JP7045469B2 - Hygroscopic non-woven fabric and its manufacturing method - Google Patents

Description

Detailed description of the invention

The present invention relates to a hygroscopic nonwoven fabric having excellent hydrophilicity and a method for producing the same. More specifically, the present invention has excellent hydrophilicity and good productivity by using a masterbatch having hydrophilicity that can be inexpensively produced by using a specific compound. The subject is a hygroscopic non-woven fabric and a method for producing the same.

In general, a non-woven fabric is a sheet or web in which textile fibers are arranged side by side in a certain direction or randomly arranged and bonded, and the raw material of these fibers is natural or artificial. .. These fibers consist of staple fibers or artificial filaments, and the manufacturing processes and methods of such non-woven fabrics are widely known, but these manufacturing processes are broadly divided into web formation, adhesion and finishing. Can be done. Among such non-woven fabrics, spunbonded non-woven fabrics made of polypropylene have excellent properties such as economy, light weight, moldability, chemical resistance, and beautiful appearance, thereby making sanitary materials and home appliances. , OA equipment packaging materials, automobile built-in materials, disposable work clothes, and other miscellaneous goods, and in particular, are widely used in hygiene products such as diapers.

However, since polypropylene fibers generally have strong hydrophobicity in polypropylene spunbonded non-woven fabrics having excellent properties as described above, they can be used as industrial non-woven fabrics and sanitary products that require hydrophilicity such as diapers. There is a problem that the application application is very limited.

Therefore, in order to solve the above-mentioned problems of the polypropylene spunbonded nonwoven fabric, a method of applying a surfactant to the nonwoven fabric has been proposed, but the nonwoven fabric produced by such a method is charged with water several times. At times, there is a problem that the surfactant is washed away and the hydrophilicity tends to be inferior. Further, when the surfactant is applied, it is applied to the entire non-woven fabric layer, so that there is a problem that it is difficult to separately realize the hydrophilic / hydrophobic non-woven fabric layer.

From this, there has been a proposal for solving the above-mentioned problem of durability of the hydrophilic non-woven fabric. For example, in Korean Patent Publication No. 2001-0019669 (Patent Document 1), a composite fiber having improved durability and hydrophilicity has been proposed. As the name, "a composite fiber in which a low melting point polymer component having a melting point difference of 20 ° C. or higher and a high melting point polymer component are combined and the low melting point polymer component occupies at least a part of the fiber surface is durable to the low melting point polymer component. It is characterized in that polyethylene glycol having a molecular weight of 600 to 20,000 as a hydrophilicity-imparting component is blended in a content of 1 to 15 weight by weight with respect to a low melting point polymer component and 1.5 to 5 weight by weight with respect to the total fiber weight. "Composite fibers with improved durability and hydrophilicity" are disclosed, and Japanese Patent Publication No. 2003-201670 (Patent Document 2) discloses "hydrophilic long fiber non-woven fabrics, composite non-woven fibers and absorbency using these." As the name of "article", a non-woven fabric having 0.1 to 2.0% by weight of a hydrophilic oil adhering to the weight of the long-fiber non-woven fabric is disclosed. However, when only polyethylene glycol is added to the low melting point polymer component as in the method presented in Patent Document 1, it takes more than one week for the hydrophilic performance to be exhibited by the migration phenomenon of the hydrophilic solid content. There is such a problem, and Patent Document 2 merely discloses that the hydrophilizing oil agent is added to the long fiber nonwoven fabric at a constant ratio. Therefore, in order to solve the problems of the invention disclosed in the patent document, the applicant has stated in Korean Patent Publication No. 2013-0005478 (Patent Document 3) that it has excellent durability against changes in the external climate. In order to provide a hydrophilic non-woven fabric that has a Disclosed is a hydrophilic non-woven fabric having excellent durability against changes in the external climate, which is characterized by the above-mentioned results. However, when the nonionic hydrophilic surfactant of Patent Document 3 is applied, there still arises a problem that the hydrophilic performance deteriorates when stored in a high temperature environment of 40 ° C. or higher for 1 year or longer. , A solution to this is required.

Therefore, an object of the present invention is to solve the problems with the nonwoven fabrics based on the background to the problems with the nonwoven fabrics conventionally manufactured with polypropylene as described above, and the main object thereof is to solve the details. The present invention is to apply a specific master batch type hydrophilic agent to a nonwoven fabric to provide a moisture-absorbing nonwoven fabric having excellent durability and absorption.

