KR20180075905A - Manufacturing method of nonwoven for carpet backing - Google Patents

Abstract

The present invention relates to a manufacturing method of a nonwoven fabric for a carpet backing having improved fixing property of a bulked continuous filament (BCF) yarn planted on a backing in a tufting process. The manufacturing method of a nonwoven fabric for a carpet backing comprises a step of crimp-processing and needle-punching a web of a stretched polyester filament. Therefore, a residual stress of the stretched polyester filament is eliminated, moldability is improved, and the fixing ability of the BCF yarn on the carpet can be improved by bridging of the polyester filament.

Description

Technical Field [0001] The present invention relates to a method of manufacturing a nonwoven fabric for a carpet bubble,

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a nonwoven fabric for carpet bubbles having improved fixing properties of BCF (yarn) deposited on a base paper in a tufting process.

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

The carpet fabric is manufactured through a manufacturing process including a tufting step of applying BCF yarn to the nonwoven fabric and a backcoating process of coating the back side of the tufted nonwoven fabric with coating liquid such as PVC, PE, EVA or SBR.

If the carpet fabric is cut into squares (for example, 50 cm × 50 cm), it becomes a tile carpet used in a hotel, an office, a home, and a car floor mat if it is molded in the shape of a car bottom.

The function of the nonwoven fabric for carpet bubbles is to fix the BCF yarn.

In the tufting process, the bubble is punctured by a needle with a hole of at least 160,000 holes per square meter. The bubbles must maintain the alignment of the BCF yarn even with such physical damage, and there should be no deformation of the shape in the post-process of the high temperature environment.

Recent trends in the tufting process are densification, pattern diversification, and the use of low denier BCF. For example, there are tendencies such as making the height of BCF yarn more than three in multi level condition, increasing tufting density by using BCF yarn as microfiber yarn, and increasing movement of needle due to use of BCF yarn of various colors As a result, the difficulty of tufting is increased. Therefore, in order to prevent the damage of the base paper, the coefficient of friction between the nonwoven fabric and the BCF yarn must be increased to improve the fixing ability of the BCF yarn in the nonwoven fabric.

In addition, conventional nonwoven fabrics for carpet bubbles are subjected to a stretching process to produce filaments having latent stresses as nonwoven fabrics through thermal or chemical bonding methods. At this time, when the residual stress of the filament is heated in the post-processing step, it is eliminated to show a high shrinkage rate, which causes a problem that the shape of the finished carpet article is deformed.

Korean Patent Laid-Open Publication No. 2015-0113327 (Spunbonded Nonwoven Fabric for Carpet Bubbles with Improved File Holding Power)

In order to solve the above problems, the present invention provides a method for manufacturing a nonwoven fabric for carpet bubbles, wherein the fixing ability of the BCF yarn is improved by improving the manufacturing method of the nonwoven fabric for carpet bubbles.

In order to solve the above-mentioned problems, the present invention provides a method for producing a stretched polyester filament fiber, comprising the steps of: Integrating the filament fibers in a web form, crimping and calendering to form a web; And needle punching the web. The present invention also provides a method for manufacturing a nonwoven fabric for a carpet bubble.

According to the present invention, the stretched polyester filament web is subjected to crimp processing and needle punching, whereby the residual stress of the drawn polyester filament is eliminated and the formability is improved, and the polyester filament is entangled The fixing ability of the BCF yarn can be improved on the carpet.

The present invention is a method for producing a nonwoven fabric for carpet bubbles, which comprises forming a drawn filament into a web, crimping, calendering and needle punching.

The filament of the present invention is produced by melting a polyester having a melting point of 250 ° C or higher, discharging it through a spinneret to form a filament, and stretching the filament at a spinning speed of 4,500 to 5,000 m / min using a high- , Filament fibers having a circular cross section with a low fineness of 4 to 7 deniers can be used.

In the present invention, when the fineness is less than 4 deniers, damage to the fibers occurs during tufting and the ability to fix the BCF yarn may be deteriorated. If the fineness is more than 7 deniers, the friction coefficient may be lowered, and improvement of the drawing strength may be difficult.

