CN116196698B - 一种高效抗菌的多功能双组分熔喷过滤材料及其制备方法与应用 - Google Patents
一种高效抗菌的多功能双组分熔喷过滤材料及其制备方法与应用 Download PDFInfo
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Abstract
本发明涉及一种高效抗菌的多功能双组分熔喷过滤材料及其制备方法与应用,属于非织造技术领域。本发明的熔喷过滤材料包括预过滤层纤维网和主过滤层纤维网;纤维网中的纤维为皮芯双组分纤维。皮芯双组分纤维皮层原料和芯层原料通过双组分熔喷装置制备出双层纤维网,并利用热粘合复合,然后进行电晕驻极处理,得到所述高效抗菌的多功能双组分熔喷过滤材料。本发明所用主体原料均为可降解材料,保护环境,具有抗菌和增能效果;其通过熔喷和电晕驻极工艺处理,最终得到的双组分皮芯纤维过滤效率高且过滤阻力低,电晕驻极电荷和抗菌助剂共同杀菌,杀菌更高效,且工艺简单,实施成本低并绿色环保。
Description
技术领域
本发明属于非织造技术领域,尤其是指一种高效抗菌的多功能双组分熔喷过滤材料及其制备方法与应用。
背景技术
COVID-19在全球的蔓延使防护用非织造过滤材料受到了广泛关注。而伴随着工业的迅速发展,空气污染也日益加重,空气中的小颗粒可以吸附有毒物质,并会进入人体呼吸道和肺部诱发一系列疾病,为人体健康造成严重危害。目前利用熔喷非织造过滤材料制成口罩或过滤器对空气中的微细颗粒物进行过滤,是防控疫情和净化空气的重要手段。因此,提高和改善熔喷非织造过滤材料的性能就显得尤为重要。
目前现有技术中使用的过滤材料具有以下缺点:(1)过滤材料利用纺粘和针刺技术通过制备成蓬松结构来降低过滤阻力,但是过滤效率较低,很难捕获一些尺寸小的颗粒物;同时也没有抗菌成分,不具备抗菌性能。(2)过滤材料通过静电纺丝制备工艺,将添加生物抗菌剂的纺丝液纺到基材上。但其所用工艺静电纺丝由于纤维直径小以及堆积密度高的原因,制成的纳米纤维结构紧密,过滤阻力较大,并且静电纺丝膜容尘量小,严重缩减其使用寿命,且抗菌效果差。(3)过滤材料的纤维原料为聚丙烯,性能单一,且聚丙烯属于无法降解的材料,过度使用不利于环境保护。
因此,现亟需一种高效抗菌的多功能双组分熔喷过滤材料,并可以解决现有技术中过滤材料的过滤阻力高和过滤效率低等问题。
发明内容
为解决上述技术问题,本发明提供了一种高效抗菌的多功能双组分熔喷过滤材料及其制备方法。本发明利用双组分熔喷工艺,采用二氧化碳基聚氨酯和PBAT两种材料结合而成的独特新型皮芯纤维材料,均为可降解材料,有利于保护环境,同时纤维材料还具有优异的延展性、断裂伸长率、耐热性和冲击性能,满足了过滤材料对性能多样化的需求。且本发明制备所得过滤材料具有抗菌和增能效果,通过熔喷和电晕驻极工艺处理,最终得到的双组分皮芯纤维过滤效率高且过滤阻力低。
本发明是通过以下技术方案实现:
本发明的第一个目的是一种高效抗菌的多功能双组分熔喷过滤材料的制备方法,包括以下步骤:
(1)将纤维皮层原料和纤维芯层原料通过喷丝制备得到纤维,调整熔喷接收距离进行熔喷,分别制备得到预过滤层纤维网和主过滤层纤维网;
(2)将步骤(1)所得预过滤层纤维网和主过滤层纤维网利用热粘合复合,电晕驻极处理后,得到所述高效抗菌的多功能双组分熔喷过滤材料。
在本发明的一个实施例中,步骤(1)中,所述纤维皮层原料通过以下方法制备得到:
将抗菌助剂与二氧化碳基聚氨酯进行混合造粒,得到改性二氧化碳基聚氨酯母粒,然后将改性二氧化碳基聚氨酯母粒与二氧化碳基聚氨酯混合,得到所述纤维皮层原料。
在本发明的一个实施例中,所述抗菌助剂占纤维皮层原料的质量百分数为3%-8%。
