KR102641445B1 - Method for manufacturing disposable protective clothing and work clothes fabric with 40% biodegradation expression - Google Patents

Abstract

The present invention relates to a method of manufacturing 40% biodegradable disposable protective clothing and workwear fabric, and more specifically, (a) supplying 40% biodegradable polyester yarn as weft and warp yarn, and processing composite yarn by ATY equipment. step; (b) weaving the composite yarn of step (a) into a fabric using a water loom; (c) dyeing and processing the fabric woven in step (b); and (d) laminating the fabric dyed and processed in step (c) using a dot-type gravure roller.

Description

Method for manufacturing disposable protective clothing and work clothes fabric with 40% biodegradation expression}

The present invention relates to a method of manufacturing 40% biodegradable disposable protective clothing and workwear fabric.

As of 2017, the domestic and overseas production of chemical fibers was 1.38 million tons domestically and 80 million tons globally. The global chemical fiber market size is growing rapidly every year, and the proportion of chemical fibers in the textile market increased from 64% in 2010 to 72% in 2017. It is increasing further in percentage.

Sales of SPA brands, also known as fast fashion, have grown rapidly since the 2000s, and the global clothing consumption growth trend is expected to reach 160 million tons in 2050. Environmental problems are emerging due to the increase in the production of chemical fibers and consumption of clothing and the large amount of waste generated due to the rapid increase in demand for household/industrial textile products after COVID-19. Consumers are turning to eco-friendly products due to concerns about the environment after COVID-19. demand is increasing.

Domestic chemical fiber production was 1.38 million tons as of 2017, maintaining a range of 1.3 to 1.4 million tons since 2013, and the textile waste counted in the Ministry of Environment's natural circulation information system was incinerated at 22,000 tons and landfilled at 0.7 million tons depending on the waste disposal method (as of 2017). , a total of 29,000 tons), the aggregate figure for textile product waste is less than 3% of production.

This shows that most of the non-aggregated textile product waste is being landfilled, and in order to reduce the environmental load caused by landfilling of such a large amount of textile product waste, the development of biodegradable fibers and biodegradation analysis methods for fibers are necessary.

In the case of existing textile product waste, toxic gases such as dioxin and hydrogen chloride are generated when incinerated, and because it is not biodegraded when landfilled, the problem of lack of landfill space is emerging.

Recently, the incineration rate has been increased to utilize the heat energy generated during incineration, and technologies are being developed to minimize the emission of toxic gases. However, incineration facilities are insufficient to incinerate the entire amount instead of landfill, and there is no way to reduce the emission of toxic gases generated during incineration. The reality is that it cannot be suppressed 100%.

Republic of Korea Patent No. 10-1225158 (registered on January 16, 2013)

The purpose of the present invention is to provide a method for manufacturing disposable protective clothing and workwear fabrics with 40% biodegradability in order to overcome the limitations of the prior art.

The method of manufacturing a 40% biodegradable disposable protective clothing and workwear fabric according to the present invention includes the steps of (a) supplying 40% biodegradable polyester yarn as weft and warp yarn, and processing the composite yarn by ATY equipment; (b) weaving the composite yarn of step (a) into a fabric using a water loom; (c) dyeing and processing the fabric woven in step (b); and (d) laminating the fabric dyed and processed in step (c) using a dot-type gravure roller.

In the process (a) according to the present invention, the nozzle of the ATY is characterized by a hole Ø0.5, a small angle, an air pressure of 1.6 kgf/cm ² , and a sand speed of 450 m/min.

The step (c) according to this ordinance includes a pretreatment process of the woven fabric, a setting process, a dyeing process, and a processing process, and the temperature conditions for each process are pretreatment process: 110 ~ 120℃, setting process: 205 ~ It is characterized by 210℃, dyeing process: 130 ~ 140℃, and processing process: 160 ~ 165℃.

In step (d) according to the present invention, the dot size of the gravure roller is 0.8 mm.

In step (d) according to the present invention, the textile fabric is characterized in that a PLA film containing 48% biomass is laminated.

