WO2022160401A1 - 可重复水洗的防护口罩及其制备工艺 - Google Patents

可重复水洗的防护口罩及其制备工艺 Download PDF

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WO2022160401A1
WO2022160401A1 PCT/CN2021/078076 CN2021078076W WO2022160401A1 WO 2022160401 A1 WO2022160401 A1 WO 2022160401A1 CN 2021078076 W CN2021078076 W CN 2021078076W WO 2022160401 A1 WO2022160401 A1 WO 2022160401A1
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layer
electret
polypropylene
powder
layers
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PCT/CN2021/078076
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English (en)
French (fr)
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叶刚
梅先明
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腾飞科技股份有限公司
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Priority to JP2021134124A priority Critical patent/JP7328288B2/ja
Publication of WO2022160401A1 publication Critical patent/WO2022160401A1/zh

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    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
    • A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
    • A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/30—Antimicrobial, e.g. antibacterial
    • A41D31/305—Antimicrobial, e.g. antibacterial using layered materials
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/48—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
    • D04H1/485—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • 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
    • D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/492—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • 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
    • D04H1/54—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 by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/555—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 by welding together the fibres, e.g. by partially melting or dissolving by ultrasonic heating

Definitions

  • the invention relates to a protective mask and a preparation process thereof, in particular to a protective mask that can be washed repeatedly and a preparation process thereof, belonging to the technical field of personal respiratory protection appliances.
  • a mask is a sanitary product, generally refers to a device worn on the mouth and nose to filter the air entering the mouth and nose, so as to block harmful gases, odors, and droplets from entering and leaving the wearer's mouth and nose. It is extremely important in the field of medical and health care. It plays an important role in the epidemic prevention project of preventing and blocking respiratory infectious diseases. Most of the protective masks in the prior art use the principle of physical interception and filtration, that is, use a certain pore size filter material to filter and intercept fine dust and particles larger than the pore size, thereby preventing bacteria and viruses attached to them from contacting the human body and entering the respiratory tract. , thereby greatly reducing the risk of infection or harm to the human body.
  • the mask body of common protective masks on the market is mostly divided into inner, middle and outer layers, and the middle layer is mostly made of ultra-fine polypropylene fiber meltblown material layer, but this kind of protective mask cannot be washed with water, and it can be used for 3-4 hours It needs to be replaced, and the replacement frequency is too fast, which causes a lot of waste for ordinary individual users. Therefore, it is necessary to provide a protective mask that can be repeatedly washed with water, and at the same time, the protective mask still has an excellent filtering effect after being washed with water.
  • the present invention provides a protective mask that can be washed repeatedly and a preparation process thereof. High filtration efficiency.
  • the invention discloses a reusable protective mask, comprising a mask body and ear straps fixed on opposite sides of the mask body, wherein the mask body comprises a surface layer, an inner layer, and An intermediate layer between the inner layers, the intermediate layer includes a first intermediate layer, a second intermediate layer and a third intermediate layer which are stacked in sequence and welded together by ultrasonic composite welding, wherein
  • the first intermediate layer and the third intermediate layer are both polypropylene spunbond non-woven layers
  • the second intermediate layer is a spunlace electret-treated polypropylene melt-blown cloth layer, and the polypropylene melt-blown cloth layer is made of polypropylene melt-blown material including 6-7wt. Polypropylene melt-blown cloth layer formed after extrusion, jet stretching and web reinforcement;
  • the electret master batch includes the following components in terms of the total mass percentage of the electret master batch: inorganic electret powder 2-3wt.%, organic electret powder 5-6wt.%, compatibilizer 3-8 wt. %, processing aid 2-8 wt. % and balance polypropylene resin.
  • the polypropylene spunbond non-woven fabric layer used in the first intermediate layer and the third intermediate layer is a single-layer double-S spunbond non-woven fabric layer with a grammage of 25-30 g/cm 2 .
  • the polypropylene melt-blown cloth layer used in the second intermediate layer is a single-layer polypropylene melt-blown cloth layer with a gram weight of 40-45 g/cm 2 , and the fiber diameter in the polypropylene melt-blown cloth layer is 0.5-0.8 microns.
  • the inorganic electret powder in the electret master batch used in the second intermediate layer is a powder mixture formed by mixing nano-tourmaline powder and nano-silicon dioxide in a mass ratio of (5-6): 1, and wherein the nano-electrical
  • the particle size D90 of the stone powder is 50-100 nm, and the particle size D90 of the nano-silica is 80-100 nm.