在本发明的一个实施例中,所述抗菌助剂为纳米氧化锌和纳米银的混合物;所述纳米氧化锌的质量百分比为60%-70%;所述纳米银的质量百分比为30%-40%。
在本发明的一个实施例中,所述造粒为通过双螺杆挤出机进行,将抗菌助剂与二氧化碳基聚氨酯分别加入双螺杆挤出机的两个喂料斗,在170℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有抗菌助剂的改性的二氧化碳基聚氨酯。
在本发明的一个实施例中,所述改性二氧化碳基聚氨酯占纤维皮层原料的质量比为16%-20%。
在本发明的一个实施例中,步骤(1)中,所述纤维芯层原料通过以下方法制备得到:
将增能助剂与聚己二酸/对苯二甲酸丁二酯混合造粒,得到改性聚己二酸/对苯二甲酸丁二酯母粒;将改性聚己二酸/对苯二甲酸丁二酯母粒与聚己二酸/对苯二甲酸丁二酯混合,得到所述纤维芯层原料。
在本发明的一个实施例中,所述增能助剂占纤维芯层原料的质量百分数为5%-10%
在本发明的一个实施例中,所述增能助剂为硬脂酸钙、硬脂酸镁和氮化硅的混合物;所述硬脂酸钙、硬脂酸镁与氮化硅的质量百分比分别为40%~50%、30%~40%与10%~30%。
在本发明的一个实施例中,步骤(1)中,满足以下条件中的一种或多种:
1)所述纤维为皮芯结构的复合型纤维;
2)所述熔喷的气流入射角为55°-65°;
3)所述预过滤层纤维网的喷丝板孔径为0.30mm-0.35mm,熔喷接收距离为15cm-20cm;
4)所述主过滤层熔喷材料的喷丝板孔径为0.20mm-0.25mm,熔喷接收距离为10cm-18cm。
在本发明的一个实施例中,所述造粒为通过双螺杆挤出机进行,将增能助剂与PBAT分别加入双螺杆挤出机的两个喂料斗,在180℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有增能助剂的改性的PBAT。
在本发明的一个实施例中,所述改性PBAT占纤维芯层原料的质量比为20%-30%。
在本发明的一个实施例中,所述纤维皮层原料中抗菌助剂的质量百分含量为3%-8%;纤维芯层原料中增能助剂的质量百分含量为5%-10%。
在本发明的一个实施例中,步骤(2)中,满足以下条件中的一种或多种:
a、所述电晕驻极的放电针尖的材质为钨;所述针尖的密度为900枚/m2~1000枚/m2;
b、所述电晕驻极的条件:电场强度为9kV/cm-11kV/cm,直流电压为95kv-105kv,充电距离为9.5cm-10.5cm;
c、所述电晕驻极的驻极时间为35s-45s。
本发明的第二个目的是提供所述的制备方法制备得到的高效抗菌的多功能双组分熔喷过滤材料。
在本发明的一个实施例中,其特征在于,所述多功能双组分熔喷过滤材料由上至下依次为预过滤层纤维网和主过滤层纤维网;所述预过滤层纤维网中纤维的直径为5μm-8μm,面密度为20g/m2-30g/m2,厚度为0.28mm-0.32mm;所述主过滤层纤维网中纤维的直径为1μm-5μm,面密度为15g/m2-25g/m2,厚度为0.07mm-0.12mm。
本发明第三个目的是提供所述的多功能双组份熔喷过滤材料在制备口罩或过滤器中的应用。
本发明的技术方案具有以下优点:
(1)本发明的高效抗菌的多功能双组分熔喷过滤材料中双层熔喷材料添加了增能助剂,明显增强材料的电荷存贮性能,显著提高了材料对微颗粒和细菌的静电吸引作用,从而提高过滤效率。
(2)本发明的高效抗菌的多功能双组分熔喷过滤材料中双层熔喷材料添加了抗菌助剂,抗菌助剂中的纳米氧化锌和二氧化碳基聚氨酯构成协同作用,二氧化碳基聚氨酯具有很强的吸水性,吸附的水能够促进纳米氧化锌产生更多的氢氧自由基,氢氧自由基具有很强的化学活性,能与大多数有机物反应,从而高效快速地杀死细菌,且纳米银作为长效型抗菌材料具有持续的高抗菌效能,保证材料无再生成细菌。
