KR101056502B1 - Manufacturing method of split microfiber nonwoven - Google Patents

Abstract

The present invention relates to a method for producing a split microfiber nonwoven fabric, and more particularly, a composite PTT in which a split microfiber web composed of split microfiber fibers is bonded to polytrimethylene terephthalate (PTT) and polyethylene terephthalate (PET). Method for manufacturing split type microfiber nonwoven fabric with excellent elasticity and excellent circular resilience by producing nonwoven fabric by combining with composite PTT web composed of fiber, nylon fiber and high shrink polyester fiber It is about.

The present invention, the step of forming a split microfiber web on a flat sheet with a split microfiber fibers, mixed with a composite PTT fiber and a high-shrinkable polyester and a general nylon fiber, and then formed a composite PTT web on a flat sheet with a mixed fiber And a needle punching step of bonding and bonding the formed composite PTT web and the split microfiber web through needle punching, a shrinking step of shrinking the needle punched web, a drying step of dehydrating and drying the shrinked web, and a dried web. It provides a split type microfiber nonwoven fabric manufacturing method comprising a calendering step of passing through a pair of top and bottom thermal calender.

Split Microfiber, Microfiber Nonwoven, Composite PTT, PTT, PET, Surface Smooth, Circular Restoration

Description

The manufacturing method of split microfiber nonwoven fabric

The present invention relates to a method for producing a split microfiber nonwoven fabric, and more particularly, a composite PTT in which a split microfiber web composed of split microfiber fibers is bonded to polytrimethylene terephthalate (PTT) and polyethylene terephthalate (PET). Method for manufacturing split type microfiber nonwoven fabric with excellent elasticity and excellent circular resilience by producing nonwoven fabric by combining with composite PTT web composed of fiber, nylon fiber and high shrink polyester fiber It is about.

As a coating material to replace paper or woven fabric, a conventional nonwoven fabric refers to a fabric made by laminating yarns without weaving cloth, and is entangled with various textile materials such as natural, chemical, recycled, etc. without having a certain direction. After forming the web in the form of), it is combined and stabilized by chemical and physical methods and manufactured like paper or cloth, and widely used in industrial materials or living environments according to its purpose of use.

In particular, as non-woven fabrics are made of artificial leather, various materials such as bags, clothing, balls, and shoes, in which natural leather is the main material, are gradually replaced by artificial leather, which is environmentally friendly, less pollution, and easy to mass-produce. As a result, researches to improve the quality and functionality of nonwoven fabrics have been actively conducted.

Among them, nonwoven fabrics manufactured using microfibers have been used for a wide range of applications due to advantages such as excellent flexibility, feel, high absorbency, and wiping properties due to the expansion of the specific surface area. The finer the fibers, the greater the flexibility and softness, the smaller the bending resistance, and the denser the tissue and the smaller the voids on the nonwoven fabric.

Non-woven fabrics made of microfibers generally use needle punching of expensive special island-in-the-sea microfibers to create a three-dimensional entangled structure and use polyurethane resins to provide elasticity, breathability, and moisture permeability. To form. The microfibers used as the raw material fibers are generally 1.0 denier fibers or less, and the fibers are two-component islands-in-the-sea yarns in which two fibers such as nylon and polyester, polyester and copolyester, or nylon and polyethylene are mixed. -island) is mainly used.

The microfiber felt produced in this way is subjected to a special and complicated process of impregnating a polyurethane resin and then solidifying, washing and drying to elute one component of the two bicomponent fibers in a sodium hydroxide solution. It is fined after. After buffing the microfiber felt thus manufactured again, coating a polyurethane resin on the surface becomes a non-woven artificial leather having 0.05 ~ 0.1 denier.

The artificial leather made in this way has a dermis effect similar to that of natural leather, which has advantages such as softness, fineness, draftness, bulkiness, moisture permeability, and thermal insulation due to microcavity between fibers, but at the cost of using expensive raw materials. Burden, the complex process of dipping in sodium hydroxide solution to elevate and eluting one of the two components, the environmental wastewater problem that may occur, the productivity problem, the tensile strength of the microfiber felt caused by elution, There was a problem such as a decrease in tear strength.

The present invention is to solve the above problems according to the prior art. That is, an object of the present invention, a composite PTT fiber and a nylon fiber and high shrinkage (polystyrene methylene terephthalate (PTT) and polyethylene terephthalate (PET) bonded to a split microfiber web composed of split microfiber fibers The present invention provides a method for producing a split microfiber nonwoven fabric having excellent elasticity and excellent circular resilience as well as excellent appearance and feel by producing a nonwoven fabric by combining with a composite PTT web mixed with polyester fibers.

