KR102600663B1 - Non-woven fabric laminate and article including the same - Google Patents

Abstract

A nonwoven laminate and an article comprising the same are disclosed. The disclosed nonwoven fabric laminate includes a first spunbonded nonwoven fabric layer, a charged meltblown nonwoven fabric layer, and a second spunbonded nonwoven fabric layer, and at least one of the first spunbonded nonwoven fabric layer and the second spunbonded nonwoven fabric layer is It includes a plurality of holes penetrating in the thickness direction, and at least one of the first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer has a hole fraction of 0.5 to 10.0% calculated by Equation 1 below:
[Equation 1]
Hole fraction (%) = (area occupied by total holes among the total surface area of the side with the largest area among the sides of the nonwoven fabric layer)/(total surface area of the side with the largest area among the sides of the nonwoven fabric layer) × 100.

Description

Non-woven fabric laminate and article including the same}

A nonwoven laminate and an article comprising the same are disclosed. More specifically, a nonwoven laminate that not only has excellent mechanical properties and fine dust removal function but also allows users to feel comfortable breathing, and an article containing the same are disclosed.

In the case of a fine dust removal mask, it is composed of a multi-layered inner and outer material and a filter material that filters fine dust in the center.

As the filter layer, electrically charged meltblown nonwoven fabric is mainly used. Meltblown nonwoven fabrics have low dimensional stability due to low mechanical strength and high flexibility, so structural deformation easily occurs due to external impact or friction. Therefore, in order to protect the meltblown nonwoven fabric layer and provide shape stability, the mask is constructed by laminating a nonwoven fabric with high mechanical properties such as shape stability and tensile strength on both sides or one side of the meltblown nonwoven fabric layer, mainly spunbond. Nonwoven fabrics are laminated through a separate laminating process.

A fine dust removal mask with a multi-layer structure of a conventional spunbond nonwoven fabric layer (inner layer), a charged meltblown nonwoven fabric layer (filter layer), and a spunbond nonwoven fabric layer (outer layer) increases pressure loss as fine dust removal efficiency increases. As the pressure also increases, there is a problem in that the user feels uncomfortable when breathing.

One embodiment of the present invention provides a non-woven laminate that not only has excellent mechanical properties and fine dust removal function, but also allows the user to feel comfortable breathing.

Another embodiment of the present invention provides an article comprising the nonwoven fabric.

One aspect of the present invention is,

Comprising a first spunbond nonwoven fabric layer, a charged meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer,

At least one of the first spunbonded nonwoven fabric layer and the second spunbonded nonwoven fabric layer includes a plurality of holes penetrating in the thickness direction,

At least one of the first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer provides a nonwoven laminate having a hole fraction of 0.5 to 10.0% calculated by Equation 1 below:

[Equation 1]

Hole fraction (%) = (area occupied by total holes among the total surface area of the side with the largest area among the sides of the nonwoven fabric layer)/(total surface area of the side with the largest area among the sides of the nonwoven fabric layer) × 100.

The nonwoven laminate may have an air permeability of 4 to 10 ccs measured according to JIS L 1096-A.

The non-woven fabric laminate may have a fine dust removal efficiency of 85.0 to 99.9% and a pressure loss of 2.0 to 10.0 mmH ₂ O.

The nonwoven laminate may have an average diameter of one hole of 0.330 to 1.80 mm and a hole density of 10 to 56 ea/cm ² .

The nonwoven fabric laminate may include the first spunbond nonwoven fabric layer, the charged meltblown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer in this order.

The first spunbond nonwoven fabric layer, the charged meltblown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer each independently contain a non-conductive polymer, and the non-conductive polymer is polyolefin, polystyrene, polycarbonate, poly It may include esters, polyamides, copolymers thereof, or combinations thereof.

The content of the charged meltblown nonwoven fabric layer may be 3 to 50 parts by weight based on 100 parts by weight of the total weight of the nonwoven fabric laminate.

Another aspect of the present invention is,

An article comprising the nonwoven laminate is provided.

The article may be a mask for removing fine dust, a filter for an air purifier, or a filter for an air conditioner.

The nonwoven fabric laminate according to one embodiment of the present invention can be applied as a material for filtering fine particles in the air.

In addition, the non-woven laminate not only has excellent mechanical properties and fine dust removal function, but also has the advantage of allowing users to feel comfortable breathing.

