Composite nonwoven fabrics and articles containing same

Abstract

Disclosed are a composite nonwoven fabric and an article comprising the same. The disclosed composite nonwoven fabric comprises a meltblown nonwoven fabric layer at least partially subjected to electrification treatment and a spunbonded nonwoven fabric layer disposed on one or both sides thereof, and the pressure loss thereof is less than or equal to 5.0 mmH 2 O, the pilling size after Martindale abrasion test is less than 5mm.

Description

Technical Field

[0001] Disclosed are a composite nonwoven fabric and an article comprising the same. More specifically, disclosed are a composite nonwoven fabric having excellent pilling resistance and breathability and an article comprising the same. Background Art

[0002] The anti-dust mask is composed of a multi-layer composite structure of inner and outer materials and a filter material in the center for filtering dust.

[0003] At present, melt-blown nonwoven fabrics that have been subjected to electrification are mainly used as filter layers. Melt-blown nonwoven fabrics have low mechanical strength, high flexibility, and poor morphological stability, so they are prone to structural deformation when subjected to external impact or friction. Therefore, in order to protect the melt-blown nonwoven fabric layer and give it morphological stability, masks are constructed by laminating nonwoven fabrics with high mechanical properties such as morphological stability and tensile strength on both sides or one side of the melt-blown nonwoven fabric layer, mainly spunbond nonwoven fabrics through a separate lamination process.

[0004] In addition, spunbond nonwoven fabrics are usually used as the inner and outer materials of one or both sides of the electrified meltblown material. Since the filaments of spunbond nonwoven fabrics are thicker and the pores are larger, they only have the function of imparting morphological stability without having anti-dust efficiency. Therefore, in the multi-layer mask nonwoven fabric structure, the filter layer located in the center will filter dust, so there is a problem that dust is concentrated and stacked on the filter layer, causing the filtration efficiency to decrease over time. In particular, in industrial sites where masks must be worn for a long time, this problem may also affect the respiratory safety of the wearer.

[0005] In addition, the non-woven fabrics used as the inner and outer layers are mainly laminated by ultrasonic welding according to the shape of the mask. Therefore, the structure of the electrified melt-blown non-woven fabric of the inner layer changes during the welding process, which may reduce the filtering performance.

[0006] In addition, the materials used for the inner and outer layers of the mask include cotton fabrics or non-woven staple fibers and spunbonded non-woven fabrics. The materials used for the inner and outer layers of the mask directly contact the user's skin, so the surface of the material may be deformed due to friction, or the surface of the material may be easily deformed due to the user's hand contact during use or contact during storage. In this case, the user may feel uncomfortable due to the abnormal touch of the appearance and the skin contact part. Summary of the invention

[0007] Technical issues

[0008] One embodiment of the present invention provides a composite nonwoven fabric having excellent pilling resistance and breathability.

[0009] Another embodiment of the present invention provides an article, which includes the composite nonwoven fabric.

[0010] Technical Solution

[0011] In one aspect, the present invention provides a composite nonwoven fabric.

[0012] The invention comprises a meltblown nonwoven fabric layer which is at least partially electrified and a spunbonded nonwoven fabric layer which is arranged on one or both sides of the meltblown nonwoven fabric layer.

[0013] The pressure loss of the composite nonwoven fabric is less than or equal to 5.0 mmH2O, and the size of the pilling blocks after the Martindale abrasion test is less than 5 mm.

[0014] The embossing ratio of the composite nonwoven fabric may be 9% to 19%.

[0015] The average area of ​​an embossed pattern of the composite nonwoven fabric can be 0.06 mm 2 Up to 0.6mm 2 .

[0016] An average aspect ratio of one embossed pattern of the composite nonwoven fabric may be 1.0 to 2.5.

[0017] The composite nonwoven fabric may include a first spunbond nonwoven fabric layer, a meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer, wherein the meltblown nonwoven fabric layer may be at least partially electrified.

[0018] The composite nonwoven fabric may include the first spunbond nonwoven fabric layer, the meltblown nonwoven fabric layer, and the second spunbond nonwoven fabric layer in the following order.

[0019] At least one of the first spunbond nonwoven layer and the second spunbond nonwoven layer may include at least one spunbond nonwoven sub-layer.

[0020] The meltblown nonwoven fabric layer may include at least one electrified meltblown nonwoven fabric sublayer.

