KR101976119B1 - Method for Manufacturing Spunbonded Nonwoven for Primary Carpet Backing with Improved Tufting - Google Patents

Abstract

The present invention relates to a method for producing a spunbonded nonwoven fabric for tufted carpet bubbles which uses a long fiber needle punching method but does not use a binder resin and thus simplifies the manufacturing process. And a second filament made of a low-melting-point copolyester having a melting point lower than that of the first filament by at least 40 占 폚, the web is laminated, the web is subjected to needle punching by calendering, .
According to the present invention, by the heat bonding method using hot air, there is no problem of dropping of the binder resin component during tufting and no problem of entanglement between tufting needles, lowering of punching resistance and excellent tufting and workability performance, The spunbonded nonwoven fabric for carpet bubble is less likely to be deteriorated and tufting needle wear is reduced, and the manufacturing cost can be lowered without using the binder resin.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a spunbonded nonwoven fabric for a carpet bubble having excellent tufting properties,

The present invention relates to a method for producing a spunbonded nonwoven fabric for carpet bubbles, which uses a long-fiber needle punching method but does not use a binder resin, thereby simplifying the manufacturing process and having excellent tufting workability.

The carpet bubble is a support for planting pile fibers. It must maintain its shape in the form of damage (puncture) caused by tufting needles used to plant pile fibers. In post-processing, Is a backcoated portion of polyvinyl chloride (PVC) or styrene butadiene rubber (SBR), and therefore, a needle punch nonwoven fabric made of a polyester-based long fiber as a carpet base paper There is no delamination between layers and the tensile strength and the shape stability at a high temperature are excellent and are widely used.

In the production of a needle punch nonwoven fabric used as a carpet bubble, a polyester-based or polyamide-dicarboxylic-based long-fiber having a denier of 3 to 30 denier is used for forming a nonwoven web or a core- Side by side composite fibers.

The long fibers are radiated to form a web on a conveyor. The fibers are first entangled through a needle punching process at a density of 40 to 120 times / cm 2, and then bonded to each other through a binder resin to form a nonwoven fabric.

The resin used as the binder is a copolymer of a monomer copolymerized with a monomer such as methyl acrylate, ethyl acrylate, butyl acrylate, ethyl methacrylate, butyl methacrylate, styrene, etc., and a binder resin solution is impregnated or sprayed on the nonwoven web And the fibers are fixed to each other through drying.

Wherein the binder resin has a glass transition temperature of -35 ° C to + 5 ° C and a softening point of -15 ° C to + 20 ° C and a difference of 5 ° C to 50 ° C between the melting point and the oil- It is mainly in the range of 5 to 30% by weight with respect to the total weight of the carpet protecting paper.

A method for obtaining a needle punch nonwoven fabric for carpet bubble is disclosed in Japanese Patent Application Laid-Open No. 09-268463.

The above patent discloses a method for manufacturing a nonwoven fabric by forming a nonwoven web with a long fiber and then performing a bonding process using a binder resin having a needle punch and a glass transition point and a softening point within a specific range, We wanted to make a nonwoven fabric for foam.

However, the strength of the resin is lowered in a high-temperature environment during the carpet manufacturing process, and the dimensional stability of the product deteriorates due to dimensional changes due to tensile stress.

In order to solve the above problems, attempts have been made to improve the temperature by a heat fusion process at a temperature lower than 30 ° C below the melting point of the long fibers (JP-A-10-273873)

As described above, the use of a binder resin for fiber-to-fiber bonding requires the step of applying a resin and drying, which complicates the manufacturing process and makes the bubbles hard due to the use of the binder. In the tufting process of planting the carpet pile fiber, And the binder component treated on the base paper increases the resistance against the direction of movement of the needle during tufting so as to increase the speed of progress of the wear of the needle, There is a problem that the replacement timing is advanced.

Accordingly, there is a demand for development of a carpet base paper having low tufting performance and good processability by a manufacturing process that does not use a binder resin.

Disclosure of Invention Technical Problem [8] Accordingly, the present invention has been made keeping in mind the above problems occurring in the prior art, and an object of the present invention is to provide a spunbonded nonwoven fabric for carpet bubbles capable of improving the retention ratio of mechanical strength and tufting workability when toughening, And a method thereof.

