TWI829062B - Spunbond non-woven, carpet comprising the same and manufacturing method thereof - Google Patents

Abstract

According to the present disclosure, there is provided a spunbond nonwoven fabric capable of providing carpets that are environmentally friendly and have excellent pullout strength because it can play the role of a latex material while having excellent mechanical properties even without the inclusion of latex or PVC layers that generate harmful substances, a carpet comprising the same, and a manufacturing method thereof.

Description

Spun bonded nonwoven fabrics, carpets including the same and methods of manufacturing the same Law [Cross-reference to related applications]

This application claims the rights and interests of Korean Patent Application No. 10-2020-0187594, which was filed on December 30, 2020, and Korean Patent Application No. 10-2021-0189932, which was filed on December 28, 2021. The full text of the disclosures in the Korean patent application is incorporated into this case for reference.

The present disclosure relates to a spun-bonded nonwoven fabric for a carpet suitable for use as a car floor material and a method of manufacturing the spun-bonded non-woven fabric.

Carpets are floor interior products used in homes, public institutions, hotels, restaurants, automobiles, etc., and are used for decoration, comfort, sound absorption, and walking convenience (cushion). ).

The existing carpet structure consists of carpet yarn (Bulky Continuous Filament (BCF) yarn (pile)), base fabric (non-woven fabric), Made of latex and polyvinyl chloride (PVC) (rubber, ethylene-vinyl acetate (EVA), etc.).

Among them, latex and PVC materials produce toxic fumes during the process of coating and finishing carpet yarns on tufted base fabric (non-woven fabric), and in the finished product, they belong to the car floor interior product group and will Produces volatile toxic fumes that pollute indoor air quality.

That is, in carpet construction, the latex coating process and the PVC layer are the layers that most often release volatile harmful substances. Furthermore, in the post-finishing step used to manufacture carpets, there is a problem that a large amount of harmful substances are released during the process of applying the PVC layer and curing it.

As a result, air quality regulations have been tightened around the world, and product development is moving toward eliminating the use of latex and PVC materials.

However, products that have excellent functionality (such as pullout strength of nonwoven fabrics) while meeting strict regulations on air quality have not yet been developed.

An object of the present disclosure is to provide a spun-bonded non-woven fabric for carpets and a manufacturing method of the spun-bonded non-woven fabric. The spun-bonded non-woven fabric may not use latex and PVC materials, but use materials with excellent functionality. The non-woven fabric used as the latex layer stably fixes the carpet yarns to the non-woven fabric.

Another object of the present disclosure is to provide a spun-bonded non-woven fabric for carpets and a manufacturing method of the spun-bonded non-woven fabric. Since no volatile toxic fumes are produced by eliminating latex and PVC materials, the spun-bonded non-woven fabric Bonded nonwovens are environmentally friendly.

According to one embodiment, a spun-bonded non-woven fabric is provided. The spun-bonded non-woven fabric includes a fiber web formed from split-type conjugate filament, and the split-type conjugate filament contains 60% to 80% by weight. Polyester filaments and 20% to 40% by weight of copolymer filaments, the polyester filaments have a melting point of 250°C or greater than 250°C, and the copolymer filaments have a melting point of 170°C or less, wherein The spunbond nonwoven fabric has a splitting rate (splitting rate) of 50% or greater according to Equation 1 below, and has a splitting rate of 18 kgf/5 cm or greater as measured according to the standard test method of KS K 0521 Room-temperature strength of 18 kgf/5cm, hot strength of 4.0kgf/3cm or less, and thermal elongation of 80% or more Rate (hot elongation).

[Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100

(In Equation 1, the number of split filaments and the number of unsplit filaments are calculated using The number of split filaments and the number of unsplit filaments observed in photos of the cross-section of the nonwoven fabric taken with a microscope (Scanning Electron Microscope, SEM) at a magnification of x200, and the splitting rate represents 10 photos average of).

According to another embodiment, a method for manufacturing a spunbonded nonwoven fabric is provided, the method comprising the following steps: spinning 60% to 80% by weight of polyester through a multi-split type spinning nozzle. The filaments and 20% to 40% by weight of the copolymer filaments are spun and stretched to prepare split type composite filaments, the polyester filaments have a melting point of 250°C or greater than 250°C, and the copolymer filaments have A melting point of 170°C or less and a melt index (MI) of 15 g/10 minutes to 25 g/10 minutes (ASTM 1238, 190°C); the composite filaments are laminated to form a fiber web ; thermally bonding the fiber web; and performing multiple splitting of the filaments in the thermally bonded web, wherein after the step of multiplely splitting the filaments in the thermally bonded web, the splitting rate is 50% according to Equation 1 below or greater than 50%.

[Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100

(In Equation 1, the number of split filaments and the number of unsplit filaments are photographs of the cross-section of the nonwoven fabric taken using a microscope (SEM) at x200 magnification The number of split filaments and the number of unsplit filaments observed in , and the splitting rate represents the average of 10 photos).

According to yet another embodiment, a carpet including the spunbonded nonwoven fabric is provided.

In the following, a carpet and a manufacturing method of the carpet according to embodiments of the present disclosure will be explained in detail.

Prior to description, unless otherwise specified throughout this specification, technical terms used herein are only used to refer to specific embodiments and are not intended to limit the disclosure.

As used herein, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.

As used herein, the terms "including" or "comprising" designate specific features, regions, integers, steps, actions, elements and/or components, but do not exclude different specific features, regions, integers, steps. , actions, elements, components and/or groups.

In addition, terms including ordinal numbers such as "first", "second", etc. are used only for the purpose of distinguishing one component from another component and are not limited by ordinal numbers. For example, a first component could be termed a second component, or, similarly, a second component could be termed a first component, without departing from the scope of the present disclosure.

Now, this disclosure will be elaborated in detail.

According to an embodiment of the present disclosure, a spunbonded nonwoven fabric can be provided, The spin-bonded nonwoven fabric includes: a fiber web formed from self-splitting composite filaments. The splitting composite filaments include 60% to 80% by weight of polyester filaments and 20% to 40% by weight of copolymer filaments. , the polyester filaments have a melting point of 250°C or greater, and the copolymer filaments have a melting point of 170°C or less, wherein the spin-bonded nonwoven fabric is as measured according to the standard test method of KS K 0521 Having a room temperature strength of 18 kgf/5cm or greater, a thermal strength of 4.0kgf/3cm or less, and a thermal elongation of 80% or greater Rate.

Based on the results of continuous research conducted by the present inventors, it was confirmed that when composite fibers composed of split fibers of a matrix and binder materials with specific content ratios and different melting points are used, even without passing through latex and PVC materials In the case of coating processes, non-woven fabrics that can exhibit the functions of latex and PVC layers can also be used to continuously manufacture carpets.

Therefore, the present disclosure has the following features: producing a nonwoven fabric that includes the function of latex material in existing carpet construction, thereby providing a carpet without a latex layer.

Specifically, in existing carpet layers, latex materials are used to secure carpet yarns (BCF yarns). However, since latex materials can cause environmental problems, the present disclosure attempts to create a non-woven fabric for carpets that includes the function of a latex layer by adding the non-woven fabric with the non-woven fabric without using a separate latex material. Manufactured for the performance of carpet yarns (pull-out strength).

Therefore, since the latex coating process is eliminated during the production of carpets, It does not produce toxic fumes and can reduce Volatile Organic Compound (VOC) (volatile toxic substances) in the finished product, so that it can be used while being environmentally friendly when used as car floor interior materials. .

The non-woven fabric according to the present disclosure has the following characteristics: the non-woven fabric is a spun-bonded non-woven fabric, the spun-bonded non-woven fabric includes: a fiber web formed from self-splitting composite filaments, the split-type composite filaments contain 60% by weight to 80% by weight of polyester filaments and 20% to 40% by weight of copolymer filaments, the polyester filaments having a melting point of 250°C or greater, and the copolymer filaments having a melting point of 170°C or less melting point.

Specifically, using polyester filaments having a melting point of 250° C. or more as the matrix material and using copolymer filaments having a melting point of 170° C. or less as the binder material, the nonwoven fabric may be Formed into a splittable type.

Split fiber as used herein has a multiple split cross-sectional shape and means that depending on the method used to produce ultrafine fibers, the two types of polymers and multiple split spinning nozzles The two types of polymers are used to make ultrafine fibers, and the internal cross-section of a single fiber includes multiple splitting types. Therefore, split fibers do not have a cross-section consisting solely of circular shapes. For example, a multi-split cross-sectional shape may include 8 to 64 split fibers, or 16 to 32 split fibers, or 32 split fibers within a single component fiber.

Therefore, since nonwovens specify the mixing ratio of matrix and binder materials, and Composite filaments consisting of 8 to 64 split fibers are used, thus imparting the functionality of the latex layer without the latex material.

Specifically, the binder material is melted during the finishing (tufting, heat treatment, backing and molding) steps used to manufacture carpets and is used to exhibit high binder elongation and Molding efficiency so that it can act as a latex layer.

