WO2021206358A1 - Composite nonwoven fabric and article including same - Google Patents

Abstract

Disclosed are a composite nonwoven fabric and an article including same. The disclosed composite nonwoven fabric comprises: a first spun-bonded nonwoven fabric layer; a melt-blown nonwoven fabric layer; and a second spun-bonded nonwoven fabric layer. At least a portion of the melt-blown nonwoven fabric layer is electrically charged, and the ratio of the filament denier of the first spun-bonded nonwoven fabric layer to the filament denier of the melt-blown nonwoven fabric layer and the ratio of the filament denier of the second spun-bonded nonwoven fabric layer to the filament denier of the melt-blown nonwoven fabric layer are each independently 20-210.

Description

Composite nonwoven fabric and articles comprising the same

Composite nonwoven fabrics and articles comprising the same are disclosed. More specifically, a composite nonwoven fabric having excellent mechanical properties and fine dust removal function, and an article including the same are disclosed.

In the case of a mask for removing fine dust, it is composed of an inner and outer skin material and a filter material that filters fine dust in the center in multiple layers.

As the filter layer, a melt-blown nonwoven fabric that has been treated is mainly used. Meltblown nonwoven fabric has low shape 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 melt-blown non-woven fabric layer and provide shape stability, a mask is formed by laminating a non-woven fabric having high mechanical properties such as shape stability and tensile strength on both sides or one side of the melt-blown non-woven fabric layer, mainly spunbond. The nonwoven fabric is laminated through a separate laminating process.

In addition, the spunbond nonwoven fabric, which is generally applied as an inner and outer skin material on one or both sides of the electrostatically treated meltblown material, has only a function of imparting shape stability with little fine dust removal efficiency because the filaments are thick and the pores are large. Therefore, among the multi-layered mask nonwoven fabric composition, since fine dust is filtered only in the filter layer located in the central part, there is a problem in that the fine dust is intensively stacked on the filter layer, so that the filtering efficiency decreases with time of use. In some countries, these issues may also affect the respiratory safety of users.

In addition, since the nonwoven fabric used as the inner and outer skin layer is mainly laminated by ultrasonic welding along the outline of the mask, the structure of the meltblown nonwoven fabric charged with the inner layer during the fusion process is changed, so that the filtering performance may be deteriorated.

One embodiment of the present invention provides a composite nonwoven fabric having excellent mechanical properties and fine dust removal function.

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

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 ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer and the ratio of the filament fineness of the second spunbonded nonwoven fabric layer to the filament fineness of the meltblown nonwoven fabric layer are each other Independently provides a composite nonwoven fabric of 20 to 210.

The filament fineness of the first spunbond nonwoven fabric layer and the filament fineness of the second spunbond nonwoven fabric layer are each independently 0.3 to 2.1 denier, and the filament fineness of the melt blown nonwoven fabric layer may be 0.01 to 0.06 denier.

The basis weight of the first spunbond nonwoven fabric layer and the basis weight of the second spunbonded nonwoven fabric layer are each independently 5 to 30g/m ² , and the basis weight of the melt blown nonwoven fabric layer is 5 to 50g/m ² can be

The composite nonwoven fabric may include the first spunbond 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 may further include at least one additional layer.

The composite nonwoven fabric has a water pressure resistance of 75 to 165 mmH ₂ O measured according to WSP 80.6 (09), an air permeability measured according to WSP 70.1 (08) of 170 to 392 ccs, and a KES-MMD (MD direction) of 0.003 to 0.014 , the fine dust removal efficiency is higher than 80%, and the pressure loss may be 1 to 5 mmH ₂ O.

The composite nonwoven fabric may have a QF factor of 0.15 to 0.90 represented by the following Equation 1:

[Equation 1]

QF factor = -ln (fine dust permeability/pressure loss)

In the above formula, the symbol "ln" means the natural logarithm.

The composite nonwoven fabric may have a tensile strength of 0.1 to 0.3 kgf/5 cm/gsm in an MD direction, a stiffness in the MD direction of 20 mm or more, and a stiffness in the CD direction of 10 mm or more.

