Method for manufacturing insect repellent masterbatch for nonwoven fabric, insect repellent masterbatch for nonwoven fabric, nonwoven fabric and articles thereof

Abstract

The present invention relates to a manufacturing method of an insect repellent masterbatch for nonwoven fabric, an insect repellent masterbatch for nonwoven fabric, a nonwoven fabric, and an article thereof, and the manufacturing method of the insect repellent masterbatch for nonwoven fabric includes a step of mixing raw materials including a base resin, a liquid insect repellent, and a carrier substance to obtain a raw material mixture, wherein the content of the liquid insect repellent in the raw material is 9,000 to 11,000 ppm by weight, and the content of the carrier substance in the raw material is 30,000 to 50,000 ppm by weight.

Description

[Technical Field]

[0001] The present invention relates to a method for producing an insect repellent masterbatch for nonwoven fabric, an insect repellent masterbatch for nonwoven fabric, nonwoven fabric, and articles thereof. More particularly, the present invention relates to a method for producing an insect repellent masterbatch for nonwoven fabric, an insect repellent masterbatch for nonwoven fabric, a nonwoven fabric, and articles thereof, which contain an insect repellent that is harmless to humans and thereby have insect repellent and insect growth inhibitory effects as well as improved antibacterial properties, and which can be used to produce nonwoven fabrics for a variety of uses such as hygiene, bedding, and agriculture, the insect repellent masterbatch for nonwoven fabric, and nonwoven fabric and articles thereof. [Background technology]

[0002] Conventional nonwoven fabrics have satisfactory mechanical strength and fine dust removal capabilities, but lack insect repellent and antibacterial properties, which can lead to problems such as insect infestation during storage and skin irritation if contaminated with bacteria. Summary of the Invention [Problem to be solved by the invention]

[0003] One embodiment of the present invention provides a method for preparing an insect repellent masterbatch for nonwoven fabrics.

[0004] Another embodiment of the present invention provides an insect repellent masterbatch for nonwoven fabrics prepared by the method for preparing an insect repellent masterbatch for nonwoven fabrics.

[0005] Yet another embodiment of the present invention provides a nonwoven fabric comprising the insect repellent masterbatch for nonwoven fabric.

[0006] Yet another embodiment of the present invention provides an article comprising the nonwoven fabric. [Means for solving the problem]

[0007] One aspect of the present invention is Mixing raw materials including a base resin, a liquid insect repellent, and a carrier material to obtain a raw material mixture; In the raw material, the content of the liquid insect repellent is 9,000 to 11,000 ppm by weight, The present invention provides a method for producing an insect repellent masterbatch for nonwoven fabric, wherein the content of the carrier material in the raw material is 30,000 to 50,000 ppm by weight.

[0008] The base resin may also include a non-conductive polymer selected from polyolefin, polystyrene, polycarbonate, polyester, polyamide, copolymers thereof, or combinations thereof.

[0009] The repellent may also include cinnamaldehyde, α-copaene, apiol, oleic acid, or a combination thereof.

[0010] The carrier material may also include silica, zeolite, kaolin, or a combination thereof.

[0011] Another aspect of the present invention is The present invention provides an insect repellent masterbatch for nonwoven fabrics, which is produced by the method for producing an insect repellent masterbatch for nonwoven fabrics.

[0012] Yet another aspect of the present invention is a method for producing a semiconductor device comprising: comprising a base resin, an insect repellent component, and a carrier material; The content of the insect repellent component is 300 to 500 ppm by weight, The content of the carrier material is 30,000 to 50,000 ppm by weight, and the insect repellent masterbatch for nonwoven fabric is provided.

[0013] The moth repellent masterbatch for nonwoven fabric also has a dispersion index of 0.6 or more and less than 1.0.

[0014] Yet another aspect of the present invention is a method for producing a semiconductor device comprising: A nonwoven fabric containing the insect repellent masterbatch for nonwoven fabric is provided.

[0015] The nonwoven fabric also contains the insect repellent masterbatch for nonwoven fabric in a ratio of 5 to 20% by weight based on the total weight of the nonwoven fabric.

[0016] The nonwoven fabric has a bacteriostatic activity value of 5.0 or more against Staphylococcus and a bacteriostatic activity value of 6.0 or more against Streptococcus pneumoniae, as measured by a bacteriostatic activity value measurement method (JIS L 1902).

[0017] The nonwoven fabric has an insect repellency rate against adult red flour beetles of 60% or more one week after treatment, and can maintain this rate at 40% or more even two weeks after treatment.

[0018] The nonwoven fabric also has a skin patch test grade of 1 or higher.

[0019] The nonwoven fabric also has a color difference meter deviation (ΔE*) of 2.0 to 3.0.

[0020] Said non-woven fabric 300~700cm 3 / cm 2 It is possible to achieve an air permeability performance of 1000 / s.

[0021] Yet another aspect of the present invention is a method for producing a semiconductor device comprising: An article is provided that includes the nonwoven fabric.

