A polytetrafluoroethylene-based medical protective material and a manufacturing method thereof

Abstract

The present invention discloses a polytetrafluoroethylene-based medical protective material and a manufacturing method thereof. The medical protective material uses polytetrafluoroethylene fabric as a base fabric, and a polytetrafluoroethylene microporous membrane is composited on one side or both sides of the polytetrafluoroethylene fabric; a color identification band is provided in the middle or at a specific position of the base fabric, and the color identification band is polytetrafluoroethylene colored yarn woven on the polytetrafluoroethylene fabric. The medical protective material is particularly suitable for front-line medical staff to wear when treating patients infected with acute respiratory syndrome such as coronavirus, and can be reused after sterilization or disinfection.

Description

Technical Field

[0001] The present invention belongs to the field of medical materials, and specifically relates to a polytetrafluoroethylene-based medical protective material used by medical personnel and a manufacturing method thereof. The medical protective material is particularly suitable for frontline medical personnel to wear when treating patients infected with a type of acute respiratory syndrome such as coronavirus, and can be reused after being sterilized or disinfected. Background Art

[0002] Current regulations provide medical protective clothing that provides barriers and protection for medical personnel who come into contact with potentially infectious patients' blood, body fluids, secretions, and airborne particles during work. Most of them are made of non-woven, woven, and knitted fabrics, and are assisted by lamination, thermal bonding, heat sealing, and coating manufacturing methods and processes. Some also use butyl rubber as a raw material. DuPont of the United States has disclosed a protective clothing made by flash steaming. Chinese patent CN102321261B discloses an anti-viral protective material prepared using chitosan polymer material as bacterial fiber. Chinese patent CN1820670A discloses a special medical protective clothing that is a three-layer composite of a polytetrafluoroethylene film protective layer, a polyurethane isolation layer, and a polypropylene fabric from the outside to the inside.

[0003] Most of the raw materials used for the above-mentioned protective materials are natural or ordinary synthetic materials such as cotton, polyester, and polypropylene. Although they are low-cost, effectively waterproof and moisture-proof, and have a barrier and protective effect on medical staff, they can only be used once. High-risk and critical wards need to wear 2-3 protective suits, which are heavy, non-breathable, and inconvenient to move, making doctors and nurses feel very "inconvenient" when they go to the bathroom, and even have to use adult diapers and other embarrassing situations.

[0004] The novel coronavirus is mainly transmitted through droplets, oral mucus and skin contact. Due to its rapid spread, it has led to a rapid demand for medical resources. It is urgent to explore a protective clothing material that can be reused multiple times after disinfection and sterilization, can be recycled, reduces costs and is easy to mark. Summary of the invention

[0005] The diameter of the new coronavirus is 80-150nm, the diameter of the SARS virus is 70-80nm, the diameter of the influenza virus is 80-120nm, and the diameter of most bacteria is 500-5000nm. The effective pore size in the vertical direction of the fabric used for medical protective materials must be less than 70nm to have a good virus protection effect.

[0006] The present invention aims at the deficiencies of the above-mentioned prior art and provides a polytetrafluoroethylene-based medical protective material with a polytetrafluoroethylene microporous breathable membrane on one side or on both sides and a preparation process thereof. The medical protective material adopts polytetrafluoroethylene high-tech fiber material and is composited with a polytetrafluoroethylene microporous membrane in a specific way, so that it has better protection and use performance and can be reused after sterilization or disinfection, achieving the economic effect of saving materials and reducing costs.

[0007] The technical solution of the present invention is specifically implemented in the following ways:

[0008] A polytetrafluoroethylene-based medical protective material uses polytetrafluoroethylene fabric as a base fabric and is composited with a polytetrafluoroethylene microporous membrane on one side or both sides of the polytetrafluoroethylene fabric.

[0009] Preferably, the polytetrafluoroethylene microporous membrane has a unidirectional permeation function. The polytetrafluoroethylene microporous membrane used has a pore size of 40-70 nm and a thickness of 0.01-0.03 mm.

[0010] Preferably, a color identification tape is provided in the middle or at a specific position of the base fabric, and the color identification tape is woven from polytetrafluoroethylene colored yarn on polytetrafluoroethylene fabric, and the fineness of the polytetrafluoroethylene colored yarn is 100D-350D. The color identification tape allows protective materials with different color identification tapes to be used differently in different wards such as intensive care units and infectious disease areas.