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The method of manufacturing 40% biodegradable disposable protective clothing and workwear fabric according to the present invention is to develop biodegradable PET-based fiber materials and products through diversification of biodegradable materials, resin and additive manufacturing technology, long and short fiber and non-woven fabric manufacturing technology. Furthermore, it is possible to utilize equipment used in existing PET-based fiber manufacturing, including application products and commercialization technology, and it is possible to respond with minimal equipment modification and development of new spinning technology, which not only makes it possible to secure price competitiveness for high-performance products, but also enables film and injection molding. Related technologies can also be applied to manufacturing fields such as molding.

In addition, the present invention domestically produces raw materials for existing biodegradable materials, which were entirely dependent on imports from overseas, through the development of biodegradable PET-based fiber materials, enabling technological independence and improving national technological competitiveness through this.

In addition, the present invention develops biodegradable PET-based fiber materials and products to prepare for the post-corona era, such as the rapidly increasing demand for disposable products and waste problems caused by the coronavirus pandemic, and to respond to global environmental regulations and domestic Green New Deal policy situations, It becomes possible to respond to domestic and international environmental issues, such as demand for eco-friendly products.

Figure 1 is a process flow diagram showing a method of manufacturing a 40% biodegradable disposable protective clothing and workwear fabric according to the present invention;
Figure 2 is a conceptual diagram of the ATY equipment of the manufacturing method according to the present invention;
Figure 3 is a photograph showing the results of checking nozzle performance;
Figure 4 is a photograph showing the nozzle material change and structure according to the present invention;
Figure 5 is a photograph showing the Spectator roller installation and overfeed operation according to the present invention;
Figure 6 is a photograph showing a water loom according to the present invention;
7 is a process diagram showing the dyeing processing process according to the present invention;
8 is a photograph showing the laminating process according to the present invention;
Figure 9 is a photograph showing the laminating surface of a 40% biodegradable functional polyester fabric manufactured according to the present invention;
10 is a photograph showing protective clothing and work clothing manufactured using fabric using the manufacturing method according to the present invention;
Figures 11 to 13 are photographs showing test reports for fabrics, protective clothing, and work clothes manufactured according to the present invention.

In order to explain the present invention, its operational advantages, and the purpose achieved by practicing the present invention, preferred embodiments of the present invention are illustrated and discussed with reference to the following.

First, the terms used in this application are only used to describe specific embodiments and are not intended to limit the present invention, and singular expressions may include plural expressions unless the context clearly indicates otherwise. In addition, in the present application, terms such as "comprise" or "have" are intended to designate the presence of features, numbers, steps, operations, components, parts, or combinations thereof described in the specification, but are not intended to indicate the presence of one or more other It should be understood that this does not exclude in advance the presence or addition of features, numbers, steps, operations, components, parts, or combinations thereof.

In describing the present invention, if it is determined that a detailed description of a related known configuration or function may obscure the gist of the present invention, the detailed description will be omitted.

As shown in Figure 1, the manufacturing method of the 40% biodegradable disposable protective clothing and workwear fabric according to the present invention is (a) supplying 40% biodegradable polyester yarn as weft and warp yarn, and processing the composite yarn by ATY equipment. (S100), (b) weaving the composite yarn of step (a) (S100) into a fabric using a water loom (S200), and (c) step (S200) of step (b). (S300) of dyeing and processing the fabric woven by (S300) and (d) laminating the fabric dyed and processed by step (c) (S300) using a dot-type gravure roller (S400). It is composed by:

As shown in Figure 1, step (a) (S100) according to the present invention is a process for supplying 40% biodegradable polyester yarn as weft and warp yarn and processing composite yarn by ATY equipment.

SDY 75/36 and SDY 75/72 yarns were used as 40% biodegradable polyester yarn, and ATY equipment was used for the yarn processing process to provide bulkiness to increase wearing comfort for users of protective clothing and workwear. Figure 2 shows a conceptual diagram of the ATY facility.

Here, other process factors such as overfeed rate, air pressure, nozzle, sand speed, and slope were adjusted.

In particular, as a result of checking the nozzle performance, it was confirmed that performance was deteriorated due to the material and wear of the nozzle, as shown in Figure 3. In addition, considering that the cause of corrosion and wear of the nozzle is air pressure, which is the most important part of air interlacing, the nozzle material and structure were changed as shown in Figure 4.

To improve the yarn quality, a stable supply of yarn was made possible by installing a Spectator roller and overfeeding as shown in Figure 5.

