KR20190142882A - Non-woven for primary carpet backing and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a manufacturing method of a nonwoven fabric for a primary backing substrate for a carpet, which has double sides with different colors and has improved mechanical properties. The primary backing substrate for a carpet is manufactured by stacking mixed yarns of a first filament containing carbon blacks and made of a first polyester having a melting point of 250°C or more and a second filament made of a second polyester having a melting point of 190°C or less in a first column and a second column and then, thermally binding the same. According to the present invention, one surface of double surfaces of a nonwoven fabric has a color ranging from white to grey while the other surface has a color ranging from dark grey to black, to relatively represent a bright color in one surface and a dark color in the other surface such that the present invention provides a nonwoven fabric for a primary backing substrate for a carpet of which double surfaces have color difference. Accordingly, any one surface between double surfaces of a nonwoven fabric is used easily and selectively depending on dark or bright colors of carpet pile yarns, and there is no need to manufacture various colors of nonwoven fabrics according to colors of carpets, thereby being easy to manage nonwoven fabric inventories, providing color harmony of carpet pile yarns with nonwoven fabrics for a primary backing substrate, and improving efficiency of a carpet manufacturing process.

Description

Non-woven for carpet bubble paper and manufacturing method thereof Non-woven for primary carpet backing and manufacturing method

The present invention relates to a method for producing a nonwoven fabric for carpet bubble paper, which is different in color on both sides and has improved mechanical properties.

Carpets are used for the purpose of comfort, antifouling, and sound insulation, as well as decoration that exhibits aesthetic effect in hotels, offices, homes, automobiles, etc., due to their soft touch with various colors and patterns.

The carpet is a tufting process (planting a carpet yarn (BCF yarn) on the nonwoven fabric) and a back coating process that fixes the carpet yarn and gives shape stability (PVC, PE, EVA on the back side of the tufted nonwoven fabric). Or it is made into a fabric for the carpet through the process of coating and curing the crude liquid such as SBR in a variety of layer configuration).

In the manufacture of carpets, bubble paper is an important factor that determines the quality of the carpet as a support of the resin layer which plays a role of fixing the carpet yarn which determines the aesthetic appearance quality of the carpet and also plays the role of walking, sound insulation and insulation of the product. .

The physical and thermal external forces that bubble paper receives are high throughout the carpet manufacturing process. In the tufting process, the hole is punctured and damaged by a needle, and in the back-coating process, the resin material is in contact with the resin.

Therefore, the carpet bubble paper directly affects the defect of the product, so the carpet bubble paper must maintain the arrangement of the carpet yarn even in physical damage, and there should be no deformation in the thermal environment.

In addition, various colors of carpet yarns are applied to develop differentiation from existing carpets by improving aesthetic performance, so that the bubbles seen between carpet yarns are required in various colors according to the color of the carpets. (White) to black (black) products are required to adjust the content. Therefore, the carpet manufacturer has a problem in that the inventory of the bubble paper according to the carpet products also by color.

Republic of Korea Patent No. 1778177 (Manufacturing method of nonwoven fabric with different color on both sides)

The present invention is to solve the problems as described above, by spinning the filament with different carbon black content is composed of different colors on both sides of the nonwoven fabric and the low-melting copolyester by interweaving a non-woven fabric having excellent mechanical properties after tufting To manufacture.

MEANS TO SOLVE THE PROBLEM In order to solve the said subject, in this nonwoven fabric which consists of a 1st surface layer and a 2nd surface layer, the said 1st surface layer and the 2nd surface layer are the 1st containing 1st polyester and carbon black whose melting | fusing point is 250 degreeC or more. The content ratio of the filament and the second filament including the second polyester having a melting point of 190 ° C. or less includes 95: 5 to 85:15 wt% of blended yarn, and the total content of the carbon black in the first surface layer is It is 0.06 ~ 0.15% by weight in total, the total content of the carbon black in the second surface layer provides a non-woven fabric for carpet foam, characterized in that 0.3 ~ 0.5% by weight.

Further, the first polyester having a melting point of 250 ° C. or higher containing carbon black of 0.07 to 0.15% by weight for the first filament and the second polyester having a melting point of 190 ° C. or lower for the second filament are respectively melted and discharged through a spinning nozzle. To thereby blend the yarns so that the content ratio of the first filament to the second filament is 95: 5 to 85: 15% by weight, thereby preparing a first row of web blend yarns; Melting and discharging the first polyester having a melting point of 250 ° C or higher and the second polyester having a melting point of 190 ° C or lower for the second filament containing 0.37 to 0.5% by weight of carbon black for the first filament, respectively, and discharging it through the spinning nozzle, Preparing a blended yarn for the web in a second row by blending the yarns such that the content ratio of the first filament to the second filament is 95: 5 to 85:15 wt%; Stacking the first row of web blend yarns to form a first row of webs, and stacking a second row of webs with the second row of web blend yarns to form a web in which the first row and the second row are stacked; And thermally bonding the laminated web to a calender process using a smooth roll and hot-bonding with hot air to prepare a nonwoven fabric, wherein the first row of webs includes 0.06 to 0.20 wt% of the carbon black. The second row of webs provides a method for producing a nonwoven fabric for carpet foam, characterized in that it comprises 0.3 to 0.5% by weight of the carbon black.

