KR101079804B1 - Polyester spunbond nonwovens and the preparation method thereof - Google Patents

Abstract

The present invention relates to a polyester long fiber spunbond nonwoven fabric and a method for producing the same, more particularly, polyester (first component) having an intrinsic viscosity (IV) of 0.655 and a melting point of 250 to 270 ° C; And a long fiber spunbond nonwoven composition comprising a copolyester (second component) having an intrinsic viscosity (IV) of 0.620 to 0.765 and a melting point of 180 ° C. or more and less than 230 ° C., and a long fiber spunbond nonwoven fabric using the same To provide.

Carpet Bubble, Spunbond Nonwoven, Tufting

Description

Polyester spunbond nonwovens and its preparation method

The present invention relates to a composition for long fiber spunbond nonwovens suitable for use as a carpet bubble paper, a polyester long fiber spunbond nonwoven fabric using the same, and a method of manufacturing the same.

Polyester spunbond nonwoven fabrics have high productivity, high power and low thickness and are used in many industrial fields. It is used in civil engineering and building applications by using high strength and excellent drainage characteristics, and is also widely used for automobiles due to its low cost and excellent durability. In particular, in recent years, due to the excellent shape stability and dust trapping ability is often used as a filter material.

Carpet bubble paper is particularly difficult to manufacture in the use of polyester spunbond nonwovens, where needles penetrate the nonwovens during tufting of the carpet yarn onto the nonwoven in the process of use. At this time, the filament fibers constituting the nonwoven fabric are damaged or broken so that the properties of the entire nonwoven fabric such as strength, elongation and tear strength decrease. In order to solve these problems, various methods have been proposed, but the technical and commercial situation is still insufficient.

Korean Patent Publication No. 1998-0061102 discloses a web by simultaneously spinning a low melting point copolyester of 230 ° C., which has a lower melting temperature than polyester and polyester, and then performs a needle punch and performs a calender roller. It provides a method of making a spunbonded nonwoven fabric for carpet bubble paper by passing it through. However, this method is not only complicated, but also has a high cutting rate of the filament after tufting, and thus it is not applicable to carpet bubble paper due to its low strength, elongation and low tear strength retention.

Republic of Korea Patent Publication No. 2001-0053138 is made of polyester and polylactic acid (PLA), a method of manufacturing a spunbond nonwoven fabric that can produce a tufted carpet bubble paper by producing a sectional cross-section yarn through a composite spinning method. Suggesting. However, such a manufacturing method is not only easy to cause cutting and spinning defects due to the extremely difficult spinning process, but also increases the manufacturing cost by using an expensive polylactic acid polymer.

US Pat. No. 4,169,176 describes a method for producing carpet bubble paper by subjecting the produced polyester spunbond nonwoven fabric to an acrylic binder treatment on one side by a separate post-processing method. However, this method is not commercially desirable because of the additional cost required for post-processing.

In addition, US Pat. No. 4,210,690 describes a method for producing a spunbond nonwoven fabric for carpet paper by modifying a low melting point copolyester. However, the method lacks the advantages and examples when used for carpet bubble paper, and is therefore not suitable for industrial use.

The present invention is to provide a long fiber spunbond nonwoven composition suitable for use as a carpet bubble paper having excellent physical properties such as tensile strength, elongation and tear strength.

The present invention also provides a polyester spunbond nonwoven fabric using the composition and a method of manufacturing the same.

In order to achieve the above object, the present invention is a polyester (first component) having an intrinsic viscosity (IV) of 0.655 and a melting point of 250 ~ 270 ℃; And an intrinsic viscosity (IV) of 0.620-0.75 and a melting point of 180 ° C. or higher and a copolyester (second component) of lower than 230 ° C.

The copolyester (second component) may be used in an amount of 8 to 30% by weight based on the total composition, and may be prepared from copolymerized monomers including adipic acid, isophthalic acid, or mixtures thereof.

In addition, the present invention (a) polyester (first component) having an intrinsic viscosity (IV) 0.655 and a melting point of 250-270 ℃; And intrinsic viscosity (IV) of 0.620 to 0.765 and melting point of 180 ° C. and lower than 230 ° C. of copolyester (second component), respectively, in the spinneret to prepare filament fibers, and (b) opening the filaments Laminating in the form of a web, (c) heat-bonding the filaments of the laminated web to fix the web to produce a spunbond nonwoven fabric, and then spraying an emulsion; And (d) performing a tufting process, which is a process of implanting a carpet yarn onto a spunbond nonwoven fabric sprayed with an emulsion.

