KR100955341B1 - Method for manufacturing synthetic fiber for substitute of non-woven fabric - Google Patents

Abstract

PURPOSE: A manufacturing method of synthetic fiber in place of non-woven fabric is provided to form fiber in place of the non-woven fabric by lowering elongation to a proper point, and to increase shrinkage rates of the fibers. CONSTITUTION: A manufacturing method of synthetic fiber in place of non-woven fabric comprises the following steps: forming fabric in place of the non-woven fabric by using polyester raw yarns(S110); napping the fabric(S120); dyeing the fabric with dye(S130); releasing braiding of fabric after dehydrating the fabric(S140); napping the fabric(S150); dropping elongation of fabric by impregnating the fabric in liquid in which a retardant and a resin finishing agent are mixed(S160); drying the fabric; and adding texture of the non-woven fabric on the fabric(S170).

Description

Method for manufacturing synthetic fiber for substitute of non-woven fabric

The present invention relates to a method for producing synthetic fibers instead of nonwovens, and more particularly, to a method for manufacturing synthetic fibers that can replace nonwovens.

In general, a main fabric and a separate Nylex fabric are wrapped around the bottom of the seat of the vehicle. However, the lower end of the sheet corresponds to an unexposed portion that is not exposed to the outside, and the cost of the Nilex fabric is not cheap.

In order to solve this problem, in recent years, the non-woven fabric cheaper than the Nilex fabric is replacing the role, but such a non-woven fabric also has a disadvantage in that the cost occurs.

An object of the present invention is to provide a method for producing a synthetic fiber substitute for a nonwoven fabric which can replace the nonwoven fabric and has excellent quality and low cost.

The present invention, the step of forming a fabric for replacing the nonwoven fabric using a polyester yarn, the first step of napping the fabric, dyeing the fabric with a dye, dewatering the fabric and the The step of releasing the twist, the second step of raising the fabric, and impregnating the fabric in a solution mixed with a flame retardant and a resin treatment agent as the post-treatment of the fabric, flame retardant treatment of the fabric and elongation of the fabric It provides a method of manufacturing synthetic fibers for non-woven fabrics, including the step of dropping, and applying heat to the fabric and drying to increase the shrinkage of the fabric to increase the tear strength and to implement the texture of the nonwoven fabric.

Here, the resin treatment agent may be PVA (Polyvinyl Acetate) resin. In addition, the flame retardant may be a permanent flame retardant for polyester of the cyclic phosphonate ester (cyclic phosphonate ester).

In addition, the step of applying heat to the fabric and drying, it is carried out while passing the fabric in the chamber, by adjusting the passing rate of the fabric, the heating temperature and the Over Feed (over feed) value to stabilize the elongation of the fabric High tear strength of nonwovens can be achieved.

Here, the drying temperature is in the range of 183 ℃ ~ 187 ℃, the passing rate is in the range of 10m / min ~ 12m / min, the overfeed value may be in the range of 28% to 32%.

And, forming the fabric for substituting the nonwoven fabric, the step of forming and fabricating the polyester yarn by the diameter of the yarn, the step of refining the fabric, and dewatering the refined fabric and twisting the fabric It may include the step of releasing.

According to the method for manufacturing nonwoven fabric substitute synthetic fibers according to the present invention, the material and the touch of the nonwoven fabric through a plurality of brushing treatment, increase the shrinkage of the fabric according to the use of the resin treatment agent and drop the elongation to an appropriate level nonwoven fabric substitute fabric To form the base of, and does not cause damage to the fabric during the manufacturing process, there is an advantage that can reduce the unit cost of the product and improve the productivity. In addition, by improving the frosting of the dye through the heat treatment of the fabric and at the same time to increase the shrinkage of the fabric and stabilize the elongation, there is an advantage that can be manufactured non-woven fabric instead of synthetic fibers having a high density per unit area and excellent tear strength.

1 is a flow chart of a nonwoven fabric synthetic fiber manufacturing method according to an embodiment of the present invention. Hereinafter, with reference to Figure 1 will be described in detail with respect to the nonwoven fabric substitute synthetic fiber manufacturing method.

