TWI565853B - Preparation of nano - silver blended natural cellulose melt - blown non - woven - Google Patents

Preparation of nano - silver blended natural cellulose melt - blown non - woven Download PDF

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TWI565853B
TWI565853B TW104114988A TW104114988A TWI565853B TW I565853 B TWI565853 B TW I565853B TW 104114988 A TW104114988 A TW 104114988A TW 104114988 A TW104114988 A TW 104114988A TW I565853 B TWI565853 B TW I565853B
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Taiwan
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cellulose
nano silver
wood pulp
nano
water
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TW104114988A
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TW201640003A (zh
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Wen Tung Chou
Ming Yi Lai
Kun Shan Huang
Shao Hua Chou
Meng Heng Hsieh
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Acelon Chem & Fiber Corp
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Priority to TW104114988A priority Critical patent/TWI565853B/zh
Priority to US14/936,882 priority patent/US10132007B2/en
Publication of TW201640003A publication Critical patent/TW201640003A/zh
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Publication of TWI565853B publication Critical patent/TWI565853B/zh

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    • D—TEXTILES; PAPER
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    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F2/00—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof
    • D01F2/02—Monocomponent artificial filaments or the like of cellulose or cellulose derivatives; Manufacture thereof from solutions of cellulose in acids, bases or salts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29B7/00—Mixing; Kneading