It provides a method for producing a long fiber spunbond nonwoven fabric comprising a.

The heat bonding is preferably made for 3 to 9 seconds through a hot air dryer.

In addition, the emulsion is sprayed in an amount of 0.2 to 2% by weight relative to the total weight of the long fiber spunbond nonwoven fabric, and may preferably be polydimethylsiloxane.

In addition,

Polyester fibers having an intrinsic viscosity (IV) of 0.655 and a melting point of 250 to 270 캜;

Copolyester fibers having an intrinsic viscosity (IV) of 0.620-0.75 and a melting point of more than 180 ° C. and less than 230 ° C .; And

A carpet yarn implanted on said polyester fibers and copolyester fibers,

Tensile strength in radial / up direction 18-23 / 16-23 Kg / 5cm, Elongation in radial / up direction 18-36 / 24-35%, Tear strength in radial / up direction 7-12 / 8- It provides a long fiber spunbond nonwoven fabric having a physical property of 12 Kgf and thermal shrinkage (150 ° C. × 3 min) 0.05-0.40%.

The spunbond nonwoven fabric includes filament fibers having a fiber thickness of 6 to 20 deniers and a density of 0.22 to 0.42 g / cm 3.

In addition, the present invention provides a carpet bubble paper prepared by including the long fiber spunbond nonwoven fabric.

Hereinafter, the present invention will be described in detail.

The prior art has been difficult to practically use industrially because the manufacturing method of the spunbond nonwoven fabric are all partially presented. Accordingly, the present invention provides a method for producing a spunbonded nonwoven fabric, and maintains the physical properties of the spunbonded nonwoven fabric before and after tufting, which is essential for post-processing, and is easy to manufacture. It is to provide a manufacturing method.

In this case, the term 'tufting process' refers to a process of grafting through a nonwoven fabric in a vertical direction by using a carpet yarn on a spunbond nonwoven fabric with a needle.

Also, in general, a method for producing a polyester spunbond nonwoven fabric in a spunbond nonwoven fabric is easy to manufacture a large amount of products because the web is produced by stretching the filament fibers at high speed. Accordingly, the present invention provides a composition comprising a polyester having a specific melting point, a spunbond nonwoven fabric using the same, and a method of manufacturing the same.

In the present invention, the polyester having the specific melting point includes a first component and a second component having different melting points. The first component is a polyester component having an intrinsic viscosity (IV) of 0.655 and a melting point of 250-270 ° C., preferably 254 ° C., and the second component is a low melting point copolyester having a lower melting point than the first component. (IV) is 0.620-0.745, preferably 0.714, and has a melting point of at least 180 ° C and less than 230 ° C.

In the present invention, the polyester (first component) may be prepared by a method known to those skilled in the art. For example, the polyester may be polyethylene terephthalate or a copolymer thereof.

In addition, the low melting copolyester (second component) may be prepared by copolymerizing a copolymerization monomer of adipic acid (Adipic acid), isophthalic acid (Isophtalic acid), or a mixture thereof. Commercially, both materials may be used to polymerize.

In particular, the melting point of the low-melting copolyester (second component) is preferably 180 ° C or more and less than 230 ° C, more preferably 220 ° C or less, and even more preferably 180-210 ° C. At this time, when the melting point of the copolyester is 230 ℃ or more, the thermal bonding and heat treatment temperature is high, it is not possible to produce a carpet bubble paper having excellent tear strength, and also the lack of flexibility of the foam paper, the tufting in post-processing When implemented, the cutting and breaking of the nonwoven filament is indicated. As a result, after tufting, the strength, elongation, and tear strength of the nonwoven fabric decrease, and thus it cannot be used for carpet bubble paper. In addition, when the melting point of the copolyester falls below 180 ° C., the viscosity of the first component polyester fiber and the low melting point copolyester, the second component that is spun at the same time at a high temperature, is severely generated, such as cutting and spinning. Defects occur in large quantities, which leads to a decrease in the productivity of the nonwovens and to a number of quality defects. In addition, when the thermal bonding temperature is 180 ° C or less due to the ultra-low melting point copolyester, the thermal shrinkage of the nonwoven fabric is increased. Too large heat shrinkage results in a lack of morphological stability, which may cause wrinkles in spunbonded foams that have been dyed or heat treated at a high temperature after tufting, resulting in uneven external dimensions of the final product, resulting in deterioration of the overall product quality. do.

