Development of Coating Technology with Ultrasonic Spray ... meeting/09. BSG- Korea.pdf · Development of Coating Technology . with Ultrasonic Spray methods . ... history and powerhouse

Development of Coating Technology

with Ultrasonic Spray methods

Oh Kyung KWON

Director/Ph.D.

BSG R&D Center

BSG Co.,Ltd, South Korea

In consideration of human and nature

CONTENTS

In consideration of human and nature 3

1. Company Profile

ADD TITLE

Company name : BSG Co.,Ltd Address : 20-1 Nowon 3-ga, Buk-gu, Daegu city CEO : Hong Jong Yoon Employees : 48 people [R&D Center : 9 people] Business area : Waterproof breathable functional fabric, Healthcare fabric Date of Establishment : 2005.6

Sports/Outdoor Healthcare

Military Protect

Business area

In consideration of human and nature

We will do our best when faced with challenges that are beyond our limit, as a leader of textile industry through the development of new materials.

BSG is the living history and powerhouse of textile processing industry of our nation’s textile industry and takes full responsibility as the leader of textile industry by striving for high quality textile development through the nation’s highest level of R&D research. As a result of reinvigoration the recessed textile industry and opening new possibilities through developing of innovative products, such as , , BSG has brought about revolution in material development, achieved KS mark, Q mark, ISO 9001:2009 / ISO 9001 : 2008 along with approvement of ‘outstanding quality’ and ‘material expertise company’. And it was chosen as an INNO-BIZ company, which approved the technical skills and quality assurance. By linking it to development of various functional materials, BSG continues to be the leader in processing the world’s high-value-added textile products.


1. Company Profile

Management Strategy

Company emphasizing nature and human

Green technology company emphasizing human and nature Expertise company drawing out humans health and life culture Loving company through trust and by receiving truth with product’s quality

Our Strategy

Consumption heading green

technology

Establishment Of discriminating

skill and system Human centered

Product and quality

World primary product Production bases

Massive consumption company and near massive market

Establishment of superb Human and infrastructure


1. Company Profile

Company History

2005 2006 2007 2009 2010 2011

Growth stage Established

BSG Co.,Ltd

Establishment of venture

company

Inno-biz Co.

Components ∙Material

specialized Company

Advance to Healthcare business

Bio-PU Technology

establishment

-Establishment of BSG, approvement as material expertise company -Merger of BSG and Beom Sam Gng Co.,Ltd.

-Establishment of venture company, BSG R&D center

-New Excellent Product certification(NEP) :Waterproof Breathable fabric

-Inno-biz Co. approval achievement

-PID Seminar :Environmentally friendly coating -Components Material specialized Company -Achievement of quality approval mark (Patients’ clothes)

-PID Seminar :Hospital antimicrobial fiber -Achievement of quality approval mark (Hospital uniforms, handle sanitary cover, sanitation clothes)

Beom Sam Gong

Co.,Ltd

1956 -Establishment of Sam Gong textiles mills company -Establishment of local products Beom Sam Gong Co.,Ltd.

Take-off stage

2014 -PIS Seminar :Bio-PU -Performance certification :Bio Label


1. Company Profile

Quality Assurance BSG always had the ideology of proving the best qualified products, and with this belief was able to value the products. To provide high quality products and to meet the expectation of the consumers, all products are strictly approved beforehand and go under severe inspection in development, production and finishing steps.

CUSTOMER

SEEDS

Technical Support

KNOW HOW

Marketing Support

NEEDS

Development Of

Merchandises

High degrees / Composition

Challenge / Innovation High level / Variety

Satisfaction

Prestige

Distinction


1. Company Profile

Research and Development

With the highest level of professional researchers and equipment, we are developing high-tech and high-functional products. BSG R&D Center, with excellent R&D personnel and infrastructure, possesses the differentiated high-tech textile fusion product through three strategies: development of demand-oriented promising fusion technology, development of symbiotic product for SMEs in this field of industry, and building production infrastructure for early industrialization.

FINE – Tech 2020

Excellence Tech

Integration Tech

Nano Tech

Fusion Tech

Fusion of nanotechnology and Surface processing technologies

Implementation of complex

Nanoparticle contamination of the surface layer

Excellence in processes and products


1. Company Profile

R&D Result

R&D Project Development period Support organizations

Development of functional sportswear with antibacterial, deodorant and ultraviolet shielding 2008.08.01~2010.07.31 Ministry of Trade, Industry and Energy

Development of fineness yarn, and high value added of lightweight fabric by convergence with nanotechnology 2008.12.01~2010.09.30 Ministry of Trade, Industry and Energy

Development of bio-safety textile product manufacturing technology for the National Household Health 2009.04.01~2011.03.31 Korean agency for technology and standards

