Integrated protective clothing and preparation method thereof

Abstract

The invention belongs to the technical field of protective equipment, and particularly relates to an integrated protective garment, the protective garment is integrally sprayed and formed on the surface of a three-dimensional mold through a high polymer material to form a continuous seamless main body structure, and the main body structure comprises a continuous seamless protective layer, a functional gradient enhancement area and an embedded interface unit; the continuous seamless protective layer is formed by coating, hot pressing and curing a polypropylene (PP) layer and a polyethylene (PE) layer on a three-dimensional mold, and the overall thickness is 0.1-0.2 mm; the functional gradient enhancement areas are distributed in the joint areas and the trunk area, the elastic modulus of the joint areas is 5 MPa, the elastic modulus of the trunk area is 50 MPa, and the gradient of the elastic modulus is achieved by adjusting the spraying proportion of PP and PE; the high polymer material is integrally sprayed and formed on the surface of the three-dimensional mold, traditional sewing or gluing seams are eliminated, the virus penetration blocking rate is high, and the weak link problem that the blocking rate of protective clothing of a sewing structure is low is solved.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of protective equipment, and particularly relates to an integrated protective garment and a preparation method thereof. BACKGROUND

[0002] With the frequent occurrence of global public health events, the demand for high-performance medical protective clothing is increasing. Traditional protective clothing is mostly made of polypropylene (PP) or polyethylene (PE) non-woven fabric through cutting, sewing, and pressing. However, there are the following outstanding problems:

[0003] 1. High risk of seam leakage: Sewing needle holes and hot sealing tapes are prone to aging, which can lead to penetration of viral aerosols. ISO 16604 tests show that the leakage rate of conventional protective clothing in the seam area can reach more than 0.5%, which is difficult to meet the requirements of high-risk environments such as P3 / P4 laboratories;

[0004] 2. Single mechanical property: Existing materials are difficult to balance the flexibility of the joint movement area and the puncture resistance of the torso area, resulting in a difficult balance between wearing comfort and protection reliability;

[0005] 3. Poor functional durability: The charge of the electret layer easily decays in a humid and hot environment, with a half-life of less than 6 months, affecting the ability to adsorb viral particles by static electricity;

[0006] 4. Difficult to recycle: The multi-layer composite structure (such as SMS+TPU film) is difficult to separate, and the recycling rate is generally less than 15%, which does not meet the trend of green manufacturing.

[0007] In recent years, spray forming technology (such as B29C41 / 22) has been tried for protective product manufacturing, but it is limited by poor coating uniformity, weak interlayer bonding, and inability to integrate functional components, and has not yet achieved large-scale application. In addition, there is a lack of effective means to control the modulus gradient distribution of the material in the existing technology, and it is also impossible to realize the "glueless and seamless" integration of the interface components.

[0008] Therefore, it is urgent to develop a new type of integrated protective garment and an efficient preparation method thereof, which can ensure high viral barrier performance while realizing structural continuity, functional gradient, interface integration, and production intelligence, breaking through the technical bottleneck of traditional protective clothing. SUMMARY

[0009] The purpose of the present application is to provide an integrated protective garment and a preparation method thereof to solve the problems presented in the background.

[0010] To achieve the above technical purpose, the technical solution adopted by the present application is as follows:

[0011] An integrated protective suit includes a continuous, seamless main structure formed by integrally spraying a polymer material onto the surface of a three-dimensional mold. The main structure includes: a continuous, seamless protective layer, a functional gradient enhancement area, and an embedded interface unit.

[0012] The continuous, seamless protective layer is formed by hot-pressing and curing a polypropylene (PP) layer and a polyethylene (PE) layer on a three-dimensional mold, with an overall thickness of 0.1–0.2 mm.

[0013] The functional gradient enhancement zone is distributed in the joint area and the trunk area. The elastic modulus of the joint area is 5 MPa and the elastic modulus of the trunk area is 50 MPa. The gradient of the elastic modulus is achieved by adjusting the spraying ratio of PP and PE.

[0014] The embedded interface unit integrates zipper, elastic band or breather valve components into the main structure through molecular diffusion welding technology, and the welding interface strength is not less than 15N / mm.