[0011] Metal conductive threads are embedded in the polytetrafluoroethylene fabric, and preferably the diameter of the metal conductive threads is 0.1-0.5 mm.

[0012] The polytetrafluoroethylene fabric adopts natural polytetrafluoroethylene filaments with a fineness of 100D-350D.

[0013] A foam coating adhesive layer is arranged between the polytetrafluoroethylene fabric and the polytetrafluoroethylene microporous membrane.

[0014] The polytetrafluoroethylene fabric adopts a twisted heald structure, and the twisted heald structure specifications are: warp density 100-140 strands / inch, weft density 60-90 strands / inch, and width 150-180cm. The specific twisted heald structure used in the present invention can overcome the problem that the surface of the polytetrafluoroethylene filament is smooth, and the warp and weft yarns are particularly prone to slippage at the interlacing points, causing the fabric to deform, and is specially designed.

[0015] The polytetrafluoroethylene based cloth used in the present invention uses polytetrafluoroethylene filaments as raw materials. The fibers have high strength, are water-repellent, oil-repellent, antibacterial, fire-retardant, wear-resistant, self-cleaning, unaffected by ultraviolet light, and have unique chemical resistance such as resistance to strong acids and alkalis and resistance to strong oxidants. At the same time, metal conductive threads are regularly arranged in the warp direction during weaving, so that the fabric has permanent antistatic properties.

[0016] The above-mentioned method for manufacturing the polytetrafluoroethylene-based medical protective material comprises the following steps:

[0017] (1) Weaving polytetrafluoroethylene substrates using natural polytetrafluoroethylene filaments, colored polytetrafluoroethylene filaments and metal conductive yarns as raw materials;

[0018] (2) performing post-treatment on the polytetrafluoroethylene substrate to obtain a polytetrafluoroethylene fabric;

[0019] (3) The polytetrafluoroethylene fabric is composited with a polytetrafluoroethylene microporous membrane by using a foam coating method.

[0020] During the warping in the above step (1), a metal conductive wire is placed on the warp beam every 10-50 mm, and colored polytetrafluoroethylene filaments with a width of 10-15 mm are arranged in the middle or at a specific position. The warping speed is 160-180 m / min; the fabric adopts a twisted heald structure, and the loom speed is 350 rpm.

[0021] The post-finishing of step (2) above adopts the setting conditions of a heat setting machine speed of 60 m / min and a heat setting temperature of 210° C. The post-finishing of the base fabric plays the role of stretching, flattening the fabric surface and setting the fabric.

[0022] The front side or both sides of the finished polytetrafluoroethylene cloth are laminated with a polytetrafluoroethylene microporous film using an adhesive, and the laminating process can be performed on a coating laminating machine.

[0023] The method preferably uses a polytetrafluoroethylene microporous membrane with a pore size of 40-70 nm and a thickness of 0.01-0.03 mm, a degradable, water-soluble formaldehyde-free polyacrylate emulsion, and a foam coating as the lamination method.

[0024] The polytetrafluoroethylene membrane with a micropore diameter of 40-70nm is selected to resist SARS virus with a diameter of 70-80nm, the new coronavirus with a diameter of 80-150nm and most bacterial viruses with a diameter of more than 500nm.

[0025] Considering the very smooth and non-fouling properties of PTFE fabric and PTFE microporous film, the following special coating process and special formula have been developed:

[0026] The preferred parameters of the foam coating in step (3) are as follows: the foam concentration of the foam generator is 40-55 g / l, the foam diameter is 0.5-4 mm, the foaming ratio is 1:2.5-1:4, the coating machine speed is 10-15 m / min, and the roller pressure is 6-10 kg / cm 2, pre-baking temperature 60-80℃, baking temperature 100-150℃. The foam coating formula is preferably: 40-50% water-soluble polyacrylic acid emulsion; 8-12% titanium dioxide; 8-10% china clay; 1-2% PF thickener; 1-2% cross-linking agent; 3-6% surface affinity agent; 1-3% A651-20 thermosetting adhesive; 1-2% ammonia water; the rest is water.

