KR20030055475A - Method for Producing Nonwaven Fabric Using Highly-Contractive Composite Monofilament - Google Patents

Abstract

PURPOSE: A manufacturing method of non-woven fabric having high density and excellent tearing strength is characterized by using high shrinkage conjugate single fiber, not needing to elute and being economical. CONSTITUTION: The manufacturing method of the non-woven fabric comprises the next steps: spinning two different polymers to manufacture conjugate single fiber; carding and needle-punching the single fiber to manufacture the non-woven fabric; and then treating the non-woven fabric with hot water or with dry heat to shrink as 10-50% and to increase separation. The polymer A has high shrinkage. The polymer B has normal shrinkage. Conjugate ratio of the polymer A and the polymer B is 85:15 - 50:50 of weight ratio.

Description

Method for manufacturing nonwoven fabric using high shrink composite yarn short fibers {Method for Producing Nonwaven Fabric Using Highly-Contractive Composite Monofilament}

In the present invention, in the production of high-density nonwoven artificial leather using microfiber, it is a microfiber component to remove one component of the short fiber composed of a two-component polymer to remove two components having different shrinkage ratios without going through an elution process, which is a general method of miniaturizing fibers. The present invention relates to a method for manufacturing a nonwoven fabric using high shrinkage composite yarn short fibers which prevents the loss of fibers and simplifies the manufacturing process by maximizing the division by physical division and hot water or dry heat shrinkage by composite spinning.

Microfibers by island-in-the-sea composite spinning have been widely used to produce artificial leather having a similar feel and quality characteristics to natural leather. The island-in-the-sea composite fiber, which is a material of artificial leather, is generally composed of two different components and is made of short fibers through processes such as spinning, stretching, crimping, and cutting. These short fibers are made of nonwoven fabric through needle punching, and again undergo a process such as sea component dissolution, polyurethane treatment, etc., to form a form of artificial leather. However, when the sea component is eluted in order to make the fiber fine after the production of the nonwoven fabric, the tear strength of the nonwoven fabric is sharply dropped. This is because the entanglement formed in the solution portion during the needle punching process is lost in the elution process, or the entanglement is loosened because the sea component is lost by elution. In addition, wastewater generated after elution has a problem of causing environmental pollution, as well as a loss of raw materials and high manufacturing costs due to elution of sea components.

Japanese Patent Laid-Open No. 61-125377 and Japanese Patent Laid-Open No. Hei 8-35120 disclose a nonwoven fabric using general high shrink polyester and side-by-side type high shrink composite yarn short fibers. High-density non-woven fabrics made of general high-side yarns or side-by-side high-side yarns do not have a fine touch feeling and have the drawback of extremely poor appearance after brushing and buffing, and poor physical properties and functionality when suede artificial leather is manufactured. . On the other hand, Japanese Patent Laid-Open No. 6-240536 discloses a method for manufacturing a high shrink composite yarn using a island-in-the-sea composite yarn of a high shrink PET and a usable PET. As described above, a non-woven fabric can obtain a fine touch feeling. There is a problem in that the elution process is required and the interlacing points between the short fibers are reduced by elution, thereby lowering the strength of the nonwoven fabric. In addition, when the split type composite yarn short fibers having a conventional structure are used to manufacture the nonwoven fabric, as the division proceeds during the needle punching process, an entanglement point must be formed by punching, and the physical force of the punching and the composite yarn As the fibers separated by the force consumed for the division and the fibers divided by the needle punching increase, the entanglement point decreases, resulting in the short fibers being pushed together with the needle punching, which is not easy to work.

The present invention is to solve the problems of the prior art as described above, does not require an elution process, economical and partitioned by physical force, the partition is increased by shrinkage by non-aqueous or dry heat treatment to excellent tear strength It is an object of the present invention to provide a method for producing a nonwoven fabric using high shrinkage composite yarn short fibers capable of efficiently producing a high density nonwoven fabric.

That is, the present invention is a method for producing a composite yarn short fibers having a split cross-section by composite spinning two different polymers A and B and carding, needle punching to produce an ultrafine nonwoven fabric, the composite yarn short fibers The present invention relates to a method for manufacturing a nonwoven fabric using high shrinkage composite yarn short fibers, which is physically divided during carding and needle punching without an elution process, and the division is further increased with 10-50% shrinkage during hot water or dry heat treatment. .

1 is a cross-sectional photograph showing an example of a conventional islands-in-the-sea high-shrink composite fiber, and

Figure 2 is a cross-sectional photograph showing an example of the split type high shrink composite fiber of the present invention.

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

A: First component B: Second component

Hereinafter, the present invention will be described in detail with reference to the drawings.

