KR101037092B1 - Needle punch carpet and manufacturing method thereof - Google Patents

Needle punch carpet and manufacturing method thereof Download PDF

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KR101037092B1
KR101037092B1 KR1020090058327A KR20090058327A KR101037092B1 KR 101037092 B1 KR101037092 B1 KR 101037092B1 KR 1020090058327 A KR1020090058327 A KR 1020090058327A KR 20090058327 A KR20090058327 A KR 20090058327A KR 101037092 B1 KR101037092 B1 KR 101037092B1
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fabric
water repellent
needle punch
punch carpet
needle
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KR1020090058327A
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Korean (ko)
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KR20110000970A (en
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전현정
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코오롱글로텍주식회사
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    • 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
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/435—Polyesters
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—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
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06C—FINISHING, DRESSING, TENTERING OR STRETCHING TEXTILE FABRICS
    • D06C3/00—Stretching, tentering or spreading textile fabrics; Producing elasticity in textile fabrics
    • 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
    • D06C7/00—Heating or cooling textile fabrics
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06M—TREATMENT, NOT PROVIDED FOR ELSEWHERE IN CLASS D06, OF FIBRES, THREADS, YARNS, FABRICS, FEATHERS OR FIBROUS GOODS MADE FROM SUCH MATERIALS
    • D06M15/00—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment
    • D06M15/19—Treating fibres, threads, yarns, fabrics, or fibrous goods made from such materials, with macromolecular compounds; Such treatment combined with mechanical treatment with synthetic macromolecular compounds
    • D06M15/21—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06M15/263—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof
    • D06M15/277—Macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds of unsaturated carboxylic acids; Salts or esters thereof containing fluorine
    • 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
    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/04—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D06N3/06—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds with polyvinylchloride or its copolymerisation products
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/06—Properties of the materials having thermal properties
    • D06N2209/067—Flame resistant, fire resistant
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/10—Properties of the materials having mechanical properties
    • D06N2209/103—Resistant to mechanical forces, e.g. shock, impact, puncture, flexion, shear, compression, tear
    • 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
    • D06N2209/00—Properties of the materials
    • D06N2209/14—Properties of the materials having chemical properties
    • D06N2209/142—Hydrophobic

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Carpets (AREA)
  • Treatments For Attaching Organic Compounds To Fibrous Goods (AREA)

Abstract

본 발명은 발포층을 포함하는 니들펀치 카페트 및 그 제조방법에 관한 것이다. 본 발명은 a) 니들펀칭되어 제조된 원단에 발수제를 함침시키는 단계; b) 상기 발수제가 함침된 원단을 건조시키는 단계; c) 상기 건조된 원단에 PVC졸을 도포하는 단계; 및 d) 상기 원단에 도포된 PVC졸을 발포시키는 단계를 포함하는 것을 특징으로 하는 니들펀치 카페트 제조방법을 제공한다. 본 발명에 따르면 니들펀치 카페트의 충격흡수성 및 내연소성을 향상시킬 수 있다는 장점이 있다.The present invention relates to a needle punch carpet and a method of manufacturing the same comprising a foam layer. The present invention comprises the steps of: a) impregnating a water repellent to the fabric produced by needle punching; b) drying the fabric impregnated with the water repellent; c) applying a PVC sol to the dried fabric; And d) provides a needle punch carpet manufacturing method comprising the step of foaming the PVC sol applied to the fabric. According to the present invention there is an advantage that the impact absorbing and combustion resistance of the needle punch carpet can be improved.

카페트, 터프팅, 니들펀칭, 발수제, PVC Carpet, Tufting, Needle Punching, Water Repellent, PVC

Description

니들펀치 카페트 및 그 제조방법{Needle punch carpet and manufacturing method thereof}Needle punch carpet and manufacturing method

본 발명은 발포층을 포함하는 니들펀치 카페트 및 그 제조방법에 관한 것이다. 더욱 상세하게는 PET 단섬유를 니들펀칭하여 형성되는 카페트 원단의 하부면에 내연성을 가지는 PVC졸을 도포하여 쿠션층을 형성한 니들펀칭 카페트와 상기 니들펀치 카페트의 제조방법에 관한 것이다.The present invention relates to a needle punch carpet and a method of manufacturing the same comprising a foam layer. More specifically, the present invention relates to a needle punching carpet and a method of manufacturing the needle punch carpet by applying a PVC sol having flame resistance to a lower surface of a carpet fabric formed by needle punching PET short fibers to form a cushion layer.