[0027] The polytetrafluoroethylene-based cloth and the microporous polytetrafluoroethylene membrane are compounded by the foam compound method, so that the coating agent can be applied to the base cloth in the form of foams of different diameters. Under the action of pressure, as the foam ruptures, a non-continuous adhesive film is formed on the cloth surface, thereby making the protective material have good air permeability and excellent filtering performance for viruses.

[0028] Compared with the prior art, the polytetrafluoroethylene-based medical protective material prepared by the manufacturing process of the present invention has the following advantages:

[0029] 1. The present invention adopts polytetrafluoroethylene filament as raw material to weave the base cloth of protective material. The intrinsic characteristics of the fiber, such as high strength, water repellency, oil repellency, antibacterial, fire retardant, wear resistance, good self-cleaning, unaffected by ultraviolet light, strong acid and alkali resistance, and strong oxidant resistance, and the conductive fiber woven into the base cloth makes it have permanent conductivity, which determines that the obtained protective material has excellent performance and meets the performance requirements of surgical gowns in the YY / T0506.2-2016 medical industry standard.

[0030] 2. The performance characteristics of the medical protective material prepared by the present invention are as follows: the thickness of the base fabric is 200 μm, which is more than 5 times the standard; the warp strength of the fabric is >1070N, the weft strength is >700N, which is 10 times the current standard; the bursting strength is ≥800N (the medical standard is the bursting strength), which is 3 times the standard, and the service life is more than 20 years. Moreover, it is not easily contaminated and can be reused many times after disinfection and sterilization.

[0031] 3. Composite polytetrafluoroethylene microporous membrane on one side or both sides of polytetrafluoroethylene cloth can play a more effective and safer protective role, ensuring that medical staff will not be cross-infected by coronavirus and respiratory infections.

[0032] 4. The usual method of combining color labels is bonding, which is easy to fall off or be contaminated by pollutants. The present invention weaves a color identification tape into the base fabric, which can avoid a series of technical problems caused by the implantation of identification tape in the subsequent production of protective clothing, and avoids the identification tape from fading and falling off during the disinfection and fumigation process after repeated use. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1Schematic diagram of the structure of medical protective materials based on polytetrafluoroethylene Figure 1 .

[0034] Figure 2 Schematic diagram of the fabric structure of polytetrafluoroethylene based cloth.

[0035] In the figure: 1 is a polytetrafluoroethylene fabric, 2 is a foam coating adhesive layer, 3 is a polytetrafluoroethylene microporous membrane, 4 is a color identification tape, 5 is a metal conductive wire, and 6 is a natural color polytetrafluoroethylene filament twisted heald structure.

[0036] Figure 3 Schematic diagram of the structure of medical protective materials based on polytetrafluoroethylene Figure 2 . DETAILED DESCRIPTION

[0037] The present invention is further illustrated by specific examples. Among them, the water-soluble polyacrylic acid emulsion is produced by Shandong Shengquan New Materials Co., Ltd., titanium dioxide is produced by Hebei Lihua Biotechnology Co., Ltd., porcelain clay is produced by Shahe Shunda Papermaking Clay Factory, PF165A thickener is a French Aisen high-performance coating printing thickener, and the cross-linking agent TAC is 99% triallyl cyanurate, produced by Shanghai Fangruida Chemical Co., Ltd.; the high-efficiency multifunctional surface affinity agent WIN-055 is produced by Suzhou Weinings Chemical Co., Ltd.; A651-20 thermosetting adhesive is produced by Fuhe New Materials Technology (Shanghai) Co., Ltd.