The final results of the new Nozzle ATY equipment test reflecting this are as follows.

[Test 1-1]

A. Product name: SDY 75/36

B. Firing speed: 450 m/min

C. Date: 2021. 6.

Nozzle specifications AirPress
(kgf/㎠) Four speeds
(m/min) bulky Hall Ø Apostle 0.7 Standard 1.6 450 Medium 0.7 Small 1.6 450 High 0.7 Small 1.6 (Loop) 450 High 0.7 Small 1.6 450 Low triangle 0.7 1.6 450 Medium triangle 0.7 1.6 450 Medium

Recommended: Hole Ø0.7 / Thread Small / Air Pressure 1.6 / Firing Speed 450

[Test 1-2]

A. Product name: SDY 75/36

B. Firing speed: 450 m/min

C. Date: 2021. 6.

Nozzle specifications AirPress
(kgf/㎠) Four speeds
(m/min) bulky Hall Ø Apostle 0.6 Standard 1.6 450 Medium 0.6 Small 1.6 450 High 0.6 Small 1.6 (Loop) 450 High 0.6 Small 1.6 450 Low triangle 0.6 1.6 450 Medium triangle 0.6 1.6 450 Medium

Recommended: Hole Ø0.6 / Thread Small / Air Pressure 1.6 / Firing Speed 450

[Test 1-3]

A. Product name: SDY 75/36

B. Firing speed: 450 m/min

C. Date: 2021. 6.

Nozzle specifications AirPress
(kgf/㎠) Four speeds
(m/min) bulky Hall Ø Apostle 0.5 Standard 1.6 450 Medium 0.5 Small 1.6 450 High 0.5 Small 1.6 (Loop) 450 High 0.5 Small 1.6 450 Low triangle 0.5 1.6 450 Medium triangle 0.5 1.6 450 Medium

Recommended: Hole Ø0.5 / Thread Small / Air Pressure 1.6 / Firing Speed 450

[Test 2-1]

A. Product name: SDY 75/72

B. Firing speed: 450 m/min

C. Date: July 2021.

Nozzle specifications AirPress
(kgf/㎠) Four speeds
(m/min) bulky Hall Ø Apostle 0.7 Standard 1.6 450 Medium 0.7 Small 1.6 450 High 0.7 Small 1.6 (Loop) 450 High 0.7 Small 1.6 450 Low triangle 0.7 1.6 450 Medium triangle 0.7 1.6 450 Medium

Recommended: Hole Ø0.7 / Thread Small / Air Pressure 1.6 / Firing Speed 450

[Test 2-2]

A. Product name: SDY 75/72

B. Firing speed: 450 m/min

C. Date: July 2021.

Nozzle specifications AirPress
(kgf/㎠) Four speeds
(m/min) bulky Hall Ø Apostle 0.6 Standard 1.6 450 Medium 0.6 Small 1.6 450 High 0.6 Small 1.6 (Loop) 450 High 0.6 Small 1.6 450 Low triangle 0.6 1.6 450 Medium triangle 0.6 1.6 450 Medium

Recommended: Hole Ø0.6 / Thread Small / Air Pressure 1.6 / Firing Speed 450

[Test 2-3]

A. Product name: SDY 75/72

B. Firing speed: 450 m/min

C. Date: July 2021.

Nozzle specifications AirPress
(kgf/㎠) Four speeds
(m/min) bulky Hall Ø Apostle 0.5 Standard 1.6 450 Medium 0.5 Small 1.6 450 High 0.5 Small 1.6 (Loop) 450 High 0.5 Small 1.6 450 Low triangle 0.5 1.6 450 Medium triangle 0.5 1.6 450 Medium

Recommended: Hole Ø0.5 / Thread Small / Air Pressure 1.6 / Firing Speed 450

It can be confirmed that the optimal yarn processing process conditions were established for both biodegradable yarns SDY 75.36 and SDY 75/72, with nozzle hole Ø0.5, yarn size Small, air pressure 1.6 kgf/㎠, and yarn speed 450 m/min.

As mentioned above, as a result of the test related to the development of the new nozzle, it can be confirmed that compared to the existing same production conditions, there is an effect of improving the overall quality by improving the whiteness of the fabric due to the stabilization of the overall bulky gap.

