KR20210125907A - Non-woven fabric composite for air filter, and article including the same - Google Patents

Abstract

Disclosed are: a composite nonwoven fabric for an air filter which can be used to remove various kinds of dust, fine dust, bacteria, and the like; and an article including the same. The disclosed composite nonwoven fabric comprises a first spunbond nonwoven fabric layer, a meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer, wherein the melt blown nonwoven fabric layer is at least partially charged. The filament fineness of the second spunbond nonwoven fabric layer is greater than the filament fineness of the first spunbond nonwoven fabric layer. The ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is 40 to 100. The ratio of the filament fineness of the second spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is 225 to 700.

Description

Non-woven fabric composite for air filter, and article including the same}

Composite nonwoven fabrics and articles comprising the same are disclosed. More particularly, a composite nonwoven fabric for an air filter, and an article including the same are disclosed.

The conventional air filter is composed of a double structure of an electrostatic melt blown nonwoven fabric layer serving as a main filter and a support layer for reinforcing the same.

In the manufacturing process of the air filter, the melt blown nonwoven fabric and the spunbond or short fiber nonwoven fabric used as the support are respectively manufactured and laminated in a separate process, and a hot-melt adhesive is used for laminating them. However, when a hot melt adhesive is used, fumes are generated during the process, causing odor, adversely affecting the health of workers, and ultimately increasing the differential pressure of the filter media produced.

In addition, in the case of melt blown nonwoven fabric, which serves as the main filter, it has low durability and low shape stability, so it is easy to detach or damage if the melt blown fabric is exposed to the outside and comes in contact with or scratched by other objects during the manufacturing process and use. It can be a problem if you use it.

One embodiment of the present invention provides a composite nonwoven fabric for an air filter.

Another aspect of the present invention provides an article comprising the composite nonwoven fabric for an air filter.

One aspect of the present invention is

A first spunbond nonwoven fabric layer, a melt blown nonwoven fabric layer and a second spunbond nonwoven fabric layer,

The melt blown nonwoven layer is at least partially charged,

The filament fineness of the second spunbond nonwoven layer is greater than the filament fineness of the first spunbond nonwoven layer,

The ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is 40-100,

The ratio of the filament fineness of the second spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is 225 to 700 to provide a composite nonwoven fabric for an air filter.

The filament fineness of the first spunbond nonwoven layer is 1 to 5 denier, the filament fineness of the melt blown nonwoven layer is 0.01 to 0.16 denier, and the filament fineness of the second spunbond nonwoven layer may be 3 to 20 denier. have.

The basis weight of the first spunbond nonwoven layer is 10 to 40 g/m ² , the basis weight of the melt blown nonwoven layer is 15 to 50 g/m ² , and the basis weight of the second spunbond nonwoven layer is 30 to It may be 100 g/m ^{2 .}

The composite nonwoven fabric for an air filter may include the first spunbonded nonwoven fabric layer, the melt blown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer in this order.

The first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer may each include a plurality of spunbond nonwoven fabric sublayers.

The melt-blown non-woven fabric layer may further include at least one non-electrostatically-treated melt-blown non-woven fabric sub-layer in addition to the at least one electrostatically treated melt-blown non-woven fabric sub-layer.

The composite nonwoven fabric for an air filter may further include at least one additional layer.

The composite nonwoven fabric for an air filter may not contain any adhesive including a hot melt adhesive.

Another aspect of the present invention is

It provides an article comprising the composite nonwoven fabric for an air filter.

The article may be a media for an air filter, an air filter or an air purifier.

The composite nonwoven fabric according to an embodiment of the present invention is manufactured in a single continuous process and does not separately use an adhesive such as a hot melt adhesive, so there is no fumes in the field, so it is environmentally friendly, can lower the filter differential pressure, and melt blown Since a separate spunbond layer serving as a pretreatment and a cover is combined on the nonwoven fabric layer, shape stability and durability are excellent, and the differential pressure is low.