The fiber which is a material of the nonwoven artificial leather according to the present invention has a cross section of the split composite fiber type illustrated in FIG. 2 that is physically divided, not the island-in-the-sea composite fiber type illustrated in FIG. Split type composite fibers are composed of two different components, one of which is a highly shrinkable polymer and the other of which is a heteropolymer, which is a general polymer.

As illustrated in FIG. 2, the high shrinkage composite yarn short fibers used characteristically in the present invention are divided composite yarns composed of two components (A and B) having different properties, and the first component (A) and the second component. (B) has different characteristics, and preferably component A has high shrinkage and component B has moderate shrinkage. As a specific example of the preferred composition of components, when component A is a high shrink polyamide based shrinkage of at least 10% in hot water at 90 ° C., component B is composed of polyester, or component A is high shrinkage at least 10% in hot water at 90 ° C. When shrink polyester, component B is composed of polyamide, or when component A is a high shrink polyamide that shrinks by more than 10% in hot water at 90 ° C., component B is shrink by 10% or more in hot water at 90 ° C. When the components A and B are high shrink polyester and high shrink polyamide, the splitting of the composite yarn, the density increase of the nonwoven fabric due to shrinkage, and the tear strength of the nonwoven fabric are excellent. .

In this case, the composite ratio of the component A and the component B is preferably set to 85:15 to 50:50, and if it is out of this range, the workability and product characteristics in the production of short fibers and non-woven fabrics become undesirable.

The high shrinkage composite yarn short fibers used in the present invention are made of short fibers after stretching and imparting crimps to the fibers along with heat stretching and cutting in the short fiber process. The cross section of the short fibers thus obtained is characterized in that 10 to 30% of the cross section of the entire sample taken arbitrarily is divided, and the average fineness of the component A after the division is 0.1 to 0.3 denier. In addition, the fine fiber short fiber has a fineness of 1 ~ 4dpf, length is 30 ~ 200mm, the number of crimp (crimp) is characterized in that the range of 5 ~ 30ea / inch. do. Particularly, since the degree of splitting must be increased physically in the post process, if the damage to the fiber becomes large, the splitting degree of the short fibers exceeds 30%, and the fine fibers split between the saggings of the carding machine cannot be discharged due to the carding process. The division within 30% is preferable because it not only causes problems with the carding equipment but also obtains a uniform web. In addition, when the fineness of component A is less than 0.1 denia, not only the radiation productivity decreases, but also the risk of curling in the blister during carding increases, and when it is larger than 0.3 denia, it is difficult to obtain a soft and luxurious touch.

The short fibers produced in the present invention do not need to add an elution process because physical division occurs during the carding and needle punching steps in the nonwoven fabric manufacturing process. According to the present invention, 10-30% split short fibers were carded in a nonwoven fabric manufacturing process to obtain 40-50% of the degree of division, and the needle punching process continuously passed 70-80% of the degree of separation through hot water. By hydrothermal shrinkage, the non-woven fabric with high degree of tear strength was obtained because the high shrinkage part of the composite yarn contracted.

Hereinafter, the present invention will be described in more detail with reference to examples, but the following examples are for the purpose of explanation and are not intended to limit the present invention.

Example 1

A high shrink polyester is used as component A, and a high shrink polyamide is used as component B. The compound is spun at 295 ° C. at a compound ratio of 80:20 to have a split cross section as shown in FIG. Short fibers were prepared by stretching, crimping, heat setting, and cutting to the extents. The short fibers were carded and needle punched to produce a nonwoven fabric having a weight of about 200 g / m ² and the results are shown in Tables 1 and 2.

Example 2

The high shrink polyamide is component A and the polyester is component B. The composite is spun at 290 ° C. at a compound ratio of 80:20 to have a split cross section as shown in FIG. Short fibers were prepared by stretching, crimping, heat-setting, and cutting them. The short fibers were carded and needle punched to produce a nonwoven fabric having a weight of about 200 g / m ² and the results are shown in Tables 1 and 2.

Example 3

With high shrinkage polyester as component A and polyamide as component B, the composites were spun at 290 ° C. at a compounding ratio of 50:50 to have a split cross section as shown in FIG. Short fibers were prepared by stretching, crimping, heat setting, and cutting to make them short. The short fibers were carded and needle punched to produce a nonwoven fabric having a weight of about 200 g / m 2, and the results are shown in Tables 1 and 2.

Comparative Example 1

Polyamide is used as the island component, and copolyester is used as the sea component to produce a single fiber by complex spinning at 290 ° C with a compound ratio of 70:30 to have a sea island-like cross section as shown in FIG. It was. The short fibers were carded and needle punched to form a nonwoven fabric, followed by weight loss treatment with caustic soda solution to prepare a nonwoven fabric with a weight of about 200 g / m ² and the results are shown in Tables 1 and 2.

