KR101280354B1 - Manufacturing method of kapok-based nonwoven fabric complex and kapok-based nonwoven fabric complex thereby - Google Patents

Abstract

PURPOSE: A manufacturing method of kapok complex non-woven fabric is provided to be excellent in being absorbent, tensil strength and fracture strength and 10-40N/5cm of fracture strength in MD direction, 50-150N/5cm in CD direction and 5-15kgf of fracture strength. CONSTITUTION: A manufacturing method of kapok complex non-woven fabric comprises the following steps. kapok fiber and thermoplastic polymer material fiber are mixed to manufacture a web by carding process. The web is cross-wrapped. The cross-wrapped web is glued. The thermoplastic polymer is a group from polyethylene, polypropylene, polyethylene terephthalate, nylon and their conjugate yarn. [Reference numerals] (A1) Example 1; (A2) Example 2; (A3) Example 3; (A4) Example 4; (A5) Example 5; (A6) Example 6

Description

Manufacturing method of KPOP composite nonwoven fabric and KPOP composite nonwoven fabric manufactured therefrom {MANUFACTURING METHOD OF KAPOK-BASED NONWOVEN FABRIC COMPLEX AND KAPOK-BASED NONWOVEN FABRIC COMPLEX THEREBY}

The present invention relates to a method for manufacturing a kapok composite nonwoven fabric and a kapok composite nonwoven fabric produced therefrom, and more particularly, by integrating kapok fibers with fibers of a thermoplastic polymer and cross-lapping a web obtained by carding, and then bonding the kapok fiber inherent. The present invention relates to a method for producing a kapok composite nonwoven fabric having not only sound absorbing properties and oil absorption properties but also excellent strength not expected from a kapok nonwoven fabric obtained by a conventional manufacturing method, and a kapok composite nonwoven fabric produced therefrom.

Kapok fiber is a seed hair fiber of kapok tree, and its origin is Malaysia, and is mainly produced in Hawaii, Java, Philippines, Taiwan, and the like. The kapok fibers are hollow natural fibers having a fiber length of 8 to 32 mm, a thickness of 30 to 35 μm, and a circular to oval cross section. The kapok fiber is characterized by its hollow shape, has a low density of 0.30 g / cc, and is about 1/5 of the light weight of cotton (density 1.54 g / cc), and is light and elastic in addition to gloss like silk. . In addition, it is a natural fiber that has a wool-level insulation and other characteristics such as sound absorption, oil absorption, antibacterial, deodorant, far-infrared radiation, etc., and is being developed.

However, since the kapok fiber has a short fiber length and a thin cell wall and can be easily cut during carding and the like, its use is limited to furniture, bedding fillers, and life preserver fillers. In addition, efforts have been made in various ways to manufacture kapok fibers with nonwoven fabrics and utilize them as thermal insulation, sound absorption and oil absorption materials.

For example, Patent Document 1 discloses a sound absorbing material using kapok fibers. However, the sound absorbing material is only filled with the kapok fibers in a porous material without any processing.

Patent Document 2 discloses an example in which a nonwoven fabric prepared by blending a kapok fiber and a PP fiber in a 1: 1 manner is manufactured and used for removing oil. A sound absorbing material is disclosed. However, the nonwovens still cannot be seen as a complete solution to problems such as fiber cutting and scattering during the use of kapok fibers, and because there is no adhesive force between the kapok fibers, there is a problem that the shape stability of the manufactured nonwoven fabrics is poor. It's still going on.

U.S. Patent 6,338,395 Republic of Korea Patent Publication No. 2009-117136 Republic of Korea Patent Publication No. 2006-13468

The object of the present invention is not only the sound absorption and oil absorption inherent to the kapok fiber, but also conventional manufacturing by cross-lapping and bonding the kapok fiber and the fiber of the thermoplastic polymer material by mixing and carding the kapok fiber and the fiber of the thermoplastic polymer. The present invention provides a method for producing a new kapok composite nonwoven fabric capable of obtaining a kapok composite nonwoven fabric having excellent strength that cannot be expected from a kapok nonwoven fabric obtained by the method.

Another object of the present invention is to provide a kapok composite nonwoven fabric produced from the manufacturing method.