As a technical idea for achieving the above object, the present invention, the step of forming a split microfiber web on a flat sheet with a split microfiber fibers, mixed with a composite PTT fiber and a high shrink polyester and general nylon fibers, Forming a composite PTT web on a flat sheet on a cotton sheet, a needle punching step of bonding the formed composite PTT web and the split microfiber web to bind by needle punching, a shrinking step of shrinking a needle punched web, and a contracted web It provides a method for producing a split microfiber nonwoven fabric comprising a drying step of dehydration and drying, and a calendering step of passing the dried web through a pair of upper and lower heat calenders.

The method of manufacturing a split microfiber nonwoven fabric according to the present invention is manufactured by combining a split microfiber web and a composite PTT web, and has been found to have excellent surface feel and surface smoothness due to good flexibility and bending of microfiber, and excellent elasticity and roundness. Also excellent in the recovery rate is excellent, it is suitable for use in high-performance materials such as artificial leather. In addition, by easily manufacturing a microfiber nonwoven product having a good performance in a simple process compared to the prior art can be applied to a variety of industrial materials, household goods and the like by mass-producing quality similar to natural leather.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

1 is a schematic cross-sectional view of a split microfiber nonwoven fabric according to an embodiment of the present invention.

As shown in FIG. 1, the split microfiber nonwoven fabric 100 according to the present invention is a split microfiber web 110 made of split microfiber fibers, a composite PTT fiber, a highly shrinkable polyester fiber, and a general nylon fiber. Composed of a composite PTT web 120 is formed. In this case, the split microfiber web 100 forming the surface layer is 10% to 40%, and the composite PTT web 120 forming the back layer is configured to have a weight ratio of 40% to 90%.

The split microfiber web 110 is formed of a planar sheet web through thermal bonding of 100% split microfiber fibers, and the split microfiber fibers have a fineness of 1.5 to 4.0De and a 40mm to 60mm thickness before splitting. After dividing the fiber having a fiber length of the card through the carding machine, after the split is used a split type microfiber fiber having a fineness of 0.01 ~ 0.2De and forms a 8-16 split, 80% -20% polyester, Nylon is configured to have a weight ratio of 80% to 20%. Unlike island-in-the-sea microfiber yarns, such split microfiber yarns can be microfiberized without undergoing an elution process, and have excellent physical properties such as high fiber density and elongation at break.

The composite PTT web 120 blends the composite PTT fiber, the high shrink polyester fiber, and the general nylon fiber, and is formed into a flat sheet web through a carding process and preliminary needle punching. At this time, the composite PTT fiber is 20% to 40%, highly shrinkable polyester fiber is 20% to 40%, general nylon fiber 20% to 40% by weight is preferably blended so that the non-woven fabric is out of this range City workability and product properties are undesirable. That is, if the high shrink polyester content is less than 20%, the nonwoven fabric does not shrink easily, and if the high shrink polyester content is over 40%, the nonwoven fabric is excessively contracted, making it unsuitable for use in the manufacture of artificial leather. do.

The composite PTT fiber is composed of poly trimethyleneterephthalate (PTT), terephthalic acid, and ethylene glycol (Ethylene Glycol), which are mainly composed of terephthalic acid and propanediol (PDO). Poly Ethylene terephthalate (PET) is spun to a weight ratio of 2: 8 to 8: 2, so that poly poly trimethylene terephthalate (PTT) and polyethylene terephthalate (PET) are bimetallic in the length direction of the fiber. It is a yarn manufactured to form a structure.

High Shrinkage Polyester is not particularly limited in its kind, but has a fineness of 1.4 ~ 3.0 denier and a fiber length of 40mm ~ 60mm, 40% when the hydrothermal shrinkage is contracted for 10 seconds at a temperature of 90 ℃. Use a shrinkage of ~ 60%.

In addition, the type of nylon fiber is not particularly limited, but the one having a fineness of 1.5 to 3.0 denier and a fiber length of 40 mm to 60 mm is used.

Hereinafter, a method of manufacturing a split microfiber nonwoven fabric according to the present invention will be described with reference to FIG. 2. 2 is a flowchart illustrating a method of manufacturing a split microfiber nonwoven fabric according to an embodiment of the present invention.

First, 100% of the split microfiber raw material is formed into a flat sheet web through thermal bonding (S202). Thermal bonding is a method of forming a flat sheet web through the heat fusion between the fibers as the fibers pass between the hot rolls, the manufacturing process is simple, there is an advantage to maximize the soft touch of the split microfiber. In the present invention, a split microfiber is formed into a flat sheet web by passing between hot rolls having a temperature of 130 ° to 170 °, a speed of 15m / min to 30m / min, and a pressure of 80pa to 120pa.

