EP2761070A1 - Tissu non tissé de polyester et son procédé de fabrication - Google Patents

Tissu non tissé de polyester et son procédé de fabrication

Info

Publication number
EP2761070A1
EP2761070A1 EP20120834841 EP12834841A EP2761070A1 EP 2761070 A1 EP2761070 A1 EP 2761070A1 EP 20120834841 EP20120834841 EP 20120834841 EP 12834841 A EP12834841 A EP 12834841A EP 2761070 A1 EP2761070 A1 EP 2761070A1
Authority
EP
European Patent Office
Prior art keywords
nonwoven fabric
sheath
polyester
filament
component
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP20120834841
Other languages
German (de)
English (en)
Other versions
EP2761070B1 (fr
EP2761070A4 (fr
Inventor
Jin Whan Choi
Jin Il Kim
Min Ho Lee
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kolon Industries Inc
Original Assignee
Kolon Industries Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
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Application filed by Kolon Industries Inc filed Critical Kolon Industries Inc
Publication of EP2761070A1 publication Critical patent/EP2761070A1/fr
Publication of EP2761070A4 publication Critical patent/EP2761070A4/fr
Application granted granted Critical
Publication of EP2761070B1 publication Critical patent/EP2761070B1/fr
Revoked legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/58—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products
    • D01F6/62—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolycondensation products from polyesters
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
    • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
    • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/425—Cellulose series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/009—Condensation or reaction polymers
    • D04H3/011—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D04H3/147—Composite yarns or filaments
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
    • Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
    • Y10T442/608—Including strand or fiber material which is of specific structural definition
    • Y10T442/609—Cross-sectional configuration of strand or fiber material is specified

