KR20220097289A - Spunbond non-woven and manufacturing method thereof - Google Patents

Abstract

Provided are a spunbond non-woven fabric, and a manufacturing method therefor. The spunbond non-woven fabric according to the present invention is configured not to include a latex layer or a PVC layer that generates harmful substances, but it can serve as a latex material while exhibiting excellent mechanical properties, thereby being able to provide an eco-friendly carpet with excellent pull-out strength.

Description

Spunbond nonwoven fabric and manufacturing method thereof

The present invention relates to a spunbond nonwoven fabric suitable for use as a material for automobile flooring and a method for manufacturing the same.

Carpets are used for decoration, comfort, sound absorption, and walking convenience (cushions) as floor interior products for homes, public institutions, hotels, restaurants, and automobiles.

The existing carpet structure is composed of carpet yarn (BCF yarn (pile)), foam paper (non-woven fabric), latex and PVC (Rubber, EVA, etc.).

Among them, the latex and PVC materials generate toxic substance fume in the process of coating the tufted foam paper (non-woven fabric) with carpet yarn, and in the finished product, they belong to the automotive floor interior product group and pollute indoor air quality. causes

That is, the latex coating process and PVC layer among the carpet components are the layers that emit the most volatile harmful substances. In addition, there is a problem in that a lot of harmful substances are released in the process of coating and curing the PVC layer among the post-processing processes for manufacturing the carpet.

Therefore, regulations on air quality are tightened around the world, and product development is being made in a direction that does not use latex and PVC materials.

However, there is still no development of a product that satisfies the strict regulations on air quality and exhibits excellent functionality such as drawing strength for non-woven fabrics.

In the present specification, it is to provide a spunbond nonwoven fabric for carpet using a nonwoven fabric that can stably fix a carpet yarn to a nonwoven fabric without the use of latex and PVC material and serves as a latex layer having excellent functionality, and a method for manufacturing the same.

In addition, in the present specification, as latex and PVC materials are excluded, volatile harmful substances (Fume) are not generated, and thus an environmentally friendly spunbond nonwoven fabric for carpets and a manufacturing method thereof are provided.

In this specification, according to one embodiment,

A fibrous web formed from composite filaments having a split yarn form comprising 60 to 80% by weight of a polyester filament having a melting point of 250° C. or higher, and 20 to 40% by weight of a copolymer filament having a melting point of 170° C. or lower,

The split ratio according to the following formula 1 is 50% or more,

It provides a spunbond nonwoven fabric having a room temperature strength of 18 kgf/5cm or more, a hot strength of 4.0 kgf/3cm or less, and a hot elongation of 80% or more according to the standard test method of KS K 0521.

[Equation 1]

Split ratio (%) = (number of split filaments) / (number of split filaments + number of unsegmented filaments) × 100

(In Equation 1,

The number of divided filaments and the number of undivided filaments are the number of divided and undivided filaments observed in a photograph taken with a microscope (SEM) of a magnification × 200 of a cross section of the nonwoven fabric, and the division rate is 10 of the photographs. represents the average value)

In addition, in the present specification, according to another embodiment,

60 to 80% by weight of a polyester filament having a melting point of 250° C. or higher, and 20 to 40% by weight of a copolymer filament having a melting point of 170° C. or less and a Melt index (MI) of 15-25 g/10 min (ASTM 1238, 190° C.) manufacturing a composite filament having a divided yarn shape by spinning and stretching through a multi-split composite spinneret;

forming a fibrous web by laminating the composite filaments;

bonding the fibrous web by thermal bonding; and

Including; splitting the filaments in the heat-bonded web;

After the step of multi-segmenting the filaments in the heat-bonded web, the split ratio according to Equation 1 is 50% or more.

[Equation 1]

Split ratio (%) = (number of split filaments) / (number of split filaments + number of unsegmented filaments) × 100

(In Equation 1,

The number of divided filaments and the number of undivided filaments are the number of divided and undivided filaments observed in a photograph taken with a microscope (SEM) of a magnification × 200 of a cross section of the nonwoven fabric, and the division rate is 10 of the photographs. represents the average value)

In addition, in the present specification, according to another embodiment, there is provided a carpet including the spunbond nonwoven fabric.

Hereinafter, a carpet and a manufacturing method thereof according to embodiments of the present invention will be described in detail.

Prior to that, unless explicitly stated herein, terminology is for the purpose of referring to specific embodiments only, and is not intended to limit the present invention.

As used herein, the singular forms also include the plural forms unless the phrases clearly indicate the opposite.

As used herein, the meaning of 'comprising' specifies a particular characteristic, region, integer, step, operation, element and/or component, and other specific characteristic, region, integer, step, operation, element, component, and/or group. It does not exclude the existence or addition of

And, in the present specification, terms including ordinal numbers such as 'first' and 'second' are used for the purpose of distinguishing one component from other components, and are not limited by the ordinal number. For example, within the scope of the present invention, a first component may be referred to as a second component, and similarly, a second component may be referred to as a first component.