In order to solve the above-described problems, the present invention provides a method for producing a filament, comprising the steps of: spinning a first filament made of polyester having a melting point of 255 캜 or higher and a second filament made of a low melting point copolyester having a melting point lower than that of the first filament by 40 캜, ; Forming a fiber layer by entangling the mixed filament yarn on the web and needle punching through a calender process; And thermally adhering the formed entangled fibrous layer with hot air. The present invention also provides a method for producing a spunbonded nonwoven fabric for carpet bubble having excellent tufting properties.

Also, the present invention relates to a thermoplastic elastomer composition having a tensile strength before tufting of 25 to 50 Kgf / 5 cm or more, a tensile strength retention after tufting of 50 to 90%, a tufting punching resistance of 15 to 25 Kgf, Thereby providing a spunbonded nonwoven fabric for this excellent carpet base foam.

According to the present invention, a spunbonded nonwoven fabric for carpet bubble is manufactured by a heat bonding method using hot air, thereby eliminating the binder resin component at the time of tufting and eliminating the problem of pinching between the tufting needles and lowering the punching resistance to achieve tufting and processability And a spun bond nonwoven fabric for a carpet bubble having a small deterioration of tufting needle is not produced even after tufting.

In addition, since the binder resin is not used, the manufacturing cost can be reduced.

1 is a conceptual diagram of a facility for measuring tufting punching resistance of a spunbonded nonwoven fabric for a carpet base foam of the present invention.

The spunbonded nonwoven fabric for carpet bubbles of the present invention is produced by spinning a first filament made of polyester having a melting point of 255 DEG C or higher and a second filament made of a low melting point copolyester having a melting point lower than that of the first filament by 40 DEG C or more Forming a fibrous layer by needle punching through a calender process, forming a entangled fibrous layer, and thermally bonding the entangled fibrous layer with hot air, .

At this time, the intrinsic viscosity (IV) of the first filament is 0.6 to 0.7 and preferably polyethylene terephthalate.

The mixed filament yarn is prepared so that the content ratio of the polyester of the first filament to the low melting point copolyester of the second filament is 95: 5 to 85:15% by weight.

At this time, when the content ratio of the second filament is 5 wt% or less, the strength and elongation of the nonwoven fabric are lowered due to the small amount of the component serving as an adhesive, making it difficult to use as a carpet bubble. If the content of the second filament exceeds 15% by weight, the adhesive component becomes excessive, and excessive adhesion between the filaments causes a large amount of filament breakage in the tufting process, thereby lowering the strength and elongation of the nonwoven fabric.

The filaments radiated in the form of the mixed-spinning radiation are sufficiently drawn by using a high-pressure air stretching device at a spinning speed of 4,500 to 5,000 m / min to produce filament fibers having a fineness of 4 to 10 denier.

If the fineness of the filament is less than 4 denier, the filaments are thin and the number of filaments per unit area is large, so that the filament breaks much in the tufting process, which is a cause of property deterioration. On the other hand, when the density exceeds 10 denier, it becomes difficult to produce the nonwoven fabric uniformly in a commercial manner.

The filament blended yarn produced by the above-mentioned mixed yarn spinning is placed on a conveyor in a web form, and then the thickness of the nonwoven fabric is adjusted through a high temperature calendering process. Then, in the needle punching process, the needle density is adjusted to 1 to 5 ea / 600 to 1,000 strokes (Stroke) to interlock the fibers.

When the needle density is less than 1 ea / cm 2, the degree of entanglement between the fibers is low, so that the number of bonding points in the subsequent heat bonding is also reduced, resulting in problems of peeling and low strength of the paper and poor strength after tufting. If the fiber length exceeds 5 ea / cm 2, the number of fibers broken by needles during needle punching increases, so that the shape stability of the nonwoven fabric may be deteriorated when tufting at a low tensile strength.

The nonwoven web prepared through the calender and the needle punching process is manufactured by using a hot air adhesion method.