(3)本发明高效抗菌的多功能双组分熔喷过滤材料的制备原理图如图1所示,其利用双组分熔喷工艺,采用二氧化碳基聚氨酯和PBAT两种材料结合而成的独特新型皮芯纤维材料,均为可降解材料,不会污染环境,且两种材料性能的组合使熔喷过滤材料具有优异的延展性和断裂伸长率,也有较好的耐热性和冲击性能,且强力大、柔软性和悬垂性好,满足了过滤材料对性能多样化的需求,是单一聚合物和其他化合物所不能取得的。
(4)本发明的高效抗菌的多功能双组分熔喷过滤材料,利用双层纤维网结构提高材料的蓬松度,降低过滤阻力,且熔喷材料微孔较大,材料不易由于粉尘堵塞而造成阻力增加,所以容尘量大,使用寿命长。
(5)本发明的高效抗菌的多功能双组分熔喷过滤材料,熔喷装置采用特殊结构的熔喷模头,使气流入射角为55°-65°,纤维纠缠程度小且不易粘结,喷丝板孔不容易阻塞,有利于生产顺利进行。
(6)本发明的高效抗菌的多功能双组分熔喷过滤材料,应用电晕驻极技术处理熔喷材料,利用100kV的超高电压和10cm的超大充电距离,并采用材质为钨的放电尖针,使驻极均匀性更好,电荷储存密度更高,明显提高材料的过滤效率,且使材料形成表面静电场,产生微电流从而刺激细菌,在原材料添加抗菌助剂情况下,进一步协同高效杀菌。
(7)本发明的高效抗菌的多功能双组分熔喷过滤材料,双组分皮芯纤维中皮层主体组分为二氧化碳基聚氨酯,芯层主体组分为PBAT,均可降解原料,不会污染环境,保护大自然。
(8)本发明制备得到的高效抗菌的多功能双组分熔喷过滤材料,经TSI8130检测,其在流速为32升/分钟,氯化钠气溶胶质量中值直径0.26μm,平均过滤效率99.2%,平均过滤阻力21Pa。
附图说明
为了使本发明的内容更容易被清楚的理解,下面根据本发明的具体实施例并结合附图,对本发明作进一步详细的说明,其中
图1是本发明中高效抗菌的多功能双组分熔喷过滤材料的制备原理图;
图2是本发明实施例中制备皮芯型双组分熔喷纤维的结构图;
图3是本发明实施例中双层熔喷纤维网的结构图;
图4是本发明实施例中制备高效抗菌的多功能双组分熔喷过滤材料的工艺流程图;
附图标记说明:11双组分熔喷纤维芯层,12双组分熔喷纤维皮层,21双层熔喷纤维网的预过滤层,22双层熔喷纤维网的主过滤层。
具体实施方式
下面结合附图和具体实施例对本发明作进一步说明,以使本领域的技术人员可以更好地理解本发明并能予以实施,但所举实施例不作为对本发明的限定。
下述实施例和对比例中,所使用的实验方法无特殊说明,均为常规方法,所用的材料、试剂等,如无特殊说明,均可从商业途径得到。
纳米银粉购于徐州捷创新材料科技有限公司,规格:粒径20nm,含量99.9%;纳米氧化锌粉购于石家庄多亿化工科技有限公司,规格:粒径20nm,含量95%;硬脂酸钙购于东莞市臻铭化工有限公司,规格:含量99%,钙含量:6.5%-7.5%;硬脂酸镁购于安徽素之味生物科技有限公司,规格:含量99%,密度1.1g/m3;氮化硅购于苏州赛隆纳诺新材料实业有限公司,规格:粒径20nm,密度3.4g/cm3;PBAT购于深圳光华伟业股份有限公司,规格:含量99.9%,密度1.2g/cm3;二氧化碳基聚氨酯购于杭州普力材料科技有限公司,规格:含量99.9%。
实施例1
本实施例提供一种高效抗菌的多功能双组分熔喷过滤材料的制备方法如下:
将抗菌助剂与二氧化碳基聚氨酯切片分别加入双螺杆挤出机的两个喂料斗,在170℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有抗菌助剂的改性二氧化碳基聚氨酯母粒。抗菌助剂为纳米氧化锌和纳米银的混合物,其中纳米氧化锌和纳米银的质量百分数分别为70%和30%。抗菌助剂占改性二氧化碳基聚氨酯母粒的质量比为30%。