In addition, the content of the copolyester (second component) of the nonwoven fabric provided in the present invention is preferably used in an amount of 8 to 30% by weight, more preferably 10 to 12% by weight based on the total composition. At this time, when the content of the copolyester is more than 30% by weight, the adhesion point and the adhesion between the fibers is too large, damage of the filaments due to the penetration of the needle when tufting. In addition, if the content of the copolyester is too low, less than 8% by weight, the adhesion of the fibers are insufficient, the physical properties of the nonwoven fabric is reduced. In addition, copolyester has a higher price than regular polyester, so a high cost of use occurs. Therefore, the content ratio of the copolyester may occur slightly depending on the manufacturing conditions, 8 ~ 30% by weight level is appropriate.

Moreover, this invention can manufacture the long fiber spun bond nonwoven fabric for carpet bubble papers by the following method using the composition for long fiber spun bond nonwoven fabric which has the said structure. That is, the method for producing a long fiber spunbond nonwoven fabric of the present invention comprises: (a) a polyester (first component) having an intrinsic viscosity (IV) of 0.655 and a melting point of 250-270 ° C .; And intrinsic viscosity (IV) of 0.620 to 0.765 and melting point of 180 ° C. and lower than 230 ° C. of copolyester (second component), respectively, in the spinneret to prepare filament fibers, and (b) opening the filaments Laminating in the form of a web, (c) thermally bonding the filaments of the laminated web to fix the web to produce a spunbond nonwoven fabric, and then spraying an emulsion; (d) performing a tufting process, which is a process of implanting a carpet yarn onto a spunbond nonwoven fabric sprayed with an emulsion.

In this case, the spunbond nonwoven fabric of the present invention should be flexible and excellent in shape stability because it is manufactured for carpet bubble paper. In order to meet these requirements, in the thermal bonding method, since the heat treatment should be given to the nonwoven fabric as uniform as possible and at least a certain time, the present invention is characterized by using a thermal bonding method through a hot air dryer. That is, the heat bonding method by the calender roll or the embossing roll method generally used for the heat bonding method of a nonwoven fabric is not used in this invention. In the spunbonded carpet bubble paper of the present invention, more uniform and long-term heat treatment is essential. In order to satisfy these requirements, the present invention is to manufacture the spunbonded nonwoven fabric for carpet bubble paper of the present invention using an adhesive method using hot air instead of the conventional simple thermal bonding method.

In more detail, the spunbond nonwoven fabric manufactured by using a conventional calender or embossing roll is not only subjected to high heat between steel rolls, but also is subjected to high pressure at the same time. Higher pressures result in thinner final nonwovens, which tends to over-dense fibers. This phenomenon has a similar result to that of the non-woven fabric made of fine-grained fibers described above, resulting in a low degree of freedom of the fibers when the needle penetrates. In other words, when the adhesive method using a roller is used, the nonwoven fabric is excessively compressed and the thickness is lowered. As a result, the fibers are excessively dense and the fibers are damaged by the needle when tufting. Finally, the physical properties of the carpet bubble paper are decreased. . In addition, the thermal bonding time is momentarily too short, so that sufficient heat treatment is not achieved. Furthermore, the residence time of the nonwoven fabric passing between the rollers at the time of production at a linear speed of 30 m / min is a short moment of not more than 0.1 second. As such, the filaments of the nonwoven fabric are not sufficiently heat treated in a short time, and when heat is applied in post-processing, wrinkles are likely to occur, and the heat shrinkage rate is also high to satisfy the final product dimensions.

Therefore, the present invention was intended to produce a carpet nonwoven fabric of the present invention by making the residence time as long as possible while the thermal bonding without thermal change. In order to solve these problems, the present invention introduced a heat setting device for injecting hot air, such as tenter (Tenter) as a hot air dryer to prepare a nonwoven fabric for carpet. That is, in order not to impart extra physical pressure to the nonwoven fabric, hot hot air is passed between the fibers of the nonwoven fabric to melt the low temperature copolyester filament present between the webs. Since the nonwoven fabric thus prepared is adhered only by hot air under conditions that are not compressed by an external force, a spunbonded nonwoven fabric having a bulky structure can be obtained because it is not accompanied by a change in the thickness. In addition, according to the present invention can be adjusted for a long time the hot air treatment time can be carried out at the same time heat bonding and heat treatment.

