KR102113352B1 - Manufacturing method of Melt Blown Non-woven Fabric and Air Filter Using Thereof - Google Patents

Abstract

The air filter comprising the melt-blown nonwoven fabric of the present invention has a high structural stability, thereby reducing the change in physical properties in post-processing processes such as lamination or bending, and the differential pressure increase and removal rate are remarkably improved due to an increase in the internal surface area.

Description

Manufacturing Method of Melt Blown Non-woven Fabric and Air Filter Using Thereof

The present invention relates to a method for manufacturing a meltblown nonwoven fabric and an air filter including the same, and more specifically, to increase the structural stability and increase the pressure difference and increase the removal rate significantly due to the increase in the internal surface area. It relates to an air filter including this.

Air purifiers are installed for the purpose of filtering and removing various foreign substances contained in the air from various devices such as internal combustion engines, gas turbines, air purifiers, and air conditioners, and various kinds of filter media are installed as filter media. . As described above, the filter media mounted on the air purifier serves to ensure normal operation of the apparatus and to extend the life of the apparatus by filtering various foreign substances contained in the air supplied for operation of the apparatus. Therefore, it is essential that such filter media must have high filtration efficiency and long-term filtration life at the same time to effectively collect foreign substances. However, in order to effectively collect various foreign substances in the air, the pores of the filter media must be formed finely. In this case, the ventilation pores are closed early to shorten the filtration life of the filter media. On the contrary, when the air permeation of the filter medium is large, the filter life is extended, and instead, the fine foreign matter is escaped through the air perforation, thereby significantly reducing the filtering efficiency of the filter medium. Therefore, there is an urgent need for the development of a filter medium for air purification having filtration efficiency and long-term filtration life, which effectively collect foreign substances.

Currently, the internal combustion engine is driven using liquid fuel such as gasoline and diesel, or gaseous fuel such as LPG, and the fuel is supplied into the combustion chamber in the form of a mixed gas mixed with air to generate a combustion explosion. Foreign substances such as dust are mixed in the air flowing into the internal combustion engine to form a mixed gas, and these foreign substances cause incomplete combustion of the mixed gas, making it difficult to operate the internal combustion engine and accumulating on the inner walls of the cylinder. This will cause a decrease in durability of the internal combustion engine.

Therefore, the internal combustion engine is formed with an air purifier that prevents foreign substances from entering the air, and a filter paper or a non-woven fabric is mainly used as the air filter media. As a filter paper for air filters, a melt-blown non-woven fabric is mainly used, and a melt-blown non-woven fabric is spun (sprayed) through a spinneret formed of hundreds of small orifices to form a polymer capable of forming thermoplastic fibers. The polymer refers to a self-bonding non-woven fabric in which ultra-fine fibers, which are ultra-fine-grained by hot air sprayed at both sides of the spinneret in a molten state, are stacked on the collector.

This melt-blown non-woven fabric exhibits excellent properties as a medium and high performance filter. The medium and high performance filters refer to filters corresponding to the MERV 7 to 16 level of the American air filter standard ANSI / ASHRAE 52.2 (1999). The higher the MERV value, the better the filter efficiency and the higher the filter rating. Medium filters are used by pleating to maximize the efficiency of the filter in use. Melt-blown non-woven fabrics have poor shape stability after bending due to their flexible properties. That is, after bending, there is a strong tendency to return to the original shape without maintaining the bending shape. Accordingly, there is a problem that the filter efficiency decreases and the pressure loss increases as the contact ability of the air and the filter decreases.

Occurs. Therefore, the shape-retaining performance of the filter is essential, especially in automobile cabin filters or high-efficiency medium filters in which a large amount of air flows into a small filter area. As described above, a method of laminating a spunbonded nonwoven fabric has been proposed in order to impart shape retention performance to the meltblown nonwoven fabric.

Japanese Patent Application No. 63-51725 discloses a nonwoven fabric in which a spunbond type nonwoven fabric is disposed on both sides of a meltblown nonwoven fabric as a nonwoven fabric used as a filter material for an air purifier, and each fiber layer is adhered using a resin adhesive. Further, Japanese Patent Application No. 62-2060 discloses a filter in which a spunbonded nonwoven fabric made of stretched fibers is bonded to a melt-blown nonwoven fabric in an unsolidified state.

However, the conventional melt blown non-woven fabric for air filter has not only a weak tensile strength, but also has problems such as an increase in the initial removal rate due to an increase in differential pressure, an increase in differential pressure due to structural deformation during use, and a decrease in product use cycle. Also, under certain conditions, there was a problem that the spinning process was impossible because it was too light.

The present invention has been devised to solve the above-mentioned problems, and a problem to be solved by the present invention is to provide a method for manufacturing a meltblown nonwoven fabric having a high structural stability and an increase in the differential pressure and the removal rate significantly due to an increase in the internal surface area. It relates to an air filter.

The method of manufacturing the melt-blown nonwoven fabric of the present invention for solving the above-mentioned problems is (1) mixing the two or more thermoplastic polymer resins having different melt flow index or the same component to prepare a mixed spinning composition ; (2) spinning the mixed spinning composition from a spinneret; And (3) laminating the spun melt-blown yarn to form a melt-blown nonwoven fabric.

According to one preferred embodiment of the present invention, the deviation of the melt flow index between the thermoplastic polymer resin having the lowest melt flow index and the thermoplastic polymer resin having the highest melt flow index of the two or more thermoplastic polymer resins is 400 g / 10 min or more. Can be.

According to another preferred embodiment of the present invention, the two or more thermoplastic polymer resins are thermoplastic polymer resins having a melt flow index of 10 to 400 g / 10 min and thermoplastics having a melt flow index of 800 to 2000 g / 10 min. It may contain a polymer resin.

According to another preferred embodiment of the present invention, the thermoplastic polymer resin having a melt flow index of 10 to 400 g / 10 minutes and the thermoplastic polymer resin having a melt flow index of 800 to 2000 g / 10 minutes are 4: 1. It may be mixed in a weight ratio of ~ 1: 3, and may be mixed in a weight ratio of 4: 1 to 1.5: 1.