[0021] The meltblown nonwoven fabric layer may include at least one electrified meltblown nonwoven fabric sublayer and at least one un-electrified meltblown nonwoven fabric sublayer.

[0022] The composite nonwoven fabric may further comprise at least one additional layer.

[0023] Another aspect of the present invention provides an article,

[0024] It comprises the composite nonwoven fabric.

[0025] The article may be a dust mask, an air purifier filter or an air conditioning filter.

[0026] Beneficial Effects

[0027] The composite nonwoven fabric according to one embodiment of the present invention has excellent pollution resistance and morphological stability and its life can be extended, and the multi-layered filter layer can improve the overall performance of the mask and the stability of anti-dust efficiency.

[0028] In addition, the composite nonwoven fabric has excellent pilling resistance and breathability.

[0029] In addition, the composite nonwoven fabric can be used to prevent various dust, fine dust, bacteria, etc., and can be used for medical or health care masks. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 is a diagram schematically showing a composite nonwoven fabric according to an embodiment of the present invention.

[0031] Figure 2 : is a diagram schematically showing a composite nonwoven fabric manufacturing apparatus for continuously manufacturing a composite nonwoven fabric according to an embodiment of the present invention. DETAILED DESCRIPTION

[0032] Hereinafter, a composite nonwoven fabric according to an embodiment of the present invention will be described in detail.

[0033] In this specification, "composite non-woven fabric (non-woven fabric composite)" refers to a non-woven fabric that is made of two or more non-woven fabrics through a continuous process and becomes one, rather than a non-woven fabric laminate made by separately manufacturing two or more non-woven fabrics and then laminating them separately. Therefore, the "composite non-woven fabric" in this specification can also be referred to as a "monolithic non-woven fabric". The composite non-woven fabric is characterized by having a higher interlayer bonding ability than the non-woven fabric laminate, and having better morphological stability and filtration performance.

[0034] In addition, the "non-woven fabric layer treated with electrification" or "non-woven fabric sub-layer treated with electrification" in this specification can be manufactured by a continuous process. Specifically, the "non-woven fabric layer treated with electrification" or "non-woven fabric sub-layer treated with electrification" can be manufactured by sequentially or simultaneously implementing "manufacturing of non-woven fabric" and "electrification treatment" in a continuous process.

[0035] In addition, "electrified treatment" in this specification means that electric charges are semi-permanently applied to non-woven fibers, thereby forming an electric field between adjacent fibers, which is characterized by higher charge density and anti-dust efficiency than non-woven fabrics that have been treated with electrification or non-electrified fabrics.

[0036] In addition, "at least partially electrified" in this specification means that when it is composed of a single layer, the entire layer is electrified, or when it is composed of multiple sublayers, some layers are electrified and the remaining sublayers are not electrified, or all sublayers are electrified.

[0037] In addition, the "charge enhancer" in this specification refers to a substance that increases the charge density.

[0038] In addition, the "fine dust permeability", "fine dust prevention efficiency" and "pressure loss" in this specification are evaluated by the following methods after the composite nonwoven fabric is produced and before use.

[0039] (1) Testing equipment: TSI-8130 model produced by TSI Company was used.

[0040] (2) Aerosol formation: The detection device evaporates the water in the sodium chloride aqueous solution mist generated by the microaerosol generating device, thereby forming a sodium chloride aerosol dispersed in the air. The average particle size of the sodium chloride particles in the formed sodium chloride aerosol is 0.3 μm, and the sodium chloride concentration in the aerosol is 18.5 mg / m 3 .

[0041] (3) Evaluation of dust penetration rate: The aerosol penetration velocity is 16 cm / sec, and the evaluation area of ​​the nonwoven fabric is 100 cm 2 The penetration rate of the aerosol particles is recorded as the fine dust penetration rate.

[0042] (4) Evaluation of fine dust prevention efficiency: The evaluation was performed using the following mathematical formula 1.

[0043]

Mathematical formula 1

[0044] Anti-dust efficiency = 100% - dust penetration rate.

[0045] (5) Evaluation of pressure loss: The aerosol penetration velocity is 5 cm / sec and the evaluation area of ​​the nonwoven fabric is 100 cm 2 .

[0046] The composite nonwoven fabric according to one embodiment of the present invention comprises a meltblown nonwoven fabric layer at least partially subjected to electrification treatment and a spunbonded nonwoven fabric layer disposed on one or both sides thereof.

[0047] The composite nonwoven fabric may have an anti-dust 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%.

