JP2016074229A - 複合構造体 - Google Patents
複合構造体 Download PDFInfo
- Publication number
- JP2016074229A JP2016074229A JP2015252820A JP2015252820A JP2016074229A JP 2016074229 A JP2016074229 A JP 2016074229A JP 2015252820 A JP2015252820 A JP 2015252820A JP 2015252820 A JP2015252820 A JP 2015252820A JP 2016074229 A JP2016074229 A JP 2016074229A
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- electrospun
- composite structure
- nanofibers
- ptfe
- Prior art date
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Classifications
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Abstract
Description
本出願は、出願日が2009年8月7日の米国仮特許出願第61/232,252号(参照により本明細書中に援用される)に対する優先権に基づくものであり、またこれを主張するものである。
本開示の或る特定の実施の形態によれば、多層電界紡糸複合体を製造する方法が提供される。本方法は、少なくとも約50000cPsの粘度を有する、高分子ナノファイバ、繊維化ポリマー及び溶媒の分散液を形成することを含む。分散液から第1のePTFE層上にナノファイバを電界紡糸する。第2のePTFE層をナノファイバ上に施して、複合構造体を形成する。複合構造体を加熱する。
1.イースピンPTFEの実施形態において、分散液の粘度は、PEOとPTFEとの比率を変えることなく、水の添加又は分散液からの水の除去によって変更し得る。
2.放射状に膨張されたePTFE管又は二軸延伸シートを、丸みのあるベースプレート又は平らなベースプレート上に設置して、所望の幾何学的形状を形成する。
3.イースピンポリマー層を、所望の厚み、通常約0.5μm〜1000μmで、ePTFE上又は後にePTFE膜に結合させる表面上に施して、複合構造体をもたらす。
4.ePTFEに湿潤させたイースピンコーティングを施すと、次のプロセスへと移る前にそれが乾燥する。しかしながら、それを単一のイースピンシートとしてプロセス処理して、乾燥させると、それは多孔質の配向ePTFE層に結合するであろう。材料間の結合プロセスは、所望の多層複合構造体が作り出されるまで複数回繰り返すことができる。
5.ePTFE/イースピン複合体をその後、焦げ付き防止用剥離フォイル(non−sticking release foil)で覆う。
6.複合体をベースツールに対して配置した後に、フォイルの表面に圧力をかけることによって、結合プロセスを促す。
7.複合構造物を、約35℃〜約485℃の温度の炉内に入れ、全材料をひとつに結合させる。結合温度の選択は材料の選択に基づく。
8.炉から一部を除去し、毎分約15度〜毎分25度の速度で冷却させたら、その覆いを外して、特定の特性について試験する。
I型構造物:ePTFE/イースピンPTFE:
80μm厚のステンレス鋼(SS)シート46cm×36cmを、回転ドラムの周りに巻き付けた。ドラムアセンブリが、旋回するドラムアセンブリの長さ全体に沿ってイースピンする位置に据えられるように、ドラムアセンブリを回転チャックに設置した。
I型構造物:ePTFE/イースピンPTFE:
実施例2〜実施例6は、実施例1から変更して同様に行い、表Iに示される。概して、平均孔径直径の主な予測因子はePTFE膜のINDである。しかしながら、孔径はまた、圧力が大きいほどより小さい孔径をもたらすという、実施例1及び実施例4の複合体の厚みの比較によって示されるような、焼結中に複合体に印加される圧力の影響を受ける。イースピンPTFE層の厚みも、厚みが大きいほどより小さい孔径をもたらすという、実施例1、実施例2及び実施例3によって示されるような効果を有する。
I型構造物:ePTFE/イースピンポリウレタン(PU)
10μm〜30μmのノード間距離(intermodal distance)(IND)、34μmの厚み、及び3μm未満のバブルポイントを有する、二軸(Biax)膨張されたおよそ35cm×40cmのePTFEシートを、46cm×36cmステンレス鋼シート上に設置して、中心を合わせた。
I型構造物:ePTFE/イースピンポリウレタン(PU):
実施例8は、表IIに示される実施例7から変更して同様に行った。同様に、イースピンPUの層が厚くなるほど、小さい孔径がもたらされた。
II型構造物:ePTFE/イースピンPTFE/ePTFE:
30μmのノード間距離(IND)、4mmの内径(ID)、0.4mmの壁厚(WT)、及び80.33%の多孔度を有する、二軸(Biax)膨張されたおよそ10cm長のePTFE管を、35cm長の10mm外径(OD)アルミニウムロッド上に伸張させて、中心を合わせた。管アセンブリが、旋回する管アセンブリの長さ全体に沿ってイースピンする位置に据えられるように、管アセンブリを回転チャックに設置した。
II型構造物:ePTFE/イースピンPTFE/ePTFE:
実施例10〜実施例15は、表IIIに示される各実施例の個々の項目を用いて同様に行った。
III型構造物:イースピンPTFE/ePTFE/イースピンPTFE:
40μm厚のアルミニウムフォイルシート46cm×6.2cmを回転ドラムの周りに巻き付けた。ドラムアセンブリが、旋回するドラムアセンブリの長さ全体に沿ってイースピンする位置に据えられるように、ドラムアセンブリを回転チャックに設置した。
IV型構造物:基板/イースピンPTFE/ePTFE:
40μm厚の焦げ付き防止用アルミニウムフォイルシート43cm×38cmを回転ドラムの周りに巻き付けた。4.997gsmの基本重量、7μmの厚み及び72%の多孔性を有するおよそ35cm×30cmのePTFEシートを、アルミニウムフォイル上に据えて、中心を合わせ、固定した。ドラムアセンブリが、旋回するドラムアセンブリの長さ全体に沿ってイースピンする位置に据えられるように、ドラムアセンブリを回転チャックに設置した。
1.多層電界紡糸複合構造体を製造する方法であって、
少なくとも約50000cPsの粘度を有する、高分子ナノファイバ、繊維化ポリマー及び溶媒の分散液を形成することと、
前記分散液から第1のePTFE層上にナノファイバを電界紡糸することと、
前記ナノファイバ上に第2のePTFE層を施すことであって、複合構造体を形成する、第2のePTFE層を施すことと、
前記複合構造体を加熱することと、
を含む、多層電界紡糸複合構造体を製造する方法。
2.前記ナノファイバがPTFEを含む、上記1に記載の方法。
3.前記分散液が約50重量パーセント〜80重量パーセントのPTFEを含む、上記2に記載の方法。
4.前記分散液が約59重量パーセント〜61重量パーセントのPTFEを含む、上記2に記載の方法。
5.前記溶媒が水を含む、上記1に記載の方法。
6.前記繊維化ポリマーがポリエチレンオキシドを含む、上記1に記載の方法。
7.前記繊維化ポリマーが、ポリアクリルアミド、ポリビニルアルコール、ポリビニルピロリドン、デキストラン、アルギン酸塩、キトサン、グアーガム化合物、デンプン、セルロース化合物、ポリアクリレート、ポリカルボキシレート、ポリ乳酸、ポリメタクリル酸、又はそれらの組合せを含む、上記1に記載の方法。
8.前記分散液が少なくとも約100000cPsの粘度を有する、上記1に記載の方法。
9.多層電界紡糸複合構造体を製造する方法であって、
少なくとも約50000cPsの粘度を有し、かつ高分子ナノファイバと、繊維化ポリマーと、溶媒とを含む分散液を、ePTFE層の第1の側面上に電界紡糸することと、
