KR20040100576A - Spunbonded non-woven fabric by sea and islands type filaments and method for preparing the same - Google Patents

Abstract

PURPOSE: A manufacturing method of long fiber non-woven fabric having uniform quality and excellent mechanical properties is characterized by manufacturing the non-woven fabric with one-step process. The non-woven fabric infiltrated into polyurethane, coated, eluted, buffed and dyed is useful for artificial leather. Spun bond comprised of densificated sea-island type superfine yarn is useful for a cleaner as a wiper. And the non-woven fabric is useful for a filter and an inner filler. CONSTITUTION: Long fiber non-woven fabric is obtained by the steps of: spinning sea-island type filament; forming web out of the filament with a spun bond method; and then heat-adhering or free needle punching the web. The sea-island type filament has 1-5denier of fineness.

Description

Long fiber nonwoven fabric made of island-in-the-sea filament fibers and its manufacturing method {SPUNBONDED NON-WOVEN FABRIC BY SEA AND ISLANDS TYPE FILAMENTS AND METHOD FOR PREPARING THE SAME}

The present invention relates to a long-fiber nonwoven fabric made of island-in-the-sea filament fibers and a method for producing the same, and more particularly, to a method for producing a long-fiber nonwoven fabric by a spunbond method using an island-in-the-sea composite long fiber.

BACKGROUND ART Conventional artificial leather or bubble paper for artificial leather is generally known using a synthetic fiber such as polyester or nylon.

For the manufacture of artificial leather using this type of microfiber, Sea and Islands microfiber or split microfiber is used, and the manufactured product is composed of microfibers of less than 0.2 denier, such as natural leather. Due to its touch and excellent washing performance, it is possible to manufacture large quantities of expensive products that surpass natural leather. That is, a composite yarn made of island-in-the-sea yarn or split type is manufactured to have a length of 5 to 100 mm, and is then constantly arranged in a nonwoven web form in a carding process that has been conventionally used. Next, in the subsequent process, needle punching is performed to raise the shape and density of the web arranged in a constant length and direction. In this case, it is important to raise the density of the nonwoven fabric to at least 0.15 gr / cm 3 in order to manufacture artificial leather bubble paper of excellent products.

That is, the conventional manufacturing method of island-in-the-sea microfiber nonwoven fabric should primarily produce short fibers by a composite spinning method. The short fibers thus prepared are packed tightly and transferred to a subsequent process. In the next step, the packaged short fiber islands are opened and the fibers are arranged in a predetermined direction to form a web. In addition, since the nonwoven web thus prepared is oriented, it undergoes a separate cross-lapping process to produce a product having a non-directionality required in the nonwoven fabric. All of the above steps go through a four-step process to enter the needle punching process having the form of a nonwoven fabric.

In order to obtain such a high-density product by the needle punching method, a needle punching machine is usually installed in a plurality of two or more in the longitudinal direction to gradually increase the density.

The nonwoven fabric thus produced should be further improved in strength and flexibility for use in artificial leather. Therefore, in the subsequent step, the dough is usually impregnated with a polyurethane-based resin, and then eluted for finer fibers. The product thus obtained is a dough of artificial leather, which is subjected to a buffing and dyeing process to obtain a final product.

The microfiber artificial leather is also used as a substitute for conventional natural leather, and the processing process is used as a variety of filter materials or cleaners by further deforming or simplifying and using the properties of microfiber.

However, non-woven artificial leather using conventional microfiber short fibers not only has the advantages of being cheaper and washable than natural leather, but is also gaining more attention due to the recent rapid increase in environmental protection and animal protection movements. Therefore, there is a disadvantage that the price of the final product is expensive.

In order to solve the above problems of the prior art, an object of the present invention is to provide an island-in-the-sea microfiber filament nonwoven fabric which can be mass-produced at a lower price with easier and simpler quality.

Another object of the present invention is to provide a method for producing a long-fiber nonwoven fabric which can obtain a uniform product while significantly shortening the time to manufacture the final product by innovatively improving the conventional microfiber yarn, in particular, the island-in-the-sea yarn nonwoven fabric manufacturing method.

Another object of the present invention is to provide a method for producing a long-fiber nonwoven fabric which directly manufactures the final product, unlike the multi-stage method used in the conventional method for producing a fine-fiber island-in-the-sea nonwoven fabric.