    • B29B7/002—Methods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/88—Adding charges, i.e. additives
    • B29B7/90—Fillers or reinforcements, e.g. fibres
    • B29B7/92—Wood chips or wood fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/80—Component parts, details or accessories; Auxiliary operations
    • B29B7/88—Adding charges, i.e. additives
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0018—Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/05—Filamentary, e.g. strands
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/14—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the particular extruding conditions, e.g. in a modified atmosphere or by using vibration
    • B29C48/147—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the particular extruding conditions, e.g. in a modified atmosphere or by using vibration after the die nozzle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/275—Recovery or reuse of energy or materials
    • B29C48/277—Recovery or reuse of energy or materials of materials
    • B29C48/278—Recovery or reuse of energy or materials of materials of additives or processing aids
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    • D01F1/02—Addition of substances to the spinning solution or to the melt
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    • D01F11/00—Chemical after-treatment of artificial filaments or the like during manufacture
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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
    • D04H1/413—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 containing granules other than absorbent substances
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    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
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    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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    • D04H1/42—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 characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
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Description

製備奈米銀掺混天然纖維素熔噴不織布的方法
本發明是關於一種「製備奈米銀掺混天然纖維素熔噴不織布的方法」，係屬於綠色環保製程製造天然纖維不織布之技術領域，其是以聚乙烯醇(PVA)粉體加入純水製成凝膠態的聚乙烯醇溶液，並加入硝酸銀(AgNO3)溶液為金屬鹽前趨體，再加入硼氫化鈉(NaBH4)，使該聚乙烯醇溶液還原形成奈米銀溶膠，接著，將該奈米銀溶膠加入木漿與氧化甲基嗎啉相混合溶解的纖維素漿液內，經去除水分後形成奈米銀天然纖維素之粘液(dope)，再以熔噴方式(meltblown)將黏液從紡口擠壓出來形成長纖維素絲束，最後經由再生、水洗、水針軋、乾燥及捲取等程序後，即可製得具有抗靜電及抗菌功能的奈米銀天然纖維素熔噴不織布。
目前將奈米銀溶膠與高聚物纖維相混合所製成的化學纖維技術，已揭露如中國專利申請號200410062799.3、200510070895.7、201010230063.8、201010285121.7及201310523647.8等，藉由於該化學纖維具有抗菌之功效而能做成具有抗菌功能的不織布，然而，前述高聚物纖維所製成的不織布在使用後成為廢棄物時，因不能被自然環境分解而對環境產生巨大的衝擊及負擔，同時在製程中也會排放有害的物質，此外，前述各製程所製得奈米銀化學纖維的不織布其抗菌功效程度不一，無法達到使用端的精確要求。
因此，如何以不危害自然環境之天然纖維素纖維，並在可精確控製的製程條件下來達成製備具有抗靜電及抗菌功能的奈米銀天然纖維素不織布，便顯得急為迫切與需要。
本發明之主要目的在提供一種「製備奈米銀掺混天然纖維素熔噴不織布的方法」，其步驟包含：a、將聚乙烯醇(Polyvinyl Alcohol，簡稱PVA)粉體加入純水攪拌形成凝膠態之PVA溶液，並加入硝酸銀(AgNO3)溶液為金屬鹽前趨體；b、加入硼氫化鈉(NaBH4)於PVA凝膠溶液內，進行攪拌滴定還原形成奈米銀溶膠；其中，該硼氫化鈉是以莫耳數比1：4~1：8進行還原滴定，滴定速率為每分鐘5~15ml，攪拌頻率在200rpm，滴定完成的反應時間為10~20分鐘，所製得奈米銀溶膠濃度為500~20,000ppm，奈米銀顆粒粒徑為10~115nm；c、將奈米銀溶膠加入木漿與氧化甲基瑪琳(N-methylmorpholine N-oxide，簡稱NMMO)混合溶解之漿液內；其先將木漿原料切碎並與NMMO、安定劑共同投入膨脹溶解槽中混合攪拌，槽內需恆溫加熱於60~80℃之間，並搭配真空冷凝設備進行除水；d、去除奈米銀天然纖維素共混漿液的水分形成紡絲粘液(dope)；其係使用真空薄膜蒸發器(Thin Film Evaporator,TFE)蒸發多餘之水份，該真空薄膜蒸發器內的真空度介於-9.39×104~-9.26×104Pa，並以80℃~130℃加熱，5分鐘內排除水分至5%~15%，即可將纖維素溶解成紡絲之粘液；e、以熔噴方式(meltblown)將黏液從紡口擠壓出來形成長纖維素絲束；其係以計量泵增壓輸送紡絲粘液，經連續過濾機(CPF)過濾、脫泡後進入紡絲箱中，藉由熱空氣持續灌入紡口並從紡口周圍排出的氣流作用，迫使黏液從紡口中被熔 噴擠壓出外部形成長纖維素絲束；f、噴出水霧使長纖維素絲束進入凝固液中凝固再生及水洗；及g、經凝固液再生水洗後之長纖維素絲束在承接網上相互堆疊成網形之不織布，再依序經水針軋、乾燥及捲取程序後，即製得奈米銀天然纖維素熔噴不織布。藉由製程中可控制該奈米銀溶膠的粒徑大小與濃度，使得製備出奈米銀天然纖維素熔噴不織布的抗菌功效，除可以滿足不同消費端對抗菌功效程度的要求外，其效果更遠超過一般市面上販售以表面處理或添加抗菌之不織布，且其使用丟棄後又可被自然分解，而成為無害自然環境之環保不織布。
