Long-acting antibacterial and mildew-proof isolation pad and preparation process thereof

Abstract

The application discloses a long-acting antibacterial and mildew-proof isolation pad and a preparation process thereof. The isolation pad comprises a breathable base layer, a slow-release antibacterial and mildew-proof functional layer and a hydrophobic isolation protective layer which are sequentially stacked. The slow-release antibacterial and mildew-proof functional layer is formed by curing an aqueous polymer emulsion containing a microencapsulated composite antibacterial and mildew-proof agent. The microencapsulated composite antibacterial and mildew-proof agent has a core-shell structure. The core layer is a ternary composite antibacterial and mildew-proof composition containing inorganic antibacterial agents, organic antibacterial agents and natural mildew-proof agents. The shell layer is a biodegradable polymer material. The ternary composite antibacterial and mildew-proof composition is released slowly through the slow degradation of the biodegradable polymer shell layer. Through the synergistic effect of the microcapsule coating technology and the ternary composite antibacterial and mildew-proof system, the problems of the prior art, such as short antibacterial and mildew-proof effect, easy loss of effective components and narrow antibacterial spectrum, are solved. Meanwhile, through the multi-layer structure design, the isolation and protection, the breathability and the use comfort are considered.

Description

Technical Field

[0001] This invention relates to the field of functional materials technology, specifically to a long-lasting antibacterial and antifungal insulating pad and its preparation process. Background Technology

[0002] With the improvement of people's living standards and the enhancement of health awareness, the requirements for environmental hygiene in various living and working environments are constantly increasing. The growth of bacteria and mold not only accelerates the aging and damage of various items, but may also spread diseases, posing a threat to human health. As a basic protective material, insulation mats are widely used in many fields such as home furnishings, medical care, food processing, and building decoration. Their antibacterial and anti-mold properties directly affect the hygiene and safety of the environment in which they are used.

[0003] Most antibacterial and antifungal protective mats currently on the market are prepared by directly mixing antibacterial and antifungal agents into the substrate or simply coating them onto the substrate surface. This method has several obvious drawbacks: First, the antibacterial and antifungal components are directly exposed to the external environment and are easily lost through friction, washing, and natural evaporation during use, resulting in a significant decrease in protective effect in a short period of time and a limited product lifespan. Second, some antibacterial and antifungal components are irritating and may cause discomfort upon direct contact with the human body; long-term exposure to the environment may also have adverse effects on the ecosystem. Third, the scope of action of a single type of antibacterial and antifungal agent is limited, making it difficult to effectively inhibit multiple bacteria and molds simultaneously, and long-term use can easily induce drug resistance in microorganisms, further reducing the protective effect.

[0004] Although microencapsulation technology has been attempted to be applied in the field of antibacterial and antifungal materials to address the problem of easy loss of active ingredients, existing technologies still have many shortcomings. Most microcapsules use non-degradable polymer materials as the shell, which means that the products will remain in the environment for a long time after disposal, causing white pollution; the release rate of microcapsules is difficult to control precisely, often resulting in excessively rapid release in the early stages and insufficient active ingredients in the later stages. Furthermore, microcapsules exhibit poor compatibility with the film-forming substrate, easily leading to aggregation, uneven coating surfaces, and even affecting the mechanical properties of the coating. Therefore, developing an antibacterial and antifungal barrier that balances long-lasting effectiveness, broad-spectrum activity, safety, and environmental friendliness has become a pressing issue in the industry. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art and provide a long-lasting antibacterial and anti-mildew isolation pad and its preparation process, so as to solve the problems of existing antibacterial and anti-mildew isolation pads having short-lasting effects, easy loss of effective ingredients, narrow antibacterial spectrum, and poor safety.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: A long-lasting antibacterial and antifungal barrier pad, characterized in that it comprises a breathable base layer, a slow-release antibacterial and antifungal functional layer, and a hydrophobic barrier protective layer stacked sequentially; the slow-release antibacterial and antifungal functional layer is formed by curing an aqueous polymer emulsion containing a microencapsulated composite antibacterial and antifungal agent, wherein the microencapsulated composite antibacterial and antifungal agent has a core-shell structure, the core layer being a ternary composite antibacterial and antifungal composition containing an inorganic antibacterial agent, an organic antibacterial agent, and a natural antifungal agent, and the shell layer being a biodegradable polymer material; the ternary composite antibacterial and antifungal composition achieves long-lasting release through the slow degradation of the biodegradable polymer shell layer.

[0007] The above solution employs a three-layer composite structure design, with each layer having a clear function and working synergistically. The breathable base layer provides basic structural support and gas exchange capacity for the isolation pad; the slow-release antibacterial and antifungal functional layer undertakes the main protective function; and the hydrophobic isolation protective layer blocks the intrusion of external liquids and pollutants. Microencapsulation technology encapsulates the antibacterial and antifungal components, preventing direct exposure of the active ingredients to the environment and reducing the likelihood of them becoming ineffective due to volatilization, loss, or decomposition. The biodegradable shell material gradually decomposes during use, facilitating the stable release of the internal antibacterial and antifungal components and avoiding the problem of insufficient effect later on due to excessively rapid initial release. The ternary compound antibacterial and antifungal system can cover a wider range of harmful microorganisms while reducing the amount of any single component used, thus reducing the possibility of microbial resistance. Using an aqueous polymer emulsion as the film-forming matrix, no harmful organic solvents are released during production and use, making it more environmentally friendly and human-friendly.

[0008] The aforementioned long-lasting antibacterial and anti-mildew insulating pad, wherein the breathable base layer is selected from one or more of non-woven fabric, needle-punched felt, woven fabric, and knitted fabric, with a surface density of 50g / m² to 500g / m² and a thickness of 0.1mm to 5mm. A variety of optional base materials are available to adapt to different usage scenarios and performance requirements. Different materials have varying mechanical strength, flexibility, and breathability, allowing selection based on actual usage requirements. A reasonable range of surface density and thickness ensures the insulating pad has sufficient tensile and tear resistance, extending its service life, while avoiding excessive thickness that would affect the convenience of installation and use, and insufficient support that would result from excessive thinness. Maintaining good breathability prevents stuffiness and dampness caused by poor air circulation during use, improving user comfort.