According to another preferred embodiment of the present invention, the thermoplastic polymer resin is any one selected from the group consisting of polypropylene, polypropylene copolymer, nylon, polyester, polyurethane, polyacrylonitrile, polyolefin and cellulose It may be abnormal.

According to another preferred embodiment of the present invention, there is provided a meltblown nonwoven fabric comprising a single meltblown yarn comprising two or more thermoplastic polymers having the same component or different melt flow index.

According to another preferred embodiment of the present invention, the deviation of the melt flow index of the thermoplastic polymer having the lowest melt flow index and the thermoplastic polymer having the highest melt flow index among the two or more thermoplastic polymers may be 400 g / 10 min or more. have.

According to another preferred embodiment of the present invention, the two or more thermoplastic polymers have a thermoplastic polymer having a melt flow index of 10 to 400 g / 10 min and a thermoplastic polymer having a melt flow index of 800 to 2000 g / 10 min. It characterized in that it comprises a melt-blown non-woven fabric.

According to another preferred embodiment of the present invention, the thermoplastic polymer having a melt flow index of 10 to 400 g / 10 min and the thermoplastic polymer having a melt flow index of 800 to 2000 g / 10 min are 4: 1 to 1 : 2 may be mixed in a weight ratio, more preferably 4: 1 to 1.5: 1 may be mixed in a weight ratio.

According to another preferred embodiment of the present invention, the thermoplastic polymer may be any one or more selected from the group consisting of nylon, polyester, polyurethane, polyacrylonitrile, polyolefin, and cellulose.

According to another preferred embodiment of the present invention, the fiber thickness of the melt-blown non-woven fabric may be 0.2 ~ 15㎛.

According to another preferred embodiment of the present invention, the thickness of the melt-blown nonwoven fabric may be 0.05 ~ 1㎜.

According to another preferred embodiment of the present invention, the melt-blown nonwoven fabric may be electrostatically treated, and in this case, the melt-blown nonwoven fabric may further include a charging agent.

According to another preferred embodiment of the present invention, the melt-blown nonwoven fabric of the present invention described above; And a filter material formed on at least one surface of the nonwoven fabric.

According to another preferred embodiment of the present invention, a pair of meltblown nonwoven fabric of the present invention; And a filter medium formed between the pair of nonwoven fabrics.

Hereinafter, terms used in the present invention will be described.

The term " meltblown " is extruded through a number of orifices to form a non-woven web shape, and then the filament is contacted through the air to micronize the filament into a fibrous form, followed by a continuous belt of thinned fibers. Refers to a nonwoven web formed by laminating on top.

The term “polyolefin” means any of the saturated, open-chain, polymeric hydrocarbon family consisting only of carbon and hydrogen atoms. Common polyolefins include various combinations of polyethylene, polypropylene, polymethylpentene and ethylene, propylene and methylpentene monomers.

The term "polypropylene" (PP) includes not only homopolymers of propylene, but also copolymers that are 40% or more repeat units.

The term “polyester” is a concept that includes a polymer that is a condensation product of dicarboxylic acid and dihydroxy alcohol that is linked by the formation of ester units and has at least 85% repeat units. It includes aromatic, aliphatic, saturated and unsaturated diacids and dialcohols.

Furthermore it includes copolymers and blends and these variants. A typical example of polyester is polyethylene terephthalate (PET), a condensation product of ethylene glycol and terephthalic acid.

The term “meltblown yarn” refers to fibers or filaments formed by extruding a melted processable polymer through a high-temperature, high-speed compressor body through a number of fine capillaries. Here, the capillary may be variously changed, such as a polygon including a circle, a triangle, and a square, an asterisk, and the like. In addition, as an example, the high-temperature, high-speed compressor body can taper the filament of the molten thermoplastic polymer material to reduce the diameter to about 0.5 to 10 μm. The melt-blown fibers may be discontinuous fibers or continuous fibers. Melt-blown yarns can form a web (non-woven fabric) of optionally dispersed fibers by irregularly depositing on the surface of a collection device included in a conventional melt-blown nonwoven fabric.

Term As used herein, the term "mixing and spinning" is a concept distinct from 'composite spinning' and 'spinning and mixing', where 'mixed spinning' refers to two or more substances. As a spinning method that forms a filament by simply mixing and then spinning the mixture, it is a spinning method that does not control the arrangement of each material within the generated filaments, whereas 'mixed yarn spinning' emits different materials to each other, so that It is a spinning method that manufactures each of a plurality of formed filaments and mixes them at the same time, and 'composite spinning' is a spinning method that allows two or more substances that are spun together to form a single filament without cis core, side-by-side fibers, etc. It corresponds.

The air filter comprising the melt-blown nonwoven fabric of the present invention has a high structural stability, thereby reducing the change in physical properties in post-processing processes such as lamination or bending, and the differential pressure increase and removal rate are remarkably improved due to an increase in the internal surface area.

1 is a schematic side view of an apparatus for manufacturing a melt-blown nonwoven fabric according to a preferred embodiment of the present invention.
Figure 2 is a cross-sectional view of the air filter media comprising a melt-blown non-woven fabric according to an embodiment of the present invention.
3 is a cross-sectional view of an air filter media including a melt-blown nonwoven fabric according to another preferred embodiment of the present invention.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

As described above, the melt blown non-woven fabric for a conventional air filter is not only weak in tensile strength, but also has a removal rate due to a differential pressure increase, and under certain conditions for manufacturing a non-woven fabric having ultra fine or fine fiber, the melted polymer is spun and shot ( There was a problem that a normal spinning process was impossible due to a shot or a fly.

Accordingly, in the present invention, (1) preparing a mixed spinning composition by mixing two or more kinds of thermoplastic polymer resins having the same component or different melt flow index; (2) spinning the mixed spinning composition from a spinneret; And (3) laminating the spun melt-blown yarn to form a melt-blown non-woven fabric, to provide a method of manufacturing a melt-blown non-woven fabric to seek to solve the above-mentioned problems. Through this, the melt-blown nonwoven fabric for the air filter has a high structural stability, and the increase in the differential pressure and the removal rate are remarkably improved due to the increase in the internal surface area.