将增能助剂与PBAT切片分别加入双螺杆挤出机的两个喂料斗,在180℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有增能助剂的改性PBAT母粒。增能助剂为硬脂酸钙、硬脂酸镁、氮化硅的混合物,其中硬脂酸钙、硬脂酸镁和氮化硅的质量百分数分别为50%、30%和20%。增能助剂占改性PBAT母粒的质量比为28.57%。
将添加有抗菌助剂的改性二氧化碳基聚氨酯母粒和常规二氧化碳基聚氨酯切片混合,混合后作为纤维皮层原料,其中改性二氧化碳基聚氨酯母粒占皮层原料的质量比为20%。抗菌助剂占皮层原料的质量比为6%。
将添加有增能助剂的改性PBAT母粒与常规PBAT切片混合,混合后作为纤维芯层原料,其中改性PBAT母粒占芯层原料的质量比为28%。增能助剂占芯层原料的8%。
制备高效抗菌的多功能双组分熔喷过滤材料的工艺流程图如图4所示,采用两个熔喷模头的双组分熔喷装置,气流入射角为60°,制备得到皮芯结构的复合纤维,其结构图图2所示;设置预过滤层熔喷材料的喷丝板孔径为0.30mm,熔喷接收距离为18cm;主过滤层熔喷材料的喷丝板孔径为0.20mm,熔喷接收距离为12cm。通过熔喷依次制备出纤维直径不同的预过滤层熔喷材料、主过滤层熔喷材料,并利用热粘合复合,其中预过滤层熔喷纤维网的纤维直径为5μm,面密度为22g/m2,厚度为0.28mm,主过滤层熔喷纤维网的纤维直径为1μm,面密度为15g/m2,厚度为0.15mm。然后将两层复合熔喷纤维网进行电晕驻极处理,放电针尖材质为钨,布针密度为1000枚/m2,电场强度为10kV/cm,直流电压为100kv,充电距离为10cm,驻极时间为40s,最终制备得到高效抗菌的多功能双组分熔喷过滤材料即双层熔喷纤维网,其结构图如图3所示。
实施例2
本实施例提供一种高效抗菌的多功能双组分熔喷过滤材料的制备方法如下:将抗菌助剂与二氧化碳基聚氨酯切片分别加入双螺杆挤出机的两个喂料斗,在170℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有抗菌助剂的改性二氧化碳基聚氨酯母粒。抗菌助剂为纳米氧化锌和纳米银的混合物,其中纳米氧化锌和纳米银的质量百分数为65%和35%。抗菌助剂占改性二氧化碳基聚氨酯母粒的质量比为27.78%。
将增能助剂与PBAT切片分别加入双螺杆挤出机的两个喂料斗,在180℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有增能助剂的改性PBAT母粒。增能助剂为硬脂酸钙、硬脂酸镁、氮化硅的混合物,其中硬脂酸钙、硬脂酸镁和氮化硅的质量百分数为45%、35%和20%。增能助剂占改性PBAT母粒的质量比为25%。
将添加有抗菌助剂的改性二氧化碳基聚氨酯母粒和常规二氧化碳基聚氨酯切片混合,混合后作为纤维皮层原料,其中改性二氧化碳基聚氨酯母粒占皮层原料的质量比为18%。抗菌助剂占皮层原料的质量比为5%。
将添加有增能助剂的改性PBAT母粒与常规PBAT切片混合,混合后作为纤维芯层原料,其中改性PBAT母粒占芯层原料的质量比为24%。增能助剂占芯层原料的6%。
采用两个熔喷模头的双组分熔喷装置,气流入射角为58°,制备得到皮芯结构的复合纤维,其结构图图2所示;设置预过滤层熔喷材料的喷丝板孔径为0.32mm,熔喷接收距离为20cm;主过滤层熔喷材料的喷丝板孔径为0.22mm,熔喷接收距离为14cm。通过熔喷依次制备出预过滤层熔喷材料和主过滤层熔喷材料,并利用热粘合复合,其中预过滤层熔喷纤维网的纤维直径为6μm,面密度为23g/m2,厚度为0.29mm;主过滤层熔喷纤维网的纤维直径为2μm,面密度为16g/m2,厚度为0.16mm。然后将两层复合熔喷纤维网进行电晕驻极处理,放电针尖材质为钨,布针密度为970枚/m2,电场强度为9kV/cm,直流电压为95kv,充电距离为10.5cm,驻极时间为40s,最终制备得到高效抗菌的多功能双组分熔喷过滤材料。
