KR100807313B1 - High density nonwovens and artificial leather made with the bi-component filament web and method thereof - Google Patents

Abstract

An ultra-fine high density non-woven fabric and an artificial leather containing the same and a manufacturing method thereof are provided to perform the mass-production of superior products through a simple technique. A sea-island fiber filament is mixed and spun so that a web of a spun bond(1) of 20-50kg/m^2 weight is formed. Thereafter, the web is processed by the cold calendering without applying the heat. Thereafter, the web is processed by the cross lapping and draft processes according to the required weight. The PPSC of a needle punching is processed by 80-800ea/cm^2 and then also processed by a water jet. The fineness of the sea-island fiber is 1.5 to 5 denier. The polymer mixing ratio of the sea-island components is about 85:15 to 50:50. The number of island components at the sea-island fiber filament is 10 to 600. The spin process is performed at the speed of at least 4000-8000m/min. In the polymer of the woven cloth, the island component is constructed by one of nylon, polyester, poly trimethylene terephthalate, and the sea component is constructed by poly lactic acid.

Description

High density nonwovens and artificial leather made with the bi-component filament web and method

1 is a morphological structural diagram of each process of the long fiber ultra-high density nonwoven fabric,

Figure 2 is a long fiber ultrafine high density nonwoven fabric and artificial leather manufacturing process using the same.

Brief description of the main parts of the drawing

A: island component (PET, PA, PTT)

B: Sea component (PLA) of island-in-the-sea microfiber,

1: sea island type spunbond web,

2: non-woven fabric structure needle-punched sea island type spunbond web,

3: Composite long fiber ultrafine nonwoven fabric in which spunbond web is combined with water punching after needle punching

The present invention relates to a nonwoven fabric made of heterogeneous filaments and artificial leather, and a method of manufacturing the same, and more particularly, to a long fiber ultra-high density nonwoven fabric prepared by a spun bond, needle punching and spunlace composite process, and an artificial leather containing the same. The manufacturing method is related.

Conventional artificial leather base material is a method of manufacturing short-fiber synthetic fiber filaments such as nylon, polyester, etc., that is, using a split or island-in-the-sea microfiber staple fiber, wherein the short fiber The length of the fiber is 5 to 100mm, short fibers (chopped fiber) is produced by the wet method, the web is produced by the water-flow bonding method, non-woven fabric by the fiber length, if the fiber length is 25mm or more short-fiber web by the carding process After the preparation was combined by needle punching. The artificial leather is manufactured using the nonwoven fabric thus manufactured, and the fineness of the constituent fibers of the artificial leather is made of microfibers of less than 0.2 denier, so it feels like soft leather, handle, draping and washing performance. washability) and the like.

Conventionally, using a non-woven fabric made of ultrafine fibers as a method of manufacturing a high-quality artificial leather as well as similar to natural leather, even if the Republic of Korea Patent Publication 97-8857, Republic of Korea Patent 98-74188, Republic of Korea Patent Publication 98-046787 A technology that generally uses a microfiber yarn is disclosed, and Korean Patent Laid-Open Publication No. 00-3012 also discloses a method of manufacturing a nonwoven artificial leather using a physically divided microfiber yarn.

In the non-woven fabric manufacturing method, in the case of island-in-the-sea type, fibers are manufactured in a sheet form by carding, non-woven fabric is produced by needle punching, and then seawater is removed by dissolution to produce artificial leather. As in the case of island-in-the-sea type, nonwoven fabric is manufactured by needle punching, and the nonwoven fabric is artificially manufactured without any elution process by inducing fiber division by physical friction by carding, needle punching, water-punching, etc. during the nonwoven fabric manufacturing process. Manufacture leather.

Particularly, the split type composite fiber has two components and is difficult to dye, so it can be used only for the production of artificial leather of the silver type, and the physical strength is reduced, so it is limited only to the use of shoe endothelium.

