳酸、聚丁二酸丁二醇酯、聚己内酯中的一种或几种。
优选地，所述复合纤维层的面密度为20-100g/m2。
优选地，所述复合纤维层的面密度为30-50g/m2，所述短纤维与熔喷纤维的质量比为0.1-0.15；短纤维的平均直径为30-50微米，平均长度为5-30mm。
优选地，所述静电纺丝纳米纤维的平均直径为100-300纳米；静电纺丝纳米纤维的面密度为1-1.2g/m2。
本发明所述多尺度纤维过滤层的制备方法，包括以下步骤：S1.复合纤维层：先制备熔喷纤维，然后将短纤维喷吹到所述熔喷纤维中，控制短纤维与熔喷纤维的质量比，控制复合纤维层面密度；
S2.以复合纤维层为接受基底，采用静电纺丝方法在所述复合纤维层表面复合一层静电纺丝纳米纤维，得到多尺度纤维过滤层。
本发明还保护一种过滤制品。所述过滤制品包含上述多尺度纤维过滤层。
本发明还保护上述多尺度纤维过滤层在口罩中的应用。
具体地，一种生物降解口罩包括过滤层、鼻夹和固定带；所述过滤层包括依次设置的内支撑层、多尺度纤维过滤层、外支撑层。
本发明所述生物降解口罩对空气动力学质量中位径在0.3微米的盐性颗粒物的过滤效率在90％以上，对金黄色葡萄球菌的细菌过滤效率在95％以上。
所述内支撑层为纯棉水刺无纺布、胶粘纤维水刺无纺布中的一种，其面密度为20-40g/m2，所述外支撑层为聚乳酸无纺布，其面密度为20-60g/m2。
所述鼻夹的制作材料为聚丁二酸丁二醇酯和聚乳酸的混合物，其中聚乳酸占比不低于40％。
所述固定带的制作材料为聚乳酸、聚丁二酸丁二醇酯、聚己二酸/对苯二甲酸丁二酯、聚己内酯中的一种或多种材料，将所述材料的纤维丝进行加弹处理后用织带机编织而成，或将所述材料的无纺布裁切成长条后使用。
与现有技术相比，本发明的有益效果是：
本发明所述多尺度纤维过滤层，具有多级过滤效果：由熔喷纤维和粗短纤维构成的复合纤维网络能够过滤大部分直径10微米以上的颗粒物，而且由于粗短纤维的引入，使得纤维网络更加蓬松，使口罩的透气性和容尘量得以提高，佩戴舒适感提高，且不容易因颗粒物堵塞孔隙导致在佩戴过程中的透气性变差；所复合的静电纺丝纳米纤维则具有超细纤维孔隙，用以过滤亚微米级颗粒物、微生物等有害物质，起到更好的防护效果。所述多尺度纤维过滤层的过滤效果主要是物理拦截作用，不同于驻极材料通过静电吸附拦截，在贮存使用过程中不易衰减，防护效果更为持久。
附图说明
图1为实施例多尺度纤维过滤层的扫描电镜图片。其中粗纤维为喷吹短纤维，中等粗细的纤维为熔喷纤维，最细的如蜘蛛丝一般的纤维为静电纺丝纳米纤维。
具体实施方式
下面结合具体实施方式对本发明作进一步的说明。实施例及对比例中的原料均可通过市售得到或可通过已知方法制备得到。另外，关于本说明书中“份”、“％”，除非特别说明，分别表示“重量份”、“质量％”。
以下实施例和对比例中所用的原料的厂家和牌号如下：
1、熔喷纤维
1)聚乳酸：重均分子量100000，IngeoTM 6252D，美国NatureWorks；
2)聚丁二酸丁二醇酯：BioPBSTM FZ71，日本三菱化学；
3)聚己内酯：Capa 6600，瑞典Perstorp公司；
2、短纤维材料
1)胶粘纤维：赛得利化纤；
2)棉纤维：细绒棉纤维，新乡新城棉织品有限公司；
3)聚乳酸短切纤维：泉州斯马丁进出口贸易有限公司；
3、静电纺丝纳米纤维材料
1)聚乳酸：IngeoTM 4060D，美国NatureWorks；
2)聚丁二酸丁二醇酯：BioPBSTM FD92，日本三菱化学；
3)聚己内酯：eSUN500C，深圳光华伟业股份有限公司；
实施例及对比例
一种多尺度纤维过滤层，包括复合纤维层、设置在所述复合纤维层表面的静电纺丝纳米纤维；所述复合纤维层由可降解的熔喷纤维和短纤维复合而成；
所述多尺度纤维过滤层的制备方法，包括以下步骤：
S1.复合纤维层：将熔喷纤维材料加入挤出机熔融塑化，再经计量泵从喷丝板喷出，同时将经过开松、梳理的短纤维喷吹到熔喷纤维中，通过控制计量泵流量、喷吹速率以及网帘线速度，控制短纤维与熔喷纤维质量比和面密度，控制短纤维与熔喷纤维的质量比，控制复合纤维层面密度；
S2.以复合纤维层为接受基底，采用静电纺丝方法在所述复合纤维层表面复合一层静电纺丝纳米纤维，得到多尺度纤维过滤层。