[0022] The article may also be a health or medical article. [Effects of the Invention]

[0023] The insect repellent masterbatch for nonwoven fabrics prepared by the method for preparing an insect repellent masterbatch for nonwoven fabrics according to an embodiment of the present invention contains an insect repellent that is harmless to humans, and therefore has improved antibacterial properties as well as insect repellent and insect growth inhibitor effects, and is applicable to nonwoven fabrics for a variety of uses, such as hygiene, bedding, and agriculture. [Brief explanation of the drawings]

[0024] [Figure 1] 1 is a schematic diagram illustrating a composite nonwoven fabric including a nonwoven fabric according to an embodiment of the present invention. [Figure 2] 1 is a schematic diagram illustrating a composite nonwoven fabric manufacturing apparatus used to continuously manufacture a composite nonwoven fabric including a nonwoven fabric according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0025] Hereinafter, a method for preparing an insect repellent masterbatch for nonwoven fabric according to an embodiment of the present invention will be described in detail.

[0026] As used herein, the term "liquid insect repellent" refers to an insect repellent in the form of a solution, oil, or suspension.

[0027] In this specification, the term "dispersion index" refers to the value obtained by dividing the discharge amount by the input amount when the insect repellent masterbatch for nonwoven fabric is spun through a spinning nozzle.

[0028] Additionally, in this specification, the term "nonwoven fabric composite" refers to a nonwoven fabric in which two or more types of nonwoven fabrics are manufactured in a single continuous process, rather than a nonwoven fabric laminate manufactured by separately manufacturing two or more types of nonwoven fabrics and then laminating them. Therefore, in this specification, the "composite nonwoven fabric" is also referred to as a "monolithic nonwoven fabric." The composite nonwoven fabric has stronger interlayer bonding than the nonwoven fabric laminate, and is characterized by excellent dimensional stability and filtration performance.

[0029] In this specification, the "charged meltblown nonwoven fabric layer" or "charged meltblown nonwoven fabric sublayer" is also one produced by a continuous process. Specifically, the "charged meltblown nonwoven fabric layer" or "charged meltblown nonwoven fabric sublayer" is one produced by sequentially or simultaneously carrying out "meltblown nonwoven fabric production" and "charging" in a continuous process.

[0030] In addition, in this specification, the term "charged" refers to a state in which an electric charge is semi-permanently imparted to the fibers of a nonwoven fabric, thereby enabling the formation of an electrostatic field between adjacent fibers. A charged nonwoven fabric is characterized by a higher charge density and fine dust removal efficiency than a nonwoven fabric that is not charged.

[0031] In this specification, "tensile strength" refers to the tensile strength measured in the MD (mechanical direction) by pulling a 5 cm wide test piece (grip spacing at the time of evaluation: 10 cm) using a tensile strength tester (Instron) based on KSK 0520 at a pulling speed of 500 mm / min.

[0032] In this specification, "bending resistance" is measured in mm in accordance with measurement standard WSP 90.1 by taking 16 samples (25 mm x 150 mm) in the MD and CD directions, placing the samples on a bending resistance tester, pushing the sample toward the inclined surface until it touches the inclined surface, and measuring the length of the sample from the point where it bends to the point where it touches the inclined surface.

[0033] In this specification, the "fine dust permeability," "fine dust removal efficiency," and "pressure loss" were evaluated for the composite nonwoven fabric after production and before use by the following methods: (1) Measuring device: TSI-8130 model from TSI was used. (2) Aerosol formation: The measuring device evaporated the water from the sodium chloride aqueous solution mist generated by the fine aerosol generator to form sodium chloride aerosol dispersed in the air. In the formed sodium chloride aerosol, the average particle size of the sodium chloride particles was 0.3 μm, and the sodium chloride concentration in the aerosol was 18.5 mg / m 3 is. (3) Fine dust permeability evaluation: The aerosol permeation surface velocity is 16 cm / sec, and the evaluation area of ​​the nonwoven fabric is 100 cm 2 The transmittance of the aerosol particles was recorded as the fine dust transmittance. (4) Aerosol removal efficiency evaluation: The aerosol penetration velocity is 16 cm / sec, and the evaluation area of ​​the nonwoven fabric is 100 cm 2 The aerosol removal efficiency was recorded as the fine dust removal efficiency. (5) Pressure loss evaluation: The aerosol penetration surface velocity was 16 cm / sec, and the evaluation area of ​​the nonwoven fabric was 100 cm 2 It was.

[0034] A method for preparing an insect repellent masterbatch for nonwoven fabric according to an embodiment of the present invention includes a step (S10) of mixing raw materials including a base resin, a liquid insect repellent, and a carrier material to obtain a raw material mixture.

[0035] In the raw material, the content of the liquid insect repellent is 9,000 to 11,000 ppm by weight, and the content of the carrier material in the raw material is 30,000 to 50,000 ppm by weight.

[0036] If the content of the liquid insecticide and the content of the carrier material are each within the above range, an insecticide masterbatch for nonwoven fabrics having excellent insecticidal performance and dispersion index can be obtained. If at least one of the content of the liquid insecticide and the content of the carrier material is outside the above range, an insecticide masterbatch for nonwoven fabrics having inferior insecticidal performance and dispersion index can be obtained.

