JP2022177805A - 親水性ポリマー・ナノコーティングを有する担体層を生成するための方法 - Google Patents
親水性ポリマー・ナノコーティングを有する担体層を生成するための方法 Download PDFInfo
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- JP2022177805A JP2022177805A JP2022077398A JP2022077398A JP2022177805A JP 2022177805 A JP2022177805 A JP 2022177805A JP 2022077398 A JP2022077398 A JP 2022077398A JP 2022077398 A JP2022077398 A JP 2022077398A JP 2022177805 A JP2022177805 A JP 2022177805A
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- layer
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- plasma
- nanocoating
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Abstract
Description
ナノファイバー織物を作製するためのプロセスは、WO2006/131081およびWO2008/106903に示され、各々は参照によりその全体が本明細書に組み込まれる。
様々な結合技術が利用可能である。ホットメルト・グラビア積層技術、超音波結合技術、浸漬結合技術、UFDファイバー・スプレイ技術(ホットメルト)、スピン織物結合技術、および熱結合技術。
カレンダリングは、布地、メッシュ、積層ベントなどの材料に使用され、材料が高温高圧でローラ間またはローラの下を通過することで、より滑らかで薄い材料を得る。細孔のサイズと形状は、カレンダリング条件によって影響を受ける可能性がある。
繊維材料のプラズマ処理は、技術的および医療用繊維のみならず複合材料のための、撥水性や撥油性などの表面特性を向上させるための繊維仕上げプロセスとして適用できる。従来の湿式化学繊維仕上げと比較して、プラズマ技術は、環境問題に関して利点を示す。PECVD処理を使用すると、たとえば接着特性の向上、親水性の向上、表面への特殊な官能基の導入、または表面形態の修正ができる。
Claims (15)
- 親水性ポリマー・ナノコーティングを有する担体層(11)を生成するための方法であって、
前記担体層(11)は、ポリマー材料の織糸で生成され、前記親水性ポリマー・ナノコーティングは、有機前駆体モノマーを使用する低圧プラズマ重合プロセスによって、前記担体層(11)上に塗布される、方法。 - 細孔構造を有する少なくとも1つの膜層(12)が設けられ、前記膜層(12)は、重ね合わされた繊維のエレクトロスピニングによって生成され、前記担体層と前記膜層(12)とを接続して複合膜(10)を形成する結合が設けられ、前記親水性ポリマー・ナノコーティングは、前記有機前駆体モノマーを使用する前記低圧プラズマ重合プロセスによって、前記担体層(11)および前記少なくとも1つの膜層(12)上に塗布される、請求項1に記載の方法。
- プラズマ処理は、好ましくは約13.56MHzの無線周波数で動作するロール・ツー・ロール・システムにおける複数のローラおよび/またはエキスパンダを有するプラズマ・チャンバー内で実行され、前記プラズマ・チャンバー内に、第1の電極セットおよび第2の電極セットがあり、
前記担体層(11)および/または前記複合膜(10)は、前記第1の電極セットと前記第2の電極セットとの間に配置され、それにより、基板の両側に処理が施される、請求項1または2に記載の方法。 - 前処理は、好ましくは約500ワットから約1800ワットである第1の電力出力で、好ましくは約2分から約5分である第1の期間、好ましくは約70mTorrから約150mTorrである第1のベース圧力で、好ましくは約20℃から約60℃である第1の温度で実行され、
コーティング・ステップは、好ましくは約100ワットから約800ワットである第2の電力出力で、好ましくは約2分から約5分である第2の期間、好ましくは約15mTorrから約100mTorrである第2のベース圧力で、好ましくは約20℃から約60℃である第2の温度で実行される、請求項1から3のいずれか一項に記載の方法。 - プラズマ活性化(前処理)のためのガス用のマス・フロー・コントローラと、前記親水性ポリマー・ナノコーティングの堆積のための液体モノマー用のモノマー蒸気供給システムとを有するプラズマ・チャンバーの幅にわたる入口システムを使用して、ガスおよびモノマー蒸気を前記プラズマ・チャンバーに均一に分布させる、請求項3または4に記載の方法。
- プラズマ処理は、規定された条件下で、基板上で実行され、官能層としての前記親水性ポリマー・ナノコーティングは、モノマーからなるモノマー蒸気、またはモノマーとヘリウムまたはアルゴンの混合物を使用して、ヒドロキシル基、カルボニル基、カルボキシル基、(アミノ基)およびこれらの混合物からなる基から選択される化学官能基で生成される、請求項1から5のいずれか一項に記載の方法。
- 前記親水性ポリマー・ナノコーティングは、1つのプロセス・ステップ、および/または、時間的にオフセットされた2つのプロセス・ステップで堆積され、第1のコーティング・ステップは、接着層として使用され、第2のコーティング・ステップは、好ましくは10から80nmの層厚を有する官能層として使用される、請求項1から6のいずれか一項に記載の方法。
- 前記担体層(11)および/または前記複合膜(10)の前処理は、接着層および/または官能層の堆積前に、アルゴン、ヘリウム、窒素および酸素、ならびにそれらの組合せを使用して実行される、請求項1から7のいずれか一項に記載の方法。
- 前記前処理、前記接着層、および前記官能層は、同じステップで、または時間的にオフセットされた3つの別個のステップで生成される、請求項1から8のいずれか一項に記載の方法。
- 前記担体層(11)および/または前記複合膜(10)は、規定された条件下でアルゴン、ヘリウム、窒素および/または水素でさらに処理され、プラズマは、各プロセス・ステップ後、時間的にオフセットされる、請求項1から9のいずれか一項に記載の方法。
- 前記親水性ポリマー・ナノコーティングは、(各プロセス・ステップあたり)約4分以下の処理時間で、前記担体層(11)および/または前記複合膜(10)上に塗布され、ASTM F1980-16に準拠した加速時効処理に対する耐性が向上し、濾過における液体の輸送、ウィッキングおよび液体スループットが向上し、および/または、水接触角が0°(完全な湿潤)から60°(中程度の湿潤)の表面張力が得られる、請求項1から10のいずれか一項に記載の方法。
- 織布メッシュが、同じポリマー材料の織糸または少なくとも2つの織糸を有する前記担体層(11)として使用され、第1の織糸は、第1のポリマー材料で作られ、第2の織糸は、前記第1のポリマー材料とは異なる第2のポリマー材料で作られる、請求項1から11のいずれか一項に記載の方法。
- 前記織布メッシュは、前記第1の織糸および前記第2の織糸を使用して異なるパターンで織られ、前記第1の織糸および前記第2の織糸は、任意の断面形状または幾何学的配置またはパターンで生成することができる、請求項12に記載の方法。
- 前記膜層(12)は、エレクトロスピニングによって、前記担体層(11)上に直接生成され、および/または、前記膜層(12)は、エレクトロスピニングによって、異なる担体基板上に生成され、次いで、結合のため積層プロセスによって、前記担体層(11)上に転写される、請求項1から13のいずれか一項に記載の方法。
- 請求項1から14のいずれか一項に記載の方法に従って生成される、親水性ポリマー・ナノコーティングを有する担体層(11)であって、
複合膜(10)を形成し、
前記親水性ポリマー・ナノコーティングは、前記担体層(11)および/または前記複合膜(10)上に塗布される、担体層(11)。
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