EP3779014B1 - Non-woven fabric for primary carpet backing and manufacturing method thereof - Google Patents
Non-woven fabric for primary carpet backing and manufacturing method thereof Download PDFInfo
- Publication number
- EP3779014B1 EP3779014B1 EP19821953.7A EP19821953A EP3779014B1 EP 3779014 B1 EP3779014 B1 EP 3779014B1 EP 19821953 A EP19821953 A EP 19821953A EP 3779014 B1 EP3779014 B1 EP 3779014B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- filament
- web
- row
- carbon black
- surface layer
- 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.)
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- 239000004745 nonwoven fabric Substances 0.000 title claims description 57
- 238000004519 manufacturing process Methods 0.000 title claims description 27
- 239000006229 carbon black Substances 0.000 claims description 46
- 229920000728 polyester Polymers 0.000 claims description 42
- 238000002844 melting Methods 0.000 claims description 38
- 230000008018 melting Effects 0.000 claims description 38
- 239000002344 surface layer Substances 0.000 claims description 35
- 238000009987 spinning Methods 0.000 claims description 29
- 238000000034 method Methods 0.000 claims description 25
- 238000009732 tufting Methods 0.000 claims description 23
- 238000010030 laminating Methods 0.000 claims description 7
- 238000007599 discharging Methods 0.000 claims description 6
- 238000003490 calendering Methods 0.000 claims description 4
- 239000003086 colorant Substances 0.000 description 16
- 230000000052 comparative effect Effects 0.000 description 14
- WNLRTRBMVRJNCN-UHFFFAOYSA-N adipic acid Chemical compound OC(=O)CCCCC(O)=O WNLRTRBMVRJNCN-UHFFFAOYSA-N 0.000 description 10
- QQVIHTHCMHWDBS-UHFFFAOYSA-N isophthalic acid Chemical compound OC(=O)C1=CC=CC(C(O)=O)=C1 QQVIHTHCMHWDBS-UHFFFAOYSA-N 0.000 description 10
- 238000000465 moulding Methods 0.000 description 6
- 229920001634 Copolyester Polymers 0.000 description 5
- 235000011037 adipic acid Nutrition 0.000 description 5
- 239000001361 adipic acid Substances 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- -1 polyethylene terephthalate Polymers 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 230000007423 decrease Effects 0.000 description 3
- 239000010410 layer Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 description 3
- 239000005020 polyethylene terephthalate Substances 0.000 description 3
- 229920005989 resin Polymers 0.000 description 3
- 239000011347 resin Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 238000009413 insulation Methods 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 230000003373 anti-fouling effect Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 229920001577 copolymer Polymers 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 230000002950 deficient Effects 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920001707 polybutylene terephthalate Polymers 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000006116 polymerization reaction Methods 0.000 description 1
- 229920000417 polynaphthalene Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Classifications
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- 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
- D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
- D04H1/5418—Mixed fibres, e.g. at least two chemically different fibres or fibre blends
-
- 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
- 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
- D04H1/542—Adhesive fibres
- D04H1/55—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
- D04H1/559—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 the fibres being within layered webs
-
- 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
- D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
- D04H3/02—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments
-
- 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
- D04H3/153—Mixed yarns or filaments
-
- 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
- D04H3/16—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 filaments produced in association with filament formation, e.g. immediately following extrusion
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N7/00—Flexible sheet materials not otherwise provided for, e.g. textile threads, filaments, yarns or tow, glued on macromolecular material
- D06N7/0063—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf
- D06N7/0068—Floor covering on textile basis comprising a fibrous top layer being coated at the back with at least one polymer layer, e.g. carpets, rugs, synthetic turf characterised by the primary backing or the fibrous top layer
-
- 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
- D01F1/00—General methods for the manufacture of artificial filaments or the like
- D01F1/02—Addition of substances to the spinning solution or to the melt
- D01F1/04—Pigments
-
- 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
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2201/00—Chemical constitution of the fibres, threads or yarns
- D06N2201/02—Synthetic macromolecular fibres
-
- D—TEXTILES; PAPER
- D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
- D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
- D06N2211/00—Specially adapted uses
- D06N2211/06—Building materials
- D06N2211/066—Floor coverings
-
- 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
- D10B2503/042—Primary backings for tufted carpets
Definitions
- the present disclosure relates to a method for manufacturing a nonwoven fabric for primary carpet backing, which has different colors on the two sides thereof and improved mechanical property.
- Carpets form various colors and patterns and have a soft touch, and thus, are used not only for decorations showing aesthetic effects in hotels, offices, homes, automobiles, etc., but also for purposes such as comfortability, antifouling, and sound insulation.
- Carpets are made of carpet fabrics through a tufting process (process of introducing a BCF carpet yarn to a non-woven fabric) and a back coating process that fixes a carpet yarn and imparts shape stability (process of coating an auxiliary solution such as PVC, PE, EVA or SBR in various layer configurations on the back surface of tufted nonwoven fabric, and then curing it).
- the primary carpet backing is an important factor that influences the quality of the carpet as a support for the resin layer, which plays the role of determining the aesthetic appearance quality of the carpet, and the role of walking comfortableness, sound insulation, and heat-retaining property of the product.
- the physical and thermal external forces that the primary carpet backing receives in the entire carpet manufacturing process is high.
