KR20180000887A - Non-woven Fabric for Primary Carpet Backing in Carpet Preparing Process, and Method for Manufacturing the Same - Google Patents

Abstract

The present invention relates to a non-woven fabric for a carpet backing fabric and a method for manufacturing the same capable of improving formability of a carpet by reversibly deforming a shape of the non-woven fabric in response to thermal and physical external force applied in a process of manufacturing the carpet through a tufting process, a back coating process, and a forming process. The non-woven fabric for the carpet backing fabric is provided to contain fabrics manufactured by a thermoplastic polymer elastomer; and improve elongation at a high temperature with elasticity at room temperature, thereby forming the carpet which is flexibly extended in response to the thermal and physical external force. The non-woven fabric for the carpet backing fabric decreases a defective forming rate and arrangement deformation of carpet yarns in the manufactured carpet and provides a uniform appearance.

Description

TECHNICAL FIELD [0001] The present invention relates to a nonwoven fabric for carpet bubbles and a method for manufacturing the same,

The present invention relates to a nonwoven fabric which is reversibly deformed in shape in response to thermal and physical external forces applied in the process of manufacturing a finished carpet product through a tufting process, a back coating process, a molding process, To a method of manufacturing a nonwoven fabric in which the moldability of a carpet is improved and a nonwoven fabric produced by the method.

Carpets are used not only for decoration in hotels, offices, homes, automobiles, but also for providing comfort and sound insulation.

Accordingly, it is required that the carpet bubble is minimally damaged by thermal external force and physical external force so that the shape deformation of the molded product is finally suppressed and the arrangement of the carpet yarn is maintained.

In addition, since the shape and depth of the carpet base mat for a floor mats for automobiles differ depending on the type of automobile, it is required to have a formability that can be formed in various forms corresponding to the automobile flooring, do.

However, there is a problem in that the arrangement of the carpet yarns is not maintained, for example, the arrangement intervals of the carpet yarns are widened at a portion where the shape deformation of the carpet base is frequently generated in the molding process.

Korean Patent Laid-Open Publication No. 10-2012-0033771 discloses a process for producing a core-sheath filament in which an olefin-based polymer is applied to a sheath portion and using the same to manufacture a nonwoven fabric for carpet bubbles, thereby improving the elongation.

However, due to the low melting temperature of the olefin-based polymer, the present invention causes morphological deformation of the nonwoven fabric due to the temperature at the time of drying ethyl vinyl acetate, styrene butadiene rubber and polyvinyl chloride components used in the back coating process, The softness of the polymer and the shape of the molded product may become somewhat poor.

As described above, various methods for solving the problems occurring in the nonwoven fabric for a base material of a carpet have been proposed and some improvements have been made in general properties such as strength and elongation. However, But still technically and commercially viable.

The present invention relates to a nonwoven fabric for carpet bubbles, in which the nonwoven fabrics for carpets are elastically and elastically stretchable and contractible in response to physical and thermal external forces applied during tufting, back coating and molding processes during the production of carpets, And a method for producing the same.

In order to solve the above-described problems, the present invention provides a laminated film comprising a first filament made of a polyester resin having a melting point of 255 캜 or higher, and a second filament made of a thermoplastic polymer elastomer having a melting point of 170 캜 to 190 캜, The hot-rolled steel sheet according to the present invention has an elongation at 180 ° C of 60 to 80% in the longitudinal direction and 60 to 80% in the width direction and a hot strength at 180 ° C of 2.5 to 4.0 kgf / 3 cm in the longitudinal direction and 2.0 To 4.5 kgf / 3 cm of the nonwoven fabric.

Further, the present invention is characterized in that 70 to 95% by weight of a polyester resin having a melting point of 255 캜 or higher and 5 to 30% by weight of a thermoplastic polymer elastomer having a melting point of 170 to 190 캜 as a resin for a second filament, Producing a filament; Forming a web by laminating the horny filaments; And thermally adhering the web to the nonwoven fabric.

