CN112726190A - Water electret method and production process method for improving mask quality - Google Patents
Water electret method and production process method for improving mask quality Download PDFInfo
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- CN112726190A CN112726190A CN202011609409.5A CN202011609409A CN112726190A CN 112726190 A CN112726190 A CN 112726190A CN 202011609409 A CN202011609409 A CN 202011609409A CN 112726190 A CN112726190 A CN 112726190A
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 107
- 239000004744 fabric Substances 0.000 claims description 51
- 238000004519 manufacturing process Methods 0.000 claims description 43
- 238000000034 method Methods 0.000 claims description 40
- 239000004745 nonwoven fabric Substances 0.000 claims description 38
- 238000001914 filtration Methods 0.000 claims description 37
- 239000010410 layer Substances 0.000 claims description 35
- 239000000463 material Substances 0.000 claims description 30
- 238000001223 reverse osmosis Methods 0.000 claims description 21
- 230000007774 longterm Effects 0.000 claims description 17
- 238000001035 drying Methods 0.000 claims description 15
- 239000004750 melt-blown nonwoven Substances 0.000 claims description 15
- -1 polypropylene Polymers 0.000 claims description 13
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 claims description 12
- 239000004743 Polypropylene Substances 0.000 claims description 12
- 238000005520 cutting process Methods 0.000 claims description 12
- 239000012528 membrane Substances 0.000 claims description 12
- 229920001155 polypropylene Polymers 0.000 claims description 11
- 239000002994 raw material Substances 0.000 claims description 11
- 238000003860 storage Methods 0.000 claims description 11
- 239000003153 chemical reaction reagent Substances 0.000 claims description 9
- 238000002360 preparation method Methods 0.000 claims description 9
- 238000003466 welding Methods 0.000 claims description 9
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 8
- 238000011156 evaluation Methods 0.000 claims description 7
- 239000003795 chemical substances by application Substances 0.000 claims description 6
- 238000004049 embossing Methods 0.000 claims description 6
- 238000001125 extrusion Methods 0.000 claims description 6
- 239000000835 fiber Substances 0.000 claims description 6
- 239000002344 surface layer Substances 0.000 claims description 6
- 239000008399 tap water Substances 0.000 claims description 6
- 235000020679 tap water Nutrition 0.000 claims description 6
- 238000012856 packing Methods 0.000 claims description 5
- 230000010287 polarization Effects 0.000 claims description 5
- 238000005507 spraying Methods 0.000 claims description 5
- 239000006004 Quartz sand Substances 0.000 claims description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 4
- 238000009287 sand filtration Methods 0.000 claims description 4
- 239000004575 stone Substances 0.000 claims description 4
- 239000004594 Masterbatch (MB) Substances 0.000 claims description 3
- 238000007599 discharging Methods 0.000 claims description 3
- 210000005069 ears Anatomy 0.000 claims description 3
- 238000005485 electric heating Methods 0.000 claims description 3
- 238000009434 installation Methods 0.000 claims description 3
- 238000002844 melting Methods 0.000 claims description 3
- 230000008018 melting Effects 0.000 claims description 3
- 238000005374 membrane filtration Methods 0.000 claims description 3
- 230000035515 penetration Effects 0.000 claims description 3
- 238000012545 processing Methods 0.000 claims description 3
- 238000000746 purification Methods 0.000 claims description 3
- 238000007493 shaping process Methods 0.000 claims description 3
- 238000012360 testing method Methods 0.000 claims description 3
- 238000007664 blowing Methods 0.000 claims description 2
- 238000002347 injection Methods 0.000 claims description 2
- 239000007924 injection Substances 0.000 claims description 2
- 239000002245 particle Substances 0.000 claims description 2
- 238000010438 heat treatment Methods 0.000 claims 1
- 230000002829 reductive effect Effects 0.000 description 5
- 238000001514 detection method Methods 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000008187 granular material Substances 0.000 description 3
- 230000001681 protective effect Effects 0.000 description 3
- 239000012792 core layer Substances 0.000 description 2
- 239000013078 crystal Substances 0.000 description 2
- 230000002045 lasting effect Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 230000003068 static effect Effects 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 208000035473 Communicable disease Diseases 0.000 description 1
- 241000700605 Viruses Species 0.000 description 1
- 230000002238 attenuated effect Effects 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000000903 blocking effect Effects 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000005611 electricity Effects 0.000 description 1
