WO2022060053A1 - 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법 및 그 난연 레이온 단섬유 적층체 - Google Patents

레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법 및 그 난연 레이온 단섬유 적층체 Download PDF

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Publication number
WO2022060053A1
WO2022060053A1 PCT/KR2021/012499 KR2021012499W WO2022060053A1 WO 2022060053 A1 WO2022060053 A1 WO 2022060053A1 KR 2021012499 W KR2021012499 W KR 2021012499W WO 2022060053 A1 WO2022060053 A1 WO 2022060053A1
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WIPO (PCT)
Prior art keywords
weight
parts
short
web
laminate
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PCT/KR2021/012499
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English (en)
French (fr)
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박윤태
허영
Original Assignee
박윤태
허영
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Application filed by 박윤태, 허영 filed Critical 박윤태
Priority to US18/043,916 priority Critical patent/US20230286248A1/en
Priority to CN202180062288.3A priority patent/CN116096959A/zh
Publication of WO2022060053A1 publication Critical patent/WO2022060053A1/ko

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    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M11/00—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising
    • D06M11/77—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof
    • D06M11/79—Treating fibres, threads, yarns, fabrics or fibrous goods made from such materials, with inorganic substances or complexes thereof; Such treatment combined with mechanical treatment, e.g. mercerising with silicon or compounds thereof with silicon dioxide, silicic acids or their salts
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    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
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Definitions

  • the present invention relates to a method for manufacturing a short-fiber laminate having flame retardancy using short rayon fibers, and to a flame-retardant short-fiber laminate using the same, and more particularly, to a paste using starch (hereinafter referred to as "starch paste") and a silica water dispersion solution
  • starch paste a paste using starch
  • silica water dispersion solution When the web made of short fibers is impregnated in the mixed flame retardant solution and dried, the silica powder is adsorbed to the short fibers by the starch and the removal is not performed, so that the flame retardant efficiency is increased, and a laminate is formed using the short fibers
  • the present invention relates to a method for manufacturing a short-fiber laminate having flame retardancy using short rayon fibers, wherein the strength is improved by starch paste, thereby improving workability and moldability, and the flame-retardant rayon short-fiber laminate.
  • Insulation materials such as rock wool, gypsum board, glass fiber, and Styropole, and hard board composed of compressed wood and adhesive are mainly used for building and industrial materials. As a result, there are problems such as causing environmental pollution.
  • a method for manufacturing a plate from waste fibers is known.
  • finely pulverize fibrous polypropylene cut chemical fibers such as acrylic, polyester, nylon, etc. to 10 mm or more and put it in a carding machine to heat the web After heating for a certain period of time in a thread, it is cut and presented as a pressure plate.
  • this method has a disadvantage in that the chemical fibers are cut into short fibers of about 10 mm, so there is less entanglement between the short fibers and they are easily broken.
  • these plates are not suitable as interior materials for buildings due to the generation of smoke and harmful gases in case of fire.
  • waste fibers are cut into long fibers of about 50 to 100 mm, and then batted in a cotton swab machine to form cotton, which is then made into a mat of a certain thickness, and then laminated in layers of appropriate thickness to form fibers.
  • a method of manufacturing a chemical fiber board by heating and pressurizing at a high deterioration and high pressure so that they become integral with each other.
  • the synthetic fiber board manufactured by the above method is molded at high temperature and high pressure, there is a problem in that the polymer material, which is a fiber constituent material, is decomposed and the intrinsic properties of the fiber are lost.
  • polyester fiber board In order to solve this problem, a method for manufacturing a polyester fiber board by fusing a web made of general polyester fibers and low-melting-point polyester fibers has been developed.
  • these polyester fiber boards are very suitable for building interior materials such as heat retention, heat insulation, shock absorption, elasticity, and appearance, but have a problem in flame retardancy in case of fire.
  • rayon fibers are impregnated with a flame retardant solution in which inorganic powder is mixed and then dried and used.
  • a flame retardant solution in which inorganic powder is mixed and then dried and used.
  • the short fibers are thickly laminated and then compressed at high density to have strength. There is a problem of environmental pollution in that a large amount of short fibers are generated when the short fibers of the single fiber are used and the short fiber laminate is disposed of.
  • the present invention which was devised in view of the above-mentioned problems of the prior art, impregnates a web made of short fibers in a flame retardant solution in which a paste using starch and a silica aqueous dispersion solution are mixed and then dries.
  • Flame-retardant rayon which powder is adsorbed to short fibers and does not remove, so flame-retardant efficiency is increased, and flame-retardant rayon that improves workability and moldability by improving strength by starch paste and flame-retardant rayon the same
  • An object of the present invention is to provide a short fiber laminate.
  • the single fiber is opened into a yarn using an opening means, and the opened fiber is carded with a certain thickness and width a carding process (S100) of forming a web using means; a web lamination process (S200) of laminating the web formed by the carding means several times to form a web laminate; a needle punching process (S300) of needle punching so that, when the web is laminated to a certain thickness, the laminated web has a binding force that can maintain the laminated shape without being entangled with each other; 25 to 30 parts by weight of silica powder, 65 to 72 parts by weight of distilled water, and 3 to 5 parts by weight of acetic acid to have a flame retardant effect on short fibers by impregnating the needle-punched web laminate into a tank filled with flame retardant solution.