[0037] The base resin may also include a non-conductive polymer selected from polyolefin, polystyrene, polycarbonate, polyester, polyamide, copolymers thereof, or combinations thereof.

[0038] The polyolefin may also include polyethylene, polypropylene, poly-4-methyl-1-pentene, polyvinyl chloride, or a combination thereof.

[0039] The polyester may also include polyethylene terephthalate, polylactic acid, or a combination thereof.

[0040] The liquid insect repellent may be a natural insect repellent extracted from a plant, for example, the liquid insect repellent may have a solid content of 3 to 5% by weight.

[0041] The liquid insect repellent may also include cinnamaldehyde, α-copaene, apiol, oleic acid, or a combination thereof.

[0042] The carrier material functions to crosslink the liquid insect repellent with the base resin and also to increase the dispersion index of the insect repellent masterbatch for nonwoven fabrics.

[0043] The carrier material may also include silica, zeolite, kaolin, or a combination thereof.

[0044] In addition, the method for preparing an insect repellent masterbatch for nonwoven fabric may further include, after the step (S10), a step (S20) of extruding and pelletizing the raw material mixture.

[0045] Another aspect of the present invention provides an insect repellent masterbatch for nonwoven fabrics produced by the above-mentioned method for producing an insect repellent masterbatch for nonwoven fabrics.

[0046] Another aspect of the present invention provides an insect repellent masterbatch for nonwoven fabrics, comprising a base resin, an insect repellent component, and a carrier material, wherein the content of the insect repellent component is 300 to 500 ppm by weight, and the content of the carrier material is 30,000 to 50,000 ppm by weight. When the contents of the insect repellent component and the carrier material are each within the above ranges, an insect repellent masterbatch for nonwoven fabrics with excellent insect repellent performance and dispersion index can be obtained. If at least one of the contents of the insect repellent component and the carrier material is outside the above ranges, an insect repellent masterbatch for nonwoven fabrics with poor insect repellent performance and dispersion index can be obtained.

[0047] The insect repellent component is also a residue of the liquid insect repellent described above.

[0048] The insect repellent masterbatch for nonwoven fabrics also has a dispersion index of 0.6 or more but less than 1.0. If the dispersion index of the insect repellent masterbatch for nonwoven fabrics is less than 0.6, when an attempt is made to produce a nonwoven fabric by adding the insect repellent masterbatch for nonwoven fabrics, spinning becomes impossible due to an increase in pressure in the extruder and die, making it impossible to use the insect repellent masterbatch for nonwoven fabrics. Furthermore, if the insect repellent masterbatch for nonwoven fabrics does not contain the carrier material, its dispersion index will be 1.0, and if it contains even a small amount of the carrier material, its dispersion index will be less than 1.0.

[0049] Another embodiment of the present invention provides a nonwoven fabric comprising the insect repellent masterbatch for nonwoven fabric.

[0050] The nonwoven fabric also contains the insect repellent masterbatch for nonwoven fabrics in a ratio of 5 to 20 wt % based on the total weight of the nonwoven fabric. If the content of the insect repellent masterbatch for nonwoven fabrics is within the above range, the nonwoven fabric can have excellent spinnability, insect repellent effect, skin patch test grade, breathability, mechanical strength, and abrasion / fuzz evaluation grade, and an appropriate level of color difference meter deviation (ΔE*).

[0051] Furthermore, the nonwoven fabric has a bacteriostatic activity value of 5.0 or more against Staphylococcus and a bacteriostatic activity value of 6.0 or more against Streptococcus pneumoniae, as measured by a bacteriostatic activity value measurement method (JIS L 1902).

[0052] Furthermore, the nonwoven fabric has an insect repellency rate against adult red flour beetles of 60% or more one week after treatment, and can maintain this rate at 40% or more even two weeks after treatment.

[0053] The nonwoven fabric also has a skin patch test grade of 1 or higher.

[0054] The nonwoven fabric also has a colorimeter deviation (ΔE*) of 2.0 to 3.0. The colorimeter deviation (ΔE*) is effective in terms of quality control. Specifically, qualitative and quantitative analysis can be performed to determine whether the insect repellent content is appropriate, but this is inefficient in terms of time and cost, and this can be easily resolved by measuring the colorimeter deviation (ΔE*). That is, if the colorimeter deviation (ΔE*) of the nonwoven fabric is 2.0 to 3.0, it is evidence that the insect repellent content is appropriate. Furthermore, if the colorimeter deviation (ΔE*) of the nonwoven fabric is 2.0 to 3.0, it will exhibit a slight brown color. However, since the colorimeter deviation (ΔE*) of organic cotton and natural pulp is at the 2.0 level, it has the advantage of appealing to consumers as an organic product.

[0055] The nonwoven fabric has a thickness of 300 to 700 cm 3 / cm 2 It is possible to achieve an air permeability performance of 1000 / s.

[0056] The nonwoven fabric has a maximum breaking strength of 40 to 60 N / 5 cm, a breaking elongation of 40 to 80%, and an abrasion fluffing evaluation grade of 1 or 2.