The composite nonwoven fabric may have a fine dust removal efficiency of 20 to 99.9%.

Another aspect of the present invention is

An article comprising the composite nonwoven fabric is provided.

The article may be a health care article.

The composite nonwoven fabric according to an embodiment of the present invention has excellent mechanical properties and fine dust removal function.

In addition, the composite nonwoven fabric may be used for the purpose of removing various kinds of dust, fine dust, bacteria, and the like, and may be applied to various health or medical articles.

1 is a view schematically showing a composite nonwoven fabric 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, a composite nonwoven fabric 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 has a strong interlayer bonding and excellent morphological stability and filtration performance compared to the nonwoven fabric laminate.

Also, in the present specification, the “electrostatically treated melt blown nonwoven fabric layer” or the “electrostatically treated melt blown nonwoven fabric sub layer” 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.

Also herein, "water pressure resistance" is measured using TEXTEST (Switzerland) according to Worldwide Strategic Partners (hereinafter simply referred to as "WSP") 80.6.

Also in this specification, "air permeability" is measured using Air Permeability FX-3000 (Switzerland) according to WSP 70.1 (08). When measuring air permeability, the measurement area is 38 cm ² , the pressure is 125 Pascal, and the measurement unit is ccs (cm ³ /cm ² /sec).

Also, in this specification, "KES-MMD (MD direction)" is measured using KES-FB4-A as the average deviation of the friction coefficient ( https://www.keskato.co.jp/archives/products/kes -fb4-a ). When measuring KES-MMD (MD direction), the size of the test piece is 100 mm×100 mm, the static friction load is 50 g, and the friction tension is 400 g.

In addition, in this specification, "tensile strength" refers to a test piece with a width of 5 cm (grip interval of 10 cm during evaluation) with a tensile speed of 500 mm/min through a tensile strength elongator (Instron) according to KSK 0520. The tensile strength in the mechanical direction was measured, respectively.

In addition, in this specification, "strength" refers to 16 samples (25 mm × 150 mm) in MD and CD directions according to the measurement standard WSP 90.1, placed on the stiffness measuring machine, and when the specimen touches the inclined surface in the inclined direction. The length of the sample from the point of bending to the point of contact with the inclined surface was measured in mm.

The composite nonwoven fabric according to an embodiment of the present invention includes a first spunbonded nonwoven fabric layer, a melt blown nonwoven fabric layer, and a second spunbonded nonwoven fabric layer. Specifically, the composite nonwoven fabric 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 comprises 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 ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer and the ratio of the filament fineness of the second spunbonded nonwoven fabric layer to the filament fineness of the meltblown nonwoven fabric layer are each other independently 20-210, 22.0-200, 22.5-180, 23.0-160, 23.5-140, 24.0-140, 24.5-120, 25.0-100, 24.5-80, 25.0-60, 27.5-52.5, 32.5-47.5 or It can be 37.5-42.5. In addition, the ratio of the filament fineness of the first spunbonded nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer and the ratio of the filament fineness of the second spunbonded nonwoven fabric layer to the filament fineness of the meltblown nonwoven fabric layer is If it is less than 20, the differential pressure of the composite nonwoven fabric itself increases, and if it exceeds 210, the performance as a pretreatment filter is insignificant and does not significantly affect filtration efficiency and collection amount, or spinning in a continuous process is difficult and the total thickness of the composite nonwoven fabric is increased too much, the workability deteriorates when working with the finished product, and the stability and lifespan of the finished product are reduced.

The filament fineness of the first spunbond nonwoven fabric layer and the filament fineness of the second spunbond nonwoven fabric layer may each independently be 0.3 to 2.1 denier.

In addition, the filament fineness of the melt-blown nonwoven fabric layer may be 0.01 to 0.06 denier or 0.01 to 0.04 denier.