[0038] Example 1

[0039] like Figure 1-2 As shown, a polytetrafluoroethylene-based medical protective material has a polytetrafluoroethylene fabric 1 as a base fabric, and a polytetrafluoroethylene microporous membrane 3 is composited on one side or both sides of the polytetrafluoroethylene fabric 1; a color identification band 4 is provided in the middle or at a specific position of the base fabric, and the color identification band 4 is polytetrafluoroethylene colored yarn woven on the polytetrafluoroethylene fabric 1. A foam coating adhesive layer 2 is provided between the polytetrafluoroethylene fabric 1 and the polytetrafluoroethylene microporous membrane 3. The polytetrafluoroethylene fabric 1 adopts a natural color polytetrafluoroethylene filament twisted heald structure, and a metal conductive wire 5 is embedded in every 30-40 warp yarns, and the diameter of the metal conductive wire 5 is 0.1-0.5mm, the fineness of the natural color polytetrafluoroethylene filament is 100D-350D, and the fineness of the polytetrafluoroethylene colored yarn is 100D-350D. The pore size of the polytetrafluoroethylene microporous membrane (3) is 40-70nm, and the thickness is 0.01-0.03mm. The specifications of the twisted heald organization adopted by the polytetrafluoroethylene fabric 1 are: warp density 100-140 strands / inch, weft density 60-90 strands / inch, and width 150-180cm.

[0040] Example 2

[0041] like Figure 2-3As shown, a polytetrafluoroethylene-based medical protective material has a polytetrafluoroethylene fabric 1 as a base fabric, and a polytetrafluoroethylene microporous membrane 3 is compounded on one side of the polytetrafluoroethylene fabric 1; a color identification band 4 is provided in the middle or at a specific position of the base fabric, and the color identification band 4 is polytetrafluoroethylene colored yarn woven on the polytetrafluoroethylene fabric 1. A foam coating adhesive layer 2 is provided between the polytetrafluoroethylene fabric 1 and the polytetrafluoroethylene microporous membrane 3. The polytetrafluoroethylene fabric 1 adopts a natural color polytetrafluoroethylene filament twisted heald structure, and a metal conductive wire 5 is embedded in every 30-40 warp yarns, and the diameter of the metal conductive wire 5 is 0.1-0.5mm, the fineness of the natural color polytetrafluoroethylene filament is 100D-350D, and the fineness of the polytetrafluoroethylene colored yarn is 100D-350D. The pore size of the polytetrafluoroethylene microporous membrane (3) is 40-70nm, and the thickness is 0.01-0.03mm. The specifications of the twisted heald organization adopted by the polytetrafluoroethylene fabric 1 are: warp density 100-140 strands / inch, weft density 60-90 strands / inch, and width 150-180cm.

[0042] Example 3

[0043] 1. Using 150D natural color polytetrafluoroethylene film split filament and blue polytetrafluoroethylene film split filament produced by Jiangsu Huayue Textile New Materials Technology Co., Ltd. and 0.15mm stainless steel wire produced by Taiwan Nanwei Company as raw materials, polytetrafluoroethylene fabrics were woven on a rapier loom produced by China Textile Machinery Group Zhengzhou Textile Machinery Co., Ltd. Among them, during warping, 1cm wide blue polytetrafluoroethylene filaments were arranged at a width of 77cm on the warp beam, and a stainless steel wire was embedded every 5cm on the warp beam, and the warping speed was 180m / min.

[0044] The obtained polytetrafluoroethylene substrate adopts a twisted heald structure with a warp and weft density of 133×72 strands / inch, a width of 157 cm, a loom speed of 350 rpm, and a humidifier is installed during weaving.

[0045] 2. The heat setting process of the polytetrafluoroethylene substrate is carried out on a heat setting machine produced by Wuxi Haida Textile Machinery Co., Ltd. The speed of the heat setting machine is 60m / min and the heat setting temperature is 210℃.

[0046] 3. The polytetrafluoroethylene fabric obtained after finishing is composited with a polytetrafluoroethylene microporous membrane on the front side by means of foam coating. The polytetrafluoroethylene microporous membrane used has a micropore diameter of 45nm and a thickness of 0.03mm.

[0047] The foam concentration of the foam generator is 50g / l, the foam diameter is 0.5-4mm, the foaming ratio is 1:3, the coating machine speed is 10m / min, and the roller pressure is 8kg / cm 2 , pre-baking temperature 70℃, baking temperature 120℃.

[0048] Foam coating formula: water-soluble polyacrylic acid emulsion: 50%; titanium dioxide: 8%; porcelain clay: 9%; PF165A thickener: 2%; cross-linking agent TAC: 1.5%; high-efficiency multifunctional surface affinity agent WIN-055: 5%; A651-20 thermosetting adhesive: 2%; ammonia water: 1.5%; the rest is water.