In addition, the composite nonwoven fabric for an air filter may be used for the purpose of removing various kinds of dust, fine dust, bacteria, and the like, and may be applied to various air filters.

1 is a view schematically showing a composite nonwoven fabric for an air filter according to an embodiment of the present invention.
2 is a view schematically showing an apparatus for manufacturing a composite nonwoven used to continuously manufacture a composite nonwoven according to an embodiment of the present invention.

Hereinafter, the composite nonwoven fabric for an air filter according to an embodiment of the present invention will be described in detail.

In the present specification, "non-woven fabric composite" is not a non-woven fabric laminate manufactured through a separate lamination (lamination) post-process after two or more kinds of non-woven fabrics are individually prepared, but two or more kinds of non-woven fabrics are one It means a nonwoven fabric that is manufactured in a continuous process in each device and integrated with each other. Therefore, in this specification, "composite non-woven fabric" may also be referred to as "monolithic non-woven fabric". The composite nonwoven fabric for an air filter has a strong interlayer bonding, and excellent shape stability and filtration performance compared to the nonwoven fabric laminate.

Also, in the present specification, the "electrostatically treated melt blown nonwoven fabric layer" or "electrostatically treated melt blown nonwoven fabric sublayer" may be manufactured by a continuous process. Specifically, the "electrostatically-treated melt-blown non-woven fabric layer" or "pre-charged melt-blown non-woven fabric sub-layer" is manufactured by sequentially or simultaneously performing "preparation of melt-blown non-woven fabric" and "electro-treatment" in a continuous process. it may have been

Also, in the present specification, "charged" means a state in which electric charges are semi-permanently applied to the non-woven fabric fibers to form an electrostatic field between adjacent fibers, and the charged non-woven fabric has a charge compared to the non-electrostatically-treated non-woven fabric. It has high density and fine dust removal efficiency.

The composite nonwoven fabric for an air filter according to an embodiment of the present invention includes a first spunbonded nonwoven fabric layer, a meltblown nonwoven fabric layer and a second spunbonded nonwoven fabric layer. Specifically, the composite nonwoven fabric for an air filter includes a first spunbond nonwoven fabric layer, a meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer, each of which is manufactured by a continuous process in one device and integrated with each other.

The melt blown nonwoven layer is at least partially charged.

The composite nonwoven fabric for an air filter includes at least a partially charged melt blown nonwoven fabric layer, characterized in that it has a fine particle collecting function. However, since the conventional spunbond-meltblown multilayer nonwoven fabric has an average pore size of several to several tens of micrometers (㎛), there is little function of removing fine particles of 0.1 to 0.6㎛ level.

The filament fineness of the second spunbond nonwoven fabric layer is greater than the filament fineness of the first spunbond nonwoven fabric layer.

For example, the filament fineness of the first spunbond nonwoven layer may be 1 to 5 denier, and the filament fineness of the second spunbond nonwoven layer may be 3 to 20 denier.

In addition, the filament fineness of the melt blown nonwoven fabric layer may be 0.01 ~ 0.16 denier.

In addition, the ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is 40-100. If the ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is less than 40, the differential pressure of the filter itself increases, and when it exceeds 100, the performance as a pretreatment filter is insignificant, so filtration efficiency and collection amount does not have a significant effect on the

In addition, the ratio of the filament fineness of the second spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is 225 to 700. When the ratio of the filament fineness of the second spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is less than 225, the differential pressure of the filter itself increases, and when it exceeds 700, spinning in a continuous process is difficult as well as filter media The thickness of the filter is increased too much, so workability deteriorates when working with the finished filter product, and the stability and lifespan of the finished filter product are reduced.

In addition, the basis weight of the first spunbond nonwoven fabric layer may be ^{10 to 40 g/m 2 .} If the basis weight of the first spunbond nonwoven fabric layer is within the above range, the filter performance can be improved by faithfully performing a role as a pre-treatment filter, and the thickness of the filter material is suitable to have excellent bendability when bending the filter material is increased, the dust filtration amount of the finished product is increased, and effects such as lowering of the differential pressure can be obtained.