First, as a step (1), a mixed spinning composition is prepared by mixing two or more types of thermoplastic polymer resins having the same component or different melting flow index. Specifically, the conventional melt-blown non-woven fabric for air filter is made of a melt-blown yarn having the same components, or a melt-blown yarn having heterogeneous components is mixed and mixed to prepare a melt-blown non-woven fabric. Furthermore, meltblown nonwoven fabrics were produced by spinning heterogeneous components in a composite spinning form (for example, composite yarns such as ciscore fibers, side-by-side fibers, and mixed yarns). In this case, it was still difficult to solve the above-mentioned problem.

However, in the present invention, two or more types of thermoplastic polymer resins, which are the same component, were mixed and single-spinned. In this case, the melt flow index (Melting flow index) is different, but mixed with the same component thermoplastic polymer resin. As a result, the fineness of the melt-blown yarn constituting the melt-blown nonwoven fabric of the present invention can be variously formed from fineness to fineness. It has been confirmed that the fineness deviation is larger than that of the existing melt blown yarn, which increases not only the structural safety, but also increases the removal rate while reducing the differential pressure when it is manufactured with an air filter. On the other hand, two or more types of thermoplastic polymer resins having the same component, for example, the same polypropylene or melt flow index means one case is 300g / 10 minutes and the other is 1000g / 10 minutes. Therefore, the heterogeneous polymer resin (e.g., one polypropylene, one melt flow index is 300g / 10 minutes, the other is polyethylene, 1000g / 10 minutes, does not fall within the scope of the present invention. Excellent compatibility and various mechanical properties.

On the other hand, in the present invention, the melt flow index (Melting flow index) refers to a value analyzed according to the method of ASTM-D-1238, preferably, the thermoplastic polymer having the lowest melt flow index of the two or more thermoplastic polymers When the deviation of the melt flow index of the thermoplastic polymer having the highest melt flow index is 400 g / 10 min or more, the overall mechanical properties are improved, more preferably, the two or more thermoplastic polymers have a melt flow of 10 to 400 g / 10 min. When the thermoplastic polymer having an index and a melt flow index of 800 to 2000 g / 10 minutes have been obtained, overall mechanical properties are significantly improved (see Table 1).

On the other hand, preferably, the thermoplastic polymer having a melt flow index of 10 to 400 g / 10 minutes and the thermoplastic polymer having a melt flow index of 800 to 2000 g / 10 minutes are mixed in a weight ratio of 4: 1 to 1: 3. It may be, more preferably 4: 1 to 1.5: 1 may be mixed in a weight ratio. This minimizes pressure loss and elongation while maximizing removal and QF factors.

The thermoplastic polymer that can be used in the present invention can be used without limitation as long as it can be used for a meltblown nonwoven fabric. Preferably, the thermoplastic polymer is meltblown ethylene, propylene, 1-butene, 1-hexene, 4 -High-pressure low-density polyethylene, linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), polypropylene (propylene homopolymer), polypropylene random copolymers, which are homopolymers or copolymers of alpha-olefins such as methyl-1-pentene and 1-octene Copolymer, polyolefin such as poly1-butene, poly4-methyl-1-pentene, ethylene propylene random copolymer, ethylene 1-butene random copolymer, propylene 1-butene random copolymer, polyester (polyethylene terephthalate, polybutyl Lenterephthalate, polyethylene naphthalate, etc.), polyamide (nylon-6, nylon-66, polymethaxyleneadipamide, etc.), poly Vinyl chloride, vinyl ethylene acetate copolymer, vinyl ethylene vinyl vinyl alcohol copolymer, ethylene (meth) acrylic acid copolymer, ethylene-acrylic acid ester-carbon monoxide copolymer, polyacrylonitrile, polycarbonate, polystyrene, ionomer (ionomer; ethylene and As a copolymer of methyl acrylic acid, a carboxyl group may be selected from the group consisting of zinc (Zn), sodium (Na), calcium (Ca) ammonium (NH ₄ ), etc. partially substituted polymer) or a mixture of two or more of these. And more preferably, any one or more selected from the group consisting of nylon, polyester, polyurethane, polyacrylonitrile, polyolefin, and cellulose, and more preferably polypropylene or polypropylene copolymer.

The fiber thickness of the melt-blown nonwoven fabric may be 0.2 to 15 μm. In addition, the thickness of the melt-blown non-woven fabric may be 0.05 ~ 1㎜.

Meanwhile, according to another preferred embodiment of the present invention, the melt-blown non-woven fabric may be electrostatically treated, and in this case, the melt-blown non-woven fabric may further include a charging agent.

The electrostatic treatment is a method of improving the collecting ability by applying a static electricity to a non-woven fabric, which is normally performed, and when the electrostatic treatment is performed on the melt-blown non-woven fabric, the filaments constituting it have a polarized electric charge therein, and accordingly polarization Non-woven fabrics made of filaments with charged charges can easily contain charged fine particles.

I'll pick it up.

This electrostatic treatment process may be performed using a corona discharge, plasma charging, friction charging, water charging through high-pressure water droplets. Among these methods, the corona discharge method is performed in a state where the free charge inside the filament fiber is relatively free because the cold corona discharge and the filament are not completely cured after the filament of the molten polymer is completely cured. There is a hot corona discharge method. The corona discharge method may be performed at a voltage of 30 ~ 60 ㎸. If the voltage is less than 30 ㎸, the desired collection efficiency cannot be obtained because the electrical polarization rate is too low. On the other hand, when the voltage exceeds 60 ㎸, defects such as holes in the non-woven fabric are likely to occur. It can be fatal. The corona discharge method may be performed at a current of 0.1 to 6.0 ㎃. If the current is less than 0.1 ㎃, a sufficient electrostatic performance cannot be imparted because the amount of electric charge is small, whereas when the current exceeds 6.0 ㎃, it may be fatal to the operator.

