CN1209178A - 高效呼吸罩织物 - Google Patents

高效呼吸罩织物 Download PDF

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Publication number
CN1209178A
CN1209178A CN96199958A CN96199958A CN1209178A CN 1209178 A CN1209178 A CN 1209178A CN 96199958 A CN96199958 A CN 96199958A CN 96199958 A CN96199958 A CN 96199958A CN 1209178 A CN1209178 A CN 1209178A
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CN
China
Prior art keywords
breathing mask
net
fiber
fabrics
mask fabrics
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Granted
Application number
CN96199958A
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English (en)
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CN1077167C (zh
Inventor
I·J·辛格
R·D·派克
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Kimberly Clark Worldwide Inc
Kimberly Clark Corp
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Kimberly Clark Worldwide Inc
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Publication of CN1209178A publication Critical patent/CN1209178A/zh
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Publication of CN1077167C publication Critical patent/CN1077167C/zh
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    • B03C—MAGNETIC OR ELECTROSTATIC SEPARATION OF SOLID MATERIALS FROM SOLID MATERIALS OR FLUIDS; SEPARATION BY HIGH-VOLTAGE ELECTRIC FIELDS
    • B03C3/00—Separating dispersed particles from gases or vapour, e.g. air, by electrostatic effect
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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Health & Medical Sciences (AREA)
  • General Health & Medical Sciences (AREA)
  • Physical Education & Sports Medicine (AREA)
  • Nonwoven Fabrics (AREA)
  • Filtering Materials (AREA)
  • Respiratory Apparatuses And Protective Means (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
  • Laminated Bodies (AREA)

Abstract