Definitions

  • the present invention relates to a polymer nonwoven fabric and a method for manufacturing the same, and more particularly, to a polyester nonwoven fabric which can be used as an useful primary backing substrate for a carpet since it exhibits good physical properties even after tufting process, and a method for manufacturing the same.
  • Carpets generally comprise a primary backing substrate and a face yarn.
  • the face yarn penetrates the primary backing substrate to form tufts projecting from one side, providing a pile surface, and stitches on an opposite side.
  • Carpets typically are made by tufting a face yarn through a primary backing substrate with reciprocating needles that carry the face yarn back and forth through the primary backing substrate to form tufts and stitches.
  • a polyester nonwoven fabric comprising polyester filaments is widely used as a primary backing substrate. During the tufting process, however, some filaments constituting the polyester nonwoven fabric are damaged by the reciprocating needle, which causes the deterioration of the physical properties such as strength, elongation, and tearing strength of the nonwoven fabric.
  • Korean Patent Application Laid-Open No. 1998-0061102 discloses a method for manufacturing a spunbond nonwoven fabric for a primary backing substrate for a carpet, the method comprising forming a web with two kinds of polyester polymers, needle-punching the web, and then passing the needle-punched web through a calendar roll.
  • the whole processes of this method is so complicated.
  • some filaments are damaged when the web is needle-punched, which makes the problem of the damages of the filaments after the tufting process more serious.
  • a nonwoven fabric produced by using such method as described above still has a problem of serious deterioration of the physical properties thereof after a tufting process, and thus it can hardly be used as a primary backing substrate for a carpet.
  • Korean Patent Application Laid-Open No. 2001-0053138 describes a method for manufacturing a primary backing substrate for a carpet, the method comprising conjugate spinning polyester and polyactic acid to form a shaped yarn.
  • the shaped yarn produced as such is likely to have lots of spinning defects caused by the bad spinnability.
  • the use of the expensive polyactic acid inevitably increases the whole cost for manufacturing the nonwoven fabric.
  • the present invention is directed to a polyester nonwoven fabric and a method for manufacturing the same capable of preventing problems due to such limitations and drawbacks of the related art as explained above.
  • An aspect of the present invention is to provide a polyester nonwoven fabric which can be used as an useful primary backing substrate for a carpet since it exhibits good physical properties even after tufting process.
  • Another aspect of the present invention is to provide a method for manufacturing a polyester nonwoven fabric which can be used as an useful primary backing substrate for a carpet since it exhibits good physical properties even after tufting process, through simple processes and at lower cost.
  • a polyester nonwoven fabric comprising: an one-component filament having a fineness of 4 to 10 denier; and a sheath-core type filament having a fineness of 4 to 10 denier, wherein the one-component filament comprises a first polyester polymerhaving a melting point of 250°C or higher, wherein the sheath-core type filament comprises the first polyester polymer of 70 to 95 wt% as a core component and a second polyester polymer of 5 to 30 wt% as a sheath component, and wherein a melting point of the second polyester polymer is lower than the melting point of the first polyester polymer by 20°C or more.
  • a method for manufacturing a polyester nonwoven fabric comprising: spinning a first polyester polymer to form an one-component filament; conjugate spinning the first polyester polymer and a second polyester polymer to form a sheath-core type filament, the first polyester polymer being a core component and the second polyester polymer being a sheath component; forming a web with the one-component filament and the sheath-core type filament; and heating the web so that the one-component filament and the sheath-core type filament can be bonded to each other.
  • a polyester nonwoven fabric of the present invention exhibits excellent physical properties such as tensile strength, elongation, tearing strength and so on even after a tufting process is performed thereon.
  • the polyester nonwoven fabric of the present invention can be used as an useful primary backing substrate for a carpet.
  • the filaments of a web can be bonded to each other by a simple process of heating the web.
  • it is not required to perform a needle punching process for web bonding.
  • the polyester nonwoven fabric of the present invention can be manufactured through simple process at lower cost.
  • a nonwoven fabric of the present invention comprises an one-component filament having a fineness of 4 to 10 denier and a sheath-core type filament having a fineness of 4 to 10 denier.
  • the one-component filament comprises a first polyester polymer having a melting point of 250°C or higher. It is formed by spinning a single dope including the first polyester polymer.
  • the sheath-core type filament comprises the first polyester polymer as a core component and a second polyester polymer as a sheath component. That is, the sheath-core type filament comprises, as a core component, the same polyester polymer as that of the one-component filament.
  • the second polyester polymer, a sheath component of the sheath-core type filament has a melting point lower than the melting point of the first polyester polymer by 20°C or more. That is, the core component of the sheath-core type filament has a melting point higher than that of the sheath component.
  • the sheath-core type filament of the nonwoven fabric of the present invention comprises the second polyester polymer having a relatively low melting point as a sheath component around the surface thereof, it can be easily bonded to the one-component filament when heated. Therefore, according to the present invention, the filaments can be easily bonded to each other, without a needle punching process performed, enabling the nonwoven fabric to be made through simple processes without any damages of the filaments which would be caused should the needle punching process be performed.