In the present invention, in order to maximize the electrostatic effect, a charging agent may be further included, and in this case, a charging agent commonly used may be further included. In this case, preferably, a hindered amine-based charging agent can be used, and in this case, N, N'-bis-3- (3 ', 5'-di-tert-butyl-4'-hydroxyphenyl) propionyl is preferable. Hexamethylenediamine, N, N'-tetramethylene-bis [3- (3'-methyl-5'-tert-butyl-4'-hydroxyphenyl) propionyl] diamine, N, N'-bis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) -propionyl] hydrazine, N-salicyloyl-N'-salicylidenehydrazine, 3- (N-salicyloyl) amino-1, And 2,4-triazole, N, N'-bis [2- {3- (3,5-di-tert-butyl-4-hydroxyphenyl) propionyloxy} ethyl] oxyamide, and the like. Most preferably poly [[6- (1,1,3,3-tetramethylbutyl) amino] -s-triazine-2,4-diyl]-[[(2,2,6,6-tetramethyl The use of -4-piperidyl) imino] hexamethylene [(2,2,6,6-tetramethyl-4-piperidyl) imino]]) is most effective for improving physical properties (see Table 1). ). The hindered amine-based charging agent is present in an amount of about 0.05 to about 5% by weight of the total polymer, more preferably the additive (s) is present in an amount of about 0.2 to about 2% by weight of the polymer, even more preferably May be present in an amount of about 0.2 to about 1% by weight of the polymer.

It may also contain antioxidants, in which case most preferably hindered phenolic antioxidants can be used. Preferred hindered phenolic antioxidants include n-octadecyl-3- (3 ', 5'-di-tert-butyl-4'-hydroxyphenyl) -propionate, n-octade

Sil-3- (3'-methyl-5'-tert-butyl-4'-hydroxyphenyl) -propionate, n-tetradecyl-3- (3 ', 5'-di-tert-butyl-4 '-Hydroxyphenyl) -propionate, 1,6-hexanediol-bis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) -propionate], 1,4-butanediol -Bis [3- (3,5-di-tert-butyl-4-hydroxyphenyl) -propionate], 2,2'-methylene-bis (4-methyl-tert-butylphenol), triethylene glycol -Bis [3- (3-tert-butyl-5-methyl-4-hydroxyphenyl) -propionate], pentaerythritol tetrakis [methylene-3- (3 ', 5'-di-tert- Butyl-4-hydroxyphenyl) propionate] methane, 3,9-bis [2- {3- (3-tert-butyl-4-hydroxy-5-methylphenyl) propionyloxy} -1,1- Dimethylethyl] 2,4,8,10-tetraoxaspiro (5,5) undecane and the like, and most preferably 2,6-di-tert-butyl-4-methylphenol is used. It is most effective for improvement. The hindered phenolic antioxidant may be present in an amount of about 0.01 to about 2% by weight of the total polymer.

Thereafter, in step (2), the mixed spinning composition is spun from a spinneret. In this case, the two or more types of thermoplastic polymers are mixed rather than composite spinning, and single spinning is performed to achieve the object of the invention. Thereafter, as a step (3), the melt-blown yarn is usually laminated to form a melt-blown nonwoven fabric.

The schematic configuration of a manufacturing apparatus for manufacturing such a meltblown nonwoven fabric is described in Wilter Albrecht et al. (Chapter 4.2.4.1.Meltblowing process, Nonwoven Fabrics: Raw Materials, Manufacture, Applications, Characteristics, Testing Processes, edited by, Wilhelm Albrecht, Hilmar Fuchs, and Walter Kittelmann, pp. 222-224, Wiley-VCH (2003), which constitute a part of the description herein, and are incorporated herein by reference.

More specifically, the melt blown non-woven fabric manufacturing apparatus 100 that can be applied to the present invention, as shown in FIG. 1, extrudes the melted thermoplastic polymer resin by heating the thermoplastic polymer resin 1 of the present invention described above. A heating extruder 2; A filament spinning part (3) for spraying the molten thermoplastic polymer resin along with a gas along its own weight direction (A) in the form of a filament (6); A cross direction gas injection section (5A, 5B) for spraying gas in a direction crossing the self-weighting direction (A) toward the injected filament (6) to twist the filament (6); It includes a collecting portion (7) for collecting the filament (6) via the cross direction gas injection portion (5A, 5B) to form a fiber web (11). Here, the filament spinning unit 3 may spray the filament and the gas in any first direction other than the self-weighting direction (A).

The injected thermoplastic polymer resin (1) is heated by the heating extruder (2), converted into a molten state, and extruded. In addition, inorganic and / or organic additives may be added. By adding these inorganic and / or organic additives, the spinning viscosity of the thermoplastic polymer resin in a molten state can be adjusted or the physical properties of the filament, that is, specific gravity and hardness can be adjusted. In addition, the filtration efficiency and durability of the filter may be improved by adding the inorganic and / or organic additives. The types and ratios of these additives are well known to those skilled in the art, so detailed descriptions thereof will be omitted.

The filament spinning part 3 is an inlet part 3B into which the molten thermoplastic polymer resin 1 supplied from the heat extruding part 2 flows, and the molten thermoplastic polymer introduced from the inlet part 3B. It includes a chamber (3C) in which the resin (1) is temporarily stored, and a plurality of filament spinning tubes (3A) formed from the chamber (3C) toward the collecting portion (7).

The plurality of filament spinning tubes 3A may be provided in various shapes such as a polygon, a star shape, and the like, including a cylinder, a triangle, and a square.

In addition, although the filament spinning tube 3A is shown as one in FIG. 1, in practice, a plurality of the filament spinning tubes are arranged along a direction perpendicular to the ground of FIG. 1.

