CN116856110A - 一种熔喷布及其制造工艺和使用该熔喷布制备的防臭型口罩 - Google Patents
一种熔喷布及其制造工艺和使用该熔喷布制备的防臭型口罩 Download PDFInfo
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Classifications
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- A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
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- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
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Abstract
本申请涉及口罩制备相关领域,具体公开了一种熔喷布及其制造工艺和使用该熔喷布制备的防臭型口罩,所述熔喷布,其由包括以下重量份的原料制成:聚醋酸乙烯酯12‑15份、聚丙烯31‑41份、聚丁烯19‑23、驻极母粒1.5‑5份,本申请制备的熔喷布及使用该熔喷布制备的口罩具有低通气阻力、过滤效率优良的效果;本申请提供的熔喷布和口罩的制备方法,具有制备便捷,制备效率高的特点。
Description
技术领域
本申请涉及口罩制备相关领域,尤其是涉及一种熔喷布及其制造工艺和使用该熔喷布制备的防臭型口罩。
背景技术
SMS型口罩,包括2层S层和1层M层,S层指外侧的纺粘层、M层指位于中部的熔喷层,熔喷层通常使用聚丙烯熔喷形成,具备较好过滤效果。
现有的熔喷布主要以聚丙烯为主要原料,空隙多、结构蓬松、抗褶皱能力好,具有独特的毛细结构的超细纤维增加单位面积纤维的数量和表面积,从而使熔喷布具有很好的过滤性和屏蔽性,但是,使用聚丙烯制备的熔喷布通气阻力通常在60Pa以上,为了提高防护效果,许多口罩会牺牲佩戴舒适度来增加口罩密封性,通过机械的方式过滤粉尘只能增加阻隔过滤元件,层层累加之后呼吸阻力就会非常大,通过增加口罩层数或是口罩厚度、封闭度来增强口罩隔离效果,虽然提高了过滤效率,但会使得佩戴者佩戴时体验感差。
因此需要研发出一种防护效果好且佩戴舒适的口罩。
发明内容
为了改善现有口罩为提升防护效果造成的佩戴不适的问题,本申请的第一个目的在于提供一种熔喷布,所制备的熔喷布具有细菌过滤效率、颗粒物过滤效率高,经时稳定性、高温稳定性好的效果。
本申请的第二个目的在于提供一种熔喷布的制备方法,所述熔喷布制备方法便捷,能够提升熔喷布生产效率。
本申请的第三个目的在于提供一种口罩的制备方法,其具有制备便捷,制备效率高的特点;制备得到的口罩具有防护效果好、佩戴时通气阻力低从而佩戴舒适性高的效果。
本申请的第四个目的在于将制备得到的口罩应用于儿童。
第一方面,本申请提供的一种熔喷布采用如下的技术方案:
一种熔喷布,由包括以下重量份的原料制成:
聚醋酸乙烯酯12-15份、
聚丙烯31-41份、
聚丁烯19-23份、
驻极母粒1.5-5份。
通过采用上述技术方案,加入聚醋酸乙烯酯、聚丁烯可相应增加聚丙烯纤维的韧性和塑性,熔融制成的纤维流动性得到提升,所制得的熔喷纤维细度高,孔隙小且均匀,叠合度高,单位面积内熔喷纤维网的支撑性能提高,从而在熔喷布较薄时也能达到较好的过滤效果,加入驻极母粒后能够提高纤维吸附性,增加其对颗粒物和细菌的吸附能力;由于吸附能力提高,所制备的熔喷纤维网在低密度、低通气阻力下仍具备优良吸附效果。