카페트는 터프팅(Tufting) 방식에 의해 제조되거나 니들펀칭(Needle punching) 방식에 의해 제조되는 것이 일반적이다.Carpets are generally manufactured by tufting or needle punching.

이 중에서 터프팅 방식에 의해 제조된 카페트는 충격흡수성과 쿠션감이 우수하다는 장점이 있는 반면에 무겁고 이물질에 의해 오염되기 쉬우며 다양하고 선명한 디자인을 구현하기 어렵다는 단점이 있다. Among them, the carpet manufactured by the tufting method has an advantage of excellent shock absorption and cushioning feeling, but has a disadvantage of being heavy, easily contaminated by foreign substances, and difficult to realize various and clear designs.

한편, 니들펀칭 방식에 의해 제조되는 카페트는 가볍고, 다양한 디자인으로 연출이 가능하다는 장점이 있으나, 터프팅 방식에 의해 제조되는 카페트에 비해 충격흡수성과 쿠션감이 좋지 않다는 문제가 있었다.On the other hand, the carpet produced by the needle punching method is light, there is an advantage that can be produced in a variety of designs, but compared to the carpet produced by the tufting method there was a problem that the shock absorption and cushioning is not good.

이러한 문제를 해결하기 위해 니들펀치 카페트 원단에 라텍스(Latex)를 코팅 처리하거나 Nylon 6,6과 PET(Polyethylen terephthalate)의 이중구조를 형성함으써 니들펀치 카페트가 가지지 못한 내연소성을 향상시키려는 노력이 있어 왔다.In order to solve this problem, there is an effort to improve the combustion resistance that needle punch carpet does not have by coating latex on the needle punch carpet fabric or forming a dual structure of nylon 6,6 and polyethylene terephthalate (PET). come.

그러나, 니들펀치 카페트 원단에 라텍스를 코팅하는 경우 라텍스가 카페트 원단에 흡수되어 소모되는 라텍스의 양과 함께 전체적인 카페트의 중량이 증가하게 되고, 코팅층의 두께도 불균일하게 형성되어 충격흡수성이 저하된다는 단점이 있다. However, when the latex is coated on the needle punch carpet fabric, the weight of the overall carpet increases with the amount of latex absorbed and consumed by the carpet fabric, and the thickness of the coating layer is also formed nonuniformly, which impairs the impact absorbency. .

또한, Nylon 6,6과 PET의 이중구조를 형성하는 카페트의 경우 우수한 내열성을 발휘하나, Nylon 6,6이 고가이기 때문에 경제성이 낮다는 문제가 있다.In addition, the carpet forming the dual structure of nylon 6,6 and PET exhibits excellent heat resistance, but there is a problem that the economic efficiency is low because nylon 6,6 is expensive.

상기한 문제점을 해결하기 위해 본 발명은 카페트의 연소성 기준을 충족시킬수 있도록 우수한 내연성과 충격흡수성을 가지며, 다양한 디자인을 구현할 수 있어 설치장소의 심미성을 향상시키는 니들펀치 카페트와 그 제조방법을 제공하는 것을 그 목적으로 한다.In order to solve the above problems, the present invention provides a needle punch carpet and a method of manufacturing the same which have excellent flame resistance and shock absorption to meet the burnability criteria of the carpet, and can implement various designs to improve the aesthetics of the installation place. For that purpose.