  • the polyester nonwoven fabric of the present invention further comprises the one-component filament in addition to the sheath-core filament, the movement of the filaments can be guaranteed in a certain degree when a tufting process to make a carpet is performed, and thus the damage of the filaments, if any, that might be caused by the reciprocating needle during the tufting process can be minimized.
  • the nonwoven fabric of the present invention is used to make a carpet, as compared to a nonwoven fabric having only sheath-core type filaments, the damage of the filaments that might be caused by the reciprocating needleduring the tufting process can be minimized, and the excellent physical properties such as tensile strength, tear strength and so on of the nonwoven fabric can be maintained after the tufting process.
  • the one-component filament and the sheath-core type filament of the nonwoven fabric of the present invention may have substantially identical fineness in the range of 4 to 10 denier.
  • a nonwoven fabric comprising a first polyester filament of a thick fineness having a relatively high melting point and a second polyester filament of a middle fineness (e.g., 3 to 5 denier) having a relatively low melting point and functioning as an adhesive is made through a spinning-and-mixing method, the nonwoven fabric made as such has relatively small pores.
  • the nonwoven fabric of the present invention comprising the one-component filament and sheath-core type filament both of which have substantially identical fineness has relatively large pores, which reduces the possibility that the filaments of the nonwoven fabric might be damaged during the tufting process.
  • the nonwoven fabric of the present invention is used to make a carpet, the deterioration of the physical properties of the nonwoven fabric, if any, can be remarkably reduced.
  • the nonwoven fabric of the present invention can be used as an useful primary backing substrate for a carpet since it exhibits good physical properties even after tufting process.
  • the polyester nonwoven fabric of the present invention comprises the sheath-core type filament in addition to the one-component filament.
  • the sheath-core type filament comprises two kinds of polyester polymers.
  • the melting point of the first polyester polymer forming the core component of the sheath-core type filament may be 250°C or more, preferably 250 to 280°C, and the melting point of the second polyester polymer forming the sheath component of the sheath-core type filament may be lower than that of the first polyester polymer by 20°C or more.
  • the melting point of the second polyester polymer is 180 to 230°C.
  • the melting point of the second polyester polymer is too low, heat contraction may occur while the primary backing substrate made from such nonwoven fabric is post-processed, and thus the dimensional stability of the primary backing substrate may be deteriorated.
  • the melting point of the second polyester polymer is too high, the heating temperature required to melt the sheath component of the sheath-core type filament to bond it to the adjacent filaments increases. If the heating temperature is too high, the physical properties such as tear strength of the nonwoven fabric, especially after the tufting process, is deteriorated.
  • a conventional polyester polymer having intrinsic viscosity (I.V.) of about 0.655 can be used as the first polyester polymer without any specific limitations.
  • polyethylene terephthalate or polynaphthalene terephthalate may be used as the first polyester polymer.
  • Various polyester polymers other than those also can be used as the first polyester polymer.
  • a copolymer having lower melting point than monomers thereof e.g., a copolymer of one of the aforementioned polyethylene terephthalate and polynaphthalene terephthalate and one of adipic acid and isophthalic acid, or a polymer originally having low melting point such as polybutylene terephthalate and polytrimethylene terephthalate can be used.
  • the ratio of the number of the one-component filament to the number of the sheath-core type filament in the polyester nonwoven fabric is 9:1 to 1:9.
  • the nonwoven fabric comprising them would have substantially same physical properties as those of the conventional nonwoven fabric which is formed of only sheath-core type filaments, and thus little improvement can be expected.
  • the heating temperature of the heating process to bond the filaments to each other needs to be increased so much that the physical properties of the nonwoven fabric such as tear strength, especially after the tufting process, is deteriorated.
  • the content of the first polyester polymer in the sheath-core type filament is 70 to 95 wt%, and the content of the second polyester polymer therein is 5 to 30 wt%.
  • the bonding power between the filaments would be so weak that it is difficult to make a nonwoven fabric of good physical properties for a primary backing substrate, and there would exist lots of processing limitations since the spinnability during the conjugate spinning process to form the sheath-core type filament would be bad. Further, there would be a problem of weak heat-bonding between the filaments since the content of the core component would be too high to be uniformly surrounded by the sheath component.
  • the content of the second polyester polymer be more than 30wt%, the bonding power between the filaments would be so strong that lots of the filaments are damaged during the tufting process and the physical properties of the nonwoven fabric after the tufting process is seriously deteriorated.
  • the content of the first polyester polymer which is the core component of the sheath-core type filament would be so low that the strength of the nonwoven fabric is deteriorated.
  • the polyester nonwoven fabric comprises the aforementioned filaments the fineness of which is adjusted into 4 to 10 denier and has substantially no filament the fineness of which is out of such range.