可选的,制备所述熔喷布的原料还包括纤维剂,所述纤维剂选自聚乳酸和铜氨纤维中的一种或两种。
可选的,所述纤维剂由聚乳酸、铜氨纤维按重量比为(6-13):(7-14)组成。
通过采用上述技术方案,聚乳酸低碳环保、可降解,天然抑菌,,铜氨纤维性能稳定,在加入聚乳酸和铜氨纤维后,制备所得的熔喷布的细菌过滤效率、颗粒物过滤效率提升;此外,与单独加入聚乳酸或铜氨纤维相比,两者混合加入时,能够对经时颗粒物过滤效率变化率、经时细菌过滤效率变化率、高温细菌过滤效率变化率产生协同效果,增强口罩的经时稳定性和耐高温能力,使得制备所得的熔喷布过滤性能、稳定性能更高,可适用于高温环境。
可选的,制备所述熔喷布的原料还包括添加剂,所述添加剂由润滑剂、稳定剂、单糖组成;
所述润滑剂为甘油三羟基硬脂酸酯、氧化聚乙烯蜡、费托蜡、硬脂酸中的一种或多种;
所述稳定剂为蓖麻酸镉、硬脂酸钙、蓖麻酸钙、硬脂酸镁中的一种或多种;
所述单糖为葡萄糖和山梨糖中的一种或两种。
优选的,所述润滑剂为甘油三羟基硬脂酸酯,所述稳定剂为蓖麻酸钙,所述单糖为山梨糖。
优选的,所述添加剂由甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖按重量比为(0.5-4):(1-4):(0.5-2)组成。
通过采用上述技术方案,加入甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖,能够提升熔喷布的细菌过滤效率、颗粒物过滤效率,同时能够降低熔喷布一定效期内的过滤效率变化率,减少制备所得口罩的细菌菌落总数,这可能是由于,加入甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖后,制备所得的熔喷纤维分散性能增强,不轻易发生粘结,且粘度合适,出丝稳定性高。
可选的,制备所述熔喷布的原料还包括0.5-1.2重量份的丁香花提取物。
通过采用上述技术方案,加入丁香花提取物制备的熔喷布细菌菌落总数降低,且色泽浅淡、气味清新,这可能是因为,丁香花提取物对霉菌能够产生抑制作用,有效地抑制霉菌生长繁殖。
可选的,所述聚丙烯为α晶型等规聚丙烯或β晶型等规聚丙烯。
优选的,所述聚丙烯为α晶型等规聚丙烯,更优选的,所述聚丙烯为含量90%的α晶型等规聚丙烯,所述α晶型等规聚丙烯MFI在400~1200g/10min,熔融指数≥1500。
通过采用上述技术方案,含量90%的α晶型等规聚丙烯制备所得的口罩通气阻力进一步降低,a晶型聚丙烯弹性模量、屈服强度较好,制备所得的熔喷布抗蠕变性能更高,使得熔喷纤维网具备稳定的支撑性能,在长期储存、高温下不轻易发生变形,纤维之间固定牢固度提升,抗冲击性和热变形温度得到平衡,从而过滤效率提升;进一步选用MFI在400~1200g/10min,熔融指数≥1500g/10min的a晶型聚丙烯,能够与聚醋酸乙烯酯及聚丁烯的融合度,使得熔喷纤维的流动性提升,纤维能够达到更高的细度和均匀度。
第二方面,本申请提供的一种熔喷布的制备方法,包括以下步骤:
将聚丙烯、聚醋酸乙烯酯、聚丁烯、驻极母粒及其它原料混合、熔融挤压形成熔融聚合物并喷出形成纤维,冷却后即为所述熔喷布。
进一步的,熔喷布的制备方法包括:
S11:将聚丙烯、聚醋酸乙烯酯、聚丁烯、驻极母粒及其他原料混合形成混合料;
S12:混合料熔融挤压形成熔融聚合物;
S13:熔融聚合物过滤,输送至熔喷模头;
S14:熔喷模头喷出的聚合物经过热空气以30km/min的速度牵引,牵引定形形成纤维;
S15:纤维经过冷空气冷却凝固,即为所述熔喷布;
优选的,熔喷布的制备方法包括:
S11:将聚丙烯、聚醋酸乙烯酯、聚丁烯、驻极母粒、纤维剂、添加剂磨碎至粒径≤3mm,混合形成混合料;
S12:原料熔融挤压形成熔融聚合物;
S13:熔融聚合物过滤,输送至熔喷模头;
S14:熔喷模头喷出的聚合物经过热空气以30km/min的速度牵引,牵引定形形成纤维;
S15:纤维经过冷空气冷却凝固,即为所述熔喷布;
通过采用上述技术方案,在原料通过研磨机磨碎至粒径≤3mm后进行挤出,使得熔融物的分散性能好,不发生结晶;且熔喷模头喷出纤维时,将热空气以30km/min的速度对纤维进行牵引,不轻易出现飞花现象,使得熔喷纤维纤度适宜,孔隙率减小,增强了纤网的捕捉能力,过滤效率增大,保持熔喷布纤维网的稳定性能。
第三方面,本申请提供的防臭型口罩的制备方法,包括以下步骤:
S1:熔喷布生成;
S2:三层复合材料SMS生成:
S21:纺粘布原料制得纺粘布;
S22:将两层纺粘布分别粘合在熔喷布两侧,制得三层复合材料SMS;
S3:三层复合材料SMS收卷、裁切成片;
S4:缝合鼻夹、热固定耳夹,裁断缝边并压片,制得所述口罩。
通过采用上述技术方案,通过一次点粘合将纺粘布热轧粘合在熔喷纤维上形成三层复合材料SMS,或是先将生产好的纺粘布和熔喷布、通过层压或其他热轧粘合方式将两层纺粘布粘贴在熔喷布两侧,制备简单,利于量产。
第四方面,本申请制备的口罩,由于通气阻力小,佩戴舒适,适用于儿童佩戴,不易出现呼吸不畅导致血气浓度不足甚至对呼吸系统造成伤害的问题,有利于儿童心肺功能发育。
综上所述,本申请包括以下至少一种有益技术效果:
1.加入聚醋酸乙烯酯、聚丁烯可相应增加聚丙烯纤维的韧性和塑性,熔融制成的纤维流动性得到提升,所制得的熔喷纤维细度高,孔隙小且均匀,叠合度高,单位面积内熔喷纤维网的支撑性能提高,从而在熔喷布较薄时也能达到较好的过滤效果,加入驻极母粒后能够提高纤维吸附性,增加其对颗粒物和细菌的吸附能力;由于吸附能力提高,所制备的熔喷纤维网在低密度、低通气阻力下仍具备优良吸附效果;
2.原料通过研磨机磨碎后进行挤出,使得熔融物的分散性能好,不发生结晶;且熔喷模头喷出纤维时,将热空气以30km/min的速度对纤维进行牵引,不轻易出现飞花现象,使得熔喷纤维纤度适宜,孔隙率减小,增强了纤网的捕捉能力,过滤效率增大,保持熔喷布纤维网的稳定性能;
3.本申请制备的口罩,由于通气阻力小,佩戴舒适,适用于儿童佩戴,不易出现呼吸不畅导致血气浓度不足甚至对呼吸系统造成伤害的问题,有利于儿童心肺功能发育。
附图说明
图1是本申请生产工艺流程示意图;
图2是本申请中熔喷布生成生产工艺流程示意图;
图3是本申请中三层复合材料SMS生成生产工艺流程示意图。
具体实施方式
以下结合实施例对本申请作进一步详细说明。下列实施例仅用于说明本申请,而不应视为限制本申请的范围。以下实施例中未注明具体条件者,按照常规条件或制造商建议的条件进行,使用的方法如无特别说明,均为本领域公知的常规方法,使用的耗材和试剂如无特别说明,均为市场购得。除非另有说明,本文中所用的专业与科学术语与本领域熟练人员所熟悉的意义相同。此外,任何与所记载内容相似或均等的方法或材料也可应用于本申请中。