[0015] The polypropylene (PP) layer comprises the following components in parts by weight:

[0016] High melt flow index polypropylene: 94.0–97.0 parts

[0017] Electret masterbatch: 2.0–4.0 parts

[0018] Compound antioxidant: 0.3-0.5 parts

[0019] Nano silver antibacterial agent: 1.0–1.8 parts

[0020] Fluorine-based processing aids: 0.1–0.2 parts

[0021] Permanent antistatic agent: 0.5–1.0 parts

[0022] The polyethylene (PE) layer comprises the following components in parts by weight:

[0023] Linear low-density polyethylene (LLDPE): 92.0–96.0 parts

[0024] Nanoelectrode synergist: 3.0–5.0 parts

[0025] Compound antibacterial agent: 1.5–2.5 parts

[0026] Peroxide degrading agent: 0.3–0.8 parts

[0027] Fluorine-based processing aids (PPA): 0.1–0.3 parts

[0028] Permanent antistatic agent: 0.5 to 1.2 parts.

[0029] The manufacturing method of the one-piece protective suit includes the following steps:

[0030] Step 1: 3D mold pretreatment. The surface of the aluminum alloy 3D mold is treated with plasma cleaning technology to make the surface dyne value > 50mN / m.

[0031] Step 2: Robotic partitioning spraying. A six-axis robotic arm is equipped with a two-component spraying head. PP and PE layers are sprayed onto the mold surface at a preset learning speed and trajectory. Modulus gradient distribution is achieved by dynamically adjusting the robotic arm's speed and trajectory. The ratio of modulus is 8:2 in the torso area and 3:7 in the joint area. The single-layer thickness control accuracy is ±5μm.

[0032] Step 3: Multi-physics field coupling curing, under hot-pressing conditions at 180℃, simultaneously applying ultrasonic vibration with a frequency of 40kHz (amplitude 20μm), wavelength of 365nm, and intensity of 50mW / cm. 2 Exposure to ultraviolet light for 30 seconds promotes cross-linking and curing of the material;

[0033] Step 4: Interface integration, using ultrasonic-assisted molecular diffusion welding technology, with an interface energy ≥100mJ / m 2 Under certain conditions, zipper, elastic band, or breather valve components are welded to the main structure as a whole.

[0034] In step 2, an AI vision system based on convolutional neural networks (CNN) is used to monitor the thickness uniformity and edge integrity of the sprayed coating in real time, and feeds the feedback to the robot control system to dynamically correct the spraying trajectory, ensuring that the coating thickness deviation is <±3μm.

[0035] The three-dimensional mold is a detachable and modular structure, including a head module, an arm module, and a torso module. The modules are connected by precision positioning pins, which supports quick demolding and cleaning maintenance.

[0036] The PP and PE materials are subjected to electret treatment before spraying, with an electret voltage of 35-40kV and an electret time of 1-3s, to enhance the material's electrostatic adsorption capacity for viral aerosols.

[0037] This invention uses polymer materials to integrally spray and form a three-dimensional mold surface, eliminating traditional stitching or adhesive seams, resulting in a high virus penetration barrier rate and solving the problem of low barrier rate in sewn protective clothing.

[0038] By dynamically adjusting the PP / PE spraying ratio (3:7 to 8:2) in the joint and torso areas, a modulus gradient distribution is achieved, which not only ensures the impact resistance of the torso but also improves the freedom of joint movement. The tensile elastic modulus covers the range of 5-50MPa, breaking through the performance limitations of traditional single materials.

[0039] This invention integrates components such as zippers and elastic bands using molecular diffusion welding technology, achieving a welding interface energy ≥100mJ / m 2 (XPS test) The strength reaches 18 N / mm (ASTM D5034), and the peel strength remains at 15 N / mm under humid and hot conditions, far exceeding that of adhesive bonding (1.8 N / cm), achieving the integration of "structure and function". Attached Figure Description

[0040] The present invention can be further illustrated by the non-limiting embodiments given in the accompanying drawings.

[0041] Figure 1 This is a schematic diagram of the structure of an integrated protective suit according to the present invention;

[0042] Figure 2 This is a flowchart illustrating the manufacturing process of an integrated protective suit according to the present invention.

[0043] Figure 3 This is a schematic diagram of the three-dimensional mold structure of the present invention. Detailed Implementation

[0044] To enable those skilled in the art to better understand the present invention, the technical solution of the present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0045] like Figures 1-3 As shown, the present invention provides an integrated protective suit. The protective suit is formed by integrally spraying polymer materials onto the surface of a three-dimensional mold to form a continuous and seamless main structure. The main structure includes: a continuous and seamless protective layer, a functional gradient enhancement area, and an embedded interface unit.