一种呼吸罩织物,该织物具有一占50到95重量百分率的由纤维构成的通气粘接驻极处理无纺微纤维第一网和一占5到50重量百分率的由纤维构成的驻极处理微纤维第二网,第一网中的纤维具有一约在10到25微米之间的平均直径,第一网具有一高于约100CFM/SF的Frazier渗透性、一处于0.015到0.15gms/cc之间的密度和一处于约67gsm到340gsm之间的基重,第二网中的纤维具有一小于约10微米的平均直径。

Description

高效呼吸罩织物
本发明总得来说涉及一种由热塑树脂的微纤维形成的无纺织物或网和将此种网做为一种组分的层制品，这些层制品已被做成一在呼吸罩如一面罩或一呼吸器中使用的过滤器。
将热塑树脂喷成纤维、织物或网已由来已久。这种做法中最常用的热塑物质是聚烯烃类物质，尤其是聚丙烯。其它材料，诸如聚酯、聚醚酯、聚酰胺和聚氨基甲酸乙酯，也可用来形成无纺微纤维织物。
无纺织物或网在一很宽的应用范围内，如尿布、妇女卫生品、毛巾、娱乐或保护织物及天然织物原料(geotextilt)和过滤介质，十分有用。在这些领域中使用的无纺网可以是简单的纺粘织物，但通常呈无纺织物层制品的样式，如纺粘/纺粘(SS)层制品或纺粘/熔喷/纺粘(SMS)层制品。层制品还可带有其它材料，如薄膜和薄织物。
作为过滤介质，无纺织物所应具有的一些特性包括被过滤的流体可以渗透过他们及他们具有一高的过滤效率。被过滤流体的可渗透性至关重要，因为低的渗透性可能导致过滤器两侧形成一高的压降。在诸如呼吸罩等领域中，高的压降就意味着戴该呼吸罩者将渡过一艰难时刻，即其不能畅快地吸入足够量的空气。在Krueger等人的美国专利第4,547,420号中给出了前述在可呼吸面罩方面尝试的一个例子，该例子中描述了带电的的双组分熔喷网。但，不幸的是，熔喷网大多只具有小尺寸的孔，这是由于其密度较高而纤维较短所致，因此压降太高不合乎需要。
织物的过滤效率通常由约0.1微米的NaCL微粒的穿透率来表示。对于呼吸面罩领域而言，通常需要一超过百分之80的NaCL效率，对于某些医学领域甚至要求超过百分之95、99或99.97。
在许多领域，要求过滤材料自身具有结实的结构并能转变成各种形状之后又能保持这种形状。呼吸面罩经常被做成一带有皱褶的形状，在相同的空间内这种皱褶形状比非皱褶形状具有更大的过滤表面积。
虽然以前已对生产微纤维呼吸面罩的进行了尝试，但是仍就需要一种具有低压降(也即高渗透性)和高NaCL效率的呼吸罩。
本发明的一个目的就是提供一种用作一具有高渗透性和高过滤效率的过滤介质的微纤维聚合物无纺织物或网。本发明的另一个目的是提供一种可以是一医用或其它用途的面罩和一工业用/商业用呼吸器的呼吸罩。
本发明的目的是通过一种呼吸面罩织物现实的，该织物具有一纤维构成的通气粘合驻极处理的无纺微纤维第一网和一纤维构成的驻极处理微纤维第二网，其中第一网占50到95重量百分率，第二网约占5到50重量百分率，第一网中的纤维的平均直径约在10到25微米之间，第二网中的纤维的平均直径约小于10微米，第一网具有一高于100CFM/SF的Frazier渗透性、一约在0.015到0.15gms/cc之间的密度、及约在100gsm到340gsm之间的基重。
图1是用于制造本发明过滤介质的生产线的示意图。图2是一种典型面罩的透视图。图3示出了一戴在佩戴者身上的面罩。
本文所采用的术语“无纺织物或网”是指一种具有单个纤维结构或单个丝结构的网，单个纤维或丝置于夹层中但不象针织织物那样可以被辨认出来。无纺织物或网可以由许多种生产方法形成，例如通过熔喷法、纺粘法、和粘梳网法形成。无纺织物的基重通常由每平方码多少盎司材料(osy)或每平方米多少克(gsm)来表示，而纤维的有效直径则通常按微米计算。(注意要想将osy转化为gsm，需要将osy乘以33.91)。
本文所采用的术语“微纤维”指的是直径很小的纤维，这种纤维的平均直径不超过约75微米，例如，这种纤维的平均直径约在0.5微米至50微米之间，更具体地说，微纤维可以具有一从约2微米到约40微米的平均直径。另一种常用来表达纤维直径的单位是但尼尔，但尼尔由每9000米纤维的克数限定，将微米计量的纤维直径取平方乘以以grams/cc为单位的密度再乘以0.00707后就可以计算出但尼尔数。低的但尼尔数意味着纤维较细，高的但尼尔数意味着纤维较粗或较重。例如，如果聚丙烯纤维的直径假定为15微米，那么将其平方后乘以89g/cc再乘00707就可以转化为但尼尔数。因此，一15微米的聚丙烯纤维具有一约为1.42的但尼尔数(15×15×0.89×0.00707＝1.415)。在美国以外，更常用的计量单位是“特克斯支数”，其由每千米纤维克数限定。将但尼尔数除9就可得到特克斯支数。