상기한 목적을 달성하기 위해 본 발명은 a) 니들펀칭되어 제조된 원단에 발수제를 함침시키는 단계; b) 상기 발수제가 함침된 원단을 건조시키는 단계; c) 상기 건조된 원단에 PVC졸을 도포하는 단계; 및 d) 상기 원단에 도포된 PVC졸을 발포시키는 단계를 포함하는 것을 특징으로 하는 니들펀치 카페트 제조방법을 제공한다.In order to achieve the above object, the present invention comprises the steps of: a) impregnating a water repellent into a fabric produced by needle punching; b) drying the fabric impregnated with the water repellent; c) applying a PVC sol to the dried fabric; And d) provides a needle punch carpet manufacturing method comprising the step of foaming the PVC sol applied to the fabric.

상기 b) 단계에서 상기 발수제가 함침된 원단은 온도가 150~180℃로 유지되는 텐터에 투입되어 건조되는 것을 특징으로 한다.The fabric impregnated with the water repellent in step b) is characterized in that the temperature is put into a tenter is maintained at 150 ~ 180 ℃ dried.

또한, 상기 d) 단계에서 상기 PVC졸을 발포시키는 것은 PVC졸이 도포된 원단을 140~190℃에서 열처리하여 수행되는 것을 특징으로 한다.In addition, the foaming of the PVC sol in step d) is characterized in that it is carried out by heat-treating the fabric to which the PVC sol is applied at 140 ~ 190 ℃.

또한, 상기 a) 단계 이전의 단계로 원단에 날염처리하는 단계를 더 포함할 수 있다.In addition, it may further comprise the step of printing the fabric to the step before the step a).

또한, 상기 a) 단계와 상기 b) 단계 사이에 상기 발수제가 함침된 원단을 압착하는 단계를 더 포함할 수 있다.In addition, the method may further include compressing the fabric impregnated with the water repellent agent between the steps a) and b).

또한, 상기 원단은 섬도가 5~20 데니어인 PET 단섬유로 형성되는 것을 특징으로 한다.In addition, the fabric is characterized in that the fineness is formed of PET short fibers 5 ~ 20 denier.

또한, 상기 발수제는 물에 희석되어 1~10%의 농도를 유지하는 불소계 발수제 인 것을 특징으로 한다.In addition, the water repellent is diluted in water to maintain a concentration of 1 to 10% fluorine-based water repellent It is characterized by that.

한편, 본 발명은 니들펀칭되어 제조된 원단에 발수제를 함침시켜 형성되는 원단층; 및 상기 원단의 하부면에 부착되고, 발포된 PVC 재질로 형성되는 쿠션층을 포함하는 것을 특징으로 하는 니들펀치 카페트를 제공한다.On the other hand, the present invention is a fabric layer formed by impregnating a water-repellent agent to the fabric produced by needle punching; And a cushion layer attached to the lower surface of the fabric and formed of a foamed PVC material.

또한, 상기 원단은 섬도가 5~20 데니어인 PET 단섬유를 니들펀칭하여 형성하는 것을 특징으로 한다.In addition, the fabric is characterized in that formed by needle punching PET short fibers having a fineness of 5 ~ 20 denier.

또한, 상기 발수제는 물에 희석되어 1~10%의 농도를 유지하는 불소계 발수제인 것을 특징으로 한다.In addition, the water repellent is characterized in that the fluorine-based water repellent is diluted in water to maintain a concentration of 1 to 10%.

본 발명에 따르면 니들펀치 카페트의 충격흡수성 및 내연소성을 향상시킬 수 있다는 장점이 있다. 또한, 발수성 및 발유성을 가지고 있어 내오염성이 향상된 니들펀치 카페트를 저렴한 비용으로 제조할 수 있어 경제적이고, 경량화된 카페트를 얻을 수 있다.According to the present invention there is an advantage that the impact absorbing and combustion resistance of the needle punch carpet can be improved. In addition, the needle punch carpet with improved water resistance and oil repellency can be manufactured at a low cost to obtain an economical, lightweight carpet.

