KR101430546B1 - Anti-fuzzing coating yarn and woven fabrics therefrom - Google Patents

Abstract

A coating yarn made of a core yarn made of a polyester resin having a melting point of 130 to 210 DEG C and a coating material containing a thermoplastic resin coated on the outer surface of the core yarn is thermally fused between a core yarn and a coating material in a tenter and a drying process And the difference in shrinkage ratio between the core yarn and the coating material is reduced, so that the punching phenomenon at the cut surface is hardly generated. Therefore, when used as blinds, flooring or other outdoor / interior materials, excellent appearance can be maintained.

Description

FIELD OF THE INVENTION [0001] The present invention relates to a coating yarn having improved purging effect and an antifouling coating yarn,

The present invention relates to a coating yarn and a fabric thereof which can be used as yarn for flooring and the like.

Coated yarn fibers have been used for many years as industrial fibers, such as blinds, as industrial fibers produced through cannons, weaving, and tentering using coated yarns coated with plastic material on core yarns. In this case, the core material is mainly used because the polyester material is excellent in elasticity, does not catch wrinkles well, has shape stability and high strength, and mainly uses polyethylene terephthalate (PET) resin in consideration of tensile strength and price Widely used. Plastic materials such as polyvinyl chloride (PVC), polyethylene (PE), polypropylene (PP), and thermoplastic polyurethane (TPU) are used as coating materials.

In particular, the fibers extruded and coated with polyvinyl chloride (PVC) on polyester yarn are excellent in elasticity, wrinkle-free, and excellent in form-sticking, antibacterial and color applicability, Decorative, electronic products and furniture. Such coated fiber is usually manufactured by adding an extrusion coating machine exhibiting a coating speed of 300 to 1100 m / min to a high-strength PET yarn in order to secure a physical property suitable for industrial use and adding flame retardancy, flame retardancy, antibacterial property and other functions have. For example, Korean Patent Laid-Open Publication No. 2005-79896 discloses a method for producing a fabric by coating a coating material containing a plasticizer and a flame retardant together with a polymer material such as PVC on the outer surface of a polyester fiber.

However, the shrinkage ratio of the coating material is higher than that of the core yarn due to the physical tensile force applied during the tentering process in the extrusion coating process at the time of manufacture or the tenter process at the time of manufacturing. When cutting woven fabric fabrics, there is a fuzzing effect, which is a phenomenon in which the core material shrinks out of the coating material due to the contraction of the coating material more than the core yarn due to the potential physical shrinkage of the coating material do. Such purging phenomenon generally becomes worse over time, and thus, when used as a blind, it damages the appearance of the interior. In addition, the puddling phenomenon becomes worse because of the load applied when the flooring is used.

In order to improve such a purging phenomenon, U.S. Patent No. 7,326,661 uses ceramic fibers such as fiber glass, quartz, silica, aluminum oxide and the like instead of polyester as a core yarn After coating yarn is produced through PVC resin coating, the fabric is woven by lamination process. When the flooring material thus produced is cut to a certain size and rubbed on the cut surface, the glass or ceramic component contained in the projected yarn can be broken and the cut surface can be easily cleaned. On the other hand, However, there is a problem that the user also has a biological risk.

Korean Patent Publication No. 2005-79896 (Alkenes Co., Ltd.) 2005.08.11. U.S. Patent No. 7,326,661 (Chilewich LLC.) Feb. 2, 2008.

Accordingly, it is an object of the present invention to provide a coating yarn improved in purging phenomenon and a fabric produced using the same.

According to the above object, the present invention provides a coating yarn made of a core yarn and a coating material coated on the outer surface of the core yarn, wherein the core yarn is made of a polyester resin having a melting point of 130 to 210 DEG C and the coating material is a thermoplastic resin The coating yarn is characterized in that it includes a coating yarn.

The present invention also provides a fabric in which the coating yarn is woven.

The coating yarn of the present invention can improve the adhesion of the physical surface due to the thermal fusion between the core yarn and the coating material in the tenter and the drying process at the time of fabric production by using the core yarn having low melting point and high shrinkage ratio, It is possible to maintain excellent appearance when used as a material for blinds, flooring or other outdoor / interior since the pearl phenomenon on the cut surface is hardly generated.