Comparative Example 2

Compound A was used as a component A, and polyamide was a component B, and the composite was spun at a compounding ratio of 8: 2 to have a cross section as shown in FIG. Carding and needle punching the short fibers to produce a nonwoven fabric of about 200g / m ² and the results are shown in Table 1 and Table 2.

Component A (dojo) Component B (sea component) Compound ratio Elution process Tear strength (kg) MD CD Example 1 High Shrink Polyester High shrink polyamide 8: 2 Unnecessary 8.8 8.6 Example 2 High shrink polyamide Polyester 8: 2 Unnecessary 8.9 8.5 Example 3 High Shrink Polyester Polyamide 5: 5 Unnecessary 8.7 8.4 Comparative Example 1 Polyamide Copolyester 7: 3 30% elution 4.8 4.5 Comparative Example 2 Polyester Polyamide 8: 2 Unnecessary 7.4 7.2

(However, MD is Machine Drection, CD: Cross Direction)

Heat shrinkage ^a Split growth rate by hot water ^a Needle Punched Nonwovens Density ^b Density of needle punched nonwoven fabric (after hydrothermal treatment) ^c Nonwoven Density Growth Rate Example 1 39% 20% 205 g / m ² 268 g / m ² 31% Example 2 24% 18% 200 g / m ² 252g / m ² 26% Example 3 15% 13% 208g / m ² 241g / m ² 16% Comparative Example 1 4% Less than 1% 210g / m ² 214g / m ² 2% Comparative Example 2 9% Less than 1% 215g / m ² 225 g / m ² 4%

※ Note: a: Thermal shrinkage rate of yarn (100 ℃, 60 seconds) and split growth rate, b: Nonwoven fabric before being put into hot water, c: Nonwoven fabric immersed in hot water at 90 ℃ for 10 seconds

Looking at the measurement results of the physical properties of the examples and comparative examples, in the tear strength evaluated as an important property in the nonwoven fabric made of microfiber, the nonwoven fabric prepared according to the present invention has superior physical properties than the nonwoven fabric eluted from the island-in-the-sea composite yarn. You can know. In the case of an elution paper nonwoven fabric made of island-in-the-sea composite yarns, the tear strength at a weight of 200 g / m ² is 5 kg or less, whereas the nonwoven fabric according to the present invention exhibits physical properties of at least 7 kg at a weight of 200 g / m ² .

In addition, it was possible to obtain a high-density nonwoven fabric having a density increased by 10% or more, which is impossible to obtain in a conventional composite yarn using physical division.

In addition, the artificial leather produced by the present invention has a significant advantage in terms of manufacturing cost and quality. In the case of island-in-the-sea composite fiber, the dissolution process not only increases the manufacturing cost but also elutes the sea component, resulting in the loss of raw materials and the problem of environmental pollution due to weight loss wastewater. In addition, quality unevenness, contamination, etc. are caused by the elution process.

The nonwoven fabric prepared according to the present invention may exhibit excellent performance even when used as a wiping material by surface treatment without polyurethane treatment. In addition, in the manufacturing method of a nonwoven fabric, it is not limited only to needle punching, It is applicable to the spunlace method.

According to the present invention, it is possible to provide a nonwoven fabric having a high density and excellent tear strength.

Claims (5)

In the method of producing a composite yarn short fibers having a split cross-section by complex spinning two different polymers A and B and carding, needle punching to produce an ultrafine nonwoven fabric, The composite yarn short fibers are physically divided during carding and needle punching without the elution process, and the division is further increased with 10-50% shrinkage during hydrothermal or dry heat treatment. Manufacturing method. The method for producing a nonwoven fabric according to claim 1, wherein the component A has high shrinkability and B has a normal shrinkage. 2. A component according to claim 1, wherein component B is a polyester based when component A is a high shrink polyamide, component A is a polyamide based when component A is a high shrink polyester or component A is a high shrink polyamide. Component B is a method for producing a nonwoven fabric using high shrink composite yarn short fibers, characterized in that the high shrink polyester. The method of claim 1, wherein the composite yarn short fibers have a composite ratio of components A and B in a weight ratio of 85:15 to 50:50. The high shrinkage according to any one of claims 1 to 4, wherein the fine yarn short fibers have a fineness of 1 to 4 dpf, a length of 30 to 200 mm, and a number of crimps of 5 to 30 ea / inch. Method for producing a nonwoven fabric using composite yarn short fibers.