이하, 본 발명의 바람직한 실시예를 첨부된 도면들을 참조하여 상세하게 설명한다. 우선 각 도면의 구성 요소들에 참조 부호를 첨가함에 있어서, 동일한 구성 요소들에 대해서는 비록 다른 도면상에 표시되더라도 가능한 한 동일한 부호를 가 지도록 하고 있음에 유의해야 한다. 또한, 본 발명의 요지를 흐릴 수 있다고 판단되는 경우에는 그 상세한 설명은 생략한다. 또한, 이하에서 본 발명의 바람직한 실시예를 설명할 것이나, 본 발명의 기술적 사상은 이에 한정하거나 제한되지 않고 당업자에 의해 실시될 수 있음은 물론이다.Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings. First of all, in adding reference numerals to the components of each drawing, it should be noted that the same reference numerals have the same reference numerals as much as possible even if displayed on different drawings. In addition, detailed description is abbreviate | omitted when it is judged that it may obscure the summary of this invention. In addition, preferred embodiments of the present invention will be described below, but the technical idea of the present invention may be implemented by those skilled in the art without being limited or limited thereto.

도 1은 본 발명의 바람직한 실시예에 따른 니들펀치 카페트의 단면도이고, 도 2는 니들펀치 카페트의 제조과정을 나타낸 흐름도이다.1 is a cross-sectional view of a needle punch carpet according to a preferred embodiment of the present invention, Figure 2 is a flow chart showing a manufacturing process of the needle punch carpet.

이하, 도 1과 도 2를 참고하여 본 발명의 바람직한 실시예에 따른 니들펀치 카페트(100)와 그 제조방법을 설명한다.Hereinafter, a needle punch carpet 100 and a manufacturing method thereof according to a preferred embodiment of the present invention will be described with reference to FIGS. 1 and 2.

도 1에 도시된 바와 같이 니들펀치 카페트(100)는 원단층(110)과 원단층(110)의 하부에 도포되어 형성되는 PVC 발포층(120)을 포함한다.As shown in FIG. 1, the needle punch carpet 100 includes a fabric layer 110 and a PVC foam layer 120 formed by being applied to the lower portion of the fabric layer 110.

원단층(110)은 PET(Polyethylen terephthalate) 단섬유를 니들펀칭(Needle punching)하여 형성한 원단으로 이루어진다. 이때, 상기 원단은 섬도가 5~20데니어(Denier)인 PET 단섬유를 사용하여 제조하는데, 섬도가 5데니어 미만이거나 20데니어를 초과할 경우에는 카페트 원단으로서의 질감을 충분히 발휘할 수 없게 된다.The fabric layer 110 is made of fabric formed by needle punching PET (Polyethylen terephthalate) short fibers. In this case, the fabric is manufactured using a PET short fiber having a fineness of 5 to 20 denier (Denier), when the fineness is less than 5 denier or exceeds 20 denier, the texture as a carpet fabric can not be fully exhibited.

또한, 원단층(110)의 두께는 3~5㎜로 형성하는데, 원단층(110)의 두께가 3㎜미만이거나 5㎜를 초과할 경우에는 카페트로서의 적당한 쿠션감을 가지기 어렵다. 또한, 두께가 5㎜를 초과하게 되면 원단의 제작 및 가공 시 생산성이 저하되며 원가가 증가된다는 문제점이 있다.In addition, the thickness of the fabric layer 110 is formed to 3 ~ 5mm, when the thickness of the fabric layer 110 is less than 3mm or more than 5mm it is difficult to have a proper cushioning feeling as a carpet. In addition, if the thickness exceeds 5mm, there is a problem that the productivity is lowered and the cost is increased during fabrication and processing of the fabric.

원단층(110)에는 니들펀치 카페트(100)가 특정한 기능을 발휘할 수 있도록 하기 위해 다양한 첨가물질을 첨가할 수 있다. 예를들어, 방향성을 발휘할 수 있도 록 하기 위해 원단의 내부에 방향물질을 함유시키거나 소취기능을 나타내도록 하기 위해 원단에 제오라이트(Zeolite)가 함유되도록 할 수도 있다.Various additives may be added to the fabric layer 110 to enable the needle punch carpet 100 to exhibit a specific function. For example, the zeolite may be contained in the fabric in order to contain the fragrance material in the fabric to exhibit the directionality or to exhibit a deodorizing function.

