JP2022036046A - 多層型銅系ゼオライト繊維医療用材料、医療用防護用品及びその製造方法 - Google Patents
多層型銅系ゼオライト繊維医療用材料、医療用防護用品及びその製造方法 Download PDFInfo
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- JP2022036046A JP2022036046A JP2021133300A JP2021133300A JP2022036046A JP 2022036046 A JP2022036046 A JP 2022036046A JP 2021133300 A JP2021133300 A JP 2021133300A JP 2021133300 A JP2021133300 A JP 2021133300A JP 2022036046 A JP2022036046 A JP 2022036046A
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- copper
- fiber
- layer
- based zeolite
- zeolite
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Abstract
Description
民生用マスクは、着用時間が短く、防護要求が低いため、細胞毒性が規定されていない。
同様に、このときの銅イオンは、ヒト細胞の負に帯電した細胞膜に作用して、細胞構造を破壊するという作用を果たすこともでき、これは、この医療用防護マスクが強い細胞毒性を持ち、生物学的安全性の要求を満たすことができないことを示している。この特許明細書で記載される「銅元素は人体に無害で、環境を汚染せず、良い抗菌性を兼有する唯一の金属元素である」という主張が誤り、多くの権威ある文献は、すべて銅元素が強い細胞毒性を有することを証明している((1)Wataha JC.Effect of cell line on in vitro metal ion cytotoxicity[J].Dental Materials,1994,10(3):156-161;(2)WatahaJC,Hanks CT,Craig RG.The in vitro effects of metal cations on eukaryotic cell metabolism.[J].Journal of Biomedical Materials Research PartA,2010,25.)。したがって、この発明に係る医療用防護マスクは、生物学的安全性を犠牲にして抗菌・抗ウイルス効果を取得するため、医療従事者が新型クラウンウイルスに対して長期間着用することに適していなく、抗新型コロナウイルスに適用しない医療用防護マスクである。
上記医療用材料の最内層は、着用者の体に貼り付ける面を指す。
上記医療用材料の最外層は、着用者の体から最も遠い面を指す。
上記ゼオライトの骨格内の銅イオンは、銅イオンとSi、Al又はO元素がゼオライトの骨格構造を構成するものを指す。
本発明の医療用材料が十分に高い抗菌・抗ウイルス性と十分に低い細胞毒性を有するメカニズムは以下の通りである:
好ましくは、上記銅系ゼオライトは、電子受容体を有する銅元素を含む。
電子受容体は、銅系ゼオライトの銅元素が、銅系ゼオライトの表面にある基から与えられた電子を受容する能力を備えるものを指す。
好ましくは、上記銅系ゼオライトの骨格外のバランス電荷の金属イオンは、Cu2+を含む。
好ましくは、上記銅系ゼオライトは、孤立電子対を含む基及び/又は共役結合を有する基を含む。
孤立電子対を含む上記基とは、上記基の少なくとも1つの原子を持つ最も外側の電子層に、共有結合の形成に使用されない非結合性電子があるものを指す。