[0057] Two or more of the nonwoven fabrics may be laminated together to form a single unit, or one or more different types of nonwoven fabric may be laminated together to form a composite nonwoven fabric.

[0058] The composite nonwoven fabric has insect repellent and antibacterial properties.

[0059] The composite nonwoven fabric also includes a first spunbond nonwoven layer, a meltblown nonwoven layer, and a second spunbond nonwoven layer, specifically, the first spunbond nonwoven layer, the meltblown nonwoven layer, and the second spunbond nonwoven layer are each manufactured by a continuous process using a single device and are integrated with one another.

[0060] At least one of the first spunbond nonwoven fabric layer and the second spunbond nonwoven fabric layer also contains the insect repellent masterbatch for nonwoven fabric.

[0061] The meltblown nonwoven fabric layer is also at least partially electrostatically treated.

[0062] The meltblown nonwoven fabric layer also contains an insect repellent, for example, the meltblown nonwoven fabric layer also contains the insect repellent masterbatch for nonwoven fabrics.

[0063] The composite nonwoven fabric is characterized by having a fine particle collection function due to the inclusion of at least a partially electrostatically treated meltblown nonwoven fabric layer. However, conventional spunbond-meltblown multilayer nonwoven fabrics have an average pore size of several to several tens of micrometers, so they have almost no ability to remove fine particles of 0.1 to 0.6 micrometers.

[0064] The composite nonwoven fabric has a QF factor of 0.15 to 0.90, as expressed by the following formula 1:

[0065] [Formula 1] QF factor = -ln (fine dust permeability / pressure loss)

[0066] In Equation 1, the symbol "ln" means natural logarithm.

[0067] 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.

[0068] The higher the QF factor, the higher the filtration performance.

[0069] The composite nonwoven fabric has a MD tensile strength of 0.1 to 0.3 kgf / 5cm / gsm, 0.15 to 0.3 kgf / 5cm / gsm, 0.20 to 0.3 kgf / 5cm / gsm, or 0.25 to 0.30 kgf / 5cm / gsm, where gsm is g / m 2 and means the weight per unit area of ​​the composite nonwoven fabric.

[0070] The composite nonwoven fabric also has a bending resistance in the MD direction of 20 mm or more, 25 mm or more, 30 mm or more, or 35 mm or more.

[0071] The composite nonwoven fabric also has a bending resistance in the CD direction of 10 mm or more, 15 mm or more, 20 mm or more, 25 mm or more, or 30 mm or more.

[0072] The composite nonwoven fabric also 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%.

[0073] The composite nonwoven fabric also has a pressure loss of 0.80 to 12 mmH2O, 1.0 to 10 mmH2O, 1.5 to 8 mmH2O, 2.0 to 6 mmH2O, 2.5 to 7 mmH2O, 3.0 to 6 mmH2O, 3.5 to 5 mmH2O, or 4.0 to 5 mmH2O.

[0074] 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 that order, but 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 another order.

[0075] The first spunbond nonwoven layer and the second spunbond nonwoven layer each include a plurality of spunbond nonwoven sublayers, specifically, the first spunbond nonwoven layer and the second spunbond nonwoven layer each include a plurality of spunbond nonwoven sublayers that are manufactured by a continuous process on a single device and integrated with one another.

[0076] The meltblown nonwoven fabric layer may also include at least one electrically charged meltblown nonwoven fabric sub-layer, and more specifically, the meltblown nonwoven fabric layer may include a single electrically charged meltblown nonwoven fabric sub-layer, or may include multiple electrically charged meltblown nonwoven fabric sub-layers that are each manufactured by a continuous process on a single device and integrated with one another.

[0077] The meltblown nonwoven fabric layer may further include at least one non-charged meltblown nonwoven fabric sub-layer in addition to at least one electrically charged meltblown nonwoven fabric sub-layer. Specifically, the meltblown nonwoven fabric layer may further include only one non-charged meltblown nonwoven fabric sub-layer in addition to at least one electrically charged meltblown nonwoven fabric sub-layer, or may further include multiple non-charged meltblown nonwoven fabric sub-layers that are each manufactured by a continuous process and integrated with one another on a single device.

[0078] At least one spunbond nonwoven, at least one electrostatically treated meltblown nonwoven, and / or at least one non-electrostatically treated meltblown nonwoven included in the composite nonwoven each independently contain a non-conductive polymer.

[0079] The non-conductive polymer is the same as the non-conductive polymer contained in the base resin of the insect repellent masterbatch for nonwoven fabric.

[0080] Each of the spunbond nonwoven fabrics, each of the electrostatically treated meltblown nonwoven fabrics, and / or each of the non-electrostatically treated meltblown nonwoven fabrics may each, independently of one another, further comprise an additive.

[0081] The additives may also 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 combinations thereof.

[0082] In one embodiment, the antioxidant can also function as a charge-enhancing agent. Possible charge-enhancing agents include thermally stable organic triazine compounds, oligomers, or combinations thereof, which compounds or oligomers further contain at least one nitrogen atom in addition to the nitrogen in the triazine ring.

