Composite nonwoven fabric and article comprising same

Patent metadata

Field	Value
Publication number	US-12415150-B2
Application number	US-202117914521-A
Country	US
Kind code	B2
Filing date	Mar 24, 2021
Priority date	Mar 26, 2020
Publication date	Sep 16, 2025
Grant date	Sep 16, 2025

Abstract

A non-woven fabric composite and an article including the same are provided. The non-woven fabric includes an electrostatically treated meltblown non-woven fabric layer and a spunbond non-woven fabric layer on one or both sides thereof, and has a fine dust removal performance retention ratio, represented by Equation 1, of 80% or more:

Fine dust removal performance retention ratio (%)=(fine dust removal efficiency after accelerated aging treatment)/(fine dust removal efficiency before accelerated aging treatment)×100  [Equation 1]

wherein, in this equation, the fine dust is an aerosol containing sodium chloride dispersed in air, and the accelerated aging treatment refers to a case where the non-woven fabric composite is stored at a temperature of 70° C. for 3 days.

First claim

The invention claimed is:

1. A non-woven fabric composite comprising:
an electrostatically treated meltblown non-woven fabric layer; and
a spunbond non-woven fabric layer on both sides of the electrostatically treated meltblown non-woven fabric layer,
wherein the meltblown non-woven fabric layer is electrostatically treated by being continuously subjected to an electrostatical treatment by being contacted with water together with air through a two-fluid nozzle in an apparatus of manufacturing the non-woven fabric composite,
wherein the non-woven fabric composite comprises a monolithic non-woven fabric manufactured according to such a method wherein two or more kinds of non-woven fabrics are prepared by using a single continuous process and thus integrally formed, wherein the non-woven fabric composite is not a non-woven fabric laminate manufactured through a separate laminating post-process after two or more kinds of non-woven fabrics are individually prepared,
wherein the non-woven fabric composite has a fine dust removal performance retention ratio of 80% or more, and the fine dust removal performance retention ratio is represented by Equation 1:
Fine dust removal performance retention ratio (%)=(fine dust removal efficiency after accelerated aging treatment)/(fine dust removal efficiency before accelerated aging treatment)×100  Equation 1

wherein, in the Equation 1, the fine dust is an aerosol containing sodium chloride dispersed in air, and the accelerated aging treatment refers to a case where the non-woven fabric composite is stored at a temperature of 70° C. for 3 days.

2. The non-woven fabric composite of claim 1 , wherein
the non-woven fabric composite has a pressure loss retention ratio of 90% or more, wherein the pressure loss retention ratio is represented by Equation 2:
Pressure loss retention ratio (%)=(pressure loss after accelerated aging treatment)/(pressure loss before accelerated aging treatment)×100  Equation 2

wherein, in the Equation 2, the pressure loss is measured using an aerosol containing sodium chloride dispersed in air, and the accelerated aging treatment refers to a case where the non-woven fabric composite is stored at a temperature of 70° C. for 3 days.

3. The non-woven fabric composite of claim 1 , wherein the fine dust removal rate after the accelerated aging treatment is 18% to 99%.

4. The non-woven fabric composite of claim 1 , wherein the electrostatically treated meltblown non-woven fabric layer and the spunbond non-woven fabric layer each independently include a non-conductive polymer, wherein the non-conductive polymer includes polyolefin, polystyrene, polycarbonate, polyester, polyamide, a copolymer thereof, or a combination thereof.

5. The non-woven fabric composite of claim 1 , wherein an amount of the electrostatically treated meltblown non-woven fabric layer is 3 parts by weight to 50 parts by weight, based on 100 parts by weight of the total weight of the non-woven fabric composite.

6. An article comprising the non-woven fabric composite according to claim 1 .

7. The article of claim 6 , wherein the article is a mask for removing fine dust, a filter for an air purifier, or a filter for an air conditioner.

Assignees

• Toray Advanced Mat Korea Inc

Inventors

• Yoon Do Kyung
• Jeong Jin Il
• Jeong Geung Sik

Classifications

• D10B2505/04

  Filters · CPC title

• D10B2401/00

  Physical properties · CPC title

• D10B2321/022

  polypropylene · CPC title

• D04H3/16 Primary

  with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion · CPC title

• D04H3/03

  at random · CPC title