本發明之另一目是在提供一種「製備奈米銀掺混天然纖維素 熔噴不織布的方法」，藉由其製程中可控製該奈米銀溶膠的粒徑大小與濃度，使得製備出奈米銀天然纖維素熔噴不織布的抗靜電功效，可以滿足不同消費端對抗靜電程度的要求，且其使用丟棄後又可被自然分解，而成為無害自然環境之環保不織布。
圖1：係本發明之製造流程方塊圖。
圖2：係本發明所使用聚乙烯醇(Polyvinyl Alcohol，簡稱PVA)之化學結構圖。
圖3：係本發明所使用氧化甲基瑪琳溶劑(N-methylmorpholine N-oxide，簡稱NMMO)之化學結構圖。
圖4：係本發明所使用木漿纖維素(Cellulose)之化學結構圖。
圖5：係本發明中1000ppm奈米銀溶膠的粒徑分佈圖。
圖6：係本發明中1000ppm奈米銀溶膠稀釋100倍後的電子顯微鏡(TEM)圖。
為進一步說明本發明之製作流程與功效，茲佐以圖示及各試 驗實例詳細說明如后：請參閱圖1至圖4所示，本發明「製備奈米銀掺混天然纖維素熔噴不織布的方法」，其步驟包含：a、將聚乙烯醇(Polyvinyl Alcohol，簡稱PVA)粉體加入純水攪拌形成凝膠態之PVA溶液，並加入硝酸銀(AgNO3)溶液為金屬鹽前趨體；其中，該PVA之添加量為5-12wt%，並採用鹼化度為86~89mole%之部份鹼化型PVA粉體，其分子量為14700~98000，化學結構圖如圖2所示，其具有聚合度低且低溫可溶於水的特性，且添加的濃度能確實包覆及保護銀微粒的生成；該硝酸銀溶液是將硝酸銀晶體溶於純水中配製而成；b、加入硼氫化鈉(NaBH4)於PVA凝膠溶液內，進行攪拌滴定還原形成奈米銀溶膠；其中，該硼氫化鈉是以莫耳數比1：4~1：8進行還原滴定，滴定速率為每分鐘5~15ml，攪拌頻率在200rpm，滴定完成的反應時間為10~20分鐘，所製得奈米銀溶膠濃度為500~20,000ppm，奈米銀顆粒粒徑為10~150nm；c、將奈米銀溶膠加入木漿與氧化甲基瑪琳(N-methylmorpholine N-oxide，簡稱NMMO)混合溶解之漿液內；其先將 木漿原料切碎並與NMMO(化學結構圖如圖3所示)、安定劑共同投入膨脹溶解槽中混合攪拌，槽內需恆溫加熱於60~80℃之間，並搭配真空冷凝設備進行除水，該膨脹溶解槽內的真空度介於-9.33×104Pa，其中，該木漿原料為長纖木漿(soft wood)與短纖木漿(hard wood)相混合，其兩者纖維素的重量比為0：100~100：0，使用之木漿聚合度為500~1200，α-纖維素含量在85%以上，其化學結構圖如圖4所示，而該混合溶解之漿液中奈米銀溶膠的比例介於5~30wt%，奈米銀粒子的濃度介於100~5000ppm；d、去除奈米銀與天然纖維素共混漿液的水分形成紡絲粘液(dope)；其係使用真空薄膜蒸發器(Thin Film Evaporator,TFE)蒸發多餘之水份，該真空薄膜蒸發器內的真空度介於-9.39×104~-9.26×104Pa，並以80℃~130℃加熱，5分鐘內排除水分至5%~15%，即可將纖維素溶解成紡絲之粘液；由於天然纖維素和PVA兩體系間具有良好的相容性的特點，其於步驟c的調漿共混過程中兩者能緊密的結合且彼此相互貫穿，再透過機械攪拌的剪切作用能形成近似連續相的結構，兩相的均化程度越高，紡絲粘液的穩定性也相對提高，並能確保奈米銀顆粒於紡絲粘液中的均勻分散；其中，粘液中各成份所佔比例為：水(H2O)佔9%~18%，氧化甲基瑪琳(NMMO)佔75%~87%，纖維素(cellulose)佔6%~11%；e、以熔噴方式(meltblown)將黏液從紡口擠壓出來形成長纖維素絲束；其係以計量泵增壓輸送紡絲粘液，經連續過濾機(CPF)過濾、脫泡後進入紡絲箱中，藉由熱空氣持續灌入紡口並從紡口周圍排出的氣流作用，迫使黏液從紡口中被熔噴擠壓出外部形成長纖維素絲束；f、噴出水霧使長纖維素絲束進入凝固液中凝固再生及水 洗；其中，凝固液濃度介於2.5%~7.0%，水洗後殘留的NMMO溶劑量低於0.1%，PVA殘留量小於0.3%；及g、經凝固液再生水洗後之長纖維素絲束在承接網上相互堆疊成網形之不織布，再依序經水針軋、乾燥及捲取程序後，即製得奈米銀天然纖維素熔噴不織布。
其中，步驟f中再生與水洗後混合溶液中的聚乙烯醇，會透 過與水液結合的方式一併溶出而必需加以處理，係將該混合溶液導入層析槽內，並依序添加芒硝100g/L(Na2SO4)、硼砂16.7g/L(Na2B4O7‧10H2O)兩種定量的配比，再加入少量的碳酸鈉(Na2CO3)做為pH調節劑，使得聚乙烯醇被凝聚、膠化析出，經由過濾後便可與NMMO溶劑相互區隔出來，可以避免影響到NMMO溶劑的回收及利用。