In addition, after mixing the composite PTT fiber, high-shrinkage polyester fiber and general nylon fiber in a certain ratio, it is formed into a flat sheet-like web through the carding process and pre-needle punching (S204).

The blending process is a process of mixing and mixing each yarn uniformly in the hopper. The present invention provides 20% to 60% of composite PTT fiber, 20% to 40% of high shrinkage polyester fiber, and 20% to 40% of general nylon fiber. To blend in a weight ratio of%.

The carding process is a process of loosening the cotton supplied in the blending process from the other surface machine to remove the impurities to form a web. Combing the surface through the other surface and the carding machine and mixing them evenly so as not to have a directivity to form a flat sheet web of a certain weight and width. Form and pre-needle punch to bond the fibers to the minimum. At this time, since the composite PTT fiber is in the form of a pigtail, it is difficult to form a uniform web because it is difficult to comb the surface. Therefore, the work roller of the carding machine is reduced from 50 m / min to 80 m / min from the conventional 80 m / min to 130 m / min, and the surface speed of the carding roller is also 600 m / min to 900 m / min at the conventional 900 m / min to 1200 m / min. Lowered to facilitate combing of the surface and to form a flat sheet web with good smoothness and homogeneity.

Subsequently, the split microfiber web formed through thermal bonding and the composite PTT web coupled with needle punching are simultaneously supplied to combine the split microfiber web and the composite PTT web through a needle punching process (S206). At this time, the split type microfiber web formed through thermal bonding intermittently sags to one side, and the split type microfiber web may partially overlap when the split type microfiber web and the composite PTT web are combined. Is installed before the punching machine so that the split microfiber web is fed straight through the anti-wrinkle device to the needle punching machine. At this time, the needles provided on the needle board of the needle punching machine is increased from 300 to 420 pieces from 200 to 320, and the draft is lowered to 20% to 30% from 35% to 50%, thereby improving the density and surface smoothness. Increase more.

Subsequently, the needle punched nonwoven fabric is overfeeded using a relax device so as not to be tensioned, and then supplied to the shrinking device to shrink. High shrink polyester is easily contracted, and the shrinkage rate varies greatly depending on the temperature, and thus the degree of contraction effect and spontaneous elongation effect is changed, and problems such as curling phenomenon and weight deviation may occur. , Divide the shrinking process into two stages. That is, after preliminarily contracting in a first step in a first hot water bath having a temperature of 50 ° C. to 98 ° C., it is transferred to a second hot water bath having a temperature of 50 ° C. to 98 ° C. for complete shrinkage.

In addition, in the shrinking process, the polyvinyl alcohol resin (PVA) is 3% to 12%, softener 1% to 10% soaking the needle-punched non-woven fabric in the hot water solution of the boiling water bath to heat shrink. Polyvinyl alcohol resin reduces resin impregnation amount and facilitates workability when impregnated with polyurethane resin, and forms porous material after washing to soften artificial leather, thereby increasing the density of split microfiber nonwoven products and maximizing microfiber effect. Surface smoothness is also excellent.

Completed shrinkage of the nonwoven fabric is dewatered by passing through a pair of dehydration rollers (S210), and then coated with a roller to improve the surface smoothness and physical properties of the split microfiber nonwoven fabric (S212), and then through a tender to keep the width constant. Drying in a drying device of the type or cylinder (S214). Drying starts the initial drying temperature at 70 ℃ and the final temperature to 170 ℃ to dry all the moisture remaining on the nonwoven fabric. The dried nonwoven fabric is passed through a pair of upper and lower thermal calenders having a constant interval to obtain a final nonwoven fabric (S216). At this time, the upper and lower pair of heat calender is adjusted so that the heating temperature is 80 ℃ ~ 170 ℃, speed 3m / min ~ 10m / min.

The split microfiber nonwoven product manufactured according to the method of the present invention has excellent appearance and feel compared to the existing product, and it can be seen that the quality is greatly improved in elasticity and circular restoration rate. Hereinafter, the quality of the nonwoven product manufactured according to the method of the present invention through various examples and comparative examples will be compared with conventional products. The following examples are only for illustrating the present invention more specifically, but the scope of the present invention is not limited to these examples.

≪ Example 1 >

Split microfiber web formed by forming 100% of split microfiber into flat sheet web through thermal bonding, 50% composite PTT fiber (weight), 25% high shrink polyester (weight), and 25% nylon fiber (weight) A nonwoven fabric was prepared by needle punching the composite PTT web formed into a flat sheet web by preliminary needle punching in a predetermined amount at the horn surface by a weight ratio of 40:60.