쿠션층(120)은 원단층(110)의 하부면에 부착된다. 쿠션층(120)은 내열성이 우수하고, 경량인 PVC(Polyvinyl chloride) 재질로 형성하여 카페트의 연소성 기준을 만족시킬 수 있도록 한다. 쿠션층(120)은 용융된 상태의 PVC인 PVC졸을 원단층(110)의 하부면에 균일하게 도포한 후 열처리하여 형성하는데, 도포과정에서 PVC 졸이 원단층(110)에 스며드는 것을 방지하기 위해 원단층(110)을 이루는 원단은 발수처리된다.The cushion layer 120 is attached to the lower surface of the far end layer 110. The cushion layer 120 is excellent in heat resistance and is formed of lightweight PVC (Polyvinyl chloride) material so as to satisfy the burnability criteria of the carpet. The cushion layer 120 is formed by uniformly applying the PVC sol in the molten state to the lower surface of the fabric layer 110 and then heat-treating, to prevent the PVC sol from seeping into the fabric layer 110 during the application process Fabric forming the fabric layer 110 is water-repellent.

이하, 도 2를 참고하여 상술한 니들펀치 카페트(100)의 제조방법을 더욱 상세하게 설명한다.Hereinafter, a method of manufacturing the needle punch carpet 100 described above with reference to FIG. 2 will be described in more detail.

먼저, PET 단섬유를 사용하여 제조한 원단에 발수제를 함침시킨다(S10). 이때, 원단은 상술한 바와 같이 섬도가 5~20데니어인 PET 단섬유를 니들펀칭하여 3~5㎜의 두께로 형성한다. First, impregnated with a water repellent on the fabric produced using short PET fibers (S10). At this time, the fabric is needle-punched PET short fibers having a fineness of 5 to 20 denier as described above to form a thickness of 3 to 5 mm.

이러한 원단에 함침되는 발수제는 실리콘 수지의 일종인 실리콘계 발수제나 퍼플루오르알킬아크릴레이트(perfluoralkylacrylate)의 공중합체인 불소계 발수제 등을 사용할 수 있다. 바람직하게는 실리콘계 발수제에 비하여 고도의 발수성, 낮은 이형성 및 발유성을 나타내는 불소계 발수제를 사용한다. The water-repellent agent impregnated in the fabric may be a silicone-based water repellent, which is a kind of silicone resin, or a fluorine-based water repellent, which is a copolymer of perfluoralkylacrylate. Preferably, a fluorine-based water repellent which exhibits a high water repellency, low mold release property and oil repellency as compared to a silicone water repellent agent is used.

발수제는 물에 희석하여 농도가 1~10%가 되도록 하고, 제조된 원단을 발수제 용액 속에 담구어 발수제가 원단 속으로 스며들게 한다. 이때, 발수제의 농도가 1%미만이면 발수성이 저하되고, 농도가 10%인 것으로 충분한 발수효과가 나타나므로 발수제의 농도가 10%를 초과하도록 하는 것은 비경제적이다. The water repellent is diluted in water so that the concentration is 1-10%, and the fabric is immersed in the water repellent solution so that the water repellent penetrates into the fabric. At this time, when the concentration of the water repellent is less than 1%, the water repellency is lowered, and since the sufficient water repellent effect is shown as the concentration is 10%, it is uneconomical to make the concentration of the water repellent exceed 10%.

한편, 심미성을 향상시키기 위하여 원단층(110)에 염료나 안료 등을 이용하여 날염을 하는 경우에는 상기 S10단계에서와 같이 제조된 원단을 발수처리하기 전에 날염하여 원단을 디자인하도록 한다.On the other hand, in the case of printing using a dye or pigment in the fabric layer 110 to improve the aesthetics to design the fabric by printing before the water-repellent treatment fabric prepared in step S10.

발수제가 함침된 원단은 압착시켜서 탈수시킨다(S20). 원심력에 의한 탈수방법을 사용하는 경우 원단에 함침된 발수제가 완전히 탈수되어 발수성능을 발휘할 수 없게 되기 때문에 발수제가 원단에 일정량이 잔존할 수 있도록 압착시켜 탈수시킨다.Fabric impregnated with a water repellent is dehydrated by pressing (S20). In the case of using the centrifugal dehydration method, the water repellent impregnated in the fabric is completely dehydrated so that the water-repellent performance can not be exhibited.