[0049] The experimental results show that the polytetrafluoroethylene-based medical protective material obtained by the above method has a fabric thickness of 220μm, a warp strength of 1080N, a weft strength of 650N, a warp elongation of 7.1%, a weft elongation of 6.5%, and an air permeability of 3000g / m 2 .d, water pressure resistance is 240 kPa, moisture permeability is 3000g / ㎡.24h, resistance to microbial penetration (wet state) is 3.8 (IB), and water permeability is 27 (cmH2O).

[0050] Example 4

[0051] 1. Using 200D natural color polytetrafluoroethylene film split filament and green polytetrafluoroethylene film split filament produced by Jiangsu Huayue Textile New Materials Technology Co., Ltd. and 0.10mm stainless steel wire produced by Taiwan Nanwei Company as raw materials, polytetrafluoroethylene fabric was woven on a rapier loom produced by China Textile Machinery Group Zhengzhou Textile Machinery Co., Ltd.

[0052] During warping, 1.2 cm wide green polytetrafluoroethylene filaments are arranged at a width of 77 cm on the warp beam, and a stainless steel wire is embedded every 3 cm on the warp beam. The warping speed is 160 m / min.

[0053] The obtained polytetrafluoroethylene substrate adopts a twisted heald structure with a warp and weft density of 122×83 strands / inch, a width of 175 cm, a loom speed of 350 rpm, and a humidifier is installed during weaving.

[0054] 2. The heat setting process of the polytetrafluoroethylene substrate is carried out on a heat setting machine produced by Wuxi Haida Textile Machinery Co., Ltd. The speed of the heat setting machine is 60m / min and the heat setting temperature is 210℃.

[0055] 3. The polytetrafluoroethylene fabric obtained after finishing is composited with a polytetrafluoroethylene microporous membrane on the front side of the fabric by means of foam coating. The polytetrafluoroethylene microporous membrane used has a micropore diameter of 50nm and a thickness of 0.03mm.

[0056] The foam concentration of the foam generator is 55g / l, the foam diameter is 0.5-3mm, the foaming ratio is 1:3.5, the coating machine speed is 10m / min, and the roller pressure is 8kg / cm 2 , pre-baking temperature 70℃, baking temperature 120℃.

[0057] Foam coating formula: 45% water-soluble polyacrylic acid emulsion; 8% titanium dioxide; 9% porcelain clay; PF165A thickener: 2%; cross-linking agent TAC 1.5%; high-efficiency multifunctional surface affinity agent WIN-055: 5%; A651-20 thermosetting adhesive: 2%; ammonia water: 1.5%; the rest is water.

[0058] The polytetrafluoroethylene-based medical protective material processed by the above method has a fabric thickness of 220 μm, a warp strength of 1100 N, a weft strength of 700 N, a warp elongation of 8.4%, a weft elongation of 7.8%, and an air permeability of 4000 g / m 2 .d, water pressure resistance is 230 kPa, moisture permeability is 3200g / ㎡.24h, resistance to microbial penetration (wet state) is 3.06 (IB), and water permeability is 27.3 (cmH2O).

[0059] Example 5

[0060] 1. Using 250D natural color polytetrafluoroethylene film split filament and red polytetrafluoroethylene film split filament produced by Jiangsu Huayue Textile New Materials Technology Co., Ltd. and 0.15mm stainless steel wire produced by Taiwan Nanwei Company as raw materials, polytetrafluoroethylene fabric was woven on a rapier loom produced by China Textile Machinery Group Zhengzhou Textile Machinery Co., Ltd.

[0061] During warping, 1 cm wide red polytetrafluoroethylene filaments are arranged at a width of 77 cm on the warp beam, and a stainless steel wire is embedded every 3 cm on the warp beam. The warping speed is 180 m / min.

[0062] The obtained polytetrafluoroethylene substrate adopts a twisted heald structure, the warp and weft density of the fabric is: 100×87 strands / inch, the width is 168 cm, the loom speed is 350 rpm, and a humidifier is installed during weaving.

[0063] 2. The heat setting process of the polytetrafluoroethylene substrate is carried out on a heat setting machine produced by Wuxi Haida Textile Machinery Co., Ltd. The speed of the heat setting machine is 60m / min and the heat setting temperature is 210℃.