- 210000004072 lung Anatomy 0.000 description 1
- 239000013618 particulate matter Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000002633 protecting effect Effects 0.000 description 1
- 230000005180 public health Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 230000000241 respiratory effect Effects 0.000 description 1
- 239000000243 solution Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M10/00—Physical treatment of fibres, threads, yarns, fabrics, or fibrous goods made from such materials, e.g. ultrasonic, corona discharge, irradiation, electric currents, or magnetic fields; Physical treatment combined with treatment with chemical compounds or elements
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D13/00—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches
- A41D13/05—Professional, industrial or sporting protective garments, e.g. surgeons' gowns or garments protecting against blows or punches protecting only a particular body part
- A41D13/11—Protective face masks, e.g. for surgical use, or for use in foul atmospheres
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/02—Layered materials
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D31/00—Materials specially adapted for outerwear
- A41D31/04—Materials specially adapted for outerwear characterised by special function or use
-
- D—TEXTILES; PAPER
- D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
- D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01D5/00—Formation of filaments, threads, or the like
- D01D5/08—Melt spinning methods
- D01D5/098—Melt spinning methods with simultaneous stretching
- D01D5/0985—Melt spinning methods with simultaneous stretching by means of a flowing gas (e.g. melt-blowing)
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4282—Addition polymers
- D04H1/4291—Olefin series
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
- D04H1/492—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres by fluid jet
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
- D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H18/00—Needling machines
- D04H18/04—Needling machines with water jets
-
- A—HUMAN NECESSITIES
- A41—WEARING APPAREL
- A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
- A41D2500/00—Materials for garments
- A41D2500/30—Non-woven
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
- D06M2101/00—Chemical constitution of the fibres, threads, yarns, fabrics or fibrous goods made from such materials, to be treated
- D06M2101/16—Synthetic fibres, other than mineral fibres
- D06M2101/18—Synthetic fibres consisting of macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D06M2101/20—Polyalkenes, polymers or copolymers of compounds with alkenyl groups bonded to aromatic groups
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Health & Medical Sciences (AREA)
- General Health & Medical Sciences (AREA)
- Physical Education & Sports Medicine (AREA)
- Respiratory Apparatuses And Protective Means (AREA)
- Filtering Materials (AREA)
Abstract
The invention relates to the technical field of protective masks, and discloses a production process method for improving the quality of a mask, which solves the technical problem that the filtering and protecting effect of the existing stored mask is reduced too fast, and relates to a manufacturing process of melt-blown cloth; s1, generating a melt-blown fabric: selecting electret high-fluidity polypropylene and adding 2% of water electret master batch; s2, preparing pure water: selecting tap water as a water source to complete the preparation of pure water; s3, water electret procedure: the prepared pure water is conveyed to a fan-shaped nozzle through a high-pressure water pump, the fan-shaped nozzle carries out spunlace injection on melt-blown fabric, charges are generated through friction between water and melt-blown fibers, the melt-blown nonwoven material is provided with stable polarization charges, and spunlace electret is completed; and S4, drying. According to the technical scheme, the stable polarization charge on the melt-blown non-woven material belt is utilized; further optimize gauze mask structure and extranal packing, realize the lasting stability of electric charge of gauze mask in long-term storage process to reach the purpose that has long-term stable filtration protective effect.
Description
Technical Field
The invention relates to the technical field of protective masks, in particular to a production process method for improving the quality of a mask.
Background
The mask is a sanitary article, is generally worn on the mouth and nose for filtering air entering the mouth and nose so as to achieve the effect of blocking harmful gas, smell, spray, virus and other substances, and is made of gauze or paper and the like. The mask has a certain filtering function on air entering the lung, and has a very good effect when being worn in respiratory infectious diseases and working in environments polluted by dust and the like.