[0048] The pressure loss of the composite nonwoven fabric may be less than or equal to 5.0 mmH2O, less than or equal to 4.0 mmH2O, less than or equal to 3.0 mmH2O, or less than or equal to 2.0 mmH2O.

[0049] In addition, the pilling size of the composite nonwoven fabric after the Martindale abrasion test may be less than 5 mm, less than 4 mm, less than 3 mm or less than 2 mm. Therefore, the composite nonwoven fabric has the advantages of inhibiting the occurrence of pilling and having high air permeability.

[0050] In addition, the embossing ratio of the composite nonwoven fabric (=total area of ​​the embossed pattern / total area of ​​the composite nonwoven fabric×100=total area of ​​the embossed pattern of the pattern roll in the calender roll / total area of ​​the upper surface of the pattern roll in the calender roll×100) can be 9% to 19%. When the embossed area of ​​the composite nonwoven fabric is within the above range, a composite nonwoven fabric with low pilling rate and small pressure loss can be obtained.

[0051] In addition, the average area of ​​one embossed pattern of the composite nonwoven fabric can be 0.06 mm 2 Up to 0.6mm 2 When the average area of ​​one embossed pattern of the composite nonwoven fabric is within the above range, a composite nonwoven fabric having a low pilling rate and a small pressure loss can be obtained.

[0052] In addition, the average aspect ratio (major axis / minor axis) of one embossed pattern of the composite nonwoven fabric may be 1.0 to 2.5. When the average aspect ratio of one embossed pattern of the composite nonwoven fabric is within the above range, a composite nonwoven fabric with a low pilling rate can be obtained.

[0053] The composite nonwoven fabric is characterized by having an excellent microparticle capture function by including at least a portion of a meltblown nonwoven fabric layer that has been subjected to an electrification treatment. However, the average pore size of the existing spunbond-meltblown multilayer nonwoven fabric is at the level of several micrometers (μm) to tens of micrometers (μm), and thus has almost no function of preventing microparticles at the level of 0.1 μm to 0.6 μm.

[0054] The composite nonwoven fabric may include a first spunbond nonwoven fabric layer, a meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer.

[0055] The meltblown nonwoven fabric layer may be at least partially electrified.

[0056] The composite nonwoven fabric may include the first spunbond nonwoven fabric layer, the meltblown nonwoven fabric layer, and the second spunbond nonwoven fabric layer in the following order. However, the present invention is not limited thereto, and the composite nonwoven fabric may include the first spunbond nonwoven fabric layer, the meltblown nonwoven fabric layer, and the second spunbond nonwoven fabric layer in other orders.

[0057] The meltblown nonwoven fabric layer may include a charge enhancer as described below.

[0058] At least one of the first spunbond nonwoven layer and the second spunbond nonwoven layer may include at least one spunbond nonwoven sublayer. For example, at least one of the first spunbond nonwoven layer and the second spunbond nonwoven layer may include a spunbond nonwoven sublayer that is integrated with each other due to being manufactured by a continuous process.

[0059] The meltblown nonwoven fabric layer may include at least one electrified meltblown nonwoven fabric sublayer. For example, the meltblown nonwoven fabric layer may include a plurality of electrified meltblown nonwoven fabric sublayers, wherein the meltblown nonwoven fabric sublayers are integrated with each other because they are manufactured by continuous processes.

[0060] The meltblown nonwoven fabric layer may include at least one electrified meltblown nonwoven fabric sublayer and at least one un-electrified meltblown nonwoven fabric sublayer. Specifically, the meltblown nonwoven fabric layer may include at least one electrified meltblown nonwoven fabric sublayer and at least one un-electrified meltblown nonwoven fabric sublayer, and the electrified meltblown nonwoven fabric sublayers are integrated with each other because they are manufactured by continuous processes respectively.

[0061] At least one spunbond nonwoven fabric, at least one electrified meltblown nonwoven fabric, and / or at least one unelectrified meltblown nonwoven fabric included in the composite nonwoven fabric may each independently include a non-conductive polymer.

[0062] The non-conductive polymer may include polyolefin, polystyrene, polycarbonate, polyester, polyamide, copolymers thereof, or combinations thereof.

[0063] The polyolefin may include polyethylene, polypropylene, poly-4-methyl-1-pentene, polyvinyl chloride, or a combination thereof.

[0064] The polyester may include polyethylene terephthalate, polylactic acid, or a combination thereof.