That is, the polymer used as the binder material functions to be melted during the heat treatment of the back surface of the tufts after the tufting process and serves as a bond between the carpet yarns (BCF yarns) and the base fabric (nonwoven fabric) Adhesive. In addition, in the final molding process for manufacturing finished car carpets, the binder polymer is in a state of melting in a high temperature environment of 180°C to 200°C, and it plays a role in exhibiting high elongation, thereby Enables molding.

At this time, when the binder content is 19% by weight or less, it is difficult to form a split fiber shape (the binder polymer may not be extruded, or it may move to one side due to uneven spinning pressure position), and the adhesion between the filaments forming the non-woven fabric is insufficient, so it is easily damaged during the finishing process. If the shape of the split fibers is uneven, the physical properties of the nonwoven fabric may vary depending on their location, which may lead to tearing and low pull-out strength values during finishing and molding processes.

In addition, when the content of the binder is 41% by weight or more, the matrix component used as a support member in the finishing process for manufacturing carpets at a temperature of 180°C or more is insufficient, which may cause Increased binder material that melts at high temperatures amount, and therefore shape deformation (shrinkage, elongation) due to external forces, and ultimately, post-finishing is impossible.

In addition, when the melting point of the binder raw material is 170°C or greater, the binder raw material does not melt at the processing temperature at which the nonwoven fabric must exhibit the effect of imparting strength, adhesion and high elongation, and therefore it cannot Used as adhesive filament.

Furthermore, the filaments may include split fibers having an average diameter before splitting of 22 to 31 microns and a fineness of 5.0 to 9.0 denier. More specifically, the split fibers may have an average diameter before splitting of 22 to 31 microns and a fineness of 5.0 to 9.0 denier. In addition, the cross section of the composite filament before being split may be a circular shape or a spherical shape divided into 8 to 64 parts.

When the cross-sectional shape of the composite filaments is a circular cross-section rather than a splittable shape, the binder filaments must be additionally spun, and the matrix filaments and the binder filaments must be mixed to form a mesh. At this time, when the filaments are mixed, the uniformity is limited, and thus portions without binder filaments are produced. Binder filaments are one factor used to express the tensile strength of the nonwoven fabric, and the tensile strength can be determined based on the presence/absence of bonding of the binder filaments. However, in the circular cross-section form, as described above, a portion without adhesive filaments is created, which may reduce strength and elongation, and also reduce pullout strength.

Furthermore, the nonwoven fabric according to the present disclosure has a splitting rate of 50% or more, 54% or more, or 56% or more according to the following Equation 1.

[Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100

(In Equation 1, the number of split filaments and the number of unsplit filaments are the number of split filaments and the number of unsplit filaments observed in a photograph of the cross-section of the nonwoven fabric taken with a microscope (SEM) at x200 magnification number, and the split rate represents the average of 10 photos).

The test piece with the nonwoven cross-section used to measure the splitting rate can be adjusted in various ways. For example, a nonwoven test piece with dimensions of 3 mm x 3 mm may be used.

When the splitting rate is less than 50%, the bonding area of the binder polymer is low, and therefore the binder is insufficient, which may cause the mechanical properties and pull-out strength of the nonwoven fabric to deteriorate.

The polyester filaments used as the matrix material may include at least one selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polynaphthyl terephthalate and recycled raw materials. A polyester polymer.

The polyester filaments may include a polyester polymer having an intrinsic viscosity (IV) of 0.60 deciliter/gram (dl/g) to 0.90 dl/g and a melting point of 250°C or greater. .

As the binder material, a copolymer filament having a melting point of 170°C or less and a melt index (MI) (ASTM 1238, 190°C) of 15 to 25 g/10 min is used.

Specifically, the copolymer filaments may be selected from the group consisting of having a melting point of 170°C or less and a melt index (MI) of 15 g/10 min to 25 g/10 min (ASTM 1238, 190°C ) at least one of the group consisting of polyolefins. The polyolefin may be polyethylene or polypropylene.

MI (Melt Index) as used herein means the value measured at 190°C according to ASTM 1238.

The nonwoven fabric provided by this method has excellent adhesion between filaments, excellent fixability of carpet yarns, and can also improve elongation compared to conventional situations. In addition, since the non-woven fabric is used as a base fabric for carpets, it can improve the pull-out strength of the final product, and in addition, it does not use latex and PVC materials that are harmful to the human body, thereby providing an environmentally friendly material.