  • the fineness of the filament is less than 4 denier, the number of the filaments per unit area increases and the filaments intersects at so many points that lots of filaments might be damaged by the reciprocating needle during the tufting process thereby resulting in the deterioration of the physical properties of the nonwoven fabric.
  • the filaments of fineness of more than 10 denier makes it difficult to commercially manufacture an uniform nonwoven fabric.
  • the polyester nonwoven fabric may further comprise an oil coated on the surface of the nonwoven fabric at an amount of 0.2 to 2.0% by weight of the nonwoven fabric.
  • an oil e.g., polydimethylsiloxane, can be used.
  • the oil is an element to inhibit the friction between the filaments of the nonwoven fabric and the needle used for the tufting process thereby minimizing the damages of the filaments. If the content of the oil is less than 0.2wt%, there occurs much friction between the filaments and the needle during the tufting process causing the damages of the filaments. On the contrary, if the content of the oil is more than 2.0wt%, it would make the nonwoven fabric sticky, and the movement of the oil might be occur when the nonwoven fabric is stored long time.
  • the polyester nonwoven fabric as explained above may have the same weight per unit area as that of the convention primary backing substrate, i.e., 120g/m 2 , to have an appropriate physical property such as strength to be used as a primary backing substrate for a carpet.
  • the polyester nonwoven fabric as described above can be preferably used as a primary backing substrate for a carpet since its filaments are prevented from being damaged during a tufting process to carry a face yarn back and forth through it and thus it can exhibit good physical property even after the tufting process. Furthermore, the polyester nonwoven fabric can be easily made through simple processes at lower costs since its filaments are bonded to each other simply by heating it.
  • a method of the present invention for manufacturing a polyester nonwoven fabric comprises spinning a first polyester polymer to form an one-component filament, conjugate spinning the first polyester polymer and a second polyester polymer to form a sheath-core type filament, the first polyester polymer being a core component and the second polyester polymer being a sheath component, forming a web with the one-component filament and the sheath-core type filament, and heating the web so that the one-component filament and the sheath-core type filament can be bonded to each other.
  • a polyester nonwoven fabric can be made which exhibits good physical properties even after a tufting process.
  • the filaments of the nonwoven fabric can easily be bonded to each other simply by applying heat thereto, which makes it needless to perform any other additional process such as a needle punching process for web bonding.
  • the first and second polyester polymers are melted in their extruders respectively. Then, the first polyester polymer is spun to form an one-component filament, and the first and second polyester polymers are conjugate spun to form a sheath-core type filament.
  • the first polyester polymer forms the core component of the sheath-core type filament
  • the second polyester polymer forms the sheath component of the sheath-core type filament.
  • the spinning and conjugate spinning may be carried out with one spinneret simultaneously.
  • the spinning and conjugate spinning may be performed at a spinning velocity of 4,500 to 5,000 m/min.
  • the one-component filament and sheath-core type filament are elongated with a high-pressure air elongator such that the one-component filament and sheath-core type filament can have a fineness of 4 to 10 denier.
  • a polyester nonwoven fabric is prepared by forming a web with the one-component filament and sheath-core type filament through an opening process and heating the web to bond the filaments to each other.
  • a calendar roll or an emboss roll of high temperature and high pressure may be used as the heat source for bonding the filaments to each other, it is more desirable to use hot air.
  • the density of the filaments becomes too high due to the tenuity of the nonwoven fabric although the physical properties of the nonwoven fabric such as strength and elongation improves.
  • the high density of the filaments inhibits the movement of the filaments and thus makes the filaments damaged by the needle during the tufting process.
  • the filaments since the filaments are melted much especially at the part embossed by the roll, the filaments might be seriously damaged when the needle passes therethrough.
  • the polyester nonwoven fabric finally obtained as such the physical properties of which would be seriously deteriorated after the tufting process cannot be used as a primary backing substrate for a carpet.
  • the polyester nonwoven fabric finally obtained as such can have good initial physical properties and exhibit the good physical properties even after the tufting process.
  • a heat-setting apparatus e.g., a tenter, blowing out hot air
  • the temperature of the hot air may be controlled into the degree corresponding to the melting point of the second polyester polymer.
  • the filaments forming the web may be slightly pressed by means of a calendar roll of low temperature and low pressure to obtain a nonwoven fabric of uniform thickness.
  • the method for manufacturing a polyester nonwoven fabric may further comprise coating an oil on the surface of the web at an amount of 0.2 to 2.0% by weight of the coated web after the web is heated for bonding the filaments to each other.
  • the friction between the filaments of the nonwoven fabric and the needle used for the tufting process and the damages of the filaments, if any,that might occur during a tufting process may be further reduced.
  • the physical properties of the nonwoven fabric after the tufting process can be maintained better.
  • the polyester nonwoven fabric manufactured according to the present invention can be made good use of as a primary backing substrate for a carpet since it has good initial physical properties and can still exhibit the good physical properties after a tufting process.