According to the present invention, one side of both sides of the nonwoven fabric appears in the range of white to gray, the opposite side of which is in the range of dark gray to black, i.e., the light of one side and the dark side of the opposite side are represented. As a result, a nonwoven fabric for carpet bubble paper having different colors on both sides is provided.

This makes it easy to selectively use either side of both sides of the nonwoven fabric to match the dark or light color of the carpet pile yarn, which makes it easier to manage the inventory of the nonwoven fabric by eliminating the need to create nonwoven fabrics of various colors according to the color of the carpet. Color matching of the carpet pile yarn and the nonwoven fabric for bubble paper is achieved, and the efficiency of the carpet manufacturing process is improved.

In addition, even if external force (physical and thermal) is applied in the carpet manufacturing process by the nonwoven fabric of the present invention, the shape deformation becomes small.

In addition, by controlling the content of the low melting point copolyester to increase the autonomy of the filament to reduce the damage of the filament when tufting to prevent the reduction of the strength reduction rate in the nonwoven fabric and carpet.

In the present invention, among the two kinds of filaments constituting the nonwoven fabric, the first filament is formed of a polyester thermoplastic resin having a melting point of 250 ° C. or more, and the second filament is formed of a copolyester thermoplastic resin having a melting point of 190 ° C. or less. In particular, the first filament by containing carbon black is made to control the color in the nonwoven fabric.

At this time, the filament spinning is divided into the first row and the second row, and by controlling the carbon black content of the first filament constituting the first row and the second row differently, the color difference between the web of the first row and the web of the second row This results in nonwoven webs of different colors on both sides.

Hereinafter, a method for manufacturing a nonwoven fabric for carpet bubble paper having different colors on both sides and improved mechanical properties will be described.

Melting the first polyester having a melting point of 250 ° C or more and the second polyester having a melting point of 190 ° C or less for the second filament containing 0.07 to 0.15% by weight of carbon black for the first filament, respectively, and ejected through the spinning nozzle, By blending the yarn so that the content ratio of the first filament to the second filament is 95: 5 to 85: 15% by weight, a step of preparing the blended yarn for the web of the first row may be performed.

In this case, as the content of carbon black increases in the first filament, the color of the nonwoven web becomes darker from white to black.

On the other hand, as the content of carbon black in the first filament decreases from less than 0.07% by weight, the color of the nonwoven web changes to white.

In the present invention, the second filament is made of polyester having a melting point of 190 ° C. or less, and is softened or melted by hot air in the heat bonding process described below to bond surrounding filaments to impart strength and rigidity to the nonwoven fabric.

In this case, when the content ratio of the second filament is less than 5% by weight, the portion of the nonwoven web that is not bonded between the filaments is increased due to the hot air, and thus the nonwoven fabric is not formed well. Problems such as tearing may occur.

In addition, when the content ratio of the second filament exceeds 15% by weight, the content of the adhesive component of the nonwoven fabric is excessive, so that the nonwoven fabric becomes less elastic (brittle), and the damage of the filament increases when tufting, so that the bubble paper after tufting The mechanical properties of can be drastically reduced.

Meanwhile, the first polyester having a melting point of 250 ° C. or higher containing 0.37 to 0.5% by weight of carbon black for the first filament and the second polyester having a melting point of 190 ° C. or lower for the second filament are respectively melted and discharged through a spinning nozzle. In this case, the blending yarn may be spun so that the content ratio of the first filament to the second filament is 95: 5 to 85: 15% by weight, thereby preparing a second blending yarn for the web.

In this case, when the content of the carbon black in the first filament exceeds 0.5% by weight, the carbon black may act as a foreign material and interfere with the formation of the filament, thereby causing a problem such as cutting and thus may not be possible to spin. In particular, in order to express a difference in color in the web of the first row and the web of the second row, a difference should be made in the content of the carbon black contained in each row.

According to the present invention, the filament spun in the form of mixed fiber spinning can be sufficiently drawn to have a spinning speed of 4,500 to 5,500 m / min using a high-pressure air drawing device, thereby producing a filament having a fineness of 4 to 10 deniers in general. .