[0083] For example, charge enhancing agents for improving charging characteristics are disclosed in U.S. Patent Nos. 6,268,495, 5,976,208, 5,968,635, 5,919,847, and 5,908,598. For example, the charge enhancing agents may include hindered amine-based additives, triazine-based additives, or combinations thereof.

[0084] As another example, the charge enhancing agent may include 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)] (CHIMASSORB 944, manufactured by BASF), (reaction products of 2,4,6-trichloro-1,3,5-triazine with 1,6-hexanediamine, N,N'-bis(2,2,6,6-tetramethyl-4-piperidinyl)polymer, N-butyl-1-butanamine, and N-butyl-2,2,6,6-tetramethyl-4-piperidinamine) (CHIMASSORB 2020, manufactured by BASF), or a combination thereof.

[0085] The charge enhancing agent can also be an N-substituted amino aromatic compound, particularly a tri-amino substituted compound, such as 2,4,6-trianilino-p-(carbo-2'-ethylhexyl-1'-oxy)-1,3,5-triazine (UVINUL T-150, manufactured by BASF). Another charge enhancing agent is 2,4,6-tris-(octadecylamino)-triazine, also known as tristearylmelamine ("TSM").

[0086] The content of the charge-enhancing agent is 0.25 to 5 parts by weight per 100 parts by weight of the total weight of each charged meltblown nonwoven fabric. If the content of the charge-enhancing agent is within this range, not only can the high level of charging performance targeted by the present invention be obtained, but also spinnability is good, the strength of the nonwoven fabric is maintained at a high level, and it is advantageous from a cost perspective.

[0087] In addition to the additives, the composite nonwoven fabric may further contain commonly known additives such as a heat stabilizer and a weathering agent.

[0088] In the composite nonwoven fabric, the total content of the electrically charged meltblown nonwoven fabric is 3 to 50 parts by weight per 100 parts by weight of the total weight of the composite nonwoven fabric. If the total content of the electrically charged meltblown nonwoven fabric is within this range, a composite nonwoven fabric with excellent filtration performance, shape stability, and durability can be obtained.

[0089] The composite nonwoven fabric has a basis weight (mass per unit area) of 10 to 500 g / m 2 , e.g., 20 to 100 g / m 2 It is also in the range of

[0090] The plurality of nonwoven fabrics included in the composite nonwoven fabric are integrated (ie, bonded) to one another by heat fusion rather than ultrasonic fusion.

[0091] The composite nonwoven fabric may further include at least one additional layer.

[0092] By way of example, each of the additional layers may include one or more separate nonwoven fabrics that are neither spunbond nor meltblown.

[0093] Alternatively, each of the additional layers may include one or more layers of other materials than nonwoven fabric.

[0094] Hereinafter, a method for manufacturing a composite nonwoven fabric according to an embodiment of the present invention will be described in detail.

[0095] A method for manufacturing a composite nonwoven fabric according to an embodiment of the present invention includes the step of continuously forming a spunbond nonwoven fabric layer (S100), and the step of continuously forming a meltblown nonwoven fabric layer on the spunbond nonwoven fabric layer (S200).

[0096] The spunbond nonwoven fabric layer continuous formation step (S100) involves melt-extruding, cooling, and stretching a blend of a thermoplastic nonconductive polymer and the insect repellent masterbatch for nonwoven fabric to form a fiber yarn, and then laminating the fiber yarn on a screen belt to form a web.

[0097] In the step of continuously forming the meltblown nonwoven fabric layer (S200), a thermoplastic non-conductive polymer (to which an electrostatic performance improver may be added) is melt-extruded, drawn with hot air, and cooled to form a fiber yarn, and then the fiber yarn is laminated on the spunbond web formed in the step of continuously forming the spunbond nonwoven fabric layer (S100) to form a web.

[0098] Specifically, the step of continuously forming the meltblown nonwoven fabric layer (S200) includes the steps of continuously forming free fibers using a nonconductive polymer (or a blend of a nonconductive polymer and the aforementioned insect repellent masterbatch for nonwoven fabric) (S200-1), continuously spinning the free fibers (S200-2), continuously spraying a polar solvent (e.g., water) onto the free fibers to continuously charge the free fibers (S200-3), and continuously collecting the free fibers to continuously form the meltblown nonwoven fabric (S200-4).

[0099] The free fiber continuous charging step (S200-3) may also be performed by continuously injecting the polar solvent together with a gas (e.g., air).

[0100] The following will explain in detail why the free fiber continuous charging step (S200-3) has a unique or significant effect compared to the prior art.

[0101] (1) Generally, the most commonly used methods for charging during the meltblowing process are those described in U.S. Patent No. 6,375,886, which involves friction between a polar solvent and the melt-spun filaments, and those described in U.S. Patent No. 6,969,484, which involve immersing a meltblown nonwoven fabric in a polar solvent and then using a suction device to allow water to pass through the nonwoven fabric, resulting in friction between the water and the nonwoven fabric. These charging methods using polar solvents require a separate post-processing step to dry the polar solvent after charging, making it essentially impossible to laminate or composite nonwoven fabrics in a continuous process. U.S. Patent Nos. 6,375,886 and 6,969,484 are incorporated herein by reference in their entireties.