On the other hand, as described in the Republic of Korea Patent Publication No. 10-2005-0034557, not the method of manufacturing short-fiber non-woven fabrics, a method for producing a nonwoven fabric composed of ultra-fine continuous fibers using a water-soluble thermoplastic resin as a sea component, Korea Method for characterized by island-in-the-sea multi-component filaments containing a polyolefin-based polymer as described in Patent No. 10-0368622, non-woven fabric is prepared by using the elutable copolyester as a sea component as disclosed in Korea Patent Publication No. 10-2004-0100576 do. In the case of the above patent, in order to manufacture artificial leather, an elution process is required, and if the sea component is a water-soluble thermoplastic resin during the elution process, a separate method for recovering the sea component is required, and in the case of copolyester, the elution is performed during elution. Due to the embrittlement of the island-based raw material by the process, there is a problem that the physical properties are rapidly reduced.

In particular, in the conventional long fiber nonwoven fabric manufacturing method, a spunbond method is used to produce a web by complex spinning two kinds of raw materials, and then, by heat calendering or preneedle punching to prepare a nonwoven fabric by water flow bonding, and then It is manufactured through polyurethane impregnation and post-treatment process.

SUMMARY OF THE INVENTION An object of the present invention is to provide a island-in-the-sea microfiber filament high density nonwoven fabric capable of mass-producing a product of superior quality in a simplified method in order to solve the above-mentioned problems of the prior art.

Another object of the present invention is to provide a manufacturing method capable of maximizing the dissipation efficiency while reducing the environmental load in the post-processing process by improving the dispersing method by the elution process in the conventional island-in-the-sea type microfiber nonwoven fabric.

Another object of the present invention is to provide a long fiber composite high-density nonwoven fabric manufacturing method for manufacturing artificial leather bubbles directly from the raw material to the nonwoven fabric, unlike the multi-stage method used in the conventional microfiber islands-in-sea nonwoven fabric manufacturing method.

It is another object of the present invention to provide an artificial leather and a method of manufacturing the same by simplifying the post-processing process by minimizing fiber damage or process problems in the splitting process using environmentally friendly raw materials as sea components.

In order to achieve the above object, the method for producing a long fiber ultra-high density nonwoven fabric according to the present invention comprises the steps of forming a web of spunbond 20-50 g / m ² weight by spun the island-in-the-sea filaments, the surface without applying heat to the web It is prepared by the step of cold calendering and the step of laminating the fiber array constituting the nonwoven fabric to the required weight so as to have an arbitrary arrangement structure, and then treating the PPSC of the needle punching to 80-800ea / cm ² and then water-flow bonding. It features.

In the method for producing a long fiber nonwoven fabric according to the present invention, the island-in-the-sea yarn has a fineness of 1.5 to 5 deniers, a polymer composite ratio of the island component and the sea component of 85:15 to 50:50, and the constituents constituting the island-in-the-sea filament. The number of minutes is characterized in that 10 to 600 degrees.

In addition, in the method for producing a long fiber nonwoven fabric according to the present invention, the polymer of the nonwoven fabric is made of any one of nylon (PA), polyester (PET), polytrimethylene terephthalate (PTT), and sea component Is characterized in that consisting of polylactic acid (PLA).

In the method for producing a long fiber nonwoven fabric according to the present invention, the spinning is performed at a spinning speed of at least 4000-8000 m / min.

In the method for producing a long fiber nonwoven fabric according to the present invention, the fineness of the island component is 0.002 to 0.4 denier.

In addition, in the method for producing a long fiber nonwoven fabric according to the present invention, the density of the nonwoven fabric by needle punching is 0.16 g / cm ³ to 0.2 g / cm ³ , and the density of the water-bonded long fiber nonwoven fabric after the needle punching is 0.23. g / cm ³ to 0.35 g / cm ³ .

In addition, in the method of manufacturing a long fiber nonwoven fabric according to the present invention, when the nonwoven fabric is produced by the water-linked alone without the needle punching in the bonding step, the density of the nonwoven fabric is 0.1 g / cm ³ To 0.3 g / cm ³ .