The molten thermoplastic polymer resin 1 temporarily stored in the chamber 3C is converted into a filament shape while passing through the filament spinning part 3 and discharged in the self-weight direction A. Here, the chamber 3C is pressurized therein by a gear pump (not shown) and the filament is injected by the pressure. Of course, in order to pressurize the interior of the chamber 3C, in addition to the above-described gear pump, various pressing means such as a hydraulic pump and a rotary pump may be employed.

Here, the filament spinning unit 3 is a downward gas injection unit that jets gas toward the filament so as to extend the filament flowing out through the filament spinning tube 3A in the longitudinal direction (self-direction (A)) (4A, 4B).

The lower gas injection portions 4A and 4B may be symmetrically arranged on the left and right sides, respectively, based on the filament spinning tube 3A, as illustrated in FIG. 1. In addition, the gas injection nozzles 12 and 13 of the lower gas injection portions 4A and 4B may be arranged to be inclined with respect to the self-weighting direction A. The gas injection nozzles 12 and 13 may be provided so that the sum of the injection directions of the gas injected from the gas injection nozzles 12 and 13 is substantially parallel to the self-weighting direction A. Here, when the gas injection nozzles (12, 13) are provided symmetrically left and right based on the longitudinal direction of the filament spinning tube (3A), the combined force of the gas injection direction from the gas injection nozzles (12, 13) It will be substantially parallel to the self-weighting direction A.

The lower gas injection portions 4A and 4B inject gas through the gas injection nozzles 12 and 13. Accordingly, the filament (melt blown yarn 6) discharged through the filament spinning tube 3A due to collision with the gas is stretched in its longitudinal direction and its diameter is reduced. Here, the gas may be a high temperature and / or high speed gas. Thereby, in the case of a high temperature and / or high speed gas, the diameter of the filament 6 can be further reduced. Here, the gas may be air in the atmosphere. Of course, the gas may be a gas composed of various mixing ratios of gaseous nitrogen, oxygen, and water vapor, or may be made of only a single component inert gas. The type of gas may be variously changed. Here, the high temperature is a temperature equal to or higher than the normal temperature, and a temperature capable of extending the filament 6 in the longitudinal direction is sufficient. Accordingly, the temperature of the gas injected by the filament injection unit 3 may be changed to various temperatures by the designer's selection. In addition, the high speed means a speed at which the gas to be injected can be injected with a predetermined directionality. The speed of the gas to be injected can be changed to various values by the designer's choice, similar to the temperature. On the other hand, the cross direction gas injection portion (5A, 5B) is toward the filament (6) sprayed through the filament spinning portion (3)

The gas is injected in a direction crossing the self-weighting direction (A).

The cross-direction gas injection portions 5A and 5B are also extended in a direction perpendicular to the ground surface of FIG. 1 like the filament spinning portion 3 to be provided to inject the gas in a predetermined width in a direction perpendicular to the ground. Can be.

Here, the gas injection width in the direction perpendicular to the ground of the gas injection sections 5A, 5B in the cross direction is greater than the width of the filament 6 injected by the filament spinning section 3 in the ground direction. The same or wide is preferred. Here, FIG. 1 shows a pair (two) as the cross-direction gas injection parts 5A and 5B, but may be provided as one in some cases.

Here, the gas may be high temperature and / or high speed air. Accordingly, as the high temperature and high speed air collides with the injected filament 6, the diameter of the filament 6 decreases by 1-60%, its length increases by 1-60%, and the filament 6 The surface area increases by 1-60%. In addition, the filament 6 has a shape twisted like a coil spring shape around the self-direction (A). Here, the components of the gas and the type of gas contained in the gas may be variously changed.

In addition, the cross-direction gas injection portions 5A, 5B and the lower gas injection portions 4A, 4B may inject gases of the same component and type. However, the pressure and temperature of the gas to be injected may vary.

Here, the cross-direction gas injection portions 5A and 5B have injection pipes 14 and 15 for spraying the gas, respectively. The injection pipes 14 and 15 may be provided as nozzles.

The cross direction gas injection portion (5A, 5B) is a vertical direction from the end of the filament spinning tube (3A) to the injection pipe (14, 15) of each of the cross direction gas injection portion (5A, 5B) ( It is preferable that the distances H1 and H2 to the self-weighting direction A) are different. This is because when the vertical distances H1 and H2 to each of the injection pipes 14 and 15 are the same, the injected gases may cancel each other. Of course, depending on the case, for example, even if the vertical distances H1 and H2 are the same, the injection speed of one of the gas injection units 5A and 5B is greater than that of the other gas injection units 5A and 5B. Even if the vertical distances H1 and H2 are the same, the twist degree, length and surface area of the filament 6 can be increased and the diameter can be reduced.

Here, the cross-direction gas injection portion 5A shown in FIG. 1 is inclined by a first angle θ1 in a counterclockwise direction based on an extension line B in the longitudinal direction of the filament spinning tube 3A. The gas in the direction can be injected toward the filament (6).

`In addition, the gas injection portion 5B in the cross direction on the right side moves the gas in a direction inclined by a second angle θ2 clockwise based on an extension line B in the longitudinal direction of the filament spinning tube 3A. It can be injected toward the filament (6). Here, the first angle θ1 and the second angle θ2 may be 90 degrees. Of course, the first angle θ1 and the second angle θ2 may be any angle in a range of 1 degree or more and 179 degrees or less. In some cases, the first angle θ1 and the second angle θ2 may be different.

The horizontal gas injection portions 5A and 5B have a horizontal distance of 0.5 to 50 cm, preferably 0.5, from the ends of the injection pipes 14 and 15 to the longitudinal extension line B of the filament spinning pipe 3A. It can be placed within the range of ~ 10cm. Of course, this arrangement is only an example.

In addition, the cross-direction gas injection portion (5A, 5B), the vertical distance from the injection pipe (14, 15) to the end of the filament spinning tube (3A) can be arranged in a 1-50cm, preferably 1-30cm have. Of course, there may be various other vertical distances.