本文所用的述语“纺粘纤维”指的是直径较小的纤维，这些纤维通过将熔化的热塑性材料从一些细小的通常为圆形的喷丝头细孔中以细丝状压喷出而形成，压喷出的细丝的直径被迅速减小，如按照如下专利的方法：APPEL等人的美国专利第4,340,563号、DORSCHNER等人的美国专利第3,692,618号、MATSUKI等人的美国专利第3,802,817号、KINNEY的美国专利第3,542,615号和3,341,394号、HARTMAN的美国专利第3,502,763号、和DOBO等人美国专利第3,542,615号。纺粘纤维在他们置于一收集表面上时通常是不粘在一起的。纺粘纤维通常是连续的并且具有一大于7微米的平均直径(采用至少10个的取样尺寸)，更具体地说，该平均直径约在10到25微米之间。
本文所用的术语“熔喷纤维”指的是通过从若干细小的通常为圆形的模具细孔中压喷出形为熔化丝或细丝的热塑性材料而形成，压喷出的熔化丝或细丝与高速的通常是热的气体(例如，空气)汇合，这种高速气体使熔化的热塑性材料细丝进一步变细以减小他们的直径，该方法可将细丝的直径减小到微纤维的直径。接下来，这些熔喷纤维被高速气体流携带着置于一收集表面以形成一熔喷纤维随机分布的网。这种方法，例如由Butin的美国专利第3,849,241号公开。熔喷纤维是微纤维，这些纤维可以是连续的也可以是不连续的，他们的平均直径通常小于10微米(采用至少10根以上的取样尺寸)，并且这些纤维在置于一收集表面上时通常是粘在一起的。
本文所用的术语“单组分“纤维指的是一种由一个或多个挤压头用同一种聚合物形成的纤维。但是，这并不意味着这些纤维中不能包括少量的出于着色、抗静电性、润滑、亲水性等目的添加的添加剂。这些添加剂，如二氧化钛，通常所占比例小于5个重量百分比大于约2个重量百分比。
本文所用术语“结合纤维”指的是那些由至少两种从单独的挤压器中喷出的聚合物形成但纺成一根纤维的纤维。结合纤维有时也被称作多组分或双组分纤维。所用的纤维通常彼此不同，但是结合纤维可以由从不同挤压器喷出的同样一种聚合物形成。这些聚合物被大体均匀地分布于结合纤维横剖面的各个区域并沿结合纤维的长度连续延伸。这种结合纤维的结构可以是，例如，一种外套/内芯布置，其中一种聚合物被另一种聚合物包围或者可以一种并排布置、一种各聚合物如馅饼片一样布置的分段布置或一种“海中岛屿”形布置。在Kaneko等人的美国专利第5,108,820、Strack等人的美国专利5,336,552、Pike等人的美国专利5,382,400中给出了一些结合纤维。对于两种组分的纤维，各聚合物所占比例可以是75/25、50/50、25/75或其它任何合适的比例。
本文所用的通气粘接或“TAB”指的是一种将无纺结合纤维粘接的方法，在该方法中温度很高足以将生产网之纤维的聚合物中的一种熔化的空气被强制通过网。空气的速度在100至500fpm(30-152m/min)之间，停留时间可以长达60秒。空气的温度可以在约230到325°F(110-162℃)之间，具体采用何种温度要取决于所用聚合物的熔点。聚合物的熔化和重新凝固就产生了粘接效果。TAB需要至少一种组分熔化以达到粘接目的，因此其限制网必须具有至少两种组分，如结合纤维或那些包括有一种粘合剂的纤维。
本文中所用的术语“超声波粘接”法指的是一种例如通过将网从一如Bornslaeger的美国专利4,374,888中所描述的声音喇叭和反射轮之间穿过而实施的方法。
Frazier渗透性：一种织物或网对空气的渗透性的测量结果就是Frazier渗透性，这种测量根据1978年7月20日颁布的第191A号联邦检测标准中的方法5450进行，并将3次取样读数的平均值作为测量结果。Frazier渗透性以每平方英尺网每分钟通过多少立方英尺空气为单位或以CFM/SF为单位测量空气流过一网的流量。将CFM/SF结果乘以304.8就可以得到每分钟每平方米多少升(LSM)的结果。
NaCl效率：NaCl效率是一种测量织物或网阻止小微粒通其的能力的方法。通常该效率越高越好，效率越高表示其除去微粒的能力越强。NaCl效率目前按照TSI公司的1993年2月实施的型号为8110的自动化过滤器检测仪的操作手册的P/N号为1980053的修定版D进行测量，在测量过程中以每分钟32升的流量通过尺寸为0.1微米的NaCl微粒，以3次取样读数的平均值作为测量结果。这种方法同时还能得到0.1微米微粒的样品压降。该手册可以从美国，MN55164，Paul街，500Cardigan路，64394邮政信箱的TSI公司得到。