In addition, in the method for producing a long fiber nonwoven fabric according to the present invention, the step-by-step application water pressure of the needle punched nonwoven fabric applied to the nonwoven fabric having a weight of 200 to 600 g / m ² is 50 to 600 bar.

In addition, the method for producing a long fiber nonwoven fabric according to the present invention is characterized in that at least 5-70% of the filaments on the surface of the nonwoven fabric are dispersed by water flow bonding after the needle punching, and thus the surface of the nonwoven fabric has an ultrafine structure before dissolution of the sea component. .

In the method for producing a long fiber nonwoven fabric according to the present invention, the sea component oligomer is biodegraded after the sea component is eluted.

In order to achieve the above object, the long fiber nonwoven fabric according to the present invention is characterized in that it is produced by any one of the above-described manufacturing method.

In addition, the artificial leather manufacturing method according to the present invention in order to achieve the above object is characterized in that the impregnated or coated with the above-described non-woven fabric, eluting, buffing and dyeing.

In addition, in the manufacturing method of artificial leather according to the present invention, the polyurethane impregnation or coating is characterized in that it is performed using a polycarbonate-based aqueous emulsion polyurethane having excellent hydrolysis resistance.

In addition, in order to achieve the above object, the artificial leather manufacturing method according to the present invention adopts a dope dyeing method in the production of the long-fiber nonwoven fabric described above to give a basic color using a master batch coloring polymer raw material (master batch) Then, it is characterized in that the artificial leather is manufactured in pastel tone-like suede and smooth type without dyeing using a toner in the polyurethane resin.

In addition, in the manufacturing method of artificial leather according to the present invention, in the case of deep color, it is characterized in that it is produced by three steps of color treatment until dyeing.

In addition, in the manufacturing method of artificial leather according to the present invention, the particle size of the organic and inorganic pigments for the coloring treatment is characterized in that 0.4 to 0.5㎛.

In addition, in order to achieve the above object, the filter or the industrial wiper according to the present invention is characterized in that it is manufactured by the method for producing a long fiber nonwoven fabric described above.

The above and other objects and novel features of the present invention will become more apparent from the description of the specification and the accompanying drawings.

First, the concept of the present invention will be described.

That is, in the present invention, the island component includes thermoplastic resins such as nylon (PA, polyamide), polyester (PET, polyester), polytrimethylene terephthalate (PTT, poly trimethylene terephthalate), and the sea component is biodegradable. Using spunbond method by using a polylactic acid (PLA), the mixing ratio is 50-85% of island component and 50-15% of sea component at high speed of spinning at 4000-8000m / min. After forming the web (20-50g / m ² ), and calendering by the cold calendering method of the surface treatment without applying heat for morphological stability of the web, the web is the required weight (200- In case of heavy weight of 80 g / m ² or more according to 600 g / m ² ), long lamination is made by cross lapping and stretching, and needle-punching PPSC with 80-800ea / cm ² , followed by water-flow bonding. Provided is a method for producing a nonwoven fabric.

The density of the nonwoven fabric in the case of general industrial wiper derivatives there preferably a 0.1-0.25g / cm ^3, preferably 0.25g / cm ³ or more for the leather-like sheet.

The present invention also provides a product such as a semiconductor wiper, a filter, a garment, and a medical gown, wherein the nonwoven fabric of the substrate is manufactured by dissolving or cosmetically dissolving the sea component by partial dispensing of the sea component or partial dispersing of the surface of the nonwoven fabric.

Hereinafter, the present invention will be described in detail.

1 is a morphological structural diagram of each of the long-fiber ultrafine high-density nonwoven fabric according to the present invention, Figure 2 is a long-fiber ultrafine high-density nonwoven fabric according to the present invention and artificial leather manufacturing process chart using the same.