  • a copolymer of adipic acid and polyethylene terephthalate [Co-PET(AA)/Melting Point: 210°C] and a polyethylene terephthalate polymer (PET/Melting Point: 255°C) were melted at 288°C in the continuous extruders respectively. Then, the PET was spun to form a one-component filament. At the same time, the PET and Co-PET(AA) were conjugate spun to form a sheath-core type filament.
  • the number of the holes of the spinneret and the injection amount therefrom were determined in such a way that the ratio of the number of the one-component filament to the number of the sheath-core type filament was 9:1 and the sheath-core type filament had 85 wt% of PET as a core component and 15 wt% of Co-PET(AA) as a sheath component.
  • the continuous filaments injected from the spinneret were solidified with the cooling air of 25°C and sufficiently elongated with high pressure air to have fineness of 10 denier at the spinning velocity of 5,000 m/min.
  • a conventional opening method was used to stack the filaments on a continuously moving metal net to form a web. Then, the web was heated by means of a hot air apparatus such that the filaments of the web were bonded to each other at the melting point of the Co-PET(AA). As a result, a polyester nonwoven fabric having a weight per unit area of 120 g/m 2 was obtained.
  • the nonwoven fabric prepared as above was treated with an oil.
  • the content of the oil in the nonwoven fabric treated as such was 1.0 wt%.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the contents of the PET and Co-PET(AA) in the sheath-core type filament were 95 wt% and 5 wt% respectively.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the contents of the PET and Co-PET(AA) in the sheath-core type filament were 70 wt% and 30 wt% respectively.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the sheath-core type filament had a copolymer of isophthalic acid and polyethylene terephthalate [Co-PET(IPA)/Melting Point: 208°C] instead of the Co-PET(AA) as the sheath component and the contents of the PET and Co-PET(IPA) in the sheath-core type filament were 85 wt% and 15 wt% respectively.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the sheath-core type filament had a polybutylene terephthalate polymer (PBT/Melting Point: 224°C) instead of the Co-PET(AA) as the sheath component and the contents of the PET and PBT in the sheath-core type filament were 85 wt% and 15 wt% respectively.
  • PBT/Melting Point: 224°C polybutylene terephthalate polymer
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the sheath-core type filament had a polytrimethylene terephthalate polymer (PTT/Melting Point: 221°C) instead of the Co-PET(AA) as the sheath component and the contents of the PET and PTT in the sheath-core type filament were 85 wt% and 15 wt% respectively.
  • PTT/Melting Point: 221°C polytrimethylene terephthalate polymer
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the one-component filament and sheath-core type filament had fineness of 4 denier.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the content of the oil in the nonwoven fabric was 0.2 wt%.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the ratio of the number of the one-component filament to the number of the sheath-core type filament was 1:9.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the one-component filament and sheath-core type filament had fineness of 3 denier.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the contents of the PET and Co-PET(AA) in the sheath-core type filament were 96 wt% and 4 wt% respectively.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the contents of the PET and Co-PET(AA) in the sheath-core type filament were 69 wt% and 31 wt% respectively.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the ratio of the number of the one-component filament to the number of the sheath-core type filament was 91:9.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the ratio of the number of the one-component filament to the number of the sheath-core type filament was 9:91.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that the nonwoven fabric was made without the one-component filament and included only the sheath-core type filament.
  • a polyester nonwoven fabric was made in the same manner as that of the Example 1 except that a PET filament of 10 denier and a Co-PET(AA) filament of 4 denier were respectively formed through a spinning-and-mixing method and the ratio of the weight of the PET filaments to that of the Co-PET(AA) filaments was 85:15.
  • PET represents polyethylene terephthalate
  • AA represents adipic acid
  • IPA represents isophthalic acid
  • PBT represents polybuthylene terephthalate
  • PTT represents polytrimethylene terephthalate.
  • the tensile strength, elongation, and tear strength of the polyester nonwoven fabrics manufactured in the Examples 1 to 9 and the Comparative Examples 1 to 7 were respectively measured before and after a tufting process in accordance with the following method, and the results of the measurements are shown Table 2 below.
  • KS K 0521 method was used to measure the tensile strength and elongation of the polyester nonwoven fabrics.
  • the tensile strength and elongation of a nonwoven fabric sample having a rectangular shape of 5cm ⁇ 20cm was measured by means of an INSTRON device at the tension speed of 200 mm/min while the sample was held by a 5cm ⁇ 5cm jig.
  • KS K 0536 method Single Tongue method was used to measure the tear strength of the polyester nonwoven fabrics.
  • the tear strength of a nonwoven fabric sample having a rectangular shape of 5cm ⁇ 20cm was measured by means of an INSTRON device at the tension speed of 300 mm/min after the sample was cut by 7cm at the center part thereof.
  • a tufting process was performed on each ofthe nonwoven fabrics by means of a tufting machine which was set up with 1/10 gauge. After the tufting process, the nonwoven fabrics were tested in accordance with the test methods described in Experiments 1 & 2 above.
  • the nonwoven fabrics of the Examples 1 to 9 have good tensile strength, elongation, and tear strength, and such good physical properties are maintained without any meaningful deterioration even after the tufting process.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