- a hole is drilled and damaged by a needle, and in the back coating process, it receives thermal external force through heating and cooling processes in a state in which the resin material is attached.
- the carpet primary backing since the carpet primary backing directly affects the defects of the product, the carpet primary backing must maintain the arrangement shape of the carpet yarns even when it is physically damaged, and there must be no shape deformation in a thermal environment.
- An object of the present disclosure is to provide a nonwoven fabric for primary carpet backing which is configured to have different colors on the two sides of the nonwoven fabric by spinning filaments having different carbon black content, and has excellent mechanical properties after tufting by bicomponent-spinning a low-melting-point copolyester.
- Another object of the present disclosure is to provide a method for manufacturing a nonwoven fabric for primary carpet backing which is configured to have different colors on the two sides of the nonwoven fabric by spinning filaments having different carbon black content, and has excellent mechanical properties after tufting by bicomponent-spinning a low-melting-point copolyester.
- a nonwoven fabric for primary carpet backing comprising: a first surface layer and a second surface layer, wherein the first surface layer and the second surface layer comprises a mixed filament yarn having a content ratio of a first filament including a first polyester having a melting point of 250°C or more and a carbon black, and a second filament including a second polyester having a melting point of 190°C or less of 95:5 to 85:15%, wherein the first filament constituting the first surface layer contains 0.07 to 0.15% by weight of carbon black, and the first filament constituting the second surface layer contains 0.37 to 0.5% by weight of carbon black, and wherein the total content of the carbon black in the first surface layer is 0.06 to 0.15% by weight, and the total content of the carbon black in the second surface layer is 0.3 to 0.5% by weight.
- a method for manufacturing a nonwoven fabric for primary carpet backing comprising the steps of: melting a first polyester having a melting point of 250°C or more containing 0.07 to 0.15% by weight of a carbon black for the first filament, and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, thereby preparing a mixed filament yarn for web of the first row; melting a first polyester having a melting point of 250°C or more containing 0.37 to 0.5% by weight of carbon black for the first filament and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by
- any one surface of the two surfaces of the nonwoven fabric appears in a range from white to gray and the opposite surface thereof appears in a range from dark gray to black, that is, it appears a relatively bright color on one surface and a dark color on the opposite surface, thereby providing a nonwoven fabric for primary carpet backing having a difference in colors of the two surfaces, and a method of manufacturing the same.
- a nonwoven fabric for primary carpet backing and a method of manufacturing the same can be provided in which any one surface of the two surfaces of the nonwoven fabric is selectively easily used in compliance with dark or light color of the carpet pile yarn, so that the separate manufacture of non-woven fabrics having various colors according to carpet colors is not required, which facilitates the inventory management of the non-woven fabric, achieves color matching between a carpet pile yarn and a nonwoven fabric for primary carpet backing, and improve the efficiency of the carpet manufacturing process.
- first or second may be used to describe various components, and such components are used only to distinguish one component from another.
- the first filament is formed of a polyester thermoplastic resin having a melting point of 250°C or more, or 255°C or more
- the second filament is formed of a copolyester thermoplastic resin having a melting point of 190°C or less, or 185°C or less, or 180°C or less.
- carbon black in the first filament, the color is adjusted in the nonwoven fabric.
- the first polyester which is the first filament component, is a general polyester having an intrinsic melting point of the resin without changing the melting point. If the melting point is 250°C or more, those for fibers manufactured by conventional manufacturing methods can be used without limitation, and for example, polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, and the like may be used.
- the first polyester which is the first filament component in the nonwoven fabric, plays a role in maintaining the shape of the desired manufacturing width by moderately stretching at a ratio similar to that of the back coating material, while having low heat shrinkage.
- the second polyester which is the second filament component
- the second polyester may be a low-melting-point polyester having a melting point of 190°C or less, for example, a polyester copolymerized with adipic acid, or a polyester copolymerized with isophthalic acid, or polyester copolymerized with adipic acid and isophthalic acid.
- the low-melting-point polyester is preferably a copolymer in which an additive such as adipic acid or isophthalic acid is mixed with the same type of polyester as the general polyester in the polymerization process, and the melting point is adjusted to 190°C or less.
- the low-melting-point polyester is melted in the thermal bonding step, and in the process of adhering general polyester fibers to each other, it can be easily bonded with general polyester, which is the same material, and therefore, it is effective in improving the adhesive strength, and improving the strength of the nonwoven fabric and reducing the shrinkage rate.
- the hot elongation of the nonwoven fabric decreases when molding at a general molding temperature, for example, 180°C or less, which may lead to problems of molding defects such as yarn rows, bursts, and wrinkles.
- the filament spinning is performed by dividing into a first row and a second row, and carbon black may be incorporated in the first filament to adjust the color of the nonwoven fabric.
- a step of preparing a mixed filament yarn for web of the first row can be performed by melting a first polyester having a melting point of 250°C or more containing 0.06 to 0.15% by weight, or 0.07 to 0.15% by weight of carbon black for the first filament and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, or 94:6 to 86:14% by weight.
- the color of the nonwoven web changes to white.
- the second filament is made of polyester having a melting point of 190°C or less, and is softened or melted by hot air in a thermal bonding process described later, thereby bonding the surrounding filaments and thus imparting strength and rigidity in the nonwoven fabric.
- the content ratio of the first filament to the second filament may be 95:5 to 85:15% by weight, or 94:6 to 86:14% by weight.