According to embodiments of the present disclosure, as measured according to the standard test method of KS K 0521, the non-woven fabric can simultaneously meet the requirements of having a room temperature strength of 18 kgf/5 cm or greater than 18 kgf/5 cm and a room temperature strength of 4.0 kgf /3 cm or less than 4.0 kgf/3 cm of thermal strength and thermal elongation of 80% or greater than 80% of the physical properties. More specifically, since the nonwoven fabric is configured such that the above-mentioned splitting rate is 54% or greater, the strength and elongation can be further optimized. Therefore, as measured according to the standard test method of KS K 0521, the nonwoven fabric may have a room temperature strength of 19 kgf/5cm or greater, and a room temperature strength of 3.0kgf/3cm or less than 3.0kg force/3cm and a thermal elongation of 81% or greater.

When the weight per unit area is 90 grams/square meter, the non-woven fabric can be Spun bonded nonwoven fabric having an apparent density of 225 g/cm3 to 310 g/cm3.

In addition, the spunbonded nonwoven fabric according to the present disclosure can improve the pull-out strength of the carpet. Therefore, based on the standard test method of KS K ISO 4919, the carpet according to the present disclosure has a pull-out strength of 2.0 (kilogram force) or greater than 2.0 (kilogram force), and can be used as a car floor material.

On the other hand, according to another embodiment of the present disclosure, a method for manufacturing a spun-bonded nonwoven fabric may be provided, the method including the following steps: spinning 60% to 80% by weight of Polyester filaments and 20% to 40% by weight of copolymer filaments are spun and stretched to prepare split composite filaments. The polyester filaments have a melting point of 250°C or greater than 250°C, and the copolymer filaments are fine The filaments have a melting point of 170°C or less and an MI (melt index) of 15 g/10 minutes to 25 g/10 minutes (ASTM 1238, 190°C); the composite filaments are laminated to form a fiber web; Thermal bonding of the fiber web; and the multiple splitting of the filaments in the thermally bonded web.

The spun-bonded nonwoven fabric for carpets according to the present disclosure includes splitting properties by composite spinning polyester filaments as a matrix and copolymer filaments with a specific melting point and MI as a binder under specific conditions. Shape fiber web, and is produced by spinning bonding method.

In the spin bonding method, polyester and copolymer are each independently melted, spun and stretched through a composite spinning nozzle that can adjust the discharge holes of different types of resins number and split cross-sections in multiple By spinning into a shape, composite filaments can be obtained.

In addition, the manufacturing method of the spunbonded nonwoven fabric can be performed using a continuous extruder, and therefore has excellent mechanical properties and splitting rate, which enables continuous manufacturing of a nonwoven fabric that effectively improves the pull-out strength of carpets.

Specifically, polyester (matrix) and copolymer (binder) are prepared, then loaded into a continuous extruder, heated and melted, and then processed through multiple split spinning nozzles Spinning. With such a process, the filaments may include split yarns in the form of multiple split cross-sections in which the interior of a single yarn is split. A multi-split spinning nozzle can be used by adjusting the number of capillaries so as to have 8 to 64 split fibers or 16 to 32 split fibers.

Furthermore, during composite melt spinning, the number of capillaries on each spinning nozzle can be adjusted so that the ratio between the matrix (polyester) and the binder (copolymer) passing through the spinning nozzle is from 60% by weight to 80% by weight or 20% to 40% by weight.

Here, the details regarding the structures of the polyester filaments as the matrix material and the copolymer filaments as the binder material are replaced by what has been explained above for the spunbonded nonwoven fabric.

Furthermore, a continuous extruder can be used to provide the spunbond nonwoven fabric.

Additionally, the step of preparing the composite filaments may include adjusting the fineness such that the composite filaments have an average diameter of 22 to 31 microns and an average diameter of 5.0 before multiple splitting of the filaments in the thermally bonded web. Denier to 9.0 denier fineness.

By using a high-pressure air drawing device to adjust the spinning speed, the composite filaments spun in the form of composite spinning are fully stretched so that the discharge volume and the number of spinning nozzle capillaries can be adjusted from 5.0 denier to 9.0 denier. Ni's level.

The drawing may be performed at a spinning speed of 3000 m/min to 5000 m/min. More specifically, in order to achieve more sufficient drawing, the spinning speed may be 4500 m/min to 5000 m/min. When the spinning speed is less than 3000 meters/minute, the problem is that due to insufficient stretching of the filaments, the non-woven fabric shrinks during the thermal bonding step, which will also affect the cooling efficiency, and insufficient cooling will occur, resulting in The drawing process causes adhesion between filaments, resulting in poor drawing and opening. Furthermore, when the spinning speed is 5000 m/min or greater, there is a problem that the filaments are cut during the drawing process without forming the planar shape of the nonwoven fabric.

The step of forming the web and the step of thermal bonding can be performed by the opening by methods well known in the art.