[0064] 3. The front and back sides of the polytetrafluoroethylene fabric obtained after finishing are composited with polytetrafluoroethylene microporous membranes. The micropore diameter of the polytetrafluoroethylene microporous membrane used is 45nm and the thickness is 0.03mm.

[0065] The foam concentration of the foam generator is 40g / l, the foam diameter is 0.5-2.5mm, the foaming ratio is 1:2.5, the coating machine speed is 10m / min, and the roller pressure is 8kg / cm 2 , pre-baking temperature 70℃, baking temperature 120℃.

[0066] Foam coating formula: 40% water-soluble polyacrylic acid emulsion; 8% titanium dioxide; 9% porcelain clay; PF165A thickener: 2%; cross-linking agent TAC 1.5%; high-efficiency multifunctional surface affinity agent WIN-055: 5%; A651-20 thermosetting adhesive: 2%; ammonia water: 1.5%; the rest is water.

[0067] The polytetrafluoroethylene-based medical protective material processed by the above method has a fabric thickness of 250μm, a warp strength of 1150N, a weft strength of 780N, a warp elongation of 8.7%, a weft elongation of 7.3%, and an air permeability of 3000g / m 2 .d, water pressure resistance is 227 kPa, moisture permeability is 3000g / ㎡.24h, resistance to microbial penetration (wet state) is 3.466 (IB), and water permeability is 28.0 (cmH2O).

Claims

1. A method for manufacturing a polytetrafluoroethylene-based medical protective material, characterized in that The method comprises the following steps: (1) Weaving polytetrafluoroethylene substrates using natural polytetrafluoroethylene filaments, colored polytetrafluoroethylene filaments and metal conductive yarns as raw materials; (2) performing post-treatment on the polytetrafluoroethylene substrate to obtain polytetrafluoroethylene fabric; (3) The polytetrafluoroethylene fabric is composited with a polytetrafluoroethylene microporous membrane on one side or both sides of the polytetrafluoroethylene fabric by foam coating; the parameters of the foam coating are as follows: the foam concentration of the foam generator is 40-55g / l, the foam diameter is 0.5-4mm, the foaming ratio is 1:2.5-1:4, the coating machine speed is 10-15m / min, and the roller pressure is 6-10kg / cm 2 , pre-baking temperature 60-80℃, baking temperature 100-150℃.

2. The method for producing a polytetrafluoroethylene-based medical protective material according to claim 1, characterized in that Step (1) During warping during weaving, a metal conductive wire is placed on the warp beam every 10-50 mm, and colored polytetrafluoroethylene filaments with a width of 10-15 mm are arranged in the middle or at a specific position. The warping speed is 160-180 m / min; the fabric adopts a twisted heald structure, and the loom speed is 350 rpm.

3. The method for producing a polytetrafluoroethylene-based medical protective material according to claim 1, characterized in that The post-finishing conditions in step (2) are as follows: a heat setting machine speed of 60 m / min and a heat setting temperature of 210°C.

4. The method for producing a polytetrafluoroethylene-based medical protective material according to claim 1, characterized in that The foam coating formula includes: 40-50% water-soluble polyacrylic acid emulsion; 8-12% titanium dioxide; 8-10% china clay; 1-2% PF thickener; 1-2% crosslinking agent; 3-6% surface affinity agent; 1-3% A651-20 thermosetting adhesive; 1-2% ammonia water; and the rest is water.

5. The method for producing a polytetrafluoroethylene-based medical protective material according to claim 1, characterized in that The diameter of the metal conductive wire is 0.1-0.05 μm.

6. The method for producing a polytetrafluoroethylene-based medical protective material according to claim 1, characterized in that The fineness of natural polytetrafluoroethylene filament is 100D-350D.

7. The method for producing a polytetrafluoroethylene-based medical protective material according to claim 1, characterized in that The polytetrafluoroethylene microporous membrane used has a pore size of 40-70 nm and a thickness of 0.01-0.03 mm.

8. The method for producing a polytetrafluoroethylene-based medical protective material according to claim 1, characterized in that The polytetrafluoroethylene fabric adopts a twisted heald structure with specifications of: warp density 100-140 strands / inch, weft density 60-90 strands / inch, and width 150-180cm.

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