少なくとも約50000cPsの粘度を有し、かつ高分子ナノファイバと、繊維化ポリマーと、溶媒とを含む分散液を、前記ePTFE層の第2の側面上に電界紡糸することであって、複合構造体を形成する、電界紡糸することと、
前記複合構造体を加熱することと、
を含む、多層電界紡糸複合構造体を製造する方法。
10.前記高分子ナノファイバの少なくとも一部がPTFEを含む、上記9に記載の方法。
11.前記分散液が約59重量パーセント〜61重量パーセントのPTFEを含む、上記9に記載の方法。
12.焼結させることを更に含む、上記9に記載の方法。
13.前記溶媒が水を含む、上記9に記載の方法。
14.多層電界紡糸複合構造体を製造する方法であって、
ポリウレタン溶液を形成することと、
前記ポリウレタン溶液から第1のePTFE層上にナノファイバを電界紡糸すること、
前記ナノファイバ上に第2のePTFE層を施すことであって、複合構造体を形成する、第2のePTFE層を施すことと、
前記複合構造体を加熱することと、
を含む、多層電界紡糸複合構造体を製造する方法。
15.多層電界紡糸複合構造体を製造する方法であって、
少なくとも約50000cPsの粘度を有する、高分子ナノファイバ、繊維化ポリマー及び溶媒の分散液を形成することと、
前記分散液から第1のePTFE層上にナノファイバを電界紡糸することと、
前記ナノファイバ上に基板を施すことであって、複合構造体を形成する、基板を施すことと、
前記複合構造体を加熱することと、
を含む、多層電界紡糸複合構造体を製造する方法。
16.前記ナノファイバがPTFEを含む、上記15に記載の方法。
17.前記分散液が約50重量パーセント〜80重量パーセントのPTFEを含む、上記16に記載の方法。
18.前記基板が織布又は不織布を含む、上記15に記載の方法。
19.前記基板がプラスチック膜又はセラミック膜を含む、上記15に記載の方法。
20.前記基板が、金網、セラミック網又はプラスチック網を含む、上記15に記載の方法。
Claims (27)
- 多層電界紡糸複合構造体を製造する方法であって、
分散液からナノファイバを静電紡糸して、電界紡糸ナノファイバのマットを生成するステップと、
前記分散液は、高分子粒子、繊維化ポリマー及び溶媒を含み、少なくとも約50,000cPsの粘度を有し、
前記電界紡糸のマットを第2の材料層を組み合わせるステップと、及び、
前記複合構造体を加熱するステップを含む、方法。 - 高分子粒子、繊維化ポリマー及び溶媒の分散液を形成するステップをさらに含み、前記分散液は、少なくとも約50,000cPsの粘度を有する、請求項1に記載の方法。
- 第2の材料層を組み合わせる前記ステップが、前記電界紡糸ナノファイバのマットを膨張ポリテトラフルオロエチレン(ePTFE)層と組み合わせるステップを含む、請求項1に記載の方法。
- 第2の材料層を組み合わせる前記ステップが、前記電界紡糸ナノファイバのマットを、天然繊維織物、人口繊維織物、天然繊維不織布、人口繊維不織布、プラスチック膜、セラミック膜、金網、セラミック網及びプラスチック網からなる群から選択される材料の層と組み合わせるステップを含む、請求項1に記載の方法。
- 前記高分子粒子がポリテトラフルオロエチレン(PTFE)を含み、前記電界紡糸ナノファイバが、紡糸PTFEナノファイバを含む、請求項1に記載の方法。
- 第3の材料層を、前記電界紡糸ナノファイバのマット及び前記第2の材料層と組み合わせるステップをさらに含み、前記複合構造体の前記マットの各々、第2の材料層、及び第3の材料層がPTFEを含む、請求項1に記載の方法。
- 前記分散液が、約50−80重量パーセントのポリテトラフルオロエチレンを含む、請求項1に記載の方法。
- 前記分散液が、約59−61重量パーセントのポリテトラフルオロエチレンを含む、請求項1に記載の方法。
- 前記溶媒が、水を含む、請求項1に記載の方法。
- 前記繊維化ポリマーが、ポリエチレンオキサイドを含む、請求項1に記載の方法。
