KR102228541B1 - Non-woven for carpet backing with improved pull-out strength and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a nonwoven fabric for a carpet base paper having improved pulling strength, and comprises a nonwoven fabric including 50 to 90% by weight of polyester filaments having a melting point of 255°C or higher and 10 to 50% by weight of a polyester filament having a melting point of 185°C or less.
According to the present invention, by using a nonwoven fabric containing polyester fibers having a low melting point as a base material and adjusting the thickness of the base material, it is possible to improve the pulling strength of the loop in the carpet, thereby suppressing the fall of the BCF yarn from the carpet.

Description

TECHNICAL FIELD [Non-woven for carpet backing with improved pull-out strength and manufacturing method thereof]

The present invention relates to a nonwoven fabric for a carpet base paper and a method of manufacturing the same, in which the dropout of the BCF (bulked continuous filament) yarn to be planted in the base fabric is suppressed when the carpet is manufactured.

Carpets are used not only for decoration in hotels, offices, homes, cars, etc., but also for providing comfort and sound insulation.

The carpet fabric is made through a manufacturing process including a tufting process in which BC is planted on a nonwoven fabric, and a back coating process in which a coating solution such as PVC, PE, EVA or SBR is coated and cured on the back of the tufted nonwoven fabric. .

When the made carpet fabric is cut into squares (for example, 50cm × 50cm), it becomes a tile carpet used in hotels, offices, and homes, and when it is molded in the shape of a car floor, it becomes a floor mat for a car.

The function of the nonwoven fabric for carpet base paper is to fix the BCF yarn.

In the tufting process, the BCF yarn penetrates the foam paper and is fixed to the foam paper by the frictional force with the foam paper.

For this penetration, a hole of at least 160,000 holes/m2 is drilled in the foam paper by means of a needle. The base paper should maintain the arrangement shape of the BCF yarn even with such physical damage, and there should be no deformation of the shape during post-processing in a high temperature environment.

Intermediate products that have undergone the tufting process may cause the BCF yarn planted in the storage and transfer process to be unwound or damage to the tufted fabric, and therefore, excellent mending properties are required for the intermediate products.

At this time, the mending includes fixing the hole if the BCF company exits the hole after the tufting process.

However, since it is difficult to perform mening on finished carpet products, it is required to prevent BCF companies from escaping from the carpet.

U.S. Patent No. 7,810,397 (Tuft gripping strength test method and apparatus for carpet primary backing mats) U.S. Patent No. 4,654,247 (Method for improving the tuft bind of textile coverings)

In order to meet the above requirements, the present invention is to provide a nonwoven fabric for a carpet base material and a method of manufacturing the same, in which the fixing ability of the BCF yarn in the carpet is improved.

In order to solve the above problems, the present invention includes 50 to 90% by weight of a polyester first filament having a melting point of 255°C or higher and 10 to 50% by weight of a polyester second filament having a melting point of 185°C or lower. Provides a nonwoven fabric for carpet base paper with improved pulling strength with a pulling strength of 2.0~3.0kgf (KS K ISO 4919 method).

In addition, the present invention is a blended spinning step of spinning and mixing a first filament made of polyester having a melting point of 255°C or higher and a second filament made of polyester having a melting point of 185°C or less; Forming a web by mixing and laminating the first filament to have a content of 50 to 90 wt% and the second filament to have a content of 10 to 50 wt% using the blended yarn spun blended yarn; Manufacturing a nonwoven fabric by passing the web through a calender roll; And tufting the nonwoven fabric and treating it with a coating solution to prepare a carpet.

According to the present invention, by using a nonwoven fabric containing a polyester fiber having a low melting point as a base material and adjusting the thickness of the base material, it is possible to improve the pull-out strength of the carpet, thereby suppressing the fall of the BCF yarn from the carpet.

The nonwoven fabric for carpet base paper of the present invention may include 50 to 90% by weight of polyester filaments having a melting point of 255°C or higher and 10 to 50% by weight of polyester filaments having a melting point of 185°C or less.

In the manufacturing method of the nonwoven fabric for carpet base paper of the present invention, the first filament is spun by spinning a polyester filament having a melting point of 255°C or higher, and a polyester filament having a melting point of 185°C or lower is spun to spun the second filament, and It is possible to perform mixed fiber spinning (Matrix & Binder) in which the 1 filament and the second filament are mixed.