以下各实施例及对比例中各组分添加量单位为Kg。
实施例
实施例1-3
以下实施例聚丙烯为β晶型等规聚丙烯,其MFI在400~1200g/10min,熔融指数≥1500g/10min;聚醋酸乙烯酯为纯度为99.6%聚醋酸乙烯酯,聚丁烯,CasNo:9003-28-5,购置于湖北恩星生物科技有限公司;驻极母粒为市售的堆积密度0.50~0.80g/cm3的驻极母粒。
实施例1-3分别提供了一种口罩。
实施例1-3中口罩的制备方法,包括以下步骤:
上述各实施例的不同之处在于:口罩中各组分的重量份,具体如表1所示。
表1:实施例1-3提供的口罩中各组分组成
聚醋酸乙烯酯 | 聚丙烯 | 聚丁烯 | 驻极母粒 | |
实施例1 | 12 | 41 | 19 | 1.5 |
实施例2 | 18 | 31 | 23 | 5 |
实施例3 | 15 | 35 | 21 | 3 |
实施例1-3中口罩的制备方法,包括以下步骤:
S1:熔喷布生成:
S11:将聚丙烯、聚醋酸乙烯酯、聚丁烯、驻极母粒计量混合形成原料;
S12:原料投入螺杆挤压装置熔融挤压形成熔融聚合物;
S13:熔融聚合物输送到过滤器过滤,经计量泵输送至熔喷模头;
S14:采用高速热空气流对熔喷模头喷丝孔挤出的聚合物熔体细流进行牵伸,热空气以30km/min的速度牵引,聚合物牵引定形后形成纤维;
S15:纤维经过冷空气冷却后,铺设在收卷辊上凝固形成所述熔喷布;
S2:三层复合材料SMS生成:
S21:纺粘布原料经挤出机熔融挤压并经过两台喷丝机制备纺粘纤维,两层纺粘纤维分别喷射在熔喷布的两侧以形成三层纤维网结构;
S22:三层纤维网结构通过铺网机移动至热轧机热轧粘合,制得三层复合材料SMS;
S3:三层复合材料SMS通过卷绕机收卷后,使用分切机裁切至预定形状;
S4:缝合鼻夹、热固定耳夹,裁断缝边并压片,制得所述口罩。
上述步骤S12中熔融聚合物性能检测如下所示:
表2:实施例1-3中S12所得熔融聚合物性能检测
实施例4-8
实施例4-8分别提供了一种口罩。
上述实施例与实施例3的不同之处在于:实施例4-8中的口罩制备还添加有纤维剂,纤维剂包括聚乳酸和铜氨纤维中的一种或两种,具体添加量如下表3所示。
实施例4-8中口罩的制备方法,包括以下步骤:
S1:熔喷布生成:
S11:选取纤维剂、聚丙烯、聚醋酸乙烯酯、聚丁烯、驻极母粒计量混合形成原料;
S12:原料投入螺杆挤压装置熔融挤压形成熔融聚合物;
S13:熔融聚合物输送到过滤器过滤,经计量泵输送至熔喷模头;
S14:采用高速热空气流对熔喷模头喷丝孔挤出的聚合物熔体细流进行牵伸,热空气以30km/min的速度牵引,聚合物牵引定形后形成纤维;
S15:纤维经过冷空气冷却后,铺设在收卷辊上凝固形成所述熔喷布;
S2:三层复合材料SMS生成:
S21:纺粘布原料经挤出机熔融挤压并经过两台喷丝机制备纺粘纤维,两层纺粘纤维分别喷射在熔喷布的两侧以形成三层纤维网结构;
S22:三层纤维网结构通过铺网机移动至热轧机热轧粘合,制得三层复合材料SMS;
S3:三层复合材料SMS通过卷绕机收卷后,使用分切机裁切至预定形状;
S4:缝合鼻夹、热固定耳夹,裁断缝边并压片,制得所述口罩。
表3:实施例3-8提供的口罩中各组分组成
实施例9-11
实施例9-11分别提供了一种口罩。