The difference between the quality of the mask made in China and the quality of the masks made by companies such as 3M company and Honeyville is large, the filtering efficiency is obviously reduced after the mask is stored for more than one year, and the shelf life of most masks made by 3M company is 5 years. The mask has a long time from the factory manufacturing to the terminal consumption, and if the mask is used as medical supply and strategic reserve materials for dealing with a great public health accident, the mask must have a long-term stable filtering and protecting effect.
Disclosure of Invention
Aiming at the technical problem that the filter protection effect of the stored mask is reduced too fast, the invention utilizes the stable polarization charge on the melt-blown non-woven material; further optimize gauze mask structure and extranal packing, realize the lasting stability of electric charge of gauze mask in long-term storage process to reach the purpose that has long-term stable filtration protective effect.
In order to achieve the purpose, the invention provides the following technical scheme:
a production process method for improving the quality of a mask comprises two parts of production processes:
firstly, manufacturing a melt-blown fabric;
s1, generating a melt-blown fabric: selecting electret high-fluidity polypropylene, adding 2% of water electret master batch, melting, and spraying a melt-blown non-woven material under the condition of high-temperature and high-pressure gas through an extrusion unit and a die;
s2, preparing pure water: selecting tap water as a water source, performing sand-stone tank filtration, active carbon filtration and quartz sand filtration on the water source, adding a reverse osmosis agent and hydrochloric acid into the filtered water source, performing reverse osmosis membrane secondary filtration on the water source, automatically detecting and adding an alkaline industrial reagent into the filtered water source, and completing pure water preparation through a pure device;
s3, water electret procedure: the prepared pure water is conveyed to a fan-shaped nozzle through a high-pressure water pump, the fan-shaped nozzle carries out spunlace injection on melt-blown fabric, charges are generated through friction between water and melt-blown fibers, the melt-blown nonwoven material is provided with stable polarization charges, and spunlace electret is completed;
s4, drying: sucking water on the melt-blown non-woven material by using negative pressure equipment, and drying to obtain melt-blown non-woven material-melt-blown cloth;
secondly, a mask making process;
a1, the mask is formed by combining multiple fabrics of a non-woven fabric layer and a melt-blown fabric layer, the melt-blown fabric layer is positioned between the two non-woven fabric layers, the multiple fabrics are respectively installed on a discharging mechanism to be discharged, and then are combined and conveyed to nose bridge strip installation equipment;
a2, unwinding the nose bridge strip and the gasket by nose bridge strip mounting equipment, superposing the nose bridge strip and the gasket together, cutting the nose bridge strip and the gasket together, and mounting the nose bridge strip and the gasket between the non-woven fabric layer and the non-woven fabric layer;
a3, two non-woven fabric layers and a middle melt-blown fabric layer are combined into a mask finishing material piece, the edge is primarily pressed and welded through an embossing mechanism, and the mask finishing material piece is primarily fixed;
a4, folding by a folding mechanism to fold the mask sheet along the central line; a5, pressing and welding the folded mask by an embossing mechanism for the second time, and making the folded mask into sheets
Shaping;
a6, cutting the shaped folded mask by a cutting mechanism, and cutting off redundant materials to form a mask sheet;
a7, welding ears on a mask sheet by welding equipment to form a finished mask;
and A8, finally, collecting and storing the finished product mask through a material receiving mechanism.