In addition, the non-woven laminate can be used for the purpose of removing various dust, fine dust, and bacteria, and can be applied not only to health masks, but also to various homes, vehicles, industrial air conditioners and air purifiers that require air purification.

1 is a diagram schematically showing a nonwoven fabric laminate according to an embodiment of the present invention.

Hereinafter, a nonwoven fabric laminate according to an embodiment of the present invention will be described in detail.

In this specification, “non-woven fabric laminate” refers to a product in which two or more types of nonwoven fabrics are individually manufactured and then undergo a separate laminating process.

The nonwoven fabric laminate according to one embodiment of the present invention includes a first spunbond nonwoven fabric layer, an electrically charged meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer.

At least one of the first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer includes a plurality of holes penetrating in the thickness direction.

In addition, at least one of the first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer has a hole fraction of 0.5 to 10.0%, 1.0 to 8.2%, 1.2 to 8.0%, and 1.4 to 7.8%, calculated by Equation 1 below. , 1.6-7.6%, 1.8-7.4%, 2.0-7.2%, 2.2-7.0%, 2.4-6.8%, 2.6-6.6%, 2.8-6.4% or 3.3-6.5%:

[Equation 1]

Hole fraction (%) = (area occupied by total holes among the total surface area of the side with the largest area among the sides of the nonwoven fabric layer)/(total surface area of the side with the largest area among the sides of the nonwoven fabric layer) × 100.

When the hole fraction in the first spunbonded nonwoven fabric layer and/or the second spunbonded nonwoven fabric layer is less than the lower limit of 0.5%, the fine dust removal rate is excellent, but the pressure loss is so large that the user feels uncomfortable when breathing, If the hole fraction exceeds the upper limit of 10.0%, the pressure loss is small and the user can feel comfortable when breathing, but the fine dust removal rate is excessively low.

The nonwoven laminate may have an air permeability of 4 to 10 ccs or 4 to 8 ccs, as measured according to JIS L 1096-A.

In addition, the non-woven fabric laminate has a fine dust removal efficiency of 85.0 to 99.9%, 90.0 to 99.9%, or 94.0 to 99.9%, and a pressure loss of 2.0 to 10.0 mmH ₂ O, 2.0 to 8.0 mmH ₂ O, 2.0 to 6.0 mmH ₂ It may be O or 2.0~4.0mmH ₂ O.

The average diameter of one hole is 0.330 to 1.80 mm or 0.8 to 1.2 mm, and the hole density may be 10 to 56 ea/cm ² or 15 to 40 ea/cm ² .

The nonwoven fabric laminate is characterized by having a fine particle collection function by including an electrically charged meltblown nonwoven fabric layer.

The nonwoven fabric laminate may include the first spunbond nonwoven fabric layer, the charged meltblown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer in this order. However, the present invention is not limited to this, and the nonwoven fabric laminate may include the first spunbond nonwoven fabric layer, the charged meltblown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer in a different order.

The first spunbond nonwoven fabric layer, the charged meltblown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer each independently contain a non-conductive polymer, and the non-conductive polymer is polyolefin, polystyrene, polycarbonate, poly It may include esters, polyamides, copolymers thereof, or combinations thereof.

The non-conductive polymer may include polyolefin, polystyrene, polycarbonate, polyester, polyamide, copolymers thereof, or a combination thereof.

The polyolefin may include polyethylene, polypropylene, poly-4-methyl-1-pentene, polyvinyl chloride, or a combination thereof.

The polyester may include polyethylene terephthalate, polylactic acid, or a combination thereof.

The first spunbond nonwoven fabric layer, the charged meltblown nonwoven fabric layer, and the second spunbond nonwoven fabric layer may further include additives independently of each other.

The additives include pigments, light stabilizers, primary antioxidants, secondary antioxidants, metal deactivators, hindered amines, hindered phenols, fatty acid metal salts, triester phosphites, phosphates, fluorine-containing compounds, nucleating agents (nucleant), or these. It may include a combination of .

Additionally, in one embodiment, antioxidants may function as charge increasers. Possible charge increasing agents include heat stable organic triazine compounds, oligomers or combinations thereof, wherein these compounds or oligomers further contain at least one nitrogen atom in addition to the nitrogen in the triazine ring.