[0009] The aforementioned long-lasting antibacterial and antifungal barrier pad, wherein the ternary composite antibacterial and antifungal composition, by weight, comprises the following components: 10 to 50 parts of inorganic antibacterial agent, 5 to 30 parts of organic antibacterial agent, 5 to 20 parts of natural antifungal agent, and 1 to 10 parts of dispersant; the inorganic antibacterial agent is selected from one or more of silver-loaded zeolite, silver-loaded zirconium phosphate, zinc-loaded zinc oxide, and nano-titanium dioxide; the organic antibacterial agent is selected from one or more of quaternary ammonium salt compounds, guanidine compounds, and isothiazolinone compounds; and the natural antifungal agent is selected from one or more of tea polyphenols, chitosan, allicin, and rosemary extract.

[0010] This scheme clearly defines the composition ratio of the composite antibacterial and antifungal system, ensuring a good synergistic effect among the components. Inorganic antibacterial agents possess good heat resistance and long-term stability, enabling them to maintain their effectiveness continuously; organic antibacterial agents have rapid bactericidal action, quickly inhibiting microbial growth; natural antifungal agents are widely available, highly safe, and environmentally friendly. The combination of these three components addresses both the need for rapid sterilization and long-term protection, while broadening the scope of antibacterial and antifungal activity. The addition of a dispersant ensures uniform dispersion of the solid components within the system, preventing aggregation and guaranteeing consistent antibacterial and antifungal performance across all functional layers. All listed raw materials are mature products commonly used in industry, facilitating procurement and large-scale production, effectively controlling production costs.

[0011] In the aforementioned long-lasting antibacterial and antifungal barrier pad, the biodegradable polymer material is selected from one or more of polylactic acid, polyhydroxyalkanoate, polycaprolactone, chitosan derivatives, and gelatin; the microencapsulated composite antibacterial and antifungal agent has a particle size of 1 μm to 50 μm, a shell thickness of 0.1 μm to 5 μm, and a core-shell mass ratio of 1:0.2 to 1:2.

[0012] This solution utilizes different types of biodegradable polymers with varying degradation rates, allowing for the selection of appropriate shell materials based on the expected protection duration, thus enabling precise control over the release rate of antibacterial and antifungal components. A suitable microcapsule particle size range ensures stable dispersion of the microcapsules in the aqueous polymer emulsion, preventing sedimentation or stratification, while maintaining the smoothness and evenness of the coating surface. An appropriate shell thickness and core-shell mass ratio effectively protect the antibacterial and antifungal components in the core layer from external factors such as acids, alkalis, and ultraviolet radiation, while ensuring the smooth release of the active ingredients after shell degradation. This avoids situations where an excessively thick shell leads to slow release and compromised protective efficacy, or an excessively thin shell causes the microcapsules to rupture easily.

[0013] In the aforementioned long-lasting antibacterial and antifungal barrier pad, the aqueous polymer emulsion is selected from one or more of acrylate emulsion, polyurethane emulsion, styrene-acrylic emulsion, and silicone-acrylic emulsion, with a solid content of 30% to 60%; in the sustained-release antibacterial and antifungal functional layer, the mass fraction of the microencapsulated composite antibacterial and antifungal agent is 5% to 30%, and the dry film thickness of the functional layer is 5 μm to 100 μm.

[0014] In this solution, different types of aqueous polymer emulsions exhibit varying film-forming properties, adhesion, and weather resistance, adapting to diverse application environments and substrate requirements. A suitable solids content range ensures the coating possesses appropriate viscosity and flowability, facilitating application and guaranteeing sufficient film density after formation. Optimal microcapsule dosage and functional layer thickness minimize production costs while achieving the desired antibacterial and antifungal effects. This avoids situations where excessive microcapsule addition reduces film flexibility and increases susceptibility to cracking, or insufficient addition leads to inadequate protection; conversely, an excessively thick functional layer hardens the barrier, while an insufficient layer results in inadequate total active ingredient content, impacting service life.

[0015] The aforementioned long-lasting antibacterial and antifungal barrier pad, wherein the hydrophobic barrier protective layer is formed by curing a fluoropolymer emulsion or a siloxane polymer emulsion, with a dry film thickness of 1 μm to 50 μm and a static water contact angle of 90° to 150° at 25°C.

[0016] In this solution, fluorinated and siloxane-based materials exhibit excellent hydrophobic properties, forming a dense hydrophobic film on the surface of the insulating pad. This effectively blocks the penetration of liquids such as water and oil, while reducing the adhesion of dust and contaminants, making the pad surface easier to clean. A suitable dry film thickness range ensures the formation of a continuous and complete hydrophobic layer for good protective performance without hindering gas permeability, maintaining the overall breathability of the pad. Clearly defined and standardized water contact angle testing conditions ensure the comparability of hydrophobic performance test results across different batches, facilitating stable quality control.

[0017] In the aforementioned long-lasting antibacterial and antifungal barrier pad, an adhesive layer is provided between the breathable base layer and the slow-release antibacterial and antifungal functional layer. The adhesive layer is a water-based pressure-sensitive adhesive layer with a thickness of 1μm to 30μm.

[0018] In this solution, an adhesive layer is added between the breathable base layer and the slow-release antibacterial and anti-mildew functional layer. This significantly enhances the bonding strength between the two layers, preventing the functional layer from detaching or peeling due to external forces such as friction, bending, and pulling during use, effectively extending the overall service life of the isolation mat. The water-based pressure-sensitive adhesive has advantages such as moderate bonding strength, environmental friendliness, non-toxicity, and ease of application, and will not have adverse effects on human health or the environment. A reasonable adhesive layer thickness range ensures sufficient bonding strength without excessively increasing the overall thickness of the isolation mat or causing adhesive overflow due to an overly thick adhesive layer.