Additionally, the step of splitting the filaments in the thermally bonded web can be performed using a water jet. That is, when the composite fiber is spun into split fibers having multiple split cross-sections and formed into a web form, it is subsequently subjected to water jet (spun lace), and the split fiber cross-sections can be split as they are.

Specifically, the prepared filament fibers are placed on a conveyor in the form of a web, and the apparent density of the web can then be adjusted to 225 to 310 g/cm3.

Perform the thermal bonding step using a calender roll or hot air Thereafter, the fiber web whose apparent density has been adjusted is passed through water injection to split the filaments into multiple split cross-sectional shapes. At this time, a spun-bonded nonwoven fabric having a thickness of 0.31 mm to 0.40 mm can be produced by gradually adjusting the water pressure of the water jet.

For example, if physical external force is applied to a nonwoven fabric that has undergone a thermal bonding process by high-pressure water jets, the filaments may take the form of split fibers. That is, in such a process, the two types of polymers that form split fibers lack compatibility (affinity) with each other, and eventually, the physical bond between the polymers may be broken and split into microfibers. . Although the pressure of the high-pressure water jet is not particularly limited, since the split fibers are split into ultrafine fibers, performing multi-stage splitting at a level of 50 bar to 280 bar and applying pressure can change the structure of the mesh. More complex, thereby further improving the strength of the nonwoven fabric.

In addition, high-pressure water injection can apply different pressure ranges in two or more steps within the pressure range. According to an embodiment of the present disclosure, the high-pressure water jet may be sequentially given a first-stage pressure intensity of 50 bar to 80 bar, a second-stage pressure intensity of 150 bar to 280 bar, and a third stage of 50 bar to 80 bar. Pressure intensity. The water pressure in each stage is adjusted according to the pressure as described above, so that not only the thickness of the nonwoven fabric can be adjusted, but also the split fiber cross-section divided into the desired level can be maintained as it is.

At this time, when applying pressure using high-pressure water jetting, if only one pressure is applied instead of multiple levels of pressure, when a single high-pressure water jetting step is applied, traces will remain in the form of stripes in the machine direction, which may cause Problems with uneven weight, thickness and splitting rate. In addition, the fewer water jet processing steps, the water jet nozzle and water pollution levels will be more affected.

Therefore, according to the present disclosure, the non-woven fabric undergoes multi-stage water injection, whereby the non-woven fabric is split several times through multiple stages to increase the splitting rate, and it can give the ability to rearrange the filaments uniformly as described above.

After multiple steps of splitting the filaments in the thermally bonded web, the splitting rate according to Equation 1 below may be 50% or greater.

[Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100

(In Equation 1, the number of split filaments and the number of unsplit filaments are the number of split filaments and the number of unsplit filaments observed in a photograph of the cross-section of the nonwoven fabric taken with a microscope (SEM) at x200 magnification number, and the split rate represents the average of 10 photos).

According to the above method, the spunbond nonwoven fabric formed from filaments having a split fiber shape in which the ratio of matrix to binder is specified can be used as a backing fabric for the production of carpets.

Therefore, according to another embodiment of the present disclosure, a carpet including the spun-bonded nonwoven fabric and a method for manufacturing the carpet may be provided.

The carpet may be provided by including tufting processes and cutting processes, using carpet yarns and spun bonded non-woven fabrics.

Specifically, since the manufacturing method of the carpet does not involve the coating process of latex and PVC layers as in conventional methods, it can not only shorten the manufacturing process, but also eliminate the need for Harmful substances are produced and therefore environmentally friendly products can be provided.

Thus, the carpet has carpet yarns secured to one surface of the nonwoven fabric and does not include a latex layer.

In addition, the carpet is produced by including the steps of fixing the carpet yarn to the non-woven fabric through a tufting process and a heat treatment process on one surface of the spun-bonded non-woven fabric and the step of cutting the non-woven fabric fixed to the carpet yarn. obtain.

In addition, between the step of fixing the carpet yarns and the cutting step, a step of laminating the backing layer on the non-woven fabric fixed to the original carpet yarns may be further included.

Specifically, planting carpet yarns in the nonwoven fabric by a tufting process on one surface of the spunbonded nonwoven fabric provided by the above method and fixing the nonwoven fabric to the carpet yarns by heat treatment can be performed steps.

At this time, the step of fixing the carpet yarns to the nonwoven fabric may include heat treating the back surface of the tufted nonwoven fabric after the tufting process.

The tufting process, the heat treatment process and the cutting process may be performed such that the carpet yarns are secured to a surface of the nonwoven fabric using needles using known methods and equipment. At this time, the tufting may be performed in a loop form under a predetermined gauge (eg, 64/5 gauge).