In addition, the basis weight of the second spunbond nonwoven fabric layer may be ^{30-100 g/m 2 .} When the basis weight of the second spunbond nonwoven fabric layer is within the above range, the shape stability of the filter media is excellent, and the thickness of the filter media is appropriate to have excellent bendability when bending the filter media, and the acid number of the filter media increases to filter the dust of the finished product. amount increases, and effects such as lowering of the differential pressure can be obtained.

In addition, the basis weight of the melt blown nonwoven fabric layer may be ^{15 ~ 50g / m 2 .} When the basis weight of the melt blown nonwoven fabric layer is within the above range, the filtration efficiency is excellent and the differential pressure is low, so that it is suitable for use in an air filter.

The composite nonwoven fabric for an air filter may include the first spunbonded nonwoven fabric layer, the melt blown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer in this order. However, the present invention is not limited thereto, and the composite nonwoven fabric for an air filter may include the first spunbond nonwoven fabric layer, the melt blown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer in a different order.

The first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer may each include a plurality of spunbond nonwoven fabric sublayers. Specifically, the first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer may each include a plurality of spunbond nonwoven fabric sub-layers that are each manufactured in a continuous process in one device and integrated with each other.

The melt-blown non-woven fabric layer may include at least one pre-treated melt-blown non-woven sub-layer. Specifically, the melt-blown non-woven fabric layer includes only one electrostatically treated melt-blown non-woven fabric sub-layer, or a plurality of electro-treated melt-blown non-woven non-woven sub-layers each manufactured in a continuous process in one device and integrated with each other. may include.

The melt-blown non-woven fabric layer may further include at least one non-electrostatically-treated melt-blown non-woven fabric sub-layer in addition to the at least one electrostatically treated melt-blown non-woven fabric sub-layer. Specifically, the melt-blown non-woven fabric layer includes at least one uncharged melt-blown non-woven fabric sub-layer in addition to at least one pre-charged melt-blown non-woven fabric sub-layer, or each of the melt-blown non-woven fabric sub-layers in one device is manufactured in a continuous process. It may further include a plurality of non-electrostatically treated meltblown nonwoven sub-layers integrated with each other.

At least one spunbond nonwoven fabric, at least one electrostatically treated meltblown nonwoven fabric and/or at least one uncharged meltblown nonwoven fabric included in the composite nonwoven fabric for an air filter each independently comprises a non-conductive polymer can do.

The non-conductive polymer may include polyolefin, polystyrene, polycarbonate, polyester, polyamide, a copolymer 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.

Each of the spunbond nonwoven fabrics, each of the electrostatically treated meltblown nonwoven fabrics and/or each of the uncharged meltblown nonwoven fabrics may each independently include an additive.

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, nucleants or these may include a combination of

Also, in one embodiment, the antioxidant may function as a charge enhancer. Possible charge enhancers include thermally stable organic triazine compounds, oligomers or combinations thereof, which 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 US Patent Nos. 6,268,495, 5,976,208, 5,968,635, 5,919,847, and 5,908,598. For example, the charge increasing agent 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)] (manufactured by BASF, CHIMASSORB 944), (2,4,6-trichloro-1,3,5-triazine with 1,6-hexanediamine-N,N'-bis(2,2,6,6-tetramethyl-4- piperidinyl)-polymer, reaction product with N-butyl-1-butanamine, N-butyl-2,2,6,6-tetramethyl-4-piperidinamine (manufactured by BASF, CHIMASSORB 2020) or combinations thereof may be included.

The charge increasing agent is an N-substituted amino aromatic compound, in particular a tri-amino substituted compound such as 2,4,6-trianilino-p-(carbo-2′-ethylhexyl-1′-oxy)- 1,3,5-triazine (manufactured by BASF, UVINUL T-150) may be used. Another charge enhancer is 2,4,6-tris-(octadecylamino)-triazine, also known as tristearyl melamine (“TSM”).