[0019] The present invention also provides a preparation process for the above-mentioned long-lasting antibacterial and antifungal barrier pad, comprising the following steps: (1) Preparation of microencapsulated composite antibacterial and antifungal agent: The ternary composite antibacterial and antifungal composition is dispersed in a suitable medium to obtain a core phase dispersion; the biodegradable polymer material is dissolved in a suitable solvent to obtain a shell phase solution; the core phase dispersion and the shell phase solution are mixed and emulsified to form an oil-in-water or water-in-oil emulsion; microcapsules are formed by solvent evaporation or in-situ polymerization, and the microencapsulated composite antibacterial and antifungal agent is obtained after filtration, washing and drying; (2) Preparation of antibacterial and antifungal coating: Microencapsulated composite antibacterial and antifungal agent is added to water-based polymer emulsion, stirred evenly, then additives are added, and stirring is continued to obtain antibacterial and antifungal coating; (3) Optionally, an adhesive layer is coated on the surface of the breathable base layer and dried; an antibacterial and antifungal coating is applied to the surface of the breathable base layer or the adhesive layer and dried and cured to form a slow-release antibacterial and antifungal functional layer; (4) Coating a protective layer: Coating a hydrophobic isolation protective layer coating on the surface of the slow-release antibacterial and anti-mildew functional layer, and drying and curing to obtain a long-lasting antibacterial and anti-mildew isolation pad.

[0020] The entire preparation process in this scheme is clear and coherent, with simple operation steps. All equipment used is conventional chemical production equipment, eliminating the need for expensive specialized equipment and facilitating large-scale industrial production. Preparing microcapsules separately before adding them to the film-forming emulsion maximizes the preservation of the microcapsule structure, preventing rupture during coating preparation. The optional adhesive layer coating step provides greater flexibility, allowing for the selection of whether or not to include an adhesive layer based on different substrate materials and application requirements. Stepwise coating and drying / curing ensure that each layer forms a structurally complete and stable film, preventing interpenetration between layers and ensuring their respective functionality.

[0021] In the above preparation process, in step (1), the emulsification process uses a high-speed shear emulsifier with a rotation speed of 5000 r / min to 20000 r / min and an emulsification time of 5 min to 60 min; the drying process uses vacuum drying with a temperature of 30℃ to 80℃ and a time of 2 h to 24 h.

[0022] High-speed shear emulsification ensures thorough mixing of the core-phase dispersion and shell-phase solution, forming an emulsion with uniform particle size and good stability. This guarantees a narrow particle size distribution and high encapsulation rate in the final microcapsules. Appropriate emulsification speed and time prevent excessively large or uneven microcapsule sizes due to incomplete emulsification, and also avoid unnecessary energy consumption and production time increases due to over-emulsification. Vacuum drying rapidly removes moisture and residual solvents from the microcapsules at relatively low temperatures, preventing the shell from softening and cracking or the internal antibacterial and antifungal components from decomposing and becoming ineffective due to high temperatures, thus ensuring the stability of the microcapsule structure and performance.

[0023] In the above preparation process, in step (2), the additives are selected from one or more of thickeners, leveling agents, defoamers, and film-forming aids, and the total mass fraction of the additives is 0.1% to 5%; the stirring speed is 300 r / min to 2000 r / min, and the stirring time is 10 min to 120 min. Adding different types of additives can specifically improve the various properties of antibacterial and antifungal coatings. Thickeners can adjust the viscosity of the coating to adapt it to different coating methods; leveling agents can enable the coating to automatically level after coating, forming a smooth and flat film; defoamers can eliminate bubbles generated during the stirring and coating process, avoiding defects such as pinholes and craters in the coating film; film-forming aids can promote the fusion of polymer emulsion particles, improving the film quality and adhesion of the coating film. A reasonable range of additive additions can fully utilize the role of various additives without negatively affecting the basic properties and antibacterial and antifungal effects of the coating. Appropriate stirring speed and time can ensure that microcapsules and various additives are uniformly dispersed in aqueous polymer emulsions, thus guaranteeing the uniformity of the overall performance of the coating.

[0024] In the above-mentioned preparation process, in steps (3) and (4), the coating method is selected from one of blade coating, roller coating, spraying, and dip coating; the drying and curing temperature is 40℃ to 120℃, and the time is 1min to 30min. Multiple optional coating methods are provided to meet the processing needs of different production scales and substrates of different shapes. Blade coating and roller coating are suitable for continuous production of large-area planar substrates, spraying is suitable for substrates with complex shapes, and dip coating is suitable for processing small batches of products. Reasonable drying and curing temperature and time can ensure that the moisture and additives in the coating film fully evaporate, allowing the polymer emulsion to completely cure into a film, forming a dense and stable functional layer and protective layer. This avoids problems such as insufficient drying of the coating film due to excessively low drying temperature or short drying time, resulting in stickiness and easy peeling; it also avoids problems such as substrate deformation, decomposition of effective components, or cracking of the coating film due to excessively high drying temperature or long drying time.

[0025] In the above preparation process, in step (3), after applying the adhesive layer, it is dried at 40°C to 80°C for 1 to 10 minutes. Clearly defining the drying conditions of the adhesive layer ensures that the water-based pressure-sensitive adhesive reaches its optimal bonding state. Controlling the drying temperature and time within a reasonable range ensures that the moisture in the pressure-sensitive adhesive evaporates sufficiently, forming an adhesive layer with sufficient bonding strength, while preventing over-drying that would cause the pressure-sensitive adhesive to lose its tackiness. This ensures that the subsequently applied slow-release antibacterial and antifungal functional layer can firmly adhere to the breathable base layer, improving the product's quality stability and reliability.