另步驟f中再生與水洗後釋出的氧化甲基瑪琳溶劑，因數量極大也必需加以全部回收來充分循環使用，其回收的步驟包含：A.先以1~20μ的PP濾芯進行第一次過濾；B.將第一次過濾後之溶劑注入絮凝槽中，絮凝劑及其配合之添加劑的投加量為1.5mg/L，處理時間1小時，溶劑中的膠體雜質受絮凝劑的作用產生聚附，溶液中非溶解性雜質可形成高聚集態的絮凝物，量大的絮凝物會開始沉降，而後再透過濾網阻隔排出；C.經凝絮處裡後的溶劑直接通入離子交換純化系統中，透過帶電性陰、陽離子的吸附、接合作用，可將溶液中的有色雜質分離，並加強溶劑的純化，該處理期間的pH範圍維持於8~9；D.再以ultrafilter(UF)及逆滲透(RO)過濾器對純化後的溶劑 進行第二次過濾；及E.最後將第二次過濾後的低濃度NMMO溶劑(3.0%~6.0%)進行濃縮處理，其採多段蒸發槽系統進行循環，在循環的過程中NMMO溶劑將會逐漸提純直至50.0%~78.0%產出而達成回收，又可將其再投入回歸生產線使用，藉由前述回收流程可使氧化甲基瑪琳的回收率達99.5%以上。
為進一步證明本發明之特點及實施功效，乃進行完成各項試驗實例並說明如后：
實施例一：
將5.0g部份鹼化型聚乙烯醇加入95.0g純水中，持續攪拌2小時即得5wt%的聚乙烯醇溶液，以適量之硝酸銀晶體溶於純水中配製成0.1N硝酸銀溶液0.5ml，並加入聚乙烯醇凝膠溶液中攪拌均勻，再以0.2N之硼氫化鈉以每分鐘5ml的速度進行還原滴定，即得1000ppm的奈米銀溶膠，還原過程中聚乙烯醇凝膠會以半透明逐漸變黃再變為黃褐色，達滴定終點時應為淺褐色。
將以上所得之奈米銀溶膠樣品進行粒徑分佈，如圖5所示。並將樣品稀釋100倍後進行電子顯微鏡(TEM)圖像驗證，如圖6所示。
由圖5中數量分析的結果可得知，1000ppm的奈米銀凝膠其粒徑分布於7~70nm，平均粒徑大小為23.5nm。再由圖6的TEM顯微圖像也顯示，其確實可還原出奈米尺度小於100nm之銀粒子。
實施例二：
將聚合度為650之木漿與NMMO溶劑混合成纖維素漿液，再添加5~35wt%之奈米銀溶膠進行摻混；其中奈米銀粒子的濃度為100~ 5000ppm，以真空薄膜蒸發器蒸發多餘之水份，以80℃~130℃加熱，5分鐘內排除水分至5%~13%，即可將纖維素溶解成紡絲黏液(dope)，紡絲黏液組成表如【表一】所示，再以熔噴方式(meltblown)將黏液以計量泵增壓輸送，經連續過濾機(CPF)過濾、脫泡後進入紡絲箱中，藉由熱空氣持續灌入紡口並從紡口周圍排出的氣流作用，迫使黏液從紡口中被熔噴擠壓出外部形成長纖維素絲束，再進入凝固液中凝固再生及水洗後，該長纖維素絲束會在承接網上相互堆疊成網形之不織布，最後依序經水針軋、乾燥及捲取程序後，即製得奈米銀天然纖維素熔噴不織布，以上所得的不織布樣品如【表一】中樣品編號1~11所示。
實施例三：將聚合度為1050之木漿與NMMO溶劑混合成纖維素漿液，再後添加5~35wt%之奈米銀溶膠進行摻混；其中奈米銀粒子的濃度為100~5000ppm，以真空薄膜蒸發器蒸發多餘之水份，以80℃~130℃加熱，5分鐘內排除水分至5%~13%，即可將纖維素溶解成紡絲黏液(dope)，紡絲黏液組成表如【表一】所示，再以熔噴方式(meltblown)將黏液以計量泵增壓輸送，經連續過濾機(CPF)過濾、脫泡後進入紡絲箱中，藉由熱空氣持續灌入紡口並從紡口周圍排出的氣流作用，迫使黏液從紡口中被熔噴擠壓出外部形成長纖維素絲束，再進入凝固液中凝固再生及水洗後，該長纖維素絲束會在承接網上相互堆疊成網形之不織布，最後依序經水針軋、乾燥及捲取程序後，即製得奈米銀天然纖維素熔噴不織布，以上所得的不織布樣品如【表一】中樣品編號12~22所示。
實施例四(抗菌功能之評估)：抗菌功能之評估採用金黃色葡萄球菌(ATCC 6538P)及肺炎桿菌(ATCC 4352)為測試菌種。奈米化的銀粒子帶正電，當奈米銀粒子處在游離態時，會與帶負電的細菌細胞膜接觸，兩者相互結合後即形成一脫氫酶-SAg之結構。進入菌體內的奈米銀會破壞其細胞活性、損傷細菌DNA以及中斷細胞信號傳導，進一步抑制細菌生長；同時奈米銀作用後的菌體細胞膜會逐漸衰弱甚至出現穿孔，導致大量的還原糖、蛋白質以及K+從菌體內洩漏，膜電位和ATP被消耗殆盡，使細菌無法呼吸、代謝和繁殖， 直至死亡。