[0102] (2) U.S. Patent No. 5,227,172 discloses a method for applying a high potential difference between a meltblown die and a collector, in which the melt-spun resin is induced and charged by the surrounding electric field while filamenting. This method allows for the production of a charged meltblown nonwoven fabric without any additional post-processing. However, nonwoven fabrics induced and charged by this potential difference exhibit a tendency for the charging efficiency to drop rapidly due to heat or the surrounding environment, making them unsuitable for applications that require long-term storage during the sales process, such as fine dust masks, or that require a long service life, such as air purifier filters. U.S. Patent No. 5,227,172 is incorporated herein by reference in its entirety.

[0103] The inventors developed a charging treatment device that sprays a polar solvent and air onto a meltblown nonwoven fabric layer in a two-fluid form, allowing the polar solvent particles, which have sufficient kinetic energy with a small amount of spray, to rub against the filaments during melt spinning, resulting in highly efficient triboelectric charging. This charging treatment device is characterized by the fact that it does not require a separate drying facility because the small amount of sprayed solvent is sufficiently heated and evaporated by heated air within the DCD (die to collector distance) section. This characteristic makes it possible to combine the charging treatment device with the nonwoven fabric manufacturing process and combine nonwoven fabrics through continuous lamination.

[0104] The nonwoven fabric obtained by charging the meltblown nonwoven fabric is in a permanently polarized state in which negative and positive charges exist semi-permanently, and such a nonwoven fabric is called an electret nonwoven fabric.

[0105] As described above, the method for manufacturing the composite nonwoven fabric does not include a separate drying step for removing the polar solvent sprayed in the free fiber continuous charging treatment step (S200-3).

[0106] As described above, the polar solvent continuously sprayed in the free fiber continuous charging treatment step (S200-3) can be continuously heated and evaporated by heated air in the DCD (die to collector distance) section of the composite nonwoven fabric manufacturing apparatus.

[0107] The method for manufacturing the composite nonwoven fabric may further include a step (S300) of continuously forming another spunbond nonwoven fabric layer on the meltblown nonwoven fabric layer in the same manner as the step (S100) of continuously forming the spunbond nonwoven fabric layer.

[0108] The method for manufacturing the composite nonwoven fabric may further include, after the step of continuously forming the meltblown nonwoven fabric layer (S200) or the step of continuously forming the other spunbond nonwoven fabric layer (S300), a step of continuously heat-compressing the respective spunbond nonwoven fabric layers to one or both sides of the meltblown nonwoven fabric layer (S40).

[0109] FIG. 1 is a schematic view of a composite nonwoven fabric 10 including a nonwoven fabric according to an embodiment of the present invention.

[0110] A 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, and a second spunbond nonwoven fabric layer 13.

[0111] At least one of the first spunbond nonwoven fabric layer 11, the meltblown nonwoven fabric layer 12, and the second spunbond nonwoven fabric layer 13 is the nonwoven fabric according to one embodiment of the present invention (i.e., the nonwoven fabric containing the insect repellent masterbatch for nonwoven fabric).

[0112] Furthermore, by modifying the manufacturing method of the composite nonwoven fabric, composite nonwoven fabrics having various structures and / or configurations can be manufactured.

[0113] Yet another aspect of the present invention provides an article comprising the nonwoven fabric or the composite nonwoven fabric.

[0114] The article may also be a health or medical article.

[0115] The present invention will be described in more detail below through examples. These examples are intended to more specifically explain the present invention, but the scope of the present invention is not limited to these examples.

[0116] Examples 1-1 to 1-3 and Comparative Examples 1-1 to 1-4: Production of insect repellent masterbatch An insect repellent masterbatch was prepared by melt-kneading using a propylene homopolymer (H7700, manufactured by LG Chem) with a melt index (MI) of 34 g / 10 min as the base resin, a liquid insect repellent mixture of cinnamaldehyde, α-copaene, apiol, and oleic acid in a weight ratio of 20:8:7:9 as the base resin, and silica as the carrier material. In Examples 1-1 to 1-3 and Comparative Examples 1-1 to 1-4, the contents (by weight) of the liquid insect repellent and the carrier material (by weight) for the raw materials consisting of the base resin, liquid insect repellent, and carrier material are shown in Table 1 below.

[0117] [Table 1]

[0118] Table 2 below shows the content (by weight) of the insect repellent component and the content (by weight) of the carrier material in the insect repellent master batches produced in Examples 1-1 to 1-3 and Comparative Examples 1-1 to 1-4.