- 前記繊維化ポリマーが、ポリアクリルアミド、ポリビニルアルコール、ポリビニルピロリドン、デキストラン、アルギン酸塩、キトサン、グアーガム化合物、デンプン、セルロース化合物、ポリアクリレート、ポリカルボキシレート、ポリ乳酸、ポリメタクリル酸、又はそれらの組合せを含む、請求項1に記載の方法。
- 前記分散液が少なくとも約100,000cPsの粘度を有する、請求項1に記載の方法。
- 焼結させるステップをさらに含む、請求項に記載の方法。
- 前記電界紡糸ナノファイバのマット及び第2の材料層を組み合わせるステップが、基板層上に前記電界紡糸ナノファイバのマットをプレスし、相補的な温度へ前記組合物を加熱するステップを含む、請求項1に記載の方法。
- 多層電界紡糸複合構造体を製造する方法であって、
分散液または溶液からナノファイバを静電紡糸して、電界紡糸ナノファイバのマットを生成するステップと、
前記電界紡糸ナノファイバのマットを、天然繊維織物、人口繊維織物、天然繊維不織布、人口繊維不織布、プラスチック膜、セラミック膜、金網、セラミック網及びプラスチック網からなる群から選択される第2の材料層と組み合わせるステップと、
前記第2の材料層上に前記電界紡糸ナノファイバのマットをプレスするステップと、及び、
相補的な温度へ前記複合構造体を加熱するステップを含む、方法。 - ナノファイバを静電防止する前記ステップが、ポリテトラフルオロエチレン(PTFE)の分散液からナノファイバを静電防止し、電界紡糸PTFEナノファイバを生成するステップを含む、請求項15に記載の方法。
- 第2の基板/材料層の第1の表面上に第1の層を規定する複数の電界紡糸ナノファイバを含む複合構造体であって、前記ナノファイバが、前記ナノファイバの接触点間に0.1μ乃至50μの距離の範囲であるような密度を有する、複合構造体。
- 前記電界紡糸ナノファイバが、ポリ(テトラフルオロエチレン)(PTFE)を含む、請求項17に記載の複合構造体。
- 前記ナノファイバが、ナイロン、ポリウレタン、ポリエステル、フッ素化エチレンプロピレン、又はそれらの組合せを含む、請求項17に記載の複合構造体。
- 前記第1の表面に対向する前記第2の基板層の第2の表面上の第2の複数の電界紡糸ナノファイバを更に含み、前記第2の複数の電界紡糸ナノファイバが、前記ナノファイバの接触点間に0.1μ乃至50μの距離の範囲であるような密度を有する、請求項17に記載の複合構造体。
- 前記第1の表面上の複数の電界紡糸ナノファイバ及び前記第2の表面上の複数の前記第2の電界紡糸ナノファイバの双方が、電界紡糸ポリ(テトラフルオロエチレン)(espunPTFE)を含む、請求項20に記載の複合構造体。
- 前記電界紡糸ナノファイバのマット及び前記第1の基板層と組み合わされた第3の材料層を更に含み、前記複合構造体の前記マット、第2の基板層及び第3の材料層が、PTFEを含む、請求項17に記載の複合構造体。
- 前記複数の電界紡糸ナノファイバが、第1のePTFE層と第2のePTFE層の間に挟まれており、第1のePTFE層及び第2のePTFE層と結合している、請求項17に記載の複合構造体。
- 前記基板層が、天然繊維織物、人口繊維織物、天然繊維不織布、人口繊維不織布、プラスチック膜、セラミック膜、金網、セラミック網及びプラスチック網からなる群から選択される材料を含む、請求項17に記載の複合構造体。
- 前記基板層が、膨張ポリテトラフルオロエチレン(ePTFE)を含む、請求項17に記載の複合構造体。
- 第3の層を更に含み、前記第3の層が、前記ナノファイバの接触点間に0.1μ乃至50μの距離の範囲であるような密度を有する複数の電界紡糸ナノファイバを含み、前記第1の層、前記第2の層又はそれらの組合せと結合されている、請求項17に記載の複合構造体。
- 第3の層を更に含み、前記第3の層が、ePTFEを含み、前記第1の層、前記第2の層又はそれらの組合せと結合されている、請求項17に記載の複合構造体。
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