이때, 발수제가 함침된 원단을 탈수시키기 위해서 망글(mangle)장치를 이용할 수 있는데, 망글에 원단을 통과시켜 원단이 압착되도록 함으로써 탈수과정을 수행할 수 있는 것이다.At this time, a mangle (mangle) device may be used to dehydrate the fabric impregnated with a water repellent, and the dehydration process may be performed by allowing the fabric to be compressed by passing the fabric through the mangle.

압착과정을 거친 원단은 건조시켜 희석된 발수제에 포함된 수분을 제거한다(S30). 여기서, 젖은 상태의 원단을 텐터(Tenter)에 투입시켜 수분을 제거할 수 있는데, 원단이 투입되는 텐터의 온도는 150~180℃로 유지한다. 텐터의 온도가 150℃ 미만이면 원단의 건조시간이 길어지게 되고, 텐터의 온도가 180℃를 초과하면 고열로 인해 발수제를 함유한 원단이 손상될 수 있다. The fabric undergoes the compression process is dried to remove the water contained in the diluted water repellent (S30). Here, the wet fabric may be put in a tenter to remove moisture. The temperature of the tenter into which the fabric is input is maintained at 150 to 180 ° C. If the temperature of the tenter is less than 150 ° C., the drying time of the fabric becomes long, and if the temperature of the tenter exceeds 180 ° C., the fabric containing the water repellent may be damaged due to high heat.

상기와 같이 제조된 원단층(110)은 발수성 및 내오염성을 가지게 된다는 장점이 있으며, 후술하는 바와 같이 원단층(110)의 하부면에 쿠션층(120)을 용이하게 형성할 수 있게 된다.The fabric layer 110 manufactured as described above has an advantage of having water repellency and stain resistance, and as described below, the cushion layer 120 may be easily formed on the lower surface of the fabric layer 110.

텐터를 통과하여 건조된 원단의 하부면에는 쿠션층(120)을 형성하기 위해 PVC졸을 도포한다(S40). PVC sol is applied to the lower surface of the fabric dried through the tenter to form a cushion layer 120 (S40).

PVC졸은 원단층(110)의 하부면에 균일한 두께로 도포하는데, 도 3에 도시된 바와 같이 나이프(Knife) 도포장치를 이용하여 도포될 수 있다. 이와 같이 PVC졸을 도포하면 PVC졸이 원단층(110)의 하부면에 형성되는 틈에 밀착되어 접착면적이 최대되기 때문에 이미 경화된 상태의 쿠션재를 원단층(110)에 접착하는 것보다 더욱 향상된 접착력을 발휘할 수 있게 된다.PVC sol is applied to a uniform thickness on the lower surface of the fabric layer 110, as shown in Figure 3 can be applied using a knife (Knife) coating device. In this way, when the PVC sol is applied, the PVC sol is in close contact with the gap formed on the lower surface of the fabric layer 110 and thus the adhesive area is maximized. The adhesive force can be exhibited.

한편, 발수처리된 원단층(110)의 하부면에 도포되는 PVC졸은 원단층(110)에 흡수되지 않기 때문에 PVC졸의 도포면을 균일하게 유지하여 균일한 쿠션감을 얻을 수 있게 되는 것이다.On the other hand, since the PVC sol applied to the lower surface of the water-repellent treated fabric layer 110 is not absorbed by the fabric layer 110, it is possible to obtain a uniform cushioning feeling by maintaining the coated surface of the PVC sol uniformly.