实施例3
本实施例提供一种高效抗菌的多功能双组分熔喷过滤材料的制备方法如下:将抗菌助剂与二氧化碳基聚氨酯切片分别加入双螺杆挤出机的两个喂料斗,在170℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有抗菌助剂的改性二氧化碳基聚氨酯母粒。抗菌助剂为纳米氧化锌和纳米银的混合物,其中纳米氧化锌和纳米银的质量百分数为65%和35%。抗菌助剂占改性二氧化碳基聚氨酯母粒的质量比为23.53%。
将增能助剂与PBAT切片分别加入双螺杆挤出机的两个喂料斗,在180℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有增能助剂的改性PBAT母粒。
增能助剂为硬脂酸钙、硬脂酸镁、氮化硅的混合物,其中硬脂酸钙、硬脂酸镁和氮化硅的质量百分数为45%、35%和20%。增能助剂占改性PBAT母粒的质量比为27.27%。
将添加有抗菌助剂的改性二氧化碳基聚氨酯母粒和常规二氧化碳基聚氨酯切片混合,混合后作为纤维皮层原料,其中改性二氧化碳基聚氨酯母粒占皮层原料的质量比为17%。抗菌助剂占皮层原料的质量比为4%。
将添加有增能助剂的改性PBAT母粒与常规PBAT切片混合,混合后作为纤维芯层原料,其中改性PBAT母粒占芯层原料的质量比为22%。增能助剂占芯层原料的6%。
采用两个熔喷模头的双组分熔喷装置,气流入射角为62°,制备得到皮芯结构的复合纤维,其结构图图2所示;设置预过滤层熔喷材料的喷丝板孔径为0.34mm,熔喷接收距离为20cm;主过滤层熔喷材料的喷丝板孔径为0.24mm,熔喷接收距离为15cm。通过熔喷依次制备出纤维不同的预过滤层熔喷材料、主过滤层熔喷材料,并利用热粘合复合,其中预过滤层熔喷纤维网的纤维直径为7μm,面密度为24g/m2,厚度为0.30mm,主过滤层熔喷纤维网的纤维直径为3μm,面密度为17g/m2,厚度为0.17mm。然后将两层复合熔喷纤维网进行电晕驻极处理,布针密度为950枚/m2,放电针尖材质为钨,电场强度为11kV/cm,直流电压为105kv,充电距离为9.5cm,驻极时间为40s,最终制备得到高效抗菌的多功能双组分熔喷过滤材料。
实施例4
本实施例提供一种高效抗菌的多功能双组分熔喷过滤材料的制备方法如下:将抗菌助剂与二氧化碳基聚氨酯切片分别加入双螺杆挤出机的两个喂料斗,在170℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有抗菌助剂的改性二氧化碳基聚氨酯母粒。抗菌助剂为纳米氧化锌和纳米银的混合物,其中纳米氧化锌和纳米银的质量百分数为60%和40%。抗菌助剂占改性二氧化碳基聚氨酯母粒的质量比为18.75%。
将增能助剂与PBAT切片分别加入双螺杆挤出机的两个喂料斗,在180℃温度下共混熔融挤出,经水浴冷却后切割成粒,再经过干燥处理后得到添加有增能助剂的改性PBAT母粒。
增能助剂为硬脂酸钙、硬脂酸镁、氮化硅的混合物,其中硬脂酸钙、硬脂酸镁和氮化硅的质量百分数为50%、30%和20%。增能助剂占改性PBAT母粒的质量比为25%。
将添加有抗菌助剂的改性二氧化碳基聚氨酯母粒和常规二氧化碳基聚氨酯切片混合,混合后作为纤维皮层原料,其中改性二氧化碳基聚氨酯母粒占皮层原料的质量比为16%。抗菌助剂占皮层原料的质量比为3%。
将添加有增能助剂的改性PBAT母粒与常规PBAT切片混合,混合后作为纤维芯层原料,其中改性PBAT母粒占芯层原料的质量比为20%。增能助剂占芯层原料的5%.