The content of the charge increasing agent may be 0.25 to 5 parts by weight based on 100 parts by weight of the total weight of each electrostatically treated melt blown nonwoven fabric. If the content of the charge increasing agent is within the above range, it is possible to obtain a high level of charging performance targeted by the present invention, as well as good spinnability, high strength of the nonwoven fabric, and advantageous in terms of cost.

The composite nonwoven fabric for an air filter may further include generally known additives such as a heat stabilizer and a weathering agent in addition to the additives.

The total content of the electrostatically treated melt blown nonwoven fabric in the composite nonwoven fabric for an air filter may be 3 to 50 parts by weight based on 100 parts by weight of the total weight of the composite nonwoven fabric for an air filter. When the total content of the electrostatically treated melt blown nonwoven fabric is within the above range, a composite nonwoven fabric having excellent filtration performance, shape stability and durability may be obtained.

The composite nonwoven fabric for the air filter may have a basis weight (mass per unit area) of 10 to 500 g/m ² , for example, 20 to 100 g/m ² .

A plurality of nonwoven fabrics included in the composite nonwoven fabric for an air filter may be integrated (ie, bonded) to each other by thermal fusion rather than ultrasonic fusion.

The composite nonwoven fabric for an air filter may further include at least one additional layer.

As an example, each of the additional layers may include at least one separate nonwoven fabric that is neither a spunbond nonwoven fabric nor a meltblown nonwoven fabric.

As another example, each of the additional layers may include one or more layers made of a material other than the non-woven fabric.

The composite nonwoven fabric for an air filter may not contain any adhesive including a hot melt adhesive.

The composite nonwoven fabric for an air filter according to an embodiment of the present invention having the above configuration is (i) the ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer, (ii) The ratio of the filament fineness of the second spunbonded nonwoven fabric layer to the filament fineness of the meltblown nonwoven fabric layer, (iii) the filament fineness of the first spunbonded nonwoven fabric layer, (iv) the filaments of the second spunbonded nonwoven fabric layer having a particular combination of fineness, (v) basis weight of said first spunbonded nonwoven layer, (vi) basis weight of said meltblown nonwoven layer, and (vii) basis weight of said second spunbonded nonwoven layer; The strength, stiffness, air permeability, shape stability, bendability and filtration efficiency are high, the collection amount is large, and the filter differential pressure can obtain an appropriate effect.

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

The method for manufacturing a composite nonwoven fabric for an air filter according to an embodiment of the present invention includes the steps of continuously forming a spunbonded nonwoven layer (S10) and continuously forming a melt blown nonwoven layer on the spunbonded nonwoven layer (S20) ) is included.

The continuous forming step (S10) of the spunbond non-woven fabric layer is to melt extruded, cooled and stretched a thermoplastic non-conductive polymer to form a fiber yarn, and then laminated the fiber yarn on a screen belt to form a web (web forming). have.

The continuous forming step (S20) of the melt-blown non-woven fabric layer is performed by melt-extruding, hot-air stretching and cooling a thermoplastic non-conductive polymer (additional charging performance enhancer) to form a fiber yarn, and then forming the fiber yarn into the spunbond non-woven fabric layer. In the continuous forming step (S10), it may be laminated on the web-formed spunbond to form a web.

Specifically, the continuous formation of the melt blown nonwoven layer (S20) includes the steps of continuously forming free fibers with a non-conductive polymer (S20-1), continuously spinning the free fibers (S20-2), and Continuously spraying a polar solvent (for example, water) onto the free fibers to continuously charge the free fibers (S20-3) and continuously integrating the free fibers to continuously form a melt-blown nonwoven fabric (S20-4) may be included.

The free fiber continuous charging step (S20-3) may be performed by continuously spraying the polar solvent together with a gas (eg, air).

Hereinafter, it will be described in detail that the free fiber continuous charging step (S20-3) has a heterogeneous or significant effect compared to the prior art.