Method for producing a kapok composite nonwoven fabric of the present invention for achieving the above object is a first step of forming a web by mixing and then carding the fibers of the kapok fiber and the thermoplastic polymer material; A second step of cross lapping the web; And a third step of adhering the cross-wrapped web.

The thermoplastic polymer material is preferably at least one selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, nylon, and composite yarns thereof. More preferably, the herbicidal composite yarn is used.

The thermoplastic polymer material is preferably short fibers having an average fiber length of 30 to 60 mm.

The blending ratio of the kapok fibers and the fibers of the thermoplastic polymer material is preferably 1:99 to 80:20, more preferably 40:60 to 80:20 in weight ratio.

The means of adhesion is preferably at least one selected from the group consisting of needle punching, thermal bonding and spunracing.

The adhesion may be achieved by performing needle punching and thermal bonding in sequence.

The thermal bonding may be achieved by sequentially performing belt laminating and calendering.

The kapok composite nonwoven fabric prepared according to the present invention has excellent sound absorption and oil absorption properties inherent to kapok fibers, and has a MD direction tensile strength of 10 to 40 N / 5 cm; CD direction tensile strength is 50 to 150N / 5cm; Burst strength has excellent properties of 5 to 15 kgf.

1 is a graph showing the results of evaluating sound absorption of composite nonwoven fabrics prepared in Examples and Comparative Examples.
FIG. 2 is a graph illustrating oil absorption evaluation results for composite nonwoven fabrics prepared in Examples and Comparative Examples. FIG.
3A to 3F are photographs of the results of measuring the water contact angle of the composite nonwoven fabrics prepared in Examples 1 to 6, respectively, and FIG. 3G is the water contact angle of the composite nonwoven fabrics prepared in Examples and Comparative Examples. This is a graph of the measurement results.
4A and 4B are graphs showing tensile and burst strengths of composite nonwoven fabrics prepared in Examples and Comparative Examples, respectively.
5A to 5D are surface SEM photographs of the composite nonwoven fabrics prepared in Examples 1, 2, 3, and 5, respectively, in order.

The method of manufacturing a kapok composite nonwoven fabric of the present invention comprises a first step of forming a web by mixing and then carding the kapok fiber and the fiber of a thermoplastic polymer material; A second step of cross lapping the web; And a third step of adhering the cross-wrapped web.

[Step 1]

In the manufacturing method of the present invention, the first step is a web forming step.

The kapok fiber used in the blend is a natural fiber obtained from the fruit of the kapok tree (Ceiba pentantra), and its shape is hollow, low specific gravity and sound absorption. Also called Java fiber, the main origin of the kapok tree is Java, Sumatra, India, Thailand and the like. The kapok fiber may be used as it is naturally collected fibers, bile fibers cut to the required length may be used.

However, the kapok fiber has a high hollow ratio of 70% or more naturally and is easily broken by an external force, and also does not have a crimp, so that the carding characteristics of the fibers connected to each other during carding are poor. Therefore, there is a problem in that it is difficult to obtain a web by using a nonwoven fabric made of only 100% kapok fibers. In the present invention, the kapok fibers and the fibers of the thermoplastic polymer material are mixed and then carded to form a web. That is, according to the manufacturing method of the present invention, the mixing of the kapok fiber and the fiber of the thermoplastic polymer material has not only an increase in strength of the composite nonwoven fabric produced, but also an additional advantage of improving carding properties.

There is no particular limitation on the fibers of the thermoplastic polymer material mixed with the kapok fibers for this purpose. Preferably, a composite yarn obtained from polypropylene, polyethylene terephthalate, nylon or a combination thereof having good adhesion to a hydrophobic kapok material is used. More preferably, at a certain temperature, a part is melted to bond with the kapok fiber, and a part of the other part that is not fused is used in the form of a deep sheath-type composite yarn that maintains the shape of the fiber to preserve strength. Composite yarns used for this purpose include, for example, PP / PE composite yarns and LM-PET.

The thermoplastic polymer material is preferably short fibers having an average fiber length of 30 to 60 mm. If the length of the short fibers does not reach 30mm, it is not preferable because the strength of the adhesion decreases due to adhesion problems, and if the length of the short fibers exceeds 60mm, a problem occurs in the dispersion of the fibers, thereby decreasing the uniformity of weight and thickness of the nonwoven fabric. There is a problem.

