CN112376119A - 一种高效、低阻过滤膜及其在口罩面料中的应用 - Google Patents

一种高效、低阻过滤膜及其在口罩面料中的应用 Download PDF

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CN112376119A
CN112376119A CN202011251221.8A CN202011251221A CN112376119A CN 112376119 A CN112376119 A CN 112376119A CN 202011251221 A CN202011251221 A CN 202011251221A CN 112376119 A CN112376119 A CN 112376119A
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membrane
low
mask
efficiency
filtering membrane
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陈杨轶
李剑超
张初阳
齐欢
田军
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Fujian Textile And Clothing Service Center For Small And Medium Sized Enterprises
Quanzhou Normal University (shishi) Eco-Intelligent Fabric Engineering Technology Research Institute
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Fujian Textile And Clothing Service Center For Small And Medium Sized Enterprises
Quanzhou Normal University (shishi) Eco-Intelligent Fabric Engineering Technology Research Institute
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    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/0007—Electro-spinning
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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
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  • Dispersion Chemistry (AREA)
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  • Separation Using Semi-Permeable Membranes (AREA)

Abstract

本发明公开了一种高效、低阻过滤膜及其在口罩面料中的应用，通过静电纺纳米纤维微多孔复合薄膜与无纺布结合的方法，实现口罩面料高效、低阻的过滤性能，具体包括1）面层无纺布的制备；2）内层复合过滤膜的制备；3）口罩的贴合。本发明能够实现口罩面料BFE过滤效率达到95%以上，PFE过滤效率达到95%以上，呼吸阻力为104~119 Pa，且具有持久过滤、轻薄透气的特点。