Another object of the present invention is to provide a method for more easily producing a hygroscopic nonwoven fabric having the above-mentioned characteristics with excellent productivity without generating smoke of a spunbonding facility.

In addition to the above-mentioned explicit purposes, the present invention also aims to achieve such purposes and other purposes that can be easily derived by ordinary persons in the art from such purposes and the general art of the present specification. It can be that purpose.

As a result of diligent research in order to recognize and solve the above-mentioned conventional problems, the present inventors have made a hydrophilic non-woven fabric without using a conventional Kiss roll type hydrophilic treatment method. Since a non-woven fabric is manufactured by providing a master batch type hydrophilic agent having a specific composition in a certain manner, it becomes possible to provide a non-woven fabric having improved durability and absorbability compared to conventional products. We have found a moisture-absorbing nonwoven fabric that can satisfy the customer's demand for a nonwoven fabric having excellent hydrophilicity and durability for agricultural use and a manufacturing process thereof, and have been able to achieve the above-mentioned object of the present invention.

The moisture-absorbing non-woven fabric of the present invention for achieving the above-mentioned object is a long fiber spunbonded non-woven fabric in which a polymer of a polyolefin base material is spun to form a web on a continuous belt and heat-bonded to the long-fiber spunbonded non-woven fabric. At room temperature with a scanning calorimeter (DSC), the temperature is raised to 300 ° C by 10 ° C per minute, and the melting temperature (Melting Polymer) is 40 to 80 ° C, 100 to 140 ° C, and 141 to 180 ° C. It is characterized in that it is produced by melt-kneading a hygroscopic master batch having all peaks in the range after adding 1 to 20% of the weight of the non-woven fabric.

According to another configuration of the present invention, the hygroscopic masterbatch comprises one or more selected from the group consisting of cationic, anionic, or nonionic surfactants.

According to another configuration of the present invention, the hygroscopic masterbatch is characterized by containing an alkyl-based (CnH _{2n + 1} ) surfactant.

According to still another configuration of the present invention, the content of the components excluding polypropylene in the hygroscopic masterbatch is 10 to 50% by weight.

According to still another configuration of the present invention, the components of the hygroscopic masterbatch excluding polypropylene are contained in a content of 1,000 ppm to 100,000 ppm based on the total weight of the nonwoven fabric. It is a feature.

According to still another configuration of the present invention, the polyolefin system is characterized in that it is at least one selected from the group consisting of polypropylene and polyethylene.

According to still another configuration of the present invention, the component in the hygroscopic masterbatch is characterized by containing one or more from the group consisting of alkyl-based (CnH _{2n + 1} ) surfactants.

According to still another configuration of the present invention, the alkyl-based (CnH _{2n + 1} ) surfactant is a group consisting of an alkyl alcohol (alkyl alcohol), an alkyl stearate, and an alkyl palmitate. It comprises one or more selected from, and is characterized by optionally further comprising stearin.

According to still another configuration of the present invention, the substance of the alkyl alcohol (Alkyl alcohol) is di (ethylene glycol) nonadecyl ether or ethylene glycol heneicosil ester. It is characterized by having one or more selected from ester).

According to still another configuration of the present invention, the nonwoven fabric is characterized in that the nonwoven fabric using the hygroscopic masterbatch constitutes a single layer or a multilayer of 2 to 6 layers.

Disposable diaper surface sheet (Top Sheet), back sheet (back Sheet), core sheet (Core sheet), agricultural and household materials and lids using the non-woven fabric of the present invention to achieve the above-mentioned other purposes. Is characterized by using the above-mentioned long fiber non-woven fabric having excellent hygroscopicity according to the present invention.

In the method for producing a moisture-absorbing nonwoven fabric of the present invention for achieving still the above-mentioned other object, a polymer of a polyolefin base material is spun to form a web on a continuous belt, and a web is formed by heat-adhesive bonding to form a long fiber spunbond. A method for producing a nonwoven fabric is characterized in that a hygroscopic masterbatch is added to the polymer in an amount of 1 to 20% of the weight of the nonwoven fabric, and then melt-kneaded and spun.