(1) Generally, as a method for charging during the melt blown process, as in US Patent No. 6,375,886, charging is performed through friction between a polar solvent and a filament being melt-spinning, as in US Patent No. 6,969,484. The melt-blown non-woven fabric was immersed in a polar solvent and charged through friction between water and non-woven fabric while water permeated through the non-woven fabric with a suction device. . As described above, the charging treatment method using a polar solvent requires a separate post-process of drying the polar solvent after the charging treatment, and therefore it is fundamentally impossible to laminate or composite the nonwoven fabric in a continuous process. U.S. Patent No. 6,375,886 and U.S. Patent No. 6,969,484 are incorporated herein by reference in their entirety.

(2) U.S. Patent No. 5,227,172 discloses a method in which a high potential difference is applied between a melt blown die and a collector so that the melt-spun resin is filamentized and inductively charged by the surrounding electric field. However, in this method, a melt-blown nonwoven fabric that has been electrostatically treated can be obtained without a separate post-processing treatment. However, since the non-woven fabric that has been inductively charged by the potential difference has a phenomenon that the charging efficiency is rapidly reduced depending on heat or the surrounding environment, it requires long-term storage in the sales process, such as a mask for removing fine dust, or with an air purifier filter. It has a disadvantage that it is difficult to apply it to a purpose where a long service life is guaranteed. U.S. Patent No. 5,227,172 is incorporated herein by reference in its entirety.

The present inventors spray a polar solvent together with air on the melt-blown nonwoven fabric layer in the form of a two-fluid body, and friction the polar solvent particles with sufficient kinetic energy with a small injection amount to the filament being melt-spun to have a high-efficiency triboelectric effect. We developed a pretreatment device to do this, and this pretreatment device is characterized in that it does not require a separate drying facility because it is sufficiently heated and evaporated by the heated air within the DCD (Die to collector distance) section due to a small injection amount. Due to these features, the pretreatment device has a feature that can compound the nonwoven fabric by continuous lamination in combination with the nonwoven fabric manufacturing process.

The nonwoven fabric obtained by electrostatically treating the melt blown nonwoven fabric is continuously polarized so that negative and positive charges exist semi-permanently, and this nonwoven fabric is referred to as an electret nonwoven fabric.

As described above, the method of manufacturing the composite nonwoven fabric for an air filter may not include a separate drying step for removing the polar solvent sprayed in the free fiber continuous charging step (S20-3).

In addition, as described above, the polar solvent continuously sprayed in the free fiber continuous charging step (S20-3) is continuously heated by heated air within the DCD (Die to collector distance) section of the composite nonwoven fabric manufacturing apparatus. may evaporate.

The method of manufacturing the composite nonwoven fabric for an air filter further includes a step (S30) of continuously forming another spunbonded nonwoven fabric layer on the melt blown nonwoven fabric layer in the same manner as the continuous forming step (S10) of the spunbonded nonwoven fabric layer can do.

The method for manufacturing the composite nonwoven fabric for an air filter is performed on one or both sides of the melt blown nonwoven fabric layer after the continuous forming step (S20) of the melt blown nonwoven fabric layer or the continuous forming step (S30) of the another spunbond nonwoven fabric layer. The step (S40) of continuously thermocompression bonding each spunbond nonwoven fabric layer may be further included.

1 is a view schematically showing a composite nonwoven fabric 10 for an air filter according to an embodiment of the present invention.

The composite nonwoven fabric 10 for an air filter according to an embodiment of the present invention includes a first spunbonded nonwoven fabric layer 11 , a melt blown nonwoven fabric layer 12 , and a second spunbonded nonwoven fabric layer 13 .

In addition, by modifying the manufacturing method of the composite nonwoven fabric for an air filter, a composite nonwoven fabric having various structures and/or configurations may be manufactured.

Another aspect of the present invention provides an article comprising the composite nonwoven fabric for an air filter.

The article may be a media for an air filter, an air filter or an air purifier.