1 is a photograph showing a purging phenomenon occurring in a fabric manufactured using a conventional coated yarn.
2 is a cross-sectional photograph of a fabric prepared using a conventional coated yarn.
3 is a cross-sectional photograph of a fabric manufactured using the coated yarn of the present invention.
4 is a photograph showing the thermal fusion between the core yarn and the coating material in the fabric of the present invention.
FIG. 5 is a photograph of a heat seal between a core yarn and a coating material when the fabric of the present invention is recycled.
Figure 6 illustrates the process of recycling the fabric of the present invention.

The coating yarn of the present invention is composed of a core yarn and a coating yarn made of a coating material coated on the outer surface of the core yarn, and these constituent components will be specifically described below.

Core yarn

The core yarn positioned at the center in the coated yarn of the present invention is made of a polyester resin. The core yarn preferably has a diameter of 50 to 500 denier.

Conventionally, polyethylene terephthalate (PET) is generally used as the core yarn, and the melting point of the PET homopolymer is 250 to 260 ° C. In order to achieve the object of the present invention, the melting point of the core yarn can be lowered to 120 to 210 ° C or lowered to 130 to 210 ° C, lowered to 160 to 210 ° C, or lowered to 130 to 180 ° C .

In addition, the core yarn may have a shrinkage of 5-20% at 165 ° C, for example 6-15%.

In order to lower the melting point of the core yarn and increase the shrinkage ratio, a copolymerized polyester may be used as the raw material resin. For example, the polyester resin constituting the core yarn may include a polyethylene terephthalate (PET) resin in which a C _3-12 alkyldiol, a C _6-12 cycloalkyldiol or a benzene series of diol is copolymerized.

It is also possible to use at least one polyester resin having a controlled melting point as a raw material resin, that is, to produce a core yarn by spinning a resin mixed with a polyester resin having a relatively high melting point and a polyester resin having a low melting point . For example, the polyester resin constituting the core yarn is a PET copolymer resin (a) having a melting point of 220 to 230 DEG C and a PET copolymer resin (b) having a melting point of 170 to 190 DEG C of 0.1 to 70: 99.9 to 30 ), Or may include a resin mixed in a weight ratio of 40 to 70: 60 to 30 (a: b).

Coating material

In the coating yarn of the present invention, the coating material coated on the outer surface of the core yarn is composed mainly of a thermoplastic resin.

The coating material may have a melting point of 130 to 200 캜, for example, 145 to 185 캜.

In addition, the shrinkage of the coating material may be from 3 to 20% at 165 캜, for example from 4 to 13%.

Examples of the thermoplastic resin as the main component of the coating yarn of the present invention include polyvinyl chloride (PVC), polyolefin (PO), thermoplastic polyurethane (TPU), or a mixed resin thereof.

Examples of the polyolefin resin include polyethylene (PE) based resin, polypropylene (PP) based resin and the like. Examples of the polyolefin resin include low density polyethylene (LDPE) resin, linear low density polyethylene (LLDPE) resin, high density polyethylene (HDPE) Ethylene vinyl acetate (EVA) copolymer resins, polypropylene resins, polypropylene block copolymer resins, polypropylene random copolymer resins, polypropylene elastomer resins, and mixed resins thereof.

When the PVC resin is used, it is preferable to use a resin having a polymerization degree of 800 to 3,000. If the degree of polymerization of the PVC resin is higher than 3000, heat resistance and aging resistance may increase, but the workability may be lowered, and the workability may become difficult as the PVC coating temperature rises. If the degree of polymerization is lower than 800, workability and surface can be improved, but heat resistance and weather resistance may be deteriorated.

The content of the thermoplastic resin in the coating material of the present invention may be from 30 to 90% by weight, for example from 50 to 80% by weight, based on the total weight of the coating composition.

Further, the coating material may include a flame retardant agent for improving flame retardancy.

Examples of the flame retardant include halogen-based flame retardants, phosphorus-based flame retardants or nitrogen-based flame retardants, and inorganic flame retardants such as metal oxides and metal hydroxides.