After the needle punching process, the nonwoven fabric is a state in which only interwoven fibers constituting the nonwoven fabric are in a state of being intertwined. In this state, problems such as tearing by the external force applied in the tufting and post- The strength and morphological stability of the nonwoven web can be improved by bonding and fixing the fibers through adhesion using hot air.

In order to use the low melting point copolyester of the second filament as an adhesive in place of the binder resin, the present invention uses a heat fixing device for injecting hot air such as a tenter, At a hot air temperature higher than the melting point of the polyester by 5 to 40 占 폚.

When the hot air temperature is lower than 5 ° C at the melting point of the low melting point copolyester, the copolyester does not change into a melting state and does not act as an adhesive. If it is higher than 40 ° C, the polyester constituting the first filament The fibers may be damaged by heat and the physical properties of the nonwoven fabric may be deteriorated.

As described above, the low-melting-point copolyester of the second filament is melted by the hot air in the heat-bonding step, so that it is more effectively worked to improve the strength of the nonwoven fabric by bonding and bonding with the polyester fibers of the first filament having a relatively high melting point do.

The spunbonded nonwoven fabric of the present invention is produced by thermally adhering without bonding by a binder resin, thereby simplifying the manufacturing process of the nonwoven fabric, eliminating the binder resin component during tufting and eliminating the problem of sticking between the tufting needles It is possible to obtain a spunbonded nonwoven fabric for a carpet bubble having less tufting and workability performance and less deterioration of physical properties even after tufting and having less tufting needle wear due to lowering of punching resistance.

Finally, a small amount of the emulsion can be evenly applied to the nonwoven fabric thus produced.

The spunbonded nonwoven fabric for carpet foam according to the present invention has a tensile strength of 25 to 50 kgf / 5 cm, a tensile strength retention after tufting of 50 to 90%, a tufting punching resistance of 15 to 25 Kgf or less And has properties that are excellent in tufting workability.

Hereinafter, the present invention will be described in detail with reference to Examples. It is to be understood, however, that these examples are for illustrative purposes only and are not to be construed as limiting the scope of the invention as defined by the appended claims. And will be apparent to those skilled in the art to which the present invention pertains.

[Example 1]

Polyethylene terephthalate having a melting point of 255 占 폚 and an intrinsic viscosity of 0.655 as a first filament and a second filament having a melting point of 210 占 폚 The low-melting copolyesters were melted at a spinning temperature of 288 ° C using a continuous extruder, and then the filament yarns prepared by spinning and spinning were mixed so that the content ratio of the first filament and the second filament was 90:10 wt% And the amount of capillary flow in the cage was controlled.

Then, the continuous filaments discharged from the capillary were solidified by cooling air at 25 DEG C, and filament fibers were prepared by drawing the filaments at a spinning rate of 5,000 m / min using a high-pressure air stretching device.

Then, the prepared filament fibers were laminated in the form of a web on a conveyor net by a common filament method, and then calendered by a calender roll having a surface temperature of 160 캜 to give smoothness and proper thickness Respectively.

The laminated filaments had a needle density of 1 ea / cm < 2 & Needle punch After a needle punching step of forming inter-fiber interlacing under the condition of 800 strokes, the spunbonded nonwoven fabric having a weight per unit area of 120 g / m 2 was thermally adhered at a hot air temperature of 230 ° C to apply a small amount of tackifier.

[Example 2]

A spunbonded nonwoven fabric was produced in the same manner as in Example 1, except that the needle density in Example 1 was changed to 3 ea / cm 2.

[Example 3]

A spunbonded nonwoven fabric was produced in the same manner as in Example 1, except that the needle density in Example 1 was 5 ea / cm 2.

[Example 4]

A spunbonded nonwoven fabric was prepared in the same manner as in Example 1, except that the needle density was set to 3 ea / cm 2 and the hot air temperature was set to 215 캜.

[Example 5]

In Example 1, the hot air temperature was changed to 250 DEG C , A spunbonded nonwoven fabric was produced in the same manner as in Example 1 above.

[Comparative Example 1]

A spunbonded nonwoven fabric was prepared in the same manner as in Example 1, except that the needle density was 1 ea / cm 2 and the fibers were entangled without heat bonding at a hot air temperature.