[0026] Compared with the prior art, the present invention has the following beneficial effects: In terms of protective efficacy, it achieves long-lasting and broad-spectrum antibacterial and antifungal effects. The controlled release technology of microcapsules completely changes the drawback of rapid loss of traditional antibacterial and antifungal agents, enabling continuous release of effective ingredients throughout the entire use cycle and maintaining stable protective capabilities. The combined use of multiple antibacterial and antifungal ingredients can simultaneously inhibit a variety of common bacteria and molds, making it suitable for different use environments and protective needs.

[0027] In terms of safety and environmental protection, the product's overall design fully considers its impact on human health and the ecological environment. It uses a water-based polymer emulsion as the film-forming substance, ensuring no harmful organic solvents are released during the entire production and use process, thus avoiding harm to the environment and human health. The biodegradable microcapsule shell material can gradually decompose in the natural environment after product disposal, preventing long-term environmental pollution. Microcapsule encapsulation technology encapsulates antibacterial and antifungal ingredients, reducing direct contact with the human body and significantly improving product safety.

[0028] In terms of performance, the product combines excellent durability and comfort. The hydrophobic protective layer not only effectively prevents liquid penetration and contaminant adhesion but also protects the internal functional layers from external damage, significantly extending the product's lifespan. The adhesive layer enhances the bonding strength between the layers, allowing the pad to withstand repeated bending and friction without easily getting damaged. The breathable base layer ensures excellent breathability, preventing stuffy and damp discomfort during use and improving the user experience.

[0029] In terms of production applications, the preparation process is simple and mature, and the raw materials used are all common industrial products with wide availability and stable prices. The entire production process does not require special equipment and can be carried out on a large scale using existing coating and textile processing production lines, which facilitates industrialization and promotion, effectively controls production costs, and has high market application value. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the structure of the long-lasting antibacterial and antifungal isolation pad of the present invention; Figure 2 This is a flowchart illustrating the preparation process of the long-lasting antibacterial and antifungal isolation pad of the present invention.

[0031] In the diagram: 1. Breathable base layer; 2. Slow-release antibacterial and mildew-proof functional layer; 3. Hydrophobic isolation and protective layer; 4. Adhesive layer. Detailed Implementation

[0032] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0033] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual images. They should not be construed as limiting the scope of this application. To better illustrate the embodiments of the present invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual dimensions of the product. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0034] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "inner," and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present application. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0035] In the description of this invention, unless otherwise explicitly specified and limited, the term "connection" or similar designation indicating a connection between components should be interpreted broadly. For example, it can refer to a fixed connection, a detachable connection, or an integral part; it can be a mechanical connection or an electrical connection; it can be a direct connection or an indirect connection through an intermediate medium; it can refer to the internal communication between two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances. Example 1

[0036] A long-lasting antibacterial and anti-mildew barrier pad, with the following structure: Figure 1 As shown, it includes a breathable base layer 1, an adhesive layer 4, a slow-release antibacterial and anti-mildew functional layer 2, and a hydrophobic isolation and protective layer 3, which are stacked in sequence.

[0037] The breathable base layer 1 is made of polypropylene nonwoven fabric with a surface density of 100g / m² and a thickness of 0.5mm.

[0038] The adhesive layer 4 is a water-based acrylic pressure-sensitive adhesive layer with a thickness of 5μm.

[0039] The sustained-release antibacterial and antifungal functional layer 2 is formed by curing an acrylic emulsion containing a microencapsulated composite antibacterial and antifungal agent, with a dry film thickness of 20 μm. The microencapsulated composite antibacterial and antifungal agent comprises 15% by mass. This microencapsulated composite antibacterial and antifungal agent has a core-shell structure, with a core layer of a ternary composite antibacterial and antifungal composition and a shell layer of polylactic acid. The ternary composite antibacterial and antifungal composition, by weight, consists of the following components: 30 parts silver-loaded zirconium phosphate, 15 parts dodecyl dimethyl benzyl ammonium chloride, 10 parts tea polyphenols, and 3 parts sodium polyacrylate dispersant. The average particle size of the microcapsules is 10 μm, the shell thickness is 1 μm, and the core-shell mass ratio is 1:0.5.

[0040] The hydrophobic protective layer 3 is formed by curing a fluorinated acrylate emulsion, with a dry film thickness of 5 μm and a static water contact angle of 110° at 25°C.

[0041] The preparation process of the above-mentioned long-lasting antibacterial and antifungal barrier pad includes the following steps: (1) Preparation of microencapsulated composite antibacterial and antifungal agent: 30 parts of silver-loaded zirconium phosphate, 15 parts of dodecyl dimethyl benzyl ammonium chloride, 10 parts of tea polyphenols and 3 parts of sodium polyacrylate were added to 100 parts of deionized water and stirred at high speed to disperse evenly to obtain a core phase dispersion; 29 parts of polylactic acid were dissolved in 100 parts of dichloromethane to obtain a shell phase solution; the core phase dispersion and the shell phase solution were mixed and emulsified at high speed at 10000 r / min for 20 min to form an oil-in-water emulsion; the emulsion was transferred to a rotary evaporator and distilled under reduced pressure at 40℃ to remove dichloromethane, filtered, washed 3 times with deionized water, and vacuum dried at 50℃ for 12 h to obtain a microencapsulated composite antibacterial and antifungal agent.

[0042] (2) Preparation of antibacterial and antifungal coating: 15 parts of microencapsulated composite antibacterial and antifungal agent were added to 80 parts of acrylic emulsion with a solid content of 45% and stirred at 500 r / min for 30 min; then 0.5 parts of thickener hydroxyethyl cellulose, 0.3 parts of leveling agent polyether modified polysiloxane, 0.2 parts of defoamer polydimethylsiloxane and 4 parts of film-forming aid alcohol ester dodecyl were added and stirred for another 30 min to obtain antibacterial and antifungal coating.