For example, charge increasing agents for improving charging characteristics are disclosed in U.S. Patent Nos. 6,268,495, 5,976,208, 5,968,635, 5,919,847, and 5,908,598. For example, the charge increaser may include a hindered amine-based additive, a triazine additive, or a combination thereof.

As another example, the charge increasing agent is poly[((6-(1,1,3,3-tetramethylbutyl)imino-1,3,5-triazine-2,4-diyl)((2, 2,6,6-tetramethyl-4-piperidyl)imino)hexamethylene ((2,2,6,6-tetramethyl-4-piperidyl)imino)] (BASF, CHIMASSORB 944) , (1,6-hexanediamine N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl) with 2,4,6-trichloro-1,3,5-triazine -Polymer, N-butyl-1-butanamine, reaction product with N-butyl-2,2,6,6-tetramethyl-4-piperidineamine) (manufactured by BASF, CHIMASSORB 2020) or a combination thereof It can be included.

The charge increasing agent is an N-substituted amino aromatic compound, especially a tri-amino substituted compound, such as 2,4,6-trianilino-p-(carbo-2'-ethylhexyl-1'-oxy)- It may be 1,3,5-triazine (UVINUL T-150 manufactured by BASF). Another charge increasing agent is 2,4,6-tris-(octadecylamino)-triazine, also known as tristearyl melamine (“TSM”).

The content of the charge increaser may be 0.25 to 5 parts by weight based on 100 parts by weight of the meltblown nonwoven fabric layer. If the content of the charge increaser is within the above range, not only can the high level of charging performance targeted by the present invention be obtained, but the spinnability is good, the strength of the nonwoven fabric is maintained high, and it is also advantageous in terms of cost.

In addition to the above additives, the nonwoven laminate may further include generally known additives such as heat stabilizers and weathering agents.

The content of the charged meltblown nonwoven fabric layer may be 3 to 50 parts by weight based on 100 parts by weight of the total weight of the nonwoven fabric laminate. If the content of the charged meltblown nonwoven layer is within the above range, a nonwoven laminate with excellent filtration performance, shape stability, and durability can be obtained.

The nonwoven laminate may have a basis weight (mass per unit area) of 10 to 500 gsm (g/m ² ), for example, 20 to 100 gsm.

Hereinafter, a method for manufacturing a nonwoven fabric laminate according to an embodiment of the present invention will be described in detail.

The method of manufacturing a nonwoven fabric laminate according to an embodiment of the present invention includes manufacturing a spunbond nonwoven fabric layer (S10), forming a through hole in the thickness direction in the manufactured spunbond nonwoven fabric layer (S20), and electrifying the nonwoven fabric layer. It includes manufacturing a meltblown nonwoven fabric layer (S30) and laminating the perforated spunbond nonwoven fabric layer one by one on both sides of the meltblown nonwoven fabric layer (S40).

The spunbond nonwoven fabric layer manufacturing step (S10) and the through hole forming step (S20) can be performed as a continuous process in one device.

Figure 1 is a diagram schematically showing a nonwoven fabric laminate 10 according to an embodiment of the present invention.

The nonwoven laminate 10 according to one embodiment of the present invention includes a first spunbond nonwoven fabric layer 11, a meltblown nonwoven fabric layer 12, and a second spunbond nonwoven fabric layer 13.

Another aspect of the present invention provides an article comprising the nonwoven laminate.

The article may be a mask for removing fine dust, a filter for an air purifier, or a filter for an air conditioner.

Hereinafter, the present invention will be described in more detail through examples. These examples are intended to illustrate the present invention in more detail, and the scope of the present invention is not limited to these examples.