  • a carding process S100
  • S200 web lamination process
  • S300 needle punching process
  • the web laminate is immersed in the mixed solution mixed with silica powder to absorb the mixed solution, the first impregnation is dried to remove moisture, and then the web laminate is secondarily impregnated with the flame retardant solution formed by mixing the starch paste with the mixed solution. It is achieved by a method for manufacturing a short fiber laminate having a flame retardancy using a short rayon fiber characterized in that.
  • the mixed solution is a first step of preparing a silica aqueous dispersion solution by mixing 25 to 30 parts by weight of silica powder, 65 to 72 parts by weight of distilled water, and 3 to 5 parts by weight of acetic acid, and the aqueous silica dispersion solution prepared by the first process
  • a second step of mixing 34 to 41 parts by weight of an alkoxysilane and 4 to 6 parts by weight of a photocatalyst with 55 to 60 parts by weight and polymerization with a mixil group, and 25 to 35 parts by weight of the condensation reaction solution prepared by the second process It is achieved by a method for producing a short fiber laminate having flame retardancy using short rayon fibers, characterized in that it is formed by mixing 55 to 70 parts by weight of silicate and 5 to 10 parts by weight of propylene.
  • the polymerization reaction is achieved by a method for producing a short fiber laminate having a flame retardancy using short rayon fibers, characterized in that the reaction heat of 65 ⁇ 75 °C is generated and reacted for 8 hours or more.
  • the short fiber laminate manufactured by the manufacturing method of the present invention is a flame retardant rayon short fiber laminate, impregnated with a web made of short fibers in a flame retardant solution in which starch using starch and a silica water dispersion solution are mixed, and then dried, starch Silica powder is adsorbed to the short fibers by the glue and removal is not performed, so flame-retardant efficiency is increased, and when a laminate is formed using the above-mentioned web, the strength is improved by starch and flame-retardant rayon, which improves workability and formability It is achieved by a short fiber laminate.
  • silica powder is adsorbed to the inside of the short rayon fibers, and silica powder to which starch paste is adsorbed and starch paste are adsorbed to the outside.
  • the present invention as described above, there is no inorganic powder (flame retardant) remaining on the surface of the short fibers, so there is no problem of powder being blown out, and the inorganic powder permeated into the fiber is not discharged to the outside even after time elapses.
  • the flame-retardant rayon staple fibers manufactured by the method for producing flame-retardant rayon staple fibers of the present invention are excellent in quality, and inorganic powder is fixed inside the fibers even over time, so there is no problem of reduced flame retardancy, and a large amount of short fibers In the manufacturing method of high-density compression in order to have strength after thick lamination, the strength is improved even when a small amount of short fibers are used. It is a useful invention that has the advantage of being generated.
  • FIG. 1 is an exemplary view showing a method of manufacturing a flame-retardant rayon staple fiber according to the present invention.
  • Figure 2 is a manufacturing process diagram showing another embodiment of the present invention.
  • FIG 3 is an exemplary view showing an example of the impregnation process, which is the technical gist of the present invention.
  • Figure 4a is a view illustrating a cross section of a short fiber after impregnating the mixed solution used in the present invention to the rayon fiber.
  • Figure 4b is a view illustrating a cross section of a short fiber after impregnating the flame retardant solution used in the present invention to the rayon fiber.
  • Figure 4c is a view illustrating a cross section of a short fiber after the rayon fiber is first impregnated with the mixed solution used in the present invention and dried and then the flame retardant solution is secondary impregnated.
  • FIG. 1 is an exemplary view showing a method of manufacturing a flame-retardant rayon staple fiber according to the present invention, according to the present invention, a single fiber is opened into a feather-like yarn using an opening means, and the opened fiber is a carding means having a certain thickness and width A carding process (S100) of forming a web using
  • the short fibers used at this time are types of fibers capable of absorbing the flame retardant liquid to be described later, that is, natural fibers, rayon, or fibers mixed with rayon and LM yarns.
  • the web formed by the carding means is spread evenly on the conveying belt and the web is laminated several times using the web laminating means to form a constant thickness to form a web stacked product (S200).
  • the laminated web is not entangled with each other and has a binding force that can maintain the laminated shape. Needle punching process (S300) of needle punching the laminated web carry out
  • the short fiber laminate may be formed by performing the thickness adjustment process (S800) so that the web laminate is compressed simultaneously with heating and laminated to a predetermined thickness, for example, 300 mm, to have a thickness of 50 mm.
  • the laminated web is not entangled with each other and has a binding force that can maintain the laminated shape. Needle punching process (S300) of needle punching the laminated web carry out
  • silica powder 25 to 30 parts by weight of silica powder, 65 to 30 parts by weight of silica powder, in order to have a flame retardant effect on short fibers by impregnating the needle-punched web laminate in a tank filled with a flame retardant solution.
  • a second step of mixing 4 to 6 parts by weight of a photocatalyst and polymerization with a mixer group and 55 to 70 parts by weight of silicate and 5 to 10 parts by weight of propylene are mixed with 25 to 35 parts by weight of the condensation reaction solution prepared by the second process
  • An impregnation process (S400) of absorbing the flame-retardant liquid is performed by impregnating the flame-retardant liquid mixed with a paste using starch at 9:1 to 8:2% by weight in the resulting mixture.
  • the lower limit of parts by weight decreases hardness but excellent adhesion, and the upper limit has excellent surface hardness, but there is a problem in that adhesion is somewhat reduced.