熔化流速：熔化流速(MFR)是一种测量聚合物之粘性的方法。MFR由一定载荷下或剪切率下在一测量时间段内从一公知尺寸的喷头流出的材料的重量表示，并可在一按照例如ASTM检测标准238-90b的设定温度和载荷下以克/10分钟为单位进行测量。
本发明实际所用的通气粘接网的微纤维可以通过纺粘法制成。纺粘法通常采用一个漏斗，该漏斗将聚合物提供给一被加热的挤压器。该挤压器将熔化的聚合物提供给一喷丝头，聚合物经过该喷丝头上一行或多行布置的细小开口时被纤维化，形成一细丝帘。这些细丝通常被一低压空气淬冷、拉拔，而后通常是气动地置于一移动的带孔垫、带或“形成线”上以形成无纺网。纺粘方法中所用的聚合物通常具有一约在400°F到610400°F(200℃到300℃)范围内的熔化处理温度。
纺粘法生产出的纤维其平均直径通常在约10到40微米范围内，具体直径由生产条件及由该纤维制造出的网的最终用途决定。例如，增加聚合物分子重量减小处理温度将获得直径较大的纤维。改变淬冷区域的温度以及气动拉拔压力也可以影响纤维的直径。
本发明织物是一种多层层制品。多层层制品的一个例子可以是一如下实施例，其中一些层是纺粘的，另一些层则是熔喷的，例如Brock等人的美国专利4,041,203和Collier等人的美国专利第5,169,706号所公开的纺粘/熔喷/纺粘(SMS)层制品，或是一种纺粘/纺粘层制品。一SMS层制品可以通过连续地先将一纺粘网层而后将一熔喷网层最后将另一纺粘层附着于一移动运输带或形成线上之后以上述方式将各层粘接而形成。也可以，先透一制造上述三网层，将他们绕成卷，而后再以一单独的粘接步骤结合在一起。这些织物通常具有一约在0.1至12osy(6到400gsm)范围内的基重，更具体地说是从约0.75到约3osy。
本发明实际所用的通气粘接网的纤维最好具有一较大松密度(bulk)或膨松度(loft)，因为通常织物的膨松度越低压降越高。膨松度可以由网密度表示，本文所用织物的网密度最好在约0.015与0.15grams/cc之间，具体地说是在约0.015到0.08gms/cc之间，更具体地说是在0.015至0.04gms/cc之间。
可以用来生产本发明通气粘接网的纺粘纤维中的一种是结合纤维，例如并排(S/S)纤维。用于生产纤维的聚合物可以是本领域所公知的任何一种可纤维化的纤维。可纤维化聚合物包括聚氨基酯、聚氯乙烯、聚四氟乙烯、聚苯乙烯、聚乙烯对酞酸盐、聚酰胺、聚碳酸酯、聚烯烃类如4甲基1戊烷、聚丁烯、聚丙烯和聚乙烯。当上述结合纤维被生产和冷却时，由于这些聚合物从熔化相转变为固相时的膨胀系数以及密度不同，再在加上其它一些因素的影响，导致这些纤维弯曲最终卷曲起来，这有些类似于通常室内恒温器中的双金属片所进行的动作。通过用热空气拉拔这些纤维可以增加这种卷曲的程度，因为这种拉拔可以激发出纤维潜在的卷曲性，Pike等人的美国专利US5,382,400对此做了详细的描述，具体内容详见该专利。卷曲的纤维比不卷曲的纤维具有优势，即他们可以生产出更加膨松的网，从而提高织物或网的渗透性。
在纺粘纤维网的生产过程中他们被一挤压轮或热空气刀处理以使网足够结实以便于进一步加工。从严格意义上讲，这种处理并不是必须的，因为，如果多加以小心，可以将网直接接受一更结实的粘接工艺，而用不进行上述操作。在网形成并且可选择地进行挤压轮或热空气刀处理之后，该网接受通气粘接。通气粘接法可以生产出一种更加膨松的网，因为这种方法不象其它方法如热点粘接法那样挤压网使网的体积密度减小。通气粘接法与热点粘接法相比具有另外的好处，即该方法不会形成限制空气流通的粘接点，而空气能否流通对于一呼吸罩来说非常重要。
在进行完通气粘接处理之后，这些网可以接受永久极化处理(驻极处理)。驻极处理由于使过滤器纤维带有电荷，这些电荷将要被过滤掉的微粒拉向过滤器纤维，从而使过滤效率进一步提高。驻极处理可以通过一些不同的技术实现。转让给美国田纳西大学研究公司的Tsai等人的美国专利第5,401,446公开了其中一种技术，具体内容见该专利。Tsai描述了一种方法，在该方法中一网或膜连续经历一系列电场，相邻电场具有彼此基本相反的极性。因此，该网或膜的一面最初受到正电荷作用时，该网或膜的另一面则最初受到负电荷的作用。而后，该网或膜的第一面受负电荷作用，而该网或膜的另一面则受正电荷的作用。这些网生产出来后具有一相对较高的电荷密度。这种处理可以通过如此过程实现，即将该网穿过一些分散的无火花电场，如从一充电导线或棒和带电轮之间穿过，根据对网所要带有电荷量的不同，可以在一定范围内调整电场和间隙。该网可以带有的电荷约在-30kVDC/cm到30kVDC/cm范围内，具体说在-10kVDC/cm到25kVDC/cm范围内，更具体地说在-5kVDC/cm到25kVDC/cm。上述间隙可以在约0.25英寸(6.5mm)到约2英寸(51mm)之间，具体说在约0.5到1.5英寸(13到38mm)之间，更具体地说约为一英寸(25.4mm)。