First, using a polyester yarn to form a fabric for replacing the nonwoven fabric (S110). 75 polyester (75D) thickness of the polyester yarn may be used, but the thickness used is not necessarily limited thereto.

Forming the fabric (S110) may be subdivided as follows. Prepare a polyester yarn (ex, 75 daa thick), and wound up to the diameter (S110a). Then, the knitted polyester yarn is woven through a knitting machine to form the fabric (S110b).

Thereafter, the fabric is refined (S110c). This refining is to remove impurities inherently contained in the polyester yarn and to remove dust, oil, and the like adhered during the cutting process.

Then, the water is removed by dewatering the refined fabric, and by using a Skacher (Scutcher) to release the twist of the fabric unfolds the fabric in the same direction (S110d).

Thereafter, the fabric is subjected to the first raising (S120). The brushing treatment is intended to express the texture and the material of the nonwoven fabric by linting the surface of the fabric. The brushing treatment can be used a variety of well-known brushing device, such as a needle bed brushing machine. In addition, the degree of fluff can be adjusted differently according to the speed of the roller used during the brushing brush treatment. This first brushing treatment may be repeated several times (ex, twice) for the fabric.

Thereafter, the fabric is stretched out taut using a tenter. During this process, the appearance inspection for contamination and wrinkles of the fabric and the effective width and density of the fabric are checked. The work using the tenter is to facilitate the dyeing process for the fabric later.

When the napping treatment for the fabric is completed, the fabric is dyed with a dye of a desired color (S130). The dye is prepared by mixing a dye, glacial acetic acid, and a dispersant. As the ratio of the dye, glacial acetic acid, and dispersant is 100% by weight of the fabric, 6.30% by weight, 0.30% by weight, and 1.00% by weight may be used in comparison thereto. After this dyeing process is completed, the washing process may be performed several times (ex, twice).

Next, dehydrate the fabric and release the twist of the fabric (S140). Since this is the same as the method used in the step S110d above, a detailed description thereof will be omitted.

Then, the fabric is subjected to the second raising (S150). The second raising can be performed in the same manner as the first raising. This second brushing treatment is performed as a second brushing treatment after the dyeing process, thereby more revealing the nonwoven fabric texture of the fabric surface, and more effectively implement the texture and material of the nonwoven fabric. The second brushing treatment may also be repeated several times (ex, twice) for the fabric.

Thereafter, the fabric is post-treated by impregnating the fabric in a solution in which a flame retardant and a resin treatment agent are mixed (S160). The flame retardant is for use in flame retardant treatment of the fabric for flame retardant processing. Such flame retardants may be used a permanent flame retardant for polyester of a cyclic phosphonate ester-based to suit the yarn material used above. For example, the flame retardant may be a phosphorus flame retardant or the like.

In addition, the resin treatment agent is to reduce the elongation of the fabric, increase the density and improve the hardness, and serves to prevent the phenomenon of the fabric to burst or tear during the manufacturing process. In addition, the resin treatment agent serves to hold the shape of the fabric and at the same time drop the elongation to form a shape base (base) of the fabric to be produced as a fabric for replacing the nonwoven fabric.

Here, the resin treatment agent may be PVA (Polyvinyl Acetate; polyvinyl acetate) resin. In addition, the mixed solution means a mixed solution of water, a flame retardant, and a resin treatment agent. For example, the water: flame retardant: resin treatment agent may be mixed in a ratio (weight ratio) of 100: 25: 20.

After that, the fabric is heated and dried (S170). As heat is applied to the fabric, dyeing of the fabric is increased and at the same time, the shrinkage (shrinkage) of the fabric is increased. Here, the higher the axial rate, the higher the density per unit area, thereby improving the tear strength and the bark strength of the fabric. In general, since the tear strength of the nonwoven fabric is excellent, the above fabric manufactured as a substitute for the nonwoven fabric should also satisfy the excellent tear strength. In addition, the texture of the nonwoven fabric is finally realized as the elongation of the fabric is increased and the elongation is lowered and stabilized. That is, the step S160 ~ S170, the step of dropping and stabilizing the elongation of the fabric close to the elongation range of the nonwoven fabric.