The moisture-absorbing non-woven fabric of the present invention and the method for producing the same, which are configured as described above, provide a specific hygroscopic agent master batch to manufacture the non-hydraulic material. In addition to being able to add hydrophilicity, it is possible to produce moisture-absorbing non-woven products without the need for additional equipment, and without the generation of smoke from spunbond equipment even on lines that do not have hydrophilic equipment in conventional equipment lines. It is an industrially useful invention that enables the development of semi-moisture-absorbing non-woven fabrics in the hydrophobic / hydrophilic form in the future.

FIG. 1 is a DSC graph for a hygroscopic agent masterbatch used in the production of a hygroscopic nonwoven fabric according to an embodiment of the present invention.

Hereinafter, the present invention will be described in more detail with reference to preferred embodiments, but the present invention is not limited to the following embodiments, and it goes without saying that the present invention can be variously modified and carried out within the scope of the gist thereof. Also, in the detailed description, well-known components, well-known behaviors and well-known techniques are not specifically described in order to avoid vague understanding of the present invention.

The terms used herein are for purposes of describing embodiments and are not intended to limit the invention. As used herein, the singular type also includes plural types unless otherwise specified in the text. Also, the components and actions referred to as "contains (or comprises)" do not preclude the existence or addition of one or more other components and actions.

As used in the present invention, the term "nonwoven fabric" means a web of fibers or filaments formed by means other than knitting or weaving and containing bonds between some or all of the fibers or filaments, such as Bonds can be formed by thermal, adhesive or mechanical means, such as entanglement. Normal non-woven is formed by spunbonding, melt blowing, carding, wet laying and air laying processes.

As a term generally used in the present invention, the term "spun bond" means that a filament spun by an extruder is stretched, laminated on a conveyor, and the laminated webs are bonded by a calendar roll or the like. It means the method of manufacturing.

As a term generally used in the present invention, the above-mentioned "migration" phenomenon means that a polymer substance applied to the surface of a non-woven fabric is placed in another place or inside a fiber due to an external medium or its own fluidity. It means the phenomenon of moving.

In the moisture-absorbing nonwoven fabric of the present invention and the method for producing the same, the conventional hydrophilic nonwoven fabric is a kiss-roll type, in which a water-soluble hydrophilic agent is immersed in water and then attached to a roll to impart the hydrophilic agent to the nonwoven fabric. However, in the present invention, a master batch type hygroscopic material is melt-spun to improve durable hydrophilicity and enable the production of a hydrophilic nonwoven fabric without hydrophilic agent equipment.

The moisture-absorbing non-woven fabric according to a preferred embodiment of the present invention is a long fiber spunbonded non-woven fabric in which a polymer of a polyolefin base material is spun to form a web on a continuous belt and heat-bonded, and the non-woven fabric has a differential scanning calorimetry. At room temperature, the temperature is raised to 300 ° C by 10 ° C per minute with a meter (DSC), and the melting temperature (Melting Temperature) is in three temperature ranges of 40 to 80 ° C, 100 to 140 ° C, and 141 to 180 ° C. It is characterized in that a hygroscopic master batch composed of three peaks having all peaks is added by 1 to 20%, preferably 1 to 10% by weight of the non-woven fabric, and then melt-kneaded. Through this, the present invention is advantageous in effectively achieving the object. If the temperature has peaks in different ranges or if it is not one of the three peaks, agglutination phenomenon of raw materials may occur or a large amount of smoke may be generated during the process. Absorption rate due to hunting of internal pressure in the ruder or volatilization of hydrophilic groups may be difficult to develop.

According to a preferred embodiment of the present invention, the hygroscopic master batch according to the present invention may contain any one or more selected from the group consisting of cationic, anionic, or nonionic surfactants, and is preferable. May contain an alkylalcohol-based surfactant. As described above, since the hygroscopic masterbatch according to the present invention is used, the durability and hydrophilicity are remarkably excellent, and the spinnability and initial inputability are good, so that the productivity is improved in the manufacturing process and troubles occur. The outbreak was eliminated.

According to a preferred embodiment of the present invention, the content of the components excluding polypropylene in the hygroscopic masterbatch can be 10 to 50% by weight, more preferably 30 to 50% by weight, and most preferably 40% by weight. If it is out of the above range, it causes smoke generation and deterioration of hydrophilicity performance, which is not preferable. In particular, when the content of the components excluding polypropylene in the hygroscopic masterbatch was 40% by weight, remarkably excellent durable hydrophilicity and productivity were exhibited.