上述实施例与实施例8的不同之处在于:实施例9-11中的口罩制备还添加有添加剂,添加剂由甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖按下表4组成。
表4:实施例8-11提供的口罩中添加剂各组分的组成
实施例9-11中口罩的制备方法,包括以下步骤:
S1:熔喷布生成:
S11:选取纤维剂、聚丙烯、聚醋酸乙烯酯、聚丁烯并加入驻极母粒计量混合形成原料;
S12:
S121:原料中加入甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖并搅拌均匀得搅拌原料;
S122:搅拌原料投入螺杆挤压装置熔融挤压形成熔融聚合物;
S13:熔融聚合物输送到过滤器过滤,经计量泵输送至熔喷模头;
S14:采用高速热空气流对熔喷模头喷丝孔挤出的聚合物熔体细流进行牵伸,热空气以30km/min的速度牵引,聚合物牵引定形后形成纤维;
S15:纤维经过冷空气冷却后,铺设在收卷辊上凝固形成所述熔喷布;
S2:三层复合材料SMS生成:
S21:纺粘布原料经挤出机熔融挤压并经过两台喷丝机制备纺粘纤维,两层纺粘纤维分别喷射在熔喷布的两侧以形成三层纤维网结构;
S22:三层纤维网结构通过铺网机移动至热轧机热轧粘合,制得三层复合材料SMS;
S3:三层复合材料SMS通过卷绕机收卷后,使用分切机裁切至预定形状;
S4:缝合鼻夹、热固定耳夹,裁断缝边并压片,制得所述口罩。
实施例12
实施例12提供了一种口罩。
实施例12与实施例11的不同之处在于:实施例12中还添加有1Kg丁香花提取物(CASNo.:84961-50-2)。
实施例12中口罩的制备方法,包括以下步骤:
S1:熔喷布生成:
S11:选取纤维剂、聚丙烯、聚醋酸乙烯酯、聚丁烯、驻极母粒计量混合形成原料;
S12:
S121:原料中加入甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖并搅拌均匀得搅拌原料;
S122:搅拌原料投入螺杆挤压装置中,将丁香花提取物加压投入螺杆挤压装置中并混合均匀,螺杆挤压装置熔融挤压至形成熔融聚合物;
S13:熔融聚合物输送到过滤器过滤,经计量泵输送至熔喷模头;
S14:采用高速热空气流对熔喷模头喷丝孔挤出的聚合物熔体细流进行牵伸,热空气以30km/min的速度牵引,聚合物牵引定形后形成纤维;
S15:纤维经过冷空气冷却后,铺设在收卷辊上凝固形成所述熔喷布;
S2:三层复合材料SMS生成:
S21:纺粘布原料经挤出机熔融挤压并经过两台喷丝机制备纺粘纤维,两层纺粘纤维分别喷射在熔喷布的两侧以形成三层纤维网结构;
S22:三层纤维网结构通过铺网机移动至热轧机热轧粘合,制得三层复合材料SMS;
S3:三层复合材料SMS通过卷绕机收卷后,使用分切机裁切至预定形状;
S4:缝合鼻夹、热固定耳夹,裁断缝边并压片,制得所述口罩。
实施例13
实施例13提供了一种口罩。
实施例13与实施例12的不同之处在于:实施例13中的聚丙烯选用α晶型等规聚丙烯。
实施例14
实施例14提供了一种口罩。
实施例14与实施例13的不同之处在于:制备方法的不同。
实施例14中口罩的制备方法,包括以下步骤:
S1:熔喷布生成
S11:选取纤维剂、聚丙烯、聚醋酸乙烯酯、聚丁烯并加入驻极母粒计量混合形成原料;
S12:
S121:原料中加入甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖并搅拌均匀得搅拌原料;