[0065] Each of the spunbond nonwoven fabrics, each of the electrified meltblown nonwoven fabrics, and / or each of the un-electrified meltblown nonwoven fabrics may further include an additive, respectively, independently of one another.

[0066] The additives may include pigments, light stabilizers, primary antioxidants, secondary antioxidants, metal deactivators, hindered amines, hindered phenols, fatty acid metal salts, triesters of phosphites, phosphates, fluorine-containing compounds, nucleating agents, or combinations thereof.

[0067] Additionally, in one embodiment, the antioxidant may function as a charge enhancer. The charge enhancer may include a thermally stable organic triazine compound, oligomer, or combination thereof, and the compound or oligomer further contains at least one nitrogen atom in addition to the nitrogen in the triazine ring.

[0068] For example, U.S. Patent Nos. 6,268,495, 5,976,208, 5,968,635, 5,919,847, and 5,908,598 disclose charge enhancers for improving charging characteristics. For example, the charge enhancer may include a hindered amine-based additive, a triazine additive, or a combination thereof.

[0069] As other examples, the charge enhancer may include poly[[6-[(1,1,3,3-tetramethylbutyl)amino]-1,3,5-triazine-2,4-diyl][(2,2,6,6-tetramethyl-4-piperidinyl)imino]-1,6-hexanediyl[(2,2,6,6-tetramethyl-4-piperidinyl)imino]] (manufactured by BASF, CHIMASSORB 944), -polymer of a reaction product of bis(2,2,6,6-tetramethyl-4-piperidinyl)-1,6-hexanediamine and 2,4,6-trichloro-1,3,5-triazine and N-butyl-1-butylamine and N-butyl-2,2,6,6-tetramethyl-4-piperidinamine (manufactured by BASF, CHIMASSORB 2020), or the charge enhancer may be an N-substituted amino aromatic compound, in particular a triamino-substituted compound, for example, ethylhexyl triazone (2,4,6-Trianilino-p-(carbo-2'-ethylhexyl-1'-oxy)-1,3,5-triazine) (manufactured by BASF, UVINUL T-150). Other charge enhancers include 2,4,6-tri-(octadecylamino)-triazine known as tristearate melamine ("TSM"), α-olefin (C20-C24) maleic anhydride-4-amino-2,2,6,6-tetrapiperidine (manufactured by BASF, Uvinul 5050H) or 4-hydroxy-2,2,6,6-tetramethyl-1-piperidine ethanol mixture (manufactured by BASF, Tinuvin 622SF).

[0070] The charge enhancer may be contained in an amount of 0.25 to 5 parts by weight based on 100 parts by weight of the total weight of each spunbonded nonwoven fabric or the total weight of each electrified meltblown nonwoven fabric. When the charge enhancer is contained in the above range, the high level of electrification performance to be achieved in the present invention can be obtained, and the spinnability is good, the nonwoven fabric maintains high strength, and the cost is favorable.

[0071] In addition to the above-mentioned additives, the composite nonwoven fabric may further include known additives such as a heat stabilizer and a weathering agent.

[0072] The total content of the electrified meltblown 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 electrified meltblown nonwoven fabric is within the above range, a composite nonwoven fabric having excellent filtering performance, morphological stability and durability can be obtained.

[0073] The basis weight (mass per unit area) of the composite nonwoven fabric may be in the range of 10 g / m 2 Up to 500g / m 2 , for example, 20g / m 2 Up to 100g / m 2 .

[0074] The plurality of nonwoven fabrics included in the composite nonwoven fabric may be integrated (ie, bonded) to each other by thermal fusion rather than by ultrasonic welding.

[0075] The composite nonwoven fabric may further comprise at least one additional layer.

[0076] For example, each of the additional layers may include at least one additional nonwoven fabric other than the spunbond nonwoven fabric and the meltblown nonwoven fabric.

[0077] For another example, each of the additional layers may include at least one layer made of a material other than non-woven fabric.

[0078] Hereinafter, a method for manufacturing a composite nonwoven fabric according to an embodiment of the present invention will be described in detail.

[0079] The method for manufacturing a composite nonwoven fabric according to an embodiment of the present invention may include the following steps: S10, continuously forming a spunbond nonwoven fabric layer; and S20, continuously forming a meltblown nonwoven fabric layer on the spunbond nonwoven fabric layer.

[0080] The spunbond nonwoven fabric layer continuous forming step S10 may be performed by forming fiber yarns by melt extruding, cooling and stretching a thermoplastic non-conductive polymer, and then laminating the fiber yarns on a mesh belt to perform webforming.