其它一些驻极处理方法也为本领域所公知，如Kubik等人的美国专利US4,215,682、Wadsworth的US4,375,718、Nakao的US4,592,815和Ando的US4,874,659中所描述的驻极方法。
许多聚烯烃类可用于生产纤维，例如聚乙烯类，如DOW化学公司的ASPUN6811A线性低密度聚乙烯、2552LLDPE和25355及12350高密度聚乙烯就是很合适的聚合物。这些聚乙烯在190°F温度2,16kg负荷下分别具有约26、40、25和12g/10分钟的熔化流速。由聚丙烯形成的纤维包括Exxon化学公司的ESCORENEPD3445聚丙烯和Himont化学公司的PF-305。在市场上还可以买到其它许多聚烯烃类。
现在参见图1，该图公开了一用于制备本发明织物或网一个实施例的生产线10。该生产线10设置用来生产结合连续细丝，但应理解到，本发明包括用具有至少两种组分的多组分细丝制成的无纺织物。例如，本发明织物可以由具有三或四种组分的细丝制成。生产线10包括一对挤压机12a和12b，他们分别挤压一种聚合物组分A和一聚合物组分B。聚合物组分A从一第一漏斗14a输入对应的挤压机12a，而聚合物组分B则从一第二漏斗国4b输入对应的挤压机12b。聚合物组分A和B经各自的聚合物管16a和16b从挤压机12a和12b输送到一喷丝头18。该用于压喷结合细丝的喷丝头对于本领域普通技术人员来说的公知的，因此在此就不再详述。简要地讲，该喷丝头18包括一个旋转接头，该接头包括若干垛叠在一起的盘，这些盘上以一种形式布置有一些孔，这孔用作引导聚合组分A和B分别流出喷丝头的流过通道。喷丝头18上的孔布置成一行或多行。这些喷丝头上的孔形成一向下挤出的细丝帘，该细丝帘由从喷丝头挤出的聚合物构成。为了达到本发明目的，喷丝头18可以被适当布置以形成并排或偏心的外套/内芯结合细丝。
生产线10还包括一个淬冷吹风机20，该吹风机20置于从喷丝头10挤出的细丝帘的附近。从该淬冷吹风机20吹出的风使从喷丝头18挤出的细丝淬冷。淬冷风可以从细丝帘的一边吹，如图1所示，也可以从细丝帘的两边同时吹。
在喷丝头18的下方置有一纤维拉拔装置或吸气机22，用于接收被淬冷的细丝。如上所述，在熔化拉拔聚合物操作中使用的纤维拉拔装置或吸气机是公知的。适于用在本发明方法中的纤维拉拔装置包括美国专利US3,802,817所示形式的直线纤维吸气机和美国专利US3,692,618及3,423,266所示形式的喷射枪，具体内容参见这些专利。
简要地说，纤维拉拔装置22包括一个细长的垂直通道，细丝通过该通道时被从通道侧壁进来的向下流过该通道的抽吸空气拔长。加热器24将热的抽吸空气输入纤维拉拔装置22内。这些热的抽吸空气将细丝拔长，而后环境空气进入纤维拉拔装置，这两个过程可以用来形成卷曲纤维。
在纤维拉拔装置22的下方设置有一循环的带孔成形表面26，用于接收从纤维拉拔装置的出口输出的连续细丝。成形表面26绕导向轮28移动。在成形表面26的下方对着细丝之处设置有一吸气机30，该吸气机30将细丝吸向成形表面。
如图所示的生产线10还包括一热空气刀34，该热空气刀34置于成形表面26上的网的上方。热空气刀是一种用于聚集一股速度非常高的被加热空气流并在无纺网形成之后立刻将这股空气导向该形成的无纺网上的装置，所聚集空气流的速度大体从每分钟1000到10000英尺(每分钟305到3050米)，更具体地说是从约每分钟3000到5000英尺(每分钟915到1525米)。热空气刀吹出的空气的温度通常在至少一种网中所用聚合物的熔点范围内，对于纺粘法中普遍采用的热塑性聚合物来说，该温度通常约在200到550°F(93到290℃)的范围内。对空气的温度、速度、压力和流量的控制以及对其它一些因素的控制有助于避免损伤网同时可以增加其结实度。HAK聚集的空气流被至少一个约1/8到1英寸(3到25mm)，更具体地说是3/8英寸(9.4mm)宽的槽布置并引导，该槽用作朝网吹出的热空气的出口，该槽基本在机器的横向并基本在网的整个宽度上延伸。在另一实施例中，可以设置一些彼此相邻但被一微小间隔分开的槽。此外，生产线包括一粘接装置，该装置是一通气粘接机36。当网穿过该通气粘接机后，再从一带电导线或棒48和一带电轮42之间穿过，而后再从一第二带电导线或棒50与轮44之间穿过。