S122:搅拌原料通过研磨机磨碎至粒径≤3mm后投入螺杆挤压装置,S123:将丁香花提取物加压投入螺杆挤压装置中并混合均匀;螺杆挤压装置熔融挤压至形成熔融聚合物;
S13:熔融聚合物输送到熔体过滤器过滤,经计量泵输送至熔喷模头;
S14:采用高速热空气流对熔喷模头喷丝孔挤出的聚合物熔体细流进行牵伸,热空气以30km/min的速度牵引,聚合物牵引定形后形成纤维;
S15:纤维经过冷空气冷却后,铺设在收卷辊上凝固形成所述熔喷布;
S2:三层复合材料SMS生成:
纺粘布层压或粘合在熔喷布两层,制得三层复合材料SMS;
S3:三层复合材料SMS通过卷绕机收卷后,使用分切机裁切至预定形状;
S4:缝合鼻夹、热固定耳夹,裁断缝边并压片,制得所述口罩。
对比例
对比例1
对比例1与实施例3的区别在于:口罩制备时未添加聚醋酸乙烯酯。
对比例2
对比例2与实施例3的区别在于:口罩制备时未添加聚丁烯。
性能检测试验
1)按照T/CDAMEI001-2020口罩用熔喷非织造布中检测方法,测试口罩的细菌过滤效率;
2)按照GB2626-2019规定条件下,熔喷布滤除颗粒的水平,测试口罩的颗粒物过滤效率;
3)YYT0969-2013的测试方法,测试口罩两侧面进行气体交换的通气阻力,应不大于49Pa/cm为合格;
4)按照T/CDAMEI001-2020口罩用熔喷非织造布中检测方法,测试口罩的过滤效率变化率;其中,在有效期内(2年)颗粒过滤效率变化率≤5%,细菌过滤效率变化率≤2%为合格;记录颗粒过滤效率变化率为A,记录细菌过滤效率变化率为B,
5)测试口罩的高温(65℃)条件下过滤效率变化率,记录为C;
6)生物学评价:
细胞毒性按GB/T16886.12的条件制备浸提液,采用GB/T16886.5的方法进行。皮肤剌激按GB/T16886.12的条件制备浸提液,采用GB/T16886.10中规定的动物皮肤刺激试验进行。迟发型超敏反应按GB/T16886.12规定的条件制备浸提液,采用GB/T16886.10中规定的迟发型超敏反应最大剂量试验进行试验
7)非灭菌口罩按GB15979附录B规定执行的方法进行试验,检测口罩的微生物指标;
8)外观检测:
外观质量6.2.1任取10个样品进行试验,目视检查;检验光线以正常自然光为准,如以日光灯照明时,照度不低于600lx。
实施例14中按规格50g/㎡制得的口罩的基本质量要求检测结果如下表5所示:
表5:实施例14制备所得口罩基本质量要求检测
实施例1-14、对比例1-2中口罩的各项性能检测结果如下:
表6:实施例1-14、对比例1-2中口罩的各项性能
记录颗粒过滤效率变化率为A(%),记录细菌过滤效率变化率为B(%),高温(65℃)条件下过滤效率变化率,记录为C(%),各项变化率检测结果如下:
表7:实施例1-14、对比例1-2中口罩的各项变化率
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结果分析
以下结合表1-7提供的实验数据,对本申请进行详细说明。
结合实施例1-14及表6,在使用聚醋酸乙烯酯、聚丙烯、聚丁烯、驻极母粒制备得到的口罩,其通气阻力在30Pa以下,细菌过滤效率达到92.5-99.4%,颗粒物过滤效率92.4-99.3%,未经灭菌时其细菌菌落总数在23-63CFU/g、未检出真菌菌落,远低于相关标准中的200CFU/g和100CFU/g含量,细菌过滤效率及颗粒物过滤效率好;通气阻力低。