[0081] The meltblown nonwoven fabric layer continuous forming step S20 can be formed by melt extrusion, hot air stretching and cooling of a thermoplastic non-conductive polymer (charge enhancer may be added) to form fiber yarns, and then the fiber yarns are laminated onto the spunbond that is meshed by the spunbond nonwoven fabric layer continuous forming step S10 for meshing.

[0082] Specifically, the step S20 of continuously forming the meltblown nonwoven fabric layer may include: S20-1, continuously forming free fibers through a non-conductive polymer (to which a charge enhancer may be added); S20-2, continuously spinning the free fibers; S20-3, continuously spraying a polar solvent (e.g., water) onto the free fibers to continuously charge the free fibers; and S20-4, continuously stacking the free fibers to continuously form a meltblown nonwoven fabric.

[0083] The free fiber continuous electrification step S20 - 3 may be performed by continuously spraying the polar solvent and gas (eg, air).

[0084] The following describes in detail the different properties or significant effects of the free fiber continuous electrification step S20-3 compared with the prior art.

[0085] (1) In general, the following methods are mainly used in the industrial field to manufacture melt-blown nonwoven fabrics that have been subjected to electrification treatment. The methods that can be subjected to electrification treatment in the melt-blowing process are, as shown in U.S. Patent No. 6,375,886, a method of conducting electrification treatment by friction between polar solvents and filaments being melt-spun, and as shown in U.S. Patent No. 6,969,484, a method of conducting electrification treatment by friction between hydrated nonwoven fabrics after immersing the melt-blown nonwoven fabric in a polar solvent and then allowing water to penetrate between the nonwoven fabrics through a water absorption device. As described above, the electrification treatment method using a polar solvent requires a subsequent process of drying the polar solvent after the electrification treatment, so in principle it is impossible to laminate or composite nonwoven fabrics through a continuous process. The disclosures of U.S. Patent No. 6,375,886 and U.S. Patent No. 6,969,484 are incorporated by reference in their entirety in this application.

[0086] (2) U.S. Patent No. 5,227,172 discloses a method of applying a high potential difference between a meltblowing die and a collector, thereby causing the melt-spun resin to be filamentized and induced to be electrified by the surrounding electric field. This method can obtain a meltblown nonwoven fabric that has been electrified without any additional post-processing. However, the efficiency of the electrification treatment of the nonwoven fabric that has been electrified by the potential difference will drop sharply due to heat or the surrounding environment, so it is difficult to use it as an item that needs to be stored for a long time during the sales process, such as a dust mask, or an item that needs a long service life, such as an air purifier filter. The disclosure of U.S. Patent No. 5,227,172 is incorporated by reference in its entirety into this application.

[0087] The inventors have developed an electrification treatment device that sprays polar solvent and air together in the form of two fluids on a melt-blown nonwoven fabric layer, thereby rubbing polar solvent particles that have obtained sufficient kinetic energy through a small amount of spraying onto the filaments being melt-spun to give them a highly efficient friction electrification effect. The device is characterized in that the air heated within the DCD (die to collector distance) interval is fully heated and evaporated due to the small amount of spraying, so no additional drying equipment is required. Due to this characteristic, the electrification treatment device has the advantage of being able to realize the composite of nonwoven fabrics by combining with the nonwoven fabric manufacturing process through continuous lamination.

[0088] The nonwoven fabric obtained by subjecting the melt-blown nonwoven fabric to electrification treatment is in a continuously polarized state so that negative charges and positive charges exist semi-permanently, and this nonwoven fabric is called an electret nonwoven fabric.

[0089] As described above, the method for manufacturing the composite nonwoven fabric may not include an additional drying step to remove the polar solvent sprayed in the free fiber continuous electrification step S20 - 3 .

[0090] In addition, as described above, the polar solvent continuously sprayed in the free fiber continuous electrification step S20-3 can be continuously heated and evaporated by heated air in the DCD (die to collector distance) section of the composite nonwoven fabric manufacturing equipment.

[0091] The method for manufacturing the composite nonwoven fabric may further include step S30 of continuously forming another spunbond nonwoven fabric layer on the meltblown nonwoven fabric layer by the same method as step S10 of continuously forming the spunbond nonwoven fabric layer.