[0119] [Table 2]

[0120] Examples 2-1 to 2-5 and Comparative Examples 2-1 to 2-6: Production of composite nonwoven fabrics The polymer used to form the spunbond nonwoven fabric layer (SB) was a propylene homopolymer (H7700, manufactured by LG Chem) with a melt index (MI) of 34 g / 10 min, and the polymer used to form the meltblown nonwoven fabric layer (MB) was a resin (H7910, manufactured by LG Chem) with a melt flow index (MFR) of 1,000 g / 10 min. To the polymer used to form the spunbond nonwoven fabric layer (SB), one of the insecticide masterbatches prepared in Examples 1-1 to 1-3 and Comparative Examples 1-1 to 1-4 was added in the proportions shown in Table 3 below, based on the total weight of the polymer. Chimassorb 944, a hindered amine light stabilizer, was added in an amount of 0.5 wt% to the polymer used to form the meltblown nonwoven fabric layer (MB). Then, a composite nonwoven fabric in the form of spunbond-meltblown-spunbond (SMS) was continuously produced using a composite nonwoven fabric production apparatus as shown in Figure 1. Specifically, the meltblown nonwoven fabric layer (MB) was continuously charged by contacting it with water and air through a two-fluid nozzle in the composite nonwoven fabric production apparatus, and then laminated on top of the spunbond nonwoven fabric layer (SB). Another spunbond nonwoven fabric layer (SB) was then laminated on top of the meltblown nonwoven fabric layer (MB). As a result, an SMS nonwoven fabric laminate was obtained. The SMS nonwoven fabric laminate was then subjected to a heat-compression process between an embossed patterned roll and a smooth roll to produce a single composite nonwoven fabric. The overall basis weight of the SMS composite nonwoven fabric was 100 gsm (g / m 2 ), where the basis weight of the meltblown nonwoven fabric layer (MB) was adjusted to 22 gsm.

[0121] [Table 3]

[0122] Evaluation example 1: Dispersion index evaluation of insect repellent masterbatch The dispersion index of the insect repellent masterbatches prepared in Examples 1-1 to 1-3 and Comparative Examples 1-1 to 1-4 was evaluated, and the results are shown in Table 4 below.

[0123] [Table 4]

[0124] Evaluation example 2: Evaluation of the physical properties of composite nonwoven fabric The physical properties of the composite nonwoven fabrics prepared in Examples 2-1 to 2-5 and Comparative Examples 2-1 to 2-6 were evaluated by the following methods, and the results are shown in Table 5 below.

[0125] (1) Spinnability: The nonwoven web was observed to see if it broke, and if it did not break, it was recorded as "good."

[0126] (2) Bacteriostatic Activity Value: The bacteriostatic activity value measurement method involves inoculating bacteria (i.e., Staphylococcus aureus or Streptococcus pneumoniae) (i.e., allowing the test sample to completely absorb the test bacteria solution), culturing for 18 hours, and then confirming the number of bacteria before and after culturing. The bacteriostatic activity value is measured as follows: When the number of bacteria after culturing in the untreated control group is C and the number of bacteria after culturing in the insect-repellent-treated product is B, the bacteriostatic activity value is calculated using the following equation 2. Here, the untreated control group and the treated product are identical in that they have a structure comprising three layers, in that order: a first spunbond nonwoven fabric layer, a meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer. However, they differ from each other in that the untreated control group has not been subjected to an insect-repellent treatment, while the treated product has been subjected to an insect-repellent treatment.

[0127] [Formula 2] Bacteriostatic activity value = Log(C / B)

[0128] (3) Insect repellency rate and durability against adult red flour beetles: The insect repellency rate against adult red flour beetles is the percentage (%) of the number of surviving red flour beetles in the treated product relative to the number of surviving red flour beetles in the untreated control group, and indicates the repellency performance of the insect-control treated product. Here, the untreated control group and the treated product are identical in that they have a configuration comprising three layers, in that order: a first spunbond nonwoven fabric layer, a meltblown nonwoven fabric layer, and a second spunbond nonwoven fabric layer, but are different in that the untreated control group has not been treated with an insect repellent, while the treated product has been treated with an insect repellent. The insect repellency rate of the adult red flour beetle is measured as follows: First, a medium for adult red flour beetles is placed in a large petri dish 1, a small petri dish 1 is placed in the center, and an untreated control group and an attractant sample are placed in the small petri dish 1. Then, a medium for adult red flour beetles is placed in a large petri dish 2, a small petri dish 2 is placed in the center, and an insect-repellent-treated product and an attractant sample are placed in the small petri dish 2. Then, they are placed in an airtight container, and after 24 hours, the small petri dish 1 and the small petri dish 2 are removed and the number of surviving mites in each is confirmed. Finally, the insect repellency rate of adult red flour beetles is calculated using the following formula 3.

[0129] [Formula 3] Insect repellency rate (%) of adult red flour beetles = (number of red flour beetles in small dish 1 - amount of red flour beetle water in small dish 2) / number of red flour beetles in small dish 1 x 100

[0130] In the above formula 3, the term "living red flour beetles" refers to adult red flour beetles that respond to external stimuli.

[0131] (3) Skin patch test grade: The skin test measurement method is as follows: (i) Sample preparation: 5cm x 5cm size per sample (ii) A sample was attached to a person's wrist and elbow, and aging was performed for 24 hours. (iii) After 24 hours, remove the sample and check for changes in the skin. - Grade 1: Same as early skin - Grade 2: slight flushing - Grade 3: More than half of the body flushed - Grade 4: Flushing of all parts

[0132] (4) Color difference meter deviation (ΔE*): The skin test measurement method was as follows: a color difference meter (CM3700D (Minolta)) was used to measure the color difference meter deviation (ΔE*) of the composite nonwoven fabric.