In Fig. 1, A is an island component (PET, PA, PTT) of islands-in-the-sea microfiber, B is a sea component (PLA) of island-in-the-sea microfiber, (1) represents an island-in-the-sea spunbond web, and (2) Denotes a nonwoven fabric of needle-punched islands-in-sea spunbond webs, and (3) shows a composite long-fiber ultrafine nonwoven fabric in which spunbond webs are water-linked after needle-punching bonds.

The island-in-the-sea microfiber high-density nonwoven fabric of the present invention has a feature of manufacturing a web using a spunbond method, which is a long fiber nonwoven fabric manufacturing method, and manufacturing a nonwoven fabric using a needle punching and water flow coupling method.

Conventional islands-in-the-sea microfiber nonwoven fabrics are complicated by a manufacturing method using short fibers, whereas the nonwoven fabric of the present invention has a separate crimp, staple fiber, mixing process, and carting ( There is a feature that can mass-produce a high quality nonwoven fabric having a long fibrous structure by a spunbond method without undergoing a carding process or the like.

In general, the spunbond nonwoven fabric is a method of manufacturing a long fiber nonwoven fabric by using a polypropylene spunbond method for manufacturing a nonwoven fabric by simple air flow by spinning at a low speed without a separate web forming device and a high speed spinning method using a separate opening device. And it is divided into a polyester spunbond manufacturing method for producing a non-woven fabric by stretching down, these spunbond manufacturing method is a method of manufacturing using a single polymer (homopolymer).

In the present invention, the nonwoven fabric is manufactured by the composite spinning method using two kinds of polymers, and the spinning speed is 4000-8000 m / min, preferably produced by spinning at a high speed of 4500 m / min or more in terms of quality.

In particular, the spunbond manufacturing method of the present invention is a rectangular method (rectangular) rather than the shape of the spinneret (tube cop), the effective area is wider than the conventional method of the circular method and less limited number of spinnerets. In addition, there is an advantage in terms of productivity because of the excellent leveling agent. The number of spinnerets of the present invention is 3000 holes / m or more.

Conventionally, the structure of the island-in-the-sea yarn used conventionally manufactures a fiber by a composite spinning method using polyester or nylon as a coating component, and copolyester or polyolefin type as a sea component. Sea component mainly arranges materials with lower melting point and easier to elute than island components. In particular, the raw material composition ratio is important for the fine fiber.

In the present invention, the island component includes thermoplastic resins such as PA, PET, and PTT, and the sea component uses PLA having biodegradable characteristics, and the mixing ratio is 50-85% of the island component and 50-15% of the sea component. In the case of industrial wipers, the mixing ratio of sea component and island component is proceeded to 50/50 or 60 / 40.For artificial leather, the composition ratio of sea component is 30-15% and the island component is 70-85. It is preferable to adjust to%.

The ultrafine fibers of the island-in-the-sea spunbond nonwoven fabric of the present invention have a fineness of 1.5 to 5 denier before dissolution, and preferably 2 to 3.5 denier. In particular, the number of island components within the island-in-the-sea filaments is preferably 10 to 600 degrees, preferably 25 to 100 degrees, and the island-in-the-sea spunbond microfiber is about 0.002 to 0.4 denier after elution, preferably 0.01 to 0.17 denier. Is advantageous. If the thickness of the fiber is less than 1.5 denier, the fiber breaks frequently during high-speed spinning, or the boundary distinction between the island and sea components is unclear, and the elution is difficult. Moreover, when it exceeds 5 denier, although radioactivity and productivity are excellent, it is difficult to adjust the fineness of a final island component to 0.17 denier or less.

In the present invention, it is preferable that the island-in-the-sea yarn spunbond manufactured by using the sea component as PLA to facilitate elution in post-processing. In addition, if the sea component is set to PLA, it is possible to induce fiber splitting of the surface of the nonwoven fabric by using a physical method without using a solvent in the water-flow bonding process in the nonwoven fabric manufacturing process. Features that can minimize the amount of use and uniform sea component eluting has the advantage of expressing excellent quality. This makes it possible to reduce the treatment time and alkali concentration within the range of 30-75% compared to conventional copolyesters.