Thereafter, the first row of web blended yarns are stacked on the conveyor net in the form of a web to form a first row of webs, and the second row of webs blended with the second row of web blended yarns is stacked on the conveyor net to form the first row and the second row. Stacking may be performed to form a web consisting of a first surface layer and a second surface layer.

Thereafter, the laminated web may be subjected to a step of adjusting the thickness through a calendering process using a heated smooth roll and thermally bonding the hot web with hot air to prepare a nonwoven fabric.

As described above, the present invention provides a nonwoven fabric by manufacturing a nonwoven fabric by a web lamination of a two-layer structure in which melting points are different, filaments containing carbon black and filaments containing no carbon black, and carbon content differs. It is possible to provide a nonwoven fabric which is made of a continuous process from spinning, the color of both sides in the nonwoven fabric and the mechanical properties of the tufting process is not impaired through low melting point copolyester content control.

Hereinafter, the present invention will be described in more detail based on the following Examples and Comparative Examples.

However, the following examples are only for illustrating the present invention, and the present invention is not limited to the following examples, and may be changed to other embodiments equivalent to substitutions and equivalents without departing from the technical spirit of the present invention. It will be apparent to those skilled in the art to which the present invention pertains.

Example 1

Extruded melt of 255 ° C polyester with side feed carbon black so that the content of carbon black is 0.07% by weight for forming the first filament and low melting point copolyester extrusion with melting point of 180 ° C for forming the second filament The melts were discharged through the spinning nozzles at the bottom of the continuous extruder, respectively, and intermixed with each other to prepare a blended yarn for the web in the first row.

Extrusion melt of 255 ° C polyester with side feed carbon black so that the content of carbon black is 0.5% by weight for forming the first filament and low melting point copolyester extrusion with melting point of 180 ° C for forming the second filament Each melt was discharged through the spinning nozzle at the bottom of the continuous extruder, and the mixed yarn yarns for the web of the second row were prepared.

In this case, the blend ratio of the first filament and the second filament was 90:10 wt%, and the ejection amount and the number of spinnerets of the nozzle were adjusted so that the fineness of the blended filament manufactured by stretching was 8 denier.

Further, after the continuous filament discharged from the spinning nozzle was solidified with cooling wind, the stretching filament was stretched to 5,000 m / min using a high-pressure air drawing apparatus.

Thereafter, the first row of web blend yarns are stacked on the conveyor net by a conventional opening method to form a first row of webs such that the carbon black content in the first row is 0.063 wt%, and the web blend fibers for the second row are formed thereon. The second row of webs were stacked so that the content of carbon black in the second row was 0.45% by weight to form a web in which the first surface layer in the first row and the second surface layer in the second row were laminated.

The laminated web was given a smoothness and proper thickness through a calendering process by a heated smooth roll, and thermally bonded with hot air to prepare a spunbonded nonwoven fabric for carpet bubble paper having a weight of 120 g / m 2 per unit area.

[Examples 2-4] and [Comparative Examples 1-4]

Spunbond for carpet foam using the same method as in Example 1, except that the blending ratio of the blending yarn, the carbon black content of the first row and the second row was as shown in Table 1 in Example 1 Nonwoven fabrics were prepared.

division Primary filament content
(weight%) Secondary filament content
(weight%) Content of First Row Carbon Black
(weight%) Content of Second Row Carbon Black
(weight%) First filament First Laminated Web First filament Second Laminated Web Example 1 90 10 0.07 0.063 0.5 0.45 Example 2 90 10 0.15 0.135 0.37 0.333 Example 3 86 14 0.15 0.129 0.37 0.318 Example 4 94 6 0.15 0.141 0.37 0.347 Comparative Example 1 90 10 0.05 0.045 0.5 0.45 Comparative Example 2 90 10 0.07 0.063 0.6 0.54 Comparative Example 3 96 4 0.07 0.067 0.5 0.48 Comparative Example 4 80 20 0.07 0.056 0.4 0.4

The properties of the spunbonded nonwoven fabric for carpet foam and the nonwoven fabric after tufting of the Examples and Comparative Examples were measured according to the following test methods and the results are shown in Table 2.

At this time, the tufting was performed under the condition of a gauge (10 ea / inch) and BCF yarn height (3 mm) in the form of a loop.

<Test method>

1. Tensile strength (unit: Kg.f / 5㎝) and tensile elongation (%)

The KS K 0521 method is used.

Specimen of width × length = 5 × 20 cm is bitten with a 5 × 5 cm jig up and down using an Instron measuring instrument and measured at a tensile rate of 200 mm / min.

2.White Index (WI)

Measure using X-rite's Color-Eye 7000A instrument.