The filament fibers are piled up on a conveyor in the form of a web, and then heat is applied thereto to crimp the filaments.

Crimp processing is a processing method of heat treatment of synthetic fiber filaments to make a thin bend, and the yarn is curled and stretched.

In the present invention, the drawn filaments are accumulated on the conveyor net and the drawn filaments can be treated at 100 to 150 ° C for 30 to 60 seconds.

The residual stress of the stretched filament is dissipated by applying heat during the crimping process to lower the shrinkage ratio, thereby improving the morphological stability. Further, a crimp is imparted to the filament constituting the nonwoven fabric to increase the friction coefficient, and finally, the fixing ability of the BCF yarn can be improved.

In the crimping process, the number of crimp of the polyester filament fiber is preferably 20 to 40 / inch. At this time, when the number of crimps is less than 20 pieces / inch, the contact points between the filaments are reduced, so that the strength and elongation of the nonwoven fabric after calendering or needle punching are lowered, and the force for fixing the BCF yarn after tufting is weakened. When the number of crimps exceeds 40 pieces / inch, the contact points become too large, and the filaments may be damaged when needle punching due to excessive adhesion between the filaments, and the friction coefficient of the nonwoven fabric is too high, Can occur.

Thereafter, the crimped web is passed through a calendering roll to adjust the thickness and needle punching to produce a nonwoven fabric having entangled filaments.

The calendering of the present invention reduces the thickness of the nonwoven fabric by applying a predetermined temperature (130 to 150 ° C) and pressure to have a thickness of 0.35 to 0.50 mm. As a result, the amount of entanglement of the filament increases due to the increase in density do.

The needle punch is preferably performed in two stages. In the pre-punching, the conditions are set at 300 to 400 stroke rpm (speed at which the nonwoven fabric is bonded to the needle during the passage of the conveyor net) A part of the web is entangled to form a web, and in the second step (main punching), the filaments are entangled entirely at 600 to 800 stroke rpm to produce a nonwoven fabric for carpet bubble.

Since the latent stress in the amorphous region oriented in the drawn filament is relieved by the crimping process, the nonwoven fabric for carpet bubble fabrics produced as described above reduces the shrinkage rate due to heat in subsequent steps and forms a curved point of the filament The tensile strength and the tearing tension in the needle punch can be increased.

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.

≪ Example 1 >

Polyethylene terephthalate (PET) for fibers having a melting point of 260 ° C was melted at 288 ° C in an extruder and discharged through the capillary holes of the spinneret. The discharged PET was solidified using a cooling wind and stretched using a stretching device Spinning at a spinning rate of 5,000 m / min to produce a filament fiber having a circular cross section with a fineness of 6.

The filament fibers were piled in the form of a web on a conveyor net by a conventional filament method and heated at 130 DEG C for 60 seconds to crimped piled filaments to form the crimp number shown in Table 1 below.

Then, calendering was carried out by passing through a heated calendering roll to give smoothness and appropriate thickness.

Then, needle punching of the first and second steps was carried out under the conditions shown in Table 1 below to prepare a nonwoven fabric for carpet bubble having a weight per unit area of 120 g / m 2 in which the filaments were entangled.

≪ Examples 2 to 4 >

A nonwoven fabric for carpet bubble was prepared using the same method as in Example 1 except that crimping and needle punching were carried out under the conditions shown in Table 1 in Example 1 above.

≪ Comparative Examples 1 to 4 >

A nonwoven fabric for carpet bubble was prepared using the same method as in Example 1 except that crimping and needle punching were carried out under the conditions shown in Table 1 in Example 1 above.

division Crimp number Step 1 Needle punch condition
(stroke rpm) Two-step needle punch condition
(stroke rpm) Example 1 20 350 700 Example 2 30 350 700 Example 3 40 350 700 Example 4 30 350 800 Comparative Example 1 15 350 700 Comparative Example 2 30 350 500 Comparative Example 3 50 350 700 Comparative Example 4 30 350 900

The above Examples and Comparative Examples were evaluated by the following evaluation methods, and the results are shown in Table 2 below.