The method of manufacturing the island-in-the-sea microfiber high-density nonwoven fabric of the present invention produces a web (20-50 g / m ² ) on a conveyor belt by spinning and downward stretching by a spunbond method as described above. The web thus manufactured takes the form of an arbitrary array structure, and the filaments constituting the web have no shape stability before bonding, and calendering is performed by cold calendering method for smooth transfer and handling in the subsequent process, and the surface treated web is Cross lapping and drawing according to the required weight, and the PPSC of the needle punched to 80-800ea / cm ² and water-flow-bonded to prepare the long-fiber ultra-high density nonwoven fabric of the present invention.

As described above, the long-fiber ultra-high density nonwoven fabric of the present invention proceeds in a batch process from the raw material to the nonwoven fabric, and is manufactured by spinning the filament at a high speed, so that uniform and excellent product can be produced.

The antistatic treatment is performed by spraying before laminating the spunbond web by the bonding method of the present invention, wherein the antistatic agent may be a general antistatic treatment agent for textiles. It is preferable that the antistatic spunbond web is stretched by 10 to 50% between web layers and fiber structures in order to laminate using a molding machine and to increase uniformity. In the present invention, the web laminated by the above method imparts a bond in a needle punching manner as in the conventional short fibers, wherein it is important that the filaments constituting the nonwoven fabric are not damaged by the vertical motion of the needle. The fiber damage due to the needle action can be minimized by the antistatic agent treated before lamination, and the purpose of needle punching is to improve the bonding strength and the softness and the draping between the web layers.

Needle punching conditions of the present invention is preferably applied to the needle punching conditions, unlike the conventional short fiber nonwoven fabric manufacturing conditions. The needle needle is preferably applied to 7.8 mm or less, more preferably 5.0 mm to 6.5 mm. In addition, the penetrations per square centimeter (PPSC) is preferably 80 to 800, and the density of the nonwoven fabric prepared as described above is preferably 0.16 g / cm ³ to 0.2 g / cm ³ . When the nonwoven fabric density is less than 0.16g / cm ³ , interlayer peeling of the manufactured nonwoven fabric may occur, and when needle punching is performed at 0.2g / cm ³ or more, the filaments constituting the nonwoven fabric are damaged by excessive movement of the needle, resulting in physical properties. This may fall.

In particular, it is important that the features of the present invention impart inter-filament bonding to the extent that no interlaminar peeling of the web constituting the nonwoven fabric occurs under needle punching conditions.

Another coupling method of the present invention, the water flow coupling has an advantage of reducing energy consumption during manufacturing by varying the manufacturing conditions according to the conditions of the nonwoven fabric produced by needle punching. Water flow coupling increases the density of the nonwoven fabric by imparting the bonding force between the filaments, and in particular, acts to enable physical division of the island-in-the-sea yarn located on the surface of the nonwoven fabric. Due to this, the density of the nonwoven fabric produced by the water flow bonding is preferably 0.23 g / cm ³ or more, more preferably 0.27 g / cm ³ to 0.35 g / cm ³ Level is preferred. This densified nonwoven fabric is capable of manufacturing high-quality artificial leather such as natural leather while reducing the amount of resin used in the post process.

The long-fiber microfiber high-density nonwoven fabric of the present invention undergoes a separate post-process when applied to artificial leather. The final product is impregnated into the polyurethane resin and eluted, and then buffed and dyed. To complete.

In particular, high-quality artificial leather (suede & smooth type) is manufactured using a polycarbonate-based aqueous emulsion polyurethane having excellent hydrolysis resistance among the resins used.

On the other hand, when manufacturing the long-fiber microfiber high-density nonwoven fabric of the present invention using a master batch coloring polymer material (pigment 1-5%) to prepare a dope dyeing (non-woven fabric), and in the production of artificial leather polyurethane resin It is possible to manufacture pastel leather suede and smooth type artificial leather without dyeing using 1-10% toner, especially in case of deep color High-quality, high-fastness artificial leather can be manufactured by three-stage coloration, in which the particle size of organic and inorganic pigments is about 0.4 to 0.5㎛.