  • a fluorocarbon resin powder may be mixed with the inorganic powder and used.
  • the silica powder and the fluorocarbon resin powder have a particle size of 100 to 200 mesh, and when the particle size is 100 mesh or less, there is a problem of easily coming out from the rayon fiber after drying. This is because there is a problem in that this is not easy and remains only on the surface.
  • the silica powder has a non-combustible effect, and the fluorocarbon resin powder has an effect of delaying ignition, and when ignited, the fluorocarbon resin powder melts and melts and flows down, thereby suppressing the progress of a fire.
  • inorganic powder that is, silica powder, absorbs moisture 2 to 3 times its own volume during firefighting even when the rayon fiber is ignited and ignition occurs, and thus absorbs moisture normally. will play a role
  • the rayon fiber is impregnated in the mixed solution that does not contain starch, and then dried. There is only powder, and while performing the moisture removal process (S500), the surface cleaning process (S600), and the drying process (S700), which will be described later, the rayon fiber The silica powder near the surface will come off.
  • the rayon fiber Starch is adsorbed on the surface, and silica powder adsorbed with starch is adsorbed to the rayon fiber, and the starch adsorbed to the rayon fiber and The silica powder to which the starch is adsorbed remains without falling off.
  • the absorption amount is small, so there is a disadvantage that the absorption amount of silica powder is also reduced.
  • a water removal process (S500) of passing through a pair of rollers to squeeze out the flame retardant liquid is performed.
  • the water removal process (S500) has a mesh shape, and it is preferable to use a presser made of a manglower comprising a pair of rollers. The reason is that it is easy to discharge moisture during compression.
  • a surface cleaning process (S600) of sucking air from the bottom while spraying air from the top is performed to remove the inorganic powder attached to the surface of the web from which the moisture has been removed.
  • the laminate moves along the transport belt and when air is sprayed on the top of the laminate through a nozzle from the top of the moving laminate, dozens of through holes are formed in the moving belt, or air can be sucked using a mesh-type transport belt. Structured conveying belt is used.
  • the reason for using air in the surface cleaning process is to shake off the inorganic powder adsorbed on the surface of the short fibers as it passes through the voids between the short fibers and to dry the surface of the short fibers, and air only from the top Inhalation must be performed because the problem that air cannot pass through the laminate may occur when spraying.
  • a drying process (S700) of drying the web laminate having agitation is performed, and the drying process (S700) uses a dryer or an oven, and the heating temperature is 60 ⁇ 90 °C.
  • the temperature range is in order not to deform the rayon fiber.
  • the maximum heat dissipation rate, shrinkage rate and elastic force of the short fiber laminate of the present invention, such as silk, and the conventional short fiber laminate, such as silk, prepared as described above were investigated through experiments as follows.
  • Ceramic flame retardant liquid one-component room temperature curing eco-friendly water-soluble inorganic ceramic resin sold by Elco City
  • Ceramic flame retardant liquid for a single fiber laminate with a weight of 780g/m2 and a thickness of 8mm needle punched using 5.6 denier 64mm long fiber made of 100% rayon.
  • the web to be laminated during web lamination is impregnated with a flame retardant, but after impregnation in the mixed solution, the flame retardant material is impregnated with the flame retardant again. It was found that the elasticity was lowered as the strength of the short fibers was hardened due to the adhesion to the fibers.
  • the present invention as described above, there is no inorganic powder (flame retardant) remaining on the surface of the short fibers, so there is no problem of powder being blown out, and the inorganic powder permeated into the fiber is not discharged to the outside even after time elapses.
  • the flame-retardant rayon staple fibers manufactured by the method for producing flame-retardant rayon staple fibers of the present invention are excellent in quality, and inorganic powder is fixed inside the fibers even over time, so there is no problem of reduced flame retardancy, and a large amount of short fibers In the manufacturing method of high-density compression in order to have strength after thick lamination, the strength is improved even when a small amount of short fibers are used. It is a useful invention that has the advantage of being generated.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
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  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)

Abstract

본 발명은 난연 레이온 단섬유의 제조방법 및 그 단섬유를 이용한 난연 레이온 단섬유 적층체에 관한 것으로 보다 상세하게는 전분과 무기분말이 혼합된 난연액에 단섬유로 이루어진 웹을 함침 후 건조시키면 전분에 의하여 무기분말이 단섬유에 흡착이 되어 탈거가 이루어지지 않아 난연 효율이 증대되며, 상기한 단섬유를 이용하여 적층체를 형성시키면 전분에 의해 강도가 향상되어 가공성 및 성형성이 향상되는 등의 효과에 그 특징이 있다.

Description

레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법 및 그 난연 레이온 단섬유 적층체
본 발명은 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법 및 그 난연 레이온 단섬유 적층체에 관한 것으로 보다 상세하게는 전분을 이용한 풀이하 "전분풀"이라 칭함)과 실리카수분산용액이 혼합된 난연액에 단섬유로 이루어진 웹을 함침 후 건조시키면 전분에 의하여 실리카파우더가 단섬유에 흡착이 되어 탈거가 이루어지지 않아 난연 효율이 증대되며, 상기한 단섬유를 이용하여 적층체를 형성시키면 전분풀에 의해 강도가 향상되어 가공성 및 성형성이 향상되는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법 및 그 난연 레이온 단섬유 적층체에 관한 것이다.