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

Example 1: Preparation of composite nonwoven fabric

A composite nonwoven fabric was prepared in the following manner using the apparatus shown in FIG. 2 . Specifically, for the preparation of the first spunbond layer (S1), a polyethylene terephthalate (PET) resin having an intrinsic viscosity (IV) of 0.650 dl/g and a melting point (Tm) of 256°C and an intrinsic viscosity (IV) of 0.650 dl /g and a melting point (Tm) of 220 ℃ poly (ethylene terephthalate-co-isophthalate) (CoPET) resin spun to a fineness level of 2.4 denier, melt flow index for the production of the melt blown layer (M) A resin having a (MFR) of 1300 g/10 min was spun, but Chimassorb 944, a hindered amine light stabilizer, was added to the melt blown layer (M) at a ratio of 0.5 wt %, and the fineness was spun to a level of 0.025 denier, and the second spun For the manufacture of the bond layer (S2), the same resin as that of the first spun bond layer (S1) was used, but the constituent fineness was spun at a level of 11.5 denier, and each layer was randomly placed on a porous conveyor belt with controlled driving speed. After the integration, the pre-heat-bonded filaments were additionally heat-bonded using an embossing method after pre-heat bonding using hot air to prepare a composite nonwoven fabric by laminating in an SMS-based form having a total basis weight of 120 gsm. At this time, the melt blown layer (M) contains Chimassorb 944, a hindered amine light stabilizer, in an amount of 0.5 wt %, and after being charged, it is laminated between the spunbond nonwoven layers (S1, S2), and a double melt blown layer The basis weight of (M) was 30 gsm.

Example 2: Preparation of Composite Nonwoven Fabric

The fineness of the first spunbond layer (S1) was spun at a level of 1.3 denier, the fineness of the melt blown layer (M) was spun at a level of 0.032 denier, and the fineness of the second spunbond layer (S2) was spun at a level of 14.7 denier. Except for spinning, a composite nonwoven fabric was prepared in the same manner as in Example 1. The basis weight of the entire SMS composite nonwoven fabric was 120 gsm, and the basis weight of the melt blown layer (M) was 30 gsm.

Example 3: Preparation of Composite Nonwovens

The fineness of the first spunbond layer (S1) was spun at the level of 2.5 denier, the fineness of the melt blown layer (M) was spun at the level of 0.025 denier, and the fineness of the second spunbond layer (S2) was spun at the level of 11.5 denier. Except for spinning, a composite nonwoven fabric was prepared in the same manner as in Example 1. The basis weight of the entire SMS composite nonwoven fabric was 120 gsm, and the basis weight of the melt blown layer (M) was 30 gsm.

Example 4: Preparation of Composite Nonwovens

The fineness of the first spunbond layer (S1) was spun at a level of 3.0 denier, the fineness of the melt blown layer (M) was spun at a level of 0.040 denier, and the fineness of the second spunbond layer (S2) was spun at a level of 9.0 denier. Except for spinning, a composite nonwoven fabric was prepared in the same manner as in Example 1. The basis weight of the entire SMS composite nonwoven fabric was 120 gsm, and the basis weight of the melt blown layer (M) was 30 gsm.

Example 5: Preparation of Composite Nonwovens

The fineness of the first spunbond layer (S1) was spun at a level of 1.9 denier, the fineness of the melt blown layer (M) was spun at a level of 0.020 denier, and the fineness of the second spunbond layer (S2) was spun at a level of 14.0 denier. Except for spinning, a composite nonwoven fabric was prepared in the same manner as in Example 1. The basis weight of the entire SMS composite nonwoven fabric was 120 gsm, and the basis weight of the melt blown layer (M) was 30 gsm.

Comparative Example 1: Preparation of composite nonwoven fabric

The fineness of the first spunbond layer (S1) was spun at a level of 0.8 denier, the fineness of the melt blown layer (M) was spun at a level of 0.025 denier, and the fineness of the second spunbond layer (S2) was spun at a level of 11.5 denier. Except for spinning, a composite nonwoven fabric was prepared in the same manner as in Example 1. The basis weight of the entire SMS composite nonwoven fabric was 120 gsm, and the basis weight of the melt blown layer (M) was 30 gsm.