Through the technical scheme, the difference of the invention from the traditional melt-blown fabric electret process is as follows: the traditional melt-blown fabric adopts corona electret, and the process characteristics of the corona electret are as follows: the electret is obvious on the surface of the melt-blown fabric, but the filtering efficiency does not reach a peak value, the storage of the electret is reduced along with the time, and the electrostatic attenuation on the surface of the material is obvious. The production process of the melt-blown fabric adopts a water electret process, the water electret melt-blown fabric is formed by conveying prepared pure water into a spunlace device through a high-pressure water pump at high pressure, and spraying the melt-blown fabric through a fan-shaped nozzle, so that static electricity is generated by friction between the melt-blown fabric and the fan-shaped nozzle. The surface condition of the water electret meltblown fabric is in electrostatic saturation, the water electret charging mode can be used for oil detection and salt detection, and the problems that the filtering efficiency of the traditional mask meltblown fabric is improved and the filtering efficiency is reduced after the traditional mask meltblown fabric is stored can be effectively solved. The water electret process has the effects that: the surface condition of the melt-blown cloth after electrostatic electret of water of the equipment is electrostatic saturation, the charging mode can be used for oil detection and salt detection, the filtration efficiency after the electrostatic electret of the melt-blown cloth is more than 99 percent plus, the static is not attenuated (more than two years), and the resistance is low (about 3 to 40 percent of resistance can be reduced), namely the filtration efficiency can be improved.
Therefore, in the process, stable polarization charges are carried on the melt-blown non-woven material by using a melt-blown fabric manufacturing process, and after analogue storage pretreatment is carried out by referring to GB32610-2019 technical Specification of daily protective masks, the particulate matter filtering efficiency is more than or equal to 95 percent, and the exhalation resistance is less than or equal to 45 Pa. Further optimizing the structure and the external package of the mask, and realizing the lasting stability of the charge of the mask in the long-term storage process. The quality guarantee period of the mask is more than or equal to 3 years.
The invention is further configured to: and in the S2, the number of the water needling channels is 2, the water needling pressure is 0.2-0.4Mpa, and the negative pressure is 2 channels for vacuum pumping.
The invention is further configured to: temperatures of respective zones of the extruder in S2: the temperature of the first area is 150-180 ℃, the temperature of the second area is 180-220 ℃, the temperature of the third area is 220-230 ℃, and the temperature of the fourth area is 230-240 ℃; the temperature of the die head is 230-240 ℃; the temperature of the cross air blow is 260-285 ℃; the speed of the drafting air is 500 to 900 m/s.
The invention is further configured to: utilize the electric charge testing arrangement to find out gauze mask surface course non-woven fabrics, inlayer non-woven fabrics and extranal packing to the influence law of sandwich layer melt-blown fabric electric charge stability, feed back in production, the production parameter of adjustment surface course non-woven fabrics, inlayer non-woven fabrics and extranal packing to realize that the gauze mask can be in the filtration efficiency and the electrified stability of long-term storage.
The invention is further configured to: the production parameters include, but are not limited to, processing temperature, finished product thickness, number of layers, weight percent, and material quality.
The invention is further configured to: and establishing a charge long-term stability evaluation record for the finished mask, feeding the charge long-term stability evaluation record back to production, and adjusting production parameters of the surface layer non-woven fabric, the inner layer non-woven fabric and the outer package so as to realize the filtering efficiency and the charged stability of the mask in long-term storage.
A water electret method, step one, melt-blow production; selecting polypropylene granules as raw materials, conveying the raw materials of a polypropylene client to an extrusion machine, ejecting the raw materials extruded by the extruder through a die head spinneret plate, wherein the direction of airflow generated by an air compressor is the same as the ejection direction of the raw materials;
step two, water purification equipment; selecting tap water as a water source, carrying out sandstone tank filtration, activated carbon filtration and quartz sand filtration on the water source, adding a reverse osmosis agent and hydrochloric acid into the filtered water source, carrying out reverse osmosis membrane secondary filtration on the water source, automatically detecting and adding an alkaline industrial reagent into the filtered water source, and completing pure water preparation through pure water equipment;
step three, an electret process; the prepared pure water is conveyed to a fan-shaped nozzle through a high-pressure water pump, the fan-shaped nozzle carries out spunlace penetration on the melt-blown fabric, negative pressure is absorbed below the melt-blown fabric, and charges are generated through friction between the pure water and the non-woven fabric to finish spunlace electret;
step four, drying process; the melt-blown fabric after spunlace electret is conveyed into a drying room through a conveying mechanism, is dried in an electric heating hot air spraying mode, and is received through a receiving roller after being dried.