  • the organic electret powder in the electret master batch used in the second intermediate layer is a fluorine-based polymer powder, and the average particle size of the fluorine-based polymer powder is 50-200 nm.
  • the fluorine-based polymer powder is at least one of polytetrafluoroethylene powder, perfluoroethylene powder and tetrafluoroethylene-perfluoroethylene copolymer powder.
  • the surface layer and the inner layer are both fabric layers formed by nylon fibers, and the grammage of the fabric layer is 100-130 g/cm 2 .
  • the surface layer and the inner layer are respectively attached to both sides of the middle layer through a polyurethane adhesive layer.
  • the invention also discloses a preparation process of the above-mentioned reusable protective mask, which mainly comprises the following steps:
  • the polypropylene melt-blown material including the electret masterbatch is melt-extruded, jet-stretched and reinforced on the melt-blown equipment to form a polypropylene melt-blown cloth layer, and then a spunlace electret equipment is used to stab in water. electret treatment of the polypropylene melt-blown cloth layer in a polar manner;
  • the two layers of nylon fiber fabrics are synchronously fed into the roll, and after spraying polyurethane adhesive on the opposite sides of the two layers of nylon fiber fabrics, the middle layer is sandwiched between the two layers of nylon fiber fabrics by lamination Between the layers, a five-layer mask body fabric is formed;
  • the middle layer of the mask of the present invention adopts a layer of polypropylene melt-blown cloth sandwiched in the middle of two layers of polypropylene spunbond non-woven fabrics, and the three layers are compounded together by means of ultrasonic welding;
  • the polypropylene spunbond non-woven fabric layer has the functions of stretching and water repellency, and the polypropylene meltblown cloth in the middle has the effect of filtering particles and carrying germs and virus droplets.
  • the setting of the three-layer structure can make the center meltblown cloth
  • the water-washing resistance is greatly increased; at the same time, the ultrasonic bonding and compounding method adopted can resist the impact caused by repeated washing, and can also greatly increase the water-washing resistance of the mask;
  • the addition amount of electret masterbatch in the polypropylene meltblown material of the polypropylene meltblown cloth layer of the mask of the present invention is increased to 6-7wt.%, and the total amount of electret powder in this electret masterbatch
  • the electret powder used adopts the method of compounding inorganic electret powder and organic electret powder.
  • the above-mentioned technical points can make the formed melt-blown cloth produced by spunlace electret.
  • the electret of the mask is greatly increased, and static electricity can be generated by friction during the washing process after use, so as to ensure that the mask still has a high filtering effect after washing;
  • the polypropylene melt-blown cloth layer of the mask of the present invention adopts a spunlace electret instead of a conventional electric electret to generate more electrets, thereby making up for the electrodes lost in the spunlace electret process, ensuring that The treated melt-blown cloth is saturated with static electricity and greatly improves the filtration efficiency.
  • it can also make the non-woven fabric have better permeability, stable electret, long retention time, strong adsorption, and low resistance. The filtration efficiency after washing is less reduced;
  • the PFE of the mask of the present invention is greater than or equal to 99% and the BEF is greater than or equal to 99%, and the number of washings can be as high as 20 times, and the filtration efficiency of the mask after washing can still reach PFE ⁇ 95% and BEF ⁇ 95%.
  • Fig. 1 is the sectional structure schematic diagram of the mask body of the present invention
  • Fig. 2 is the physical plan view of the intermediate layer of the present invention.
  • the protective mask includes a mask body and ear straps fixed on opposite sides of the mask body, wherein the ear straps are arranged in a conventional technical solution in the art , which will not be repeated in this specific embodiment.
  • the mask body comprises a surface layer 1, an inner layer 2 and an intermediate layer 3 arranged between the surface layer and the inner layer, wherein the surface layer 1 and the inner layer 2 are respectively attached to both sides of the intermediate layer 3 through the polyurethane adhesive layer.
  • the specific bonding method and the adopted polyurethane adhesive layer are all conventional technical solutions in the art, which will not be repeated in this specific embodiment.
  • the above-mentioned surface layer 1 is the side away from the human face after the wearer puts on the mask, and the inner layer 2 is the side facing the human face after the wearer puts on the mask.
  • the surface layer 1 and the inner layer 2 are made of the same material, both are fabric layers made of nylon fibers, and the gram weight of the fabric layer is 100-130 g/cm 2 .