Development of multi-functional green interior products by using depolymerization recycled materials 2009.06.01~2011.05.31 Ministry of Trade, Industry and Energy

Development of eco-green functional coating technology by using UV irradiation, and construction of equipment 2010.11.01~2011.10.31 Small and Medium Business

Administration

Development of IT fusion versatile product by using fiber based textile sensor 2009.01.01~2011.12.31 Ministry of Trade, Industry and Energy

Development of super fiber fusion product for next-generation military special purpose clothing. 2010.06.01~2012.05.31 Ministry of Trade, Industry and Energy

Development of complexation processing technology about multi-functional multi-layer architecture material 2009.10.01~2012.09.30 Ministry of Trade, Industry and Energy

Development of multi-functional eco healthcare textile product with antibacterial / flame retardant / UV shielding properties, by using natural / synthetic composite materials 2011.06.01~2013.05.31 Ministry of Trade, Industry and Energy

Development of high durable health / comfortable functional materials, and biological features suitable sweatsuit 2011.06.01~2013.05.31 Small and Medium Business

Administration

The development of ecological uni-skin for transportation industies 2011.07.01~2014.4.30 Ministry of Trade, Industry and Energy

Development of green-market deal with convergence textile products and high-function of breathable-waterproof PU film using plant-derived polyol 2013.06.01~2018.05.31 Ministry of Trade, Industry and Energy

Textile ergonomic platform for performance-enhancing air resistance to more than 3% reduction in winter sports and premium clothing system development 2013.06.01~2016.5.30 Ministry of Trade, Industry and Energy

Development of thermo-regulating mattress for sleeponomics market 2012.08.01~2015.4.30 Ministry of Trade, Industry and Energy

Development of Textile-based Wearable Rechargeable Batteries 2013.06.01~2015.5.30 Ministry of Trade, Industry and Energy

Nanostructured photocatalytic textiles 2013.12.01~2016.11.30 Ministry of Trade, Industry and Energy

Development of snowsuit integument and endothelial, suitable for military operation environment of South Korea 2014. ~ 2016 Ministry of National Defense


1. Company Profile

R&D Result Patent number / Patent name

No. 10-0881088 Multi-functional flame-retardant polyurethane film

No. 10-0909677 Method of preparing non swelling multilayer film

No. 10-0926702 Method of preparing non-swelling polyurethane beadcon film

No. 10-0955237 Manufacturing method of Light-sensitive textile materials and adhesive film for production

No. 10-1015024 Method for manufacturing functional fabric material having heat and light and sound shielding

No. 10-1038192 Multi functional house wrap having excellent heat shielding, moisture-permeable and water-proof properties and preparing method for the same No. 10-1078687 Intelligent cooling pad and a method of fabricating the same

No. 10-1065741 A conductivity blowing flim and It's manufacturing method

No. 10-1165729 High durable, antimicrobial and deodorant, yarn, fabrics pepared thereof and a method preparing the same

No. 10-1106983 Patient's garment with excellent infection proofing property

No. 10-1207457 Fabric used in manufacturing hospital cloths with excellent infection proofing property and method of manufacturing the same

No. 10-1296823 Compositions of eco-friendly water-proof film, Water-proof film having the same and Preparing method thereof

Main performance

Flame retardant performance Thermal insulating performance Light shielding performance

Non-swelling performance Light weight performance Breathable performance

Non-swelling performance High breathable performance

Body protection Light-sensitive color change

Thermal insulating performance Light shielding performance Noise shielding performance

Thermal insulating performance Heat-retaining performance Breathable performance

Thermal insulating performance Noise shielding performance Insulation performance

Conductive performance

UV shielding performance Deodorant performance Antibacterial performance



Water pressure resistance Breathable performance

Industrial Materials

Protective Clothing

Outdoor Products

Medical Products

Interior Products


1. Company Profile

Portfolio

Sports / Outdoor Textiles

With the water vapour permeability and waterproof function, it maintains a fresh environment and wear comfort. Especially, high functional products, with a water resistance higher than 10,000mm H2O and water vapour permeability higher than 20,000g/m²24hrs, can manifest outstanding function when producing outdoor and sportswear.

Military / Protective Textiles

It functions as protection from extreme environments, is flexible in low temperatures, and has a heatresisting property that endures high temperatures. With superb protection, it vaporizes sweat and is very suitable, which allows it to adapt easily to fireretardant clothes when making military clothes.

Health care / Medical Textiles

To offset the external contamination factors, it offers an excellent soil proof and deodorizing effect. These antimicrobial products are able to maintain a safe and pleasant environment to prevent cross-contamination of microorganisms and laundry and superior durability. It is applied to hospital uniforms, beds, sanitation clothes and food service uniforms.