In the present invention, the temperature of the hot air processor is used by setting the temperature equal to or slightly lower than the melting point of the copolyester. That is, when using a copolyester having a melting point of 205 ℃ hot air temperature is controlled to 205 ℃ ~ 200 ℃ level. Bonding at a temperature higher than the melting point of the copolyester causes the filaments to adhere too much and the degree of freedom of the fibers required for tufting decreases, resulting in severe drop in properties after tufting. And when the bonding temperature is too low below 200 ℃ heat bonding does not occur, the physical properties of the nonwoven fabric is too low to use for the carpet.

The non-woven fabric stays in the hot air treatment unit is preferably 3 seconds to 9 seconds, preferably 4 seconds-9 seconds, more preferably 5 seconds-9 seconds. In practice, the time required for thermal bonding in a hot air handler is less than 2 seconds. Therefore, the residence time of 2 seconds or more corresponds to the heat treatment time. The longer the heat treatment time, the better the shape stability, but in general, if the heat shrinkage behavior is maintained stable for more than 3 seconds except the heat bonding time, it is not necessary to waste heat by increasing the residence time excessively.

In addition, the present invention is uniformly applied to the non-woven fabric subjected to the heat bonding and heat treatment process finally to the oil base containing polydimethylsiloxane uniformly in order to finally achieve the product completeness of the spunbonded nonwoven fabric for carpet. The coating amount of the emulsion is preferably 0.2 to 2% by weight based on the total weight of the spunbond nonwoven fabric, preferably 0.3-2% by weight, more preferably 0.4-2% by weight. At this time, if the amount of oil coating is less than 0.2% by weight, not only the oil does not penetrate uniformly into the nonwoven fabric constituting fibers, but also there is a problem that the absolute amount is insufficient to form a film of sufficient oil on the fiber surface layer. If this happens, the fibers are destroyed when tufting. In addition, if the amount of oil coating is 2% by weight or more, there is no big problem in using the product, but if too many oils are applied in the process, problems arise in maintaining the cleanliness of the process due to the scattering of the oil, and the excess oil adheres to the nonwoven fabric and is sticky. It is preferable to maintain an appropriate amount of adhesion because the particles are easily attached to particles such as insects and dusts, and problems such as migration of oil and leakage occur during long-term storage.

In this way, when the oil is applied onto the nonwoven fabric, the friction between the needle and the nonwoven fabric generated during needle penetration in the tufting process can be minimized, thereby minimizing fiber damage, and also reducing the friction and heat generation of the needle. This is extended. Therefore, the tanning process in the present invention must be made essentially, it is indispensable in the manufacture of spunbond nonwoven fabric for carpet.

As described above, the spunbonded nonwoven fabric of the present invention may perform a tufting method of grafting carpet yarns on the nonwoven fabric. The kind of the carpet yarn is not particularly limited, and for example, nylon 6, nylon 66, polypropylene, acrylic yarn, wool yarn, cotton yarn, or the like can be used.

The present invention also provides a long-fiber spunbond nonwoven fabric for carpet bubble paper produced by the above-described method and a carpet bubble paper comprising the same.

The long-fiber spunbond nonwoven fabric of the present invention has a tensile strength of 18-23 / 16-23 Kg / 5cm in the longitudinal direction after the tufting process, which is a process of implanting a carpet yarn in a nonwoven fabric having properties equal to or greater than the conventional one. Elongation 18-36 / 24-35% in the direction / up direction, tear strength 7-12 / 8-12 Kgf in the radial direction / up direction, and 0.05-0.40% heat shrinkage (150 ° C. × 3 minutes). In addition, the long fiber spunbond nonwoven fabric of the present invention is polyester fiber having an intrinsic viscosity (IV) of 0.655 and melting point of 250 ~ 270 ℃; Copolyester fibers having an intrinsic viscosity (IV) of 0.620-0.75 and a melting point of more than 180 ° C. and less than 230 ° C .; Carpet yarns implanted on the polyester fibers and copolyester fibers. The nonwoven fabric of the present invention may also comprise an emulsion applied on the polyester fibers and copolyester fibers.