- the content ratio of the second filament is less than 5% by weight, the part of the nonwoven web that are not bonded between filaments due to hot air is increased, and thus, the shape of the nonwoven fabric is not formed. A uniform deformation is not achieved in the molding process after manufacture of the carpet, and thus, problems such as tearing may occur.
- the adhesive component content of the nonwoven fabric is excessive, so the nonwoven fabric becomes less elastic (brittle), and the damage to the filament during tufting may be increased, and the mechanical properties of the primary backing after tufting may be rapidly decreased.
- a step of preparing a mixed filament yarn for web of the second row can be performed by melting a first polyester having a melting point of 250°C or more containing carbon 0.3 to 0.5% by weight, or 0.37 to 0.5% by weight of black for the first filament and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, or 94:6 to 86:14% by weight.
- the content ratio of the first filament to the second filament may be 95:5 to 85:15% by weight, or 94:6 to 86:14% by weight.
- the content ratio of the second filament is less than 5% by weight, the part of the nonwoven web that are not bonded between filaments due to hot air is increased, and thus, the shape of the nonwoven fabric is not properly formed. And, a uniform deformation is not achieved in the molding process after manufacture of the carpet, and thus, problems such as tearing may occur.
- the adhesive component content of the nonwoven fabric is excessive, so the nonwoven fabric becomes less elastic (brittle), and the damage to the filament during tufting may be increased, and the mechanical properties of the primary backing after tufting may be rapidly decreased.
- the filament spun in the form of mixed filament yarn according to the present disclosure can be sufficiently drawn so that the spinning speed is 4,500 to 5,500 m/min using a high-pressure air drawing device, so that a filament having a fineness of usually 4 to 10 denier can be produced.
- a step of forming a web composed of a first surface layer and a second surface layer can be performed by laminating the mixed filament yarns for web of the first row in the form of a web on a conveyor net to form a web of the first row, and laminating a web of the second row with the mixed filament yarns for web of the second row thereon, so that the first row and the second row are laminated.
- a step of manufacturing the nonwoven fabric can be performed by subjecting the laminated web to a calendering process using a smooth roll and then thermally bonding the web with hot air.
- any one surface of the two surfaces may appear in a range of white to gray, and the opposite surface may appear in a range of dark gray to black.
- the value of the white index (WI) measured using the X-rite's Color-Eye 7000A device may be 5.3 to 17.0, or 5.5 to 16.5 for the first surface layer, and may be 4.0 to 5.2, or 4.2 to 5.2 for the second surface layer.
- relatively one surface can appear a light color and the opposite surface thereof can appear a dark color, and thus, it is possible to provide a nonwoven fabric for primary carpet backing having different colors on the two sides thereof.
- a reduction rate of the tensile strength before and after tufting may be 70% or less, or 68% or less.
- the reduction rate of the tensile strength before and after tufting is 70% or less, the shape stability is excellent, so it can fix BCF yarn and prevent damage and shape deformation of the nonwoven fabric due to tension between coating processes.
- the manufacture of the nonwoven fabric is carried out in a continuous process from spinning. And, by adjusting the content of the low-melting-point copolyester even while the colors of the two surfaces of the non-woven fabric are different, it is possible to provide a nonwoven fabric in which mechanical properties are not impaired by the tufting process.
- the bicomponent spinning was made such that the content ratio of the first filament and the second filament was 90:10 wt%, and the discharge amount and the number of spinning nozzles were adjusted so that the fineness of the mixed filament produced by drawing was 8 denier.
- the continuous filaments discharged from the spinning nozzle were solidified with a cooling air, and then drawn so that the spinning speed was 5,000 m/min using a high-pressure air drawing device.
- the mixed filament yarn for web of the first row was laminated on a conveyor net by a conventional opening method to form a web of the first row such that the content of the carbon black of the first row was 0.063 wt%, and a web of the second row was laminated with the mixed filament yarn for web of the second row thereon so that the content of carbon black of the second row was 0.45wt%, to thereby form a web in which the first surface layer by the first row and the second surface layer by the second row were laminated.
- the web thus laminated was subjected to a calendering process using a heated smooth roll to impart smoothness and appropriate thickness, and thermally bonded through hot air.
- a nonwoven fabric for primary carpet backing having a weight per unit area of 120 g/m2 was prepared by thermal bonding through hot air.
- Example 1 The nonwoven fabrics for primary carpet backing were manufactured in the same manner as in Example 1, except that in Example 1, the bicomponent-spinning ratio of the mixed filament yarn and the carbon black content in the first row and the second row are as shown in Table 1 below.
- Table 1 Category Content of first filament (wt%) Content of second filament (wt%) Content of carbon black of first row (wt%) Content of carbon black of second row (wt%) First filament First laminated web First filament Second laminated web
- Example 1 90 10 0.07 0.063 0.5 0.45
- Example 2 90 10 0.15 0.135 0.37 0.333
- Example 3 86 14 0.15 0.129 0.37 0.318
- Comparative Example 1 90 10 0.05 0.045 0.5 0.45 Comparative Example 2 90 10 0.07 0.063 0.6 0.54 Comparative Example 3 96 4 0.07 0.067 0.5 0.48 Comparative Example 4 80 20 0.07 0.056 0.4 0.4
- the tufting was performed under the conditions of a gauge (10 ea/inch) and a BCF yarn height (3mm) in a loop form.