共役結合を有する上記基とは、上記基にΠ電子が含まれ、共役系の電子雲の分布を変更することができるものを指す。
上記銅系ゼオライトは、-COOH基及び/又は-COO-基を含む。
好ましくは、上記銅系ゼオライトは、孤立電子対を含むN基を含み、好ましくは、孤立電子対を含む上記N基は、-NH2基を含む。
好ましくは、第1の中間層と第2の中間層との間にメルトブロー不織布層を加えることができる。
好ましくは、上記第2の中間層の銅系ゼオライト繊維層の孔隙サイズは、最内層の親水性繊維層の孔隙サイズよりも大きい。
上記金属イオン含有量は、金属イオン原子数の割合を指す。
上記銅系ゼオライトのSi/Al比は、両者の原子数の比(モル比)である。
好ましくは、上記繊維表面に独立して分散している銅系ゼオライトでは、銅系ゼオライトの微粒子ごとに独自の境界がある。
好ましくは、上記銅系ゼオライトは、ゼオライトナノ粒子で構成されている。
本発明の第2の目的は、多層型銅系ゼオライト繊維医療用材料の製造方法を提供することである。上記方法は、
1)疎水性繊維層、親水性繊維層を作製するステップと、
2)銅系ゼオライト繊維層を製作するステップであって、銅系ゼオライト繊維層の製作方法が、
(b)銅系ゼオライトを含む上記の繊維糸を縦糸及び横糸として銅系ゼオライト繊維層に編むステップとを含むステップと、
好ましくは、疎水性繊維層と親水性繊維層との間にメルトブロー不織布層を加えることができる。
上記マスクの最内層は、着用者の顔に貼り付ける面を指す。
上記マスクの最外層は、着用者の顔から最も遠い面を指す。
上記マスクは、マスク本体と、マスク本体の両側に接続されたイヤーストラップとを含む。
細胞毒性検出験(国家基準「医療機器の生物学的評価 第5部:インビトロ細胞毒性試験」GB/T 16886.5-2017/ISO 10993-5:2009を参照):医療用材料を0.1g/mLの割合でMEM培養液で24h浸漬した後、医療用材料の浸出液を得る。Vero細胞培養培地(1×105)をCO2インキュベーターに22~26h培養する。培地を除去し、医療用材料の浸出液を加え、CO2インキュベーターに入れて24h培養する。ベロ(Vero)細胞の形態学的変化を顕微鏡で観察し、培地を除去し、50μLのMTT溶液を加え、CO2インキュベーターに入れて2h培養し、MTT溶液を除去し、各細孔に100μLのイソプロパノールを加え、滴定プレートを振って、吸光度を570nmで測定する。測定された吸光度に応じて、細胞に対応する生存率に換算する。
実施例1
本発明に係るマスク1の製造方法は、次のステップを含む。
最内層は、吸水性不織布層である。
ここで、最外層と第2の中間層の銅系ゼオライト繊維層の作製方法は以下のとおりである。
(2)銅系ゼオライトを含む上記繊維糸を縦糸及び横糸として銅系ゼオライト繊維層に編む。銅系ゼオライト繊維層の孔隙サイズは100μmに設定される。
上記の銅系ゼオライト繊維層、疎水性繊維層、銅系ゼオライト繊維層、親水性繊維層を順次ヒートシールして、本発明のマスク1のマスク本体を作製する。
比較例1
実施例1で作製した銅系ゼオライト繊維層を比較例1として実施例1と比較する。
比較例2
比較例3
銅系ゼオライト繊維層、銅系ゼオライト繊維層及び親水性繊維層を順次ヒートシールして、比較マスクのマスク本体2を得て、実施例1と比較する。
比較例4
銅系ゼオライト繊維層、疎水性繊維層及び銅系ゼオライト繊維層を順次ヒートシールして、比較マスクのマスク本体3を得て、実施例1と比較する。
比較例5
中国の発明CN111469498Aの銅イオン抗菌生地を含む医療用防護材料の製造方法を参照する。
比較例6
ここで、最外層と第2の中間層の銅系ゼオライト繊維層の作製方法は以下のとおりである。