In the horn fiber, the method is not particularly limited, and methods known in the art may be used. However, the blending ratio of the kapok fiber and the fiber of the thermoplastic polymer material is preferably 1:99 to 80:20 in weight ratio, and more preferably 40:60 to 80:20. The weight ratio of the kapok fiber can be appropriately adjusted according to the desired physical properties in the range exceeding 1%. However, when the weight ratio of the kapok material at the time of blending exceeds 80% by weight, there is a problem in that the carding property is poor and the web formation is not smooth.

The blend is formed into a web after a carding process using a carding machine. Carding is a process by which interwoven fiber aggregates are evenly paralleled to a certain level, forming a thin web. The shape of the web obtained through the carding is a sliver in a thin film form, in which fiber assemblies are arranged in the machine direction by wires of the carding machine and connected to each other between the constituent fibers.

There is no particular limitation on the carding method available in the carding process of the present invention. For example, a carding method known in the art such as a roller card, a flat card, and a union card may be used.

The shape of the web obtained through the carding is connected to each other between the constituent fibers while the fiber assemblies are arranged in the machine direction by the wires of the carding machine to have a thin film-like sliver state.

[Step 2]

In the method for producing a composite nonwoven fabric according to the present invention, the second step is to cross-wrap the formed web.

The web formed through the carding machine in the first step is large in volume but very low in density. Therefore, when it is bonded as it is, the nonwoven fabric produced is too thin to reach the target weight. Therefore, cross-lapping of the webs as necessary to each other in accordance with the target weight of the nonwoven fabric is essential.

[Step 3]

The cross-wrapped web is finally bonded in a third step to produce a kapok composite nonwoven fabric. In this case, the means for adhesion may be one or more selected from the group consisting of needle punching, heat bonding and spun lacing.

Needle punching is a method of physically bonding the web through needling. In the case of needle punching, physical properties increase up to a certain level of sedimentation density, but thereafter, physical properties may decrease. Conventional needle punching is weakly bonded by pre-punching and then strongly bonded by main punching. In the present invention, because of the hollow properties of the kapok fiber, it is preferable that the kapok fiber can be easily broken by needling, so that punching is performed at relatively low conditions.

As another adhesive means applicable in the third step of the present invention, a spunlacing method may be used. Spunracing is a method of using a high pressure water jet to induce physical entanglement between interlayers of web stacks and / or fibers within webs.

Thermal bonding is a method of bonding a kapok fiber and a thermoplastic polymer fiber by applying heat above the glass transition temperature or melting point of the thermoplastic polymer material. The temperature and method of the thermal bonding may vary depending on the type of thermoplastic polymer fiber. For example, in the embodiments of the present invention using PP / PE or LM-PET as the thermoplastic polymer fiber, thermal bonding was performed by a method of belt laminating at 200 ° C., but is not necessarily limited thereto.

As a means of heat bonding, preferably only belt laminating alone; Alternatively, belt laminating and calendering may be used sequentially.

Belt laminating is a means for bonding the fibers between the laminated webs and the inside of the web while placing the web to be thermally bonded between two heating belts. It is a suitable means for the thermal bonding method in the nonwoven fabric manufacturing method of the present invention having a large volume of the web formed by cross lapping.

On the other hand, calendaring is a means for bonding fibers between and within the laminated web by heating and pressing while passing the web between two rotating heating rollers. In the case of calendering, the process is performed under conditions of high pressure as compared to belt laminating.

In the case of belt laminating, it is a means for applying heat by fixing between two upper and lower belts, while calendering has the advantage of being able to pressurize simultaneously with heating. However, since the cross-laminated web laminate obtained as an intermediate product in the manufacturing method according to the present invention is bulky, when the thermal bonding is performed by performing only calendering, a phenomenon in which a part is pushed out is not smoothly introduced between rolls, It becomes the cause of the thickness defect of the finally obtained composite nonwoven fabric. Therefore, in the case of using calendering as a means of thermal bonding according to the present invention, it is preferable to reduce the thickness of the cross-laminated web laminate to a predetermined level by belt laminating in advance and then perform the calendering sequentially.

Hereinafter, the present invention will be described in more detail with reference to Examples. This is for explaining the present invention more specifically, but the scope of the present invention is not limited to these Examples.