- a specimen having a size of width ⁇ length 5 ⁇ 20 cm is clamped with a jig with a size of top/bottom 5 ⁇ 5 cm using Instron's testing equipment, and then measured at a tensile speed of 200 mm/min.
- the first surface layer appears in a range of white to gray
- the second surface layer appears in a dark gray to black range
- the first and second surface layers show different colors of relatively light and dark colors which are clearly contrasting, and thus, it is possible to select and use a surface appearing light or dark color in compliance with the final color of the carpet.
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- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Nonwoven Fabrics (AREA)
- Carpets (AREA)
Description
- The present disclosure relates to a method for manufacturing a nonwoven fabric for primary carpet backing, which has different colors on the two sides thereof and improved mechanical property.
- Carpets form various colors and patterns and have a soft touch, and thus, are used not only for decorations showing aesthetic effects in hotels, offices, homes, automobiles, etc., but also for purposes such as comfortability, antifouling, and sound insulation.
- Carpets are made of carpet fabrics through a tufting process (process of introducing a BCF carpet yarn to a non-woven fabric) and a back coating process that fixes a carpet yarn and imparts shape stability (process of coating an auxiliary solution such as PVC, PE, EVA or SBR in various layer configurations on the back surface of tufted nonwoven fabric, and then curing it).
- In the manufacture of carpets, the primary carpet backing is an important factor that influences the quality of the carpet as a support for the resin layer, which plays the role of determining the aesthetic appearance quality of the carpet, and the role of walking comfortableness, sound insulation, and heat-retaining property of the product.
- The physical and thermal external forces that the primary carpet backing receives in the entire carpet manufacturing process is high. In the tufting process, a hole is drilled and damaged by a needle, and in the back coating process, it receives thermal external force through heating and cooling processes in a state in which the resin material is attached.
- Therefore, since the carpet primary backing directly affects the defects of the product, the carpet primary backing must maintain the arrangement shape of the carpet yarns even when it is physically damaged, and there must be no shape deformation in a thermal environment.
- In addition, various colors of carpet yarns are applied in an attempt to differentiate from the existing carpet through improvement of aesthetic performance, and the primary backing visible between the carpet yarns also requires various colors according to the color of the carpet. Consequently, by adjusting the carbon black content of the polymer, products within a range from white to black are needed. Therefore, carpet manufacturers have problems that the primary backing should manage the inventory for each color depending on the carpet product.
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- (Patent Literature 1)
Korean Patent Registration No. 1778177 - (Patent Literature 2)
Korean Patent Application 2015/0113327 - An object of the present disclosure is to provide a nonwoven fabric for primary carpet backing which is configured to have different colors on the two sides of the nonwoven fabric by spinning filaments having different carbon black content, and has excellent mechanical properties after tufting by bicomponent-spinning a low-melting-point copolyester.
- Another object of the present disclosure is to provide a method for manufacturing a nonwoven fabric for primary carpet backing which is configured to have different colors on the two sides of the nonwoven fabric by spinning filaments having different carbon black content, and has excellent mechanical properties after tufting by bicomponent-spinning a low-melting-point copolyester.
- There is provided a nonwoven fabric for primary carpet backing, comprising: a first surface layer and a second surface layer, wherein the first surface layer and the second surface layer comprises a mixed filament yarn having a content ratio of a first filament including a first polyester having a melting point of 250°C or more and a carbon black, and a second filament including a second polyester having a melting point of 190°C or less of 95:5 to 85:15%, wherein the first filament constituting the first surface layer contains 0.07 to 0.15% by weight of carbon black, and the first filament constituting the second surface layer contains 0.37 to 0.5% by weight of carbon black,
and wherein the total content of the carbon black in the first surface layer is 0.06 to 0.15% by weight, and the total content of the carbon black in the second surface layer is 0.3 to 0.5% by weight. - There is also provided a method for manufacturing a nonwoven fabric for primary carpet backing, the method comprising the steps of: melting a first polyester having a melting point of 250°C or more containing 0.07 to 0.15% by weight of a carbon black for the first filament, and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, thereby preparing a mixed filament yarn for web of the first row; melting a first polyester having a melting point of 250°C or more containing 0.37 to 0.5% by weight of carbon black for the first filament and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, thereby preparing a mixed filament yarn for web of the second row; laminating the mixed filament yarns for web of the first row to form a web of the first row, and laminating a web of the second row with the mixed filament yarn for web of the second row thereon to form a web in which the first row and the second row are laminated; and subjecting the laminated web to a calendering process using a smooth roll and then thermally bonding the web with hot air to manufacture the nonwoven fabric, wherein the first filament constituting the first surface layer contains 0.07 to 0.15% by weight of carbon black, and the first filament constituting the second surface layer contains 0.37 to 0.5% by weight of carbon black,
wherein the web of the first row contains 0.06 to 0.15% by weight of the carbon black, and the web of the second row contains 0.3 to 0.5% by weight of the carbon black. - According to the present disclosure, any one surface of the two surfaces of the nonwoven fabric appears in a range from white to gray and the opposite surface thereof appears in a range from dark gray to black, that is, it appears a relatively bright color on one surface and a dark color on the opposite surface, thereby providing a nonwoven fabric for primary carpet backing having a difference in colors of the two surfaces, and a method of manufacturing the same.