According to the present invention, the nonwoven fabric for carpet bubbles has elasticity at room temperature, and the elongation at high temperature is improved. The nonwoven fabric for carpet bubbles is stretched and expanded flexibly in response to thermal and physical external forces, And the appearance can be made uniform.

The nonwoven fabric for carpet foam according to the present invention has a first filament made of a polyester resin having a melting point of 255 ° C or higher of 70 to 95 wt% and a second filament made of a thermoplastic polymer elastomer having a melting point of 170 to 190 캜, %.

The material of the first filament is preferably polyethylene terephthalate (PET), and the material of the second filament is a polymer which is flexible at high temperatures and can be molded like plastic and exhibits properties of a rubber elastic body at room temperature, Rubber, olefinic thermoplastic rubber, urethane-based thermoplastic rubber, amide-based thermoplastic rubber, and polyester-based thermoplastic rubber.

The second filaments may exhibit an adhesive function between the filaments constituting the nonwoven fabric so that the nonwoven fabric can be retained while being provided with the shape of the nonwoven fabric.

When the melting point of the second filament is less than 170 캜, the second filament is redissolved in the carpet manufacturing process, and thus the breakage of the foam is easy to occur, and the heat shrinkage rate is increased to shorten the width and length of the finished carpet. The shape of the carpet may be twisted due to the difference in heat shrinkage ratio, or the edge of the carpet may be lifted up.

If the melting point of the second filament is higher than 190 캜, the heat shrinkage rate of the nonwoven fabric is stabilized, so that the judgment of the foaming property and lack of the width and length of the finished product are not observed during the carpet manufacturing process. However, Since the flexibility of the nonwoven fabric is lowered in the high temperature coating and heat treatment and drying processes in which the non-woven carpet yarn is dropped or a fine tensile force is applied, the flexible material such as polyvinyl chloride, polyurethane and asphalt coated on the bottom of the nonwoven fabric .

Such minute difference is not a problem in the product immediately after the production, but as the use period of the carpet is increased, the potential stress due to the difference in elongation between the coating material and the nonwoven fabric causes the carpet to peel off.

If the second filament is less than 5% by weight in the prepreg, the portion to be bonded between the filaments is reduced, so that the nonwoven fabric may not be well formed and may be folded.

On the other hand, when the amount is more than 30% by weight, the elastic properties of the nonwoven fabric are excessively strengthened, so that it is difficult for the needles to penetrate in the tufting step, resulting in poor workability and a large number of defects.

The nonwoven fabric for carpet bubbles of the present invention is characterized in that the resin for the first filament and the resin for the second filament are melted in respective extruders through a feeder and discharged through a spinning nozzle and mixed And then laminated to form a web. The filaments are thermally adhered using hot air at a temperature in the range of 占 0 占 폚 at the melting point of the resin for the second filament , And an emulsion.

The filaments having a fineness of 4 to 10 deniers can be produced by sufficiently stretching the above-mentioned mixed-spinning yarn using a high-pressure air drawing device at a spinning speed of 4,500 to 5,000 m / min.

When the filament is less than 4 denier, the filament is thin, the strength is weak, and the number of filaments per unit area is increased, so that the filament breakage occurs in the tufting process to cause deterioration of physical properties of the paper. The cooling length for the crystallization of the filament is increased to 2 m or longer, making it difficult to produce the nonwoven fabric commercially uniformly, and it is difficult to control the content ratio of the first filament and the second filament, making it difficult to produce a uniform nonwoven fabric.

The filaments may be laminated on a conveyor in the form of a web by a conventional filament method, and then calendered using calender rolls or the like.

Since the nonwoven fabric for a carpet base fabric of the present invention is manufactured by thermally adhering after forming a web, the filament fibers are thermally adhered to each other even if the needle punch or the like is not carried out separately. Therefore, the manufacturing process of the nonwoven fabric is simple, The fiber can be prevented from being damaged, and the adhesion of the fibers is made by heat, not by external force, so that the nonwoven fabric having a bulky structure can be obtained without a change in thickness.