[0043] (3) Coating the adhesive layer: A water-based acrylic pressure-sensitive adhesive is roller coated on the surface of the polypropylene nonwoven fabric at a coating amount of 5g / m², and dried at 60℃ for 5min to form an adhesive layer.

[0044] (4) Coating functional layer: Apply antibacterial and antifungal coating to the surface of the adhesive layer by roller, with a coating amount of 20g / m², and dry at 80℃ for 10min to form a slow-release antibacterial and antifungal functional layer.

[0045] (5) Coating protective layer: A fluorinated acrylate emulsion is rolled onto the surface of the slow-release antibacterial and antifungal functional layer at a coating amount of 5 g / m², and dried at 80°C for 5 min to obtain a long-lasting antibacterial and antifungal isolation pad. Example 2

[0046] A long-lasting antibacterial and anti-mildew barrier pad includes a breathable base layer, a slow-release antibacterial and anti-mildew functional layer, and a hydrophobic barrier protective layer stacked in sequence.

[0047] The breathable base layer is made of polyester needle-punched felt with a surface density of 200g / m² and a thickness of 1mm.

[0048] The sustained-release antibacterial and antifungal functional layer is formed by curing a polyurethane emulsion containing a microencapsulated composite antibacterial and antifungal agent, with a dry film thickness of 30 μm. The microencapsulated composite antibacterial and antifungal agent comprises 20% by mass. This microencapsulated composite antibacterial and antifungal agent has a core-shell structure, with a core layer of a ternary composite antibacterial and antifungal composition and a shell layer of chitosan. The ternary composite antibacterial and antifungal composition, by weight, consists of the following components: 25 parts silver-loaded zeolite, 20 parts polyhexamethylene guanidine hydrochloride, 8 parts chitosan, and 2 parts sodium hexametaphosphate dispersant. The average particle size of the microcapsules is 15 μm, the shell thickness is 1.5 μm, and the core-shell mass ratio is 1:0.8.

[0049] The hydrophobic protective layer is formed by curing methylsiloxane emulsion, with a dry film thickness of 8μm and a static water contact angle of 105° at 25℃.

[0050] The preparation process of the above-mentioned long-lasting antibacterial and antifungal barrier pad includes the following steps: (1) Preparation of microencapsulated composite antibacterial and antifungal agent: 25 parts silver-loaded zeolite, 20 parts polyhexamethylene guanidine hydrochloride, 8 parts chitosan and 2 parts sodium hexametaphosphate were added to 100 parts deionized water and stirred at high speed to disperse evenly to obtain a core phase dispersion; 44 parts chitosan were dissolved in 100 parts 1% acetic acid aqueous solution to obtain a shell phase solution; the core phase dispersion and shell phase solution were mixed and emulsified at high speed at 8000 r / min for 30 min to form an emulsion; 25% glutaraldehyde aqueous solution was added dropwise to the emulsion for cross-linking and curing, and stirring was continued for 2 h after the addition was completed. The mixture was filtered, washed with deionized water until neutral, and vacuum dried at 45℃ for 18 h to obtain the microencapsulated composite antibacterial and antifungal agent.

[0051] (2) Preparation of antibacterial and antifungal coating: 20 parts of microencapsulated composite antibacterial and antifungal agent were added to 75 parts of polyurethane emulsion with a solid content of 40% and stirred at 600 r / min for 40 min; then 0.8 parts of thickener polyurethane thickener, 0.4 parts of leveling agent acrylate leveling agent, 0.3 parts of defoamer organosilicon defoamer and 3.5 parts of film-forming aid ethylene glycol butyl ether were added and stirred for another 40 min to obtain antibacterial and antifungal coating.

[0052] (3) Coating functional layer: Spray antibacterial and mildew-proof coating on the surface of polyester needle-punched felt at a coating amount of 30g / m², and dry at 90℃ for 15min to form a slow-release antibacterial and mildew-proof functional layer.

[0053] (4) Coating protective layer: Methylsiloxane emulsion is sprayed onto the surface of the slow-release antibacterial and antifungal functional layer at a coating amount of 8g / m², and dried at 90℃ for 8min to obtain a long-lasting antibacterial and antifungal isolation pad. Example 3

[0054] A long-lasting antibacterial and anti-mildew barrier pad includes a breathable base layer, an adhesive layer, a slow-release antibacterial and anti-mildew functional layer, and a hydrophobic barrier protective layer, which are stacked in sequence.

[0055] The breathable base layer is made of woven cotton fabric with a surface density of 150g / m² and a thickness of 0.8mm.

[0056] The adhesive layer is a water-based polyurethane pressure-sensitive adhesive layer with a thickness of 8μm.

[0057] The sustained-release antibacterial and antifungal functional layer is formed by curing a silicone-acrylic emulsion containing a microencapsulated composite antibacterial and antifungal agent, with a dry film thickness of 25 μm. The mass fraction of the microencapsulated composite antibacterial and antifungal agent is 18%. The microencapsulated composite antibacterial and antifungal agent has a core-shell structure, with a core layer of a ternary composite antibacterial and antifungal composition and a shell layer of polyhydroxyalkanoates. The ternary composite antibacterial and antifungal composition, by weight, consists of the following components: 35 parts nano-titanium dioxide, 12 parts isothiazolinone, 7 parts allicin, and 4 parts sodium lignosulfonate dispersant. The average particle size of the microcapsules is 12 μm, the shell thickness is 1.2 μm, and the core-shell mass ratio is 1:0.6.

[0058] The hydrophobic protective layer is formed by curing a perfluorooctyl ethyl acrylate copolymer emulsion, with a dry film thickness of 6 μm and a static water contact angle of 120° at 25°C.