In step S170, the fabric is heated by applying heat to the fabric in the chamber while passing the fabric in the chamber. In addition, when adjusting the passage speed, the heating temperature and the over feed value of the fabric, it is possible to express the nonwoven fabric with a desired soft texture by changing the elongation of the fabric.

For example, if the elongation of the fabric is excessively dropped by the passage speed of the fabric and the heating temperature conditions in step S170, the stiffness characteristic of the fabric may be increased to reduce the softness. In this case, when the overfeed value is increased, the elongation can be increased, thereby realizing a soft texture such as the nonwoven fabric. Here, since the overfeed value is obvious to those skilled in the art, a detailed description thereof will be omitted. In addition, the effects on the fabric during the adjustment of the overfeed value will be described later.

The drying temperature is used in the range of 183 ℃ ~ 187 ℃. This range narrowly limits the temperature range in order to maintain a stable drying temperature range. For example, in the temperature range of 183 ℃ or less, especially at a temperature of less than 173 ℃ 10 ℃ lower than that due to undried dyeing falls, the flame retardant is not properly dried, whitening phenomenon occurs, the fabric in the final process There is a disadvantage that the winding is not performed properly. In addition, in the temperature range of 187 ℃ or more, especially at a temperature of 192 ℃ higher than 15 ℃ higher than the light resistance due to the destruction of the dye, there is a disadvantage that hardening occurs.

The passing speed is used in the range of 10m / min ~ 12m / min, especially when the passing speed is 8 / min (6) or less has the disadvantage of increasing the risk of discoloration and defects, and more than 18 / min (16) Due to the drying of the dye fall off, the flame retardant is not dried, whitening occurs, there is a disadvantage that the winding of the fabric is not performed properly in the completion process.

In addition, the overfeed value is used in the range of 28% to 32%, when the overfeed value is 28% or less, wrinkles may occur, the elongation may decrease, the fabric may be thinner, and the tear strength may be lowered. This excessive increase in fabric costs can lead to higher costs.

Table 1 shows a comparative example of the nonwoven fabric substitute synthetic resin fabric prepared by the above method, and the conventional Nilex fabric, its drying temperature, passing speed and overfeed value during the drying process of the fabric.

division Nonwoven Substitute Fabric Conventional Nilex Fabric compare Drying temperature 185 ℃ 180 ℃ 5 ℃ ↑ Passing speed 11m / min 21m / min 10 m / min ↓ Overfeed 100 90 10 ↑

The drying temperature used for the nonwoven fabric substitute fabric in S170 used a higher temperature than in the case of the conventional Nilex fabric, it can further increase the dyeing and shrinkage of the fabric. In addition, the pass rate used for the nonwoven fabric substitute fabric used a lower pass rate than in the case of the conventional Nilex fabric, thereby increasing the time to receive heat per unit area to increase the texture of the fabric to a desired level.

On the other hand, when the overfeed value is increased, the elongation of the fabric is increased and the softness of the fabric is emphasized. Normally the overfeed value is expressed in percentage (%), but it should be understood that in the case of Table 1 the actual gauge reading is omitted from the unit on the chamber. Here, the overfeed value used for the non-woven fabric substitute fabric is set to a slightly higher value than that of the conventional Nilex fabric, so that the elongation of the fabric during the step S170 is excessive. It will not fall, stabilize the elongation of the fabric and increase the axial rate to improve the tear strength. This is because non-woven fabrics generally exhibit higher tear strength than Nilex fabrics.

FIG. 2 is a photograph showing an example of a conventional Nilex fabric, and FIG. 3 is a photograph showing an example of a non-woven synthetic fiber fabric manufactured by the method of FIG. 1. In each figure, (a) shows the surface photograph of the whole fabric, (b) shows the enlarged photograph of some surfaces in (a). Synthetic fiber fabric instead of the manufactured nonwoven fabric, it can be seen that the fluff and soft texture as well as the existing nonwoven fabric is revealed well.