Description

一种高效、低阻过滤膜及其在口罩面料中的应用
技术领域
本发明属于过滤材料技术领域，具体涉及一种高效、低阻过滤膜及其在口罩面料中的应用。
背景技术
医用防护口罩是人们日常生活中的必需品。市面上可起到病毒防护作用的口罩主要为一次性医用口罩以及N95/KN95型口罩，两种口罩的核心为熔喷无纺布。该类口罩主要通过熔喷无纺布表面富集的静电，将靠近的含病毒飞沫吸附在外侧无纺布的表面，起到对病毒的过滤与隔离的功能。
但是诸如N95型静电吸附口罩缺陷明显。由于人体呼气的相对湿度远远大于90％，随着佩戴时间的增加，呼气中的大量水蒸气在离开呼吸道到达口罩过滤层后会逐渐积累并凝结成液态，使熔喷布变成导体，导致静电吸附作用减弱甚至消失，无法实现持久的有效过滤。其次，由于采用的SMS三层结构，N95型口罩外观厚重，长时间佩戴会影响人体舒适性。
纳米纤维微多孔膜作为一类新型过滤材料，其宏观状态为薄膜状材料，微观结构是由大量纳米纤维层层叠加在一起的微多孔膜，可以根据具体过滤条件的要求，制备成一定量化孔径的膜材料，具备良好的表面过滤功能，在口罩用过滤材料领域具有良好的发展前景。这类膜材料包括：静电纺纳米纤维膜、聚酰胺纳米纤维膜、聚四氟乙烯纳米纤维膜等纳米纤维为主体的微多孔膜。此类纳米纤维微多孔膜可以根据口罩使用的具体需求制备成相应孔径的膜材料。由于这类材料依靠表面与内部高密度的微孔通道实现病毒聚集颗粒的过滤，因此具备阻隔效率高、性能持久，且呼吸阻力小，能够保证足够的透气量以防呼吸不适。
发明内容
本发明的目的是提供一种高效、低阻过滤膜及其在口罩面料中的应用，实现细菌过滤效率(BFE)达到95％以上，粒子过滤效率(PFE)达到95％以上，呼吸阻力为104～119Pa，具有持久过滤、轻薄透气性。
为了实现上述目的，本发明采用以下技术方案：
一种高效、低阻过滤膜的制备方法：通过高分子(聚氯乙烯、聚苯乙烯、聚四氟乙烯、聚偏氟乙烯)溶液或乳液静电纺丝技术在亲水性的高分子微孔薄膜(聚酰胺6、聚酰胺66、聚丙烯腈、聚砜、聚乙烯醇)表面构建一层纳米纤维微多孔膜，静电纺丝电压为10～30KV，喷丝距离为5～10cm，控制静电纺薄膜厚度为0.2～2μm，等效孔径为0.2～0.4μm，孔隙率为 70～90％。
一种口罩面料的制备方法，包括以下步骤：
1)面层无纺布的制备：将低熔点卷曲涤纶短纤与ES纤维混合进行针刺，其中低熔点涤纶短纤的占比为10～30wt％，针刺频率为20～40Hz，纤网速度为10～30m/min，经单面烫光工艺，压光速度为20～40m/min，温度为130～150℃，得到面层针刺无纺布，控制克重为60～100g/m2；
2)内层复合过滤膜的制备：通过高分子(聚氯乙烯、聚苯乙烯、聚四氟乙烯、聚偏氟乙烯)静电纺丝技术在亲水性的高分子微孔薄膜(聚酰胺6、聚酰胺66、聚丙烯腈、聚砜、聚乙烯醇)表面构建一层纳米纤维微多孔膜，静电纺丝电压为10～30KV，喷丝距离为5～10cm，控制静电纺薄膜厚度为0.2～2μm，等效孔径为0.2～0.4μm，孔隙率为70～90％；
3)口罩面料的贴合：利用环保、无气味、无毒的热熔胶将内层复合过滤膜与面层针刺无纺布在60～80℃温度下进行贴合。
本发明与现有技术相比，其有益效果是：(1)利用纳米纤维微多孔膜的微孔结构实现过滤性能，相对于传统驻级材料熔喷无纺布，具备阻隔效率高，呼吸阻力小，使用寿命长的优点；(2)内层为亲水膜，可实现水蒸气由内侧向外侧的定向“搬运”，舒适透气；(3)内层复合薄膜与外层无纺布结合，代替传统SMS三层结构，克重大大降低，轻薄柔软。(4)本发明能够实现口罩面料BFE过滤效率达到95％以上，PFE过滤效率达到95％以上，呼吸阻力为104～119Pa。
附图说明
图1为口罩面料结构示意图，内层为复合过滤膜，包括内层1纳米纤维微多孔膜以及内层2亲水性的微孔薄膜，面层为针刺无纺布。
具体实施方式
为使本发明的目的、技术方案更加清晰明了，下面通过实例对本发明技术方案进行以下详细说明，但不限于这些实施例。
实施例1
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率20Hz，纤网速度10m/min，其中低熔点涤纶短纤占比为10wt％。经单面烫光工艺，压光速度20m/min，温度为130℃，开发面层针刺无纺布，克重为60g/m2。
内层复合过滤膜的制备：通过聚氯乙烯静电纺丝技术在聚酰胺6微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压10KV，喷丝距离5cm，控制静电纺薄膜厚度为0.2μm，等效孔径为0.2μm，孔隙率为70％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在60℃进行贴合。
实施例2
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率20Hz，纤网速度10m/min，其中低熔点涤纶短纤占比为14wt％。经单面烫光工艺，压光速度20m/min，温度为135℃，开发面层针刺无纺布，克重为65g/m2。
内层复合过滤膜的制备：通过聚苯乙烯静电纺丝在聚酰胺66微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压10KV，喷丝距离6cm，控制静电纺薄膜厚度为0.25μm，等效孔径为0.2μm，孔隙率为75％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在60℃进行贴合。
实施例3
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率25Hz，纤网速度15m/min，其中低熔点涤纶短纤占比为18wt％。经单面烫光工艺，压光速度25m/min，温度为135℃，开发面层针刺无纺布，克重为70g/m2。
内层复合过滤膜的制备：通过聚氯乙烯静电纺丝技术在聚丙烯腈微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压15KV，喷丝距离7cm，控制静电纺薄膜厚度为0.5μm，等效孔径为0.2μm，孔隙率为75％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在65℃进行贴合。
实施例4
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率25Hz，纤网速度15m/min，其中低熔点涤纶短纤占比为22wt％。经单面烫光工艺，压光速度30m/min，温度为140℃，开发面层针刺无纺布，克重为70g/m2。
内层复合过滤膜的制备：通过聚四氟乙烯乳液静电纺丝技术在聚酰胺66微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压15KV，喷丝距离6cm，控制静电纺薄膜厚度为0.8μm，等效孔径为0.2μm，孔隙率为80％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在70℃进行贴合。
表1为本实施例内层复合过滤膜的呼吸阻力以及过滤效率参数。
表1内层复合过滤膜各项参数
Figure RE-GDA0002886125710000041
实施例5
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率30 Hz，纤网速度20m/min，其中低熔点涤纶短纤占比为26wt％。经单面烫光工艺，压光速度30m/min，温度为135℃，开发面层针刺无纺布，克重为65g/m2。
内层复合过滤膜的制备：通过聚四氟乙烯静电纺丝技术在聚酰胺66微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压15KV，喷丝距离6cm，控制静电纺薄膜厚度为0.5μm，等效孔径为0.2μm，孔隙率为80％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在70℃进行贴合。
实施例6
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率35 Hz，纤网速度25m/min，其中低熔点涤纶短纤占比为20wt％。经单面烫光工艺，压光速度30m/min，温度为135℃，开发面层针刺无纺布，克重为65g/m2。
内层复合过滤膜的制备：通过聚偏氟乙烯静电纺丝技术在聚酰胺66微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压20KV，喷丝距离8cm，控制静电纺薄膜厚度为0.25μm，等效孔径为0.2μm，孔隙率为85％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在75℃进行贴合。
实施例7
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率40 Hz，纤网速度30m/min，其中低熔点涤纶短纤占比为20wt％。经单面烫光工艺，压光速度35m/min，温度为135℃，开发面层针刺无纺布，克重为65g/m2。
内层复合过滤膜的制备：通过聚偏氟乙烯静电纺丝技术在聚酰胺66微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压25KV，喷丝距离8cm，控制静电纺薄膜厚度为0.8μm，等效孔径为0.25μm，孔隙率为90％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在80℃进行贴合。
实施例8
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率40 Hz，纤网速度30m/min，其中低熔点涤纶短纤占比为20wt％。经单面烫光工艺，压光速度40m/min，温度为150℃，开发面层针刺无纺布，克重为80g/m2。
内层复合过滤膜的制备：通过聚偏氟乙烯静电纺丝技术在聚酰胺66微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压30KV，喷丝距离10cm，控制静电纺薄膜厚度为0.5μm，等效孔径为0.25μm，孔隙率为90％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在80℃进行贴合。
实施例9
一种高效、低阻过滤膜及口罩面料的制备方法，包括以下步骤：
面层无纺布的制备：利用低熔点卷曲涤纶短纤与ES纤维混合进行针刺，针刺频率30 Hz，纤网速度25m/min，其中低熔点涤纶短纤占比为30wt％。经单面烫光工艺，压光速度40m/min，温度为150℃，开发面层针刺无纺布，克重为100g/m2。
内层复合过滤膜的制备：通过聚四氟乙烯乳液静电纺丝技术在聚乙烯醇微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺电压30KV，喷丝距离10cm，控制静电纺薄膜厚度为1μm，等效孔径为0.2μm，孔隙率为85％。
口罩面料的贴合：利用环保、无气味、无毒的热熔胶将复合过滤膜与针刺无纺布在80℃进行贴合。