In order to achieve the above object, the present invention provides a method for producing a long-fiber nonwoven fabric produced by spinning a sea island filament to form a web by a spunbond method, and heat-bonding or pre-needle punching the web.

The present invention also provides a long fiber nonwoven fabric prepared by the above-described method.

The nonwoven fabric preferably has a density of 0.15 to 0.50 gr / cm 3.

In addition, the present invention provides an artificial leather produced by impregnating or coating the nonwoven fabric of the substrate in polyurethane, eluting, buffing, and dyeing.

Moreover, this invention provides the filter manufactured by eluting the nonwoven fabric of the said base material.

Moreover, this invention provides the wiper manufactured by eluting the nonwoven fabric of the said base material.

Hereinafter, the present invention will be described in detail.

The island-in-the-sea microfiber nonwoven fabric of this invention has the characteristics manufactured using the spun bond manufacturing method which is a long fiber nonwoven fabric.

Conventional islands-in-the-sea microfiber nonwoven fabrics are made of short fibers, and thus, the manufacturing process is complicated. However, the nonwoven fabric of the present invention uses a spunbond method composed of long fibers, so that a simple, inexpensive and high-quality product can be produced in large quantities.

In general, there are two methods for producing a spunbond long fiber nonwoven fabric depending on the material. That is, the polypropylene spunbond method of manufacturing a nonwoven fabric by a simple air flow without a separate web forming device with a low spinning speed, and spinning the filaments at a high speed of spinning speed of at least 4,500 m / min. There is a polyester spunbond manufacturing method for producing nonwoven fabrics by web forming the corrugated filaments by corona charging or impingement plate charging. The island-in-the-sea microfiber spunbond of the present invention is preferably manufactured on the basis of the polyester spunbond method of producing a filament nonwoven fabric of uniform quality using the latter high speed spinning method and a separate opening method. At this time, even in the method of manufacturing a polypropylene spunbond which does not require the low-speed spinning method and the opening method separately, the spinning speed is adjusted to 4,000 m / min or more, preferably 4,500 m / min or more, and the weight of the nonwoven fabric produced is 200 gr / m 2. If the above-mentioned heavy weight product is manufactured, the island-in-the-sea type microfiber spun bond of this invention can be manufactured also by the polypropylene spun bond manufacturing method. However, the polyester spunbond method is more advantageous in terms of quality, so the description in the present invention focuses on the polyester spunbond method.

Another important part of the present invention is the part related to the radiation of island-in-the-sea microfiber. In general, a spinning device, a polymer, and the like related to short-fiber island-in-the-sea yarn spinning are used as it is in spinning of the spunbond method. However, the spinning and manufacturing speed of short fiber islands is only about 1,000 m / min, while the spunbond method should be manufactured at high speed of at least 4,500 m / min. Therefore, it is particularly important to maintain the stability of operation. . For this purpose, care must be taken to maintain uniform quality of the raw polymer used and to design and install a filter device.

Currently, the island-in-the-sea yarn composition is mainly made of polyester, nylon, or copolyester to produce fibers by a composite spinning method. The sea component mainly arranges materials with lower melting point and easier to elute than island components. In other words, polyester acts as a coating component in polyester and nylon combinations, and polyester is a coating component in polyester and copolyester combinations, and nylon is used as a coating component in copolyester and nylon combinations. Since the island-in-the-sea microfiber performs fine fibers while eluting in a later step, the composite ratio of the raw material is particularly important. That is, since the sea component is completely removed by the solvent in the elution step, and the remaining sea component is miniaturized in the elution step, it is advantageous in many ways to keep the ratio as low as possible.

The ultrafine fibers of the island-in-the-sea spunbond nonwoven fabric of the present invention have a fineness of 1 to 5 deniers before dissolution, and preferably 2 to 3 deniers. It is preferable that the polymer composite ratio of said island component and sea component is 80: 20-50: 50, but it is more preferable to keep the ratio of sea component low. However, when the ratio of sea component is less than 20%, the boundary between island component and sea component becomes unclear and the phenomenon of sticking of island components occurs frequently. On the other hand, if the ratio of the sea component exceeds 50%, the raw material cost unnecessarily rises, so that the dissolution process is also difficult to maintain a uniform quality. In addition, if the thickness of the fiber is less than 1 denier, cutting occurs frequently during spinning at high speed, and the boundary between the island component and the sea component tends to become obscured and is not used well. In addition, if it exceeds 5 denier, the radioactivity is excellent, but there is a problem that it is difficult to adjust the fineness of the final island component to a microfiber of 0.2 denier or less.