將對本發明所製備出的含奈米銀粒子之天然纖維素熔噴不 織布進行抗菌性的試驗，測試其是否具備抗菌性。
【表二】、【表三】為含奈米銀粒子天然纖維素熔噴不織布抗 菌功能之試驗結果。本試驗方法為JIS L1902-1998定量法，試驗菌種為金黃色葡萄球菌(ATCC 6538P)及肺炎桿菌(ATCC 4352)。其中，植菌濃度在1.0±0.3E+5(菌數/毫升)內表示實驗有效，Ma=未加工樣品0小時立即沖刷後菌數，Mb=未加工樣品18~24小時培養後菌數，Mc=加工樣品18~24小時培養後菌數；細菌成長活性值=logMb-logMa，細菌成長活性值>1.5表示實驗有效，抑菌值=logMb-logMc，殺菌值=logMa-logMc；依據日本纖維製品新機能評價協議會(JAFET)之抗菌標準，抑菌值大於2.2表示測試樣本有抑菌效果，殺菌值大於0表示測試樣本有殺菌效果；1.3E+4表示13000，依此類推。
由【表二】及【表三】可知，經由本發明所製備出的含奈米 銀粒子天然纖維素熔噴不織布，本身對於金黃色葡萄球菌及肺炎桿菌具備了相當良好的抑菌效果及殺菌效果。
各樣品之抗菌試驗結果如【表二】、【表三】所示
本試驗方法為JIS L1902-1998定量法，試驗菌種為金黃色葡萄球菌(ATCC 6538P)。
本試驗方法為JIS L1902-1998定量法，試驗菌種為肺炎桿菌(ATCC 4352)。
實施例五(水洗10次後之抗菌功能評估)：各樣品以5g/L之洗衣精，在70℃之熱水中清洗45分鐘10次，將所得各樣品進行抗菌試驗，所得之結果如【表四】所示。
本試驗方法為JIS L1902-1998定量法，試驗菌種為肺炎桿菌(ATCC 4352)。
由【表二】、【表三】含奈米銀粒子之纖維素熔噴不織布抗菌功能試驗結果顯示，本發明之纖維素熔噴不織布中所添加的奈米銀粒子之濃度達100ppm以上即具有殺菌之功效，添加濃度若超過1500ppm即顯現出其優異的抑菌性。由【表二】、【表三】之實例皆可證明，本發明之含奈米銀粒子之纖維素熔噴不織布確實能達到抗菌之功效，且其抗菌效力隨奈米銀粒子濃度的增加而提升。
另由【表四】含奈米銀粒子天然纖維素熔噴不織布經水洗10次後抗菌功能試驗結果顯示，本發明之含奈米銀粒子天然纖維素熔噴不織布經10次之熱水及清潔劑處理後，不織布之抗菌功能效果仍然維持原來未水洗前之90%以上，由此結果顯示本發明之含奈米銀粒子天然纖維素熔噴不織布為一具有長效型之抗菌纖維素不織布，其效果遠超過一般市面上販售以表面處理或添加抗菌劑之不織布。
實施例六(抗靜電功能評估)：抗靜電功能檢測依抗靜電紡織品標準FTTS-FA-009，並參考AATCC76的規範以同心圓電極表面電阻進行，測試各樣本之表面電阻值，藉以評價含奈米銀粒子天然纖維素熔噴不織布之抗靜電功效。
由【表五】的結果顯示，含奈米銀粒子天然纖維素熔噴不織 布除添加含量低於100ppm的樣品外，均為等級2之規範等級；即表示其抗靜電效果為”好”的評價，且纖維的表面電阻值(resistance)，也會隨著所添加奈米銀粒子濃度的增加而提升。此外，本發明製備出的含奈米銀粒子天然纖維素熔噴不織布，其抗靜電性能也遠高於一般市面上販售的不織布。
綜上所述，本發明所製備的含奈米銀粒子天然纖維素熔噴不 織布，其具有明顯抗菌功能之效果，故有利於提高紡織品的價值及應用層面，並能滿足消費端對抗菌程度的要求，藉由該含奈米銀粒子天然纖維素熔噴不織布能有效抑制微生物(包含細菌、黴菌或真菌)的繁殖和生長，甚至滅殺病菌，同時可達成避免細菌的交叉感染、控制疾病的傳播，而有利於提升健康、清潔、舒適的生活。此外，其更因具有好的抗靜電能力，故該含奈米銀粒子天然纖維素熔噴不織布，亦能有效的避免冬季穿脫衣物時發生的觸電情況，因而達成減少靜電積累對人體血液循環、免疫和神經 系統所造成的負面影響。其確為一相當實用的創新發明，應符合專利申請條件，爰依法提出申請。

Claims (6)