[0059] Reference Figure 2 The preparation process of the above-mentioned long-lasting antibacterial and antifungal isolation pad includes the following steps: (1) Preparation of microencapsulated composite antibacterial and antifungal agent: 35 parts of nano titanium dioxide, 12 parts of isothiazolinone, 7 parts of allicin and 4 parts of sodium lignosulfonate were added to 100 parts of deionized water and stirred at high speed to disperse evenly to obtain a core phase dispersion; 32.4 parts of polyhydroxy fatty acid ester were dissolved in 100 parts of chloroform to obtain a shell phase solution; the core phase dispersion and the shell phase solution were mixed and emulsified at high speed of 12000 r / min for 15 min to form an oil-in-water emulsion; the emulsion was transferred to a rotary evaporator and chloroform was removed by vacuum distillation at 35℃, filtered, washed 3 times with deionized water, and vacuum dried at 55℃ for 10 h to obtain a microencapsulated composite antibacterial and antifungal agent.

[0060] (2) Preparation of antibacterial and antifungal coating: 18 parts of microencapsulated composite antibacterial and antifungal agent were added to 77 parts of silicone acrylic emulsion with a solid content of 48% and stirred at 700 r / min for 25 min; then 0.6 parts of thickener carboxymethyl cellulose, 0.3 parts of leveling agent fluorocarbon leveling agent, 0.2 parts of defoamer polyether defoamer and 3.9 parts of film-forming aid propylene glycol methyl ether acetate were added and stirred for another 25 min to obtain antibacterial and antifungal coating.

[0061] (3) Applying an adhesive layer: Apply water-based polyurethane pressure-sensitive adhesive to the surface of the cotton woven fabric with a scraper. The amount of adhesive is 8g / m². Dry at 55℃ for 6min to form an adhesive layer.

[0062] (4) Coating functional layer: Apply antibacterial and antifungal coating to the surface of the adhesive layer with a scraper, with a coating amount of 25g / m², and dry at 85℃ for 12min to form a slow-release antibacterial and antifungal functional layer.

[0063] (5) Coating protective layer: A perfluorooctyl ethyl acrylate copolymer emulsion is coated on the surface of the slow-release antibacterial and antifungal functional layer by scraping. The coating amount is 6g / m². The emulsion is dried at 85℃ for 6min to obtain a long-lasting antibacterial and antifungal isolation pad.

[0064] Comparative Example 1 A common antibacterial isolation pad was prepared by directly adding 15 parts of an unmicroencapsulated ternary composite antibacterial and antifungal composition (the same as in Example 1) to 80 parts of acrylic emulsion to form an antibacterial coating. This coating was then applied to the surface of a polypropylene nonwoven fabric, the same as in Example 1, and dried to obtain an antibacterial isolation pad with a dry film thickness of 20 μm.

[0065] Performance testing The isolation pads prepared in Examples 1-3 and Comparative Example 1 were tested for antibacterial properties, antifungal properties, and durability. The results are shown in the table below:

[0066] Note: Antibacterial performance testing was conducted in accordance with GB / T20944.3-2008 "Evaluation of antibacterial properties of textiles - Part 3: Vibration method"; mildew resistance testing was conducted in accordance with GB / T24346-2009 "Evaluation of mildew resistance of textiles"; accelerated aging testing was conducted using a xenon lamp aging test chamber to simulate the aging process under natural conditions, with 1000 hours of accelerated aging equivalent to approximately 3 years of actual use.

[0067] The test results show that the long-lasting antibacterial and antifungal isolation pads prepared in Examples 1-3 of this invention have excellent antibacterial and antifungal properties. The antibacterial rate against *Escherichia coli* and *Staphylococcus aureus* is above 99%, and the antifungal rating against *Aspergillus niger* and *Aspergillus flavus* is level 0. After 1000 hours of accelerated aging, the antibacterial and antifungal properties of Examples 1-3 remained good, while the antibacterial and antifungal properties of Comparative Example 1 decreased significantly. This indicates that the present invention, through the synergistic effect of microencapsulation technology and the ternary composite antibacterial and antifungal system, significantly improves the long-lasting effect and durability of the antibacterial and antifungal isolation pads.

[0068] Furthermore, in the long-lasting antibacterial and antifungal barrier pad of this application, the effective release half-life of the microencapsulated composite antibacterial and antifungal agent in the sustained-release antibacterial and antifungal functional layer is... Satisfy the following equation: ; in: —Effective release half-life, in days (d); —Average thickness of the microcapsule shell, unit: The values ​​were obtained by statistical averaging using SEM / TEM, with a range of 0.1 to 5. —Degradation rate constant of the shell material, unit: The microcapsules were placed in a simulated humid environment (40℃, 90%RH), and the change in shell thickness was measured periodically. The calculated linear regression slope is the degradation rate constant of the shell material, with a value range of 0.01~0.5. —Empirical synergy factor, dimensionless, with a value range of 0.05~0.25, obtained through nonlinear fitting of multiple sets of orthogonal experimental data; —Dry film thickness of the sustained-release antibacterial and antifungal functional layer, unit: The value is obtained by measuring the coating thickness with a range of 5 to 100. —Median particle size of microcapsules, unit: The value range is 1 to 50; —Volume fraction of microcapsules in the sustained-release antibacterial and antifungal functional layer, dimensionless, ranging from 0.05 to 0.30. ,in This is the mass fraction (5%~30%). The average density of the microcapsules is approximately 1.1~1.5 g / cm³. The density of the polymer dry film is approximately 1.0~1.2 g / cm³. —Static water contact angle of the hydrophobic protective layer at 25°C, unit: degrees (°), range of values. .

[0069] Example based on Implementation 1: Example 1 data: ; Shell polylactic acid, experimentally measured ; (Preliminary experimental fitted values); ; ; Microcapsule mass fraction 15%, , Calculated ; ,but , ; Substitute into the equation: ; First calculate the internal calculations of the exponent: , , ; ; This half-life corresponds to the time required for 50% of the active ingredient to be released. In Example 1, after accelerated aging for 1000 hours (approximately 41.7 days), the antibacterial rate was still >99%, as expected. At this point, approximately 75% of the active ingredient was released, and the remaining 25% was still above the antibacterial threshold, maintaining effective protection.