采用两个熔喷模头的双组分熔喷装置,气流入射角为60°,制备得到皮芯结构的复合纤维,其结构图图2所示;设置预过滤层熔喷材料的喷丝板孔径为0.35mm,熔喷接收距离为17cm;主过滤层熔喷材料的喷丝板孔径为0.25mm,熔喷接收距离为11cm。通过熔喷依次制备出纤维直径不同的预过滤层熔喷材料、主过滤层熔喷材料,并利用热粘合复合,其中预过滤层熔喷纤维网的纤维直径为8μm,面密度为25g/m2,厚度为0.31mm,主过滤层熔喷纤维网的纤维直径为4μm,面密度为18g/m2,厚度为0.18mm。然后将两层复合熔喷纤维网进行电晕驻极处理,放电针尖材质为钨,布针密度为925枚/m2,电场强度为10kV/cm,直流电压为100kv,充电距离为10cm,驻极时间为40s,最终制备得到高效抗菌的多功能双组分熔喷过滤材料。
对比例1
本对比例中过滤材料的制备方法同实施例1类似,其区别仅在于,二氧化碳基聚氨酯切片不需要和抗菌助剂造粒,皮层原料只有常规二氧化碳基聚氨酯切片,不加入添加有抗菌助剂的改性二氧化碳基聚氨酯母粒。
对比例2
本对比例中过滤材料的制备方法同实施例1类似,其区别仅在于,PBAT切片不需要和增能助剂造粒,芯层原料只有常规PBAT切片,不加入添加有增能助剂的改性PBAT母粒。
对比例3
本对比例中过滤材料的制备方法同实施例1类似,其区别仅在于,采用一个熔喷模头的熔喷装置,只制备预过滤层熔喷材料,不制备主过滤层熔喷材料。
对比例4
本对比例中过滤材料的制备方法同实施例1类似,其区别仅在于,采用一个熔喷模头的熔喷装置,只制备主过滤层熔喷材料,不制备预过滤层熔喷材料。
性能测试
对上述实施例1-4和对比例1-4所制备的一种高效抗菌的多功能双组分熔喷过滤材料进行抗菌性能、过滤性能、降解性能测试依据的标准如下:
抗菌性能测试指标:GB/T 20944.3-2008《纺织品抗菌性能的评价第3部分:振荡法》。
过滤性能测试指标:参照GB2626-2019《呼吸防护自吸过滤式防颗粒物呼吸器》。其中采用TSI8130检测,使用氯化钠气溶胶作为过滤颗粒,设定的测试流量为32L/min,测量十次取平均值。
降解性能测试指标:GB T 22047-2008《土壤中塑料材料最终需氧生物分解能力的测定通过测定密闭呼吸机中需氧量或测定释放的二氧化碳的方法》。
实施例1-4和对比例1-4中所得高效抗菌的多功能双组分熔喷过滤材料的性能测试结果如表1所示:
表1过滤材料的性能测试结果
由表1的结果显示,实施例1制备的高效抗菌的多功能双组分熔喷过滤材料的抗菌助剂、增能助剂添加的量和喷丝板孔径设置的大小最为合适,故抑菌性能、过滤性能最优秀,而实施例2-4制备的高效抗菌的多功能双组分熔喷过滤材料的抗菌助剂、增能助剂添加的量依次减少和喷丝板孔径依次增大,故抑菌性能和过滤性能依次减弱。
对比例1制备的高效抗菌的多功能双组分熔喷过滤材料没有添加抗菌助剂,故抑菌率最低,抑菌性能较差。
对比例2制备的高效抗菌的多功能双组分熔喷过滤材料没有添加增能助剂,故过滤效率有所降低,过滤性能较差。
对比例3制备的高效抗菌的多功能双组分熔喷过滤材料只制备预过滤层熔喷材料,不制备主过滤层熔喷材料,故过滤效率、过滤阻力最低,过滤性能最差。
对比例4制备的一种高效抗菌的多功能双组分熔喷过滤材料只制备主过滤层熔喷材料,不制备预过滤层熔喷材料,故过滤效率、过滤阻力降低,过滤性能较差。