One. Example  And Comparative example

1.1. material

The kapok fiber used in this study is Java Java, Indonesia with an average fiber length of about 18 mm and a diameter of 20 to 25 ㎛. The following bicomponent composite yarn short fibers were used to prepare a kapok composite nonwoven fabric by a dry process using kapok fiber as a main raw material. LM-PET (low melt-PET, Huvis Co., Ltd.) with a fineness of 4 denier and 51 mm of fiber length, and PP / PE (Hubis Co., Ltd.) short fiber of 38 mm of fineness are used.

1.2. Nonwoven fabric manufacturing

For the preparation of the kapok composite nonwoven fabric, the mixing ratio of the kapok fiber and the sheath / core bi-component fiber was mixed at 5/5 and 7/3. PP / PE or LM-PET fibers were used as the myocardial bicomponent fibers.

After the opening of the mixed fibers (opening) process proceeds to form a web using a carding machine.

After the cross-lapping process to match the web to the target weight, the weight of the web was overlapped to control the weight, and the cross-lapping web was bonded through a process such as needle punching, heat bonding, calendering, and the like. Nonwoven fabrics were prepared. The blending ratio and bonding method of the fibers are shown in Table 1 below.

Furtherance Mixing ratio Weight (g / m ² ) Coupling method Example 1 K-width / LM 5/5 80 BL Example 2 K-width / LM 5/5 130 NP + BL Example 3 K-width / LM 5/5 80 NP + BL Example 4 K-width / LM 7/3 100 BL Example 5 K width / (PP / PE) 5/5 100 NP + BL + CA Example 6 K width / (PP / PE) 7/3 150 BL + CA

BL: Belt-laminating. Belt laminating was performed by applying heat while maintaining a temperature of 1 mm and a temperature of 200 ° C. between the belts.

NP: Needle Punching. Needle punching was weakly primary punched at 100 ~ 300 times / min, and then strongly punched by secondary punching at 500 ~ 900 times / min.

CA: Calendering. Calendering was pressed between two heating rollers to form a nonwoven fabric. The distance between the two rollers was 0.6 mm, the heating temperature was 120 ° C., and the pressure was 45 kgf / cm ² .

2.1 Sound absorption characteristics

2.1.1 Evaluation Method

Sound absorption evaluation is measured in the range of 400 ~ 5,000 Hz using a sound absorption tester (01dB), the experiment is in accordance with the KS F 2814 standard.

2.2.2 Evaluation Results

In order to compare the sound absorption characteristics of the KPOP composite nonwoven fabric, PET hollow fiber (Woongjin Chemical) was selected, and the test analysis was conducted under the same conditions as the KPOP nonwoven fabric after manufacturing the nonwoven fabric.

Sound absorption performance analysis results are summarized in Table 2 and FIG. In Table 2 and FIG. 1, the change of the sound absorption coefficient according to the frequency change was examined, and 1k, 2k, 3.15k and 5k are sound absorption coefficients measured at 1000, 2000, 3150 and 5000 Hz, respectively. .

Referring to Table 2 and Figure 1, the sound absorption coefficient was increased as the frequency was increased, the sound absorption performance according to the kapok fiber content was not significantly different. The sound absorption characteristics at 5000Hz were about 46% higher than the nonwoven fabric composed of PET hollow fiber and binder. From this, it was confirmed that the composite nonwoven fabric prepared according to the present invention can effectively absorb sound waves as compared to the conventional PET hollow fiber.

Furtherance Mixing ratio Sound absorption characteristics 1k 2k 3.15k 5k Example 1 K-width / LM 5/5 0.05 0.11 0.19 0.31 Example 2 K-width / LM 5/5 0.05 0.10 0.18 0.31 Example 3 K-width / LM 5/5 0.05 0.11 0.20 0.35 Example 4 K-width / LM 7/3 0.04 0.09 0.17 0.29 Example 5 K width / (PP / PE) 5/5 0.08 0.09 0.15 0.25 Example 6 K width / (PP / PE) 7/3 0.04 0.09 0.16 0.25 Comparative example PET-hollow - 0.05 0.10 0.15 0.24

2.2 Oil absorption characteristics

2.2.1 Evaluation method

According to the KS K 1600 oil adsorption cloth test method, cut each test piece into 10x10cm size, soak it in light oil and hydraulic oil, leave it for 5 minutes, take it out, leave it for 5 minutes, and measure the weight. Was evaluated to evaluate the oil absorption characteristics.