In particular, the polyester spunbond nonwoven fabric according to the present invention must maintain a constant thickness (fineness) of the filament fibers constituting the nonwoven fabric. That is, the polyester filament fibers of the nonwoven fabric for carpet bubble paper provided in the present invention should maintain a certain thickness or more. The fiber of the filament fiber of the nonwoven fabric provided in the present invention has a thickness of 6-20 denier, preferably 7-12 denier or more, and more preferably 8-12 denier. Although not determined in a general polyester spunbond manufacturing method, it is difficult to commercially uniformly produce more than 20 deniers in the thickness of the fiber. Therefore, the filament fibers of the nonwoven fabric for carpet bubble paper provided in the present invention should maintain the thickness of at least 6 denier or more than 20 denier. At this time, if the thickness of the filament is less than 6 denier, the number of fibers in the nonwoven fabric having the same weight is increased and the intersection points between the fibers are increased. The spunbonded nonwoven fabric thus constructed can exhibit high strength, but is difficult to move between the fibers, so that the fibers are easily cut or broken and damaged when the needle penetrates when tufted. Therefore, after tufting, the strength, elongation, and tear strength of the nonwoven fabric are sharply lowered, which is difficult to use for carpet bubble paper. In addition, if the thickness of the fiber is composed of more than 6 denier as in the present invention, the movement of the fibers relatively smooth and free in the nonwoven fabric, it is possible to minimize the damage of the fiber when tufting. The larger the thickness of the fiber, the more clearly this behavior is observed, and there is no significant difference above 8 denier.

In addition, the spunbonded nonwoven fabric of the present invention retains bulkiness while maintaining a uniform back. The density of the nonwoven fabric for carpet bubble paper produced by the thermal bonding method of the present invention is 0.22 to 0.42 g / cm 3, more preferably 0.26 to 0.34 gr / cm 3. If the density of the nonwoven fabric is less than 0.22 g / cm 3, a bulky nonwoven fabric can be obtained, but the adhesion between the fibers is weak and the strength and elongation are too low. In addition, when the density is 0.42 g / cm 3 or more, the closeness between the fibers becomes so dense that the fibers are damaged by the needle and the strength and elongation of the nonwoven fabric decrease after the tufting.

According to the present invention, by controlling the intrinsic viscosity and melting point of the low-melting copolyester and its content in a specific range, by adjusting the heat bonding method and the amount of emulsion applied through a hot air dryer, the tensile strength, elongation after the tufting process than conventional It is possible to provide a long fiber spunbond nonwoven fabric having excellent tear strength and heat shrinkage. In addition, all of the nonwoven fabrics are suitable for use in carpet bubble paper, and because they can be manufactured quickly in a commercial one-step (One step) process has an excellent economic effect.

Hereinafter, the present invention will be described in more detail with reference to the following examples. However, the scope of the present invention is not limited to the following examples.

In the present invention, the measurement standard used a JIS L 1906 long fiber spunbond nonwoven fabric measuring method.

Tensile strength and elongation were borrowed from Cut-Strip in this standard, and the tearing strength was Tongue method.

In the present invention, the density measurement method was taken by measuring the weight of each 10cm × length, and then measured the weight of the four sides and the center to calculate the average value was made to the thickness of the sample. In addition, the volume of the nonwoven fabric was calculated using this, and then the density was obtained by dividing the measured weight. Six or more samples were measured in this manner for a 1 M nonwoven product width and the average was calculated.

Example  1-3 and Comparative Example 1 -2

A polyester chip (first component) having an intrinsic viscosity (IV) of 0.655 and a melting temperature of 254 ° C. and a low melting point copolymer having a lower melting point than the first component as shown in Table 1 below. The ester chip (second component) was melted and spun at a spinning temperature of 288 ° C. in a conventional spunbond manufacturing apparatus. Adipic acid or isophthalic acid was used as the copolymerization monomer of the low melting point copolyester chip, and the melting temperature was adjusted by adjusting the input amount and the mixing amount. At this time, the capillary number and discharge amount of the spinneret were adjusted so that the diameter of the filament fibers laminated in the form of a web after the stretching was 9 denier. In addition, the ratio of the discharge amount of the polyester (first component) and the copolyester (second component) was adjusted to be 80% by weight and 20% by weight, respectively.