Comparative Example 2: Preparation of composite nonwoven fabric

The fineness of the first spunbond layer (S1) was spun at a level of 1.4 denier, the fineness of the melt blown layer (M) was spun at a level of 0.012 denier, and the fineness of the second spunbond layer (S2) was spun at a level of 5.5 denier. Except for spinning, a composite nonwoven fabric was prepared in the same manner as in Example 1. The basis weight of the entire SMS composite nonwoven fabric was 120 gsm, and the basis weight of the melt blown layer (M) was 30 gsm.

Comparative Example 3: Preparation of composite nonwoven fabric

The fineness of the first spunbond layer (S1) was spun at a level of 3.8 denier, the fineness of the melt blown layer (M) was spun at a level of 0.04 denier, and the fineness of the second spunbond layer (S2) was spun at a level of 8.0 denier. Except for spinning, a composite nonwoven fabric was prepared in the same manner as in Example 1. The basis weight of the entire SMS composite nonwoven fabric was 120 gsm, and the basis weight of the melt blown layer (M) was 30 gsm.

Comparative Example 4: Preparation of composite nonwoven fabric

The fineness of the first spunbond layer (S1) was spun at the level of 2.4 denier, the fineness of the melt blown layer (M) was spun at the level of 0.025 denier, and the fineness of the second spunbond layer (S2) was spun at the level of 18.8 denier. Except for spinning, a composite nonwoven fabric was prepared in the same manner as in Example 1. The basis weight of the entire SMS composite nonwoven fabric was 120 gsm, and the basis weight of the melt blown layer (M) was 30 gsm.

The fineness ratio (S1/M) and the fineness ratio (S2/M) of the composite nonwoven fabrics prepared in Examples 1 to 5 and Comparative Examples 1 to 4 are summarized and shown in Table 1 below.

fineness ratio Example comparative example One 2 3 4 5 One 2 3 4 S1/M 96 40 100 75 95 32 117 95 96 S2/M 460 459 460 225 700 460 458 200 752

Evaluation Example: Evaluation of Physical Properties of Composite Nonwoven Fabric

The physical properties of the composite nonwoven fabrics prepared in Examples 1 to 5 and Comparative Examples 1 to 4 were evaluated in the following manner, and the results are shown in Table 2 below.

(1) Filter differential pressure and particle filtration efficiency: Using TSI Model 8130A equipment, each filter fabric was measured 3 times by the EN 143 NaCl method, and the average value was recorded as the filter differential pressure and particle filtration efficiency. Here, "filter fabric" means a composite nonwoven fabric.

(2) Dimensional change rate of filter fabric: Only the MD value of 5.9.1 dry heat dimensional change rate among the general long fiber nonwoven fabric test method of KS K 0756 was measured. Here, "filter fabric" means a composite nonwoven fabric.

(3) MD tensile strength: It was measured according to the general long fiber nonwoven fabric test method of KS K 0756.

(4) Ring crush compressive strength measurement method: According to the JIS P8126 method, under the condition of a test speed of 10mpm, a sample with a size of 15cm x 3cm is made into a ring shape with an inner diameter of 4.5cm, and the part where the sheets overlap is fixed with a stapler, and then compressive strength test The load value taken when pressing the ring-shaped sheet was measured and recorded as the ring crush compressive strength.

Example comparative example One 2 3 4 5 One 2 3 4 filter differential pressure
(mmH ₂ O) 13.56 14.13 13.33 13.31 14.87 16.21 17.56 15.25 13.22 Dimensional change rate of filter fabric (%) less than 0.5 less than 0.5 less than 0.5 less than 0.5 less than 0.5 less than 0.5 less than 0.5 less than 0.5 2.40 Particle Filtration Efficiency
(%) 99.63 99.41 99.62 99.59 99.41 99.51 99.61 99.34 99.48 MD tensile strength
(kgf/5cm) 30 31 30 30 31 31 31 28 26 Ring crush compressive strength (N) 15 16 16 14 17 14 9 12 16

Referring to Table 2, the composite nonwoven fabric prepared in Examples 1 to 5 _{has a low filter differential pressure of less than 15 mmH 2} O, a dimensional change rate of a filter fabric is also low as less than 0.5%, and a particle filtration efficiency is high as 99% or more. , MD tensile strength was high as 30kgf/5cm or more, and ring crush compressive strength was also high as 14N or more.