In addition, the basis weight of the first spunbond nonwoven fabric layer and the basis weight of the second spunbond nonwoven fabric layer may each independently be 5 to 30g/m ² . When the basis weight of the first spunbond nonwoven fabric layer and the basis weight of the second spunbond nonwoven fabric layer are within the above ranges, respectively, it is possible to obtain a composite nonwoven fabric having the effect of increasing the amount of dust filtration by improving the filtration efficiency.

In addition, the basis weight of the melt-blown nonwoven fabric layer may be ^{5 to 50 g/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 a mask or an air filter.

The composite nonwoven fabric may include the first spunbond 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 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 may each independently comprise a non-conductive polymer. .

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, 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 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) , (1,6-hexanediamine with 2,4,6-trichloro-1,3,5-triazineN,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl) -polymer, N-butyl-1-butanamine, reaction product with N-butyl-2,2,6,6-tetramethyl-4-piperidinamine) (manufactured by BASF, CHIMASSORB 2020) or a combination thereof may include

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 may further include generally known additives such as heat stabilizers and weathering agents in addition to the additives.

The total content of the electrostatically treated melt blown nonwoven fabric in the composite nonwoven fabric may be 3 to 50 parts by weight based on 100 parts by weight of the total weight of the composite nonwoven fabric. 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 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 may be integrated (ie, bonded) to each other by thermal fusion rather than ultrasonic fusion.

The composite nonwoven fabric 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 may not include any adhesive including a hot melt adhesive.

In addition, the composite nonwoven fabric may have a water pressure resistance of 75 to 165 mmH ₂ O, 81 to 140 mmH ₂ O, or 88 to 138 mmH ₂ O, measured according to WSP 80.6 (09).

In addition, the composite nonwoven fabric may have an air permeability measured according to WSP 70.1 (08) of 170 to 392 ccs, 190 to 390 ccs, 240 to 385 ccs, or 246 to 362 ccs.

In addition, the composite nonwoven fabric may have a KES-MMD (MD direction) of 0.003 to 0.014, 0.008 to 0.013, or 0.010 to 0.011.

In addition, the composite nonwoven fabric may have a fine dust removal efficiency of 80% or more, 85% or more, 90% or more, 95% or more, or 99% or more.

In addition, the composite nonwoven fabric may have a pressure loss of 1 to 5 mmH ₂ O, 1-3 mmH ₂ O, or 3 to 4 mmH ₂ O.

The composite nonwoven fabric 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 meltblown nonwoven fabric layer, (ii) the meltblown nonwoven fabric layer The ratio of the filament fineness of the second spunbond nonwoven layer to the filament fineness of the raw nonwoven layer, (iii) the filament fineness of the first spunbond nonwoven layer, (iv) the filament fineness of the second spunbond nonwoven layer, ( v) having a special combination of the basis weight of the first spunbond nonwoven layer, (vi) the basis weight of the meltblown nonwoven layer, and (vii) the basis weight of the second spunbond nonwoven layer, whereby water pressure resistance, air permeability and fine dust removal efficiency are both excellent and KES-MMD (MD direction) is low.

In addition, the composite nonwoven fabric may have a QF factor of 0.15 to 0.90 represented by Equation 1 below:

[Equation 1]

QF factor = -ln (fine dust permeability/pressure loss)

In the above formula, the symbol "ln" means the natural logarithm.

For example, the QF factor may be 0.20 to 0.90, 0.25 to 0.90, 0.30 to 0.90, 0.35 to 0.90, 0.40 to 0.90, 0.50 to 0.90, 0.60 to 0.90, 0.70 to 0.90, or 0.8 to 0.90.

The higher the QF factor, the higher the filtration performance.

The composite nonwoven fabric may have a tensile strength of 0.1 to 0.3 kgf/5 cm/gsm, 0.15 to 0.3 kgf/5 cm/gsm, 0.20 to 0.3 kgf/5 cm/gsm, or 0.25 to 0.30 kgf/5 cm/gsm in the MD direction. Here, gsm is ^{an abbreviation of g/m 2} , which means the weight per unit area of the composite nonwoven fabric.