In addition, the number of island components in the island-in-the-sea filament is preferably 10 to 100 degrees. The spunbond islands-in-the-sea microfiber yarn is manufactured at a high spinning speed, so that the cross-section of the fiber is uniform and clean, and thus the quality is excellent. In addition, since the boundary between sea component and island component tends to be clear, uniform quality can be obtained even at a compounding ratio of 20%. The fineness of the island component is preferably 0.01 to 0.2 denier after elution.

The raw material used in the present invention may be used differently depending on the purpose and purpose of use in addition to general-purpose polyester or nylon. That is, since the island-in-the-sea type spunbond of the present invention can be produced using a copolyester, styrene or olefin-based material, the island-in-the-sea type spunbond of the present invention is not limited to the above-described material. Preferably, at least one polymer selected from the group consisting of polyester, nylon, copolyester, olefin, and styrene-based may be used as sea component and island component according to the purpose and use.

The present invention is more preferably an island-in-the-sea yarn spunbond manufactured by using a copolyester specially prepared to facilitate elution in post-processing as a sea component and a general-purpose polyester as a sea component. The spun bond thus prepared exhibits excellent quality due to its rapid and uniform dissolution rate. Also, the same effect is obtained when the same copolyester is used as the sea component and nylon is used as the island component.

As described above, the island-in-the-sea type microfiber spunbond nonwoven fabric of the present invention is spunbonded and opened to form a nonwoven web as described above. The web thus produced usually has a non-orientation, and the filaments forming the web are still before bonding, so that the nonwoven fabric of the present invention is manufactured by thermally bonding or pre-needle punching separately.

As described above, the island-in-the-sea type microfiber spunbond of the present invention is manufactured directly from a raw material resin to a product nonwoven fabric in an integrated process. Moreover, since the filaments are produced by stretching the filaments at high speed, not only the island components constituting the fibers can be uniform, but also the ratio of sea components can be kept low. In addition, since the fibers constituting the nonwoven fabric are made of long fibers rather than short short fibers of 5 to 100 mm, they have excellent physical properties.

The nonwoven fabric produced by the method of the present invention needs to be processed to further improve the performance of the product. In general, the nonwoven fabric composed of island-in-the-sea yarn is often processed into artificial leather bubble paper. In the present invention, a separate processing step is required to use the nonwoven fabric pre-bonded by the above-mentioned manufacturing method for artificial leather, which is similar to the conventional short fiber nonwoven microfiber artificial leather processing method. That is, two or more needle punches are arranged in the longitudinal direction to bond to the nonwoven fabric which is sequentially moved to increase the density to 0.15 gr / cm 3 or more. At this time, if excessive needle punching is performed, fibers constituting the nonwoven fabric may be cut by vertical reciprocating movement of the needle punch's entanglement needle, thereby deteriorating physical properties. In some cases, lubricating oil may be applied to the dough. The lubricating oil may be a fiber oil, which is commonly used, and is mainly composed of mineral oil and stearic acid.

As such, the needle punch method is a method widely used to improve the density of the nonwoven fabric, but the above disadvantage may appear. If this is a concern, a water punch can be used. The island-in-the-sea microfiber spunbond composed of the long fibers of the present invention is particularly advantageous for density improvement by water punching. That is, since the long fiber obtained by the spunbond method does not have lubricating oil, it can be processed cleanly without excessive load on the water treatment system of the water puncher, and above all, a uniform product can be obtained at the same time without breaking the fiber. However, the nonwoven fabric of the present invention cannot be manufactured by the needle punch method, and the design and manufacture of the product can be sufficiently performed by setting the appropriate manufacturing conditions of the needle punch. In other words, when manufacturing the nonwoven fabric of the present invention, pre-bonding is a conventional needle punch, and full-scale bonding is a method using a water punch.

This method is particularly advantageous for the production of heavy products with a thickness of at least 500 gr / m 2, with processing machines off-line from one another or with a thickness of at least 5 mm. However, if two processing machines are configured on-line in this way, it is natural that several kinds of products can be manufactured in the same facility, which is particularly advantageous for the design and manufacture of functional products.