Comparative Example 1-Conventional Nonwoven Fabric

The microfiber felt composed of 100% islands-in-the-sea microfiber was impregnated with a polyurethane resin, eluted to a sodium hydroxide solution through a solidification, washing, and drying process, and then manufactured to a nonwoven fabric through a buffing process.

Comparative Example 2-Conventional Nonwoven Fabric

A nonwoven fabric was prepared by metering 40% (weight) of high shrink polyester and 60% (weight) of nylon fiber in a predetermined amount at the horn surface.

<Test Example 1>

Morphological analysis of Example 1 and Comparative Examples 1 and 2 was performed using a scanning electron microscope SEM-SRK-WIO-P31 instrument.

2 is a scanning electron micrograph of the surface of Example 1 and Comparative Examples 1 and 2 magnified by 40 times and 150 times, respectively, through the morphology analysis of <Test Example 1>.

As shown in Figure 2, the nonwoven fabric prepared according to the present invention (Example 1) was found to have a very good flexibility and flexibility of microfiber compared to the conventional nonwoven fabrics (Comparative Examples 1, 2), the density of the product It was also shown to be very high, and the nonwoven fabric prepared according to the present invention was found to have a very good surface feel and surface flatness compared to the conventional nonwoven fabric.

<Test Example 2>

Evaluation item Test Act Weight (g / ㎡) KSK 0514 (0.001g Balance) Thickness (mm) KSK 0506 (Dlal Gauge) Tensile strength (kgf / 2.5㎝) KSK 0520 (2.5cm Cut Strip Method) Shinto (%) KSK 0520 (2.5cm Cut Strip Method)

After measuring the weight and thickness of the test pieces of Example 1 and Comparative Examples 1 and 2, the tensile strength and elongation for measuring the elasticity were evaluated by the KS standard test method of Table 1, and the results are shown in Table 2. It was.

<Test Example 3>

After maintaining the grip interval of the tensile tester at an interval of 7.5 cm, color marking was applied to the end portions of the test specimens of Example 1 and Comparative Examples 1 and 2, and the elongation was 20% and 50%, respectively, on the display of the tensile tester. After indicating the stop operation of the tensile tester to measure the reduced length by releasing the grip, the recovery rate is calculated according to the following equation 1 and the results are shown in Table 2. In this case, the grip and the grip interval of 7.5cm were excluded from the recovery rate calculation.

division Example 1 Comparative Example 1 Comparative Example 2 Thickness (mm) 1.1 1.42 1.12 Density (g / cm 3) 0.29 0.19 0.25 The tensile strength
(kg / in) MD 23 34.9 32 CD 16 25.5 23 Elongation
(%) MD 113 74.8 105 CD 195 110 162 % Recovery 91 26 48

(At this time, MD is Machine Drection, CD: Cross Direction)

Looking at the measurement results of the Examples and Comparative Examples, Example 1 has a lower tensile strength than Comparative Examples 1 and 2, but also shows excellent cutting elongation and recovery rate, it can be seen that the excellent elasticity and circular recovery rate is excellent. . In other words, the nonwoven fabric prepared according to the present invention (Example 1) can be effectively stretched with a small force compared to the conventional nonwoven fabrics (Comparative Examples 1 and 2), and the elongation at break is not easily broken even if it is stretched to some extent. Of course, it can be seen that by showing an excellent circular recovery rate, the tensile force is easily restored to a circular shape within a short time.

In conclusion, the split microfiber nonwoven fabric produced by combining the split microfiber web and the composite PTT web according to the present invention was found to have excellent surface feel and surface smoothness due to its flexibility and bending ability, and has excellent elasticity and circular restoration rate. In addition, it is shown that the moonlight is excellent, showing the characteristics suitable for use as a high functional material such as artificial leather.

In addition, the split microfiber nonwoven fabric can be easily manufactured through the simple process of combining the split microfiber web formed through thermal bonding and the composite PTT web combined through needle punching with needle punching, and at the same time, the soft touch of the split microfiber fabric. There is an advantage that can be maximized.

The split microfiber nonwoven fabric according to the present invention may prepare a multi-layer composite nonwoven fabric by inserting a web on a woven or knitted flat sheet to reduce damage of the split microfiber fibers by needling during the nonwoven fabric manufacturing process. 3 is a schematic cross-sectional view of a split microfiber nonwoven fabric in which a woven or knitted web is inserted according to an embodiment of the present invention.