When the long fiber microfiber high density nonwoven fabric of the present invention is applied for artificial leather, the dissolution of the marine component is the same as the conventional treatment process, but the treatment conditions are preferably treated within 5 minutes with 3% NaOH solution. As described above, the artificial leather product using the long fiber nonwoven fabric produced by the present invention has a higher strength, higher density, and higher quality than the short fiber product manufactured by the same post-processing method, so that shoes, furniture and interior, clothing, transportation, ball artificial leather Suitable for use as

Hereinafter, preferred examples are provided to help understanding of the present invention. However, the following examples are presented to more easily understand the present invention, and the present invention is not limited to the following examples.

(Example 1)

Extruded island-in-the-sea yarns by melting nylon 6 with a relative viscosity (RV) of 2.6 and a melting temperature of 222 ° C, melting it at a spinning temperature of 280 ° C with PLA as a sea component It was. The island-in-the-sea yarn spinning device used for spinning was configured to have 25 degrees per filament, and the discharge amount was adjusted to be 3 denier after stretching. At this time, the composite ratio of island component and sea component was 70:30, and dope dying was performed. The fibers thus produced are microfibers of 0.08 denier level after elution.

The island-in-the-sea filament extruded through the spinneret was cooled and solidified, and at this time, the spinning speed was stretched downward at 4500 m / min and laminated on the moving conveyor belt to prepare a web (40 g / m ² ). The produced web was subjected to cold calendering by a point adhesive method on the surface portion by a compression roll located at the belt end portion. The surface-treated web was subjected to an antistatic treatment by a spray method before lamination to a required weight, and a long fiber nonwoven fabric was prepared by needle punching and water flow bonding after lamination and stretching. The manufacturing conditions applied for each process are shown in Table 1.

<Table 1>

 Manufacturing condition and method Spunbond web Lamination Needle punching Spunlace Dope dyeing (40g / m ² ) 7 layer 38gauge PPSC 100 PD 6.5mm Apply water pressure in 6 stages after pre-wetting (maximum water pressure: 150bar 3 times) 9 layers 38gauge PPSC 100 PD 7.8㎜ Apply water pressure in 6 stages after pre-wetting (maximum water pressure: 170bar 3 times)

The weight of the nonwoven fabric after needle punching is applied as is 359g / m ² when a 281g / m ^2, 9-ply laminate when the laminated seven layers, each density was 0.165g / cm ³ and 0.179g / cm ^3, needle punching The obtained nonwoven fabric was subjected to water flow bonding under the above conditions to prepare a long fiber nonwoven fabric. Thus the weight of the final non-woven fabric was prepared 7-layer laminate if a 287g / m ^2, 9-fold when the laminate has a 378g / m ² density, respectively 0.24g / cm ³ and 0.27g / cm ^3.

(Example 2)

The nonwoven fabric prepared in Example 1 was eluted to prepare a long fiber microfiber nonwoven fabric. At this time, the processing conditions were immersed in 3% NaOH solution, 95 ℃ for 5 minutes to elute the sea component and dried. The cosmetics were not detected at all in the long fiber microfiber nonwoven fabric thus prepared, and showed a uniform fiber diameter, which was suitable for use as a wiper or filter material.

On the other hand, compared to the copolyester used in the conventional manufacturing method and the environmental impact of the eluted sea component is shown in Table 2.

<Table 2>

                                      (Based on 30% sea component of island-in-the-sea microfiber)

 Environmental category N _i W _i Target substance L _j (g / fu) Environmental impact (Ti) Substance E _{i , j} PLA Co-PET PLA Co-PET Eutrophication 1.31E + 04 1.0 BOD 2.20E-02 4.8E + 05 5.0E + 06 0.81 8.46 Ecotoxicity (Water Quality) 1.50E + 06 1.0 Aromatic components 2.90E + 01 - 1.26E + 05 - 2.44 Total environmental impact TI ) 0.81 10.90

In Table 2, the environmental effects of sea components in wastewater from the islands are expected to be affected in two categories: eutrophication and ecotoxicity. Co-PET has a greater environmental impact than 13.6 times that of PLA.