  • the above-mentioned intermediate layer 3 includes a first intermediate layer 31, a second intermediate layer 32 and a third intermediate layer 33 that are laminated and composited in sequence, and the first intermediate layer 31, the second intermediate layer 32 and the third intermediate layer 33 are laminated and arranged. Then, the intermediate layer 3 is formed by ultrasonic composite welding.
  • the first intermediate layer 31 and the third intermediate layer 33 in the intermediate layer 3 are both polypropylene spunbond non-woven fabric layers, and the polypropylene spunbond non-woven fabric layer is preferably a single gram weight of 25-30 g/cm 2 .
  • Layer double S spunbond nonwoven layer is preferably a single gram weight of 25-30 g/cm 2 .
  • the second intermediate layer 33 in the intermediate layer 3 is a polypropylene melt-blown cloth layer that has undergone hydroentanglement electret treatment, and the polypropylene melt-blown cloth layer is made of polypropylene melt-blown including 6-7 wt.% electret masterbatch.
  • the electret master batch in the above polypropylene melt-blown material includes the following components in terms of the total mass percentage of the electret master batch: inorganic electret powder 2-3wt.%, organic electret powder 5-6wt.% %, compatibilizer 3-8wt.%, processing aid 2-8wt.% and balance polypropylene resin.
  • inorganic electret powder is a powder mixture formed by mixing nano tourmaline powder and nano silicon dioxide according to the mass ratio of (5-6): 1, and wherein the particle size D90 of the nano tourmaline powder is 50-100nm, and the nanometer two The particle size D90 of the silicon oxide is 80-100 nm.
  • the organic electret powder is fluorine-based polymer powder, and the average particle size of the fluorine-based polymer powder is 50-200 nm.
  • the preferred fluorine-based polymer powder is polytetrafluoroethylene powder, perfluoropolymer powder At least one of polyethylene powder and tetrafluoroethylene-perfluoroethylene copolymer powder.
  • the compatibilizer is at least one of maleic anhydride grafted polypropylene and glycidyl methacrylate grafted polypropylene.
  • the processing aid includes at least one of polypropylene wax, stearic acid or stearate, and a silane coupling agent. Wherein the polypropylene adopts at least one of homopolymerized polypropylene and copolymerized polypropylene with melt index of 1500-2000 g/10min at 230°C/2.16kg.
  • the polypropylene melt-blown material including the electret masterbatch is melt-extruded, jet-stretched and reinforced on the melt-blown equipment to form a polypropylene melt-blown cloth layer, and then a spunlace electret equipment is used to stab in water. electret treatment of the polypropylene melt-blown cloth layer in a polar manner;
  • the two layers of nylon fiber fabrics are synchronously fed into the roll, and after spraying polyurethane adhesive on the opposite sides of the two layers of nylon fiber fabrics, the middle layer is sandwiched between the two layers of nylon fiber fabrics by lamination Between the layers, a five-layer mask body fabric is formed;
  • Surface layer 1 a fabric layer made of nylon fibers, with a gram weight of 100g/cm 2 ;
  • Inner layer 2 a fabric layer made of nylon fibers, with a gram weight of 120g/cm 2 ;
  • the first intermediate layer 31 single-layer double-S spunbond non-woven fabric layer, gram weight 25g/cm 2 ;
  • the second intermediate layer 32 a polypropylene melt-blown cloth layer with a gram weight of 45g/cm 2 and a fiber diameter of 0.6 microns;
  • the third intermediate layer 33 a single-layer double-S polypropylene spunbond non-woven fabric layer, with a grammage of 25 g/cm 2 .
  • the polypropylene melt-blown cloth layer is a polypropylene melt-blown cloth layer formed by sequentially melt extrusion, jet stretching and reinforcement of the polypropylene melt-blown material including 6 wt.% electret masterbatch. Stab electret treatment.
  • the electret master batch in the above-mentioned polypropylene melt-blown material comprises the following components by the total mass percentage of this electret master batch:
  • organic electret powder formed by mixing polytetrafluoroethylene powder (average particle size 90nm) and perfluoropolyethylene powder (average particle size 95nm) in a mass ratio of 3:1;
  • Polypropylene resin homopolypropylene with melt index of 1500g/10min at 230°C/2.16kg.