The nonwoven fabric of the present invention, which is finally manufactured by needle punch or water punch, depends on the use, but the density must be maintained at 0.15 gr / cm 3 or more, which is excellent in shape stability and convenient for application. It is preferable that it is 0.2 gr / cm <3> or more for artificial leather, and it is more preferable if it is 0.25 gr / cm <3> level or more. Thus, the nonwoven fabric of the present invention having an improved density is used as a form that can be sold according to the use, and further post processing is performed to improve the quality.

In general, the product of the filter or wire form is sold by performing the elution processing separately the density improving nonwoven product of the present invention. If necessary, calendering or surface foam coating may be used to suppress the occurrence of blemishes on the surface of the product. Foam coating products are expensive, but have the advantage of extending the life of the product and improved performance. The product composed of the nonwoven fabric of the present invention has a high strength and uniform fiber diameter, and exhibits uniform and high performance in terms of pressure loss, efficiency, and the like, which determine filter characteristic values.

In the wiper type product, even if fine dust or fiber debris does not remain on the surface of the cleaning object, the nonwoven fabric of the present invention made of long fibers is particularly useful. Conventional zehum made of short-fiber microfiber is entangled in the form of partially cut each other, the weakness of the bond between the fibers due to strong external pressure or frequent use, the fine fiber droppings appear to degrade performance . However, the ultrafine nonwoven fabric of the present invention made of long fibers does not exhibit any of these disadvantages, thereby increasing the frequency of use and the period of use, thereby facilitating user convenience.

In addition, the present invention is subjected to a separate post-process for artificial leather, impregnated in the polyurethane resin in the same manner as the conventional artificial leather, the impregnation of the nonwoven fabric of the present invention with improved density in the needle punch or water punch, elution processing Then, the final product is completed by buffing and dyeing. Artificial leather products using the long fiber nonwoven fabric produced by the present invention is high strength and uniform density than the short fiber products manufactured by the same post-processing method is suitable for use in furniture, shoes, bags and clothes.

Hereinafter, preferred examples are provided to aid in understanding the present invention. However, the following examples are provided only to more easily understand the present invention, and the present invention is not limited to the following examples.

EXAMPLE

Polyethylene terephthalate (PET) for clothing has an intrinsic viscosity (IV) of 0.650 and a melting temperature of 254 ° C. The copolyester with an intrinsic viscosity (IV) of 1.110 and a melting temperature of 230 ° C is used as a sea component. Melted at a spinning temperature of 280 ° C. to extrude the island-in-the-sea yarn fibers. At this time, the copolyester used is to improve the elution process of the seaweed powder, it is prepared by mixing 8.5 parts by weight of DMIS (Di-methyl-iso-sulponate) and 0.3 parts by weight of polyethylene glycol (PEG). The island-in-the-sea yarn spinning device used for spinning was configured to have 36 degrees per filament, and the discharge amount was adjusted so that the fineness was 3 denier after stretching, and the composite ratio of island component and sea component was 70:30, respectively. The fibers thus produced are microfibers of 0.05 denier level after elution.

After cooling and solidifying the island-in-the-sea filament extruded through the spinneret, it is stretched by air stretching at a spinning speed of 4,500 m / min using a conventional spunbond method, and opened on a moving net, and the speed of the net is adjusted. To prepare a nonwoven web. Thereafter, the nonwoven web was lightly heat bonded using a pair of calender rolls located at the ends of the moving net and wound around a winder to prepare a island-in-the-sea type microfiber spunbond of the present invention. At this time, the surface of the calender roll used had no concave-convex pattern, and the surface temperature was fixed at 170 ° C. so that the thermal adhesion of the filaments did not appear excessively. The weight of the nonwoven fabric produced was 320 gr / cm 3.

The nonwoven fabric obtained above was sequentially passed through a needle punch line composed of seven pieces in the longitudinal direction to obtain a needle punch density-improved nonwoven fabric of the present invention. In this case, the PPS given in the needle punch nonwoven fabric was 1,500, the needle depth was 7.5 mm, and the density of the final nonwoven fabric was 0.17 gr / cm 3.

(Example 2)

Manufactured in the same manner as in Example 1, the temperature of the pair of calender rolls located at the end of the net was set to 140 ℃, immediately pre-punched needle punched. At this time, only one needle punch was passed, and the coupling condition was PPS 80 and needle depth 8.0 mm.