Additionally, carpet yarns used in the tufting process may include BCF yarns as are well known in the art. Carpet yarns may have aesthetic and cushioning functions, and may have predetermined fineness (eg, 500 to 3000 denier) and height (eg, 3.0 to 7 mm). Through the tufting process, the carpet yarns are planted so that they are visually discernible from one side of the nonwoven.

The step of laminating the backing layer can also be performed by methods well known in the art. Specifically, a high weight web may be laminated on the backing layer, and for the high weight web, a web in the form of staple fiber or long fiber nonwoven fabric may be used.

The carpet may be provided by a method including the step of laminating a backing layer, by seeding the carpet yarns into the nonwoven fabric by a tufting process on one surface of the spun bonded nonwoven fabric. ; The step of fixing the carpet yarns by heat treatment of the tufted nonwoven fabric; the step of laminating the backing layer; and the step of cutting the laminated carpet.

Therefore, carpets in accordance with the present disclosure may be constructed to include a spunbond nonwoven, carpet yarns, and a backing layer without a latex layer.

According to a preferred embodiment, the nonwoven fabric utilizes endless polypropylene BCF (bulky continuous filament) yarns of approximately 3000 denier/150 filament on the surface at a gauge of approximately 64/5 (at In tufting machines, the needle spacing is indicated in inches as a unit of needle density, and the density of a tufted carpet in the width direction is determined by the gauge) and is about 13/1 stitch (tufted The density of pile carpet in the longitudinal direction) undergoes tufting (the process of planting yarn into a nonwoven fabric). Then, the back surface of the tufted product is heat treated using a heat chamber at about 180° C., and finally a cutting process (standard: 50 cm × 50 cm) is performed so that a carpet can be provided. Before the cutting step for the carpet heat-treated by the above method, a step of laminating high-weight long fibers or short fibers as a backing layer may be further included.

The carpet provided in this way has high performance and as per KS The standard test method of K ISO 4919 measures the pull-out strength (strength of pulling out the ring after ring tufting) of about 2.0 kgf, and can therefore be used in various fields and, in particular, its Can be used as car floor interior material.

According to the present disclosure, a spun-bonded non-woven fabric that can be used as a latex material while having excellent mechanical properties is included as the base fabric, and therefore the latex and PVC coating processes are eliminated, thereby no toxic smoke is generated, and the VOC of the finished product can be reduced (volatile hazardous substances), so as to provide a carpet that can be used as a vehicle floor interior product and a manufacturing method of the carpet.

Hereinafter, the functions and effects of the present invention will be explained in more detail with reference to specific examples of the present invention. However, these examples are presented for illustrative purposes only, and the scope of the invention is not limited thereto in any way.

[Example 1]

A matrix made of a polyethylene terephthalate (PET) material with a melting point of 255° C. and a binder made of a polyethylene material (MI: 20) with a melting point of 137° C. were prepared. , and then put it into a continuous extruder, heat and melt it, and then perform composite spinning on it through a spinning nozzle, so that it becomes an orange-shaped cross-section divided into 32 parts (orange cross-section) form of filaments. At this time, adjust the number of capillaries in the spinning nozzle so that the The ratio between matrix (polyester) and binder (copolymer) of the spinning nozzle is 70% by weight: 30% by weight.

Then, the 32 split-spun composite filaments discharged through the spinning nozzle were solidified using cooling air at 15° C., and then fully stretched using a high-pressure air stretching device such that the spinning speed was 5000 meters/minute. Thus, composite filament fibers having a fineness of 5.0 denier to 9.0 denier and an orange cross-sectional shape were prepared.

Next, the prepared composite filament fibers are laminated in the form of a mesh on a continuously moving metal conveyor mesh by a conventional fiber opening method, and then subjected to calendering using a flat roll with a flat surface. The calendering process gives it an apparent density of 270 g/cm3.

After that, the non-woven fabric that has completed the calendering process is passed through the water jet, and the pressure is sequentially applied to the non-woven fabric with a pressure intensity of lower (70 bar) - upper (250 bar) - lower (50 bar) pressure, thereby gradually By carefully adjusting the water pressure, the thickness of the nonwoven fabric was adjusted, and a final spun-bonded nonwoven fabric was produced (weight per unit area: 90 g/m2, thickness: 0.33 mm).

The nonwoven fabric produced was tufted (cut type, 64/5 inch gauge, 13/1 inch stitch, polypropylene carpet yarn (BCF) 1200 denier', pile yarn height 4 mm) , and then heat-treated the back surface of the tufts at 235°C to fix the carpet yarns (BCF yarns), thereby manufacturing the carpet. Tufted samples were used to measure pullout strength.