  • the middle layer of the protective mask of the present invention adopts a layer of polypropylene melt-blown cloth sandwiched between two layers of polypropylene spunbond non-woven fabrics, and the three layers are combined together by ultrasonic welding;
  • the propylene spunbond non-woven fabric layer has the functions of stretching and water repellency, and the polypropylene meltblown cloth in the middle has the effect of filtering particles and carrying germs and virus droplets.
  • the water-washing resistance is greatly increased; at the same time, the ultrasonic bonding and compounding method adopted can resist the impact brought by repeated washing, and can also greatly increase the water-washing resistance of the mask.
  • the addition amount of electret master batch in the polypropylene melt-blown material of the polypropylene melt-blown cloth layer of the mask of the present invention is increased to 6-7 wt.%, and the total amount of electret powder in this electret master batch reaches 7 -9wt.%, at the same time, the electret powder used adopts the method of compounding inorganic electret powder and organic electret powder.
  • the above-mentioned technical points can make the formed melt-blown cloth produced by hydroentanglement electret.
  • the polar body is greatly increased, and static electricity can be generated by friction during the washing process after use, so as to ensure that the mask still has a high filtering effect after washing.
  • the polypropylene meltblown cloth layer in the mask can generate more electrets by using spunlace electret instead of conventional electric electret, so as to make up for the electrodes lost during the spunlace electret process, which can ensure the molten electret after treatment.