[0046] The continuous, seamless protective layer is formed by hot-pressing and curing a polypropylene (PP) layer and a polyethylene (PE) layer on a three-dimensional mold, with an overall thickness of 0.1–0.2 mm.

[0047] The functional gradient enhancement zone is distributed in the joint area and the trunk area. The elastic modulus of the joint area is 5 MPa and the elastic modulus of the trunk area is 50 MPa. The gradient of the elastic modulus is achieved by adjusting the spraying ratio of PP and PE.

[0048] The embedded interface unit integrates zipper, elastic band or breather valve components into the main structure through molecular diffusion welding technology, and the welding interface strength is not less than 15N / mm.

[0049] Mold preparation

[0050] The aluminum alloy modular mold, 3D printed using selective laser melting (SLM) technology, comprises three detachable modules: head 101, arm 102, and torso 103 (see...). Figure 3The modules are fitted together with conical surfaces and locating pins to ensure an assembly accuracy of ≤0.1mm, which facilitates demolding and cleaning.

[0051] Material preparation

[0052] Prepare PP and PE functional masterbatches according to the following formulas:

[0053] The PP layer contains the following components by weight:

[0054] High melt flow index polypropylene (melt flow rate ≥ 35 g / 10 min): 94.15 parts

[0055] Electret masterbatch (containing tourmaline and silica composite particles): 3 parts

[0056] Compound antioxidant (composed of antioxidants 1010 and 168 in a 1:1 mass ratio): 0.4 parts

[0057] Nano silver antibacterial agent (particle size ≤ 50nm): 1.5 parts

[0058] Fluorine-based processing aid (PPA): 0.15 parts

[0059] Permanent antistatic agent: 0.8 parts

[0060] The PE layer contains the following components in parts by weight:

[0061] Linear low-density polyethylene (LLDPE): 92.3 parts

[0062] Nanoelectrode synergist: 4.0 parts

[0063] Compound antibacterial agent (containing quaternary ammonium salt active ingredients): 2.0 parts

[0064] Peroxide degrader: 0.5 parts

[0065] Fluorine-based processing aids (PPA): 0.2 parts

[0066] Permanent antistatic agent: 1.0 part.

[0067] III. Spraying and Molding Process Parameters

[0068] Area: Trunk area

[0069] PP layer:PE layer ratio (layer thickness ratio): 8:2

[0070] Coating thickness: 0.18mm

[0071] Curing conditions: 180℃ hot pressing + 40kHz ultrasonic (20μm) + 365nm UV (50mW / cm) 2 ×30s)

[0072] Electret voltage: 40kV

[0073] Area: Joint area

[0074] PP layer:PE layer ratio (layer thickness ratio): 3:7

[0075] Coating thickness: 0.15mm

[0076] Curing conditions: 150℃ hot pressing + 40kHz ultrasonic (20μm) + 365nm UV (50mW / cm) 2 ×30s)

[0077] Electret voltage: 35kV

[0078] The spraying process is performed by a six-axis robot equipped with an AI vision system (based on a ResNet-50 convolutional neural network) that analyzes the coating image in real time and adjusts the nozzle path and flow rate accordingly to keep the thickness fluctuation within ±3μm.

[0079] Interface integration

[0080] Ultrasonic welding equipment (frequency 20kHz, power 300W) was used to perform molecular diffusion welding on zippers and elastic bands. The welding pressure was 0.4MPa, the time was 2s, and the interfacial bonding energy was measured to be ≥100mJ / m. 2 (XPS measurement) The welding strength reaches 18 N / mm.

[0081] In the aforementioned spraying and molding process parameters, the spraying and curing conditions for each region have been meticulously designed to ensure the performance of the final product. In the torso region, an 8:2 PP to PE layer ratio is used, with a spray thickness of 0.18 mm. Curing is achieved through 180°C hot pressing combined with 40kHz ultrasonic vibration and 365nm UV irradiation for 30 seconds, with an electret voltage of 40kV. These conditions aim to provide high strength and durability. In the joint region, to increase flexibility and comfort, the PP to PE layer ratio is adjusted to 3:7, with a spray thickness of 0.15 mm. The curing conditions are adjusted to 150°C hot pressing combined with the same ultrasonic vibration and UV irradiation conditions, with an electret voltage of 35kV. This differentiated spraying and curing treatment not only meets the functional requirements of different regions but also ensures the continuity and seamless characteristics of the overall structure.