The test specimens were used with a minimum diameter of 40 mm or more, and the average value was measured after three measurements were taken for each sample.

Higher value of the measured value WI means white.

division The tensile strength
MD / CD
(Kg.f / 5cm) Tensile strength reduction rate after tufting
MD / CD
(%) Tensile elongation
MD / CD
(%) White index
(1st floor layer /
2nd layer) Final color
(1st floor layer /
2nd layer) Remarks Before tufting After tufting Example 1 27.2 / 28.4 11.4 / 13.1 58/54 56.6 / 58.1 16.4 / 4.2 Light gray / black Example 2 26.8 / 27.3 10.5 / 10.4 61/62 57.1 / 57.8 5.7 / 5.1 Gray / dark gray Example 3 29.5 / 30.1 9.4 / 10.2 68/66 51.3 / 52.8 5.8 / 5.2 Gray / dark gray Example 4 26.2 / 26.7 11.5 / 12.8 56/52 59.4 / 60.2 5.5 / 4.9 Gray / dark gray Comparative Example 1 27.6 / 28.4 13.2 / 13.1 52/54 57.4 / 58.3 18.3 / 4.4 White / black Comparative Example 2 - - - - - - Poor radiation Comparative Example 3 17.5 / 19.5 8.6 / 9.9 51/49 56.9 / 58.2 16.4 / 4.3 Light gray / black Poor strength Comparative Example 4 31.4 / 33.1 9.1 / 8.3 71/75 38.6 / 39.7 16.5 / 4.3 Light gray / black Bad tufting

Carpet bubble paper nonwoven fabric according to the present invention from the results of Table 2, the first surface layer is in the range of white to gray, the second surface layer is shown in the dark gray to black range, the contrast between the first surface layer and the second surface layer clearly It is confirmed that it is possible to select and use a face that represents a light or dark color to match the final color of the carpet, since it represents different colors of relatively light and dark colors.

On the other hand, when the content of the second filament in the blended yarn decreases (see Comparative Example 3), the tensile strength of the nonwoven fabric decreases, and when it increases (see Comparative Example 4), the decrease rate of the tensile strength increases after tufting, thereby deteriorating the physical properties after tufting. do.

In addition, when the content of carbon black in the first filament is increased (see Comparative Example 2), it is confirmed that cutting and clogging of the spinning nozzle occur, so that spinning is not performed properly, and thus, the nonwoven web is not formed.

Claims (5)

In a nonwoven fabric comprising a first surface layer and a second surface layer,
The first and second surface layers have a content ratio of 95: 5 to 1 filament containing a first polyester having a melting point of 250 ° C. or higher and carbon black, and a second filament containing a second polyester having a melting point of 190 ° C. or lower. 85:15 wt% of blended yarn,
The total content of the carbon black in the first surface layer is a total of 0.06 ~ 0.15% by weight,
The total content of the carbon black in the second surface layer is a non-woven fabric for carpet foam, characterized in that 0.3 to 0.5% by weight. The method of claim 1,
The first filament constituting the first surface layer comprises 0.07 to 0.15% by weight of the carbon black,
The first filament constituting the second surface layer comprises 0.37 to 0.5% by weight of the carbon black. The method of claim 1,
The White Index is a non-woven fabric for carpet bubble, characterized in that the first surface layer is 5.3 ~ 17.0, the second surface layer is 4.0 ~ 5.2. The method of claim 1,
A nonwoven fabric for carpet foam, characterized in that the tensile strength reduction rate before and after tufting is 70% or less when tufting is performed to manufacture carpet. Melting the first polyester having a melting point of 250 ° C. or higher for the first filament and the second polyester having a melting point of 190 ° C. or lower for the second filament, respectively, and melting through the spinning nozzle to discharge the first filament Preparing a blended yarn for the web in the first row by blending and spinning the content ratio of the second filament to 95: 5 to 85:15 wt%;
Melting the first polyester having a melting point of 250 ° C. or higher for the first filament and the second polyester having a melting point of 190 ° C. or lower for the second filament, respectively, and melting through the spinning nozzle to discharge the first filament Mixing the yarn to make the content ratio of the second filament be 95: 5 to 85: 15% by weight, thereby preparing a blend yarn for the web of the second row;
Stacking the first row of web blend yarns to form a first row of webs, and stacking a second row of webs with the second row of web blend yarns to form a web in which the first row and the second row are stacked; And
It includes a step of producing a nonwoven fabric by thermally bonding the laminated web through a calender process by a smooth roll and hot air;
The first row of webs comprises 0.06 to 0.15 wt% of the carbon black, and the second row of webs comprises 0.3 to 0.5 wt% of the carbon black.