As shown in FIG. 3, 100% polyester or 100% cotton, or a blend of both, is made into a flat sheet web through a carding process, and the fabric or knitted web 130 thus prepared is divided. Non-woven fabric produced by combining the microfiber web 110 and the composite PTT web 120 by needle punching, whereby the split microfiber web 110 and the woven or knitted web 130 and the composite PTT web 120 are joined together. Can be obtained.

Accordingly, the needle punching prevents the fibers of the composite PTT web having a finer thickness than the split microfiber fibers from proliferating and protruding to the surface of the composite sheet, thereby preventing the problem that the artificial leather feels rough and hard.

The present invention described above is not limited to the above-described embodiments and the accompanying drawings, and various substitutions, modifications, and changes are possible in the art without departing from the technical spirit of the present invention. It will be clear to those of ordinary knowledge.

1 is a schematic cross-sectional view of a split microfiber nonwoven fabric according to an embodiment of the present invention.

Figure 2 is a flow chart showing a split type microfiber nonwoven fabric manufacturing method according to an embodiment of the present invention.

Figure 3 is a scanning electron micrograph of the surface of Example 1 and Comparative Examples 1, 2 magnified by 40 times and 150 times, respectively.

Figure 4 is a schematic cross-sectional view of a split microfiber nonwoven fabric inserted into a fabric or knitted sheet according to an embodiment of the present invention.

* Description of the symbols for the main parts of the drawings *

100: split microfiber nonwoven fabric 110: split microfiber web

120: composite PTT web 130: web on woven or knitted flat sheet

Claims (10)

In the method of manufacturing a split microfiber nonwoven fabric, Forming a split microfiber web on a planar sheet with split microfiber fibers; Mixing the composite PTT fibers with the highly shrinkable polyester and the normal nylon fibers, and then forming the composite PTT web on the flat sheet with the blended cotton; A needle punching step of bonding and bonding the formed composite PTT web and the split microfiber web through needle punching; A contraction step of contracting the needle punched web; A drying step of dewatering and drying the shrunken web; A calendering step of passing the dried web through a pair of upper and lower thermal calenders; Split type microfiber nonwoven fabric manufacturing method characterized in that it comprises a. The method of claim 1, Forming the split microfiber web, A method of manufacturing a split microfiber nonwoven fabric, wherein the split microfiber fibers are formed into a split microfiber web on a flat sheet through thermal bonding. 3. The method of claim 2, The thermal bonding, Process for producing a split microfiber nonwoven fabric, characterized in that carried out under the conditions of temperature 130 ° ~ 170 °, speed 15 m / min ~ 30 m / min, pressure 80 pa ~ 120 pa. The method of claim 1, The raw material used as a material for forming the composite PTT web, Method for producing a split microfiber nonwoven fabric, characterized in that blended to have a weight ratio of 20 to 60% composite PTT fiber, 20% to 40% high shrink polyester fiber, 20% to 60% general nylon fiber. The method according to claim 1 or 4, The composite PTT fiber, A method for producing a split microfiber nonwoven fabric, characterized in that the yarn is made of polytrimethylene terephthalate (PTT) and polyethylene terephthalate (PET) bonded to form a bimetal structure. The method of claim 1, Forming the composite PTT web, A method of manufacturing a split microfiber nonwoven fabric comprising forming a mixed fiber into a composite PTT web on a flat sheet through needle punching. The method of claim 1, Split type microfiber web supplied to the needle punching step, A method of manufacturing a split microfiber nonwoven fabric, which is supplied through an anti-wrinkle device. The method of claim 1, In the contraction step, A method of manufacturing a split microfiber nonwoven fabric, characterized in that the polyvinyl alcohol resin (PVA) is immersed in a hot water solution in which 3 to 12% and 1 to 10% of a softener is dissolved. In the method of manufacturing a split microfiber nonwoven fabric, Forming a split microfiber web on a planar sheet with split microfiber fibers; Mixing the composite PTT fibers with the highly shrinkable polyester and the normal nylon fibers, and then forming the composite PTT web on the flat sheet with the blended cotton; A needle punching step of inserting a flat sheet-like web of a woven fabric or knitted fabric between the formed composite PTT web and the split microfiber web, and then bonding and binding the composite PTT web through needle punching; A contraction step of contracting the needle punched web; A drying step of dewatering and drying the shrunken web; A calendering step of passing the dried web through a pair of upper and lower thermal calenders; Split type microfiber nonwoven fabric manufacturing method characterized in that it comprises a. The method of claim 9, The web on the flat sheet of the fabric or knit, A method for producing a split microfiber nonwoven fabric, characterized in that the fiber consists of 100% polyester or 100% cotton or a mixture of both.

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