[0082] In the spraying and forming process parameters, the application of an AI vision system further enhances the automation and intelligence of the manufacturing process. Based on a ResNet-50 convolutional neural network, this system can monitor coating thickness uniformity and edge integrity in real time, and its high-precision analysis capabilities ensure the stability and consistency of coating quality. By providing real-time feedback to the robot control system, the spraying trajectory is dynamically corrected, controlling the coating thickness deviation within ±3μm. This technological innovation significantly improves production efficiency and product quality.

[0083] Furthermore, the detachable and modular design of the 3D mold facilitates rapid demolding, cleaning and maintenance, and flexible mold configuration. The head, arm, and torso modules are connected by precision positioning pins, ensuring assembly accuracy and allowing for modular adjustments to meet different needs, thus enhancing the flexibility and adaptability of the manufacturing process.

[0084] Electret treatment, another key technology, effectively enhances the electrostatic adsorption capacity of PP and PE materials for viral aerosols by applying an electret voltage of 35-40kV for 1-3 seconds. This treatment step not only enhances the protective performance of protective clothing but also provides strong support for its application in special environments.

[0085] In summary, the integrated protective suit and its manufacturing method described in this invention have undergone comprehensive and meticulous design in terms of spraying and molding process parameters. They combine multiple innovative technologies such as AI vision system, detachable and modular mold, and electret treatment to ensure the high performance, high quality, and good adaptability of the final product.

[0086] In the preparation process, each step is strictly controlled and optimized to ensure the consistency and reliability of the final product. In particular, in the interface integration stage, ultrasonic welding equipment is used to perform molecular diffusion welding on the zipper and elastic band. This not only ensures the strength of the interface, but also maintains the continuity and seamless characteristics of the overall structure. During the welding process, high strength and high quality welding results are achieved by precisely controlling the welding pressure, time and energy of the welding interface.

[0087] Further optimization of the preparation method also considered the environmental friendliness and sustainability of the materials. Polypropylene (PP) and polyethylene (PE), as the main materials, not only possess excellent physical properties and chemical stability but are also widely used environmentally friendly materials. Through meticulous formulation design and preparation process, the emission of harmful substances is minimized, meeting the requirements of modern industry for green production.

[0088] In practical applications, the seamless main structure, functional gradient enhancement zone, and embedded interface unit design of this integrated protective suit provide users with comprehensive protection. Especially in high-risk environments such as medical, chemical, and biological laboratories, this protective suit can effectively block the intrusion of viral aerosols, harmful chemicals, and microorganisms, ensuring the safety and health of workers.

[0089] In summary, this invention demonstrates superior performance and advantages in material selection, formulation design, manufacturing process, and practical application. Its innovative technical solution and comprehensive design considerations not only meet the modern industrial demand for high-performance, high-quality protective clothing but also make a positive contribution to promoting technological progress and industrial development in related fields.

[0090] Performance test results

[0091] Test item Test standard Test result Virus penetration barrier rate ISO 16604 ＞99.99％ Seam / weld strength ASTM D5034 18 N / mm Tensile elastic modulus ISO 527 5 MPa→50 MPa Electret charge half-life JIS L 1094B method >18 months Wet heat peel strength Customized 15 N / mm Single-piece production time _____ 18 minutes Recycling rate GB / T 16572 82％

[0092] Technology Comparison

[0093] Technical index The present application Comparative example (CN1125875B) Seam leakage rate 0.001％ 0.52% (seam structure) Wet heat peel strength 15 N / mm 1.8 N / cm (adhesive) Recycling rate 82％ 13% (multilayer composite film) Coating thickness control accuracy <±3 μm (AI closed loop) ±20 μm (manual spraying)

[0094] 1. Molecular diffusion welding interface energy ≥100mJ / m 2 Significantly higher than traditional adhesive bonding processes (≤50mJ / m 2 This enables "seamless embedded integration".

[0095] 2. AI vision + robot collaborative spraying system achieves coating thickness deviation of <±3μm on complex curved surfaces, ensuring consistent protection;

[0096] 3. PP / PE gradient spraying + multi-field coupling curing breaks through the bottleneck of traditional blow molding or casting processes that cannot achieve local performance control.