In addition, the composite nonwoven fabric may have a stiffness in the MD direction of 20 mm or more, 25 mm or more, 30 mm or more, or 35 mm or more.

In addition, the composite nonwoven fabric may have a stiffness of 10 mm or more, 15 mm or more, 20 mm or more, 25 mm or more, or 30 mm or more in the CD direction.

In addition, the composite nonwoven fabric has a fine dust removal efficiency of 20 to 99.9%, 30 to 99.9%, 40 to 99.9%, 50 to 99.9%, 60 to 99.9%, 70 to 99.9%, 80 to 99.9%, or 90 to 99.9% can be

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

A method for manufacturing a composite nonwoven fabric 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) do.

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) In general, as a method for electrostatic treatment 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 characteristics, 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 for manufacturing the composite nonwoven fabric 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 manufacturing method of the composite nonwoven fabric may further include a step (S30) of continuously forming another spunbond 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. .

The manufacturing method of the composite nonwoven fabric is the melt blown nonwoven fabric layer continuous forming step (S20) or the other spunbond nonwoven fabric layer continuous forming step (S30) on one or both sides of the melt blown nonwoven fabric layer after each spunbond layer The step of continuously thermocompressing the nonwoven layer (S40) may be further included.

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

The composite nonwoven fabric 10 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, 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.

The article may be a health care article.

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 using the apparatus shown in FIG. 2 . Specifically, polypropylene having a melt index (MFR) of 34 g/10 min was used as a raw material for manufacturing the spunbond nonwoven fabric, and the constantly supplied raw material was melt-kneaded in an extruder to form a filament through a spinneret, and then cooled air A first spunbond nonwoven fabric layer (S1) and a second spunbond nonwoven fabric layer (S2) were respectively formed on a continuously driven conveyor belt by furnace cooling and stretching with suction air below the belt. When forming the filament, the fineness of the spunbond is adjusted by adjusting the pump discharge amount and the cooling air speed of the first spunbond nonwoven fabric layer (S1) and the second spunbond nonwoven fabric layer (S2) in the case of the first spunbond nonwoven fabric layer (S1) was adjusted to 0.4 denier, and in the case of the second spunbond nonwoven fabric layer (S2), it was adjusted to 2.1 denier. Polypropylene having a melt index (MFR) of 1100 g/10 min was used as a raw material for manufacturing melt blown nonwoven fabric. Fineness was adjusted to 0.02 denier. In this case, the basis weight of the first spunbond nonwoven fabric layer (S1) and the second spunbond nonwoven fabric layer (S2) was 20 g/m ² , respectively, and the basis weight of the melt blown nonwoven fabric layer was 12 g/m ² . For the expression of the charging effect, as in US Patent No. 6,375,886, a method of charging through friction between a polar solvent and a filament being melt-spun was used. At this time, the filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond and meltblown nonwoven fabric layer was 20, and the filaments of the second spunbond nonwoven fabric layer (S2) and the meltblown nonwoven fabric layer The fineness ratio (S2/M) was 105.

Example 2: Preparation of Composite Nonwoven Fabric

Change the filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond nonwoven fabric layer to 210, and the filaments of the second spunbond nonwoven fabric layer (S2) and the meltblown nonwoven fabric layer A composite nonwoven fabric was prepared in the same manner as in Example 1, except that the fineness ratio (S2/M) was maintained at 105.

Example 3: Preparation of Composite Nonwovens

The filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond nonwoven fabric layer is changed to 105, and the filaments of the second spunbond nonwoven fabric layer (S2) and the meltblown nonwoven fabric layer are A composite nonwoven fabric was prepared in the same manner as in Example 1, except that the fineness ratio (S2/M) was maintained at 105.

Example 4: Preparation of Composite Nonwovens

The filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond and meltblown nonwoven fabric layer is changed to 105, and the filaments of the second spunbond nonwoven fabric layer (S2) and the meltblown nonwoven fabric layer A composite nonwoven fabric was prepared in the same manner as in Example 1, except that the fineness ratio (S2/M) was changed to 20.