[0092] After the step S20 of continuously forming the meltblown nonwoven fabric layer or the step S30 of continuously forming another spunbond nonwoven fabric layer, the method for manufacturing the composite nonwoven fabric layer may further include S40, continuously hot-pressing each spunbond nonwoven fabric layer on one side or both sides of the meltblown nonwoven fabric layer.

[0093] The heat pressing step S40 can be performed by passing the meltblown nonwoven fabric layer and the at least one spunbonded nonwoven fabric layer between calendering rollers, wherein the calendering rollers include a first roller (i.e., a pattern roller) formed with a plurality of embossed patterns having the same shape and a second roller (a smooth roller) without concave and convex shapes. By adjusting the area ratio of the upper surface of the embossed pattern formed on the surface of the first roller in the calendering roller (= the area of ​​the embossed pattern of the first roller / the total area of ​​the upper surface of the first roller × 100), the size of the upper surface, and the shape of the upper surface, the embossing ratio, the average area of ​​an embossed pattern, and the average aspect ratio of an embossed pattern of the composite nonwoven fabric finally produced can be adjusted.

[0094] Figure 1 is a diagram schematically showing a composite nonwoven fabric 10 according to an embodiment of the present invention.

[0095] The composite nonwoven fabric 10 according to one embodiment of the present invention includes a first spunbond nonwoven fabric layer 11 , a meltblown nonwoven fabric layer 12 at least partially subjected to electrification treatment, and a second spunbond nonwoven fabric layer 13 .

[0096] In addition, by changing the manufacturing method of the composite nonwoven fabric, composite nonwoven fabrics having various structures and / or compositions can be manufactured.

[0097] Hereinafter, an article according to an embodiment of the present invention is described in detail.

[0098] An article according to an embodiment of the present invention includes the above-mentioned composite nonwoven fabric.

[0099] The article may be a dust mask, an air purifier filter or an air conditioning filter.

[0100] Hereinafter, the present invention will be described in detail by way of examples. This example is intended to further describe the present invention in detail, but the scope of the present invention is not limited thereto.

[0101] Example 1: Manufacturing composite nonwoven fabric

[0102] A propylene homopolymer (LG Chemical, H7900) with a melt index (MI) of 34 g / 10 min was used as a polymer for forming the spunbond nonwoven fabric layer (SB), and a resin (LG Chemical, H7910) with a melt flow rate (MFR) of 1000 g / 10 min was used as a polymer for forming the meltblown nonwoven fabric layer (MB). In addition, a hindered amine light stabilizer Chimasorb 944 was added to the polymer for forming the meltblown nonwoven fabric layer (MB) at a content of 0.5 wt%. Then, as Figure 1 As shown, a composite nonwoven fabric in the form of spunbond-meltblown-spunbond (SMS) is continuously manufactured using a composite nonwoven fabric manufacturing device. Specifically, the meltblown nonwoven fabric layer (MB) is continuously electrified by contacting water together with air through a two-fluid nozzle in the composite nonwoven fabric manufacturing device, and then laminated on top of the spunbond nonwoven fabric layer (SB), and another spunbond nonwoven fabric layer (SB) is laminated on top of the meltblown nonwoven fabric layer (MB). Finally, an SMS nonwoven fabric laminate is obtained. Then, the SMS nonwoven fabric laminate is made into a composite nonwoven fabric form by a hot pressing process between calender rollers, and the calender rollers include a first roller formed with a plurality of embossed patterns of the same shape and a second roller without bumps. Among them, the embossing ratio of the calender roller is 14%, and the average area of ​​an embossed pattern is 0.33mm 2 The average aspect ratio of an embossed pattern is 1.75. The total basis weight of the SMS composite nonwoven fabric is adjusted to 100 gsm (g / m 2 ), the basis weight of the meltblown nonwoven fabric layer (MB) was adjusted to 22 gms.

[0103] Example 2: Manufacturing composite nonwoven fabric

[0104] In addition to replacing the calender roll with an embossing ratio of 9% and an average area of ​​0.33mm 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 1.75 was used.

[0105] Example 3: Manufacturing composite nonwoven fabric

[0106] In addition to replacing the calender roll with an embossing ratio of 19% and an average area of ​​0.33mm 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 1.75 was used.

[0107] Example 4: Manufacturing composite nonwoven fabric

[0108] In addition to replacing the calender roll with an embossing ratio of 14% and an average area of ​​0.06mm 2An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 1.75 was used.