[Example 2]

A spunbonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the conjugate ratio of matrix:binder was changed to 80% by weight:20% by weight.

[Comparative example 1]

A spunbond nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the cross-sectional shape of the filaments was changed to a circular shape instead of an orange shape and the fibers were split.

[Comparative example 2]

A spun-bonded nonwoven fabric and carpet were produced in the same manner as in Example 1, except that the binder material was changed to nylon 6.

[Comparative example 3]

A spun-bonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the compound ratio of matrix:binder was changed to 50% by weight:50% by weight.

[Comparative example 4]

A spun-bonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the compound ratio of matrix:binder was changed to 90% by weight:10% by weight.

[Comparative example 5]

A spun-bonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the spinning speed was set to 6000 meters/minute.

[Comparative example 6]

A spun-bonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the spinning speed was set to 2500 meters/minute.

[Comparative Example 7]

A spunbonded nonwoven as well as a carpet was produced in the same manner as in Example 1, except that water punching was carried out on the produced nonwoven only at a water pressure of 294 bar without applying a tertiary pressure.

[Test example]

The physical properties of the examples, reference examples, and comparative examples were measured according to the measurement method for each evaluation item below, and the results are shown in Table 1.

1. Split rate (%)

The splitting rate was calculated according to the following Equation 1 by taking 10 photographs of the cross-section of the nonwoven fabric using a microscope with a magnification of ×200.

[Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100

(In Equation 1, the number of split filaments and the number of unsplit filaments are the number of split filaments and the number of unsplit filaments observed in a photograph of the cross-section of the nonwoven fabric taken with a microscope (SEM) at x200 magnification, And the split rate represents the average of 10 photos).

2. Room temperature strength (kilogram force/5 cm)

Room temperature strength was measured using the standard test method according to KS K 0521.

Specifically, using INSTRON measuring equipment, by The test piece with the dimensions of width × length = 5 cm × 20 cm was fixed by a clamp with upper/lower dimensions of 5 cm × 5 cm, and then performed at a tensile speed of 200 mm/min. Said measurement.

3. Thermal strength (kilogram force/3 cm), thermal elongation (%)

Thermal strength and thermal elongation were measured using standard test methods according to KS K 0521.

Specifically, Instron measuring equipment is used to fix the test piece with dimensions of width × length = 3 cm × 10 cm by a clamp with upper/lower dimensions of 5 cm × 5 cm, and A thermal chamber was then preheated at 180°C for 3 minutes, and the measurements were performed at a tensile rate of 200 mm/min.

4. Pull-out strength (%)

The nonwoven fabric was tufted as described above (cut type, 64/5 inch gauge, 13/1 inch stitch, pile height 4 mm), and the back surface of the tufts was then heat treated, and Carpet yarns (BCF yarns) were fixed to prepare tufted samples.

In the sample thus prepared, one pile to be measured in the tufted sample is fixed to the measuring device according to the KS K ISO 4919 standard, and one pile to be measured in the tufted sample is The head is fixed to the measuring device. The ring to be measured and adjacent rings on both sides were cut. Then, take the intensity (peak) value that occurs when the pile to be measured is pulled out in a direction perpendicular to the direction of the sample using the Instron measuring device. Repeat this method 5 times and take the average value. Three samples were prepared for the test and evaluated in duplicate.

According to the results in Table 1, it was confirmed that since Examples 1 and 2 included the spun-bonded nonwoven fabric used as latex, compared with the cases of Comparative Examples 1 to 7, the splitting rate was higher, and the room temperature strength, Excellent thermal strength and thermal elongation. In addition, the examples exhibited excellent pull-out strength of 2.0 (kilogram force) or greater than 2.0 (kilogram force).

On the other hand, Comparative Example 1 showed a circular cross-sectional shape and used unsplit nonwoven fabric, and therefore showed low mechanical properties, and specifically, showed poor pull-out strength of 1.2 kgf.

In addition, in Comparative Example 2, since nylon was used as the binder, the latex function could not be performed, and both the mechanical properties and pull-out strength were poor.

In Comparative Examples 3 and 4, since the contents of the matrix and binder materials are outside the range of the present disclosure, the splitting rate is poor or not splitting, and the nonwoven fabric is poorly formed, making it difficult to manufacture the carpet.

In addition, as shown in Table 1, in Comparative Examples 5 and 6, spinning The speed is outside the scope of the present disclosure and the nonwoven cannot be produced due to filament cutting in the drawing step or shrinkage during thermal bonding. In Comparative Example 7, high-pressure water injection was only used in a single step, and compared with Examples 1 and 2, the splitting rate was reduced, resulting in reduced strength, elongation, and pull-out strength.