结合实施例1-14及表7,实施例1-14制备得到的口罩,经时颗粒物过滤效率变化率能够控制在5%以内,细菌过滤效率变化率控制在2%以内,高温细菌过滤效率变化率控制在2.5%以内,性能稳定,可耐高温,生产后一定期效内过滤效果稳定。
实施例1-3考察了聚醋酸乙烯酯、聚丙烯、聚丁烯、驻极母粒的组分和配比对制备所得口罩的影响,虽然细菌菌落总数及真菌菌落总数未变化,但是实施例3制得的口罩通气阻力更低,细菌过滤效率、颗粒物过滤效率更高,从而实施例3为较优实施例。
以实施例4为对照,实施例4-8考察了聚乳酸和铜氨纤维对制备所得口罩的影响,在单独加入聚乳酸或铜氨纤维时,通气阻力降低在2.6个变化单位内,细菌过滤效率、颗粒物过滤效率提升均在2个变化单位内,且经时颗粒物过滤效率变化率(A)在3.5%以上、经时细菌过滤效率变化率(B)在1.6%以上、高温细菌过滤效率变化率(C)在1.82%以上,实施例8为较优实施例。
通过将聚乳酸和铜氨纤维混合加入后,相较于两者分别添加的方式,混合加入后通气阻力降低幅度更大,且细菌过滤效率、颗粒物过滤效率提升均至96%以上,且经时颗粒物过滤效率变化率(A)在3%以下、经时细菌过滤效率变化率(B)在1.6%以下、高温细菌过滤效率变化率(C)在1.4%以上;可见聚乳酸和铜氨纤维混合加入后,能够对熔喷布的通气阻力、经时颗粒物过滤效率变化率(A)、经时细菌过滤效率变化率(B)、高温细菌过滤效率变化率(C)产生协同效果,增强口罩的经时稳定性和耐高温能力。
以实施例8为对照,实施例8-11考察了添加剂的不同配比对制备所得口罩的影响,加入添加剂时,口罩的通气阻力变化、高温细菌过滤效率变化率(C)均不明显,但细菌菌落总数下降,细菌过滤效率、颗粒物过滤效率提升均至97%以上;且经时颗粒物过滤效率变化率(A)在1.7%以下、经时细菌过滤效率变化率(B)在1.2%以下,可见添加剂能够降低制备所得口罩的细菌菌落总数,提升细菌过滤效率、颗粒物过滤效率,且对经时颗粒物过滤效率变化率(A)、经时细菌过滤效率变化率(B)产生积极影响;综合考虑下,甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖按照3:4:3加入时,熔喷布各项性能表现更佳,实施例11为较优实施例。
以实施例11为对照,实施例12考察了丁香花提取物对制备所得口罩的影响,虽然入丁香花提取物后高温细菌过滤效率变化率(C)、经时细菌过滤效率变化率(B)、通气阻力变化不大,但是,制备所得的口罩细菌菌落总数进一步降低至23CFU/g,细菌过滤效率、颗粒物过滤效率得到一定程度提升,这可能是因为,丁香花提取物对熔喷布生产过程中的霉菌能够产生抑制作用,有效地抑制霉菌生长繁殖,因此制备得到的口罩具有良好的除臭效果。
以实施例12为对照,实施例13考察了聚丙烯的性能对制备所得口罩的影响,在选用MFI在400~1200g/10min,熔融指数≥1500的α型等规聚丙烯后,制备所得的口罩通气阻力降低,细菌过滤效率、颗粒物过滤效率提升均至99%以上;经时颗粒物过滤效率变化率(A)、经时细菌过滤效率变化率(B)、高温细菌过滤效率变化率(C)降低至1%以下;这可能是由于MFI在400~1200g/10min,熔融指数≥1500的α型等规聚丙烯制备的纤维达到更高的细度,过滤效果得到提升;制备所得的熔喷布抗蠕变性能更高,使得熔喷纤维网具备稳定的支撑性能,在长期储存、高温下不轻易发生变形,纤维之间固定牢固度提升。