(1)ゼオライト前駆体溶液を調製し、起始物料を8Na2O:Al2O3:9SiO2:180H2Oのモル比で構成し、ゼオライト前駆体溶液を合成する。
銅系ゼオライトを含む60本の繊維を、銅系ゼオライトを含む繊維糸に撚り合わせて紡糸する。
比較例7
ここで、最外層と第2の中間層の銅系ゼオライト繊維層の作製方法は以下のとおりである。
実施例2
本発明に係るマスク2の製造方法は、次のステップを含む。
ここで、最外層と第2の中間層の銅系ゼオライト繊維層の作製方法は以下のとおりである。
(2)銅系ゼオライトを含む上記繊維糸を縦糸及び横糸として銅系ゼオライト繊維層に編む。
(3)銅系ゼオライトの表面を-COO-基で修飾する。
上記の銅系ゼオライト繊維層、疎水性繊維層、銅系ゼオライト繊維層及び親水性繊維層を順次ヒートシールして、本発明のマスク2のマスク本体を作製する。
実施例3
本発明に係るマスク3の製造方法は、次のステップを含む。
ここで、最外層と第2の中間層の銅系ゼオライト繊維層の作製方法は以下のとおりである。
(2)銅系ゼオライトを含む上記繊維糸を縦糸及び横糸として銅系ゼオライト繊維層に編む。
(3)銅系ゼオライトの表面を-NH2基で修飾する。
上記銅系ゼオライト繊維層、疎水性繊維層、銅系ゼオライト繊維層及び親水性繊維層を順次ヒートシールして、本発明のマスク3のマスク本体を作製する。
実施例4
本発明に係るマスク4の製造方法は、次のステップを含む。
ここで、最外層と第2の中間層の銅系ゼオライト繊維層の作製方法は以下のとおりである。
(2)銅系ゼオライトを含む上記繊維糸を縦糸及び横糸として銅系ゼオライト繊維層に編む。
(3)銅系ゼオライトの表面を-NH2基と-COO-基で同時に修飾する。
上記の銅系ゼオライト繊維層、疎水性繊維層、銅系ゼオライト繊維層、親水性繊維層を順次ヒートシールして、本発明のマスク4のマスク本体を作製する。
実施例5
本発明に係るマスク5の製造方法は、次のステップを含む。
(2)銅系ゼオライトを含む上記繊維糸を縦糸及び横糸として銅系ゼオライト繊維層に編む。
実施例6-11
Claims (23)
- 多層型銅系ゼオライト繊維を含む医療用材料であって、
前記医療用材料は、外側から順に、最外層、第1の中間層、第2の中間層及び最内層を含み、
前記最外層及び第2の中間層は、銅系ゼオライト繊維層であり、第1の中間層は、疎水性繊維層であり、最内層は、親水性繊維層であり、
前記最外層の銅系ゼオライト繊維層の孔隙サイズは、第1の中間層の疎水性繊維層の孔隙サイズよりも大きく、
前記銅系ゼオライト繊維層は、銅系ゼオライト及び繊維糸を含み、
前記繊維糸は、巻回した繊維からなり、銅系ゼオライトが繊維の表面に分散し、
銅系ゼオライトの質量は、前記繊維糸の径方向外側から内側に向けて段階的に減少することを特徴とする繊維医療用材料。 - 前記銅系ゼオライトは、電子受容体を有する銅元素を含むことを特徴とする請求項1に記載の医療用材料。
- 前記銅系ゼオライトの表面、ゼオライト骨格内又はゼオライト骨格外に銅イオンが含まれることを特徴とする請求項1に記載の医療用材料。
- 前記銅系ゼオライトは、孤立電子対を含む基及び/又は共役結合を有する基を含むことを特徴とする請求項1に記載の医療用材料。
- 前記銅系ゼオライトは、-COOH基及び/又は-COO-基を含むことを特徴とする請求項1に記載の医療用材料。
- 前記銅系ゼオライトは、孤立電子対を有するN基を含むことを特徴とする請求項1に記載の医療用材料。
- 第1の中間層と第2の中間層との間に設置されたメルトブロー不織布層を含むことを特徴とする請求項1-6のいずれか一項に記載の医療用材料。
- 前記第2の中間層の銅系ゼオライト繊維層の孔隙サイズは、最内層の親水性繊維層の孔隙サイズよりも大きいことを特徴とする請求項1-7のいずれか一項に記載の医療用材料。