  • the static electricity of spray cloth is saturated and the filtration efficiency is greatly improved, it can also make the non-woven fabric have better permeability, stable electret, long holding time, strong adsorption, low resistance, and filtration after use and washing. Less efficiency reduction.
  • the mask of the present invention has PFE ⁇ 99% and BEF ⁇ 99%, the number of times of washing can be as high as 20 times, and the filtration efficiency of the mask after washing can still reach PFE ⁇ 95% and BEF ⁇ 95%.

Abstract

一种可重复水洗的防护口罩及其制备工艺，属于个人呼吸防护用具技术领域。该口罩的口罩本体包括面层（1）、内层（2）和设置在两者之间的中间层（3），中间层（3）包括依次层叠设置并超声波复合的第一中间层（31）、第二中间层（32）和第三中间层（33），其中第一中间层（31）、第三中间层（33）均为聚丙烯纺粘无纺布层，第二中间层（32）为经水刺驻极处理的聚丙烯熔喷布层，该聚丙烯熔喷布层是由包括6-7wt.％驻极母粒的聚丙烯熔喷料加工形成的聚丙烯熔喷布层，且驻极母粒包括无机驻极粉体、有机驻极粉体、相容剂、加工助剂和聚丙烯树脂。通过工艺形成的防护口罩的PFE≥99％且BEF≥99％，水洗次数可高达20次，且该口罩水洗后的过滤效率依然能够达到PFE≥95％且BEF≥95％。

Description

可重复水洗的防护口罩及其制备工艺 技术领域
本发明涉及一种防护口罩及其制备工艺，尤其涉及一种可重复水洗的防护口罩及其制备工艺，属于个人呼吸防护用具技术领域。
背景技术
口罩是一种卫生用品，一般指戴在口鼻部位用于过滤进入口鼻的空气，以达到阻挡有害的气体、气味、飞沫进出佩戴者口鼻的用具，其在医疗卫生领域具有极其重要的意义，尤其在预防和阻断呼吸道传染疾病的防疫工程中充当了重要角色。现有技术中的大部分防护口罩是利用物理拦截过滤原理即利用一定孔径滤材将大于该孔径的微尘和颗粒过滤拦截下来，从而避免附着于其上的细菌病毒等与人体接触并进入呼吸道，进而大大降低人体被感染或受危害的风险。
目前市场上常见的防护口罩的口罩本体部分大多分为内、中、外三层，中间层大多采用超细聚丙烯纤维熔喷材料层，但这种防护口罩不能水洗，且使用3-4小时就需要更换，更换频率太快，对于普通个人用户而言，造成很大的浪费。因此，需要提供一种能够重复水洗的防护口罩，同时经水洗后该防护口罩仍具有优异的过滤效果。
发明内容
为了解决上述背景技术中提出的各项技术问题，本发明提供了一种可重复水洗的防护口罩及其制备工艺，该口罩具有过滤效率高的特点，且能够在历经20次水洗后仍然具有较高的过滤效率。
本发明的技术方案是：
本发明公开了一种可重复水洗的防护口罩，包括口罩本体和固定设于该口罩本体上相对两侧处的耳带，所述口罩本体包括面层、内层和设置在所述面层及所述内层之间的中间层，所述中间层包括依次层叠设置并通过超声波复合焊接在一起的第一中间层、第二中间层和第三中间层，其中
所述第一中间层和第三中间层均为聚丙烯纺粘无纺布层；
所述第二中间层为经水刺驻极处理的聚丙烯熔喷布层，该聚丙烯熔喷布层是由包括6-7wt.％驻极母粒的聚丙烯熔喷料依次经熔融挤出、喷射拉伸和成网加固后形成的聚丙烯熔喷布层；
其中所述驻极母粒包括按该驻极母粒总质量百分比计的下述各组分：无机驻极粉体2-3wt.％、有机驻极粉体5-6wt.％、相容剂3-8wt.％、加工助剂2-8wt.％和余量聚丙烯树脂。
其进一步的技术方案是：
所述第一中间层和第三中间层所使用的聚丙烯纺粘无纺布层为克重25-30g/cm 2的单层双S纺粘无纺布层。
其进一步的技术方案是：
所述第二中间层所使用的聚丙烯熔喷布层为克重40-45g/cm 2的单层聚丙烯熔喷布层，且该聚丙烯熔喷布层中的纤维直径为0.5-0.8微米。
其进一步的技术方案是：
所述第二中间层所使用驻极母粒中的无机驻极粉体为纳米电气石粉和纳米二氧化硅按照质量比为(5-6):1混合形成的粉体混合物，且其中纳米电气石粉的粒径D90为50-100nm，纳米二氧化硅的粒径D90为80-100nm。