(Example 3)

After impregnating the nonwoven fabric prepared in Example 1 into polyurethane, the suede artificial leather was prepared by eluting the sea component under the conditions of Example 2 and performing a buffing process. The weight and thickness of the manufactured artificial leather were 244 g / m ² and 0.7 mm when the nonwoven fabric prepared by laminating 7 layers was used as a base material, and 357 g / m ² and 1.0 mm when 9 layers were laminated.

The artificial leather thus prepared was suitable for use as an artificial leather for shoes, furniture, transportation, clothing, and balls.

(Example 4)

It was prepared in the same manner as in Example 1, but the PTT was used as the intrinsic viscosity (IV) of 1.1.

(Example 5)

Manufactured in the same manner as in Example 1, PET having an intrinsic viscosity (IV) of 0.64 was used as a component.

(Example 6)

The PTT and PET island-in-the-sea island yarns of Examples 5 and 6 were eluted in the same manner as in Example 2 to prepare a non-woven fabric for wipers.

(Example 7)

The long-fiber nonwoven fabric prepared by the method of Examples 5 and 6 was manufactured in the same manner as in Example 3 by artificial leather through polyurethane impregnation, sea component reduction and buffing processing.

That is, the present invention is a method for producing ultra-fine filament nonwoven fabric and artificial leather manufactured by a spunbond, needle punching and spunlace composite process, and is made from filaments which satisfy all of the following conditions (A) to (D). It is to provide an application product such as artificial leather manufactured using a nonwoven fabric and a nonwoven fabric base material.

(A) The filament forming the nonwoven fabric is made of island-in-sea type, and the sea component is a fiber-forming polymer having a biodegradable function.

(B) The degree of dispersion of island-in-the-sea filaments on the surface of the nonwoven fabric is within the range of 5-70% by spunlace during the spunbond web bonding process.

(C) It is possible to reduce the alkali treatment time and the treatment concentration within the range of 30-75% compared to the conventional method when dissolving the sea component.

(D) Master batch colored polymer raw material (pigment 1-5%) is used to make long-fiber non-woven fabric, and base color is given by dope dyeing method. Toner is applied to polyurethane resin when manufacturing artificial leather. tonner) Pastelton suede and smooth artificial leather can be manufactured without dyeing using 1-10%.

As mentioned above, although the invention made by this inventor was demonstrated concretely according to the said Example, this invention is not limited to the said Example and can be variously changed in the range which does not deviate from the summary.

As described above, according to the present invention, the long-fiber ultra-high density nonwoven fabric and the artificial leather containing the same and the manufacturing method thereof provide a simplification of the conventional multi-stage nonwoven fabric manufacturing process in a batch process from raw polymer to nonwoven fabric production. In addition, it is possible to provide high quality nonwoven fabrics with uniform web characteristics, as well as to provide high quality nonwoven fabrics with an MD / CD strength ratio of 1/1 due to the isotropic fiber arrangement in machine direction (MD) and transverse direction (CD). Is obtained.

In addition, according to the present invention, the long-fiber ultra-high density nonwoven fabric and artificial leather containing the same and its manufacturing method can supply environmentally friendly nonwoven fabric manufacturing technology and dispensing technology. It is possible to supply nonwoven fabric manufacturing technology of (dope dyeing), and since the nonwoven fabric is made of microfiber, it can be used as various filters or industrial wipers, and in particular, it can be used for semiconductor wipers in long fiber structure.

In addition, according to the present invention, the long-fiber ultra-high density nonwoven fabric and artificial leather containing the same and a method for manufacturing the same are used in the case of using an environmentally friendly water-soluble polyurethane in the manufacture of artificial leather. Contamination can be prevented, and in particular, the provision of an artificial leather having a performance such as natural leather with excellent touch and mechanical properties can be used for footwear, transportation, furniture and interior, clothing, and ball.

