Waved meltblown fiber web and preparation method therefor

Abstract

A waved meltblown fiber web of the present invention relates to a fiber web prepared by a meltblown method and is characterized by a preparation method in which a meltblown microfiber comes in contact with collection portions having different surface velocities so as to be collected. The waved meltblown fiber web of the present invention is characterized in that: a part of meltblown microfibers reaches a low velocity collection portion so as to be horizontally layered, thereby forming a horizontal fiber layer ( 10 ); another part of the meltblown microfibers reaches a high velocity collection portion of which the surface velocity is greater that of the low velocity collection portion so as to form a serpentine vertical fiber layer ( 20 ); and the upper end of the vertical fiber layer ( 20 ) becomes entangled so as to form a wave shaped wave layer ( 30 ) forming the uppermost portion of the fiber web.

1 . A waved meltblown fiber web produced by a melt-blown method, the meltblown fiber web comprising a horizontal fiber layer  10 , a vertical fiber layer  20  formed on the horizontal fiber layer, and a waved layer  30  forming an uppermost portion of the vertical fiber layer  20 ,
 wherein the horizontal fiber layer  10  is formed by allowing a portion of meltblown microfibers to reach a low-velocity collection portion and to be deposited on the low-velocity collection portion in a horizontal orientation; 
 the vertical fiber layer  20  is formed in a serpentine shape by allowing the other portion of the meltblown microfibers to reach a high-velocity collection portion having a surface velocity higher than that of the low-velocity collection portion; and 
 the waved layer  30  is formed by entanglement of the microfibers at a top of the vertical fiber layer  20  and forms the uppermost portion of the fiber web. 
 
     
     
         2 . The waved meltblown fiber web of  claim 1 , wherein the waved layer  30  is formed such that lines defined by peaks and valleys of the wave of the waved layer  30  are arranged at irregular intervals in a horizontal direction. 
     
     
         3 . A waved meltblown fiber web produced by a melt-blown method comprising collecting meltblown microfibers by bringing them into contact with collection portions having different surface velocities,
 the meltblown fiber web comprising a waved layer  30  forming an uppermost portion of the fiber web,   wherein the waved layer  30  is formed such that lines defined by peaks and valleys of the wave of the waved layer  30  are arranged at irregular intervals in a horizontal direction.   
     
     
         4 . The waved meltblown fiber web of  claim 1 , wherein when one side of the waved layer  30  is pulled, the waved layer  30  is separated on the whole from the vertical fiber layer  20 . 
     
     
         5 . The waved meltblown fiber web of  claim 1 , further comprising staple fibers which serve to intertangle the meltblown microfibers together. 
     
     
         6 . The waved meltblown fiber web of  claim 1 , further comprising a covering fabric  40  covering the meltblown fiber web, in which the covering fabric  40  is a nonwoven fabric made of spunbond fibers. 
     
     
         7 . The waved meltblown fiber web of  claim 1 , wherein the ratio of the thickness of the horizontal fiber layer  10  to the thickness of the vertical fiber layer  20  is 1:1 to 1:9 in a state in which an external compressive load is not applied to the fiber web and the fiber web is freely spread out, or in a state in which an external compressive load is not applied to the fiber web and the fiber web is covered with the covering fabric  40  and is freely spread out, or in a state in which the fiber web is pulled up upwardly by an external force 0.1-2 times the total thickness of the fiber web in a load-free state. 
     
     
         8 . The waved meltblown fiber web of  claim 5 , wherein the staple fibers are present in an amount of 5-90 wt % based on the total weight of the waved meltblown fiber web in a state in which the fiber web is not covered with the covering fabric  40 . 
     
     
         9 . The waved meltblown fiber web of  claim 8 , wherein the staple fibers are mesofibers which are either synthetic polymer fibers selected from the group consisting of olefinic fibers such as polypropylene fibers, polyethylene fibers, polyethylene terephthalate fibers, nylon fibers, glass fibers, and carbon-based fibers, or natural polymer fibers selected from the group consisting of cotton fibers, hemp fibers and pulp fibers; or
 the staple fibers are mesofibers selected from among staple fibers, hollow fibers, multi-lobal fibers, and electrostatically treated staple fibers, and have a dual structure.   
     
     
         10 . A method of producing a waved meltblown fiber web by a melt-blown method,
 the waved meltblown fiber web being produced by a method comprising collecting meltblown microfibers by bringing them into contact with collection portions having different surface velocities,   the method comprising the steps of:   (S1) feeding a thermoplastic resin composition into an extruder;   (S2) extruding the thermoplastic resin composition;   (S3) spinning the extruded thermoplastic composition with a high-temperature and high-pressure gas in a form of filaments;   (S4) depositing a portion of the spun filaments on a low-velocity collection portion in a single orientation and in a predetermined pattern to form a horizontal fiber layer  10 , and bringing the other portion of the spun filaments into contact with a high-velocity collection portion to form a vertical fiber layer  20 ; and   (S5) winding the produced meltblown fiber web.