[0070] Technical effects: Quantitative design and long-term effectiveness: By adjusting the measurable parameters ( It can accurately predict the effective protection time of a product, avoid lengthy real-time aging tests, and significantly shorten the R&D cycle.

[0071] Multi-factor synergistic optimization: The equations explicitly reveal the exponential amplification effect of the hydrophobic layer contact angle and functional layer structure on the release half-life, providing a clear technical path for improving product lifespan (e.g., appropriately increasing...). or (Can extend the protection period several times over).

[0072] Cost control: There is no need to overuse expensive antibacterial agents. By optimizing structural parameters, the cost of raw materials can be reduced while meeting the requirements for long-lasting effects.

[0073] Quality evaluation criteria: It can be used as a mathematical model for quickly estimating product lifespan before shipment and for judging batch-to-batch consistency.

[0074] Working principle and process: S1, Moisture / Enzyme Permeation Stage: Moisture vapor or microbial secretions from the environment first come into contact with the hydrophobic protective layer. The water contact angle of this layer... Determines the blocking ability, The larger the size, the more difficult it is to penetrate.

[0075] S2, Shell Degradation Stage: A small amount of permeate reaches the functional layer and contacts the microcapsules. The shell material degrades at a rate... Gradual etching, thickness Determines the time required for complete degradation of a single microcapsule .

[0076] S3, Ingredient Diffusion Stage: The released antibacterial and antifungal ingredients need to penetrate the functional layer thickness. .

[0077] Number of microcapsule layers along the thickness direction and bulk density These factors together constitute diffusion resistance, causing the release time to be extended exponentially.

[0078] S4. Synergistic Enhancement Stage: The above factors are coupled through an exponential function to ultimately obtain the half-life. The higher this value, the longer the product provides effective protection in real-world usage environments.

[0079] This equation unifies the multilayer structure, microcapsule parameters, and release kinetics into a computable mathematical model, providing quantitative theoretical support for the core technology of long-acting and controllable release in this invention.

[0080] In summary, the working principle of the long-lasting antibacterial and antifungal isolation pad and its preparation process provided in this application is as follows: The long-lasting antibacterial and anti-mildew barrier pad of the present invention adopts a multi-layer composite structure design, with each layer having a clear division of labor and working together to achieve excellent comprehensive performance.

[0081] The breathable base layer, serving as the supporting framework for the entire insulation pad, provides the product with the necessary mechanical strength and flexibility, enabling it to withstand the stretching, bending, and friction during daily use. Simultaneously, the breathable base layer itself has a good porous structure, ensuring free airflow and preventing moisture buildup due to poor air circulation, thus reducing conditions for mold growth at the source.

[0082] The central, slow-release antibacterial and antifungal functional layer is the key component for achieving the protective effect. This layer uses an aqueous polymer emulsion as the film-forming matrix, and uniformly disperses a large number of microencapsulated composite antibacterial and antifungal agents with a core-shell structure. The core layer of the microcapsules contains three antibacterial and antifungal components with different mechanisms of action, while the shell layer is made of a biodegradable polymer material. During use, the shell layer of the microcapsules slowly degrades under the influence of environmental factors. As the shell layer gradually decomposes, the antibacterial and antifungal components encapsulated inside are continuously and steadily released to the surface of the functional layer, thus maintaining a stable antibacterial and antifungal effect over a longer period. The three different types of antibacterial and antifungal components work synergistically to inhibit the growth and reproduction of microorganisms through multiple pathways, not only expanding the scope of protection but also reducing the concentration of any single component, effectively reducing the possibility of microbial resistance.

[0083] The outermost hydrophobic protective layer forms a dense physical barrier on the surface of the isolation pad. This layer is made of a material with low surface energy, allowing liquids such as water and oil to bead up and roll off, making it difficult for them to penetrate the pad's interior. Simultaneously, this low surface energy property also makes it difficult for dust and contaminants to adhere to the pad's surface, significantly reducing cleaning difficulty. Furthermore, the hydrophobic protective layer also blocks external ultraviolet rays, acids, and alkalis from eroding the internal slow-release antibacterial and antifungal functional layer, protecting the integrity of the microcapsule structure and further extending the product's lifespan.

[0084] When an adhesive layer is placed between the breathable base layer and the slow-release antibacterial and anti-mildew functional layer, the adhesive layer can significantly enhance the interfacial bonding force between the two layers, preventing the functional layer from falling off or peeling due to external forces during use, and ensuring the stability and durability of the isolation pad structure.

[0085] Furthermore, the long-lasting antibacterial and anti-mildew barrier mat of this invention is extremely easy to use, requiring no complicated installation steps. Depending on the specific needs of the actual application scenario, simply use ordinary cutting tools to cut the barrier mat to the appropriate size and shape, and then directly lay it on the surface that needs protection.

[0086] This insulating mat has a wide range of applications. It can be used in home environments such as inside cabinets, wardrobe shelves, under mattresses, under sofas, and bathroom floors to effectively prevent furniture from getting damp and moldy, maintaining a clean and hygienic home environment. In medical settings, it can be laid on surfaces such as hospital beds, examination tables, and infusion chairs to reduce the risk of cross-infection. In the food processing industry, it can be used on workbenches, floors, and shelves to inhibit the growth of harmful microorganisms and ensure food production safety. In the construction and decoration field, it can be used for moisture-proof and mold-proof treatment of walls and floors, and is especially suitable for damp environments such as basements, kitchens, and bathrooms.

[0087] Routine maintenance is very simple. When the surface of the isolation mat gets dirty, simply wipe it gently with a clean, damp cloth to remove the stains; no special cleaning agents are needed. Due to its long-lasting antibacterial and anti-mildew properties, it does not require frequent replacement, effectively reducing long-term operating costs. During installation, ensure the isolation mat adheres smoothly to the surface being protected, avoiding wrinkles and curling edges to ensure optimal protection.