[0097] The above embodiments are merely illustrative of the principles and effects of the present invention and are not intended to limit the invention. Any person skilled in the art can modify or alter the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or alterations made by those skilled in the art without departing from the spirit and technical concept disclosed in the present invention should still be covered by the claims of the present invention.

Claims

1. A one-piece protective suit, characterized in that: The protective suit is formed by integrally spraying polymer materials onto the surface of a three-dimensional mold to create a continuous, seamless main structure. The main structure includes: a continuous, seamless protective layer, a functional gradient enhancement area, and an embedded interface unit. The continuous, seamless protective layer is formed by hot-pressing and curing a polypropylene (PP) layer and a polyethylene (PE) layer on a three-dimensional mold, with an overall thickness of 0.1–0.2 mm. The functional gradient enhancement zone is distributed in the joint area and the trunk area. The elastic modulus of the joint area is 5 MPa and the elastic modulus of the trunk area is 50 MPa. The gradient of the elastic modulus is achieved by adjusting the spraying ratio of PP and PE. The embedded interface unit integrates zipper, elastic band or breather valve components into the main structure through molecular diffusion welding technology, and the welding interface strength is not less than 15N / mm.

2. The integrated protective suit according to claim 1, characterized in that: The polypropylene (PP) layer comprises the following components in parts by weight: High melt flow index polypropylene: 94.0–97.0 parts Electret masterbatch: 2.0–4.0 parts Compound antioxidant: 0.3-0.5 parts Nano silver antibacterial agent: 1.0–1.8 parts Fluorine-based processing aids: 0.1–0.2 parts Permanent antistatic agent: 0.5 to 1.0 parts.

3. The integrated protective suit according to claim 1, characterized in that: The polyethylene (PE) layer comprises the following components in parts by weight: Linear low-density polyethylene (LLDPE): 92.0–96.0 parts Nanoelectrode synergist: 3.0–5.0 parts Compound antibacterial agent: 1.5–2.5 parts Peroxide degrading agent: 0.3–0.8 parts Fluorine-based processing aids (PPA): 0.1–0.3 parts Permanent antistatic agent: 0.5 to 1.2 parts.

4. The method for preparing the integrated protective suit according to any one of claims 1-3, characterized in that: Includes the following steps: Step 1: 3D mold pretreatment. The surface of the aluminum alloy 3D mold is treated with plasma cleaning technology to make the surface dyne value > 50mN / m. Step 2: Robotic partitioning spraying. A six-axis robotic arm is equipped with a two-component spraying head. PP and PE layers are sprayed onto the mold surface at a preset learning speed and trajectory. Modulus gradient distribution is achieved by dynamically adjusting the robotic arm's speed and trajectory. The ratio of modulus is 8:2 in the torso area and 3:7 in the joint area. The single-layer thickness control accuracy is ±5μm. Step 3: Multi-physics field coupling curing, under hot-pressing conditions at 180℃, simultaneously applying ultrasonic vibration with a frequency of 40kHz (amplitude 20μm), wavelength of 365nm, and intensity of 50mW / cm. 2 Exposure to ultraviolet light for 30 seconds promotes cross-linking and curing of the material; Step 4: Interface integration, using ultrasonic-assisted molecular diffusion welding technology, with an interface energy ≥100mJ / m 2 Under certain conditions, zipper, elastic band, or breather valve components are welded to the main structure as a whole.

5. The method for preparing the integrated protective suit according to claim 4, characterized in that: In step 2, an AI vision system based on convolutional neural networks (CNN) is used to monitor the thickness uniformity and edge integrity of the sprayed coating in real time, and feeds the feedback to the robot control system to dynamically correct the spraying trajectory, ensuring that the coating thickness deviation is <±3μm.

6. The method for preparing the integrated protective suit according to claim 4, characterized in that: The three-dimensional mold is a detachable and modular structure, including a head module, an arm module, and a torso module. The modules are connected by precision positioning pins, which supports quick demolding and cleaning maintenance.

7. The method for preparing the integrated protective suit according to claim 4, characterized in that: The PP and PE materials are subjected to electret treatment before spraying, with an electret voltage of 35-40kV and an electret time of 1-3s, to enhance the material's electrostatic adsorption capacity for viral aerosols.

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