However, the composite nonwoven fabric prepared in Comparative Example 1 had a low dimensional change rate of less than 0.5%, a high particle filtration efficiency of 99% or more, a high MD tensile strength of 30kgf/5cm or more, and a ring crush compressive strength of 14N. Although higher than that, the filter differential pressure was found to be high in excess _{of 15 mmH 2 O.}

In addition, the composite nonwoven fabric prepared in Comparative Example 2 had a low dimensional change rate of less than 0.5%, a high particle filtration efficiency of 99% or more, and a high MD tensile strength of 30kgf/5cm or more, but the filter differential pressure was 15mmH ₂ O It was found that the compressive strength of ring crush was also low as less than 14N.

In addition, the composite nonwoven fabric prepared in Comparative Example 3 had a low dimensional change rate of less than 0.5% and a high particle filtration efficiency of 99% or more, but had a high filter differential pressure _{exceeding 15mmH 2} O, and had a high MD tensile strength of 30 kgf / It was found to be as low as less than 5cm, and the ring crush compressive strength was also as low as less than 14N.

In addition, the composite nonwoven fabric prepared in Comparative Example 4 had a _{low filter differential pressure of less than 15 mmH 2} O, a high particle filtration efficiency of 99% or more, and a high ring crush compressive strength of 14N or more, but the dimensional change rate of the filter fabric was 0.5%. It was found to be high, and the MD tensile strength was also low, less than 30kgf/5cm.

Although the present invention has been described with reference to the drawings and embodiments, it will be understood by those skilled in the art that various modifications and equivalent other embodiments are possible therefrom. Accordingly, the true technical protection scope of the present invention should be determined by the technical spirit of the appended claims.

10: Composite nonwoven fabric for air filter 11: First spunbond nonwoven fabric layer
12: melt blown nonwoven layer 13: second spunbond nonwoven layer

Claims (10)

A first spunbond nonwoven fabric layer, a melt blown nonwoven fabric layer and a second spunbonded nonwoven fabric layer,
The melt blown nonwoven layer is at least partially charged,
The filament fineness of the second spunbond nonwoven layer is greater than the filament fineness of the first spunbond nonwoven layer,
The ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is 40-100,
The ratio of the filament fineness of the second spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer is 225-700 for an air filter composite nonwoven fabric. According to claim 1,
The filament fineness of the first spunbond nonwoven layer is 1 to 5 denier, the filament fineness of the melt blown nonwoven layer is 0.01 to 0.16 denier, and the filament fineness of the second spunbond nonwoven layer is 3 to 20 denier air Composite non-woven fabric for filters. According to claim 1,
The basis weight of the first spunbond nonwoven layer is 10 to 40 g/m ² , the basis weight of the melt blown nonwoven layer is 15 to 50 g/m ² , and the basis weight of the second spunbond nonwoven layer is 30 to Composite nonwovens for air filters of 100 g/m ^{2 .} According to claim 1,
The composite nonwoven fabric for an air filter includes the first spunbond nonwoven fabric layer, the melt blown nonwoven fabric layer, and the second spunbonded nonwoven fabric layer in this order. According to claim 1,
The first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer each include a plurality of spunbond nonwoven fabric sublayers. According to claim 1,
The melt-blown non-woven fabric layer further comprises at least one uncharged melt-blown non-woven fabric sub-layer in addition to the at least one electrostatically treated melt-blown non-woven fabric sub-layer. According to claim 1,
A composite nonwoven fabric for an air filter further comprising at least one additional layer. According to claim 1,
Composite nonwovens for air filters that do not contain any adhesives, including hot melt adhesives. An article comprising the composite nonwoven for an air filter according to any one of claims 1 to 8. 10. The method of claim 9,
The article is an air filter media, an air filter or an air purifier.

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