This separately spun filament fibers were accumulated on a moving net conveyor, and then passed through at a low temperature of 120 ° C. or lower using a calender roll to impart some focus, and then heat-bonded using a hot air treatment. Thereafter, an emulsion containing polydimethylsiloxane as a main component was sprayed onto a spunbond nonwoven fabric prepared to be about 1.0% by weight, and wound around a winding machine to prepare a long fiber spunbond nonwoven fabric.

At this time, the spunbonded nonwoven fabric for carpet bubble fabric was arbitrarily adjusted to have a weight of 120 gsm, and the heat adhesion temperature of the hot air treatment was adjusted to be 0 ° C. to 4 ° C. lower than the melting point of the used copolyester.

The spunbonded nonwoven fabric thus prepared was tufted with a 1/10 gauge using a tufting machine, and carpet yarns were made of nylon 6 1 dyed yarn 1240 denier. Tensile strength, elongation, and tear strength after tufting were measured by the method after removing all the nylon yarns implanted in the nonwoven fabric and the results are shown in Table 1. In addition, heat shrinkage was measured by the dry heat shrinkage measuring method of JIS L 1906, and the results are shown in Table 2.

TABLE 1

division Item unit Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Copolyester Melting point ℃ 205 226 183 234 178 Copolymer - AA AA IPA + AA AA IPA Intrinsic viscosity - 0.715 0.704 0.742 0.685 0.746 Non-woven
Biophysical properties The tensile strength Kg / 5cm 24/22 23/23 24/23 25/24 24/23 Shinto % 32/34 28/26 36/37 26/23 38/38 Phosphorus strength Kgf 11/12 10/11 14/15 8/9 15/16 After tufting
Properties The tensile strength Kg / 5cm 20/18 19/18 22/21 12/13 16/16 Shinto % 29/28 26/24 36/35 18/16 24/22 Phosphorus strength Kgf 9/8 8/8 11/12 2/3 5/6 Note) The property value is the value of radial / upward direction.
AA: adipic acid, IPA: isophthalic acid

In the results of Table 1, in the case of the present invention it can be seen that the tensile strength, elongation and tear strength after tufting is very excellent compared to the comparative example. On the other hand, the copolyester nonwoven fabric physical properties of the melting temperature of 234 ℃ of Comparative Example 1 is similar to the examples, but the non-woven fabric is too stiff so that the rate of decrease in strength, elongation and tear strength after tufting is too high. In addition, in Comparative Example 2, the melting temperature of 178 ° C copolyester nonwoven fabric also shows a high physical property fall rate and a high shrinkage rate. In addition, the spinning non-woven fabric at a high temperature is a lot of spinning defects such as cutting appeared to be difficult to apply commercially.

TABLE 2

division unit Example 1 Example 2 Example 3 Comparative Example 1 Comparative Example 2 Thermal contraction rate (150 ℃ x 3 minutes) % 0.14 0.08 0.24 0.06 0.45

Example  4-6, Comparative example  3-4

A conventional spun with a polyester chip (first component) having an intrinsic viscosity (IV) of 0.655 and a melting temperature of 254 ° C. and a copolyester chip (second component) having an intrinsic viscosity (IV) of 0.715 and a melting temperature of 205 ° C. It melted and spun at a spinning temperature of 288 ° C. in a bond manufacturing apparatus. Other manufacturing conditions were the same as in Example 1, to change the content of copolyester as shown in Table 3 to prepare a spunbond nonwoven fabric.

[Table 3]

division Item unit Example 4 Example 5 Example 6 Comparative Example 3 Comparative Example 4 Copolyester content wt% 8 15 30 5 35 Non-woven
Biophysical properties The tensile strength Kg / 5cm 20/19 24/22 28/27 16/15 33/32 Shinto % 32/34 31/33 26/23 24/21 21/18 Phosphorus strength Kgf 14/15 13/14 11/11 15/15 6/5 After tufting
Properties The tensile strength Kg / 5cm 18/16 20/19 23/22 8/6 12/11 Shinto % 28/29 28/30 24/26 14/13 10/13 Phosphorus strength Kgf 11/11 11/10 9/10 2/2 2/2 Note) The property value is the value of radial / upward direction.