Hereinafter, the present invention will be described in detail.

According to one embodiment of the invention, 60 to 80% by weight of a polyester filament having a melting point of 250° C. or higher, and 20 to 40% by weight of a copolymer filament having a melting point of 170° C. or less formed from a composite filament having a split yarn shape A spunbond nonwoven fabric comprising a fiber web, having a room temperature strength of 18 kgf / 5 cm or more, a hot strength of 4.0 kgf / 3 cm or less, and a hot elongation of 80% or more according to the standard test method of KS K 0521 can be provided.

As a result of continuous research by the present inventors, when using a composite fiber composed of split yarns of a matrix and binder material having different specific content ratios and melting points, it is possible to exhibit latex and PVC layer functions without going through the coating process of latex and PVC materials. It was confirmed that a carpet using a nonwoven fabric can be continuously manufactured.

Therefore, in the present specification, it is characterized in that the non-woven fabric including the function of the latex material among the existing carpet configurations is manufactured to provide a carpet without a latex layer.

In particular, the latex material in the existing carpet layer serves to fix the carpet yarn (BCF yarn). However, since the latex material causes environmental problems, in the present specification, the non-woven fabric for carpet including the role of the latex layer by increasing the function (drawing strength) of the carpet yarn to the non-woven fabric without using a separate latex material. .

Accordingly, since the latex coating process is removed during the manufacture of the carpet, it is possible to reduce the occurrence of harmful fumes and VOCs (volatile hazardous substances) of the finished product, so that it can be used environmentally friendly when applied as an interior material for the floor of a car.

The nonwoven fabric according to the present specification is formed from a composite filament having a split yarn form including 60 to 80% by weight of a polyester filament having a melting point of 250° C. or higher, and 20 to 40% by weight of a copolymer filament having a melting point of 170° C. or less. It is characterized by being a spunbond nonwoven including a fibrous web.

Specifically, the nonwoven fabric may be formed in the form of split yarns using a polyester filament having a melting point of 250° C. or higher as a matrix material and a copolymer filament having a melting point of 170° C. or lower as a binder material.

In the present specification, the split yarn has a multi-split cross-section, and the two kinds of polymers and the multi-segmented composite spinneret are used according to the manufacturing method of the ultra-fine fibers, the two kinds of polymers are micro-fine, and the inner cross section of the single yarn It means to include this multi-divided shape, and it does not have a cross section consisting of only a circular shape. For example, the multi-split cross-sectional shape may include 8 to 64 split yarns or 16 to 32 split yarns or 32 split yarns inside the single yarn.

Accordingly, the nonwoven fabric can provide the functionality of the latex layer without the latex material by specifying the mixing ratio of the matrix and the binder material, and at the same time using a composite filament including 8 to 64 split yarns.

In particular, the binder material is melted in the post-processing (tufting, heat treatment, backing and molding) process of carpet manufacturing, and serves to express high elongation for adhesive and molding performance, so that the role of the latex layer can be performed.

That is, the role of the polymer used as the binder material is melted during the heat treatment of the rear surface of the tufting after the tufting process, and serves as an adhesive between the carpet yarn (BCF yarn) and the base paper (non-woven fabric). In addition, in the final molding process for manufacturing automobile carpets, the binder polymer is in a state just before melting in a high temperature environment of 180 to 200 ° C.

At this time, when the content of the binder is 19% by weight or less, it is difficult to form a split yarn form (the binder polymer may not be extruded or may be driven to one side due to non-uniform spinning pressure) and the bonding force between the filaments constituting the nonwoven fabric is insufficient in the post-processing process. prone to breakage If the split yarn shape is not uniform, the physical properties of the nonwoven fabric may be different depending on the location, which may cause tearing and low pull-out strength values in the post-processing molding process.

In addition, when the content of the binder is 41% by weight or more, the matrix component serving as a support in the post-processing process for manufacturing the carpet at 180° C. or higher is insufficient, and accordingly, the amount of binder raw material that is in a molten state at high temperature increases due to external force. Post-processing is impossible due to shape deformation (shrinkage, elongation).

In addition, when the melting point of the binder raw material is 170° C. or higher, it cannot function as a binder filament because it does not melt at the process temperature at which the role of imparting strength to the nonwoven fabric, adhesive material, and high elongation must be expressed.

In addition, the filament may include divided yarns having an average diameter of 22 to 31 μm before division and a fineness of 5.0 to 9.0 denier. More specifically, the divided yarn may have an average diameter of 22 to 31 μm before division and a fineness of 5.0 to 9.0 denier. In addition, the cross-section before division of the composite filament may be 8 divided to 64 divided circular or spherical shape.

