EP3476991A1 - Procédé de fabrication de tissu non tissé pour support de mousse de tapis - Google Patents
Procédé de fabrication de tissu non tissé pour support de mousse de tapis Download PDFInfo
- Publication number
- EP3476991A1 EP3476991A1 EP17887808.8A EP17887808A EP3476991A1 EP 3476991 A1 EP3476991 A1 EP 3476991A1 EP 17887808 A EP17887808 A EP 17887808A EP 3476991 A1 EP3476991 A1 EP 3476991A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- woven fabric
- carpet
- base cloth
- web
- filament
- 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
Links
- 239000004745 nonwoven fabric Substances 0.000 title claims abstract description 38
- 238000000034 method Methods 0.000 title claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 title description 3
- 239000006260 foam Substances 0.000 title 1
- 239000004744 fabric Substances 0.000 claims abstract description 26
- 238000004080 punching Methods 0.000 claims abstract description 18
- 238000009732 tufting Methods 0.000 claims abstract description 18
- 229920000728 polyester Polymers 0.000 claims abstract description 11
- 238000012545 processing Methods 0.000 claims abstract description 11
- 239000000835 fiber Substances 0.000 claims description 13
- 238000003490 calendering Methods 0.000 claims description 8
- 238000002788 crimping Methods 0.000 claims description 3
- 230000000052 comparative effect Effects 0.000 description 15
- 238000010438 heat treatment Methods 0.000 description 4
- 238000011156 evaluation Methods 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 description 3
- 239000005020 polyethylene terephthalate Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 238000009987 spinning Methods 0.000 description 2
- 229920001410 Microfiber Polymers 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- -1 Polyethylene terephthalate Polymers 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000003658 microfiber Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000003672 processing method Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
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
- 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
- D04H1/44—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling
- D04H1/46—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 the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
-
- 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
- D01D5/08—Melt spinning methods
- D01D5/088—Cooling filaments, threads or the like, leaving the spinnerettes
-
- 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
- D01D5/08—Melt spinning methods
- D01D5/098—Melt spinning methods with simultaneous stretching
-
- 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
- D01D5/22—Formation of filaments, threads, or the like with a crimped or curled structure; with a special structure to simulate wool
-
- 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
- D04H13/00—Other non-woven fabrics
-
- 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
- D04H3/10—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 yarns or filaments made mechanically
- D04H3/105—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 yarns or filaments made mechanically by needling
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
- D06C15/00—Calendering, pressing, ironing, glossing or glazing textile fabrics
- D06C15/02—Calendering, pressing, ironing, glossing or glazing textile fabrics between co-operating press or calender rolls
-
- D—TEXTILES; PAPER
- D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
- D10B2503/00—Domestic or personal
- D10B2503/04—Floor or wall coverings; Carpets
- D10B2503/041—Carpet backings
Definitions
- the present invention relates to a method of preparing non-woven fabric for base cloth of carpet, which has an improved fixability of BCF (bulked continuous filament) yarn inserted on a base cloth in a tufting process for manufacturing a carpet.
- BCF bulk continuous filament
- Carpets are used not only for decoration in hotels, offices, homes, cars, but also for providing amenity and sound insulation.
- the carpet fabric is manufactured through a process including a tufting step of introducing BCF yarn to a non-woven fabric and a back coating step of coating a solution such as PVC, PE, EVA or SBR, etc. the back side of the tufted non-woven fabric and curing.
- the carpet fabric is cut into squares (for example, 50 cm ⁇ 50 cm) to be used as tile carpets in hotels, offices, homes, etc., and molded in the form of a car floor to be used as a car floor mat.
- the function of the base cloth of carpet is to fix the BCF yarn.
- the base cloth is punctured by a needle to have open hole of at least 160,000 holes/m 2 .
- the base cloth must maintain the arrangement of the BCF yarns in even though such physical damage and have no deformation of the shape in the post-process at the high temperature environment.