From the results of Table 3, it can be seen that, as in Comparative Examples 3 and 4, if the content of the copolyester is too large or insufficient, the drop in physical properties is severely shown.

Example  1, 7-8, Comparative example  5

A conventional spun with a polyester chip (first component) having an intrinsic viscosity (IV) of 0.655 and a melting temperature of 254 ° C. and a copolyester chip (second component) having an intrinsic viscosity (IV) of 0.715 and a melting temperature of 205 ° C. It melted and spun at a spinning temperature of 288 ° C. in a bond manufacturing apparatus. Other manufacturing conditions were the same as in Example 1, to prepare a spunbond nonwoven fabric while adjusting the thickness of the filament fibers laminated in the form of a web (Web) after stretching as shown in Table 4.

[Table 4]

division Item unit Example 7 Example 1 Example 8 Comparative Example 5 The thickness of the fiber Denier - 6 9 12 4 Non-woven
Biophysical properties The tensile strength Kg / 5cm 28/26 24/22 21/20 33/35 Shinto % 34/36 32/34 28/29 35/34 Phosphorus strength Kgf 10/11 11/12 15/16 8/9 After tufting
Properties The tensile strength Kg / 5cm 21/22 20/18 20/18 9/8 Shinto % 22/26 29/28 26/28 16/15 Phosphorus strength Kgf 8/9 9/8 12/12 3/2 Note) The property value is the value of radial / upward direction.

Looking at the results of Table 4, it can be seen that the embodiment of the present invention shows a stable physical properties while increasing the thickness of the fiber. However, in Comparative Example 5, although the thickness of the fiber is lowered, the strength and elongation are increased, but the physical properties after tufting are drastically decreased and thus cannot be used for carpet bubble paper.

Example  1, 9-10, Comparative example  6-7

A conventional spun with a polyester chip (first component) having an intrinsic viscosity (IV) of 0.655 and a melting temperature of 254 ° C. and a copolyester chip (second component) having an intrinsic viscosity (IV) of 0.715 and a melting temperature of 205 ° C. It melted and spun at a spinning temperature of 288 ° C. in a bond manufacturing apparatus. Other manufacturing conditions were the same as in Example 1, to prepare a spunbond non-woven fabric while adjusting the temperature of the calender roll and hot air treatment to the conditions of Table 5. Thus, the density of the nonwoven fabric for carpet bubble papers could be adjusted, and the heat shrinkage rate was evaluated by adjusting the processing time at the time of manufacture.

TABLE 5

division Item unit Example 9 Example 1 Example 10 Comparative Example 6 Comparative Example 7 Nonwoven Density g / cm 3 0.22 0.31 0.40 0.19 0.44 Heat treatment time Sec. 9 6 8 4 10 Non-woven
Biophysical properties The tensile strength Kg / 5cm 22/21 24/22 32/30 14/12 36/37 Shinto % 33/36 32/34 24/25 17/15 26/24 Phosphorus strength Kgf 14/14 11/12 8/10 19/20 6/5 After tufting
Properties The tensile strength Kg / 5cm 19/20 20/18 22/23 4/4 8/7 Shinto % 29/26 29/28 18/19 8/10 15/12 Phosphorus strength Kgf 10/12 9/8 7/8 15/15 2/2 Thermal contraction rate (150 ℃ x 3 minutes) % 0.15 0.14 0.09 0.57 0.11 Note) The property value is the value of radial / upward direction.

As can be seen in Table 5, if the nonwoven fabric prepared as in Comparative Example 6 is too bulky (bulky) and the heat treatment time is short, it can be seen that the tensile strength and elongation decreases and the heat shrinkage rate increases. On the contrary, when the density was too high as in Comparative Example 7, it was difficult to maintain physical properties after tufting.

Example  1, 11-12, Comparative example  6-7

A conventional spun polyester polyester chip (first component) having an intrinsic viscosity (IV) of 0.655 and a melting temperature of 254 ° C. and a copolyester chip (second component) having an intrinsic viscosity (IV) of 0.715 and a melting temperature of 205 ° C. It melted and spun at a spinning temperature of 288 ° C. in a bond manufacturing apparatus. Other manufacturing conditions were the same as in Example 1, and the spunbond nonwoven fabric was prepared by spraying uniformly continuously on the nonwoven fabric after heat-treating the oil agent mainly containing polydimethylsiloxane under the conditions of Table 6 below. In this way, the coating amount of the oil of the spunbonded nonwoven fabric for carpet foam was able to be adjusted, and the tufting performance evaluation was performed according to the amount of oil coating.