最后，该生产线10包括一卷筒46，用于承载制造好的织物。
为了使该生产线10工作，漏斗14a和14b被分别填满聚合物组分A和B。聚合物组分A和B被熔化并被各自的挤压机12a和12b挤压通过聚合物管管16a和16b和喷丝头18。尽管聚合物的熔化温度取决于所用聚合物，但当将聚丙烯和聚乙烯分别作用组分A和B时，聚合物的较佳温度在370°到约530°F范围内，最佳范围是400°到约450°F。
当被挤出的细丝从喷丝头18下方伸出后，来自淬冷吹风机20的一股空气至少将细丝部分淬冷以在细丝内产生一潜在的螺旋卷曲趋势，这股空气的温度约在45°到约90°F之间，其速度从约每分钟100英尺至每分钟400英尺。
淬冷后，细丝被来自加热器24的一热空气流吸入纤维拉拔装置22的垂直通道并穿过该纤维拉拔装置。纤维拉拔装置最好置于喷丝头18底部下方30到60英寸范围内。加热器24提供的空气的温度应足够高以便在与随细丝一起吸入的较冷环境空气混合后仍可以将细丝加热到卷曲纤维所需的温度，如果纤维是可卷曲的，该温度是激励潜在卷曲趋势所需的温度。激励热的可卷曲细丝的潜在卷曲趋势所需的温度分布在约110°F到一最大温度的范围内，该最大温度小于低熔点组分的熔点，对于通气粘接材料该低熔点组分是第二组分B。为了达到不同水平的卷曲度来自加热器24的空气的温度以及该空气将细丝加热到的温度都是可以改变的。大体上讲，空气温度越高，产生卷曲的数目也越多。可卷曲细丝实际表现出的卷曲度能够被控制，这种能力非常有好处的，因为只需通过对纤维拉拔装置内的空气的温度进行简单调整就可以改变织物的最终密度和孔尺寸分布。
在挤压之后，细丝通过纤维拉拔装置22的出口落在移动成形表面26上。吸气机30将细丝吸向成形表面26以形成一连续细丝构成的未粘接的无纺网。接下来，热空气刀34使该网具有一定程度的结实性，而后在通气粘接机36中通气被通气粘接。
通常具有一高于组分B熔化温度但低于组A熔化温度的温度的空气从罩40导入在通气粘接机36内，而后穿过网，进入穿孔轮38。注意，如果控制时能够多加仔细，并留意不要让网本身的温度超过组分A的熔点，采用温度高于组分A熔点的空气也是可以的。通气粘接机也可以是一扁平布置，空气垂直向下导向网上。两种结构的工作条件相同，主要不同在于粘接时网的几何形状。热空气将低熔点聚合物B熔化从而在结合细丝之间形成粘接从而将网形成一体。当聚丙烯和聚乙烯被分别用作组分A和B时，流过通气粘接机的空气通常具有一从约230°F到约325°F(110℃到162℃)的温度范围，并具有一从每分钟100英尺到每分钟400英寸的速度。但是，应理解到，通气粘接机的参数取决于诸如所用聚合物种类及网的厚度等因素。
而后，网穿过带电棒或导线48与带电鼓或轮42之间的带电场，之后穿过一带电棒或导线50与带电鼓或轮44之间形成的极性相反的第二带电场。这样网就带有了约-5kVDC/cm到25kVDC/cm范围内的电荷。
最后，制成的网被卷在卷筒46上，以备进一步处理或使用。
用于呼吸罩的过滤织物所应具有的最重要的特性是Frazier渗透性和NaCl效率。我们认为这种织物的较大的纤维层应具有一超过100CFM/SF的Frazier渗透性，整个织物应具有一高于80％的NaCl效率。适于用作一呼吸罩的织物最好具有一约在100到340gsm之间的基重。
尽管已发现只经过驻极处理的通气粘接纺粘织物就可以达到所需的NaCl效率和Frazier渗透性，但是所得呼吸罩的生产成本相对较高，这是因为所需材料之厚度的缘故。本发明人已发现把一细小的微纤维层用于一大纤维网附近或与之结合会使得所用大纤维网在保持原有NaCl效率和Frazier渗透性的情况下更轻一些。这种新颖的发明形成一种比仅具有纺粘纤维的呼吸罩重量更轻成本更低的呼吸罩，更具体地说，形成一种织物，这种织物由纤维构成的占50到95重量百分率的通气粘接驻极处理无纺微纤维第一网和由纤维构成的占5到50重量百分率的驻极处理微纤维第二网结合而成，第一网中的纤维具有一约在10到25微米之间的平均直径，该第一网具有一高于约100CFM/SF的Frazier渗透性、一0.015到0.15gms/cc之间的密度和一在约100gsm和340gsm之间的基重，第二网中的纤维具有一小于10微米的平均直径，这样的构成形成一种重量足够轻又可渗透并具有所需过滤效率的织物。