- Recent trends in the tufting process are densification, diversification of pattern and the use of low denier BCF. For example, there is a tendency to increase the tufting density by using microfibers of BCF yarns, to make at least three BCF yarns at multilevel conditions, and to increase the movement of needles by using BCF yarns of various colors. Tufting becomes more difficult. Accordingly, the fixability of the BCF yarn in the non-woven fabric for base cloth has to be improved by increasing the coefficient of friction between the non-woven fabric and the BCF yarn so as to prevent the damage to the base cloth.
- conventional non-woven fabric for base cloth of carpet is produced by stretching and a thermal or chemical bonding of the filaments having potential stress. After that the residual stress of the filament is removed by heating in the post-processing for the manufacture of carpet, thereby exhibiting a high shrinkage ratio. Due to this, there is a problem that the shape of the final carpet product is deformed.
- the present invention provides a method of preparing non-woven fabric for base cloth of carpet, which has an increased fixability of BCF by improving a method of preparing non-woven fabric for base cloth of carpet.
- the present invention provides a method of preparing non-woven fabric for base cloth of carpet comprising: preparing stretched polyester filament fiber having circular cross section; forming a web by integrating the filament fiber in a web form, crimp processing and calendering it; and needle punching the web.
- the web with the stretched polyester filament is crimp processed and needle punched.
- the residual stress of the stretched polyester filament is eliminated and the formability is improved, and the fixability of the BCF yarn can be improved by interlacing polyester filament.
- the present invention relates to a method of preparing non-woven fabric for base cloth of carpet comprising: preparing stretched filament to form a web, crimp processing and calendering and needle punching the web.
- the present invention may use filament fibers having a circular cross section and a low fineness such as 4 to 7 deniers, which is produced by melting a polyester having a melting point of at least 250 °C, discharging it through a spinneret to form a filament and stretching the filament to a spinning speed of 4,500 to 5,000 m/min using an air stretching device of high pressure.
- the fineness when the fineness is less than 4 deniers, the damage of fibers occurs during tufting and the fixability of the BCF yarn may be deteriorated, and when the fineness is more than 7 deniers, the coefficient of friction may be lowered and it can be difficult to improve the pullout strength.
- the flexibility of the filament may be given by piling up the filament fibers on the conveyor in the form of a web and heating and crimp processing them.
- the crimp processing is a processing method of heat treatment of synthetic fiber filament to form a thin curvature, and the yarn becomes curl and flexible accordingly.
- the stretched filaments may be piled up on a conveyor net and at the same time, be treated at 100 to 150 °C for 30 to 60 seconds.
- the shrinkage rate of the filament is lowered and the shape stability can be improved. Further, since the filament constituting the non-woven fabric is provided with a crimp and has a high coefficient of friction, and finally the fixability of the BCF yarn can be improved.
- the number of crimps of the polyester filament fiber in the crimping process is preferably 20 to 40 /inch. At this time, if the number of crimps is less than 20 /inch, the contact points between the filaments are decreased and the strength and elongation of the non-woven fabric after calendering or needle punching are lowered, and the force to fix the BCF yarn after tufting is weakened. When the number of crimps exceeds 40 /inch, the contact points become too large and the filaments may be damaged due to excessive adhesion between the filaments during needle punching and the coefficient of friction of the non-woven fabric is too high, thus BCF yarn with a low fineness may be damaged when tufting.
- a non-woven fabric in which interlacing is formed between the filaments can be produced by passing crimp processed web through a calendering roll to adjust its thickness and needle punching it.
- the calendering of the present invention has a thickness of 0.35-0.50 mm by applying a predetermined temperature (130-150 °C) and pressure to reduce the thickness of the non-woven fabric. Accordingly, the density increases and the amount of filament for interlacing increases.
- the needle punch is performed in two steps.
- the first step pre-punching
- the second step main punching
- the filaments are interlaced entirely with a condition of 600 to 800 stroke rpm to produce a non-woven fabric for base cloth of carpet.