The invention is further configured to: the temperature of the extruder is adjusted to 180 ℃ at the first section, 220 ℃ at the second section, 230 ℃ at the third section, 235 ℃ at the fourth section, 240 ℃ at the die, and the rotating speed of the extruder is 7 Hz.
The invention is further configured to: the temperature of the spinneret plate is adjusted to 238 ℃, the temperature of the air heater is adjusted to 260 ℃, and the rotating speed of the air compressor is 22 Hz.
The invention is further configured to: the conditions of the electret treatment include: the PH value of the alkaline industrial reagent is adjusted to be 5-6, the water quality filtered by a first-stage reverse osmosis membrane in the reverse osmosis membrane filtration reaches the conductivity of 40-45um/s, the water pressure filtered by a second-stage reverse osmosis membrane reaches the conductivity of 4-5um/s, the water pressure of a high-pressure water pump is adjusted to be 2MPa, the temperature of a drying room is set to be 70-90 ℃, and the water content of dried non-woven fabrics is less than 0.02%.
In conclusion, the invention has the following beneficial effects:
(1) the filtering efficiency of the particles is more than or equal to 95 percent, and the expiratory resistance is less than or equal to 45 Pa;
(2) the quality guarantee period of the mask is more than or equal to 3 years.
Detailed Description
The present invention will be described in further detail with reference to examples, but the present invention is not limited to these examples.
Preparation example: manufacturing process of melt-blown fabric
Mainly comprises the following steps:
(1) through the structural modification of the extruder set, the polymer melt flows and simultaneously realizes thermal electret, so that the melt-blown nonwoven material is provided with stable polarization charges.
(2) The controllable preparation of the electret charge quantity and the charge stability is realized by controlling the fiber surface roughness, the crystal structure and the fiber web dimension stability of the melt-blown non-woven material.
(3) The influence rule of the mask surface layer, the inner layer and the outer package on the charge stability of the melt-blown non-woven material of the core layer is proved, and the filtering efficiency and the charging stability of the mask in long-term storage are realized.
(4) And establishing a charge long-acting stability evaluation method.
Specifically, the method comprises the following steps:
s1, generating a melt-blown fabric: selecting electret high-fluidity polypropylene, adding 2% of water electret master batch, melting, blowing out melt-blown non-woven material under the condition of high-temperature and high-pressure gas through an extrusion unit and a die, wherein the electret high-fluidity polypropylene is PP (polypropylene) granules with more than 1000 dissolved fat;
s2, preparing pure water: selecting tap water as a water source, performing sand-stone tank filtration and active carbon filtration on the water source, adding a reverse osmosis agent and hydrochloric acid into the filtered water source, performing reverse osmosis membrane secondary filtration on the water source, automatically detecting and adding an alkaline industrial reagent into the filtered water source, and completing pure water preparation through pure water equipment;
s3, water electret procedure: s4, drying: specifically, a water electret method, step one, melt-blown production; selecting polypropylene granules as raw materials, conveying the raw materials of a polypropylene client to an extrusion machine, ejecting the raw materials extruded by the extruder through a die head spinneret plate, wherein the direction of airflow generated by an air compressor is the same as the ejection direction of the raw materials; step two, water purification equipment; selecting tap water as a water source, performing sand-stone tank filtration and active carbon filtration on the water source, adding a reverse osmosis agent and hydrochloric acid into the filtered water source, performing reverse osmosis membrane secondary filtration on the water source, and automatically detecting to add an alkaline industrial reagent into the filtered water source to finish the preparation of pure water; step three, an electret process; the prepared pure water is conveyed to a fan-shaped nozzle through a high-pressure water pump, the fan-shaped nozzle carries out spunlace penetration on the melt-blown fabric, and charges are generated through friction between the pure water and the non-woven fabric to finish spunlace electret; step four, drying process; the non-woven fabric after being spun-laced and electret is conveyed into a drying room through a conveying mechanism, and is dried in an electric heating hot air spraying mode and then received through a receiving roller.