As shown in Figure 1, step (b) (S200) according to the present invention is a process of weaving a fabric using the composite yarn of step (a) (S100) using a water loom.

DY 72/36 and SDY 7572 composite yarns that underwent the ATY process were used. To improve weaving properties, the warp yarn was subjected to a SIZING process, and the weft yarn was weaved in a lead-free manner.

In addition, the width, shrinkage, number of warp yarns, and density were kept the same, and the fabric patterns were changed to PLAIN, 2/2 TWILL, and SATIN, and a total of 6 types of weaving were designed and weaved.

The equipment used was a 190TYPE water loom as shown in Figure 6, and when weaving was performed under the conditions of the weaving design, the continuity of the weaving process was calculated to be the same as the average daily weaving amount compared to the existing general polyester fabric, enabling a stable weaving process. I was able to.

As shown in Figure 1, step (c) (S300) according to the present invention is a process for dyeing and processing the fabric woven in step (b) (S200).

In step (c) (S300), the optimal conditions are established for the pretreatment process, setting process, dyeing process, and processing process as shown in FIG. 7 based on data on the pretreatment and dyeing processing conditions of the existing polyester fabric as follows. did.

1) Pretreatment conditions: 110~120℃, 60min (pretreatment equipment)

2) Setting conditions (S/T): 205~210℃, width 60 inches (Tenter)

3) Dyeing conditions: 130~140℃, 60min (Rapid dyeing machine)

4) Processing conditions: Low temperature processing 160~165℃, width 60 inches (Tenter)

This is to improve processability by smoothing the fabric surface for the laminating post-processing process.

As shown in Figure 1, step (d) (S400) according to the present invention is a process of manufacturing fabric by laminating the fabric dyed and processed in step (c) (S300) using a dot-type gravure roller. .

In step (d) (S400), adhesion was secured using a gravure roller suitable for textile fabrics and membranes, as shown in FIG. 8. In addition, the application amount per unit area was controlled using a dot-type gravure roller, and the adhesive performance was confirmed through a peel strength test.

First, to control the adhesive application amount to maximize adhesion, the application amount was controlled by adjusting the hardness and pressure of the back-up roller, and the application amount was controlled by controlling the viscosity and fabric penetration according to the temperature of the hot-melt adhesive and adjusting the gravure cell size. .

In addition, to control the amount of adhesive penetration, the pressure and temperature of the Nip roll were controlled, and the surface of the fabric and film was treated with IR-Radiation.

In addition, in order to minimize the left and right performance deviation of the fabric, the pressure of the back-up roll and the left and right pressure balance of the nip roll were controlled to minimize the left and right performance deviation of the fabric.

In particular, laminating of a PLA film containing 48% biomass was carried out to realize biodegradability and comfort. Since the difference in physical properties of biodegradable yarn is similar to that of existing polyester yarn, the laminating process was carried out using a hot melt method, and it was confirmed that the adhesion was excellent. I was able to.

Table 7 and Table 8 below show the laminating conditions for biodegradable fabric.

laminating process conditions Biodegradable polyester fabric Gravure roller
(dot size) mm CP 95_0.68mm Membrane Type PTFE
(25㎛ single type, YMT) Adhesive - PLA containing 48% biomass
(Viscosity 10,000 cps) Line speed m/min 7 Oil heating ℃ 106 Plate Temp. ℃ 104 Hose1 Temp. ℃ 105 Hose2 Temp. ℃ 105 Doc. Blade ℃ 105 IR Heater % - Gap left coat. mm -0.1 Gap right coat. mm -0.1 Gap left Laminat. mm -0.1 Gap right Laminat. mm -0.1 speed laminating cyl. % 3 Humidifier on/off off Accum. Tension N 31 dancer before accumulator bar 1.5 Film Tension N 35 Laminat. Tension N 33 central winder dancer bar 2.1 batch dancer bar 4

laminating process conditions Biodegradable polyester fabric Gravure roller
(dot size) mm CP52_0.8mm Membrane Type PTFE
(25㎛ single type, YMT) Adhesive - PLA containing 48% biomass
(Viscosity 10,000 cps) Line speed m/min 7 Oil heating ℃ 106 Plate Temp. ℃ 104 Hose1 Temp. ℃ 105 Hose2 Temp. ℃ 105 Doc. Blade ℃ 105 IR Heater % - Gap left coat. mm -0.1 Gap right coat. mm -0.1 Gap left Laminat. mm -0.1 Gap right Laminat. mm -0.1 speed laminating cyl. % 3 Humidifier on/off off Accum. Tension N 31 dancer before accumulator bar 1.5 Film Tension N 35 Laminat. Tension N 33 central winder dancer bar 2.1 batch dancer bar 4