其进一步的技术方案是：
所述第二中间层所使用驻极母粒中的有机驻极粉体为氟类聚合物粉体，且该氟类聚合物粉体的平均粒径为50-200nm。
其进一步的技术方案是：
所述氟类聚合物粉体为聚四氟乙烯粉体、全氟聚乙烯粉体和四氟乙烯-全氟乙烯共聚物粉体中的至少一种。
其进一步的技术方案是：
所述面层和内层均为采用锦纶纤维成网的布料层，且该布料层的克重为100-130g/cm 2。
其进一步的技术方案是：
所述面层和内层分别经聚氨酯胶黏剂层贴合于所述中间层的两侧。
本发明还公开了一种上述可重复水洗的防护口罩的制备工艺，该制备工艺主要包括如下步骤：
S1，将包括驻极母粒的聚丙烯熔喷料在熔喷设备上经熔融挤出、喷射拉伸和成网加固后形成聚丙烯熔喷布层，然后采用水刺驻极设备用水刺驻极的方式对该聚丙烯熔喷布层进行驻极处理；
S2，将五层构成口罩本体的原料卷轴按顺序放置在输送原料卷轴的输送装置上，先将一层经水刺驻极处理后的聚丙烯熔喷布层和两层聚丙烯纺粘无纺布层同步进卷，使聚丙烯熔喷布层夹设在两层聚丙烯纺粘无纺布层之间，然后进入复合装置中采用超声波复合方式将该三层复合在一起形成中间层；
S3，将两层锦纶纤维布料层同步进卷，并在该两层锦纶纤维布料层的相对两侧面上喷涂聚氨酯胶黏剂后，通过贴合方式将中间层夹设在该两层锦纶纤维布料层之间，形成五层的口罩本体面料；
S4，将该五层的口罩本体面料输送到口罩成型装置进行成型后，形成所述可重复水洗的防护口罩。
本发明的有益技术效果是：
1、本发明所述口罩的中间层采用在两层聚丙烯纺粘无纺布中间夹设一层聚丙烯熔喷布，并采用超声波焊接的方式将该三层复合在一起；其中两侧的聚丙烯纺粘无纺布层具有拉伸和拒水的功效，中间的聚丙烯熔喷布具有过滤颗粒和携带病菌及病毒飞沫的功效，该三层结构的设置能够让居中的熔喷布可耐水洗性能大大增加；同时所采用的超声波粘接复合的方式能够抵抗重复洗水带来的冲击，也能够大大增加该口罩的耐水洗性能；
2、本发明所述口罩的聚丙烯熔喷布层的聚丙烯熔喷料中驻极母粒的添加量增加到6-7wt.％，且该驻极母粒中驻极粉体的总量达到7-9wt.％，同时所使用的驻极粉体采用无机驻极粉体和有机驻极粉体复配的方式，上述技术要点能够使所形成的熔喷布经水刺驻极后产生的驻极体大大增加，并且能够在使用后的水洗过程中进行摩擦产生静电，从而能够确保该口罩在水洗后仍然具有较高的过滤效果；
3、本发明所述口罩的聚丙烯熔喷布层采用水刺驻极而非常规电驻极的方式能够产生更多的驻极体，从而弥补水刺驻极过程中损失的电极，能够保证处理后的熔喷布静电量饱和并大大提升过滤效率的同时，还能使无纺布通透性更好，驻极体稳定，保持时间长，吸附性强，阻力低，以及经使用并进行水洗后的过滤效率降低少；
4、本发明所述口罩的PFE≥99％且BEF≥99％，水洗次数可高达20次，且该口罩水洗后的过滤效率依然能够达到PFE≥95％且BEF≥95％。
附图说明
图1是本发明的口罩本体的剖面结构示意图；
图2是本发明所述中间层的实物平面图；
其中：
1、面层；2、内层；3、中间层；31、第一中间层；32、第二中间层；33、第三中间层。
具体实施方式
为了能够更清楚了解本发明的技术手段，并可依照说明书的内容予以实施，下面结合附图和实施例，对本发明的具体实施方式作进一步详细描述，以下实施例用于说明本发明，但不用来限制本发明的范围。
本具体实施例详细记载了一种可重复水洗的防护口罩，该防护口罩包括口罩本体和固定设于该口罩本体上相对两侧处的耳带，其中耳带的设置方式为本领域常规技术方案，本具体实施例中不再赘述。
口罩本体包括面层1、内层2和设置在面层及内层之间的中间层3，其中面层1和内层2分别经聚氨酯胶黏剂层贴合于中间层3的两侧上，该具体的贴合方式以及所采用的聚氨酯胶黏剂层均为本领域中常规的技术方案，本具体实施例中不再赘述。
上述的面层1为佩戴者将该口罩戴上后远离人体面部的一侧，内层2为佩戴者将该口罩戴上后朝向人体面部的一侧。该面层1和内层2的材质一样，均为采用锦纶纤维成网的布料层，且该布料层的克重为100-130g/cm 2。
上述的中间层3包括依次层叠复合设置的第一中间层31、第二中间层32和第三中间层33，且该第一中间层31、第二中间层32和第三中间层33层叠设置后经超声波复合焊接形成中间层3。
该中间层3中的第一中间层31和第三中间层33均为聚丙烯纺粘无纺布层，且该聚丙烯纺粘无纺布层优选为克重25-30g/cm 2的单层双S纺粘无纺布层。