The production process parameters are as follows: the temperature of the extruder was adjusted to 180 ℃ for the first stage, 220 ℃ for the second stage, 230 ℃ for the third stage, 240 ℃ for the fourth stage, 240 ℃ for the die, and 7Hz for the extruder. The spinneret temperature was adjusted to 238 deg.C, the air heater temperature was adjusted to 260 deg.C, and the air compressor speed was 22 Hz. The conditions of the electret treatment include: the PH value of the alkaline industrial reagent is adjusted to be 5-6, the water quality filtered by a first-stage reverse osmosis membrane in the reverse osmosis membrane filtration reaches the conductivity of 40-45um/s, the water filtered by a second-stage reverse osmosis membrane reaches the conductivity of 4-5um/s, the water pressure of a high-pressure water pump is adjusted to be 2MPa, the temperature of a drying room is set to be 70-90 ℃, and the water content of the dried non-woven fabric is less than 0.02%.
S5, loop feedback adjustment: controlling the fiber surface roughness, the crystal structure and the fiber web size stability of the melt-blown non-woven material by adjusting production process parameters, and realizing the controllable preparation of electret charge quantity and charge stability;
s6, detecting the influence rule of the mask surface layer non-woven fabric, the inner layer non-woven fabric and the outer package on the charge stability of the core layer melt-blown fabric by using a charge testing device, feeding back the influence rule to production, and adjusting the production parameters of the surface layer non-woven fabric, the inner layer non-woven fabric and the outer package to realize the filtering efficiency and the electrification stability of the mask in long-term storage, wherein the production parameters include but are not limited to processing temperature, finished product thickness, layer number, weight percentage and material quality;
s7, establishing a charge long-term stability evaluation record for the finished mask, feeding the charge long-term stability evaluation record back to production, and adjusting production parameters of the surface layer non-woven fabric, the inner layer non-woven fabric and the outer package to realize the filtering efficiency and the charging stability of the mask in long-term storage.
Wherein the number of the water needling channels in the S2 is 2, the water needling pressure is 0.2-0.4Mpa, and the negative pressure is 2. Temperatures of respective zones of the extruder in S2: the temperature of the first area is 150-180 ℃, the temperature of the second area is 180-220 ℃, the temperature of the third area is 220-230 ℃, and the temperature of the fourth area is 230-240 ℃; the temperature of the die head is 230-240 ℃; the temperature of the cross air blow is 260-280 ℃; the speed of the drafting air is 500 to 900 m/s.
Example (b): mask making process
A production process method for improving the quality of a mask comprises the following process steps:
a1, the mask is formed by combining multiple fabrics of a non-woven fabric layer and a melt-blown fabric layer, the melt-blown fabric layer is positioned between the non-woven fabric layers, the multiple fabrics are respectively installed on a discharging mechanism to be discharged, and then are combined and conveyed to nose bridge strip installation equipment;
a2, unwinding the nose bridge strip and the gasket by nose bridge strip mounting equipment, superposing the nose bridge strip and the gasket together, cutting the nose bridge strip and the gasket together, and mounting the nose bridge strip and the gasket between the non-woven fabric layer and the non-woven fabric layer;
a3, two non-woven fabric layers and a middle melt-blown fabric layer are combined into a mask finishing material piece, the edge is primarily pressed and welded through an embossing mechanism, and the mask finishing material piece is primarily fixed;
a4, folding by a folding mechanism to fold the mask sheet along the central line; a5, pressing and welding the folded mask by an embossing mechanism for the second time, and making the folded mask into sheets
Shaping;
a6, cutting the shaped folded mask by a cutting mechanism, and cutting off redundant materials to form a mask sheet;
a7, welding ears on a mask sheet by welding equipment to form a finished mask;
and A8, finally, collecting and storing the finished product mask through a material receiving mechanism.
The above description is only a preferred embodiment of the present invention, and the protection scope of the present invention is not limited to the above embodiments, and all technical solutions belonging to the idea of the present invention belong to the protection scope of the present invention. It should be noted that modifications and embellishments within the scope of the invention may occur to those skilled in the art without departing from the principle of the invention, and are considered to be within the scope of the invention.