- the potential stress of the amorphous region oriented in the stretched filament is eliminated by the crimp processing.
- the shrinkage rate is reduced due to heat and the curvature is formed to increase the interlacing point of the filament.
- increased tensile strength and tear tension of the non-woven fabric may exhibit in the needle punching process.
- PET Polyethylene terephthalate
- the crimp processing was performed such that the filament fiber was piled up on a conveyor net in form of a web and simultaneously the stacked filament was heated at 130 °C for 60 seconds to form a crimp number as shown in the following Table 1.
- the calendering was carried out by passing through a heated calendering roll to have smoothness and appropriate thickness to the non-woven fabric.
- a non-woven fabric for base cloth of carpet was prepared by the same method as the Example 1, except that crimp processing and needle punching were carried out in the conditions shown in Table 1 in the Example 1.
- a non-woven fabric for base cloth of carpet was prepared by the same method as the Example 1, except that crimp processing and needle punching were carried out in the conditions shown in Table 1 in the Example 1.
- Example 1 20 350 700
- Example 2 30 350
- Example 3 40 350
- Example 4 30 350
- 800 Comparative Example 1 15 350
- Comparative Example 2 30 350 500 Comparative Example 3 50 350 700 Comparative Example 4 30 350 350 900
- KS K 0521 method was used.
- the non-woven fabric is preheated at 180 °C for 3 minutes in a preheating plate and the molding is performed using a square mold having a size of 20 cm x 20 cm with the engraved lower plate and the embossed upper plate.
- the number of lattice patterns at the torn portion in the non-woven fabric was counted to obtain the width of the torn portion.
- Loft type tufting is performed at a speed of 800 rpm under the condition of 10 needles per inch in the width direction and 13 needles per inch in the length direction when tufting. After tufting, one adjacent loop to the loop to be measured is cut off and a loop with 10 loops apart on the opposite side is cut off. An average of 10 intensity peaks appearing when the loops to be measured are pulled in a direction perpendicular to that of the non-woven fabric using an Instron is calculated. The number of specimens is three.
- the non-woven fabric according to the present invention is improved in formability and pullout strength in the process of preparing a carpet, thereby contributing the improvement of productivity and quality of the carpet.
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Nonwoven Fabrics (AREA)
- Carpets (AREA)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
KR1020160179842A KR20180075905A (ko) | 2016-12-27 | 2016-12-27 | 카펫 기포지용 부직포의 제조방법 |
PCT/KR2017/014819 WO2018124566A1 (fr) | 2016-12-27 | 2017-12-15 | Procédé de fabrication de tissu non tissé pour support de mousse de tapis |
Publications (3)
Publication Number | Publication Date |
---|---|
EP3476991A1 true EP3476991A1 (fr) | 2019-05-01 |
EP3476991A4 EP3476991A4 (fr) | 2020-03-11 |
EP3476991B1 EP3476991B1 (fr) | 2021-04-14 |
Family