具体地，各实施例和对比例的多尺度纤维过滤层情况如表1～4所示。
表1
表2
表3
表4
性能测试
采用上述制备得到的多尺度纤维过滤层制备，采用如下方法制备成口罩：
采用25g/m2的纯棉水刺布作为内支撑层，用40g/m2的聚乳酸热轧无纺布作为外支撑层，将内支撑层、多尺度纤维过滤层和外支撑层依次放置，用超声焊接方法制备成口罩体。如图1所示，图1为多尺度纤维过滤层的扫描电镜图片，其中粗纤维为喷吹短纤维，中等粗细的纤维为熔喷纤维，最细的如蜘蛛丝一般的纤维为静电纺丝纳米纤维。
将聚丁二酸丁二醇酯和聚乳酸按照30：70的质量比混合均匀，经挤出拉条，冷却裁切制成鼻梁条。将聚乳酸纤维加弹丝和聚己二酸/对苯二甲酸丁二酯纤维加弹丝用织带机编织得到耳带。将上述口罩体、耳带和鼻梁条用口罩机固定组装在一起，得到口罩。
对所得的口罩的性能进行测试评价，具体测试方法及条件如下：
1、过滤效率测试评价方法
采用YY 0469-2011《医用外科口罩》标准中5.6.2的方法测试颗粒物过滤效率。同一样品在60℃，60％相对湿度的湿热老化箱中放置14天之后，再次测试过滤效率，以此评价滤效的保持率。
2、降解性能
采用GB/T 19277.2-2013《受控堆肥条件下材料最终需氧生物分解能力的测定采用测定释放的二氧化碳的方法》标准进行降解率测试。本发明测试180天后的降解率。降解率越高越好，一般地，降解率大于70％为良，降解率大于80％为优。
3、透气性
在测试过滤效率时，读取初始时刻的通气阻力数据。其中，30Pa以下为优， 30-40Pa为良，40Pa以上为差。
各实施例和对比例的性能测试结果如表5所示。
表5实施例和对比例的性能测试结果
显然，本发明的上述实施例仅仅是为清楚地说明本发明所作的举例，而并非是对本发明的实施方式的限定。对于所属领域的普通技术人员来说，在上述说明的基础上还可以做出其它不同形式的变化或变动。这里无需也无法对所有的实施方式予以穷举。凡在本发明的精神和原则之内所作的任何修改、等同替换和改进等，均应包含在本发明权利要求的保护范围之内。

Claims (10)

1.一种多尺度纤维过滤层，其特征在于，包括复合纤维层、设置在所述复合纤维层表面的静电纺丝纳米纤维；
所述复合纤维层由可降解的熔喷纤维和短纤维复合而成，复合纤维层的面密度为30-50g/m2，所述短纤维与熔喷纤维的质量比为0.1-0.15；熔喷纤维的平均直径为1-10微米，短纤维的平均直径为20-150微米，平均长度为1-50mm；
所述静电纺丝纳米纤维的平均直径为100-300纳米；静电纺丝纳米纤维的面密度为1-1.2g/m2。
2.根据权利要求1所述多尺度纤维过滤层，其特征在于，所述熔喷纤维材料中聚乳酸含量≥80wt％，余量为聚丁二酸丁二醇酯、聚己二酸/对苯二甲酸丁二酯、聚己内酯中的一种或多种。
3.根据权利要求2所述的多尺度纤维过滤层，其特征在于，所用聚乳酸的重均分子量为50000-150000。
4.根据权利要求1所述多尺度纤维过滤层，其特征在于，所述短纤维为胶粘纤维、棉纤维、竹纤维、聚乳酸短切纤维中的一种或多种。
5.根据权利要求1所述多尺度纤维过滤层，其特征在于，所述静电纺丝纳米纤维的材料为聚乳酸、聚丁二酸丁二醇酯、聚己内酯中的一种或几种。
6.根据权利要求1所述的多尺度纤维过滤层，其特征在于，所述短纤维的平均直径为30-50微米，平均长度为5-30mm。
7.权利要求1～6任一项所述多尺度纤维过滤层的制备方法，其特征在于，包括以下步骤：
S1.复合纤维层：将熔喷纤维材料熔融塑化，从喷丝板喷出，同时将经过开松、梳理的短纤维喷吹到熔喷纤维中，控制短纤维与熔喷纤维的质量比，控制复合纤维层面密度；
S2.以复合纤维层为接受基底，采用静电纺丝方法在所述复合纤维层表面复合一层静电纺丝纳米纤维，得到多尺度纤维结构的过滤层。
8.一种过滤制品，其特征在于，包含权利要求1～6任一项所述多尺度纤维过滤层。
9.权利要求1～6任一项所述多尺度纤维过滤层在口罩中的应用。
10.一种生物降解口罩，其特征在于，包括过滤层、鼻夹和固定带；所述过滤层包括依次设置的内支撑层、权利要求1～6任一项所述多尺度纤维过滤层、外支撑层。
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