Claims (10)
1. A production process method for improving the quality of a mask is characterized by comprising two parts of production processes:
firstly, manufacturing a melt-blown fabric;
s1, generating a melt-blown fabric: selecting electret high-fluidity polypropylene, adding 2% of water electret master batch, melting, and blowing out the melt-blown non-woven material through an extrusion unit and a die under the condition of high-temperature and high-pressure gas;
s2, preparing pure water: selecting tap water as a water source, carrying out sand-stone tank filtration, active carbon filtration and quartz sand filtration on the water source, adding a reverse osmosis agent and hydrochloric acid into the filtered water source, carrying out reverse osmosis membrane secondary filtration on the water source, automatically detecting and adding an alkaline industrial reagent into the filtered water source, and completing pure water preparation through pure water equipment;
s3, water electret procedure: the prepared pure water is conveyed to a fan-shaped nozzle through a high-pressure water pump, the fan-shaped nozzle carries out spunlace injection on melt-blown fabric, charges are generated through friction between water and melt-blown fibers, the melt-blown nonwoven material is provided with stable polarization charges, and spunlace electret is completed;
s4, drying: sucking water on the melt-blown non-woven material by using negative pressure equipment, and drying to obtain melt-blown non-woven material-melt-blown cloth;
secondly, a mask making process;
a1, the mask is formed by combining multiple fabrics of a non-woven fabric layer and a melt-blown fabric layer, the melt-blown fabric layer is positioned between the non-woven fabric layers, the multiple fabrics are respectively installed on a discharging mechanism to be discharged, and then are combined and conveyed to nose bridge strip installation equipment;
a2, unwinding the nose bridge strip and the gasket by nose bridge strip mounting equipment, superposing the nose bridge strip and the gasket together, cutting the nose bridge strip and the gasket together, and mounting the nose bridge strip and the gasket between the non-woven fabric layer and the non-woven fabric layer;
a3, two non-woven fabric layers and a middle melt-blown fabric layer are combined into a mask finishing material piece, the edge is primarily pressed and welded through an embossing mechanism, and the mask finishing material piece is primarily fixed;
a4, folding by a folding mechanism to fold the mask sheet along the central line;
a5, finishing the folded mask, performing secondary impression welding by an embossing mechanism, and shaping the folded mask;
a6, cutting the shaped folded mask by a cutting mechanism, and cutting off redundant materials to form a mask sheet;
a7, welding ears on a mask sheet by welding equipment to form a finished mask;
and A8, finally, collecting and storing the finished product mask through a material receiving mechanism.
2. The production process method for improving the quality of the mask according to claim 1, wherein the production process method comprises the following steps: and in the S2, the number of the water needling channels is 2, the water needling pressure is 0.2-0.4Mpa, and the negative pressure is 2.
3. The production process method for improving the quality of the mask according to claim 1, wherein the production process method comprises the following steps: temperatures of respective zones of the extruder in S2: the temperature of the first area is 150-180 ℃, the temperature of the second area is 180-220 ℃, the temperature of the third area is 220-230 ℃, and the temperature of the fourth area is 230-240 ℃; the temperature of the die head is 230-240 ℃; the temperature of the cross air blow is 260-285 ℃; the speed of the drafting air is 500 to 900 m/s.
4. The production process method for improving the quality of the mask according to claim 1, wherein the production process method comprises the following steps: utilize the electric charge testing arrangement to find out gauze mask surface course non-woven fabrics, inlayer non-woven fabrics and extranal packing to the influence law of sandwich layer melt-blown fabric electric charge stability, feed back in production, the production parameter of adjustment surface course non-woven fabrics, inlayer non-woven fabrics and extranal packing to realize that the gauze mask can be in the filtration efficiency and the electrified stability of long-term storage.
5. The production process method for improving the quality of the mask according to claim 8, wherein the production process method comprises the following steps: the production parameters include, but are not limited to, processing temperature, finished product thickness, number of layers, weight percent, and material quality.
6. The production process method for improving the quality of the mask according to claim 1, wherein the production process method comprises the following steps: and establishing a charge long-term stability evaluation record for the finished mask, feeding the charge long-term stability evaluation record back to production, and adjusting production parameters of the surface layer non-woven fabric, the inner layer melt-blown fabric and the outer package so as to realize the filtering efficiency and the charged stability of the mask in long-term storage.