The filament 6 may be twisted to some extent by the gas injection portions 4A and 4B below the injection portion 3 of the cross direction gas injection portions 5A and 5B, but the cross direction gas injection portions 5A, 5B) further maximizes the twist of the filament 6. Accordingly, the diameter of the filament 6 can be further reduced, and its length can be extended. As the filament 6 is made in a more twisted form, the bulkiness of the nonwoven fabric, which is a laminate of these filaments 6, can be greatly improved.

Here, the bulky (bulky) property means a bulky compared to the weight, thereby making it possible to manufacture a lighter nonwoven fabric.

The functions of the cross-direction gas injection units 5A and 5B will be described in more detail as follows. The filament 6 injected from the filament spinning unit 3 to the collecting unit 7 rapidly cools the surface when it comes into contact with air at room temperature between the filament spinning unit 3 and the collecting unit 7. Due to this, the filament 6 is cured to diameter,

Its appearance, such as length and surface area, is almost impossible to deform.

Therefore, when the filament injected from the filament spinning unit 3 falls below a deformable temperature, a high temperature and / or high speed gas is injected to the filament 6 in the cross direction to collide with the filament 6 Thermal energy and collision energy are transmitted to the filament, and the diameter of the filament 6 is not only thinner but also more twisted.

Here, the gas velocity injected from the gas injection portions 5A and 5B in the cross direction is in the range of 5 to 90% of the gas velocity injected from the gas injection portions 4A and 4B in the downward direction of the filament spinning portion 3 It is desirable. Because, when the lateral gas velocity injected by the crossing gas injection portions 5A, 5B is similar to or greater than the longitudinal gas velocity injected by the downward gas injection portions 4A, 4B (90 This is because it is difficult to maintain gas flow from the filament spinning portion 3 to the collecting portion 7). In addition, when the lateral gas velocity injected by the crossing gas injection portions 5A, 5B is too small compared to the longitudinal gas velocity injected by the downward gas injection portions 4A, 4B (less than 5%), the This is because it is not possible to transmit enough impact energy to modify the surface of the filament 6.

The gas temperature injected from the gas injection parts 5A and 5B in the cross direction is higher as the distance from the filament spinning part 3 (distance in the direction of the extension line B in the longitudinal direction) increases under the same speed condition. desirable. This is because, as described above, since the filament located at a position far from the filament spinning unit 3 is contacted with external air and cooled more, more thermal energy is required to deform the shape of the filament 6.

Here, the filament 6 hit the gas stream injected by the cross-direction gas injection portions 5A and 5B is collected at a constant weight in the collecting portion 7. At this time, a gas suction part 8 to be described later may be disposed below the collecting part 7. By this, even if gas is injected in the cross direction by the cross direction gas injection parts 5A and 5B, a constant air flow from the filament spinning part 3 to the gas suction part 8 is formed. Due to this, the transport path of the filament 6 is substantially constant.

On the other hand, the collecting part 7 is a belt 7c on which the filaments 6 are stacked via the cross-direction gas injection parts 5A, 5B and a pair of rollers 7a driving the belt 7c. , 7b). In some cases, the collecting part 7 may be provided as a rotating cylindrical drum.

In addition, the melt-blown non-woven fabric manufacturing apparatus 100 according to the present invention, the gas suction portion (8) disposed under the filament spinning portion (3) so that the transport direction of the filament ejected from the injection portion (3) is constant ) May be further included. The gas suction unit 8 sucks the gas injected from the downward gas injection units 4A and 4B of the injection unit 3. Accordingly, the conveying direction of the filament, which is transferred due to the flow of the injected high-speed gas, that is, the spraying direction may also be generally maintained. Here, the injection direction of the filament is generally parallel to the longitudinal extension line B of the filament spinning tube 3A of the filament spinning unit 3.

Here, the filament spinning tube 3A may be arranged such that its longitudinal direction is generally self-weighting direction A. In addition, the injection direction of the filament 6 injected by the filament spinning unit 3 may be a self-weight direction (A). However, as in the case where the longitudinal direction of the filament spinning tube 3A is not made into the self-weighting direction, the injection direction of the filament 6 may not be the self-weighting direction A, as necessary. Here, the injection direction of the filament 6 injected by the filament spinning unit 3 may be referred to as a first direction.

In addition, the melt-blown nonwoven fabric manufacturing apparatus 100 according to the present invention may further include a winding portion 9 for winding the fiber web (nonwoven fabric) collected by the collecting portion 7. The winding portion 9 may be provided with a pair of rollers (9a, 9b) rotating opposite to each other. Any one of the pair of rollers 9a and 9b may receive the fiber web 11 collected on the belt 7c of the collecting portion 7 and wind the fiber web 11 on its outer surface. . The winding part 9 is only an example and may be variously changed, and may be omitted in some cases.

The air filter of the present invention may be provided with a melt-blown nonwoven fabric of the present invention described above on at least one surface of a support for an air filter that is commonly used as a filter medium. Specifically, FIG. 2 is a cross-sectional view of an air filter media according to a preferred embodiment of the present invention, and the meltblown nonwoven fabric 310 of the present invention is provided as a media on one surface of the air filter support 300. It is also possible that the melt-blown nonwoven fabric is provided on both sides of the support. What can be used as the air filter support of the present invention are spunbond (SB) nonwoven fabric, melt blown (MB) nonwoven fabric, nano spinning nonwoven fabric, needle punch (NP) nonwoven fabric, thermal bond (TB) nonwoven fabric, airlaid (AL) nonwoven fabric , Wet non-woven fabric and the like may be used, but is not limited thereto. The thickness may be 0.1 to 10 mm, but is not limited thereto. On the other hand, the bonding of the melt-blown non-woven fabric and the filter paper or non-woven fabric as a support is performed by a known bonding method such as hot-melt bonding, ultrasonic bonding, chemical bonding, heat treatment after needle punching, and the bonding method if necessary. By mixing, the meltblown nonwoven fabric and filter paper or nonwoven fabric can be bonded to form a filter media layer.