  1. 一種「製備奈米銀掺混天然纖維素熔噴不織布的方法」，其步驟包含：a、將聚乙烯醇(Polyvinyl Alcohol，簡稱PVA)粉體加入純水攪拌形成凝膠態之PVA溶液，並加入硝酸銀(AgNO3)溶液為金屬鹽前趨體；其中，該PVA的添加量為5-12wt%，並採用鹼化度為86~89mole%之部份鹼化型PVA粉體，其分子量為14700~98000，該硝酸銀溶液是將硝酸銀晶體溶於純水中配製而成；b、加入硼氫化鈉(NaBH4)於PVA凝膠溶液內，進行攪拌滴定還原形成奈米銀溶膠；其中，該硼氫化鈉是以莫耳數比1：4~1：8進行還原滴定，滴定速率為每分鐘5~15ml，攪拌頻率在200rpm，滴定完成的反應時間為10~20分鐘，所製得奈米銀溶膠濃度為500~20,000ppm，奈米銀顆粒粒徑為10~150nm；c、將奈米銀溶膠加入木漿與氧化甲基瑪琳(N-methylmorpholine N-oxide，簡稱NMMO)混合溶解之漿液內；其先將木漿原料切碎並與NMMO、安定劑共同投入膨脹溶解槽中混合攪拌，槽內需恆溫加熱於60~80℃之間，並搭配真空冷凝設備進行除水，該膨脹溶解槽內的真空度介於-9.33×104Pa，其中，該混合溶解之漿液中奈米銀溶膠的比例介於5~30wt%，奈米銀粒子的濃度介於100~5000ppm；d、去除奈米銀與天然纖維素共混漿液的水分形成紡絲粘液(dope)；其係使用真空薄膜蒸發器(Thin Film Evaporator,TFE)蒸發多餘之水份，該真空薄膜蒸發器內的真空度介於-9.39×104~-9.26×104Pa，並以80℃~130℃加熱，5分鐘內排除水分至5%~15%，即可將纖維素溶解成紡絲之粘液；其中，粘液中各成份所佔比例為：水(H2O)佔9%~18%，氧化甲基瑪琳(NMMO)佔75%~87%，纖維素(cellulose)佔6%~11 %；e、以熔噴方式(meltblown)將黏液從紡口擠壓出來形成長纖維素絲束；其係以計量泵增壓輸送紡絲粘液，經連續過濾機(CPF)過濾、脫泡後進入紡絲箱中，藉由熱空氣持續灌入紡口並從紡口周圍排出的氣流作用，迫使黏液從紡口中被熔噴擠壓出外部形成長纖維素絲束；f、噴出水霧使長纖維素絲束進入凝固液中凝固再生及水洗；其中，凝固液濃度介於2.5%~7.0%，水洗後殘留的NMMO溶劑量低於0.1%，PVA殘留量小於0.3%；及g、經凝固液再生水洗後之長纖維素絲束在承接網上相互堆疊成網形之不織布，再依序經水針軋、乾燥及捲取程序後，即製得奈米銀天然纖維素熔噴不織布。
  2. 如申請專利範圍第1項所述之「製備奈米銀掺混天然纖維素熔噴不織布的方法」，其中，步驟c中該木漿原料為長纖木漿(soft wood)與短纖木漿(hard wood)相混合，其兩者纖維素的重量比為0：100~100：0，使用之木漿聚合度為500~1200，α-纖維素含量在85%以上。
  3. 如申請專利範圍第1項所述之「製備奈米銀掺混天然纖維素熔噴不織布的方法」，其中，步驟c中該木漿原料為長纖木漿(soft wood)，使用之木漿聚合度為500~1200，α-纖維素含量在85%以上。
  4. 如申請專利範圍第1項所述之「製備奈米銀掺混天然纖維素熔噴不織布的方法」，其中，步驟c中該木漿原料為短纖木漿(hard wood)，使用之木漿聚合度為500~1200，α-纖維素含量在85%以上。
  5. 如申請專利範圍第1項所述之「製備奈米銀掺混天然纖維素熔噴不織布的方法」，其中，步驟f中再生與水洗後混合溶液中的聚乙烯醇，係將其導入層析槽內，並依序添加芒硝100g/L(Na2SO4)、硼砂16.7g/L(Na2B4O7． 10H2O)兩種定量的配比，再加入少量的碳酸鈉(Na2CO3)做為pH調節劑，使得聚乙烯醇被凝聚、膠化析出。
  6. 如申請專利範圍第1項所述之「製備奈米銀掺混天然纖維素熔噴不織布的方法」，其中，步驟f中再生與水洗後釋出的氧化甲基瑪琳溶劑的回收步驟包含：A.先以1~20μ的PP濾芯進行第一次過濾；B.將第一次過濾後之溶劑注入絮凝槽中，絮凝劑及其配合之添加劑的投加量為1.5mg/L，處理時間1小時，溶劑中的膠體雜質受絮凝劑的作用產生聚附，溶液中非溶解性雜質可形成高聚集態的絮凝物，量大的絮凝物會開始沉降，而後再透過濾網阻隔排出；C.經凝絮處裡後的溶劑直接通入離子交換純化系統中，透過帶電性陰、陽離子的吸附、接合作用，可將溶液中的有色雜質分離，並加強溶劑的純化，該處理期間的pH範圍維持於8~9；D.再以ultrafilter(UF)及逆滲透(RO)過濾器對純化後的溶劑進行第二次過濾；及E.最後將第二次過濾後的低濃度NMMO溶劑(3.0%~6.0%)進行濃縮處理，其採多段蒸發槽系統進行循環，在循環的過程中NMMO溶劑將會逐漸提純直至50.0%~78.0%即可產出達成回收。
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