Example 1: Preparation of non-woven laminate

First, two spunbond nonwoven layers (SB1, SB2) were manufactured using propylene homopolymer (LG Chemical, H7700) with a melt index (MI) of 34 g/10 min. Thereafter, each of the spunbond nonwoven fabric layers (SB1, SB2) was passed between pattern rolls to form a through hole in the thickness direction. The pattern roll was composed of a first roll having a plurality of pin-shaped protrusions on its surface and a second roll having a plurality of grooves of an opposite shape to the protrusions. As a result, a plurality of through holes were formed in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 3.3%, an average diameter of one hole of 0.8 mm, and a hole density of 24 (ea)/cm ² . formed. Afterwards, a meltblown nonwoven layer (MB) was manufactured using a resin (LG Chemical, H7910) with a melt flow rate (MFR) of 1000 g/10 min. In addition, Chimassorb 944, a hindered amine light stabilizer, was added to the meltblown nonwoven layer (MB) resin (LG Chemical, H7910) at an amount of 0.5 wt%. Additionally, the meltblown nonwoven fabric layer (MB) was charged by contacting it with water and air through a two-fluid nozzle. Thereafter, the perforated spunbond nonwoven fabric layers (SB1, SB2) were laminated one by one on both sides of the meltblown nonwoven fabric layer (MB) to prepare an SMS type nonwoven laminate. Here, the total basis weight of the SMS type nonwoven fabric laminate was adjusted to 100gsm (g/m ² ), and the basis weight of the meltblown nonwoven layer (MB) was adjusted to 22gsm.

Example 2: Preparation of nonwoven laminate

By replacing the pattern roll, a plurality of penetrations are made in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 0.8mm, and a hole density of 24 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Example 3: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of holes are formed in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 6.5%, an average diameter of one hole of 0.8mm, and a hole density of 24 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Example 4: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of penetrations are made in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 0.55 mm, and a hole density of 15 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Example 5: Preparation of nonwoven laminate

By replacing the pattern roll, a plurality of penetrations are made in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 0.55 mm, and a hole density of 40 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Example 6: Preparation of nonwoven laminate

By replacing the pattern roll, a plurality of holes are formed in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 1.2 mm, and a hole density of 15 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Example 7: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of holes are formed in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 1.2 mm, and a hole density of 40 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Comparative Example 1: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of holes are formed in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 0.3%, an average diameter of one hole of 0.8 mm, and a hole density of 24 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Comparative Example 2: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of penetrations are made in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 15%, an average diameter of one hole of 0.8 mm, and a hole density of 24 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Comparative Example 3: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of holes are formed in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 0.2 mm, and a hole density of 24 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Comparative Example 4: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of holes are formed in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 2.0 mm, and a hole density of 24 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Comparative Example 5: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of holes are formed in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 0.8mm, and a hole density of 5 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

Comparative Example 6: Preparation of non-woven laminate

By replacing the pattern roll, a plurality of penetrations are made in each of the spunbond nonwoven layers (SB1, SB2) with a hole fraction of 4.6%, an average diameter of one hole of 0.8 mm, and a hole density of 60 (ea)/cm ² A nonwoven fabric laminate was manufactured in the same manner as Example 1, except that holes were formed.

A plurality of through holes formed in two spunbond nonwoven fabric layers (SB1, SB2) laminated on both sides of the meltblown nonwoven fabric layer (MB) in the nonwoven laminates prepared in Examples 1 to 7 and Comparative Examples 1 to 6. The fraction, average diameter of one hole, and hole density are summarized in Table 1 below.

Example One 2 3 4 5 6 7 Hole fraction (%)
(SB1,SB2) 3.3 4.6 6.5 4.6 4.6 4.6 4.6 Average diameter of one hole (mm)
(SB1,SB2) 0.8 0.8 0.8 0.55 0.55 1.2 1.2 Hole density (ea/cm ² )
(SB1,SB2) 24 24 24 15 40 15 40 Comparative example One 2 3 4 5 6 Hole fraction (%)
(SB1, SB2) 0.3 15 4.6 4.6 4.6 4.6 Average diameter of one hole (mm)
(SB1,SB2) 0.8 0.8 0.20 2.0 0.8 0.8 Hole density (ea/cm ² )
(SB1,SB2) 24 24 24 24 5 60

Evaluation example: Evaluation of physical properties of nonwoven laminate

The air permeability, fine dust removal efficiency, and pressure loss of each nonwoven fabric laminate prepared in Examples 1 to 7 and Comparative Examples 1 to 6 were evaluated by the following methods, and the results are shown in Table 2 below.

(1) Measuring device: TSI's TSI-8130 model was used.

(2) Aerosol formation: The measuring device contacted air with an aqueous sodium chloride solution and then evaporated the water to form an aerosol containing sodium chloride dispersed in the air with an average particle diameter of 0.3㎛ and a sodium chloride particle concentration of 18.5mg/m ³ . .