[0109] Example 5: Manufacturing composite nonwoven fabric

[0110] In addition to replacing the calender roll with an embossing ratio of 14% and an average area of ​​0.6mm per embossing pattern, 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 1.75 was used.

[0111] Example 6: Manufacturing composite nonwoven fabric

[0112] In addition to replacing the calender roll with an embossing ratio of 14% and an average area of ​​0.33mm 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calender roll having an average aspect ratio of an embossed pattern of 1.0 was used.

[0113] Example 7: Manufacturing composite nonwoven fabric

[0114] In addition to replacing the calender roll with an embossing ratio of 14% and an average area of ​​0.33mm 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 2.5 was used.

[0115] Comparative Example 1: Manufacturing of composite nonwoven fabric

[0116] In addition to replacing the calender roll with an embossing ratio of 8% and an average area of ​​0.33mm 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 1.75 was used.

[0117] Comparative Example 2: Manufacturing of composite nonwoven fabric

[0118] In addition to replacing the calender roll with an embossing ratio of 20% and an average area of ​​0.33mm 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 1.75 was used.

[0119] Comparative Example 3: Manufacturing of composite nonwoven fabric

[0120] In addition to replacing the calender roll with an embossing ratio of 14% and an average area of ​​0.05mm 2An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 1.75 was used.

[0121] Comparative Example 4: Manufacturing of composite nonwoven fabric

[0122] In addition to replacing the calender roll with an embossing ratio of 14% and an average area of ​​0.7mm 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calendering roll having an average aspect ratio of an embossed pattern of 1.75 was used.

[0123] Comparative Example 5: Manufacturing of composite nonwoven fabric

[0124] In addition to replacing the calender roll with an embossing ratio of 14% and an average area of ​​0.33mm 2 An SMS composite nonwoven fabric was manufactured in the same manner as in Example 1, except that a calender roll having an average aspect ratio of 3.0 for the embossed pattern was used.

[0125] The embossing ratio (%) (=total area of ​​the embossing pattern of the first roller / total upper surface area of ​​the first roller × 100), the average area of ​​an embossing pattern and the average aspect ratio (length of the major axis / length of the minor axis) of the composite nonwoven fabrics produced in Examples 1 to 7 and Comparative Examples 1 to 5 were detected, and the results are shown in Table 1 below.

[0126] [Table 1]

[0127]

[0128] Evaluation example: Evaluation of the physical properties of nonwoven fabrics

[0129] The pressure loss, weight, pressure loss / weight, pilling size and process stability of each composite nonwoven fabric produced in Examples 1 to 7, Comparative Examples 1 to 5 and Reference Example 1 were evaluated by the following methods, and the results are shown in Table 2 below.

[0130] (1) Testing equipment: TSI-8130 model produced by TSI Company was used.

[0131] (2) Forming aerosol: The sodium chloride aqueous solution is brought into contact with air through the detection device to evaporate water, thereby forming an aerosol containing sodium chloride dispersed in the air with an average particle size of 0.3 μm and a sodium chloride particle concentration of 18.5 mg / m 3 aerosol.

[0132] (3) Evaluation of anti-aerosol efficiency: Aerosol permeability is 95 L / min, and the evaluation area of ​​the nonwoven fabric is 100 cm 2 .

[0133] (4) Evaluation of pressure loss: Aerosol permeability is 30 L / min, and the evaluation area of ​​the nonwoven fabric is 100 cm 2 .

[0134] (5) Evaluation weight: The test was conducted in accordance with ASTM D 3776-1985.

[0135] (6) Evaluation of pilling block size: "Pilling resistance" was evaluated by performing a Martindale abrasion test. This test detects the relative resistance of nonwoven fabrics to abrasion by evaluating the appearance of small blocks formed after pilling or entanglement of fibers constituting the nonwoven fabric due to wear after contact with an abrasive. The test was performed using a Martindale abrasion tester of model 404, etc. commercially available from James H. Heal & Company, Ltd. (West Yorkshire, UK). The abrasive used was a silicone rubber wheel (manufacturer: VIP Rubber & Plastic Company. Inc., model: 86045K21-50A). The abrasion test was performed in accordance with ASTM D4966-98. The following appearance deformations occurred due to wear. That is, the appearance deformation occurred in the order of fuzzy, pill (the shape of blocks formed after pilling and entanglement), rope, and spider-web. The short fibers generated on the surface of the nonwoven fabric due to wear are called fuzzy. Taking non-woven fabrics with low resistance to abrasion as an example, non-woven fabrics with a fuzz size greater than or equal to 5 mm or a rope or spider web with a height greater than or equal to 5 mm produced by the entanglement of fuzz and fluff cannot be used for masks. In this manual, "fuzz", "rope" and "spider web" are collectively referred to as pilling blocks. The detection of the size of pilling blocks in this manual is to detect the height of the block shape protruding in the form of fuzz, rope or spider web after being wrapped on the upper end surface of the non-woven fabric, and the reference surface for the detection is the upper end surface of the non-woven fabric. During the detection, the height of the pilling was detected on the side with a ruler without applying external pressure to the non-woven fabric. Fluff in the form of unentangled short fibers was not evaluated.