[0088] The above are merely preferred embodiments of the present invention and are not intended to limit the implementation methods and protection scope of the present invention. Those skilled in the art should recognize that any equivalent substitutions and obvious changes made based on the description and illustrations of the present invention should be included within the protection scope of the present invention.

Claims

1. A long-lasting antibacterial and anti-mildew barrier mat, characterized in that, The product comprises a breathable base layer, a slow-release antibacterial and antifungal functional layer, and a hydrophobic isolation and protective layer, which are stacked sequentially. The slow-release antibacterial and antifungal functional layer is formed by curing an aqueous polymer emulsion containing a microencapsulated composite antibacterial and antifungal agent. The microencapsulated composite antibacterial and antifungal agent has a core-shell structure, with its core layer being a ternary composite antibacterial and antifungal composition containing an inorganic antibacterial agent, an organic antibacterial agent, and a natural antifungal agent, and its shell layer being a biodegradable polymer material. The ternary composite antibacterial and antifungal composition achieves long-term release through the slow degradation of the biodegradable polymer shell layer.

2. The long-lasting antibacterial and antifungal barrier mat according to claim 1, characterized in that, The breathable base layer is selected from one or more of non-woven fabric, needle-punched felt, woven fabric, and knitted fabric, with a surface density of 50g / m² to 500g / m² and a thickness of 0.1mm to 5mm.

3. The long-lasting antibacterial and antifungal barrier mat according to claim 1, characterized in that, The ternary composite antibacterial and antifungal composition comprises, by weight, the following components: 10 to 50 parts of inorganic antibacterial agent, 5 to 30 parts of organic antibacterial agent, 5 to 20 parts of natural antifungal agent, and 1 to 10 parts of dispersant; wherein the inorganic antibacterial agent is selected from one or more of silver-loaded zeolite, silver-loaded zirconium phosphate, zinc-loaded zinc oxide, and nano-titanium dioxide; wherein the organic antibacterial agent is selected from one or more of quaternary ammonium salt compounds, guanidine compounds, and isothiazolinone compounds; and wherein the natural antifungal agent is selected from one or more of tea polyphenols, chitosan, allicin, and rosemary extract.

4. The long-lasting antibacterial and antifungal barrier mat according to claim 1, characterized in that, The biodegradable polymer material is selected from one or more of polylactic acid, polyhydroxyalkanoate, polycaprolactone, chitosan derivatives, and gelatin; the microencapsulated composite antibacterial and antifungal agent has a particle size of 1 μm to 50 μm, a shell thickness of 0.1 μm to 5 μm, and a core-shell mass ratio of 1:0.2 to 1:

2.

5. The long-lasting antibacterial and antifungal barrier mat according to claim 1, characterized in that, The aqueous polymer emulsion is selected from one or more of acrylate emulsion, polyurethane emulsion, styrene-acrylic emulsion, and silicone-acrylic emulsion, with a solid content of 30% to 60%; in the sustained-release antibacterial and antifungal functional layer, the mass fraction of the microencapsulated composite antibacterial and antifungal agent is 5% to 30%, and the dry film thickness of the functional layer is 5 μm to 100 μm.

6. The long-lasting antibacterial and antifungal barrier mat according to claim 1, characterized in that, The hydrophobic protective layer is formed by curing a fluoropolymer emulsion or a siloxane polymer emulsion, with a dry film thickness of 1 μm to 50 μm and a static water contact angle of 90° to 150° at 25°C.

7. The long-lasting antibacterial and antifungal barrier mat according to claim 1, characterized in that, An adhesive layer is provided between the breathable base layer and the slow-release antibacterial and antifungal functional layer. The adhesive layer is a water-based pressure-sensitive adhesive layer with a thickness of 1μm to 30μm.

8. A preparation process for a long-lasting antibacterial and antifungal barrier pad according to any one of claims 1-7, characterized in that, Includes the following steps: (1) Preparation of microencapsulated composite antibacterial and antifungal agent: The ternary composite antibacterial and antifungal composition is dispersed in a suitable medium to obtain a core phase dispersion; the biodegradable polymer material is dissolved in a suitable solvent to obtain a shell phase solution; the core phase dispersion and the shell phase solution are mixed and emulsified to form an oil-in-water or water-in-oil emulsion; microcapsules are formed by solvent evaporation or in-situ polymerization, and the microencapsulated composite antibacterial and antifungal agent is obtained after filtration, washing and drying; (2) Preparation of antibacterial and antifungal coating: Microencapsulated composite antibacterial and antifungal agent is added to water-based polymer emulsion, stirred evenly, then additives are added, and stirring is continued to obtain antibacterial and antifungal coating; (3) Optionally, an adhesive layer is coated on the surface of the breathable base layer and dried; an antibacterial and antifungal coating is applied to the surface of the breathable base layer or the adhesive layer and dried and cured to form a slow-release antibacterial and antifungal functional layer; (4) Coating a protective layer: Coating a hydrophobic isolation protective layer coating on the surface of the slow-release antibacterial and anti-mildew functional layer, and drying and curing to obtain a long-lasting antibacterial and anti-mildew isolation pad.

9. The preparation process of the long-lasting antibacterial and antifungal isolation pad according to claim 8, characterized in that, In step (1), the emulsification process uses a high-speed shear emulsifier with a rotation speed of 5000 r / min to 20000 r / min and an emulsification time of 5 min to 60 min; the drying process uses vacuum drying with a temperature of 30℃ to 80℃ and a time of 2 h to 24 h.

10. The preparation process of the long-lasting antibacterial and antifungal isolation pad according to claim 8, characterized in that, In step (2), the additive is selected from one or more of thickeners, leveling agents, defoamers, and film-forming aids, and the total mass fraction of the additive is 0.1% to 5%; the stirring speed is 300 r / min to 2000 r / min, and the stirring time is 10 min to 120 min.

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