[Comparative Example 2]

A spunbonded nonwoven fabric was produced in the same manner as in Example 1, except that the needle punching step was omitted in Example 1.

[Comparative Example 3]

Except that the needle density was set to 3 ea / cm < 2 > in Example 1, and binder resin was adhered so that the solid content of the acrylic binder (AB480, ADKORIA) 1, a spunbond nonwoven fabric was produced.

[Comparative Example 4]

Except that the needle density was set to 3 ea / cm < 2 > in Example 1, and binder resin adhesion treatment was performed so that the solid content of the acrylic binder (AB480, ADKORIA) 1, a spunbond nonwoven fabric was produced.

[Comparative Example 5]

Except that the needle density was set to 3 ea / cm < 2 > in Example 1, and binder resin adhesion treatment was performed so that the solid content of the acrylic binder (AB480, ADKORIA) 1, a spunbond nonwoven fabric was produced.

The production conditions of the above Examples and Comparative Examples are summarized in Table 1 below.

division Adhesion method Needle density
(ea / cm2) Hot air temperature
(° C) Binder resin
Solid content (%) Example 1 Needle punching + hot air adhesion One + 20 ° C - Example 2 Needle punching + hot air adhesion 3 + 20 ° C - Example 3 Needle punching + hot air adhesion 5 + 20 ° C - Example 4 Needle punching + hot air adhesion 3 + 5 ° C - Example 5 Needle punching + hot air adhesion 3 + 40 ° C - Comparative Example 1 Needle punching 3 - - Comparative Example 2 Hot wind adhesion 0 + 20 ° C - Comparative Example 3 Needle Punching + Binder Resin 3 - 10 Comparative Example 4 Needle Punching + Binder Resin 3 - 20 Comparative Example 5 Needle Punching + Binder Resin 3 - 30

The tensile strength, tufting punching resistance, peeling strength, and needle replacement amount of the nonwoven fabrics prepared by the following evaluation methods were measured for the above Examples and Comparative Examples, and the results are shown in Table 2 Respectively.

<Evaluation method>

1. Tensile strength

Using a KS K 0521 method, a specimen of 5 cm × 20 cm in width × length was bored with a 5 cm × 5 cm jig using an INSTRON measuring device at a tensile speed of 200 mm / min .

2. Tensile strength after tufting

The tufting was performed under the conditions of GPI (Gage per Inch) 1/10 and SPI (Stroke per Inch) 1/10 using laboratory scale tufting equipment, and then measured by the above 1. tensile strength evaluation method.

3. Tufting punching resistance

A specimen of 8 cm in width x 14 cm in length was fixed with a screw of 5 cm width x 15 cm x thickness 2 cm as shown in Fig. 1 by screwing the specimen 1.5 cm in width and parallel to the floor, 8 cm and fix it to INSTRON measurement equipment.

Lower (fixed thickness of all fixtures is 2 cm) Kneeders (size: 3 cm wide x 10 cm long) with 1/10 GPI (Gage per Inch) are lowered at 200 mm / min to the specimen. Measure the force received by the INSTRON load cell (the force transmitted in the opposite direction to the needle plate travel direction) as the needle plate penetrates the specimen.

4. Peeling strength

ASTM D 903 method was used.

Using a pilot-tufting device, loop-type files were fabricated with a fiber height of 5 mm, a GPI 10/1, SPI 13/1, a tufting speed of 400 RPM, a pile fiber nylon-6 condition of 1 m wide, 5,000 m long, After removal, the specimens of 2.5 cm × 20 cm in width × length were measured with a 2.5 cm × 2.5 cm jig using an INSTRON measuring instrument at a tensile speed of 100 mm / min.