[0136] (7) Evaluation of process stability: When the integrated composite nonwoven fabric is manufactured by the hot melt process, the nonwoven fabric passes between two calender rolls. At this time, the nonwoven fabric is hot-melted in the shape of the embossed pattern due to the heat and pressing force transmitted to the nonwoven fabric. When the area of ​​the embossed pattern protruding from the surface of the calender roll becomes smaller, the shape of the embossed pattern formed on the composite nonwoven fabric is damaged during the hot pressing between the rolls, so that normal hot pressing cannot be performed. After observing whether such damage to the embossed pattern occurs, it is evaluated that the process stability is good if it does not occur.

[0137] [Table 2]

[0138]

[0139] Referring to the above Table 2, the composite nonwoven fabrics manufactured in Examples 1 to 7 showed a pressure loss of less than or equal to 5 mmH2O, pilling blocks with a size of less than 5 mm, and good process stability.

[0140] However, the composite nonwoven fabrics produced in Comparative Examples 1, 4, and 5 showed a pressure loss of 5 mmH2O and good process stability, but showed pilling blocks with a size of 5 mm or more.

[0141] In addition, the composite nonwoven fabric manufactured in Comparative Example 2 showed pilling pieces with a size of less than 5 mm and good process stability, but showed a pressure loss of more than 5 mmH2O.

[0142] In addition, the composite nonwoven fabric manufactured in Comparative Example 3 showed a pressure loss of less than or equal to 5 mmH2O and pilling blocks with a size of less than 5 mm, but showed poor process stability due to the damage of the embossed pattern.

[0143] Although the present invention has been described with reference to the accompanying drawings and embodiments, this is only exemplary, and those skilled in the art will appreciate that various modifications and other equivalent embodiments may be made therefrom. Therefore, the true technical protection scope of the present invention should be determined by the technical conception of the appended claims.

Claims

1. A composite nonwoven fabric, include: A meltblown nonwoven fabric layer at least partially subjected to electrification treatment; and a spunbond nonwoven fabric layer on one or both sides thereof, Among them, its pressure loss is less than or equal to 5.0mmH 2 O, after Martindale abrasion test, the pilling size is less than 5mm, The embossing ratio is 9% to 19%, and the average area of ​​one embossing pattern is 0.06mm 2 Up to 0.6mm 2 , and an average aspect ratio of an embossing pattern is 1.0 to 2.

5.

2. The composite nonwoven fabric according to claim 1, in, The composite nonwoven fabric comprises a first spunbond nonwoven fabric layer, a meltblown nonwoven fabric layer and a second spunbond nonwoven fabric layer, wherein at least a portion of the meltblown nonwoven fabric layer is subjected to a charging treatment.

3. The composite nonwoven fabric according to claim 2, in, The composite nonwoven fabric includes the first spunbond nonwoven fabric layer, the meltblown nonwoven fabric layer, and the second spunbond nonwoven fabric layer in the following order.

4. The composite nonwoven fabric according to claim 2, in, At least one of the first spunbond nonwoven layer and the second spunbond nonwoven layer includes at least one spunbond nonwoven sublayer.

5. The composite nonwoven fabric according to claim 2, in, The meltblown nonwoven fabric layer includes at least one electrified meltblown nonwoven fabric sublayer.

6. The composite nonwoven fabric according to claim 5, in, The meltblown nonwoven fabric layer includes at least one electrified meltblown nonwoven fabric sublayer and at least one un-electrified meltblown nonwoven fabric sublayer.

7. The composite nonwoven fabric according to claim 1, further comprising at least one additional layer.

8. An article, which include: The composite nonwoven fabric according to any one of claims 1 to 7.

9. The article according to claim 8, in, The items described are dust masks, air purifier filters or air conditioning filters.

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