L'invention concerne un tissu non tissé de polyester qui peut être utilisé en tant que substrat de support primaire utile pour une moquette étant donné qu'il présente de bonnes propriétés physiques même après un procédé de touffetage, et un procédé de fabrication de ce tissu. Le tissu non tissé de polyester de la présente invention comprend un filament à un composant et un filament de type gaine-âme, les deux ayant une finesse de 4 à 10 deniers. Le filament à un composant comprend un premier polymère de polyester ayant un point de fusion de 250°C ou plus, le filament de type gaine-âme comprend le premier polymère de polyester de 70 à 95 % en poids comme composant âme et un second polymère de polyester de 5 à 30 % en poids comme composant gaine, et un point de fusion du second polymère de polyester est inférieur au point de fusion du premier polymère de polyester de 20°C ou plus.
EP12834841.4A 2011-09-30 2012-09-25 Tissu non tissé touffeté de polyester et son procédé de fabrication Revoked EP2761070B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
KR20110099700A KR20130035414A (ko) 2011-09-30 2011-09-30 폴리에스테르계 부직포 및 그 제조 방법
PCT/KR2012/007690 WO2013048077A1 (fr) 2011-09-30 2012-09-25 Tissu non tissé de polyester et son procédé de fabrication

Publications (3)

Publication Number Publication Date
EP2761070A1 true EP2761070A1 (fr) 2014-08-06
EP2761070A4 EP2761070A4 (fr) 2015-05-27
EP2761070B1 EP2761070B1 (fr) 2018-11-07

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EP12834841.4A Revoked EP2761070B1 (fr) 2011-09-30 2012-09-25 Tissu non tissé touffeté de polyester et son procédé de fabrication

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US (1) US20140154943A1 (fr)
EP (1) EP2761070B1 (fr)
KR (1) KR20130035414A (fr)
WO (1) WO2013048077A1 (fr)

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KR102036670B1 (ko) * 2013-05-21 2019-10-25 도레이첨단소재 주식회사 열성형이 가능한 폴리에스테르 부직포의 제조방법
KR102037496B1 (ko) * 2013-06-27 2019-10-28 코오롱인더스트리 주식회사 성형성이 우수한 카펫 기포지용 스펀본드 부직포 및 이의 제조방법
KR102031790B1 (ko) * 2013-12-24 2019-10-14 코오롱인더스트리 주식회사 열 성형성이 우수한 카펫 기포지용 스펀본드 부직포 및 이의 제조방법
KR102502868B1 (ko) * 2017-02-09 2023-02-23 도레이 카부시키가이샤 열접착성 심초형 복합 섬유 및 트리코트 편지
JP6671690B2 (ja) * 2017-04-19 2020-03-25 ユニチカ株式会社 繊維ボードの製造方法
KR102326009B1 (ko) * 2018-03-28 2021-11-11 코오롱인더스트리 주식회사 섬유유연제 함침성이 향상된 폴리에스테르 부직포의 제조방법
KR102362233B1 (ko) 2018-12-21 2022-02-10 코오롱인더스트리 주식회사 드라이어 시트용 부직포
KR102306736B1 (ko) * 2020-03-31 2021-09-29 코오롱인더스트리 주식회사 스펀본드 부직포 및 이를 이용한 타일카페트
CN113430722A (zh) * 2021-08-10 2021-09-24 扬州阿特兰新材料有限公司 便于直接成型加工的无纺布及其生产方法与用途
KR20230072287A (ko) * 2021-11-17 2023-05-24 코오롱인더스트리 주식회사 부직포, 그 제조방법, 그 제조장치 및 물품

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WO1997037071A1 (fr) * 1994-09-28 1997-10-09 Toray Industries, Inc. Textile non-tisse pour filtre plisse et procede de fabrication
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Publication number Publication date
KR20130035414A (ko) 2013-04-09
EP2761070B1 (fr) 2018-11-07
WO2013048077A1 (fr) 2013-04-04
EP2761070A4 (fr) 2015-05-27
US20140154943A1 (en) 2014-06-05

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