- 前記銅系ゼオライトの粒径D90は、0.5~20μmであることを特徴とする請求項1-8のいずれか一項に記載の医療用材料。
- 前記銅系ゼオライト繊維層中の銅元素の質量分率は、0.02~4wt%であることを特徴とする請求項1-9のいずれか一項に記載の医療用材料。
- 前記銅イオンは、Cu2+を含み、前記Cu2+は、銅系ゼオライトの骨格外のバランス電荷の金属イオン含有量の5%~40%を占めることを特徴とする請求項3に記載の医療用材料。
- 前記銅系ゼオライトのSi/Alモル比は、1.5~5であることを特徴とする請求項1-11のいずれか一項に記載の医療用材料。
- 前記銅系ゼオライトは、ゼオライトナノ粒子で構成されている
ことを特徴とする請求項1-12のいずれか一項に記載の医療用材料。 - 前記銅系ゼオライトは、X型ゼオライト、Y型ゼオライト、A型ゼオライト、チャバザイト、L型ゼオライト及びP型ゼオライトのうちのいずれか1種類又は複数種類から選択されることを特徴とする請求項1-12のいずれか一項に記載の医療用材料。
- 前記銅系ゼオライト繊維層の繊維は、レーヨン繊維、アセテート繊維、カルボキシメチルセルロース、竹繊維、綿繊維、木質繊維、ポリプロピレン繊維及びポリエチレン繊維のうちのいずれか1種類又は複数種類から選択されることを特徴とする請求項1-12のいずれか一項に記載の医療用材料。
- 前記親水性繊維層は、親水性繊維で構成されることを特徴とする請求項1-12のいずれか一項に記載の医療用材料。
- 前記疎水性繊維層は、ポリエチレン、ポリプロピレン、ポリエステル、変性ポリエチレン、変性ポリプロピレン及び変性ポリエステルのうちのいずれか1種類又は複数種類から選択されることを特徴とする請求項1-12のいずれか一項に記載の医療用材料。
- 多層型銅系ゼオライト繊維を含む医療用材料の製造方法であって、
1)疎水性繊維層、親水性繊維層を作製するステップと、
2)銅系ゼオライト繊維層を製作するステップであって、
(a)繊維を巻回して繊維糸を形成し、繊維糸をゼオライトの核成長のためのステントとして銅系ゼオライトを含む繊維糸を合成するステップで、銅系ゼオライトの含有量が前記繊維糸の径方向外側から内側に向けて段階的に減少する、ステップと、
(b)銅系ゼオライトを含む前記繊維糸を縦糸及び横糸として銅系ゼオライト繊維層を編むステップ、とを含むステップと、
3)銅系ゼオライト繊維層、疎水性繊維層、銅系ゼオライト繊維層及び親水性繊維層の順に積層して抗菌・抗ウイルス医療用材料を作製するステップであって、前記最外層の銅系ゼオライト繊維層の孔隙サイズは、疎水性繊維層の孔隙サイズよりも大きい、ステップとを含むことを特徴とする医療用材料の製造方法。 - 疎水性繊維層と親水性繊維層との間にメルトブロー不織布層を設置するステップを含むことを特徴とする請求項20に記載の製造方法。
- 前記親水性繊維層は、親水性繊維で構成されることを特徴とする請求項18又は19に記載の製造方法。
- 前記疎水性繊維層の疎水性繊維は、ポリエチレン、ポリプロピレン、ポリエステル、変性ポリエチレン、変性ポリプロピレン、及び変性ポリエステルのうちのいずれか1種類又は複数種類から選択さることを特徴とする請求項18又は19に記載の製造方法。
- マスクの本体が請求項1-17のいずれか一項に記載の医療用材料を含むことを特徴とする防護用品。
- 前記防護用品は、抗菌・抗ウイルス用医療従事者の着用品であり、防護服、フェイススクリーン、手袋、靴、ブーツ、帽子及びイヤーマフのうちから選択されることを特徴とする請求項22に記載の防護用品。
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