원단층(110)의 하부면에 균일하게 도포된 PVC졸은 발포시켜 쿠션층(120)을 형성한다(S50). S40단계를 거친 후 PVC졸이 도포된 원단층(110)은 PVC졸을 발포 및 경화시키기 위해 열처리 장비에 투입된다. 이때, PVC졸에 열을 가하기 위한 수단으로 텐터와 같은 장비가 사용될 수 있다. 이때, PVC졸을 발포시키기 위한 텐터의 내부온도는 140~190℃로 유지하도록 한다. PVC졸이 열처리되는 온도가 140℃ 미만이면 PVC의 발포가 원활히 수행되지 않아 쿠션감이 저하되고, 경화시간이 지연되는 문제가 있다. 또한, 온도가 190℃를 초과하는 경우에는 원단층(110)이 손상될 수 있다.PVC sol uniformly coated on the lower surface of the fabric layer 110 is foamed to form a cushion layer 120 (S50). After the S40 step, the PVC sol-coated fabric layer 110 is put into heat treatment equipment to foam and cure the PVC sol. At this time, a device such as a tenter may be used as a means for applying heat to the PVC sol. At this time, the internal temperature of the tenter for foaming the PVC sol is maintained at 140 ~ 190 ℃. When the temperature at which the PVC sol is heat-treated is less than 140 ° C., the foaming of the PVC is not performed smoothly, thereby lowering the cushioning feeling and delaying the curing time. In addition, when the temperature exceeds 190 ° C., the far-end layer 110 may be damaged.

상기와 같은 방법으로 형성된 쿠션층(120)은 우수한 내열성을 가지는 PVC재질로 형성되어 카페트의 연소성 기준을 충족시킬 수 있게 된다. 또한, 쿠션층(120)을 PVC로 형성함으로써 니들펀치 카페트(100)를 경량화할 수 있으며, 우수한 쿠션 감을 제공한다.The cushion layer 120 formed by the above method may be formed of a PVC material having excellent heat resistance to satisfy the burnability criteria of the carpet. In addition, by forming the cushion layer 120 of PVC, the needle punch carpet 100 can be reduced in weight, and provides an excellent cushioning feeling.

이상의 설명은 본 발명의 기술 사상을 예시적으로 설명한 것에 불과한 것으로서, 본 발명이 속하는 기술 분야에서 통상의 지식을 가진 자라면 본 발명의 본질적인 특성에서 벗어나지 않는 범위 내에서 다양한 수정, 변경 및 치환이 가능할 것이다. 따라서 본 발명에 개시된 실시예 및 첨부된 도면들은 본 발명의 기술 사상을 한정하기 위한 것이 아니라 설명하기 위한 것이고, 이러한 실시예 및 첨부된 도면에 의하여 본 발명의 기술 사상의 범위가 한정되는 것은 아니다. 본 발명의 보호범위는 아래의 청구 범위에 의해서 해석되어야 하며, 그와 동등한 범위 내에 있는 모든 기술 사상은 본 발명의 권리 범위에 포함되는 것으로 해석되어야 할 것이다.The above description is merely illustrative of the technical idea of the present invention, and various modifications, changes, and substitutions may be made by those skilled in the art without departing from the essential characteristics of the present invention. will be. Accordingly, the embodiments disclosed in the present invention and the accompanying drawings are not intended to limit the technical spirit of the present invention but to describe the present invention, and the scope of the technical idea of the present invention is not limited by the embodiments and the accompanying drawings. The scope of protection of the present invention should be construed according to the following claims, and all technical ideas within the scope of equivalents thereof should be construed as being included in the scope of the present invention.

도 1은 본 발명의 바람직한 실시예에 따른 발포층을 포함하는 니들펀치 카페트의 단면도이다.1 is a cross-sectional view of a needle punch carpet including a foam layer according to a preferred embodiment of the present invention.

도 2는 발포층을 포함하는 니들펀치 카페트의 제조과정을 나타낸 흐름도이다.2 is a flowchart illustrating a process of manufacturing a needle punch carpet including a foam layer.

도 3은 도 2의 S40 및 S50 단계를 개략적으로 도시한 도면이다.3 is a view schematically showing the steps S40 and S50 of FIG.