The non-woven synthetic resin fabric prepared in this way can be used for wrapping the lower end of the seat of the vehicle. The lower end of the seat of the vehicle is conventionally used as a non-exposed part of the Nylex fabric (Nylex) fabric, recently, as well as the Nylex fabric (non-woven fabric of lower cost) is also used.

Here, the non-woven fabric substitute synthetic resin fabric produced by the above method is made of a non-woven fabric to increase the shrinkage and elongation of the non-woven fabric by increasing the shrinkage and elongation of the fabric according to the use of the resin treatment agent by using a plurality of brushing treatment To form the base of the fabric, there is an advantage that does not cause damage to the fabric during the manufacturing process. In addition, there is an advantage that can stabilize the elongation through the subsequent heat treatment to produce a secondary fabric of excellent properties.

That is, the manufactured nonwoven fabric substitute synthetic fiber fabric may be used as a cover of the unexposed portion of the lower portion of the car seat in place of the nonwoven fabric. For the nonwoven fabric substitute synthetic fiber fabric of Figure 3 and the conventional nonwoven fabric, the result of comparing the unit price of the product produced when the cover for the lower end of the sheet, see Table 2.

division Nonwoven Substitute Fabric Conventional nonwoven fabric Difference Unit price per unit area (㎡) 1650 won 1321won 329 won ↓

Referring to Table 2, the non-woven fabric instead of synthetic fiber, there is a cost savings effect of 329 won compared to the conventional nonwoven fabric. Therefore, the non-woven fabric substitute synthetic fiber fabric has the advantage of reducing the cost of the product while also excellent product quality.

Here, the non-woven fabric instead of synthetic fiber fabric is not limited to the above cover of the car seat, it can be used as a cover of various applications not listed.

Table 4 and Table 5, which shows the test report for the non-woven fabric instead of the synthetic fiber fabric prepared by the method of Figure 1, commissioned by the Korea Environmental Testing Research Institute (KATRI) Industrial Environment Research Center It was tested by the method of Table 5.

Test Items Test result Sample 1  Odor (Grade): MS 300-34 4.22 DRY WET Note) 1. Drying test condition: 80 ± 2 ℃, 2 hours. Combustibility (mm / min): MS 300-08-Condition Combustion distance (mm) Combustion time (s) Combustibility (mm / min) Note) 1. SE: Self-extinguishing. Tear Strength (N): MS 300-32 4.7 A Method Vertical Horizontal Rod Strength (N): MS 300-32 4.9.1 Vertical Horizontal   3 2 0 0 0 0 0/5 = 0 0 0 0 0 0/5 = 0 SE SE SE SE SE / 5 = SE 21 29 461 451

Test Items Test result Sample 1  Heavy metal content (mg / kg): MS 201-02 Cd Pb CrVI Hg * Not detected: below detection limit * Detection limit: ① Cd: 5mg / kg ② Pb: 10mg / kg ③ CrVI: 1mg / kg ④ Hg: 1mg / kg Note) 1.Preparation of sample 1) Cd: EPA 3052 (1996) conformity 2) Pb: EPA 3052 (1996) conformity 3) CrVI: EPA 3060A (1996) conformity 2) Hg: EPA 3052 (1996) conformity 2. Analysis Instrument 1) Cd, Pb: ICP / AES 2) CrVI: UV / VIS 3) Hg: Mercury analyzer    Not detected not detected not detected not detected

Table 3 is a test result of odor, combustibility, tear strength, bark strength for the nonwoven fabric substitute synthetic fiber fabric. And, Table 4 is a test result of the heavy metal content of the nonwoven fabric substitute synthetic fiber fabric.

Table 5 compares the characteristics of the conventional nonwoven fabric and the nonwoven fabric substitute synthetic fiber fabric, and summarizes the management criteria of the conventional nonwoven fabric and the test results of the nonwoven fabric substitute synthetic fiber fabric.