Tech-Industrial Textiles

It is used by specific industries, products, processes, and high-strength fibers that are used as a functional purpose as a textile, high elasticity, heat resistant, abrasion resistant and superior performance, which is the needs of the product, as well as automotive interiors, tents, aviation, marine, and industrial materials.


1. Company Profile

Main process facility

Laminating M/C UV-Ray M/C

Hot-Melt Laminating M/C

Dry Coating M/C

Gravure M/C Wet Coating M/C


1. Company Profile

Product brand

It is a BSG registered trademark, which can be used in medical institutions or health care institutions, thanks to antistatic and deodorization secondary prevention of infection antibacterial materials.

Based on highly-durable, breathable and waterproof functionality, it is registered as the trademark of BSG that has various functions, which suits with the excellence of products and use.


1. Company Profile

Directions

Daegu Airport

www.bsgbsg.co.kr


2. Ultrasonic spray system process technology establishment

System design

[The side portion]

[The upper portion]

• Specification - Installation size : 215cm(L) x 90cm(W) 170cm(h) - Width of fabric processing : 100-400mm - Max temperature : 250 ℃ - Max flow of pump : 80ml/m - Spray : Ultrasonic spray Impact type - Dispersion particle size : 0.050mm ~ 0.060 mm

[Ultrasonic spray installation view]

Design and Construction of system

• The optimum nozzle / Generator, and an optimum pump selection and review • Constructed wide tabletop form Ultrasonic-spray system, by considering efficiency and ease of processing of textile products



[Impact nozzle]

[Composition of Impact nozzle] [Actual image of Impact nozzle]

WideTrack System MicroMist Accumist Vortex

[Kind of ultrasonic spray nozzles]


Nozzle selection

• The width of the processing textiles are 100 ~ 400mm, and the particle size will 0.050 ~ 0.060 mm, the particle size control in uniform will be required.

• Nozzle should be compatible with gear metering pump, and smooth flow of the processing agent is must available.



[Gear pump] • Pump actuated by the engagement of two gears of the same shape • The structure is simple and easy, and it can be applied to variety of capacities

[Syringe pump] • The form of a syringe • Pump can be control the small amount of the processing agent in precisely. • The maximum amount to control is very small(1~10g)

[Gravity pumps] • The operation using the position energy, delivered by the height difference between the ultrasonic nozzle and the tank • Suitable for pilot scale equipment, but it is not suitable to apply the RTR process

[Pressure pump] • Need to install additional gas tanks, and pumps suitable for large scales


Generator selection

Pump selection

• Gear pump was selected because it is easy to apply on mass production, and easy to control the flow.

• The size particles of the photocatalyst finishing agent is hundred nm.

• Designed to 0.050 ~ 0.060mm particle size in order to injecting uniformly and efficiently

• The generator power for this processing was designed to 40khz(1 to 400,000 times per second vibration)



Control box Nozzle

Pump Generator Air compressor

Remove part

[Actual image of system]


Systems construction

• The optimum nozzle / Generator, and an optimum pump selection and review • Constructed wide tabletop form Ultrasonic-spray system, by considering efficiency and ease of processing of textile products



• Experiments was conducted in the textile finishing conditions range(150 ~ 200 ℃)

• Divided into five sections(20cm unit) in heat area a position, and also recording the

temperature after stabilized(2 minutes).

• The set temperature and the actual temperature was more than 95% match at the

section 2, 3 and 4.

• The actual dry section is the 2,3,4 section (60 cm), and the conveyor speed can be

set based on this experiment during thermal curing.

Established of operating conditions

Compared the actual temperature with the setting temperature



Established of operating conditions

Spray-coating the surface of the processing uniformity

Pump output(%)

Flow (ml/min)

Generator output(watt)

Pick-up ratio(%)

40 25 2.5 40

50 40 2.7 62

60 60 3.0 85

70 85 3.2 98

*Heat temp. 140~180℃, conveyor speed 0.15m/min * base-fabric : 75D polyester

[Pump output 40% Spray, A4 paper]

[Side part]

[Pump output 40% Spray, A4 paper]

20cm

• The flow rate are determined according to the output of the pump.

• If the output of the pump is 40% or less, the processing agent of a sufficient

amount can be passed not to the nozzle

• If the output of the pump are more than 80%, by shortage of generator's

output, uniformity of the particle is low

• According to conveyor speed by the dry time and pump output and flow are

can control fabric's pick-up ratio

[Front part]

Ultrasonic spray form image (Methylene blue solution)

Flow in accordance with the pump output per units hour - Pick-up ratio


3. Textile products processing cases with ultrasonic spray system

Water-repellent processing

Control the pick-up ratio

Pick-up ratio : 20~120%

[Chamber ]

120℃~180 ℃ 2~6min

• The difference between dipping method and ultrasonic spray

method is the control of the pick up ratio does not depend on

mangle, is rely on uniform spray by the ultrasonic

• Pick-up ratio can be controlled to 20 to 120%

• Ultrasonic spray system can be applied using increased by two to

three times the concentration of the processing agent, compared

with dipping method.