Finally, a small amount of tanning agent (0.4 to 1.0 wt%) can be uniformly applied to the nonwoven fabric thus prepared, and the basis weight of the nonwoven fabric thus prepared is suitably 100 to 140 g / m 2.

The nonwoven fabric for a carpet bubble of the present invention produced as described above has a thermal elongation at 180 ° C of 60 to 80% in the longitudinal direction and 60 to 80% in the width direction and a hot strength of 2.5 to 4.0 kgf in the longitudinal direction (MD) / 3 cm and a width direction (CD) of 2.0 to 4.5 kgf / 3 cm. As a result, it has excellent strength at high temperature and has an improved elongation, so that it can be flexibly expanded and contracted against thermal external force and physical external force The formability is improved and the arrangement of the carpet yarns is not disturbed.

Hereinafter, the present invention will be described in more detail with reference to the following examples and comparative examples.

It is to be understood, however, that the invention is not to be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Will be apparent to those skilled in the art to which the present invention pertains.

<Examples 1 to 4> and <Comparative Examples 1 to 4>

The resin of the first filament used as the raw material used was polyethylene terephthalate having a melting point of 255 캜, and the resin of the second filament used the resin shown in Table 1 below.

The resin of the first filament and the filament of the two filaments was injected into each of two rows of continuous extruders operated at 288 ° C and melted. Then, the first filament and the second filament were discharged from the spinneret, and the ratio of the contents of the first filament and the second filament Were mixed and dispersed at a composition ratio shown in Table 1 below.

At this time, the filament discharged from the spinneret was solidified by cooling wind and stretched at a spinning speed of 5,000 m / min using a high-pressure air stretching device to produce a filament yarn having a fineness of 8 denier.

The horny filament yarn was laminated in a web form on a net of a conveyor continuously moving in a normal filament method, calendered by a heated calender roller, and subjected to a calendering process for imparting smoothness and appropriate thickness.

Thereafter, a filament was thermally adhered by a hot air having a temperature equal to the melting point of the second filament by using a drier to prepare a nonwoven fabric having a weight per unit area of 120 g / m 2, followed by coating the surface of the nonwoven fabric with an emulsion to prepare a nonwoven fabric for carpet bubble.

The second filament
Material The second filament
Melting point (캜) From Horn Island Temple
The second filament
Content (% by weight) From Horn Island Temple
The first filament
Content (% by weight) Example 1 TPEE 190 10 90 Example 2 TPEE 190 20 80 Example 3 TPEE 190 25 75 Example 4 TPU 180 20 80 Comparative Example 1 TPEE 190 4 96 Comparative Example 2 TPEE 190 35 65 Comparative Example 3 PET 255 20 80 Comparative Example 4 PP 135 20 80 TPEE: thermoplastic polyester elastomer, TPU: thermoplastic polyurethane, PET: polyethylene terephthalate, PP: polypropylene

&Lt; Evaluation Method 1 >

Using KS K 0521 method, specimens of 3 × 10 ㎝ in width × length were preheated in a hot chamber at 180 ° C. for 3 minutes by using INSTRON (US) measuring equipment, And measured at a tensile rate of 200 mm / min.

&Lt; Evaluation Method 2 >

Using KS K 0521 method, specimens of 3 × 10 ㎝ in width × length were preheated in a hot chamber at 180 ° C. for 3 minutes by using INSTRON (US) measuring equipment, And measured at a tensile rate of 200 mm / min.

<Evaluation method 3> When the tufting is carried out,

Measure the number of carpet yarns that can not be fixed after performing loop type tufting (100 m) on the condition that the number of needles per inch is 10, the number of needles per one inch is 13, and the speed is 800 rpm in the width direction.

&Lt; Evaluation Method 4 >

A polyvinyl chloride solution was applied to the back surface of the tufted nonwoven fabric under the condition of the above evaluation method 3 and dried to prepare a specimen having a size of 50 x 50 cm in width and length.