For the first filament, polyester with a melting point of 255℃ or higher is supplied to an extruder and melted, then discharged through the discharge hole of the spinneret and solidified with cooling air, and the spinning speed is 4,000 to 6,000 m/min using a high-pressure air stretching device. It can be stretched so that it has a fineness of 4 to 10 denier.

The second filament may be the same as the manufacture of the first filament, but may have a fineness of 1 to 5 denier.

In the present invention, if the fineness of the first filament is less than 4 denier, the fiber may be damaged during tufting and the ability to fix the BCF yarn may decrease. If it exceeds 10 denier, the coefficient of friction is lowered, thereby improving the pullout strength. It can be difficult.

In the present invention, when the fineness of the second filament is less than 1 denier, the filament becomes too thin and the strength is weak, and when it exceeds 5 denier, the spinnability is deteriorated due to cooling problems in the mixed fiber spinning process, thereby reducing the quality of the nonwoven fabric. can do.

Thereafter, the spun first and second filaments may be mixed and stacked on a conveyor net to be stacked in the form of a web.

Since the second filament has a melting point below the drying temperature of the carpet manufacturing process, it is possible to more firmly fix the tufted BCF yarn by melting in the carpet manufacturing process.

In this case, preferably, in the nonwoven web, the first filament may have a content of 50 to 90% by weight and the second filament may have a content of 10 to 50% by weight.

If the content of the second filament is less than 10% by weight, the improvement of the pull-out strength in the carpet is insignificant, and if it exceeds 50% by weight, the cooling of the second filament in the mixed fiber spinning process is insufficient to form a coarse filament. It causes quality problems such as defects (defects, filament agglomeration, roughness of the surface, etc.) and is not good economically.

Thereafter, the web may be passed through a calender roll device heated to 140 to 160° C. and a thermal bonding process to produce a nonwoven fabric with controlled filament bonding, smoothness, and thickness.

In the thermal bonding process, the fibers of the nonwoven web are melted and bonded by a hot air through method using an air flow of 170 to 190°C. In this case, due to a temperature higher than the melting point of the second filaments, the second filaments may be bonded to each other between the first filaments.

At this time, preferably, the thickness of the non-woven fabric is 0.33 to 0.46 mm, and if the thickness is less than 0.33 mm, the density of the non-woven fabric increases, making it difficult for the coating liquid to penetrate, so the pull-out strength of the carpet decreases, and if it exceeds 0.46 mm, the layer separation of the laminated web It is difficult to manufacture a nonwoven fabric completed with a single layer due to peeling.

As described above, the thickness of the present invention affects the density and formability by the thermal bonding function of the second filament in the nonwoven fabric including the first filament and the second filament. The density of the non-woven fabric may affect the ability of the coating crude to penetrate into the non-woven fabric and bond and fix it. Accordingly, as the thickness of the nonwoven fabric increases, the density decreases, and thus the permeability of the coating solution increases, thereby improving the fixing ability of the BCF yarn.

Hereinafter, the present invention will be described in more detail based on the following examples and comparative examples.

However, the following examples are for illustrative purposes only, and the present invention is not limited by the following examples, and can be substituted and equivalent to other examples within the scope not departing from the technical spirit of the present invention. It will be apparent to those of ordinary skill in the art to which the present invention pertains.

<Example 1>

Polyethylene terephthalate (PET) for fibers with a melting point of 260°C as the first filament and polyethylene terephthalate copolymer (Co-PET) for fibers with a melting point of 180°C as the second filament are melted at 288°C in each extruder. It was discharged through a capillary hole, and the discharged polyester was solidified using a cooling air and then stretched using a stretching device, followed by blend spinning so that the spinning speed was 5,000 m/min. At this time, the discharge amount and the number of capillaries of the spinneret were adjusted so that the fineness of the first filament was 7 denier, and the fineness of the second filament and the fineness was 3 denier.

The first and second filaments were mixed on a conveyor net, and laminated in the form of a web so that the contents of the first and second filaments were 80% by weight and 20% by weight. At the same time, the moving speed of the net was adjusted so that the basis weight was 90 gsm.

Thereafter, calendering was performed by passing through a heated calender roll, and a thermal bonding process of applying hot air of 180° C. was performed to produce a nonwoven fabric having a smoothness and a thickness of 0.36 mm.