According to still another preferred embodiment of the present invention, the components of the hygroscopic masterbatch excluding polypropylene based on the total weight of the nonwoven fabric may be contained in a content of 1,000 ppm to 100,000 ppm.

According to still another preferred embodiment of the invention, the polyolefin-based can be any one or more selected from the group consisting of polypropylene and polyethylene.

According to still another preferred embodiment of the present invention, the alkyl-based (CnH _{2n + 1} ) surfactant which is a component in the hygroscopic agent master batch is an alkyl alcohol or an alkyl stearate. , One or more from the group consisting of alkyl palmitate, and optionally further stearin.

Further, as the alkyl alcohol, one or more selected from di (ethylene glycol) nonadecyl ether or ethylene glycol heneicosyl ester can be used. ..

In the present invention, depending on the characteristics of the nonwoven fabric used for various purposes, the nonwoven fabric using the hygroscopic masterbatch according to the present invention constitutes a single layer of the nonwoven fabric layer or a nonwoven fabric having two to six layers. Can be provided.

The above-mentioned long fiber non-woven fabric having excellent hygroscopicity according to the present invention can be used for various purposes, and is not particularly limited thereto, for example, a disposable diaper surface sheet (Top Sheet), a back sheet (back Sheet). ), Core sheets, agricultural and domestic materials and lids.

Hereinafter, the present invention will be described in more detail with reference to Examples and Comparative Examples. It goes without saying that the following examples are for explaining the present invention in detail and do not limit the scope of the present invention.

<Example 1>
In the method of producing a non-woven fabric, polypropylene and a hygroscopic master batch are transmitted to an extruder at a constant ratio using a Dosing system for measuring raw materials to spin a mixture, and the spun filament is obtained. It was solidified by the cooling air ejected through the honeycomb-shaped chamber, stretched by the pressure of the air blown from the upper part and the air sucked in the lower part of the non-woven fabric belt, and laminated on the non-woven fabric belt with a constant weight to form a web. After that, thermal bonding was performed to produce a non-woven fabric.

The hygroscopic masterbatch used contained 40% by weight of the active ingredient, excluding polypropylene, the active ingredient being composed of di (ethylene glycol) nonadesyl ether and stearin. The hygroscopic masterbatch used had peaks at 60.33 ° C., 119.70 ° C. and 157.30 ° C., respectively, and had a total of 3 peaks, as can be confirmed from the DSC graph in FIG. It was used.

Further, 2.5 parts by weight of the hygroscopic masterbatch was added based on the weight of the non-woven fabric. The characteristics of the produced non-woven fabric were measured, and the results are shown in Table 1 below.

<Example 2>
As shown in Table 1 below, the same procedure as in Example 1 was repeated except that the hygroscopic masterbatch was 3.5 parts by weight based on the weight of the non-woven fabric, and the characteristics of the non-woven fabric were measured. The results are shown in Table 1 below.

<Comparative Example 1>
As shown in Table 1 below, the same procedure as in Example 1 was repeated except that the hygroscopic masterbatch was 0.9 parts by weight based on the weight of the non-woven fabric, and the characteristics of the non-woven fabric were measured. The results are shown in Table 1 below.

<Comparative Example 2>
As shown in Table 1 below, the same procedure as in Example 1 was repeated except that the hygroscopic masterbatch was 22 parts by weight based on the weight of the non-woven fabric, and the characteristics of the non-woven fabric were measured. The results are presented in Table 1 below.

<Experimental example>
1. 1. Absorption degree (strike through, Strike through)
A sample was taken from the non-woven fabric, cut into an appropriate size, and the absorbency of the sample was measured. The size of the sample was 10 cm × 10 cm, and the average value was compared 10 times for each sample. A non-woven fabric sample was prepared, placed on absorbent paper, and then evaluated by the time for absorbing 5 ml of 0.9% NaCl solution. EDANA 150.5-02 was referred to.

2. 2. Rewetting (Re-wet)
A sample was taken from the non-woven fabric, cut into an appropriate size, and the absorbency of the sample was measured. The size of the sample was 10 cm × 10 cm, and the average value was compared 10 times for each sample. After placing the non-woven fabric sample on the absorbent paper, 20 ml of 0.9% NaCl solution was added, a weight of 5 kg was added, and then the amount of liquid reabsorbed was evaluated. EDANA 151.3-02 was referred to.