The specimen was placed in a grid pattern with intervals of 2 cm and preheated at 180 DEG C for 3 minutes in a preheating plate. The bottom plate with a size of 20 x 20 cm was molded in a mold having a concave shape and a top plate, Count the grid pattern of the tearing area to determine the width of the tearing area.

Example of area calculation: When the number of cells in the torn area is 2 2 × 2 = 4 cm 2

<Evaluation Method 5> Number of carpet yarns after molding

The number of carpet pads arranged per inch in the longitudinal direction is measured in the carpet formed in the above evaluation method 5.

The nonwoven fabrics prepared in Examples and Comparative Examples were evaluated using the above evaluation method, and the results are shown in Table 2 below.

Hot Strength
MD / CD
(Kgf / 3 cm
at 180 C) Thermal elongation
MD / CD
(%
at 180 C) Number of carpets damaged when touched
(100M) Molding performance
(㎠) Number of carpet yarns after molding
(Heat / inch) Final evaluation Example 1 3.8 / 4.1 62/65 0 0 13 ◎ Example 2 2.9 / 3.2 69/64 0 0 13 ◎ Example 3 2.3 / 2.1 75/79 One 0 13 ○ Example 4 3.1 / 2.8 67/64 0 0 13 ◎ Comparative Example 1 5.8 / 7.2 46/51 19 6 13.5 × Comparative Example 2 1.9 / 1.6 89/92 16 0 13 △ Comparative Example 3 8.3 / 7.9 38/31 6 20 13 × Comparative Example 4 5.6 / 6.7 48/52 8 16 14 × ?: Very excellent,?: Excellent,?: Fair, X: poor

The results of Table 2 show that the nonwoven fabric of the embodiment has a thermal expansion coefficient of 60 to 80% in the longitudinal direction, 60 to 80% in the width direction, 2.5 to 4.0 kgf / 3 cm in the longitudinal direction, 2.0 to 4.5 kgf / 3 cm, and exhibited better tufting defect rate, moldability, arrangement of carpets after molding, and better overall properties than comparative examples.

As the content of the thermoplastic polymer elastomer increases, the hot elongation increases and the hot strength decreases. However, it can be confirmed that the hot stretching ratio and the hot strength range of the present invention exhibit excellent properties in the manufacture of carpets. On the other hand, if the content of the thermoplastic polymer elastomer is too large, the hot strength becomes too low and the tufting defect rate increases, which is not preferable (Comparative Example 2).

Claims (5)

A first filament made of a polyester resin having a melting point of 255 캜 or higher and a second filament made of a thermoplastic polymer elastomer having a melting point of 170 캜 to 190 캜 are mixed and web-
The hot stretch ratio at 180 占 폚 is 60 to 80% in the longitudinal direction and 60 to 80% in the width direction and the hot strength at 180 占 폚 is 2.5 to 4.0 kgf / 3 cm in the longitudinal direction and 2.0 to 4.5 kgf / 3 cm Non-woven fabric for carpets. The method according to claim 1,
Wherein the thermoplastic polymer elastomer is selected from the group consisting of a styrenic thermoplastic rubber, an olefinic thermoplastic rubber, a urethane-based thermoplastic rubber, an amide-based thermoplastic rubber, and a polyester-based thermoplastic rubber. The method according to claim 1,
Wherein the first filaments and the second filaments are mixed at 70 to 95: 5 to 30 wt%. 70 to 95% by weight of polyester having a melting point of not less than 255 캜 as a resin for the first filament and 5 to 30% by weight of a thermoplastic polymer elastomer having a melting point of 170 to 190 캜 as a resin for a second filament, ;
Forming a web by laminating the horny filaments; And
And thermally adhering the web to the nonwoven fabric. 5. The method of claim 4,
Wherein the thermal bonding temperature in the step of thermally adhering is such that hot air having a temperature within a range of 占 0 占 폚 from the melting point of the resin for the second filament is used.