5. Needle replacement quantity

Loft type file with a pilot tufting device When toughened to a width of 1 M and a length of 5,000 meters with fiber height 5 mm, GPI 10/1, SPI 13/1, tufting speed 400 RPM, pile fiber nylon -6 conditions, The number of needles to be replaced (broken fingers or needles worn and the pile fibers not to be fixed in the bubble paper) among the total needle number of 400 ea were measured.

division Tensile strength (Kgf / 5 cm)
After tufting
The tensile strength
Retention rate (%)
(MD / CD) Tufting
Punching
Resistance
(Kgf) After tufting
Peeling
burglar
(N) You guys
Replacement Quantity
(dog) Before Tufting
(MD / CD) After tufting
(MD / CD) Example 1 29.1 / 27.1 19.4 / 18.9 66.7 / 69.7 15.7 18.9 0 Example 2 37.2 / 38.7 26.5 / 27.4 71.2 / 70.8 19.3 21.8 0 Example 3 44.3 / 45.8 34.1 / 36.9 77.0 / 80.6 24.4 22.7 0 Example 4 28.6 / 26.5 17.2 / 14.1 60.1 / 53.2 17.1 19.4 0 Example 5 48.7 / 49.8 36.4 / 35.8 74.7 / 71.9 24.7 24.6 0 Comparative Example 1 21.3 / 19.5 5.7 / 4.2 26.8 / 21.5 24.9 16.2 0 Comparative Example 2 26.0 / 28.6 15.7 / 14.2 60.4 / 49.7 28.9 0* 0 Comparative Example 3 28.2 / 21.4 7.8 / 6.1 27.7 / 24.0 35.1 34.1 2 Comparative Example 4 34.8 / 35.6 24.3 / 24.2 69.8 / 68.0 49.7 38.4 2 Comparative Example 5 42.4 / 44.7 36.4 / 35.0 86.3 / 78.3 68.4 43.8 4 * Natural exfoliation

The results of Table 2 show that the tensile strength before and after tufting and the tensile strength retention after tufting are superior to those of Comparative Examples 1 to 3 in the nonwoven fabric of Examples, and the tufting punching resistance, peeling strength after tufting, The number of needle replacement was superior to that of Comparative Examples 1 to 3.

Comparative Examples 4 to 5 were obtained by increasing the solids content of the binder resin. Although the tensile strength and tensile strength retention after tufting were excellent, evaluation items of tufting punching resistance, peeling strength after tufting, and needle replacement amount were found to be drastically worsened .

Comparative Example 1 shows only a needle punching without thermal bonding, and from the result that the tensile strength and the tensile strength retention after tufting are drastically lowered, needle punching and thermal bonding must be performed at the same time to improve the tensile strength and tensile strength retention. .

Comparative Example 2 shows that the conditions of heat bonding and heat bonding contributed to improvement in the tensile strength and tensile strength retention ratio as a result of the fact that the tensile strength and the tensile strength retention after tufting were drastically deteriorated as a result of only thermal bonding without needle punching .

Comparative Example 3 shows that the solid content of the binder resin is 10% by weight, and as a result, the tensile strength retention after tufting is drastically lowered. Therefore, it is understood that the content of the binder resin is increased to contribute to the improvement of the retention ratio.

INDUSTRIAL APPLICABILITY As described above, the spunbonded nonwoven fabric for carpet bubbles according to the present invention has an excellent effect of maintaining the tensile strength retention after tufting and improving the tufting processability.

Claims (5)

A mixed fiber spinning step of spinning and mixing a first filament made of polyester having a melting point of 255 캜 or higher and a second filament made of a low melting point copolyester having a melting point of 40 캜 or higher than that of the first filament;
Forming a fiber layer by entangling the mixed filament yarn on the web and needle punching through a calender process; And
And thermally bonding the formed entangled fibrous layer with hot air,
The content of the first filament and the second filament is 95: 5 to 85:15% by weight,
Wherein the temperature of the hot air is 5 to 40 占 폚 higher than the melting point of the low melting point copolyester constituting the second filament. delete The method according to claim 1,
Characterized in that the needle density is 1 to 5 ea / cm &lt; 2 &gt; at the time of needle punching in the step of forming the entangled fibrous layer. delete A process for producing a polyurethane foam according to any one of claims 1 to 3, wherein the tensile strength before tufting is 25 to 50 Kgf / 5 cm or more, the tensile strength retention after tufting is 50 to 90%, the tufting punching resistance is 15 to 25 Kgf A spunbonded nonwoven fabric for carpet bubbles having excellent ease of interfitting.

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