Examples of the halogen-based flame retardant include decabromodiphenyl oxide (DBDPO), decabromodiphenylethane (DBDPE), hexabromocyclodecane (HBCD), 1,2,5,6,9,10-hexabromocyclo Dodecane (HBCD), tetrabromobisphenol A (TBBA), tetrabromobisphenol A bis (2,3-dibromopropyl ether) (BDDP), and the like.

Phosphorous flame retardants include melamine phosphate (MP), melamine polyphosphate (MPP), ammonium phosphate, ammonium polyphosphate (APP), red phousphorus, tris (2-chloroethyl) phosphate (TCEP) (IPPP), triphenylphosphate (TPP), triethylphosphate (TEP), resorcinol diphosphate (RDP), tricresylphosphate TCP), dimethylmethylphosphonate, diethylethylphosphonate, dimethylpropylphosphonate, diethyl N, N-bis (2-hydroxyethyl) aminomethylphosphonate, phosphonic acid, methyl Methyl-1,3,2-dioxaphosphorinan-5-yl) methyl ester P, P'-dioxide, phosphonic acid, 9,10-dihydro-9-oxa-10-phosphaphenanthrene -10-oxide (DOPO), poly (1,3-phenylene methylphosphonate), hexaphenoxitate recyclophosphazene, phospho I like Trent.

Examples of the nitrogen-based flame retardant include melamine phosphate (MP), nitrilotris (methylphosphonamidic acid), and melamine cyanurate.

Examples of the inorganic flame retardant include magnesium dihydroxide (MDH), aluminum trihydroxide (ATH), zinc borate, graphite, antimony trioxide and the like.

Of these, phosphorus and / or inorganic flame retardants are preferably used in order to improve environmental friendliness and flame retardancy. Examples thereof include melamine phosphate, melamine polyphosphate, ammonium phosphate, isopropylphenyldiphenyl phosphate (IPPP), triphenyl phosphate (TPP), triethyl phosphate (TEP), resorcinol diphosphate (RDP), tricresyl phosphate (TCP), magnesium dihydroxide (MDH), aluminum trihydroxide, zinc borate It is preferable to use trioxide or the like.

The flame retardant used in the present invention may be a mixture of one or more of the above materials.

The content of the flame retardant may be 5 to 60 wt%, for example, 15 to 50 wt%, based on the total weight of the coating material.

Other additives may be added to the coating composition according to the present invention. For example, a lubricant, a UV stabilizer, an antibacterial agent, a fluorine-based drip burn inhibitor, and other functional fillers may be mixed. The content of the additive may be 0.1 to 10% by weight based on the total weight of the coating composition. The lubricant is used for improving the content of the stearic acid lubricant in general and for smoothly mixing it, and the amount of the lubricant may be 1 to 3% by weight based on the total weight of the coating composition. Ultraviolet stabilizers can be benzophenone or titanium oxide. Other functional fillers include calcium carbonate, talc, silica, glass fiber, and the like.

Coating yarns and fabrics

The coating yarn of the present invention may be a coating material coated on the outer surface of the core yarn with a thickness of 100 to 600 mu m and the diameter of the entire coating yarn including the core yarn and the coating material may be in a range of 250 to 1250 mu m.

The coating yarn of the present invention is characterized in that the difference in melting point and shrinkage ratio between the core yarn and the coating material is smaller than the conventional one.

In particular, the difference in melting point between the core yarn and the coating material may be 0 to 50 캜, for example 10 to 30 캜.

Also, the difference in shrinkage between the core yarn and the coating material can be 0-17% at 165 ° C, for example 3-15%.

Further, the coating yarn of the present invention is excellent in elasticity, wrinkle-free, and has excellent form-sticking property, antibacterial property, color applicability and the like.

Specifically, the coating yarn of the present invention may exhibit a hardness of 50 to 100 on the basis of Shore A, which is a satisfactory range that the preferable hardness range for weaving is 10 to 70 or 40 to 65 on a Shore D basis. Also, the tensile strength can be 10N or more on the basis of 200 mu m coated yarn, and the elongation can be 50% or more based on 200 mu m coated yarn.