건축자재 및 산업용 자재 등에는 주로 암면, 석고보드, 유리섬유, 스티로폴 등 단열재와 압축목재와 접착제로 구성된 하드보드 등이 사용되고 있으나, 이러한 판재들은 인체에 유해한 물질을 배출하는 것으로 알려져 있으며 또한 재활용이 불가능하여 환경공해를 일으키는 등의 문제점이 있다.
종래 폐화섬유로 판재를 제조하는 방법이 알려져 있다. 예를 들어 한국공개 특허공보 공고 87-5764호에 의하면, 섬유상의 폴리프로필렌을 잘게 분쇄하고 이에 아크릴, 폴리에스테르, 나일론 등의 화학섬유를 10mm 이상으로 절단하여 소면기에 넣어 만든 웹(web)을 가열실에서 일정시간 가열한 후 절단하여 압압판으로 화섬판재가 제시된다. 그러나 이 방법은 화섬물을 10mm 정도의 단섬유로 절단함으로써 단섬유들 간의 엉킴이 적어 잘 부서지는 단점이 있는 것이다. 또한 이러한 판재는 화재시 연기 및 유해가스의 발생으로 인하여 건축내장재로서 부적합한 것이다.
한편 한국 특허 공보 공고 95-6863호에 의하면 폐화섬유를 50～100mm 정도의 장섬유로 절단하여 타면기에서 타면하여 솜 상태로 하고 이를 일정두께의 매트형태로 한 다음 이들을 적당한 두께의 층으로 적층하여 섬유끼리 서로 일체가 되도록 고 열화 고압으로 가열 가압함으로써 화섬판재를 제조하는 방법이 알려져 있다. 그러나 상기한 방법으로 제조한 화섬판재는 고온 및 고압에서 성형되므로 섬유구성물질인 고분자 물질의 분해를 초래하게 되고 섬유의 고유특성이 상실되는 문제점이 있는 것이다.
이러한 문제점을 해소하기 위하여 일반 폴리에스테르 섬유와 저융점 폴리에스테르 섬유로 이루어진 웹을 융착하여 폴리에스터 섬유판재를 제조하는 방법이 개발되어 있다. 그러나 이러한 폴리에스터 섬유판재는 보온성, 단열성, 충격흡수성, 탄성, 외관 등 건축내장재로서 매우 적합한 것이나, 화재 시 방염성에 문제가 있는 것이다.
또한 상기한 종래의 방법들은 화학섬유를 이용하기 때문에 작업환경이 불량하고 환경공해물질을 발생시키는 문제점을 안고 있는 것이기도 하다. 또한 이러한 판재는 화재시 연기 및 유해가스의 발생으로 인하여 건축내장재로서 부적합한 것이다.
상기한 종래 문제를 해소하기 위하여 레이온 섬유에 무기분말이 혼합되어 있는 난연액에 함침시킨 후 건조하여 사용하고 있으나 상기 종래 난연 레이온 단섬유를 이용한 적층체는 단섬유 표면에 남아 있는 무기분말이 떨어져 분말가루가 날리는 문제가 있으며, 단섬유 표면에 잔류하는 무기분말을 털어 낸다 하더라도 섬유 내부에 스며들어간 무기분말이 시간의 경과시 고정되어 있지 않기 때문에 외부로 나와 난연성이 저하되는 문제가 있고, 종래 레이온 단섬유를 적층하여 형성된 적층체의 경우 강도가 현저히 낮아 성형성과 가공성이 떨어지는 문제가 있다.
상기와 같은 종래 문제점을 보안하고자 강도를 증대시키기 위해서는 단섬유를 두껍게 적층한 후 강도를 갖게 하기 위하여 고밀도로 압착하여 형성시켜 사용하고 있으나 고밀도 압착으로 인해 강도는 증가하지만 흡음성이 저하되는 문제와 많은 양의 단섬유가 사용되어 상기 단섬유 적층체의 폐기시 많은 양의 단섬유가 발생되는 환경오염의 문제가 있다.
상기한 종래 문제점을 감안하여 안출한 본 발명은 전분을 이용한 풀과 실리카수분산용액이 혼합된 난연액에 단섬유로 이루어진 웹을 함침 후 건조시키면 실리카파우더가 전분을 흡수하고 있어 전분풀에 의하여 실리카파우더가 단섬유에 흡착되어 탈거가 이루어지지 않아 난연 효율이 증대되며, 전분풀에 의해 강도가 향상되어 가공성 및 성형성이 향상되는 난연 레이온 단섬유를 이용한 단섬유 적층체의 제조방법 및 그 난연 레이온 단섬유 적층체를 제공하는데 목적이 있다.