Example 5: Preparation of Composite Nonwovens

The filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond and meltblown nonwoven fabric layer is changed to 105, and the filaments of the second spunbond nonwoven fabric layer (S2) and the meltblown nonwoven fabric layer A composite nonwoven fabric was prepared in the same manner as in Example 1, except that the fineness ratio (S2/M) was changed to 210.

Comparative Example 1: Preparation of composite nonwoven fabric

The filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond nonwoven fabric layer was changed to 15, and the filaments of the second spunbond nonwoven fabric layer (S2) and the meltblown nonwoven fabric layer were changed to 15. A composite nonwoven fabric was prepared in the same manner as in Example 1, except that the fineness ratio (S2/M) was maintained at 105.

Comparative Example 2: Preparation of composite nonwoven fabric

Change the filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond nonwoven fabric layer to 215, and the filaments of the second spunbond nonwoven fabric layer (S2) and the melt blown nonwoven fabric layer A composite nonwoven fabric was prepared in the same manner as in Example 1, except that the fineness ratio (S2/M) was maintained at 105.

Comparative Example 3: Preparation of composite nonwoven fabric

The filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond nonwoven fabric layer is changed to 105, and the filaments of the second spunbond nonwoven fabric layer (S2) and the meltblown nonwoven fabric layer are A composite nonwoven fabric was prepared in the same manner as in Example 1, except that the fineness ratio (S2/M) was changed to 15.

Comparative Example 4: Preparation of composite nonwoven fabric

The filament fineness ratio (S1/M) of the first spunbond nonwoven fabric layer (S1) and the spunbond nonwoven fabric layer is changed to 105, and the filaments of the second spunbond nonwoven fabric layer (S2) and the meltblown nonwoven fabric layer are A composite nonwoven fabric was prepared in the same manner as in Example 1, except that the fineness ratio (S2/M) was changed to 215.

The filament fineness ratio (S1/M) and the second spunbond of the first spunbond nonwoven layer (S1) and the spunbond and meltblown nonwoven fabric layer of the composite nonwoven fabric prepared in Examples 1 to 5 and Comparative Examples 1 to 4 The filament fineness ratio (S2/M) of the nonwoven fabric layer (S2) and the melt blown nonwoven fabric layer is summarized in Table 1 below.

	Example					comparative example
	One	2	3	4	5	One	2	3	4
S1/M	20	210	105	105	105	15	215	105	105
S2/M	105	105	105	20	210	105	105	15	215

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) Hydrostatic pressure: evaluated according to WSP 80.6 (09).

(2) Air permeability: was evaluated according to WSP 70.1 (08).

(3) KES-MMD (MD direction): evaluated according to KES-F7 Labo.

(4) "Fine dust removal efficiency", "QF Factor" and "pressure loss" were evaluated by the following method for the composite nonwoven fabric after production and before use:

1) Measurement device: TSI-8130 model from TSI was used.

2) Aerosol Formation: The measuring device evaporated the water of the sodium chloride aqueous solution mist generated by the fine aerosol generating device to form a sodium chloride aerosol dispersed in the air. The average particle diameter of sodium chloride particles in the formed sodium chloride aerosol is 0.3 μm, and the concentration of sodium chloride in the aerosol is 18.5 mg/m ³ .

3) Evaluation of aerosol removal efficiency: The permeation surface velocity of the aerosol was 16 cm/sec, and the evaluation area of the nonwoven fabric was 100 cm ² . The aerosol removal efficiency was recorded as fine dust removal efficiency.

4) Pressure loss evaluation: The permeation surface velocity of the aerosol was 16 cm/sec, and the evaluation area of the nonwoven fabric was 100 cm ² .

5) QF factor evaluation: It was calculated according to Equation 1 using the fine dust removal efficiency and pressure loss.

(5) MD and CD tensile strength: evaluated according to WSP110.1 (09).