<Evaluation method>

1. Tensile strength (kgf / 5 cm) and elongation (%)

KS K 0521 method was used. A specimen having a size of 5 cm × 5 cm × width × 5 cm is placed on a 5 cm × 5 cm jig using an Instron measuring apparatus and then measured at a tensile speed of 200 mm / min.

2. Molding performance

After applying PVC solution to the back of the nonwoven fabric and drying it, a grid pattern of 2 cm spacing is drawn on the specimen of size = 50 cm × 50 cm. Thereafter, the nonwoven fabric is preheated at 180 ° C for 3 minutes in a preheating plate, and molding is performed using a square mold having a size of 20 cm x 20 cm with the lower plate being engraved and the upper plate being embossed. After forming, count the grid pattern of the portion to be torn by the nonwoven fabric to obtain the width of the torn portion.

Ex) Number of cells in the torn area = 2 cells = 2 × 2 = 4

3. Drawing strength (gf)

Loft type tufting is performed at a speed of 800 rpm under the condition of 10 needles per inch in the width direction and 13 needles per inch in the length direction when tufting. After tufting, cut off one loop adjacent to the loop to be measured, and cut the loop with 10 loops apart. An average of 10 intensity peaks appear when the loops to be measured are pulled in a direction perpendicular to the nonwoven fabric using an Instron. The number of specimens shall be three.

The tensile strength
(MD / CD,
kgf / 5 cm) Tensile elongation
(MD / CD,
%) Molding performance
(Cm x cm) Drawing strength
(gf) Overall assessment Example 1 14.1 / 15.7 34.2 / 35.9 0 2.1 ○ Example 2 15.9 / 16.3 31.4 / 34.3 0 2.6 ◎ Example 3 18.8 / 20.7 28.3 / 29.2 0 2.8 ◎ Example 4 17.3 / 18.8 29.4 / 30.1 0 2.7 ◎ Comparative Example 1 10.1 / 12.5 40.6 / 37.4 7 Unable to tuft × Comparative Example 2 14.3 / 15.1 30.3 / 34.7 3 2.3 △ Comparative Example 3 23.8 / 24.7 38.9 / 37.6 4 2.4 △ Comparative Example 4 10.8 / 11.7 39.8 / 38.1 15 Unable to tuft ×

When the number of crimps of the filament constituting the nonwoven fabric was small (Comparative Example 1), tufting was impossible from the results of Table 2, which is considered to be because the number of contact points was small and the improvement of the friction coefficient was insignificant. When the number of filaments is large (Comparative Example 2), the mechanical strength is improved, but the nonwoven fabric is stiff and the formability is deteriorated.

When the needle punch was excessive (Comparative Example 4), tufting was impossible, which can be confirmed by the damage of the filament. In the case where the needle punch is excessively small (Comparative Example 2), improvement in mechanical strength is not exhibited, and consequently, molding performance is deteriorated.

On the other hand, it is confirmed that the nonwoven fabric according to the embodiment of the present invention improves the formability and the drawing strength in the carpet manufacturing process.

Claims (4)

Producing stretched polyester filament fibers of circular cross section;
Integrating the filament fibers in a web form, crimping and calendering to form a web; And
And needle punching the web. &Lt; RTI ID = 0.0 &gt; 11. &lt; / RTI &gt; The method according to claim 1,
Characterized in that the stretched filament fibers are stacked on a conveyor net for forming the web and the stretched filaments are treated at 100 to 150 ° C for 30 to 60 seconds. Way. The method according to claim 1,
Wherein the needle punching is performed in a first step and a second step, wherein the first step is performed under the condition of 300 to 400 stroke rpm, and the second step is performed in the range of 600 to 800 stroke rpm. A method for producing a nonwoven fabric. [Claim 1] Characterized in that it comprises a polyester filament fiber having a monofilament fineness of 4 to 7 denier and a drawn strength of 2.0 to 3.0 gf (strength to pull the loop after loop type tufting), which is manufactured by the method of any one of claims 1 to 3, Nonwoven fabrics.