以实施例13为对照,实施例14考察了制备方法对制备所得的口罩的影响,在原料通过研磨机磨碎至粒径<3mm后进行挤出,且熔喷模头喷出纤维时,将热空气以30km/min的速度对纤维进行牵引,制备所得的口罩通气阻力降低至16Pa以下,且经时颗粒物过滤效率变化率(A)、经时细菌过滤效率变化率(B)、高温细菌过滤效率变化率(C)降低至1%以下;这可能是因为原料磨碎后,能够使得熔融物的分散性能好,不轻易发生结晶。
以实施例3为对照,对比例1-2分别考察了未添加聚醋酸乙烯酯、未添加聚丁烯的情况下,对具备所得口罩的影响,其中,对比例1和对比例2的其他部分性能能够达到标准,但是,通气阻力均≥67Pa,且经时细菌过滤效率变化率(B)在4.5%以上、高温细菌过滤效率变化率(C)达到3.5%以上,口罩通气阻力,佩戴体验感不佳,且口罩稳定性表现效果不佳。
此外,从表5可见,实施例3制备得到的口罩抗断裂能力较高,皮肤刺激性小,迟发型超敏反应为1级,因此适用于儿童日常防护佩戴,能够兼顾防护性能与舒适性能,儿童长时间佩带也不会因呼吸不畅导致血气浓度不足或对呼吸系统造成伤害,有利于儿童心肺功能发育。
本具体实施例仅仅是对本申请的解释,其并不是对本申请的限制,本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改,但只要在本申请的权利要求范围内都受到专利法的保护。
Claims (10)
1.一种熔喷布,其特征在于,由包括以下重量份的原料制成:
聚醋酸乙烯酯12-15份、
聚丙烯31-41份、
聚丁烯19-23份、
驻极母粒1.5-5份。
2.根据权利要求1所述的熔喷布,其特征在于:制备所述熔喷布的原料还包括纤维剂,所述纤维剂选自聚乳酸和铜氨纤维中的一种或两种。
3.根据权利要求2所述的熔喷布,其特征在于:所述纤维剂由聚乳酸、铜氨纤维按重量比为(6-13):(7-14)组成。
4.根据权利要求1所述的熔喷布,其特征在于:制备所述熔喷布的原料还包括添加剂,所述添加剂由润滑剂、稳定剂、单糖组成;
所述润滑剂为甘油三羟基硬脂酸酯、氧化聚乙烯蜡、费托蜡、硬脂酸中的一种或多种;
所述稳定剂为镉、、蓖麻酸钙、硬脂酸镁中的一种或多种;
所述单糖为葡萄糖和山梨糖中的一种或两种。
5.根据权利要求4所述的熔喷布,其特征在于:所述添加剂由甘油三羟基硬脂酸酯、蓖麻酸钙、山梨糖按重量比为(0.5-4):(1-4):(0.5-2)组成。
6.根据权利要求1所述的熔喷布,其特征在于:制备所述熔喷布的原料还包括0.5-1.2重量份的丁香花提取物。
7.根据权利要求1所述的熔喷布,其特征在于:所述聚丙烯为α晶型等规聚丙烯或β晶型等规聚丙烯。
8.一种权利要求1-7中任一项所述的熔喷布的制备工艺,其特征在于,包括以下步骤:
将聚丙烯、聚醋酸乙烯酯、聚丁烯、驻极母粒及其他原料混合、熔融挤压形成熔融聚合物并喷出形成纤维,冷却后即为所述熔喷布。
9.根据权利要求8中所述的熔喷布的制备工艺,其特征在于,包括以下步骤:
将聚丙烯、聚醋酸乙烯酯、聚丁烯、驻极母粒、纤维剂、添加剂磨碎至粒径≤3mm,和其他原料混合均匀、熔融挤压形成熔融聚合物并喷出形成纤维,冷却后即为所述熔喷布。
10.一种防臭型口罩,其特征在于,由权利要求1-9中任一项所述熔喷布制备得到。
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