该中间层3中的第二中间层33为经水刺驻极处理的聚丙烯熔喷布层，该聚丙烯熔喷布层是由包括6-7wt.％驻极母粒的聚丙烯熔喷料依次经熔融挤出、喷射拉伸和成网加固后形成的聚丙烯熔喷布层，且该聚丙烯熔喷布层为克重40-45g/cm 2的单层聚丙烯熔喷布层，该聚丙烯熔喷布层中的纤维直径为0.5-0.8微米。
上述聚丙烯熔喷料中的驻极母粒包括按该驻极母粒总质量百分比计的下述各组分：无机驻极粉体2-3wt.％、有机驻极粉体5-6wt.％、相容剂3-8wt.％、加工助剂2-8wt.％和余量聚丙烯树脂。其中的无机驻极粉体为纳米电气石粉和纳米二氧化硅按照质量比为(5-6):1混合形成的粉体混合物，且其中纳米电气石粉的粒径D90为50-100nm，纳米二氧化硅的粒径D90为80-100nm。其中的有机驻极粉体为氟类聚合物粉体，且该氟类聚合物粉体的平均粒径为50-200nm，优选的氟类聚合物粉体为聚四氟乙烯粉体、全氟聚乙烯粉体和四氟乙烯-全氟乙烯共聚物粉体中的至少一种。其中的相容剂为马来酸酐接枝聚丙烯和甲基丙烯酸缩水甘油酯接枝聚丙烯中的至少一种。其中的加工助剂包括聚丙烯蜡、硬脂酸或硬脂酸盐中的至少一种和硅烷偶联剂。其中的聚丙烯采用230℃/2.16kg下熔融指数为1500-2000g/10min的均聚聚丙烯和共聚聚丙烯中的至少一种。
本具体实施例所述防护口罩的制备工艺主要包括如下步骤：
S1，将包括驻极母粒的聚丙烯熔喷料在熔喷设备上经熔融挤出、喷射拉伸和成网加固后形成聚丙烯熔喷布层，然后采用水刺驻极设备用水刺驻极的方式对该聚丙烯熔喷布层进行驻极处理；
S2，将五层构成口罩本体的原料卷轴按顺序放置在输送原料卷轴的输送装置上，先将一层经水刺驻极处理后的聚丙烯熔喷布层和两层聚丙烯纺粘无纺布层同步进卷，使聚丙烯熔喷布层夹设在两层聚丙烯纺粘无纺布层之间，然后进入复合装置中采用超声波复合方式将该三层复合在一起形成中间层；
S3，将两层锦纶纤维布料层同步进卷，并在该两层锦纶纤维布料层的相对两侧面上喷涂聚氨酯胶黏剂后，通过贴合方式将中间层夹设在该两层锦纶纤维布料层之间，形成五层的口罩本体面料；
S4，将该五层的口罩本体面料输送到口罩成型装置进行成型后，形成所述防护口罩。
具体实施例
面层1：锦纶纤维成网的布料层，克重为100g/cm 2；
内层2：锦纶纤维成网的布料层，克重为120g/cm 2；
第一中间层31：单层双S纺粘无纺布层，克重25g/cm 2；
第二中间层32：聚丙烯熔喷布层，克重45g/cm 2，纤维直径为0.6微米；
第三中间层33：单层双S聚丙烯纺粘无纺布层，克重25g/cm 2。
聚丙烯熔喷布层由包括6wt.％驻极母粒的聚丙烯熔喷料依次经熔融挤出、喷射拉伸和成网加固后形成的聚丙烯熔喷布层，成网加固后进行水刺驻极处理。
上述聚丙烯熔喷料中的驻极母粒包括按该驻极母粒总质量百分比计的下述各组分：
纳米电气石粉(D90为80nm)和纳米二氧化硅(D90为90nm)按照质量比为5:1混合形成的无机驻极粉体3wt.％；
聚四氟乙烯粉体(平均粒径90nm)和全氟聚乙烯粉体(平均粒径95nm)按照质量比为3:1混合形成的有机驻极粉体6wt.％；
马来酸酐接枝聚丙烯6wt.％，其中马来酸酐接枝率为8％；
加工助剂聚丙烯蜡3wt.％、硬脂酸0.5wt.％、硅烷偶联剂1.0wt.％；
聚丙烯树脂：230℃/2.16kg下熔融指数为1500g/10min的均聚聚丙烯。
对上述可重复水洗的防护口罩进行性能检测，结果如下所述：
水性前：过滤效率PFE≥99％且BEF≥99％，通气阻力为32Pa/cm 2；
经20次水洗后：过滤效率PFE≥95％且BEF≥95％，通气阻力为34Pa/cm 2。
本发明所述防护口罩的中间层采用在两层聚丙烯纺粘无纺布中间夹设一层 聚丙烯熔喷布，并采用超声波焊接的方式将该三层复合在一起；其中两侧的聚丙烯纺粘无纺布层具有拉伸和拒水的功效，中间的聚丙烯熔喷布具有过滤颗粒和携带病菌及病毒飞沫的功效，该三层结构的设置能够让居中的熔喷布可耐水洗性能大大增加；同时所采用的超声波粘接复合的方式能够抵抗重复洗水带来的冲击，也能够大大增加该口罩的耐水洗性能。且，本发明口罩的聚丙烯熔喷布层的聚丙烯熔喷料中驻极母粒的添加量增加到6-7wt.％，且该驻极母粒中驻极粉体的总量达到7-9wt.％，同时所使用的驻极粉体采用无机驻极粉体和有机驻极粉体复配的方式，上述技术要点能够使所形成的熔喷布经水刺驻极后产生的驻极体大大增加，并且能够在使用后的水洗过程中进行摩擦产生静电，从而能够确保该口罩在水洗后仍然具有较高的过滤效果。此外，口罩中聚丙烯熔喷布层采用水刺驻极而非常规电驻极的方式能够产生更多的驻极体，从而弥补水刺驻极过程中损失的电极，能够保证处理后的熔喷布静电量饱和并大大提升过滤效率的同时，还能使无纺布通透性更好，驻极体稳定，保持时间长，吸附性强，阻力低，以及经使用并进行水洗后的过滤效率降低少。本发明所述口罩的PFE≥99％且BEF≥99％，水洗次数可高达20次，且该口罩水洗后的过滤效率依然能够达到PFE≥95％且BEF≥95％。