• It is possible to reduce the production cost like the amount of the

solvent used, waste water treatment costs.

Visualize of Ultrasonic spray method & Dipping method

Processing agent design

Textile processing test according to the control of pick-up ratio

Water repellent

agent

Dipping method Spray method

5% 15% 20%

Textile 75D Dewspo(polyester 100%)

Pick-up ratio 100% 50% 50%

Dry conditions (Temp / Time) 180℃, 4min 180℃, 2min 180℃, 2min

Pick-up ratio : 70~90%

[Ultrasonic spray method]

[Dipping method]



Water repellent agent

Dipping method

Spray method

5% 15% 20%

Weight change ratio 3% 5% 5.5%

Water repellency

Initial 100% 100% 100%

After wash

20 times 85% 85% 90%

After wash

30 times 80% 80% 80%

Chalk mark X X O

70

75

80

85

90

95

100

105

Dipping 5% Spray 15% Spray 20%

Initial

After wash 20times

After wash 30times

* Water repellency test method : AATCC Test Method 22-2010 Wash method : KSK K ISO 6330

Processing conditions & Results

Water-repellent finishing of textile products

100 point : Indicates no wetting on the face side. 90 point : Indicates slight wetting on the face side. 80 point : Indicates wetting on the face side at the point where the water falls. 70 point : Indicates partial wetting on half of the face side. 50 point : Indicates wetting on the entire face side. 0 point : Indicates complete wetting on the face side.



Processing agent design

Configuration of Standard Oil repellent agent

Oil repellent agent 1 Absorbent enhance agent Softener Catalyst & Crosslinker

5% 1% 2% 1%

• Dry conditions : 160~180℃, 2~4 min • Processing method : Ultrasonic spray system

[Oil repellent processed textile]

Standard processing conditions

• Because the standard processing have weak oil-repellency, designed to enhance the oil repellency of the processing

agent by add another agent

• Dry conditions and processing method is the same

• This processing needs two kinds of processing agent

- Oil repellent agent 1 is absorbent enhanced oil repellent agent

- Oil repellent agent 2 is the main agent to express the oil repellent performance

Configuration of oil-repellency enhanced Oil repellent agent

Oil repellent agent 1 Oil repellent agent 2 Absorbent enhance agent Softener Catalyst & Crosslinker

2% 3% 1% 2% 1%

Oil repellency enhanced processing conditions

Oil-repellent finishing of textile products



Processing conditions

Water repellent agent

Oil repellent agent 1 3%

Oil repellent agent 2 2%

Absorbent enhance agent 1%

Softener 2%

Catalyst & Crosslinker 1%

Textile PET 100% knit

Pick-up ratio 100%

Dry conditions (Temp) 160℃ 170℃

Dry conditions (Time) 2min 3min 4min 2min 3min 4min

• After making the samples for each of the process conditions, sample was washing 20 times to 10 times

• Because the standard test method for each sample are not exist, the performance were evaluated by simplified testing

* Wash method : KSK K ISO 6330




Test conditions & Result

After wash 10 times After wash 20 times

Dry conditions (Temp) 160℃ 170℃ 160℃ 170℃

Dry conditions (Time) 2min 3min 4min 2min 3min 4min 2min 3min 4min 2min 3min 4min

Oil repellency △ ○ ○ ◎ ◎ ◎ X △ △ ◎ ◎ ◎

Prevention of recontamination △ ○ ○ ◎ ◎ ◎ X △ △ ○ ◎ ◎

◎ : Very good, ○ : Good, △ : Bad, X : No function

• Oil repellency was evaluated visually, by dropping of the oil-based

pollutants.

• recontamination prevention performance was evaluated, by the degree

of contamination remaining after immersion in contaminants, and

washing

• Initial oil repellency and prevention of recontamination of the every

sample was very good

• 170℃ sample showed high washing durability, but 160℃ sample

showed bad washing durability

[160℃ / 2min] [160℃ / 4min] [170℃ / 4min]

[Oil repellency after wash 20 times]

[Prevention of recontamination]

[Contaminated] [After washed]

O : Untreated fabric B : Treated fabric [170℃ / 4min / After wash 10 times] D : Treated fabric [170℃ / 4min / After wash 20 times]


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Development of Coating Technology with Ultrasonic Spray ... meeting/09. BSG- Korea.pdf · Development of Coating Technology . with Ultrasonic Spray methods . ... history and powerhouse