3 is a cross-sectional view of an air filter media according to another preferred embodiment of the present invention, and includes the meltblown nonwoven fabric 310 of the present invention between a pair of supports 300. 320 of the present invention. As a result, the structural stability of the melt-blown non-woven fabric having bulkiness can be imparted, thereby simultaneously providing molding stability and mechanical stability of the air filter module having a bent shape.

Meanwhile, the air filter may further include an adsorption / deodorization layer selected from the group consisting of activated carbon fiber, carbon nanotube (CNT), zeolite, silica gel, activated alumina, ion exchange resin, and ion exchange fiber, and accordingly support It is included in the scope of the present invention that such an adsorption / deodorization layer is added between and the meltblown nonwoven fabric of the present invention.

Hereinafter, the present invention will be described in more detail through examples, but the following examples are not intended to limit the scope of the present invention, which should be interpreted to help understand the present invention.

<Example 1>

Polypropylene (polymirae, HP563S) having a melt index of 38 g / 10 min and polypropylene (polymirae, HP461Y) polymer resin having a melt index of 1300 g / 10 min were mixed in a weight ratio of 2: 1. Poly [[6- (1,1,3,3-tetramethylbutyl) amino] -s-triazine-2,4-diyl]-[[(2,2,6, 6-tetramethyl-4-piperidyl) imino] hexamethylene [(2,2,6,6-tetramethyl-4-piperidyl) imino]]) (Chimasorb 911, Ciba Geiger) 0.5 weight % And preferably 0.1% by weight of 2,6-di-tert-butyl-4-methylphenol (BHT, Daejung Gold Co., Ltd.) as an antioxidant was prepared by mixing. The spinning composition was single-spun to spray the melt-blown yarn and processed it into a melt-blown nonwoven fabric. The thickness of the nonwoven fabric is 250 μm. Subsequently, the electrostatic treatment was performed by frictional contact charging using a water spraying method using a high pressure nozzle to prepare an electrostatic nonwoven fabric.

<Example 2>

Resin is carried out except that the polypropylene polymer resin with a melt index of 38 g / 10 min (HP563S) and a polypropylene polymer resin with a melt index of 1300 g / 10 min (HP461Y) sold at PolyMirae Co., Ltd. is mixed at a weight ratio of 1: 1. An electrostatic melt-blown nonwoven fabric was prepared in the same manner as in Example 1.

<Example 3>

Resin is carried out except that the polypropylene polymer resin with a melt index of 38g / 10 min (HP563S) and a polypropylene polymer resin with a melt index of 1300g / 10 min (HP461Y) sold at PolyMirae Co., Ltd. are mixed at a weight ratio of 1: 2. An electrostatic melt-blown nonwoven fabric was prepared in the same manner as in Example 1.

<Example 4>

Resin is carried out except that the polypropylene polymer resin with a melt index of 38g / 10 min (HP563S) and a polypropylene polymer resin with a melt index of 1300g / 10 min (HP461Y) sold in PolyMirae Co., Ltd. are mixed at a weight ratio of 1: 5. An electrostatic melt-blown nonwoven fabric was prepared in the same manner as in Example 1.

<Example 5>

A polypropylene resin having a melt flow index of 180 g / 10 min (LG Chem, H7900) and a polypropylene resin having a melt flow index of 180 were added by adding 3% by weight of a peroxide, which is a melt flow index increase agent, and poly having a melt flow index of 400 g / 10 min. An electrostatic melt-blown nonwoven fabric was prepared in the same manner as in Example 1, except that the propylene polymer resin was mixed in a weight ratio of 2: 1.

<Example 6>

The resin is a polypropylene polymer resin with a melt index of 38g / 10 min (HP563S), 800g / 10 min (HP561X), and 1300g / 10 min (HP461Y) sold by PolyMirae Co., Ltd. in a weight ratio of 2: 1: 1. Except that it was carried out in the same manner as in Example 1 to prepare an electrostatic melt-blown nonwoven fabric.

<Comparative Example 1>

An electrostatic melt-blown nonwoven fabric was prepared in the same manner as in Example 1, except that only the polymer resin having a melt flow index of 38 g / 10 min was used.

<Comparative Example 2>

An electrostatic melt-blown nonwoven fabric was prepared in the same manner as in Example 1, except that only the polymer resin having a melt flow index of 1300 g / 10 min was used.

<Comparative Example 3>

The resin is a polybial resin with a melt index of 38g / 10 min (HP563S) and a polypropylene resin with a melt index of 1300g / 10 min (HP461Y) sold by PolyMirae Co., Ltd., except for compound spinning. Melt-blown nonwoven fabric was prepared in the same manner as in Example 2.

<Experimental Example>

The following evaluation was performed on the electrostatic melt blown manufactured through the above Examples and Comparative Examples, and the results are shown in Table 1.

1. Collection efficiency (%) and pressure loss (mmAq) measurement

In general, it was measured in a manner measured by an air filter. Specifically, the aerosol containing sodium chloride was passed through a nonwoven fabric sample at an air flow rate of 32 LPM (cotton wind velocity of 5.33 cm / sec) to measure the sodium chloride concentration before and after passage to calculate the amount of sodium chloride collected by the nonwoven fabric. After dividing it by the amount of sodium chloride before passing, the percentage was measured for collection efficiency. At this time, the aerosol was prepared by dissolving sodium chloride in distilled water to make a 20% by weight aqueous sodium chloride solution, and then vaporizing moisture by a heater device so that sodium chloride had a size of about 0.3 μm. In this way, the collection efficiency (%) for particles was measured by an automated efficiency tester (TSI, Model 8130, Sightfall, Minn.).

The pressure loss (mmAq) was measured from the pressure loss value before and after the passage of the nonwoven sample at a flow rate of 32 LPM of the applied air volume, similar to the collection efficiency measurement method.

2. QF factor measurement (1 / mmH ₂ 0)

The quality factor (QF) is a kind of means of expressing filter performance combining filtration efficiency and differential pressure, and is generally calculated according to the following relationship, and the higher the value, the better the air filter performance.

All.