상기한 과제를 해결한 본 발명의 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법에 있어서, 단섬유를 개섬수단을 이용하여 원사로 개섬하고 개섬된 섬유를 일정한 두께와 폭을 갖는 카딩수단을 이용하여 웹을 형성하는 카딩공정(S100)과; 상기 카딩수단에 의하여 형성된 웹을 수회 적층하여 웹적층물을 형성시키는 웹적층공정(S200)과; 상기 웹이 일정한 두께로 적층되면 적층된 웹이 서로 엉켜 흐트러지지 않고 적층된 형태를 유지할 수 있는 결속력을 갖도록 니들펀칭하는 니들펀칭공정(S300)과; 상기 니들펀칭된 웹적층물을 난연액이 충전된 탱크에 함침시켜 단섬유에 난연효과를 갖도록 하기 위하여 실리카파우더 25내지 30중량부, 증류수 65내지 72 중량부, 초산 3내지 5중량부 혼합하여 실리카수분산용액을 제조하는 제1공정과, 상기 제1공정에 의해 제조된 실리카수분산용액 55내지 60중량부에 알콕시실란 34 내지 41중량부, 광촉매재 4 내지 6중량부를 혼합한고 믹실기로 중합반응시키는 제2공정과 상기 제2공정에 의해 제조된 축합반응용액 25내지 35중량부에 규산염 55 내지 70중량부, 프로필렌 5 내지 10중량부를 혼합하여 형성된 혼합액에 전분을 이용한 풀을 9:1 ~ 8:2 중량％로 혼합한 난연액에 함침시켜 난연액을 흡수하도록 한 함침공정(S400)과; 상기 함침된 웹의 수분을 제거하기 위하여 1쌍으로 이루어진 로울러를 통과시키는 수분제거공정(S500)과; 상기 수분이 제거된 웹의 표면에 부착된 무기분말을 제거하기 위해 에어를 상부에서 분무하면서 하부에서 에어를 흡입하는 표면정리공정(S600)과; 상기 표면정리공정 수행 후 젖음성을 갖는 웹 적층물을 건조시키는 건조공정(S700)순에 의해 제조되는 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법에 의해 달성된다.
상기 함침공정은 실리카파우더가 혼합된 혼합액에 웹적층물을 담그어 혼합액을 흡수하도록 1차 함침 건조시켜 수분을 제거한 후 상기 혼합액에 전분풀을 혼합하여 형성된 난연액에 웹적층물을 2차 함침시키는 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법에 의하여 달성된다.
상기 혼합액은 실리카파우더 25 내지 30중량부, 증류수 65 내지 72 중량부, 초산 3 내지 5중량부 혼합하여 실리카수분산용액을 제조하는 제1공정과, 상기 제1공정에 의해 제조된 실리카수분산용액 55 내지 60중량부에 알콕시실란 34 내지 41중량부, 광촉매재 4 내지 6중량부를 혼합하고 믹실기로 중합반응시키는 제2공정과, 상기 제2공정에 의해 제조된 축합반응용액 25 내지 35중량부에 규산염 55 내지 70중량부, 프로필렌 5 내지 10중량부를 혼합하여 형성된 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법에 의하여 달성된다.
상기 중합반응은 65~75℃의 반응열이 발생되며 8시간 이상 반응시키는 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법에 의하여 달성된다.
이러한 본 발명의 제조방법에 의해 제조된 단섬유 적층체는 난연 레이온 단섬유 적층체에 있어서, 전분을 이용한 풀과 실리카수분산용액이 혼합된 난연액에 단섬유로 이루어진 웹을 함침 후 건조시키면 전분풀에 의하여 실리카파우더가 단섬유에 흡착이 되어 탈거가 이루어지지 않아 난연 효율이 증대되며, 상기한 웹을 이용하여 적층체를 형성시키면 전분에 의해 강도가 향상되어 가공성 및 성형성이 향상되는 난연 레이온 단섬유 적층체에 의하여 달성된다.
한편 상기 레이온 단섬유의 내측으로 실리카파우더가 흡착되며 외측으로는 전분풀이 흡착된 실리카파우더와 전분풀이 흡착되어 이루어진 것을 특징으로 하는 난연 레이온 단섬유 적층체에 의하여 달성된다.
이와 같은 본 발명은 단섬유 표면에 무기분말(난연소제)이 남아 있지 않아 분말가루가 날리는 문제가 없으며, 시간이 경과되어도 섬유 내부에 스며들어간 무기분말이 외부로 토출되지 않는 등의 이점으로 상기한 본 발명인 난연 레이온 단섬유의 제조방법에 의해 제조된 난연 레이온 단섬유는 품질이 우수하며, 시간의 경과에도 무기분말이 섬유 내부에 고착화 되어 있어 난연성이 저하되는 문제가 없으며, 많은 양의 단섬유를 두껍게 적층한 후 강도를 갖게 하기 위하여 고밀도로 압착하던 제조방법에서 적은 양의 단섬유를 사용하여도 강도가 향상되기 때문에 성형성과 가공성 및 흡음성이 향상되고 단섬유 적층체의 폐기시 적은 양의 단섬유가 발생되는 이점 등이 있는 유용한 발명이다.
도 1은 본 발명인 난연 레이온 단섬유의 제조방법을 보여주는 예시도.
도 2는 본 발명의 다른 실시예를 보여주는 제조공정도.
도 3은 본 발명의 기술적 요지인 함침공정의 일예를 보여주는 예시도.
도 4a는 레이온 섬유에 본 발명에 사용되는 혼합액을 함침시킨 후 단섬유의 단면을 예시한 도면.
도 4b는 레이온 섬유에 본 발명에 사용되는 난연액을 함침시킨 후 단섬유의 단면을 예시한 도면.
도 4c는 레이온 섬유에 본 발명에 사용되는 혼합액을 1차함침시켜 건조한 후 난연액을 2차 함침시켠 후 단섬유의 단면을 예시한 도면.
이하, 본 발명의 바람직한 실시예를 첨부된 도면에 의거하여 상세히 설명하면 다음과 같다.