Claims (18)

Complex spinning the island-in-the-sea filaments to form a web having a spunbond 20-50 g / m ² weight, Cold calendering the web without applying heat; and Method for producing a long-fiber nonwoven fabric, characterized in that the fiber array constituting the nonwoven fabric is laminated by the required weight so as to have an arbitrary arrangement structure, and then treated by PPSC of the needle punching to 80-800ea / cm ² and then combined with water flow . The method of claim 1, The island-in-the-sea yarn has a fineness of 1.5 to 5 deniers, a polymer composite ratio of the island component and the sea component is 85:15 to 50:50, and the number of island components constituting the island-in-the-sea filament is 10 to 600 degrees. Method for manufacturing nonwoven fabrics. The method of claim 2, The polymer of the nonwoven fabric is made of any one of nylon (PA), polyester (PET), polytrimethylene terephthalate (PTT) in the case of the island component, the sea component is characterized in that made of polylactic acid (PLA) Method for producing fibrous nonwovens. The method of claim 3, And the spinning is carried out at a spinning speed of at least 4000-8000 m / min. The method of claim 4, wherein The fineness of the island component is a long fiber nonwoven fabric manufacturing method, characterized in that 0.002 to 0.4 denier. The method of claim 1, The density of the nonwoven fabric by needle punching is 0.16g / cm ³ to 0.2g / cm ³ , and the density of the water-bonded long fiber nonwoven fabric after the needle punching is 0.23g / cm ³ to 0.35g / cm ³ Method for producing a long fiber nonwoven fabric. The method of claim 1, When the water flow in the bonding step producing a non-woven fabric bonded to the water flow field alone process for producing a fiber non-woven fabric to the density of the non-woven fabric characterized in that the 0.1g / cm ³ to 0.3g / cm ^3. The method of claim 3, A method for producing a long fiber nonwoven fabric, characterized in that the applied water pressure of the needle punched nonwoven fabric applied to the nonwoven fabric having a weight of 200 to 600 g / m ² is 50 to 600 bar. The method of claim 3, At least 5-70% of the filaments on the surface of the nonwoven fabric by water flow bonding after needle punching to form an ultrafine structure of the surface of the nonwoven fabric before dissolution of the sea component. The method of claim 3, A method for producing a long fiber nonwoven fabric characterized in that the sea component oligomer is biodegraded after the sea component is eluted. Claims Claims 1 to 10, characterized in that the nonwoven fabric produced by the method for producing a long fiber nonwoven fabric of any one of claims. Claims of claim 11 Impregnated or coated the nonwoven fabric of polyurethane, eluting, buffing and dyeing manufacturing method characterized in that the artificial leather. The method of claim 12, The polyurethane impregnation or coating is a method of manufacturing artificial leather, characterized in that carried out using a polycarbonate-based aqueous emulsion polyurethane excellent in hydrolysis resistance. Claims 1 to 10 in the manufacturing of the long-fiber nonwoven fabric of any one of the doped dyeing (dope dyeing) method to give a basic color using a master batch coloring polymer raw material, Thereafter, the artificial leather manufacturing method, characterized in that the artificial leather is manufactured in pastel tone (suede) suede and smooth type (smooth type) without dyeing using a toner in the polyurethane resin. The method of claim 14, In the case of deep color artificial leather manufacturing method characterized in that it is produced by three steps of color treatment until dyeing. The method of claim 15, Particle size of the organic and inorganic pigments for the coloring treatment is a method of manufacturing artificial leather, characterized in that 0.4 to 0.5㎛. Claim 1 to 10, wherein the filter is produced by eluting the nonwoven fabric produced by the method for producing the long fiber nonwoven fabric of any one of claims 1 to 10. Claims Claim 1 to 10, characterized in that the industrial wiper is produced by a nonwoven fabric produced by the method for producing a long fiber nonwoven fabric of any one of claims.

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