In addition, fabrics fabricated by weaving coated yarns of the present invention are excellent in flame retardancy and color fastness, and specifically can exhibit an oxygen index value of 27 or more and light fastness of 8 or more in a fabric.

In particular, fabrics produced by weaving the coating yarns of the present invention cause thermal fusion between the core yarn and the coating material in the tenter and drying processes during fabrication of the fabrics and reduce the difference in shrinkage rate between the core yarn and the coating material, The phenomenon hardly occurs.

4 is a photograph showing thermal fusion between a core yarn and a coating material in a fabric manufactured according to the present invention. As shown in FIG. 4, when heat is applied, the fusing and shrinkage of the yarn and the coating material can be prevented and the purging can be prevented.

Accordingly, the fabric of the present invention can maintain excellent appearance when used as a blind, flooring, or other outdoor / interior material.

In addition, the coated yarn or fabric of the present invention can be recycled, and in particular, when heat is applied at the time of recycling, a thermally fused fiber can be formed by thermal fusion between the core yarn and the coating material (see FIG. Thus, the flooring material produced using the fabric of the present invention can be recycled after the milling and kneading process (see FIG. 6).

Manufacturing method

Hereinafter, an example of a method for producing a coated yarn and a fabric according to the present invention will be described.

a) Manufacture of core yarn

The core yarn can be prepared by mixing a low melting point polyester resin and a high melting point polyester resin to lower the melting point and then spinning at a temperature of 200 to 250 ° C. At this time, the types and mixing ratios of the resins that can be mixed are as described above.

b) Preparation of coating material composition

First, the raw material resin (thermoplastic resin and the like) of the coating material and the plasticizer (in the case of PVC) are added to the compounding machine at room temperature in an amount of 30 to 90% by weight based on the total coating composition and dispersed for 1 to 10 minutes.

To add flame retardancy thereto, the flame retardant may be added in an amount of 5 to 60% by weight based on the total coating composition and dispersed for 3 to 10 minutes so that the oxygen index value is 28% or more

In addition, additives (lubricants, pigments, ultraviolet stabilizers, antimicrobial agents and other fillers) that can impart other functionality are further added. The functional additive may be prepared by mixing during extrusion compounding using a master batch. If the additive is less than 5% by weight based on the total coating composition, the functional additive may be directly added during the dispersion of the raw resin to proceed dispersion .

The extrusion compounding process can be carried out after the dispersion is finally finished. For compounding extruders, an extruder equipped with a twin screw (double screw) is preferably used to optimize the dispersion of the coating composition. The temperature of the extruder is adjustable from 130 to 210 DEG C and the length of the cylinder is preferably 1 m or more. The dispersion-completed composition is fed into a hopper of a twin extruder and subjected to an extrusion process at a temperature of 150 to 210 ° C. The functional additives (lubricants, pigments, ultraviolet stabilizers, antibacterial agents and other fillers) in the composition can be subjected to an extrusion compounding process by adding a specific proportion to the extruder hopper using the master batch.

In addition, a flame retardant and an additive may be first processed and recycled, and a green process may be implemented using a twin extruder having a gas discharge facility in consideration of characteristics of a flame retardant sensitive to moisture and gas.

c) Manufacture of coated yarn

The core yarn produced in step (a) is installed in an extrusion coating machine in a direction of warp or weft in the coating direction of the extruder, and the yarn is passed through a die nozzle of the extruder, and the coating composition compounded in step (b) Coating and winding. The extrusion coater may be an extruder equipped with a single screw, a coating temperature range of 130 to 210 ° C and a temperature of 150 to 180 ° C in consideration of the melting characteristics of the yarn and the coating agent. Lt; / RTI > The coating speed can be 300 to 1100 m / min.

d) Fabrication of fabrics

The coating yarn produced in the above step may be fabricated through the following regular, woven, and tenter processes.

The canning process refers to an operation of winding a warp yarn (longitudinal yarn) onto a beam so as to match the length, density, width, etc. of the designed fabric, and winds the desired number of yarns of the desired yarn to a desired length.