첨부도면 도 1은 본 발명인 난연 레이온 단섬유의 제조방법을 보여주는 예시도로써 이에 따른 본 발명은 단섬유를 개섬수단을 이용하여 새털 같은 원사로 개섬하고 개섬된 섬유를 일정한 두께와 폭을 갖는 카딩수단을 이용하여 웹을 형성하는 카딩공정(S100)을 수행한다. 이때 사용되는 단섬유는 후술하는 난연액을 흡수할 수 있는 섬유 종류 즉, 천연섬유, 레이온, 또는 레이온과 LM사를 혼합한 섬유이다.
상기 카딩수단에 의하여 형성된 웹을 이송벨트 상에 골고루 펼쳐지게 깔고 일정한 두께를 형성하도록 웹적층수단을 이용하여 웹을 수회 적층하여 웹적층물을 형성시키는 웹적층공정(S200)을 수행한다.
상기 웹적층공정(S200)에 의해 단섬유 적층체가 제조되면 적층된 웹이 서로 엉켜 흐트러지지 않고 적층된 형태를 유지할 수 있는 결속력을 갖도록 니들펀칭기로 적층된 웹을 니들펀칭하는 니들펀칭공정(S300)을 수행한다.
한편 첨부도면 도 2에 도시된 바와 같이 웹적층공정(S200)과 니들펀칭공정(S300) 사이에 상기 웹적층수단에 의하여 일정한 높이로 적층되어 형성된 웹적층물을 이송벨드로 이송하면서 가열/압착수단을 경유시 웹적층물이 가열과 동시에 압착되어 일정한 두께 예컨대 300mm로 적층된 웹적층물을 50mm의 두께를 갖도록 두께 조절공정(S800)을 수행하여 단섬유 적층체를 형성시킬 수도 있다.
상기 두께 조절공정(S800)에 의해 단섬유 적층체가 제조되면 적층된 웹이 서로 엉켜 흐트러지지 않고 적층된 형태를 유지할 수 있는 결속력을 갖도록 니들펀칭기로 적층된 웹을 니들펀칭하는 니들펀칭공정(S300)을 수행한다.
한편 첨부도면 도 1 내지 도 2에 도시된 바와 같이 상기 니들펀칭된 웹적층물을 난연액이 충전된 탱크에 함침시켜 단섬유에 난연효과를 갖도록 하기 위하여 실리카파우더 25 내지 30중량부, 증류수 65 내지 72 중량부, 초산 3 내지 5중량부 혼합하여 실리카수분산용액을 제조하는 제1공정과, 상기 제1공정에 의해 제조된 실리카수분산용액 55 내지 60중량부에 알콕시실란 34 내지 41중량부, 광촉매재 4 내지 6중량부를 혼합하고 믹실기로 중합반응시키는 제2공정과 상기 제2공정에 의해 제조된 축합반응용액 25 내지 35중량부에 규산염 55 내지 70중량부, 프로필렌 5 내지 10중량부를 혼합하여 형성된 혼합액에 전분을 이용한 풀을 9:1 ~ 8:2 중량％로 혼합한 난연액에 함침시켜 난연액을 흡수하도록 한 함침공정(S400)을 수행한다.
상기 난연액의 제조공정에서 중량부의 하한값은 경도 저하되나 부착성이 우수하며 상한값은 표면경도 우수하나 부착성이 다소 저하되는 문제가 있다. 한편 상기 무기분말에 불소탄화수지 분말을 혼합하여 사용할 수 있다.
한편 상기 실리카파우더와 불소탄화수지 분말의 입도 크기를 100∼200메쉬의 것을 사용하며 입도크기가 100메쉬 이하일 경우 건조 후 레이온 섬유에서 쉽게 빠져나오는 문제가 있고 입도크기가 200메쉬 이상일 경우 레이온 섬유에 함침이 용이하지 않게 되어 표면에만 남게 되는 문제가 있기 때문이다.
상기 실리카파우더는 불연의 효과를 갖으며 불소탄화수지 분말은 착화를 지연시키는 효과를 갖으며 발화시 불소탄화수지 분말이 용융되어 녹아 흘러내리도록 하여 화재가 진행되는 것을 억제시키는 효과를 갖는다.
또한 무기분말 즉, 실리카파우더는 화재발생시 레이온 섬유가 착화되는 것과 발화가 이루어져도 진화시 수분을 자기 부피의 2∼3배를 흡수함으로 평상시 수분을 흡수하고 있게 되어 발화시 수분을 배출하여 발화를 억제하는 역할을 하게 된다.
첨부도면 도 4a에 도시된 바와 같이 상기 함침공정(S400)을 전분이 포함되어 있지 않은 혼합액에 레이온 섬유를 함침 후 건조시키고 단면의 구성을 살펴보면 혼합액을 흡착한 레이온섬유의 내측에 무기분말 즉, 실리카파우더만이 존재하게 되는데 후술하는 수분제거공정(S500), 표면정리공정(S600), 건조공정(S700)을 수행하면서 레이온 섬유의 표면에 가까운 부분의 실리카파우더는 떨어져 나가게 된다.