- Specifically, a nonwoven fabric for primary carpet backing and a method of manufacturing the same can be provided in which any one surface of the two surfaces of the nonwoven fabric is selectively easily used in compliance with dark or light color of the carpet pile yarn, so that the separate manufacture of non-woven fabrics having various colors according to carpet colors is not required, which facilitates the inventory management of the non-woven fabric, achieves color matching between a carpet pile yarn and a nonwoven fabric for primary carpet backing, and improve the efficiency of the carpet manufacturing process.
- Further, even when an external force (physical or thermal) is applied in the carpet manufacturing process, shape deformation is small, and thus, it is possible to provide a nonwoven fabric for primary carpet backing having excellent mechanical properties and a method for manufacturing the same.
- In addition, by increasing the autonomous mobility of the filament through adjustment of the content of the low-melting-point copolyester, it is possible to provide a nonwoven fabric for primary carpet backing that reduces damage to filaments during tufting and prevents a reduction in strength of the nonwoven fabric or carpet, and a method for manufacturing the same.
- Hereinafter, a nonwoven fabric for primary carpet backing and a method of manufacturing the same according to a specific embodiment of the present disclosure will be described in more detail.
- Terms such as first or second may be used to describe various components, and such components are used only to distinguish one component from another.
- According to the present disclosure, in the two types of filaments constituting the nonwoven fabric, the first filament is formed of a polyester thermoplastic resin having a melting point of 250°C or more, or 255°C or more, and the second filament is formed of a copolyester thermoplastic resin having a melting point of 190°C or less, or 185°C or less, or 180°C or less. In particular, by incorporating carbon black in the first filament, the color is adjusted in the nonwoven fabric.
- The first polyester, which is the first filament component, is a general polyester having an intrinsic melting point of the resin without changing the melting point. If the melting point is 250°C or more, those for fibers manufactured by conventional manufacturing methods can be used without limitation, and for example, polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, and the like may be used.
- When a tensile force is applied under a high temperature environment at the time of processing the nonwoven fabric and molding the carpet, the first polyester, which is the first filament component in the nonwoven fabric, plays a role in maintaining the shape of the desired manufacturing width by moderately stretching at a ratio similar to that of the back coating material, while having low heat shrinkage.
- Meanwhile, the second polyester, which is the second filament component, may be a low-melting-point polyester having a melting point of 190°C or less, for example, a polyester copolymerized with adipic acid, or a polyester copolymerized with isophthalic acid, or polyester copolymerized with adipic acid and isophthalic acid.
- Further, the low-melting-point polyester is preferably a copolymer in which an additive such as adipic acid or isophthalic acid is mixed with the same type of polyester as the general polyester in the polymerization process, and the melting point is adjusted to 190°C or less. The low-melting-point polyester is melted in the thermal bonding step, and in the process of adhering general polyester fibers to each other, it can be easily bonded with general polyester, which is the same material, and therefore, it is effective in improving the adhesive strength, and improving the strength of the nonwoven fabric and reducing the shrinkage rate.
- At this time, if the melting point of the second polyester exceeds 190°C, the hot elongation of the nonwoven fabric decreases when molding at a general molding temperature, for example, 180°C or less, which may lead to problems of molding defects such as yarn rows, bursts, and wrinkles.
- Meanwhile, the filament spinning is performed by dividing into a first row and a second row, and carbon black may be incorporated in the first filament to adjust the color of the nonwoven fabric.
- At this time, by differently adjusting the carbon black content of the first filaments constituting the first row and the second row, a nonwoven web having different colors on the two sides thereof is formed due to a color difference between the web of the first row and the web of the second row.
- Hereinafter, a method of manufacturing a nonwoven fabric for primary carpet backing having different colors on the two sides thereof and improved mechanical properties according to the present disclosure will be described.
- A step of preparing a mixed filament yarn for web of the first row can be performed by melting a first polyester having a melting point of 250°C or more containing 0.06 to 0.15% by weight, or 0.07 to 0.15% by weight of carbon black for the first filament and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, or 94:6 to 86:14% by weight.
- At this time, as the content of carbon black in the first filament increases, the color of the nonwoven web becomes darker from white to black.
- Meanwhile, as the content of carbon black in the first filament decreases from less than 0.07% by weight, the color of the nonwoven web changes to white.
- In the present disclosure, the second filament is made of polyester having a melting point of 190°C or less, and is softened or melted by hot air in a thermal bonding process described later, thereby bonding the surrounding filaments and thus imparting strength and rigidity in the nonwoven fabric.
- Meanwhile, in the mixed filament yarn for web of the first row, the content ratio of the first filament to the second filament may be 95:5 to 85:15% by weight, or 94:6 to 86:14% by weight. At this time, when the content ratio of the second filament is less than 5% by weight, the part of the nonwoven web that are not bonded between filaments due to hot air is increased, and thus, the shape of the nonwoven fabric is not formed. A uniform deformation is not achieved in the molding process after manufacture of the carpet, and thus, problems such as tearing may occur.
- When the content ratio of the second filament exceeds 15% by weight, the adhesive component content of the nonwoven fabric is excessive, so the nonwoven fabric becomes less elastic (brittle), and the damage to the filament during tufting may be increased, and the mechanical properties of the primary backing after tufting may be rapidly decreased.