After that, weaving is done by using the lightweight fibers and the coated yarns. The weaving process refers to a process of making a fabric by intersecting weft yarns at right angles to the warp yarns in an oblique one strand or two strands downward according to a certain rule. In this process, a desired pattern can be expressed.

The woven product is then tentered to produce a fabric. The tenter process is one of finishing process steps in the production of fabrics, that is, a process of fixing the width constantly using a tentering machine. In the tentering process, both sides of the fabric are held by pins or clips, The temperature of the tenter can be raised to 130 to 210 DEG C and fixed.

Examples and Test Examples

Hereinafter, the present invention will be described in more detail by way of examples. The following examples are illustrative of the present invention, but the present invention is not limited to the following examples.

Example 1: Preparation of core yarn

The following master batches A and B were uniformly mixed and the obtained mixed resin was spun at a temperature of 210 DEG C to obtain a core yarn having a thickness of 250 denier:

70% by weight of Masterbatch A (melting point 230 占 폚, 2-methyl-1,3-propanediol copolymerized PET, trade name: MPDiol Glycol-co-PET, by Lyondell); And

30% by weight of Masterbatch B (PET having a melting point of 180 占 폚, 2-methyl-1,3-propanediol copolymerized with MPDiol Glycol-co-PET manufactured by Lyondell).

Example 2-1: Preparation of coating material composition (PVC series)

The composition obtained by mixing the following ingredients was plasticized at 60 to 120 ° C using a blender equipped with a cylindrical stirrer, compounded at 160 to 210 ° C using a single or twin extruder, and then calcined at 80 ° C for 2 hours The coating composition composition was prepared by drying:

- raw material resin (PVC resin LS100) 50 parts by weight;

- raw material resin (EVA, vinyl acetate 18%, Hanwha Chemical) 20 parts by weight;

- 27 parts by weight of a plasticizer (DINP Aikyoung Chemical);

- 0.5 part by weight of lubricant (zinc stearate, Hebei Yibo Nano Chemical);

- 0.5 part by weight of antimicrobial agent (BAC-300Z, Aseong Fine Chemical); And

- 2 parts by weight of ultraviolet stabilizer (benzophenone type, LOWILITE 26, Miwon Superior Co.).

Example 2-2: Preparation of coating material composition (TPO series)

The composition obtained by mixing the following ingredients was compounded at 190-210 ° C using a twin extruder and dried at 80 ° C for 2 hours to prepare a coating material composition:

50 parts by weight of raw material resin (polypropylene homopolymer, HJ500, manufactured by Samsung Total);

- raw material resin (EVA, vinyl acetate 18%, Hanwha Chemical) 20 parts by weight;

- Flame retardant (metal phosphorus, Exolite OP 930, Clariant) 25 parts by weight;

- 1 part by weight of lubricant (zinc stearic acid, Hebei Yibo Nano Chemical);

- 1 part by weight of antibacterial agent (BAC-300Z, Aseong Fine Chemical);

- 1 part by weight of a dripping inhibitor (fluorine-based, DAL-ELTM PPA, Daikin); And

- 2 parts by weight of ultraviolet stabilizer (benzophenone type, LOWILITE 26, Miwon Superior Co.).

Test Example 1: Melting point measurement

The partial melting points of the core yarn prepared in Example 1 and the coating material compositions prepared in Examples 2-1 and 2-2 were measured with DSC TA equipment.

As a result, the melting point of the PET-based core yarn prepared in Example 1 was measured at 207 占 폚, the melting point of the PVC-based coating material composition prepared in Example 2-1 was measured at 175 占 폚, The melting point of the TPO-based coating composition prepared was measured at 165 ° C.

Example 3-1: Preparation of coating yarn (PVC-based coating material)

Using the single extrusion coater, the core-yarn prepared in Example 1 was coated with the PVC-based coating composition prepared in Example 2-1 at an average coating thickness of 440 μm at a coating rate of 600 m / min at 180 ° C, . In the coating process, the coating material composition was injected into the hopper while the yarn was passed through the nozzle and fixed to the winder to adjust the discharge amount from the extruder to perform the extrusion coating.