综上,预过滤层和主过滤层分别为粗滤和细滤,结合起来过滤性能更好。而由于主过滤层纤维直径更细,材料孔径更小,所以过滤性能比预过滤层高很多。
显然,上述实施例仅仅是为清楚地说明所作的举例,并非对实施方式的限定。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变化或变动。这里无需也无法对所有的实施方式予以穷举。而由此所引申出的显而易见的变化或变动仍处于本发明创造的保护范围之中。
Claims (8)
1.一种高效抗菌的多功能双组分熔喷过滤材料的制备方法,其特征在于,包括以下步骤:
(1)将纤维皮层原料和纤维芯层原料通过喷丝制备得到纤维,调整熔喷接收距离进行熔喷,分别制备得到预过滤层纤维网和主过滤层纤维网;
(2)将步骤(1)所得预过滤层纤维网和主过滤层纤维网利用热粘合复合,电晕驻极处理后,得到所述高效抗菌的多功能双组分熔喷过滤材料;
步骤(1)中,所述纤维皮层原料通过以下方法制备得到:
将抗菌助剂与二氧化碳基聚氨酯进行混合造粒,得到改性二氧化碳基聚氨酯母粒,然后将改性二氧化碳基聚氨酯母粒与二氧化碳基聚氨酯混合,得到所述纤维皮层原料;
步骤(1)中,所述纤维芯层原料通过以下方法制备得到:
将增能助剂与聚己二酸/对苯二甲酸丁二酯混合造粒,得到改性聚己二酸/对苯二甲酸丁二酯母粒;将改性聚己二酸/对苯二甲酸丁二酯母粒与聚己二酸/对苯二甲酸丁二酯混合,得到所述纤维芯层原料;
所述抗菌助剂为纳米氧化锌和纳米银的混合物;
所述增能助剂为硬脂酸钙、硬脂酸镁和氮化硅的混合物。
2.根据权利要求1所述的制备方法,其特征在于,所述纳米氧化锌的质量百分比为60%-70%;所述纳米银的质量百分比为30%-40%。
3.根据权利要求1所述的制备方法,其特征在于,所述硬脂酸钙、硬脂酸镁与氮化硅的质量百分比分别为40%~50%、30%~40%与10%~30%。
4.根据权利要求1所述的制备方法,其特征在于,步骤(1)中,满足以下条件中的一种或多种:
1)所述纤维为皮芯结构的复合型纤维;
2)所述熔喷的气流入射角为55°-65°;
3)所述预过滤层纤维网的喷丝板孔径为0.30 mm-0.35 mm,熔喷接收距离为15 cm-20cm;
4)所述主过滤层熔喷材料的喷丝板孔径为0.20 mm-0.25 mm,熔喷接收距离为10 cm-18 cm。
5.根据权利要求1所述的制备方法,其特征在于,步骤(2)中,满足以下条件中的一种或多种:
a、所述电晕驻极的放电针尖的材质为钨;所述针尖的密度为900枚/m²~1000枚/m²;
b、所述电晕驻极的条件:电场强度为9 kV/cm-11 kV/cm,直流电压为95 kv-105 kv,充电距离为9.5 cm-10.5 cm;
c、所述电晕驻极的驻极时间为35 s-45 s。
6.根据权利要求1-5任一项所述的制备方法制备得到的高效抗菌的多功能双组分熔喷过滤材料。
7.根据权利要求6所述的多功能双组份熔喷过滤材料,其特征在于,所述多功能双组分熔喷过滤材料由上至下依次为预过滤层纤维网和主过滤层纤维网;所述预过滤层纤维网中纤维的直径为5 μm-8 μm;所述主过滤层纤维网中纤维的直径为1 μm-5 μm。
8.权利要求6所述的多功能双组份熔喷过滤材料在制备口罩或过滤器中的应用。
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