Claims (8)

1.一种高效、低阻过滤膜的制备方法，其特征在于：通过高分子静电纺丝技术在亲水性的高分子微孔薄膜表面构建一层纳米纤维微多孔膜，静电纺丝电压为10~30 KV，喷丝距离为5~10 cm，控制静电纺薄膜的厚度为0.2~2 μm，等效孔径为0.2~0.4 μm，孔隙率为70~90%。
2.根据权利要求1所述的一种高效、低阻过滤膜的制备方法，其特征在于：静电纺丝高分子为聚氯乙烯、聚苯乙烯、聚四氟乙烯、聚偏氟乙烯中的一种溶液或乳液。
3.根据权利要求1所述的一种高效、低阻过滤膜的制备方法，其特征在于：所述亲水性的高分子微孔薄膜为聚酰胺6、聚酰胺66、聚丙烯腈、聚砜、聚乙烯醇中的一种或多种。
4.一种口罩面料，其特征在于：其由权利要求1~3任一制备方法得到的过滤膜制备而成。
5.一种如权利要求4所述口罩面料的制备方法，其特征在于：包括以下步骤：
面层无纺布的制备：将低熔点涤纶短纤与ES纤维混合进行针刺，针刺频率为20~40 Hz，纤网速度为10~30 m/min，经单面烫光工艺，压光速度为20~40 m/min，温度为130~150 oC，得到面层针刺无纺布；
内层复合过滤膜的制备：采用权利要求1 ~3任一制备方法得到内层复合过滤膜；
口罩面料的贴合：利用热熔胶将内层复合过滤膜与面层针刺无纺布进行贴合。
6.根据权利要求5所述口罩面料的制备方法，其特征在于：低熔点涤纶短纤与ES纤维的混合纤维中，低熔点涤纶短纤的占比为10~30 wt%。
7.根据权利要求5所述口罩面料的制备方法，其特征在于：所述面层针刺无纺布的克重控制为60~100 g/m2。
8.根据权利要求5所述口罩面料的制备方法，其特征在于：所述贴合温度为60~80 oC。
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