与粗纤维网结合使用的细纤维网仍应驻极处理.这种驻极处理的实施方式与纺粘网的驻极处理实施方式相同。进过处理的细纤维网可以带有上述针对纺粘网所给范围内的电荷。细纤维网可以由任何本领域技术人员所公知的适于生产细纤维产品适于驻极处理的聚合物制成。聚烯烃类尤其值得考虑，特别是聚丙烯。
可以通过任何本领域公知的有效方法将本发明织物制成一呼吸罩。例如，图2中示出了一个典型的面罩，图3中示出了戴在穿戴者身上的面罩。在Grier-Idris的普通转让美国专利4,662,005中还可以发现更多的有关面罩的信息，具体内容详见该专利。在采用多层(一层以上)的呼吸罩的结构中，例如一纺粘和熔喷层，与许多无纺申请中通常所为不同，在本发明中该纺粘和熔喷层并非在整个织面上都粘在一起，而是仅仅绕边缘利用超声波粘接，因为粘接通常会减小空气流过织物的面积。也就是说，由在多层形成的织物的大部分上各层之间并不粘接，仅仅是通过周边超声粘接法彼此紧靠地保持在适当位置。
出于各种具体的应用的目的，还可以将一薄织物或膜叠置在本发明网上。为了提高面罩与皮肤接触面的柔软性在公知呼吸罩上使用的薄织物是公知的。膜可以用来增加飞溅保护性，当然这种用于本发明中的膜必须是可透气的。
为了检测本发明生产出了各种网，表1对他们做了具体描述。在表中，所有的纺粘织物样品均是并排结合纤维。结合纺粘法中采用的聚合物是作为组分A的Exxon公司生产的ESCORENEPD3445聚丙烯和作为组分B的Bow公司生产的ASPUN6811A线性低密度聚乙烯，两种组分各占50％。样品1、7和8中的纺粘网的密度约为0.04gm/cc，样品2、9和10中的纺粘网的密度约为0.11gms/cc。熔喷网由Exxo公司的3746G聚丙烯制成，这种聚丙烯具有一约800的熔化流速，该熔化流被以每英寸每孔2磅的速度(phi)挤压出来，其形成高度为11英寸(28cm)。网全部被驻极处理。纺粘网按照-5KVDC/cm到25KVDC/cm进行驻极处理。熔喷网则按照12KVDC/cm到5KVDC/cm进行驻极处理。在多层网中，各层不粘在一起，检试时仅仅彼此相邻而置。
做成之后，通过所示方法对网的压降和过滤效率进行检测。结果由表1示出。
                                表1
  样品 纺粘层基重(gsm) 熔喷层基重(gsm)   Frazier渗透性(ft3/min/ft2)     ％效率(0.1μm NaCl)    压差
    1     102     0         429       70    0.23
    2     102     0         233       81    0.53
    3     0     9         303       63    0.40
    4     0     17         111       84    1.00
    5     0     20         90       85    1.60
    6     0     34         52       94    3.00
    7     102     9         190       91    0.70
    8     102     17         111       96    1.27
    9     102     9         136       94    1.00
    10     102     17         84       97    1.60
该表示出了粗纤维纺粘层虽具有一较高的Frazier渗透性但效率较低，细纤维熔喷层虽具有一较低的Frazier渗透性但效率较高。将各层叠在一起神奇地产生出一种织物，这种织物不仅具有熔喷材料所特有的高效率同时还保持了一可以接受的高Frazier渗透性。这种结果同时还反映在压降数据上，该压降数据示出了多层层制品具有一可接受的压降。
尽管，上面只详细描述了本发明几个示例性的实施例，但是本领域技术人员很容易理解在不实质上背离本发明之新颖学说及优点的前提下可以对这些示例性实施例上进行许多改进。因此，所有这种改进都要包括在后面权利要求所限定的本发明保护范围内。在这些权利要求中，装置加功用的权利要求用来覆盖文中所述实现所引证功能的结构、此种结构的等同物以及此种结构的等同结构。因此尽管一枚钉子与一个螺钉不是结构等同物，因为钉子用一个圆柱表面将木质部件固定在一起而螺钉却用一个螺旋表面，但是就固定木质部件的场合而言，钉子与螺钉可以算是等同结构。

Claims (27)

1.一种呼吸罩过滤织物包括：