2.2.2 Evaluation Results

In order to compare the oil adsorption characteristics of the manufactured KPOP composite nonwoven fabric, a polyolefin melt blown material which is generally used as an oil adsorbent is selected, and a bulky PP melt blown nonwoven fabric having the same weight as that of the KPOP nonwoven fabric is selected. The test analysis was carried out under the conditions.

The oil absorption evaluation results are summarized in Table 3 and FIG. 2. As a result of measuring the hydraulic oil adsorption amount, as shown in Table 3 and FIG. 2, the PP melt blown material adsorbed 27.5 times its own weight, whereas the kapok nonwoven fabric adsorbed the oil up to 44 times or more. Compared to the PP melt blown, the kapok composite nonwoven fabric had much better oil adsorption, which is believed to adsorb a large amount of oil due to its lightness due to the lipophilic and hollow properties of the kapok fiber. From the above evaluation results, it was confirmed that the kapok composite nonwoven fabric can be applied to the oil adsorption cloth.

Furtherance Mixing ratio Adsorption amount (times) Diesel Hydraulic oil Example 1 K-width / LM 5/5 25.7 33.8 Example 2 K-width / LM 5/5 35.8 44.3 Example 3 K-width / LM 5/5 24.4 27.7 Example 4 K-width / LM 7/3 30.5 35.7 Comparative example PP melt blown - 20.5 27.5

2.3. Oil and Water Separation Characteristics

2.3.1 Evaluation method

The contact angle was measured using a drop shape analysis system (DSA 100) to indirectly evaluate the oil-water separation characteristics. Drop volume (Dosing volume) was set to 2ul.

2.3.2 Evaluation Results

The contact angle evaluation results are summarized in Table 4 below, and FIGS. 3A to 3F are photographs of the results of measuring the water contact angle 0 of the composite nonwoven fabrics prepared in Examples 1 to 6, respectively, and FIG. It is a graph showing the water contact angle measurement results for the composite nonwoven fabrics produced in the comparative examples. Referring to Table 4 and Figures 3a to 3g, as a result of the contact angle measurement, PP melt blown is known to be excellent in water repellency was 127 ° and the kapok nonwoven fabrics can be confirmed that all of the 129 ° or more compared to the PP melt blown. In particular, Example 4 and Example 6 containing a lot of kapok was measured at 140 ° or more was evaluated as having a super water repellency. This is believed to be due to the hydrophobicity and lipophilic properties of kapok fibers.

Due to such water repellent properties, it is expected that KPOP composite nonwoven fabrics can be applied as oil-separated materials.

Furtherance Mixing ratio weight Coupling method Contact angle (°) Example 1 K-width / LM 5/5 80 BL 129.1 Example 2 K-width / LM 5/5 130 NP + BL 136.0 Example 3 K-width / LM 5/5 80 NP + BL 140.9 Example 4 K-width / LM 7/3 100 BL 150.9 Example 5 K width / (PP / PE) 5/5 100 NP + BL + CA 132.4 Example 6 K width / (PP / PE) 7/3 150 BL + CA 146.2 Comparative example PP melt blown - - - 127.0

2.4 strength

2.4.1 Evaluation Method

The tensile strength of the sample was measured using UTM equipment according to KS K ISO 9073-3 (Textile-Non-Woven Test Method-Part 3-Tensile Strength and Elongation Measurement). Samples were prepared at 5 × 25 cm and clamped at 20 cm, clamping speed of 100 mm / min to obtain results.

The bursting strength was measured by the bursting strength test method (ball bursting method) of KS K 0350 fabric.

2.4.2 Evaluation Results

Tensile strength and burst strength evaluation results are summarized in Table 5, Table 6, Figures 4a and 4b. Referring to these, in the case of the kapok composite nonwoven fabric produced by wet-laid, the bond strength between the constituent fibers is weak, and the morphological stability of the nonwoven fabric is reduced, so that the tensile strength is difficult to measure, but the kapok composite nonwoven fabric manufactured by the dry process is a sound absorbing material. It can be seen that it has strength that can be used for oil adsorption cloth and oil separation.