- Meanwhile, a step of preparing a mixed filament yarn for web of the second row can be performed by melting a first polyester having a melting point of 250°C or more containing carbon 0.3 to 0.5% by weight, or 0.37 to 0.5% by weight of black for the first filament and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, or 94:6 to 86:14% by weight.
- At this time, if the content of carbon black in the first filament exceeds 0.5% by weight, carbon black acts as a foreign substance and interferes with the formation of filaments, which can cause problems such as yarn breakage, whereby spinning may not be possible. In particular, in order to express a difference in color between the web of the first row and the web of the second row, there should be a difference in the content of carbon black contained in each row.
- Meanwhile, in the mixed filament yarn for web of the second row, the content ratio of the first filament to the second filament may be 95:5 to 85:15% by weight, or 94:6 to 86:14% by weight. At this time, when the content ratio of the second filament is less than 5% by weight, the part of the nonwoven web that are not bonded between filaments due to hot air is increased, and thus, the shape of the nonwoven fabric is not properly formed. And, a uniform deformation is not achieved in the molding process after manufacture of the carpet, and thus, problems such as tearing may occur. When the content ratio of the second filament exceeds 15% by weight, the adhesive component content of the nonwoven fabric is excessive, so the nonwoven fabric becomes less elastic (brittle), and the damage to the filament during tufting may be increased, and the mechanical properties of the primary backing after tufting may be rapidly decreased.
- The filament spun in the form of mixed filament yarn according to the present disclosure can be sufficiently drawn so that the spinning speed is 4,500 to 5,500 m/min using a high-pressure air drawing device, so that a filament having a fineness of usually 4 to 10 denier can be produced.
- Subsequently, a step of forming a web composed of a first surface layer and a second surface layer can be performed by laminating the mixed filament yarns for web of the first row in the form of a web on a conveyor net to form a web of the first row, and laminating a web of the second row with the mixed filament yarns for web of the second row thereon, so that the first row and the second row are laminated.
- Subsequently, a step of manufacturing the nonwoven fabric can be performed by subjecting the laminated web to a calendering process using a smooth roll and then thermally bonding the web with hot air.
- Meanwhile, as described above, in the nonwoven fabric for primary carpet backing, any one surface of the two surfaces may appear in a range of white to gray, and the opposite surface may appear in a range of dark gray to black.
- As an example, for a specimen having a minimum diameter of 40 mm or more, the value of the white index (WI) measured using the X-rite's Color-Eye 7000A device may be 5.3 to 17.0, or 5.5 to 16.5 for the first surface layer, and may be 4.0 to 5.2, or 4.2 to 5.2 for the second surface layer.
- In other words, relatively one surface can appear a light color and the opposite surface thereof can appear a dark color, and thus, it is possible to provide a nonwoven fabric for primary carpet backing having different colors on the two sides thereof.
- Further, in the nonwoven fabric for primary carpet backing, when tufting is performed to manufacture a carpet, a reduction rate of the tensile strength before and after tufting may be 70% or less, or 68% or less.
- At this time, the tensile strength can be measured after clamping a specimen having a size of width × length = 5 × 20 cm with a zig with a size of top/bottom 5 × 5 cm using the method of KS K 0521 as in the Experimental Example described later, and then measuring at a tensile speed of 200 mm/min.
- If the reduction rate of the tensile strength before and after tufting is 70% or less, the shape stability is excellent, so it can fix BCF yarn and prevent damage and shape deformation of the nonwoven fabric due to tension between coating processes.
- As described above, according to the present disclosure, by producing a mixed filament yarn of filaments having different melting points and containing carbon black and filaments that do not contain it, and a web laminating of two-layered structure having different carbon black content, the manufacture of the nonwoven fabric is carried out in a continuous process from spinning. And, by adjusting the content of the low-melting-point copolyester even while the colors of the two surfaces of the non-woven fabric are different, it is possible to provide a nonwoven fabric in which mechanical properties are not impaired by the tufting process.
- Hereinafter, the present disclosure will be described in more detail with reference to the following examples and comparative examples.
- However, the following examples are for illustrative purposes only, and the present disclosure is not limited thereby. It will be apparent to those of ordinary skill in the art that substitutions and other equivalent modifications can be made to the invention without departing from the technical spirit of the present disclosure.
- An extruded melt of polyethylene terephthalate having a melting point of 255°C which was obtained by side-feeding carbon black so that the content of carbon black was 0.07wt% to form the first filament, and an extruded melt of polyethylene terephthalate having a melting point of 180°C which was obtained by copolymerizing adipic acid and isophthalic acid to form a second filament, were respectively discharged through a spinning nozzle at the bottom of the continuous extruder, and bicomponent-spun to produce a mixed filament yarn for web of the first row.
- An extruded melt of polyester having a melting point of 255°C which is obtained by side-feeding carbon black so that the content of carbon black was 0.5wt% to form the first filament, and an extruded melt of polyester having a melting point of 180°C which was obtained by copolymerizing adipic acid and isophthalic acid to form a second filament, were respectively discharged through a spinning nozzle at the bottom of the continuous extruder, and bicomponent-spun to produce a mixed filament yarn for web of the second row.
- At this time, the bicomponent spinning was made such that the content ratio of the first filament and the second filament was 90:10 wt%, and the discharge amount and the number of spinning nozzles were adjusted so that the fineness of the mixed filament produced by drawing was 8 denier.