[0133] (5) Air permeability: Using an FX3300 air permeability measuring instrument, the sample was placed in the measuring instrument and the air permeability (air permeability) was measured under the measuring area and measuring pressure according to the KSK 0507 method.

[0134] (6) Breaking strength and breaking elongation: Using a tensile strength and elongation tester (Instron) measuring equipment, a 5 cm wide test piece was pulled at a grip spacing of 10 cm and a pulling speed of 500 mm / min according to the KSK 0520 method to measure the breaking strength and breaking elongation.

[0135] (7) Abrasion and fuzzing: Using a Martindale 404 measuring device, a 15 cm piece was rubbed several times using the measuring device according to the KSK 0504 method, and fuzzing was measured.

[0136] [Table 5]

[0137] Referring to Table 5, it can be seen that the composite nonwoven fabrics prepared in Examples 2-1 to 2-3 were excellent in spinnability, insect repellency, skin patch test grade, breathability, mechanical strength, and abrasion / fuzz evaluation grade, and the color difference meter deviation (ΔE*) was at an appropriate level.

[0138] However, in Comparative Examples 2-1, 2-3 and 2-4, spinning itself was impossible, and nonwoven fabrics could not be produced.

[0139] In addition, the composite nonwoven fabrics produced in Comparative Examples 2-2, 2-5, and 2-6 were shown to have poor insect repellent effects. In particular, the composite nonwoven fabric produced in Comparative Example 2-5 had a color difference meter deviation (ΔE*) that was outside the appropriate level, making it impossible to appeal to consumers as being organic.

[0140] Although the present invention has been described with reference to the drawings and embodiments, they are merely illustrative, and those skilled in the art will understand that various modifications and equivalent embodiments are possible therefrom. Therefore, the true technical scope of protection of the present invention is defined by the technical spirit of the claims.

Claims

1. Mixing raw materials including a base resin, a liquid insect repellent, and a carrier material to obtain a raw material mixture; In the raw material, the content of the liquid insect repellent is 9,000 to 11,000 ppm by weight, In the raw material, the content of the carrier material is 30,000 to 50,000 ppm by weight; The liquid insect repellent has a solid content of 3 to 5% by weight, The method for producing an insect repellent masterbatch for nonwoven fabrics, wherein the carrier material comprises silica, zeolite, kaolin, or a combination thereof.

2. 2. The method for producing an insect repellent masterbatch for nonwoven fabrics according to claim 1, wherein the base resin comprises a non-conductive polymer selected from the group consisting of polyolefin, polystyrene, polycarbonate, polyester, polyamide, copolymers thereof, and combinations thereof.

3. 2. The method for producing an insect repellent masterbatch for nonwoven fabrics according to claim 1, wherein the liquid insect repellent comprises cinnamaldehyde, α-copaene, apiol, oleic acid, or a combination thereof.

4. An insect repellent masterbatch for nonwoven fabrics, produced by the method for producing an insect repellent masterbatch for nonwoven fabrics according to any one of claims 1 to 3.

5. comprising a base resin, an insect repellent component, and a carrier material; The content of the insect repellent component is 300 to 500 ppm by weight, The content of the carrier material is 30,000 to 50,000 ppm by weight, The nonwoven fabric insect repellent masterbatch, wherein the carrier material comprises silica, zeolite, kaolin, or a combination thereof.

6. 6. The insect repellent masterbatch for nonwoven fabric according to claim 5, wherein the dispersion index of the insect repellent masterbatch for nonwoven fabric is 0.6 or more and less than 1.

0.

7. A nonwoven fabric comprising the insect repellent masterbatch for nonwoven fabric according to claim 6.

8. The nonwoven fabric according to claim 7, wherein the nonwoven fabric contains the insect repellent masterbatch for nonwoven fabric in an amount of 5 to 20% by weight based on the total weight of the nonwoven fabric.

9. 8. The nonwoven fabric according to claim 7, wherein the nonwoven fabric has a bacteriostatic activity value against Staphylococcus of 5.0 or more and a bacteriostatic activity value against Streptococcus pneumoniae of 6.0 or more, as measured by a bacteriostatic activity value measurement method (JIS L 1902).

10. The nonwoven fabric according to claim 7, wherein the nonwoven fabric exhibits an insect repellency rate against adult red flour beetles of 60% or more one week after treatment, and a sustained insect repellency rate of 40% or more even two weeks after treatment.

11. The nonwoven fabric according to claim 7 , wherein the nonwoven fabric has a skin patch test grade of grade 1 or higher.

12. The nonwoven fabric according to claim 7, wherein the nonwoven fabric has a color difference meter deviation (ΔE*) of 2.0 to 3.

0.

13. The nonwoven fabric has a thickness of 300 to 700 cm ３ / cm ２ The nonwoven fabric according to claim 7, which exhibits an air permeability performance of 100 / s.

14. An article comprising the nonwoven fabric of claim 13.

15. 15. The article of claim 14, wherein the article is a health or medical article.

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