TABLE 6

division Item unit Example 11 Example 1 Example 12 Comparative Example 8 Comparative Example 9 Emulsion weight - wt% 0.3 1.0 2.0 No treatment 0.1 Non-woven
Biophysical properties The tensile strength Kg / 5cm 24/23 24/22 23/22 23/21 24/22 Shinto % 34/32 32/34 33/35 31/33 31/33 Phosphorus strength Kgf 11/11 11/12 12/11 12/11 11/11 After tufting
Properties The tensile strength Kg / 5cm 18/19 20/18 21/20 7/8 12/12 Shinto % 26/25 29/28 27/28 14/18 19/18 Phosphorus strength Kgf 8/8 9/8 10/9 2/1 3/2 Note) The property value is the value of radial / upward direction.

As shown in Table 6, if there is no emulsion treatment or is applied at a very low throughput, it can be seen that there is a sharp drop in properties after tufting. Therefore, the amount of emulsion deposition must be treated uniformly over a certain amount.

Although the preferred embodiments of the present invention have been described above, the present invention is not limited thereto, and various modifications and changes can be made within the scope of the claims and the detailed description of the invention and the accompanying drawings. Naturally, it belongs to the scope of the invention.

The long fiber spunbond nonwoven fabric of the present invention has excellent physical properties and can be used for carpet production.

Claims (14)

delete delete delete (a) a polyester (first component) having an intrinsic viscosity (IV) of 0.655 and a melting point of 250-270 ° C .; And filament fibers by spinning and stretching the copolyester (second component) having an intrinsic viscosity (IV) of 0.620 to 0.765 and a melting point of 180 ° C to 226 ° C, respectively, (b) opening the filaments and laminating them in the form of a web; (c) thermally bonding the filaments of the laminated web to fix the web to produce a spunbond nonwoven fabric, and then spraying an emulsion; (d) performing a tufting process, which is a process of implanting a carpet yarn onto a spunbond nonwoven fabric sprayed with an emulsion, The heat adhesion is made for 3 to 9 seconds through a hot air dryer, The polyester (first component) is polyethylene terephthalate or a copolymer thereof, The copolyester (second component) is a method for producing a long fiber spunbond nonwoven fabric prepared from a copolymerization monomer comprising adipic acid, isophthalic acid or a mixture thereof. delete The method of claim 4, wherein the emulsion is sprayed in an amount of 0.2 to 2% by weight relative to the total weight of the long fiber spunbond nonwoven fabric. The method of claim 6, wherein the emulsion is polydimethylsiloxane. Polyester fibers having an intrinsic viscosity (IV) of 0.655 and a melting point of 250 to 270 캜; Copolyester fibers having an intrinsic viscosity (IV) of 0.620-0.75 and a melting point of 180 ° C. to 226 ° C .; And A carpet yarn implanted on said polyester fibers and copolyester fibers, The polyester fiber is polyethylene terephthalate or a copolymer thereof, The copolyester fibers are made from copolymerized monomers comprising adipic acid, isophthalic acid or mixtures thereof, Density ranges from 0.22 to 0.42 g / cm 3, tensile strength in the radial / up direction 18-23 / 16-23 Kg / 5cm, elongation in the radial / up direction 18-36 / 24-35%, radial / up direction The long fiber spunbond nonwoven fabric having a tear strength of 7-12 / 8-12 Kgf and a thermal contraction rate (150 ° C. X 3 minutes) of 0.05-0.40%. 9. The long fiber spunbond nonwoven fabric of claim 8, wherein the spunbond nonwoven fabric comprises filament fibers having a fiber thickness of 6 to 20 deniers. delete delete delete 10. The long fiber spurbond nonwoven fabric of claim 8, wherein the carpet yarn is selected from the group consisting of nylon 6, nylon 66, polypropylene, acrylic yarn, wool yarn and cotton yarn. Carpet bubble paper prepared by comprising a long fiber spunbond nonwoven fabric according to claim 8.