그러나 첨부도면 도 4b에 도시된 바와 같이 난연액에 레이온섬유를 합침시키면 레이온 섬유의 표면에 전분이 흡착되고 또한 전분이 흡착된 실리카파우더가 레이온 섬유에 흡착되며 후술하는 수분제거공정(S500), 표면정리공정(S600), 건조공정(S700)을 수행하면서 레이온 섬유에 흡착된 전분과 전분이 흡착된 실리카파우더는 떨어져 나가지 않고 남아 있게 된다. 하지만 전분풀의 성질에 의해 흡수량이 적기 때문에 실리카파우더의 흡착량도 적어지는 단점이 있다.
이러한 성질을 이용하여 첨부도면 도 3에 도시된 바와 같이 함침공정(S400)을 1차 혼합액 함침 후 2차 난연액 함침으로 나누어 실시하면 첨부도면 도 4c에 도시된 바와 같이 레이온섬유의 내측은 전분이 흡착되지 않은 실리카파우더가 흡착되어 있으며 외부 표면 쪽으로는 전부를 흡착한 실리카파우더와 전분이 잔류하기 때문에 전분이 흡착되지 않은 실리카파우더가 레이온섬유 내측에 전분에 의하여 밖으로 나가지 못하고 포위되어 갇혀지는 형태를 갖게 된다.
한편 상기 함침공정(S400)의 수행으로 웹적층물에 난연액이 흡입되어 있어 난연액을 짜내기 위하여 1쌍으로 이루어진 로울러를 통과시키는 수분제거공정(S500)을 수행한다. 상기 수분제거공정(S500)은 매쉬 형태를 갖으며 한 쌍의 로울러로 이루어진 망글로울러로 이루어진 압착기를 사용하는 것이 바람직하다. 그 이유는 압착시 수분의 배출이 용이하기 때문이다.
상기에서와 같이 수분제거공정(S500)이 완료되면 수분이 제거된 웹의 표면에 부착된 무기분말을 제거하기 위해 에어를 상부에서 분무하면서 하부에서 에어를 흡입하는 표면정리공정(S600)을 수행한다. 적층물은 이송벨트를 따라 이동하며 이동되는 적층물의 상부에서 노즐을 통해 에어를 적층물의 상부에 분사하면 이동벨트에는 다스의 통공이 형성되거나 메쉬형태의 이송벨트를 사용하여 에어를 흡입할 수 있도록 한 구조의 이송벨트를 사용한다.
상기 표면정리공정(S600)에서 에어를 이용하는 이유는 단섬유와 단섬유 사이의 공극을 지나가면서 단섬유 표면에 흡착되어진 무기분말을 털어내기 위함이며 또한 단섬유 표면을 건조시키기 위함이며, 상부에서만 에어를 분사하면 적층물을 에어가 통과하지 못하게 되는 문제가 발생할 수 있기 때문에 흡입을 반드시 실시하여야 한다.
한편 상기 표면정리공정 수행 후 젓음성을 갖는 웹 적층물을 건조시키는 건조공정(S700)을 실시하며 상기한 건조공정(S700)은 건조기 또는 오븐을 이용하며 가열 온도는 60 ~ 90℃이다. 온도범위는 레이온 섬유를 변형시키지 않도록 하기 위함이다.
상기와 같이 제조된 본 발명의 단섬유 적층체 예컨대 견면과 종래 단섬유 적층체 예컨대 견면의 최대열방출율, 수축율 및 탄성력을 아래와 같이 실험을 통해 알아보았다.
실험방법 :KS F 2271
실험방법 : KS F ISO 5660-1(연소성능시험)
실험조건 :
[비교예1]
레이온100%로 이루어진 5.6데니아 길이 64mm 섬유를 이용하여 중량 780g/m2, 두께 8mm 니들펀칭한 단섬유 적층체를 세라믹난연액((주)엘코씨티에서 판매하는 일액형 상온경화 친환경 수용성 무기질 세라믹수지)을 이용하여 함침 후 건조하여 제조.
[실험예1]
레이온100%로 이루어진 5.6데니아 길이 64mm 섬유를 이용하여 중량 780g/m2, 두께 8mm 니들펀칭한 단섬유 적층체를 난연액에 함침 후 건조하여 제조.
[실험예2]
레이온100%로 이루어진 5.6데니아 길이 64mm 섬유를 이용하여 중량 780g/m2, 두께 8mm 니들펀칭한 단섬유 적층체를 혼합액에 함침 후 건조시키고 다시 난연액에 함침 후 건조하여 제조.
비교예 실시예1 실시예2
잔염 6초 없음 없음
외관 깨끗함 깨끗함 깨끗함
탄성력 종음 딱딱함 매우딱딱함
최대열방출율(Kw/m2) 85.1 68.3 61.4
수축율(%) 8.3 6.5 4.6
상기에서 표 1 에서 알 수 있는 바와 같이 웹적층시 적층되는 웹을 난연제에 함침시키되 혼합액에 함침 후 다시 난연재에 함침시키면 단섬유 적층체의 표면은 물론이고 내부까지도 난연재가 침투하여 난연성이 향상됨과 난연제에 접착성이 부여되어 단섬유들의 강도가 딱딱하게 되면서 탄성력이 저하되는 것을 알 수 있었다.