- Further, the continuous filaments discharged from the spinning nozzle were solidified with a cooling air, and then drawn so that the spinning speed was 5,000 m/min using a high-pressure air drawing device.
- Subsequently, the mixed filament yarn for web of the first row was laminated on a conveyor net by a conventional opening method to form a web of the first row such that the content of the carbon black of the first row was 0.063 wt%, and a web of the second row was laminated with the mixed filament yarn for web of the second row thereon so that the content of carbon black of the second row was 0.45wt%, to thereby form a web in which the first surface layer by the first row and the second surface layer by the second row were laminated.
- The web thus laminated was subjected to a calendering process using a heated smooth roll to impart smoothness and appropriate thickness, and thermally bonded through hot air. Thereby, a nonwoven fabric for primary carpet backing having a weight per unit area of 120 g/m2 was prepared by thermal bonding through hot air.
- The nonwoven fabrics for primary carpet backing were manufactured in the same manner as in Example 1, except that in Example 1, the bicomponent-spinning ratio of the mixed filament yarn and the carbon black content in the first row and the second row are as shown in Table 1 below.
[Table 1] Category Content of first filament (wt%) Content of second filament (wt%) Content of carbon black of first row (wt%) Content of carbon black of second row (wt%) First filament First laminated web First filament Second laminated web Example 1 90 10 0.07 0.063 0.5 0.45 Example 2 90 10 0.15 0.135 0.37 0.333 Example 3 86 14 0.15 0.129 0.37 0.318 Example 4 94 6 0.15 0.141 0.37 0.347 Comparative Example 1 90 10 0.05 0.045 0.5 0.45 Comparative Example 2 90 10 0.07 0.063 0.6 0.54 Comparative Example 3 96 4 0.07 0.067 0.5 0.48 Comparative Example 4 80 20 0.07 0.056 0.4 0.4 - The properties of the spunbond nonwoven fabric for primary carpet backing and the nonwoven fabric after tufting in the Examples and Comparative Examples were measured according to the following test method, and the results are shown in Table 2 below.
- At this time, the tufting was performed under the conditions of a gauge (10 ea/inch) and a BCF yarn height (3mm) in a loop form.
- The method of KS K 0521 was used.
- A specimen having a size of width × length = 5 × 20 cm is clamped with a jig with a size of top/bottom 5 × 5 cm using Instron's testing equipment, and then measured at a tensile speed of 200 mm/min.
- Measured using X-rite's Color-Eye 7000A device.
- For the evaluation specimen, a minimum diameter of 40 mm or more was used, and the average value was shown after measuring three times for each sample.
- As the numeral value of the measured value WI is higher, it means white.
[Table 2] Category Tensile strength MD/CD (Kg.f/5cm) Reduction rate of tensile strength after tufting MD/CD (%) Tensile elongation MD/CD (%) White Index (first surface layer/second surface layer) Final color (first surface layer/second surface layer) Remark Before tufting After tufting Example 1 27.2/28.4 11.4/13.1 58/54 56.6/58.1 16.4/4.2 Light gray/black Example 2 26.8/27.3 10.5/10.4 61/62 57.1/57.8 5.7/5.1 Gray/dark gray Example 3 29.5/30.1 9.4/10.2 68/66 51.3/52.8 5.8/5.2 Gray/dark gray Example 4 26.2/26.7 11.5/12.8 56/52 59.4/60.2 5.5/4.9 Gray/dark gray Comparative Example 1 27.6/28.4 13.2/13.1 52/54 57.4/58.3 18.3/4.4 White/black Comparative Example 2 - - - - - - Defective Comparative Example 3 17.5/19.5 8.6/9.9 51/49 56.9/58.2 16.4/4.3 Light gray/black Strength failure Comparative Example 4 31.4/33.1 9.1/8.3 71/75 38.6/39.7 16.5/4.3 Light gray/black Tufting failure - From the results of Table 2, it is confirmed that in the nonwoven fabric for primary carpet backing according to the present disclosure, the first surface layer appears in a range of white to gray, the second surface layer appears in a dark gray to black range, and the first and second surface layers show different colors of relatively light and dark colors which are clearly contrasting, and thus, it is possible to select and use a surface appearing light or dark color in compliance with the final color of the carpet.
- On the other hand, when the content of the second filament in the mixed filament yarn decreases (see Comparative Example 3), the tensile strength of the nonwoven fabric is lowered, and when the content of the second filament is increased (see Comparative Example 4), the reduction rate of tensile strength after tufting is increased, so that the physical properties after tufting are deteriorated.
- In addition, when the content of carbon black in the first filament is increased (see Comparative Example 2), it is confirmed that yarn breakage and clogging of the spinning nozzle occur and spinning is not performed properly, and thus, the nonwoven web is not formed.
Claims (4)
- A nonwoven fabric for primary carpet backing, comprising: a first surface layer and a second surface layer,wherein the first surface layer and the second surface layer comprises a mixed filament yarn having a content ratio of a first filament including a first polyester having a melting point of 250°C or more and a carbon black, and a second filament including a second polyester having a melting point of 190°C or less of 95:5 to 85:15%,wherein the first filament constituting the first surface layer contains 0.07 to 0.15% by weight of carbon black, and the first filament constituting the second surface layer contains 0.37 to 0.5% by weight of carbon black,
andwherein the total content of the carbon black in the first surface layer is 0.06 to 0.15% by weight, and the total content of the carbon black in the second surface layer is 0.3 to 0.5% by weight. - The nonwoven fabric for primary carpet backing according to claim 1, wherein a white index is 5.3 to 17.0 for the first surface layer, and 4.0 to 5.2 for the second surface layer, wherein the white index is measured according to the description.