重量上占百分之50到95的一种纤维构成的通气粘接驻极处理无纺微纤维第一网，其中所述纤维具有一在约10到约25微米之间的平均直径，所述第一网具有一高于约100CFM/SF的Frazier渗透性、一在约0.015到0.15gms/cc之间的密度和一大到约340gsm的基重，及
重量上占百分之5到50的一种纤维构成的驻极处理微纤维第二网，其中所述纤维具有一小于约10微米的平均直径。
2.如权利要求1所述的呼吸罩织物，其特征在于：该织物被制成带有皱褶。
3.如权利要求1所述的呼吸罩织物，其特征在于：所述第一网的微纤维由处于一种结合纺粘结构的聚合物组成。
4.如权利要求3所述的呼吸罩织物，其特征在于：所述结合纺粘结构是并排结构。
5.如权利要求3所述的呼吸罩织物，其特征在于：所述结合纺粘结构是外套/内芯结构。
6.如权利要求3所述的呼吸罩织物，其特征在于：所述聚合物是聚丙烯和聚乙烯。
7.如权利要求5所述的呼吸罩织物，其特征在于：所述聚合物是聚乙烯和聚酰胺。
8.如权利要求1所述的呼吸罩织物，其特征在于：所述第二网的微纤维由聚丙烯组成。
9.如权利要求1所述的呼吸罩织物，其特征在于：所述第一和第二网已经被周边粘接。
10.如权利要求9所述的呼吸罩织物，其特征在于：所述周边粘接通过超声波实现。
11.如权利要求1所述的呼吸罩织物，其特征在于：所述所述织物具有一至少为百分之80的NaCl效率。
12.如权利要求1所述的呼吸罩织物，其特征在于：所述所述织物具有一至少为百分之95的NaCl效率。
13.如权利要求1所述的呼吸罩织物，其特征在于：所述所述织物具有一至少为百分之99的NaCl效率。
14.如权利要求1所述的呼吸罩织物，其特征在于：所述所述织物具有一至少为百分之99.7的NaCl效率。
15.如权利要求1所述的呼吸罩织物，其特征在于：所述第一网具有一处于约0.015到0.08gms/cc之间的密度。
16.如权利要求1所述的呼吸罩织物，其特征在于：所述第一网具有一处于约0.015到0.04gms/cc之间的密度。
17.一种包括权利要求1所述织物的面罩。
18.一种包括权利要求1所述织物的呼吸器。
19.一种呼吸罩过滤织物包括：
重量上占百分之80到90的一种由结合纤维构成的通气粘接驻极处理纺粘网，其中所述网具有一高于100CFM/SF的Frazier渗透性、一处于约0.015到0.08gms/cc之间的密度和一大到约200gsm的基重，及；
重量上占百分之10到20的一种驻极处理熔喷聚丙烯网。
20.如权利要求19所述的呼吸罩织物，其特征在于：所述结合纤维被布置成一种并排结构。
21.如权利要求20所述的呼吸罩织物，其特征在于：所述结合纤维由聚丙烯和聚乙烯组成。
22.如权利要求19所述的呼吸罩织物，其特征在于：所述第一和第二网已经被周边粘接。
23.如权利要求22所述的呼吸罩织物，其特征在于：所述周边粘接通过超声波实现。
24.如权利要求19所述的呼吸罩织物还包括一个膜。
25.如权利要求19所述的呼吸罩织物还包括一薄织物。
26.一种包括权利要求19所述织物的面罩。
27.一种包括权利要求19所述织物的呼吸器。
CN96199958A 1995-12-22 1996-12-11 高效呼吸罩织物 Expired - Fee Related CN1077167C (zh)

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US5817584A (en) 1998-10-06
CN1077167C (zh) 2002-01-02
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DE69620227T2 (de) 2002-12-12
CA2239789A1 (en) 1997-07-03
WO1997023246A2 (en) 1997-07-03
WO1997023246A3 (en) 1997-08-21
JP2000502574A (ja) 2000-03-07
EP0868553A2 (en) 1998-10-07
AU1685097A (en) 1997-07-17
AU699795B2 (en) 1998-12-17
BR9612266A (pt) 2001-02-28
DE69620227D1 (de) 2002-05-02
KR19990076687A (ko) 1999-10-15

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