以上所述仅是本发明的优选实施方式，并不用于限制本发明，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明技术原理的前提下，还可以做出若干改进和变型，这些改进和变型也应视为本发明的保护范围。

Claims (9)

  1. 一种可重复水洗的防护口罩，包括口罩本体和固定设于该口罩本体上相对两侧处的耳带，其特征在于：所述口罩本体包括面层(1)、内层(2)和设置在所述面层及所述内层之间的中间层(3)，所述中间层(3)包括依次层叠设置并通过超声波复合焊接在一起的第一中间层(31)、第二中间层(32)和第三中间层(33)，其中
    所述第一中间层(31)和第三中间层(33)均为聚丙烯纺粘无纺布层；
    所述第二中间层(33)为经水刺驻极处理的聚丙烯熔喷布层，该聚丙烯熔喷布层是由包括6-7wt.％驻极母粒的聚丙烯熔喷料依次经熔融挤出、喷射拉伸和成网加固后形成的聚丙烯熔喷布层；
    其中所述驻极母粒包括按该驻极母粒总质量百分比计的下述各组分：无机驻极粉体2-3wt.％、有机驻极粉体5-6wt.％、相容剂3-8wt.％、加工助剂2-8wt.％和余量聚丙烯树脂。
  2. 根据权利要求1所述可重复水洗的防护口罩，其特征在于：所述第一中间层(31)和第三中间层(33)所使用的聚丙烯纺粘无纺布层为克重25-30g/cm 2的单层双S纺粘无纺布层。
  3. 根据权利要求1所述可重复水洗的防护口罩，其特征在于：所述第二中间层(32)所使用的聚丙烯熔喷布层为克重40-45g/cm 2的单层聚丙烯熔喷布层，且该聚丙烯熔喷布层中的纤维直径为0.5-0.8微米。
  4. 根据权利要求1所述可重复水洗的防护口罩，其特征在于：所述第二中间层(32)所使用驻极母粒中的无机驻极粉体为纳米电气石粉和纳米二氧化硅按照质量比为(5-6):1混合形成的粉体混合物，且其中纳米电气石粉的粒径D90为50-100nm，纳米二氧化硅的粒径D90为80-100nm。
  5. 根据权利要求1所述可重复水洗的防护口罩，其特征在于：所述第二中间层(32)所使用驻极母粒中的有机驻极粉体为氟类聚合物粉体，且该氟类聚合物粉体的平均粒径为50-200nm。
  6. 根据权利要求5所述可重复水洗的防护口罩，其特征在于：所述氟类聚合物粉体为聚四氟乙烯粉体、全氟聚乙烯粉体和四氟乙烯-全氟乙烯共聚物粉体中的至少一种。
  7. 根据权利要求1所述可重复水洗的防护口罩，其特征在于：所述面层(1)和内层(2)均为采用锦纶纤维成网的布料层，且该布料层的克重为100-130g/cm 2。
  8. 根据权利要求1所述可重复水洗的防护口罩，其特征在于：所述面层(1)和内层(2)分别经聚氨酯胶黏剂层贴合于所述中间层(3)的两侧。
  9. 一种权利要求1至8中任一权利要求所述可重复水洗的防护口罩的制备工艺，其特征在于，主要包括如下步骤：
    S1，将包括驻极母粒的聚丙烯熔喷料在熔喷设备上经熔融挤出、喷射拉伸和成网加固后形成聚丙烯熔喷布层，然后采用水刺驻极设备用水刺驻极的方式对该聚丙烯熔喷布层进行驻极处理；
    S2，将五层构成口罩本体的原料卷轴按顺序放置在输送原料卷轴的输送装置上，先将一层经水刺驻极处理后的聚丙烯熔喷布层和两层聚丙烯纺粘无纺布层同步进卷，使聚丙烯熔喷布层夹设在两层聚丙烯纺粘无纺布层之间，然后进入复合装置中采用超声波复合方式将该三层复合在一起形成中间层；
    S3，将两层锦纶纤维布料层同步进卷，并在该两层锦纶纤维布料层的相对两侧面上喷涂聚氨酯胶黏剂后，通过贴合方式将中间层夹设在该两层锦纶纤维布料层之间，形成五层的口罩本体面料；
    S4，将该五层的口罩本体面料输送到口罩成型装置进行成型后，形成所述可重复水洗的防护口罩。
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