- The nonwoven fabric for primary carpet backing according to claim 1, wherein in the case of tufting to manufacture a carpet, a reduction rate of tensile strength before and after tufting is 70% or less.
- A method for manufacturing a nonwoven fabric for primary carpet backing, the method comprising the steps of:melting a first polyester having a melting point of 250°C or more containing carbon black for the first filament and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, thereby preparing a mixed filament yarn for web of the first row;melting a first polyester having a melting point of 250°C or more containing carbon black for the first filament and a second polyester having a melting point of 190°C or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, thereby preparing a mixed filament yarn for web of the second row;laminating the mixed filament yarns for web of the first row to form a web of the first row, and laminating a web of the second row with the mixed filament yarn for web of the second row thereon to form a web in which the first row and the second row are laminated; andsubjecting the laminated web to calendering process using a smooth roll, and then thermally bonding the web with hot air to manufacture the nonwoven fabric,wherein the first filament constituting the first surface layer contains 0.07 to 0.15% by weight of carbon black, and the first filament constituting the second surface layer contains 0.37 to 0.5% by weight of carbon black,wherein the web of the first row contains 0.06 to 0.15% by weight of the carbon black, and the web of the second row contains 0.3 to 0.5% by weight of the carbon black.
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JPH0611945B2 (en) * | 1986-10-24 | 1994-02-16 | 東リ株式会社 | Conductive makeup sheet |
JP3567480B2 (en) * | 1993-05-26 | 2004-09-22 | チッソ株式会社 | Filter medium and method for producing the same |
DE69634749T2 (en) * | 1996-03-29 | 2006-01-12 | Toray Industries, Inc. | NONWOVENS FOR PLASED FILTER, AND METHOD FOR THE PRODUCTION THEREOF |
DE19934442C2 (en) * | 1999-07-26 | 2001-09-20 | Freudenberg Carl Fa | Process for producing a nonwoven and nonwoven for producing cleanroom protective clothing |
US7951452B2 (en) * | 2002-09-30 | 2011-05-31 | Kuraray Co., Ltd. | Suede artificial leather and production method thereof |
KR100847955B1 (en) * | 2005-02-04 | 2008-07-22 | 도레이 가부시끼가이샤 | Artificial suede-type leather and process for producing the same |
KR100742962B1 (en) * | 2005-11-16 | 2007-07-25 | 도레이새한 주식회사 | Polypropylene spunbond nonwoven fabric having multi-layer for mulching and manufacturing method thereof |
EP1985737A1 (en) * | 2007-04-27 | 2008-10-29 | Colbond B.V. | Process to manufacture tufted backing materials |
KR101802130B1 (en) * | 2011-12-30 | 2017-11-29 | 코오롱인더스트리 주식회사 | Method for Manufacturing Polyester Spunbond Nonwoven Fabric |
KR20150113327A (en) * | 2014-03-27 | 2015-10-08 | 코오롱인더스트리 주식회사 | Spunbonded Nonwoven for Primary Carpet Backing Having Higher Pile Yarn Holding Strength Property |
EP3020860A1 (en) * | 2014-11-11 | 2016-05-18 | Bonar B.V. | Primary Carpet Backing for Latex Free Tufted Carpets |
JP6370328B2 (en) * | 2016-04-11 | 2018-08-08 | ユニチカ株式会社 | Primary base fabric for tufted carpet and manufacturing method thereof |
KR102448619B1 (en) * | 2016-06-24 | 2022-09-27 | 코오롱인더스트리 주식회사 | Non-woven Fabric for Primary Carpet Backing in Carpet Preparing Process, and Method for Manufacturing the Same |
KR101905958B1 (en) * | 2016-06-30 | 2018-10-18 | 현대자동차주식회사 | Sound reduction material and manufacturing method thereof and a Carpet for vehicle using the same |
KR101778177B1 (en) | 2016-12-24 | 2017-09-14 | (주)세종씨엔더블유 | Double side different color nonwoven fabric of manufacturing method |
-
2018
- 2018-06-19 KR KR1020180070113A patent/KR102362231B1/en active IP Right Grant
-
2019
- 2019-06-11 JP JP2020565919A patent/JP2021524786A/en active Pending
- 2019-06-11 WO PCT/KR2019/007015 patent/WO2019245217A1/en unknown
- 2019-06-11 CN CN201980039394.2A patent/CN112262234A/en active Pending
- 2019-06-11 US US17/058,389 patent/US20210198821A1/en not_active Abandoned
- 2019-06-11 EP EP19821953.7A patent/EP3779014B1/en active Active
Also Published As
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KR102362231B9 (en) | 2023-05-11 |
KR102362231B1 (en) | 2022-02-10 |
EP3779014A1 (en) | 2021-02-17 |
US20210198821A1 (en) | 2021-07-01 |
CN112262234A (en) | 2021-01-22 |
WO2019245217A1 (en) | 2019-12-26 |
EP3779014A4 (en) | 2022-02-16 |
JP2021524786A (en) | 2021-09-16 |
KR20190142882A (en) | 2019-12-30 |
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