Claims (14)

A spin-bonded nonwoven fabric, comprising: a fiber web formed from self-splitting composite filaments, the splitting composite filaments comprising 60 to 80 wt% polyester filaments and 20 to 40 wt% copolymers Filament, the polyester filament has a melting point of 250°C or greater, the copolymer filament has a melting point of 170°C or less, wherein the spin-bonded nonwoven fabric has a melting point according to the following Equation 1 A splitting rate of 50% or greater, and the spin-bonded nonwoven fabric has a room temperature strength of 18 kgf/5cm or greater than 18kgf/5cm as measured according to the standard test method of KS K 0521 , a thermal strength of 4.0 kgf/3cm or less than 4.0kgf/3cm and a thermal elongation of 80% or greater: [Equation 1] Splitting rate (%) = (number of split filaments)/( The number of split filaments + the number of unsplit filaments) × 100 In Equation 1, the number of split filaments and the number of unsplit filaments are obtained when the spin bond was photographed using a scanning electron microscope at a magnification of x200 The number of split filaments and the number of unsplit filaments observed in photos of cross-sections of nonwoven fabrics, and the split rate represents the average of 10 photos. The spun-bonded non-woven fabric as claimed in claim 1, wherein as measured according to the standard test method of KS K 0521, the spun-bonded non-woven fabric has a strength of 19 kgf/5 cm or greater than 19 kgf/5 cm The room Warm strength, the thermal strength of 3.0 kgf/3cm or less, and the thermal elongation of 81% or greater than 81%. The spun-bonded nonwoven fabric according to claim 1, wherein the splitting rate is 54% or greater. The spun-bonded nonwoven fabric according to claim 1, wherein the cross-section before splitting the split composite filaments is a circular or spherical shape divided into 8 to 64 parts. The spun-bonded nonwoven fabric of claim 1, wherein the split composite filaments have an average diameter of 22 to 31 microns and a fineness of 5.0 to 9.0 denier before splitting. The spun-bonded nonwoven fabric of claim 1, wherein the polyester filaments comprise an intrinsic viscosity (IV) of 0.60 to 0.90 deciliter/g and a melting point of 255°C or greater. At least one polyester polymer selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polynaphthyl terephthalate and their recycled raw materials group. The spin-bonded nonwoven fabric of claim 1, wherein the copolymer filaments comprise a material selected from the group consisting of having a melting point of 170°C or less and a melt index of 15 to 25 g/10 minutes ( At least one of the group consisting of polyolefins MI) (ASTM 1238, 190° C.). A method for manufacturing spunbonded nonwoven fabrics, the method comprising the following steps: Spinning and drawing 60% to 80% by weight of polyester filaments and 20% to 40% by weight of copolymer filaments through multiple splitting type spinning nozzles to prepare split type composite filaments. The polyester filaments have a melting point of 250°C or greater, the copolymer filaments have a melting point of 170°C or less and a melt index of 15 g/10 minutes to 25 g/10 minutes ( MI) (ASTM 1238, 190° C.); laminating the split composite filaments to form a fiber web; thermally bonding the fiber web; and multiple splitting the filaments in the thermally bonded web, wherein After performing the step of multiple splitting on the filaments in the thermally bonded web, the splitting rate is 50% or greater according to the following equation 1: [Equation 1] splitting rate (%) = (split filaments Number of filaments)/(Number of split filaments + Number of unsplit filaments) The number of split filaments and the number of unsplit filaments observed in photos of the cross-section of the spin-bonded nonwoven fabric, and the split rate represents the average of 10 photos. The method for manufacturing a spunbonded nonwoven fabric according to claim 8, wherein the step of preparing the split composite filaments includes the step of performing the multiple splits on the filaments in the thermally bonded web. The fineness is previously adjusted so that the split composite filaments have an average diameter of 22 microns to 31 microns and are 5.0 denier. to the stated fineness of 9.0 denier. The method for manufacturing a spunbonded nonwoven fabric as claimed in claim 8, wherein the cross-section before splitting the split composite filaments is a circular or spherical shape divided into 8 to 64 parts. The method for manufacturing spin-bonded nonwoven fabric as described in claim 8, wherein the stretching is performed at a spinning speed of 3000 m/min to 5000 m/min. The method for manufacturing a spunbonded nonwoven fabric as claimed in claim 8, wherein the stretching is performed using water jets. A carpet, including the spun-bonded nonwoven fabric as described in any one of claims 1 to 7. The carpet of claim 13, wherein the carpet has a pull-out strength of 2.0 kgf or greater as measured according to the standard test method of KS K ISO 4919, and is used as a car floor material.