이와 같은 본 발명은 단섬유 표면에 무기분말(난연소제)이 남아 있지 않아 분말가루가 날리는 문제가 없으며, 시간이 경과되어도 섬유 내부에 스며들어간 무기분말이 외부로 토출되지 않는 등의 이점으로 상기한 본 발명인 난연 레이온 단섬유의 제조방법에 의해 제조된 난연 레이온 단섬유는 품질이 우수하며, 시간의 경과에도 무기분말이 섬유 내부에 고착화 되어 있어 난연성이 저하되는 문제가 없으며, 많은 양의 단섬유를 두껍게 적층한 후 강도를 갖게 하기 위하여 고밀도로 압착하던 제조방법에서 적은 양의 단섬유를 사용하여도 강도가 향상되기 때문에 성형성과 가공성 및 흡음성이 향상되고 단섬유 적층체의 폐기시 적은 양의 단섬유가 발생되는 이점 등이 있는 유용한 발명이다.
[부호의 설명]
S100 : 카딩공정
S200 : 웹적층공정
S300 : 니들펀칭공정
S400 : 함침공정
S500 : 수분제거공정
S600 : 표면정리공정
S700 : 건조공정
S800 : 두께 조절공정

Claims (6)

  1. 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법에 있어서,
    단섬유를 개섬수단을 이용하여 원사로 개섬하고 개섬된 섬유를 일정한 두께와 폭을 갖는 카딩수단을 이용하여 웹을 형성하는 카딩공정(S100)과;
    상기 카딩수단에 의하여 형성된 웹을 수회 적층하여 웹적층물을 형성시키는 웹적층공정(S200)과;
    상기 웹이 일정한 두께로 적층되면 적층된 웹이 서로 엉켜 흐트러지지 않고 적층된 형태를 유지할 수 있는 결속력을 갖도록 니들펀칭하는 니들펀칭공정(S300)과;
    상기 니들펀칭된 웹적층물을 난연액이 충전된 탱크에 함침시켜 단섬유에 난연효과를 갖도록 하기 위하여 실리카파우더 25 내지 30중량부, 증류수 65 내지 72 중량부, 초산 3 내지 5중량부 혼합하여 실리카수분산용액을 제조하는 제1공정과, 상기 제1공정에 의해 제조된 실리카수분산용액 55 내지 60중량부에 알콕시실란 34 내지 41중량부, 광촉매재 4 내지 6중량부를 혼합하고 믹실기로 중합반응시키는 제2공정과 상기 제2공정에 의해 제조된 축합반응용액 25 내지 35중량부에 규산염 55 내지 70중량부, 프로필렌 5 내지 10중량부를 혼합하여 형성된 혼합액에 전분을 이용한 풀을 9:1~8:2 중량％로 혼합한 난연액에 함침시켜 난연액을 흡수하도록 한 함침공정(S400)과;
    상기 함침된 웹의 수분을 제거하기 위하여 1쌍으로 이루어진 로울러를 통과시키는 수분제거공정(S500)과;
    상기 수분이 제거된 웹의 표면에 부착된 무기분말을 제거하기 위해 에어를 상부에서 분무하면서 하부에서 에어를 흡입하는 표면정리공정(S600)과;
    상기 표면정리공정 수행 후 젖음성을 갖는 웹 적층물을 건조시키는 건조공정(S700)순에 의해 제조되는 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법.
  2. 제 1 항에 있어서,
    상기 함침공정은 무기분말이 혼합된 혼합액에 웹적층물을 담그어 혼합액을 흡수하도록 1차 함침한 후 건조시켜 수분을 제거한 후 상기 혼합액에 전분풀을 혼합하여 형성된 난연액에 웹적층물을 2차 함침시키는 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법.
  3. 제 1 항에 있어서,
    상기 혼합액은 실리카파우더 25 내지 30중량부, 증류수 65 내지 72 중량부, 초산 3 내지 5중량부 혼합하여 실리카수분산용액을 제조하는 제1공정과, 상기 제1공정에 의해 제조된 실리카수분산용액 55 내지 60중량부에 알콕시실란 34 내지 41중량부, 광촉매재 4 내지 6중량부를 혼합하고 믹실기로 중합반응시키는 제2공정과, 상기 제2공정에 의해 제조된 축합반응용액 25 내지 35중량부에 규산염 55 내지 70중량부, 프로필렌 5 내지 10중량부를 혼합하여 형성된 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법.
  4. 제 1 항에 있어서,
    상기 실리카파우더에 불소탄화수지 분말을 혼합한 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법.
  5. 제 1 항에 있어서,
    상기 중합반응은 65~75℃의 반응열이 발생되며 8시간 이상 반응시키는 것을 특징으로 하는 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법.
  6. 레이온 단섬유를 이용한 난연 레이온 단섬유 적층체에 있어서,
    전분을 이용한 풀과 실리카수분산용액이 혼합된 난연액에 단섬유로 이루어진 웹을 함침 후 건조시키면 전분풀에 의하여 실리카파우더가 단섬유에 흡착이 되어 탈거가 이루어지지 않아 난연 효율이 증대되며, 상기한 웹을 이용하여 적층체를 형성시키면 전분에 의해 강도가 향상되어 가공성 및 성형성이 향상되며,
    상기 레이온 단섬유의 내측으로 실리카파우더가 흡착되며 외측으로는 전분이 흡착된 실리카파우더와 전분풀이 흡착되어 이루어진 것을 특징으로 하는 난연 레이온 단섬유 적층체.
PCT/KR2021/012499 2020-09-16 2021-09-14 레이온 단섬유를 이용한 난연성을 갖는 단섬유 적층체의 제조방법 및 그 난연 레이온 단섬유 적층체 WO2022060053A1 (ko)

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