The manufactured nonwoven fabric was tufted to have a single level loop with a pile height of 5 mm.

Thereafter, the tufted nonwoven fabric was thermally bonded by passing through a mangle roll to which a pressure of 1 kgf/cm 2 is applied together with a PVC crude liquid having a viscosity of 24,000 cP.

Thereafter, it was dried at a drying temperature of 180° C. to prepare a carpet.

<Examples 2 to 6>

In Example 1, a carpet was manufactured using the same method as in Example 1, except that the carpet was manufactured under the conditions of Table 1 below.

<Comparative Examples 1-6>

In Example 1, a carpet was manufactured using the same method as in Example 1, except that the carpet was manufactured under the conditions of Table 1 below.

The pull-out strength of the carpets prepared in Examples and Comparative Examples was measured in the following manner, and is shown in Table 1 below.

<Pull strength measurement test>

It is measured according to the standard of KS K ISO 4919 (Carpet-tuft pullout force measurement).

Fix one loop to be measured on the tufted sample to the measuring device. Cut both loops adjacent to the loop to be measured. Take the peak value that appears when the loop to be measured is pulled in the direction perpendicular to the sample using an Instron measuring device. Repeat this 5 times to take the average value. Three samples were prepared and evaluated repeatedly.

division Of the second filament
Melting point(℃) Of the second filament
Content (% by weight) After the non-woven fabric
(mm) Pulling strength
(kgf) Example 1 180 20 0.36 2.59 Example 2 180 15 0.36 2.30 Example 3 180 13 0.36 2.20 Example 4 180 11 0.36 2.06 Example 5 180 13 0.33 2.14 Example 6 180 13 0.40 2.31 Comparative Example 1 180 9 0.36 1.82 Comparative Example 2 180 60 0.44 - Comparative Example 3 190 11 0.36 1.98 Comparative Example 4 200 11 0.36 1.92 Comparative Example 5 180 13 0.30 1.83 Comparative Example 6 180 13 0.48 2.41 The second filament of Comparative Example 2 had poor spinnability, so the quality of the nonwoven fabric was lost.
Peeling occurred in the nonwoven fabric of Comparative Example 6

From the results of Table 1, it is confirmed that the carpet of the example according to the present invention has superior pull-out strength than the carpet of the comparative example.

In addition, from the results of Examples 5, 3, and 6, it is also confirmed that the higher the thickness of the nonwoven fabric, the better the pulling strength of the carpet.

As described above, since the pull-out strength of the carpet is improved according to the present invention, the removal of the BCF yarn from the carpet is suppressed, thereby improving the quality of the carpet.

Claims (7)

50 to 89% by weight of the first polyester filament having a melting point of 255°C or higher; And 11 to 50% by weight of the second polyester filament having a melting point of 185° C. or less,
Of loops from the carpet Non-woven fabric for carpet base paper with improved pull-out strength of 2.0~3.0kgf (KS K ISO 4919 method). The method of claim 1,
The non-woven fabric is a non-woven fabric for carpet base paper having improved pulling strength, characterized in that the thickness of the non-woven fabric is 0.33 ~ 0.46mm. The method of claim 1,
The first filament has a fineness of 4 to 10 denier, and the second filament has a fineness of 1 to 5 denier. The method of claim 1,
The nonwoven fabric is characterized in that the first filament and the second filament are thermally bonded by hot air by an air flow of 170 to 190°C. 50 to 89% by weight of the first polyester filament having a melting point of 255°C or higher; And 11 to 50% by weight of the second polyester filament having a melting point of 185° C. or less,
Loop of Carpet with pull-out strength of 2.0~3.0kgf (KS K ISO 4919 method). A blended spinning step of spinning and mixing a first filament made of polyester having a melting point of 255°C or higher, and a second filament made of polyester having a melting point of 185°C or less;
Forming a web by mixing and laminating the first filament to have a content of 50 to 89% by weight and 11 to 50% by weight of the second filament using the blended blended yarn;
Manufacturing a nonwoven fabric by passing the web through a calender roll; And
Including; tufting the non-woven fabric and treating it with a coating solution to prepare a carpet;
Loop of A method of manufacturing a carpet with a pull-out strength of 2.0~3.0kgf (KS K ISO 4919 method). The method of claim 6,
The non-woven fabric is characterized in that the first filament and the second filament are thermally bonded by hot air by an air current of 170 to 190°C.