[Relationship]

QF index (1 / mmAq) = [-ln ((100-R) / 100)] / ΔP

However, R is the collection efficiency, and ΔP is the differential pressure.

3. Elongation (%)

The elongation measurement method was measured using a constant rate of extension type tensile tester according to KS K ISO 9073-3. Five specimens were collected in the length direction and the width direction, respectively, and at least 100 mm away from both sides, and the same width and length directions were not included. It is advantageous that the elongation is low.

4. Melt flow index (g / 10 min)

It was analyzed according to the method of ASTM-D-1238 at a load condition of 2.16 Kg at 230 ° C.

Pressure loss Removal rate (%) QF Thickness (㎛) Elongation (%) Example 1 1.2 95.5 2.28 250 36 Example 2 1.5 96.2 2.18 262 45 Example 3 1.8 97.2 1.99 276 48 Example 4 2.1 97 1.67 283 56 Example 5 2.6 94.8 1.14 260 59 Example 6 1.19 35.8 0.37 254 37 Comparative Example 1 0.8 86 2.46 245 21 Comparative Example 2 2.9 98.2 1.39 250 62 Comparative Example 3 2.8 95.3 1.09 262 54

As can be seen in Table 1, Examples 1 to 6 in which a polymer resin having a different melt flow index was mixed showed superior physical properties compared to Comparative Examples 1 to 2 in which it was not used. In addition, the physical properties of Example 2, in which single spinning was performed by mixing the same composition or composition, were superior to Comparative Example 3 in which composite spinning was performed. In addition, Examples 1 to 3 in which resins having a melt flow index of 300 or less and 800 or more were mixed in a range of 4: 1 to 1: 3 exhibited superior effects compared to Example 4 out of this. In addition, Example 1 satisfying the range of 4: 1 to 1.5: 1 was the best.

The melt-blown nonwoven fabric of the present invention can be widely used in air filters, masks, and the like.

Claims (19)

(1) Two or more thermoplastic polymer resins having the same components but different melting flow indexes, having the lowest melt flow index and the highest melt flow index among the two or more thermoplastic polymer resins. Preparing a mixed spinning composition by mixing a thermoplastic polymer resin having a deviation of a melt flow index of the thermoplastic polymer resin of 400 g / 10 min or more;
(2) mixing and spinning the mixed spinning composition from spinneret; And
(3) A method of manufacturing a meltblown nonwoven fabric comprising the step of forming the meltblown nonwoven fabric by laminating the spun meltblown yarn. delete According to claim 1,
The two or more types of thermoplastic polymer resin melt melt characterized in that it comprises a thermoplastic polymer resin having a melt flow index of 10 ~ 400 g / 10 minutes and a thermoplastic polymer resin having a melt flow index of 800 ~ 2000 g / 10 minutes Method of manufacturing a new nonwoven fabric. According to claim 3,
The thermoplastic polymer resin having a melt flow index of 10 to 400 g / 10 minutes and the thermoplastic polymer resin having a melt flow index of 800 to 2000 g / 10 minutes are mixed in a weight ratio of 4: 1 to 1: 3. Melt blown non-woven fabric manufacturing method. According to claim 3,
The thermoplastic polymer resin having a melt flow index of 10 to 400 g / 10 minutes and the thermoplastic polymer resin having a melt flow index of 800 to 2000 g / 10 minutes are mixed in a weight ratio of 4: 1 to 1.5: 1. Melt blown non-woven fabric manufacturing method. According to claim 1,
The thermoplastic polymer resin is a method of manufacturing a melt-blown non-woven fabric, characterized in that at least one selected from the group consisting of nylon, polyester, polypropylene, polypropylene copolymer, polyurethane, polyacrylonitrile, polyolefin and cellulose. . A thermoplastic polymer having the same component but containing two or more thermoplastic polymers having different melting flow indices, and having the lowest melt flow index among the two or more thermoplastic polymers and the thermoplastic polymer having the highest melt flow index. Melt blown non-woven fabric comprising a single melt blown yarn with a deviation of the melt flow index of 400 g / 10 min or more. delete The method of claim 7,
The two or more thermoplastic polymers are melt blown non-woven fabrics, characterized in that it comprises a thermoplastic polymer having a melt flow index of 10 to 400 g / 10 minutes and a thermoplastic polymer having a melt flow index of 800 to 2000 g / 10 minutes. The method of claim 9,
Melt characterized in that the thermoplastic polymer having a melt flow index of 10 to 400 g / 10 minutes and the thermoplastic polymer having a melt flow index of 800 to 2000 g / 10 minutes are mixed in a weight ratio of 4: 1 to 1: 2. Troubled non-woven fabric. The method of claim 10,
Melt characterized in that the thermoplastic polymer having a melt flow index of 10 to 400 g / 10 minutes and the thermoplastic polymer having a melt flow index of 800 to 2000 g / 10 minutes are mixed in a weight ratio of 4: 1 to 1.5: 1. Troubled non-woven fabric. The method of claim 7,
The thermoplastic polymer is a melt-blown non-woven fabric, characterized in that at least one selected from the group consisting of nylon, polyester, polyurethane, polyacrylonitrile, polyolefin and cellulose. The method of claim 7,
The meltblown nonwoven fabric has a fiber thickness of 0.2 to 15 μm. The method of claim 7,
The melt-blown nonwoven fabric has a thickness of 0.05 to 10 mm. The method of claim 7,
The melt-blown non-woven fabric is a melt-blown non-woven fabric, characterized in that the electrostatic treatment. The method of claim 15,
The melt-blown non-woven fabric further comprises a charging agent (charging agent) and antioxidant. Support; And
An air filter comprising the melt-blown nonwoven fabric of any one of claims 7 and 9 to 16 provided on at least one surface of the support. The method of claim 17,
Air filter characterized in that the melt-blown non-woven fabric is provided on both sides of the support. A pair of the melt-blown non-woven fabric of any one of claims 7 and 9 to 16; And
An air filter comprising a support provided between the pair of nonwoven fabrics.

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