In the case of the bursting strength, the value of Example 3 was determined to be two or more times higher than that of Comparative Example 1 prepared by the wet process.

Furtherance Mixing ratio weight The tensile strength
(N / 5cm) MD CD Example 1 K-width / LM 5/5 80 21.49 63.85 Example 2 K-width / LM 5/5 130 32.48 75.40 Example 3 K-width / LM 5/5 80 31.20 57.15 Example 4 K-width / LM 7/3 100 34.92 127.95 Example 5 K width / (PP / PE) 5/5 100 29.60 57.3 Example 6 K width / (PP / PE) 7/3 150 19.99 75.90

Furtherance Mixing ratio weight Burst Strength (kgf) Example 1 deflation K-width / LM 5/5 80 6.27 Example 2 deflation K-width / LM 5/5 130 14.36 Example 3 deflation K-width / LM 5/5 80 7.95 Example 4 deflation K-width / LM 7/3 100 13.58 Comparative Example 1 Wet K-width / LM 5/5 91 3.6 Comparative Example 2 Wet K-width / LM 7/3 94 1.7

2.5 SEM

2.5.1 Evaluation method

In order to observe the surface of the prepared kapok nonwoven fabric, it was observed by magnifying 500 times using a scanning electron microscope (Heatach S-4800).

2.5.2 Evaluation Results

5a to 5d are scanning electron micrographs of 500 times the surface of the kapok composite nonwoven fabric prepared in the embodiments of the present invention. 5a to 5d, the surface difference according to the inter-fiber bonding method was not seen, it can be seen that the inter-fiber bonding is good overall.

Although the present invention has been described in detail only with respect to the embodiments described, it will be apparent to those skilled in the art that various modifications and variations are possible within the technical spirit of the present invention, and such modifications and modifications belong to the appended claims. .

The nonwoven fabric of the present invention can be used as all the filling materials having the form stability, such as sound absorbing materials, construction and various industrial sound absorbing materials, oil absorbent fabrics, oil and water separation materials and insulation, bedding, bedding, life jackets, etc. .

Claims (13)

A first step of mixing the kapok fibers with the fibers of the thermoplastic polymer material and then carding them to form a web;
A second step of cross lapping the web; And
And a third step of adhering the cross-wrapped web. The method of claim 1, wherein the thermoplastic polymer material is at least one selected from the group consisting of polyethylene, polypropylene, polyethylene terephthalate, nylon, and composite yarns thereof. The method of claim 1, wherein the thermoplastic polymer material fiber is a sheath type composite yarn. The method of claim 1, wherein the thermoplastic polymer material is a short fiber having an average fiber length of 30-60 mm. The method of claim 1, wherein the mixing ratio of the kapok fiber and the fiber of the thermoplastic polymer material is 1:99 to 80:20 by weight ratio. The method of claim 1, wherein the mixing ratio of the kapok fiber and the fiber of the thermoplastic polymer material is 40:60 to 80:20 by weight ratio. The method of claim 1, wherein the means for bonding is one or more selected from the group consisting of needle punching, spun lacing, and thermal bonding. The method of claim 1, wherein the adhesion is achieved by needle punching and thermal bonding are performed sequentially. 9. The method of claim 8, wherein the thermal bonding is achieved by sequentially performing belt laminating and calendering. A kapok composite nonwoven fabric in which kapok fibers and fibers of a thermoplastic polymer are mixed in a weight ratio of 1:99 to 80:20, and then cross-laminated and bonded. 11. The kapok composite nonwoven fabric of claim 10, wherein the kapok fibers and the fibers of the thermoplastic polymer material are mixed in a weight ratio of 40:60 to 80:20, and then cross-laminated and bonded. 11. The kapok composite nonwoven fabric as claimed in claim 10, wherein the fiber of the polymer material is PP / PE or LM-PET sheath type composite yarn. 12. The method of claim 10, wherein the MD non-woven fabric has a tensile strength of 10 to 40 N / 5 cm, and a CD direction of 50 to 150 N / 5 cm; The rupture strength of the composite composite nonwoven fabric, characterized in that 5 to 15kgf.

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