3. 3. Initial input property The initial input property of the spunbond equipment was evaluated by visually confirming the raw material input property of the hydrophilic master batch (master batch) and judging according to the following criteria.

◯: Excellent initial input. There is no abnormality in masterbatch input.

×: Poor initial input. The masterbatch sticks to the raw material input section. Mutual aggregation phenomenon occurs between raw materials 4. Smoke generation The evaluation of smoke generation in the spunbond facility was made based on 10 points by visually confirming the monomer emission (Monomer exhaust) with a die when the raw material of the hydrophilic masterbatch was charged.

0 point: No smoke is generated.

10 points: A level that cannot be applied to a hydrophilic masterbatch due to the generation of a large amount of smoke.

In the detailed description of the present invention, a preferred embodiment of the moisture-absorbing non-woven fabric and a method for producing the same has been described, but the content thereof is not limited to the content described in the embodiment and is claimed within the following claims. It can be said that the technical spirit of the present invention is to the extent that any person having ordinary knowledge in the field to which the present invention belongs can carry out various changes without deviating from the gist of the present invention.

Claims (7)

In a long fiber spunbonded non-woven fabric in which a polymer of a polyolefin base material is spun to form a web on a continuous belt and heat-bonded.
The non-woven fabric contains a hygroscopic masterbatch with a weight ratio of 1 to 20% of the non-woven fabric and a polymer of the polyolefin base material.
The hygroscopic masterbatch has a total of three peaks when the melting temperature (Melting Temperature) is measured by raising the temperature to 300 ° C. at room temperature by 10 ° C. per minute with a differential scanning calorimeter (DSC). The three peaks have one peak in each of the three temperature ranges of 40-80 ° C, 100-140 ° C and 141-180 ° C.
The hygroscopic masterbatch contains polypropylene, and the content of the components excluding polypropylene is 10 to 50% by weight.
The components excluding polypropylene include an alkyl-based (Cn H _{2n + 1} ) surfactant and stearin.
The alkyl-based (Cn H _{2n + 1} ) surfactant is at least one selected from the group consisting of alkyl alcohols, alkyl stearates, and alkyl palmitates . A moisture-absorbing non-woven fabric that is characterized by its ability. The hygroscopic masterbatch is characterized in that the remaining components of the hygroscopic masterbatch excluding polypropylene are contained in a content of 1,000 ppm to 100,000 ppm based on the total weight of the nonwoven fabric. The moisture-absorbing nonwoven fabric according to claim 1. The hygroscopic nonwoven fabric according to claim 1, wherein the polymer of the polyolefin base material is any one or more selected from the group consisting of polypropylene and polyethylene. The moisture-absorbing nonwoven fabric according to claim 1, wherein the nonwoven fabric using the hygroscopic agent masterbatch constitutes a single layer or a multilayer of 2 to 6 layers. An article using the hygroscopic non-woven fabric according to any one of claims 1 to 4 . The article according to claim 5 , wherein the article is a disposable diaper surface sheet (Top Sheet), back sheet (back Sheet), core sheet (Core sheet) or agricultural and domestic materials . In a method of spinning a polymer of a polyolefin substrate to form a web on a continuous belt and heat-bonding to produce a long fiber spunbonded nonwoven fabric.
After adding 1 to 20% of the weight of the non-woven fabric to the polymer, melt-knead and spin .
The hygroscopic masterbatch has a total of 3 peaks when the melting temperature (Melting Temperature) is measured by raising the temperature to 300 ° C. at room temperature by 10 ° C. per minute with a differential scanning calorimeter (DSC), and the total of 3 peaks. The peaks have one peak in each of the three temperature ranges of 40-80 ° C, 100-140 ° C and 141-180 ° C.
The hygroscopic masterbatch contains polypropylene, and the content of the components excluding polypropylene is 10 to 50% by weight.
The components excluding polypropylene include an alkyl-based (Cn H _{2n + 1} ) surfactant and stearin.
The alkyl-based (Cn H _{2n + 1} ) surfactant is at least one selected from the group consisting of an alkyl alcohol, an alkyl steaterate, and an alkyl palmitate. A method for producing a moisture-absorbing non-woven fabric.

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