Management topics Conventional nonwoven fabric (management standard) Non-woven fabric substitute (property property) Tear strength Horizontal 2.0㎏f or more Vertical 2.0㎏f or more 2.9㎏f length 2.1㎏f Light-resistant Level 3 or higher (based on 84mj) Level 3 smell Grade 3 or above Grade 2 Combustibility 80mm or less Self-extinguishing  heavy metal lead Less than 100 Not detected Mercury Less than 100 Not detected Cadmium Less than 70 Not detected Hexavalent chrome Less than 100 Not detected

Referring to Table 5, the synthetic nonwoven fabric prepared by the above method exhibits tear strength characteristics of 2.9 kgf in width and 2.1 kgf in length, which is equivalent to or better than that of conventional nonwoven fabrics. It can be seen. This tear strength property is dependent on a specific sample submitted at the time of requesting a test report, and when the sample is changed by adjusting the temperature condition, time condition, and overfeed value in step S170, it is possible to obtain better strength as a result of self test. It was confirmed that it can be represented.

In addition, the light resistance is not included in the test report, but satisfies the characteristics of Class 3, which is a standard of the conventional nonwoven fabric as a result of its own test. In addition, the odor characteristics showed good grade 2 properties. In addition, although the conventional nonwoven fabric has a combustibility problem, it can be seen that the nonwoven fabric substitute synthetic fiber fabric exhibits excellent fire resistance because it is confirmed to exhibit self-extinguishing in terms of its combustibility. This means that the nonwoven fabric substitute complements the unstable combustibility of the conventional nonwoven fabric. In addition, in the non-woven fabric substitute fabric, no heavy metal (lead, mercury, cadmium, hexavalent chromium) components were detected.

Although the present invention has been described with reference to the embodiments shown in the drawings, these are merely exemplary and those skilled in the art will understand that various modifications and equivalent other embodiments are possible. Therefore, the true technical protection scope of the present invention will be defined by the technical spirit of the appended claims.

1 is a flow chart of a nonwoven fabric synthetic fiber manufacturing method according to an embodiment of the present invention.

2 is a photograph showing an example of a conventional Nilex fabric.

Figure 3 is a photograph showing an example of a non-woven substitute synthetic fiber fabric prepared by the method of Figure 1;

Claims (6)

Forming a fabric for the nonwoven substitute using a polyester yarn; First raising the fabric; Dyeing the fabric with a dye; Dewatering the fabric and releasing the twist of the fabric; Second raising the fabric; Impregnating the fabric by impregnating the fabric with a solution in which a flame retardant and a resin treatment agent are mixed, thereby flame retarding the fabric and reducing elongation of the fabric; And Applying heat to the fabric and drying to increase the shrinkage of the fabric to increase tear strength, thereby implementing a texture of the nonwoven fabric; The step of heating and drying the fabric, While passing through the fabric in the chamber is carried out, by adjusting the passing rate of the fabric, the heating temperature and the Over Feed value to stabilize the elongation of the fabric to implement a high tear strength of the nonwoven fabric, the drying temperature Is 183 ℃ ~ 187 ℃ range, the passing speed is 10m / min ~ 12m / min range, the overfeed value is a nonwoven fabric substitute synthetic fiber manufacturing method ranges from 28% to 32%. The method according to claim 1, The resin treatment agent, Nonwoven fabric substitute synthetic fiber manufacturing method of PVA (Polyvinyl Acetate) resin. The method according to claim 1 or 2, The flame retardant, A method for producing a nonwoven fabric substitute synthetic fiber which is a permanent flame retardant for polyester of a cyclic phosphonate ester system. delete delete The method according to claim 1, Forming the fabric for replacing the nonwoven fabric, The step of forming the fabric by squeezing and knitting the polyester yarn; Refining the fabric; And Dewatering the refined fabric and releasing the twist of the fabric nonwoven fabric substitute synthetic fiber manufacturing method comprising the step.

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