<도면의 주요 부분에 대한 부호의 설명><Explanation of symbols for the main parts of the drawings>

100 : 니들펀치 카페트 110 : 원단층100: needle punch carpet 110: fabric layer

120 : 쿠션층120: cushion layer

Claims (10)

a) 니들펀칭되어 제조된 원단에 발수제를 함침시키는 단계;a) impregnating a water repellent agent into the fabric produced by needle punching; b) 상기 발수제가 함침된 원단을 건조시키는 단계;b) drying the fabric impregnated with the water repellent; c) 상기 건조된 원단에 PVC졸을 도포하는 단계; 및c) applying a PVC sol to the dried fabric; And d) 상기 원단에 도포된 PVC졸을 발포시키는 단계를 포함하는 것을 특징으로 하는 니들펀치 카페트 제조방법.d) a needle punch carpet manufacturing method comprising the step of foaming the PVC sol applied to the fabric. 제 1 항에 있어서,The method of claim 1, 상기 b) 단계에서In step b) 상기 발수제가 함침된 원단은 온도가 150~180℃로 유지되는 텐터에 투입되어 건조되는 것을 특징으로 하는 니들펀치 카페트.The needle punch carpet, characterized in that the fabric impregnated with the water repellent is added to the tenter is maintained at a temperature of 150 ~ 180 ℃. 제 1 항에 있어서,The method of claim 1, 상기 d) 단계에서 In step d) 상기 PVC졸을 발포시키는 것은 Foaming the PVC sol PVC졸이 도포된 원단을 140~190℃에서 열처리하여 수행되는 것을 특징으로 하는 니들펀치 카페트 제조방법.Needle punch carpet manufacturing method characterized in that the PVC sol is applied to the fabric is heat-treated at 140 ~ 190 ℃. 제 1 항에 있어서,The method of claim 1, 상기 a) 단계 이전의 단계로To step before step a) 원단에 날염처리하는 단계를 더 포함하는 것을 특징으로 하는 니들펀치 카페트 제조방법.Needle punch carpet manufacturing method comprising the step of printing the fabric further. 제 1 항에 있어서,The method of claim 1, 상기 a) 단계와 상기 b) 단계 사이에Between step a) and step b) 상기 발수제가 함침된 원단을 압착하는 단계를 더 포함하는 것을 특징으로 하는 니들펀치 카페트 제조방법.Needle punch carpet manufacturing method characterized in that it further comprises the step of pressing the fabric impregnated with the water repellent. 제 1 항에 있어서,The method of claim 1, 상기 원단은 섬도가 5~20 데니어인 PET 단섬유로 형성되는 것을 특징으로 하는 니들펀치 카페트 제조방법.The fabric is a needle punch carpet manufacturing method, characterized in that the fine fiber is formed of 5 to 20 denier PET short fibers. 제 1 항에 있어서,The method of claim 1, 상기 발수제는 물에 희석되어 1~10%의 농도를 유지하는 불소계 발수제인 것을 특징으로 하는 니들펀치 카페트 제조방법.The water repellent is a needle punch carpet manufacturing method, characterized in that the dilution in water to maintain a concentration of 1 to 10% fluorine-based water repellent. 니들펀칭되어 제조된 원단에 발수제를 함침시켜 형성되는 원단층; 및A fabric layer formed by impregnating a water repellent agent on a fabric produced by needle punching; And 상기 원단의 하부면에 부착되고, 발포된 PVC 재질로 형성되는 쿠션층을 포함하는 것을 특징으로 하는 니들펀치 카페트.Needle punch carpet is attached to the lower surface of the fabric, characterized in that it comprises a cushion layer formed of foamed PVC material. 제 9 항에 있어서,The method of claim 9, 상기 원단은 섬도가 5~20 데니어인 PET 단섬유를 니들펀칭하여 형성하는 것을 특징으로 하는 니들펀치 카페트.The fabric is a needle punch carpet, characterized in that formed by needle punching PET short fibers having a fineness of 5 ~ 20 denier. 제 9 항에 있어서,The method of claim 9, 상기 발수제는 물에 희석되어 1~10%의 농도를 유지하는 불소계 발수제인 것을 특징으로 하는 니들펀치 카페트.The needle punch carpet, characterized in that the water repellent is a fluorine-based water repellent diluted in water to maintain a concentration of 1 ~ 10%.
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KR101174593B1 (en) 2011-03-02 2012-08-20 정금필 Forms a printing layer textile awning productive method and the textile awning

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