(6) MD and CD stiffness: evaluated according to WSP 90.1 (09).

	Example					comparative example
	One	2	3	4	5	One	2	3	4
water pressure (mmH 2 O)	163	143	152	159	145	526	138	513	139
Air Permeability (ccs)	186	387	231	176	377	79	402	88	430
KES-MMD (MD direction)	0.077	0.011	0.008	0.067	0.010	0.002	0.012	0.054	0.011
QF factor	0.67	0.59	0.61	0.64	0.71	0.77	0.50	0.59	0.63
Fine dust removal efficiency (%)	89	81	85	88	83	98	65	96	78
Pressure loss (mmH 2 O)	3.3	2.8	3.1	3.3	2.5	5.1	2.1	5.5	2.4
MD Tensile strength (kgf/5cm/g/m 2 )	0.22	0.18	0.20	0.24	0.19	0.31	0.16	0.28	0.17
CD Tensile strength (kgf/5cm/g/m 2 )	0.15	0.12	0.13	0.15	0.11	0.17	0.10	0.20	0.12
MD stiffness (mm)	66	57	62	64	55	68	54	67	56
CD stiffness (mm)	56	42	54	57	47	59	41	60	44

Referring to Table 1, the composite nonwoven fabrics prepared in Examples 1 to 5 had a water pressure resistance of 75 to 165 mmH ₂ O, an air permeability of 170 to 392 ccs, and a KES-MMD (MD direction) of 0.003 to 0.014, and fine dust. The removal efficiency is higher than 80%, and the pressure loss is 1~5mmH ₂ O, which is KF80 or KF94 standard level. On the other hand, the composite nonwoven fabric prepared in Comparative Examples 1 to 4 has an air permeability lower than 170ccs or higher than 392ccs, KES-MMD (MD direction) lower than 0.003 or higher than 0.014, or a pressure loss of 5mmH ₂ It was found to be higher than O, or the fine dust removal efficiency was lower than 80%.

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.

Claims (10)

1. 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 ratio of the filament fineness of the first spunbond nonwoven fabric layer to the filament fineness of the melt blown nonwoven fabric layer and the ratio of the filament fineness of the second spunbonded nonwoven fabric layer to the filament fineness of the meltblown nonwoven fabric layer are each from each other Independently 20-210 composite nonwovens.
2. According to claim 1,

   The filament fineness of the first spunbond nonwoven fabric layer and the filament fineness of the second spunbonded nonwoven fabric layer are each independently 0.3 to 2.1 denier, and the filament fineness of the melt blown nonwoven fabric layer is 0.01 to 0.06 denier composite nonwoven fabric.
3. According to claim 1,

   The basis weight of the first spunbond nonwoven fabric layer and the basis weight of the second spunbonded nonwoven fabric layer are each independently 5 to 30g/m ² , and the basis weight of the melt blown nonwoven fabric layer is 5 to 50g/m ² Phosphorus composite non-woven fabric.
4. According to claim 1,

   The composite nonwoven fabric comprises the first spunbond nonwoven fabric layer, the melt blown nonwoven fabric layer and the second spunbonded nonwoven fabric layer in this order.
5. 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.
6. According to claim 1,

   The meltblown nonwoven fabric layer further comprises at least one uncharged meltblown nonwoven sublayer in addition to the at least one charged meltblown nonwoven sublayer.
7. According to claim 1,

   A composite nonwoven further comprising at least one additional layer.
8. According to claim 1,

   Water pressure measured according to WSP 80.6 (09) is 75 to 165 mmH ₂ O, air permeability measured according to WSP 70.1 (08) is 170 to 392 ccs, KES-MMD (MD direction) is 0.003 to 0.014, and fine dust Composite nonwoven fabric with a removal efficiency higher than 80% and a pressure loss of 1 to 5 mmH _{2 O.}
9. 9. An article comprising the composite nonwoven according to any one of claims 1 to 8.
10. 10. The method of claim 9,

    The article is an article for health use.

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