ID=62709960
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP17887808.8A Active EP3476991B1 (fr) | 2016-12-27 | 2017-12-15 | Procédé de fabrication de tissu non tissé pour support de mousse de tapis |
Country Status (6)
Country | Link |
---|---|
US (1) | US20190186061A1 (fr) |
EP (1) | EP3476991B1 (fr) |
JP (1) | JP6792695B2 (fr) |
KR (1) | KR20180075905A (fr) |
CN (1) | CN109563663B (fr) |
WO (1) | WO2018124566A1 (fr) |
Family Cites Families (19)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPH07142155A (ja) * | 1993-11-19 | 1995-06-02 | Akira Kitahara | 不織布を用いた電気暖房具の製造方法とそれに関わる 器具 |
WO1995019465A1 (fr) * | 1994-01-14 | 1995-07-20 | Danaklon A/S | Fibres de polyolefines hydrophobes, cardables, contenant des apprets de filage cationiques |
CN1156487A (zh) * | 1994-08-31 | 1997-08-06 | 纳幕尔杜邦公司 | 潮湿稳定的簇绒带地毯 |
KR100212752B1 (ko) * | 1995-11-29 | 1999-08-02 | 정몽규 | 섬유웹 형성판재 및 그의 제조방법 |
JP4034520B2 (ja) * | 2001-02-09 | 2008-01-16 | 日本バイリーン株式会社 | 伸縮性不織布及びその製造方法 |
JP2003293255A (ja) * | 2002-02-04 | 2003-10-15 | Asahi Kasei Corp | ニードルパンチ不織布 |
US20040097154A1 (en) * | 2002-11-19 | 2004-05-20 | Vishal Bansal | Multi-layer mechanically needed spunbond fabric and process for making |
JP2005029052A (ja) * | 2003-07-08 | 2005-02-03 | Japan Vilene Co Ltd | 自動車フロアマット用裏材及び自動車フロアマット |
JP4114681B2 (ja) * | 2005-06-10 | 2008-07-09 | 東レ株式会社 | 長繊維不織布およびタフテッドカーペット用基布およびタフテッドカーペット |
US20070298208A1 (en) * | 2006-06-27 | 2007-12-27 | Aseere Lester M | Process of preparing carpet backing using nonwoven material |
CN100485121C (zh) * | 2007-04-24 | 2009-05-06 | 江苏中联地毯有限公司 | 复合粘合可成型汽车地毯及其制造方法 |
JP4968840B2 (ja) * | 2007-09-18 | 2012-07-04 | 住江織物株式会社 | カーペット用セカンド基布及びその製造方法 |
JP2010007190A (ja) * | 2008-06-25 | 2010-01-14 | Fuji Corp | 滑り止めマット裏面材とその製造法 |
JP5712465B2 (ja) * | 2009-04-24 | 2015-05-07 | Jnc株式会社 | 生分解性不織布およびそれを用いた繊維製品 |
KR101035110B1 (ko) * | 2010-07-26 | 2011-05-19 | 송욱 | 혼방 부직포의 제조 방법 및 시스템 |
JP6172902B2 (ja) * | 2012-08-20 | 2017-08-02 | クラレクラフレックス株式会社 | 高消臭機能を有する不織布シート |
KR101976119B1 (ko) * | 2013-09-27 | 2019-05-07 | 코오롱인더스트리 주식회사 | 터프팅성이 우수한 카페트 기포지용 스펀본드 부직포의 제조방법 |
CN105818526B (zh) * | 2016-03-31 | 2017-08-25 | 上海特安纶纤维有限公司 | 高寿命低收缩热转移印花毛毯及其制备方法 |
CN106222884A (zh) * | 2016-08-29 | 2016-12-14 | 山东胜伟园林科技有限公司 | 一种阻燃无纺布材料及其制备方法 |
-
2016
- 2016-12-27 KR KR1020160179842A patent/KR20180075905A/ko not_active Application Discontinuation
-
2017
- 2017-12-15 JP JP2019501970A patent/JP6792695B2/ja active Active
- 2017-12-15 EP EP17887808.8A patent/EP3476991B1/fr active Active
- 2017-12-15 WO PCT/KR2017/014819 patent/WO2018124566A1/fr unknown
- 2017-12-15 US US16/323,284 patent/US20190186061A1/en not_active Abandoned
- 2017-12-15 CN CN201780047606.2A patent/CN109563663B/zh active Active
Also Published As
Publication number | Publication date |
---|---|
JP2019527098A (ja) | 2019-09-26 |
JP6792695B2 (ja) | 2020-11-25 |
EP3476991A4 (fr) | 2020-03-11 |
US20190186061A1 (en) | 2019-06-20 |
CN109563663B (zh) | 2021-08-24 |
WO2018124566A1 (fr) | 2018-07-05 |
EP3476991B1 (fr) | 2021-04-14 |
KR20180075905A (ko) | 2018-07-05 |
CN109563663A (zh) | 2019-04-02 |
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