(3) Evaluation of aerosol removal efficiency: The aerosol permeation flow rate was 95 L/min, and the evaluation area of the nonwoven fabric was 100 cm ² . Aerosol removal efficiency was recorded as fine dust removal efficiency.

(4) Pressure loss evaluation: The aerosol permeation flow rate was 30 L/min, and the evaluation area of the nonwoven fabric was 100 cm ² .

(5) Air permeability: “Air permeability” was measured using Air Permeability FX-3000 (Switzerland) according to JIS L 1096-A. When measuring air permeability, the measured area was 38cm ² , the pressure was 125 Pascal, and the unit of measurement was ccs (cm ³ /cm ² /sec).

Example One 2 3 4 5 6 7 air permeability
(ccs) 4.6 5.0 5.6 4.2 6.0 4.4 6.2 Fine dust removal efficiency
(%) 95.2 94.8 95.6 95.4 95.7 95.0 95.8 pressure loss
(mmH ₂ O) 3.2 3.6 3.3 3.2 3.7 3.4 3.4 Comparative example One 2 3 4 5 6 air permeability
(ccs) 2.0 19.0 3.2 22.5 2.2 30.7 Fine dust removal efficiency
(%) 95.4 77.8 94.8 81.6 95.1 76.1 pressure loss
(mmH ₂ O) 12.6 2.1 12.3 1.7 13.7 1.8

Referring to Table 2, the nonwoven fabric laminates prepared in Examples 1 to 7 showed high air permeability of more than 4 ccs, high fine dust removal efficiency of more than 94%, and low pressure loss of less than 4 mmH ₂ O.

However, the nonwoven fabric laminates prepared in Comparative Examples 1, 3, and 5 had a high fine dust removal efficiency of over 94%, but had low air permeability of less than 4 ccs and pressure loss of more than 12 mmH ₂ O.

In addition, the nonwoven fabric laminates prepared in Comparative Examples 2, 4, and 6 had high air permeability of more than 4 ccs and low pressure loss of less than 4 mmH ₂ O, but the fine dust removal efficiency was found to be low at less than 85%.

The present invention has been described with reference to the drawings and examples, but these are merely illustrative, and those skilled in the art will understand that various modifications and equivalent implementations can be made therefrom. Therefore, the true scope of technical protection of the present invention should be determined by the technical spirit of the appended claims.

10: Nonwoven laminate 11: First spunbond nonwoven layer
12: Meltblown nonwoven layer 13: Second spunbond nonwoven layer

Claims (9)

Comprising a first spunbond nonwoven fabric layer, a charged meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer,
At least one of the first spunbonded nonwoven fabric layer and the second spunbonded nonwoven fabric layer includes a plurality of holes penetrating in the thickness direction,
The average diameter of one hole is 0.330~1.80mm, and the hole density is 10~56ea/cm ² ,
At least one of the first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer has a hole fraction of 3.3 to 6.5% calculated by Equation 1 below:
[Equation 1]
Hole fraction (%) = (area occupied by total holes among the total surface area of the side with the largest area among the sides of the nonwoven fabric layer)/(total surface area of the side with the largest area among the sides of the nonwoven fabric layer) × 100. According to paragraph 1,
Nonwoven laminate with an air permeability of 4 to 10 ccs measured according to JIS L 1096-A. According to paragraph 2,
A non-woven laminate with a fine dust removal efficiency of 85.0~99.9% and a pressure loss of 2.0~10.0mmH ₂ O. delete According to paragraph 1,
The nonwoven laminate includes the first spunbond nonwoven fabric layer, the charged meltblown nonwoven fabric layer, and the second spunbond nonwoven fabric layer in this order. According to paragraph 1,
The first spunbond nonwoven fabric layer, the charged meltblown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer each independently contain a non-conductive polymer, and the non-conductive polymer is polyolefin, polystyrene, polycarbonate, poly A nonwoven laminate comprising ester, polyamide, copolymers thereof, or a combination thereof. According to paragraph 1,
The content of the charged meltblown nonwoven fabric layer is 3 to 50 parts by weight based on 100 parts by weight of the total weight of the nonwoven fabric laminate. An article comprising a nonwoven laminate according to any one of claims 1 to 3 and 5 to 7. According to clause 8,
The above products are masks for removing fine dust, filters for air purifiers, or filters for air conditioners.