The nonwoven fabric thus prepared was subjected to water flow interaction in a separate water puncher to prepare a nonwoven fabric of the present invention having improved density. Water punching was prepared by treating the water pressure 80 bar twice, the water pressure 300 bar six times on both sides. The final nonwoven fabric produced had a density of 0.24 gr / cm 3 and a weight of 480 gr / m 2.

(Example 3)

A nonwoven fabric of improved density was prepared by sequentially passing a nonwoven fabric having a density of 0.17 gr / cm 3 in Example 1 through a needle punch line composed of five longitudinally. At this time, the prepared nonwoven fabric had a density of 0.25 gr / cm 3, and the needle punching machine had a total PPS of 2,500. In addition, 0.2 parts by weight of mineral oil was pre-assigned to the nonwoven fabric to minimize fiber density improvement and damage.

(Example 4)

The nonwoven fabric prepared in Examples 1 to 3 was eluted to prepare a nonwoven fabric. At this time, processing conditions were obtained by immersing the nonwoven fabric of this invention in 95 degreeC hot water of 1.0 weight part of NaOH. The elution time was about 50 minutes. After elution, the nonwoven fabric was dried by drying in a 120 ° C. tenter dryer.

The long-fiber microfiber nonwoven fabric thus prepared maintained a uniform fiber diameter, and beauty cosmetics were not detected at all. The eluted nonwoven fabric of the present invention was suitable for use as a bubble paper for filters and a bubble paper for wipers.

(Example 5)

After the nonwoven fabric prepared in Examples 1 to 3 was incorporated, an elution treatment was performed as in Example 4. The final products were all suitable for use as artificial leather.

(Example 6)

Prepared in the same manner as in Example 1, but the nylon-6 material having a relative viscosity (RV) of 2.52 was used as the material of the island component.

(Example 7)

The nylon island-in-the-sea island yarn of Example 6 was subjected to a water flow tangential treatment in the same manner as in Example 2.

(Example 8)

The spunbonded island-in-the-sea type microfiber artificial leather of the present invention was prepared by impregnating and eluting the nonwoven fabric of Example 7 in the same manner as in Example 5.

As described above, the method of manufacturing the long fiber nonwoven fabric of the present invention not only provides an innovative method of manufacturing the nonwoven fabric in one step by combining all the conventional four-step processes, the uniformity of the quality and excellent mechanical properties The final product can be manufactured quickly and inexpensively. Therefore, the nonwoven fabric of the present invention is used as an artificial leather through a process such as polyurethane impregnation or coating, dissolution, buffing, dyeing, or by simply eluting a spunbond made of island-in-the-sea fine microfiber with high density, such as a wiper. It can also be used as a cleaner, and can be used as an internal filling material using various filters and excellent touch and elasticity by using a microfiber.

Claims (11)

A method for producing a long fiber nonwoven fabric, which is produced by spinning a sea island filament to form a web by a spunbond method, and heat-bonding or pre-needle punching the web. The method of claim 1, wherein the island-in-the-sea yarn has a fineness of 1 to 5 denier, the polymer composite ratio of the island component and the sea component is 80: 20 to 50: 50, the number of island components in the island-in-the-sea filament is 10 to 100 degrees Method for producing a long fiber nonwoven fabric. The method of claim 2, wherein the polymer is selected from the group consisting of polyester, nylon, copolyester, olefin, and styrene. The method of claim 1, wherein the spinning is carried out at a spinning speed of at least 4,500 m / min. The method of manufacturing a long fiber nonwoven fabric according to claim 1, wherein the nonwoven fabric has a fineness of 0.01 to 0.2 denier. The method of manufacturing a long fiber nonwoven fabric according to claim 1, wherein the nonwoven fabric is further subjected to a needle punch, a water punch, or a mixed processing thereof. A long fiber nonwoven fabric prepared by any one of claims 1 to 6. 8. The long fiber nonwoven fabric of claim 7, wherein the nonwoven fabric has a density of 0.15 to 0.50 gr / cm3. Artificial leather produced by impregnating or coating the nonwoven fabric of claim 7 in polyurethane, eluting, buffing, and dyeing. The filter manufactured by eluting the nonwoven fabric of Claim 7. The wiper manufactured by eluting the nonwoven fabric of Claim 7.