Example 3-2: Preparation of coating yarn (TPO-based coating material)

The procedure of Example 3-1 was repeated to prepare coated yarn except that the TPO-based coating composition prepared in Example 2-2 was used and the temperature at coating was adjusted to 175 ° C.

Test Example 2: Shrinkage Measurement

The core yarn prepared in Example 1 was placed in a 165 ° C oven for 30 minutes, and the ratio of the final length to the initial length was calculated. As a result, the contraction ratio of the PET-based core yarn of Example 1 was measured at 12% at 165 캜.

As a result of measuring the shrinkage ratio of the coating yarn prepared in Example 3-1 under the same conditions as above, the shrinkage percentage of the coating material alone in the coated yarn was measured at 8 to 10% at 165 ° C.

Example 4-1: Fabrication of fabric (PVC-based coating material)

The coated yarn obtained in Example 3-1 was warp wound and wound to a net shape of 2.5 m in width and weighed using an IR tenter to measure an average temperature of 185 ° C and a maximum maximum temperature of 210 ° C The tentering process was carried out to obtain a fabric.

Example 4-2: Fabrication of fabric (TPO-based coating material)

The same procedure as in Example 4-1 was repeated to obtain a fabric, except that the IR tenter process was adjusted to an average temperature of 155 캜 and a partial maximum temperature of 180 캜.

Comparative Example 1: Fabrication of a fabric using a conventional coating yarn

The procedures of Examples 1, 2-1, 3-1, and 4-1 were repeated, except that the PET homopolymer was used as the raw resin for the core yarn.

Test Example 3: Evaluation of purging phenomenon

The fabrics obtained in Comparative Examples 1 and 4-1 were cut and their cross-sectional photographs are shown in Figs. 2 and 3, respectively. As shown in FIG. 2, the fabric using the conventional coating yarn is protruded from the end face to deteriorate the appearance, while the fabric of the present invention has a smooth surface without purging as shown in FIG.

Example 5-1: Preparation of flooring material (PVC-based coating material)

A hot-melt adhesive film having a thickness of 0.5 mm and a thickness equal to that of the polyurethane-based high-density foam sheet (density 15 to 25 lb / ft ³ ) having a width of 20 cm, a length of 30 cm and a thickness of 6 mm was placed on the polyurethane- The fabric prepared in Example 4-1 was cut and cut to the same area size, and rolled at a speed of 0.1 mPm at 160 캜 to complete a flooring.

Example 5-2: Preparation of flooring material (TPO-based coating material)

The same procedure as in Example 5-1 was repeated except that the fabric prepared in Example 4-2 was used to produce a flooring.

Example 6: Recycling process

The fabric obtained in Example 4-2 was pulverized by a low-speed pulverizer (3 horsepower, 29 rpm, manufactured by T & K Kogyo Co., Ltd.), mixed in a kneader at a temperature of 210 ° C for 30 minutes, pulverized, (See Fig. 6).

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, It is to be understood that the invention may be practiced within the scope of the appended claims.

Claims (7)

A coating yarn comprising a core yarn and a coating material coated on its outer surface,
Wherein the core yarn is made of a polyester resin having a melting point of 130 to 210 DEG C and has a shrinkage ratio of 5 to 20% at 165 DEG C,
Characterized in that the coating material comprises a thermoplastic resin.
delete The method according to claim 1,
Characterized in that the coating material has a melting point of 130 to 200 占 폚 and a shrinkage of 3 to 20% at 165 占 폚.
The method according to claim 1,
Wherein the melting point difference between the core yarn and the coating material is 0 to 50 DEG C and the difference in shrinkage percentage at 165 DEG C is 0 to 17%.
The method according to claim 1,
Wherein the polyester resin constituting the core yarn is a polyester resin,
(A) and a PET copolymer resin (b) having a melting point of 170 to 190 캜 in a weight ratio of 0.1 to 70: 99.9 to 30 (a: b) Coating yarns characterized by.
The method according to claim 1,
Wherein the thermoplastic resin of the coating material is selected from the group consisting of a polyvinyl chloride (PVC) resin, a polyolefin (PO) resin, a thermoplastic polyurethane (TPU) resin and a mixed resin thereof.
A fabric in which the coating yarn of claim 1 is woven.

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