7. A water electret method is characterized in that:
step one, melt-blown production; selecting polypropylene particles as a raw material, conveying the polypropylene raw material to an extrusion machine, ejecting the raw material extruded by the extruder through a die head spinneret plate, heating the airflow generated by an air compressor in the same direction as that of the ejection of a die by using an air heater, receiving the product ejected by the die head spinneret plate by using a receiving roller, and forming melt-blown cloth after the receiving roller receives the product;
step two, water purification equipment; selecting tap water as a water source, carrying out sandstone tank filtration, activated carbon filtration and quartz sand filtration on the water source, adding a reverse osmosis agent and hydrochloric acid into the filtered water source, carrying out reverse osmosis membrane secondary filtration on the water source, automatically detecting and adding an alkaline industrial reagent into the filtered water source, and completing pure water preparation through pure water equipment;
step three, an electret process; the prepared pure water is conveyed to a fan-shaped nozzle through a high-pressure water pump, the fan-shaped nozzle carries out spunlace penetration on the melt-blown fabric, electric charges are generated through friction between the pure water and the non-woven fabric, and negative pressure absorbs water in the melt-blown fabric to complete spunlace electret;
step four, drying process; and conveying the spunlaced electret melt-blown fabric into an oven through a conveying mechanism, drying by adopting an electric heating hot air spraying mode, and receiving by a receiving roller after drying.
8. A water electret method according to claim 7, wherein: the temperature of the extruder is adjusted to 180 ℃ at the first section, 220 ℃ at the second section, 230 ℃ at the third section, 235 ℃ at the fourth section, 240 ℃ at the die, and the rotating speed of the extruder is 7 Hz.
9. A water electret method according to claim 7, wherein: the temperature of the spinneret plate is adjusted to 240 ℃, the temperature of the air heater is adjusted to 260 ℃, and the rotating speed of the air compressor is 22 Hz.
10. A water electret method according to claim 7, wherein: the conditions of the electret treatment include: the PH value of the alkaline industrial reagent is adjusted to be 5-6, the water quality filtered by a first-stage reverse osmosis membrane in the reverse osmosis membrane filtration reaches the conductivity of 40-45um/s, the water filtered by a second-stage reverse osmosis membrane reaches the conductivity of 4-5um/s, the conductivity of pure water is less than 1um/s, the water pressure of the high-pressure water pump is adjusted to be 2MPa, the temperature of a drying room is set to be 70-90 ℃, and the water content after the meltblown fabric is dried is less than 0.02%.
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| CN113337964A (en) * | 2021-06-03 | 2021-09-03 | 上海盈兹无纺布有限公司 | Processing method of water electret melt-blown fabric |
| CN113699783A (en) * | 2021-09-01 | 2021-11-26 | 浙江普罗斯通医疗器械有限公司 | Sterilization fabric |
| CN113774561A (en) * | 2021-08-19 | 2021-12-10 | 国桥实业(深圳)有限公司 | Melt-blown cloth production process and high-efficiency low-resistance mask |
| CN113981613A (en) * | 2021-10-21 | 2022-01-28 | 上海豆婧环保科技有限公司 | Melt-blown filter material and preparation method thereof |
| CN114108305A (en) * | 2021-11-25 | 2022-03-01 | 青岛华世洁环保科技有限公司 | Water electret meltblown fabric and preparation method and application thereof |
| CN114232208A (en) * | 2021-12-27 | 2022-03-25 | 浙江蓝禾医疗用品有限公司 | Production process of super-breathable melt-blown non-woven fabric |
| CN115486597A (en) * | 2022-09-14 | 2022-12-20 | 河南省超亚医药器械有限公司 | Medical mask with low resistance and high air permeability |
| WO2023138144A1 (en) * | 2022-01-24 | 2023-07-27 | 华南理工大学 | Recyclable electret filtering membrane, preparation method therefor and cleaning and charge regeneration method therefor |
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