Among the laminating conditions, it was confirmed that the adhesion between the fabric and the film was excellent under the process conditions shown in Table 8.

In other words, it can be confirmed that when the dot size of the gravure roller is 'CP 52_0.8mm', the adhesion between the PLA film containing 48% biomass and the fabric is excellent.

Figure 9 is an enlarged photograph of the laminating surface and the film surface of the 40% biodegradable functional polyester fabric produced by the manufacturing method according to the present invention.

Disposable protective clothing and work clothes manufactured by the fabric manufacturing method of the present invention configured as described above are manufactured as shown in FIG. 10.

Figures 11 to 13 are test reports for tensile strength, artificial blood penetration resistance, and bacterial phage penetration resistance for fabrics, protective clothing, and work clothes manufactured through the manufacturing method according to the present invention.

Figure 11 shows the results of testing the tensile strength, water repellency, and moisture permeability after washing 10 times, Figure 12 shows the test results for artificial blood penetration resistance Step6=Class6, and Figure 13 shows the test results for bacterial phage penetration resistance.

As such, the present invention has been described with reference to an embodiment shown in the drawings, but this is merely illustrative, and various modifications and other equivalent embodiments can be made by those skilled in the art. You will understand.

Therefore, the true technical protection scope of the present invention should be determined by the technical spirit of the attached claims.

Claims (6)

(a) supplying 40% biodegradable polyester yarn as weft and warp yarn, and processing composite yarn by ATY equipment (S100);
(b) weaving the composite yarn of step (a) (S100) into a fabric using a water loom (S200);
(c) dyeing and processing the fabric woven in step (b) (S200) (S300); and
(d) laminating the fabric dyed and processed in step (c) (S300) using a dot-type gravure roller (S400);
In step (a) (S100), the nozzle of the ATY has a hole of Ø0.5, a small angle, an air pressure of 1.6 kgf/cm ² , and a sand speed of 450 m/min,
Step (c) (S300) includes a pretreatment process for the woven fabric, a setting process, a dyeing process, and a processing process, and the temperature conditions for each process are pretreatment process: 110 to 120°C, setting process: 205 to 210°C. ℃, dyeing process: 130 ~ 140℃ and processing process: 160 ~ 165℃,
In step (d) (S400), the dot size of the gravure roller is 0.8 mm,
The amount of adhesive applied is controlled by adjusting the hardness and pressure of the back-up roller, and is controlled by controlling the viscosity and penetration power according to the temperature of the hot-melt adhesive and adjusting the gravity cell size.
Controls the penetration amount of adhesive through nip roll pressure, temperature control, and IR-radiation treatment of the fabric and film surface.
The left and right performance deviation of the fabric is controlled by controlling the pressure of the back-up roll and the left and right pressure balance of the nip roll.
In step (d) (S400), the textile fabric is laminated with a PLA film containing 48% biomass,
The process conditions for laminating the PLA containing 48% of biomass to the fabric by the gravure roller dot size of 0.8mm are
Line speed: 7m/s, Oil heating: 106℃, Plate Temp. : 104℃, Hose1 Temp. : 105℃, Hose2 Temp. : 105℃, Doc. Blade: 105℃, Gap left coat. : -0.1mm, Gap right coat. : -0.1mm, Gap left Laminat. : -0.1mm., Gap right Laminat. : -0.1mm., speed laminating cyl. : 3%, Humidifier : off, Accum. Tension: 31N, dancer before accumulator: 1.5bar, Film Tension: 35N, Laminat. Tension: 33N, central winder dancer: 2.1 bar, batching dancer: 4 bar. Method for manufacturing 40% biodegradable disposable protective clothing and workwear fabric. delete delete delete delete delete