When the cross-sectional shape of the composite filament is a circular cross-section rather than a split yarn form, a web must be formed by additionally spinning a binder filament and mixing the matrix filament and the binder filament. At this time, when the filaments are mixed, there is a limit to the uniformity, so a portion without a binder filament occurs. The binder filament is a factor for expressing the tensile strength of the nonwoven fabric, and the tensile strength may be determined according to the presence/absence of bonding state of the binder filament. However, in the circular cross-sectional shape, a portion without a binder filament is generated as described above, and accordingly, strength and elongation may be lowered, and the pulling strength may also be lowered.

In addition, the nonwoven fabric according to the present specification may have a split ratio of 50% or more, 54% or more, or 56% or more according to Equation 1 below.

[Equation 1]

Split ratio (%) = (number of split filaments) / (number of split filaments + number of unsegmented filaments) × 100

(In Equation 1,

The number of divided filaments and the number of undivided filaments are the number of divided and undivided filaments observed in a photograph taken with a microscope (SEM) of a magnification × 200 of a cross section of the nonwoven fabric, and the division rate is 10 of the photographs. represents the average value)

The specimen of the nonwoven cross-section used for measuring the split ratio can be variously adjusted, for example, a nonwoven specimen having a size of 3 mm×3 mm may be used.

When the split ratio is less than 50%, the adhesive area of the binder polymer is low, and the binder is insufficient, so that mechanical properties and pulling strength of the nonwoven fabric may be deteriorated.

The polyester filament used as the matrix material may include at least one polyester polymer selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polynaphthalene terephthalate, and recycled raw materials thereof.

The polyester filament may include a polyester polymer having an intrinsic viscosity (IV) of 0.60 to 0.90 dl/g and a melting point of 250° C. or higher.

As the binder material, a copolymer filament having a melting point of 170° C. or less and an MI (melt index) of 15 to 25 g/10 min (ASTM 1238, 190° C.) is used.

Specifically, the copolymer filament may be at least one selected from the group consisting of polyolefins having a melting point of 170° C. or less and a melt index (MI) of 15 to 25 g/10 min (ASTM 1238, 190° C.). The polyolefin may be polyethylene or polypropylene.

In this specification, MI (melt index) means ASTM 1238, 190 ℃ measurement value.

The nonwoven fabric provided according to such a method has excellent inter-filament adhesion, and thus has excellent fixability of the carpet yarn and can also improve elongation compared to the prior art. In addition, as the nonwoven fabric is used as a base paper for the carpet, the drawing strength of the final product can be improved, and since latex and PVC materials harmful to the human body are not used, an environmentally friendly material can be provided.

According to an example of the invention, the nonwoven fabric can simultaneously satisfy physical properties having a room temperature strength of 18 kgf / 5 cm or more, a hot strength of 4.0 kgf / 3 cm or less, and a hot elongation of 80% or more, measured according to the standard test method of KS K 0521. have. More specifically, as the nonwoven fabric is configured as a case in which the above-described split ratio is 54% or more, strength and elongation can be further optimized. Accordingly, the nonwoven fabric may have a room temperature strength of 19 kgf / 5 cm or more, a hot strength of 3.0 kgf / 3 cm or less, and a hot elongation of 81% or more according to the standard test method of KS K 0521.

The nonwoven fabric may be a spunbond nonwoven fabric having an apparent density of 225 to 310 g/cm 3 when the weight per unit area is 90 g/m 2 .

In addition, the spunbond according to the present specification can improve the pulling strength of the carpet. Therefore, the carpet according to the present specification has a pull-out strength of 2.0 (kgf) or more according to the standard test method of KS K ISO 4919, and can be used as a flooring material for automobiles.

On the other hand, according to another embodiment of the invention, 60 to 80% by weight of a polyester filament having a melting point of 250° C. or higher, and a melting point and MI (melt index) of 15 to 25 g/10min (ASTM 1238, 190° C.) of 170° C. or less manufacturing a composite filament having a split yarn shape by spinning and stretching 20 to 40 wt% of a copolymer filament having a multi-split type composite spinneret; forming a fibrous web by laminating the composite filaments; bonding the fibrous web by thermal bonding; and splitting multiple filaments in the thermally bonded web.

The spunbond nonwoven fabric for carpet according to the present specification includes a fiber web in the form of split yarns by which a polyester filament as a matrix and a copolymer filament having a specific melting point and MI as a binder are composite spun under certain conditions. manufactured by law.

In the spunbond method, the polyester and the copolymer are each independently melted to control the number of ejection holes of different resins, and are spun and drawn through a single composite spinneret that is spun in a multi-divided cross-sectional form to form a composite filament. can be obtained.

In addition, the manufacturing method of the spunbond nonwoven fabric can be carried out using a continuous extruder, so that it is possible to continuously manufacture a nonwoven fabric that effectively improves the drawing strength of the carpet due to excellent mechanical properties and split rate.

Specifically, after preparing the polyester (matrix) and the copolymer (binder), they are put into a continuous extruder to melt by heating, and then spun through a spinneret of a multi-split type. Through this process, the filament may include divided yarns in the form of multiple divisions in which the inside of the single yarn is divided. The multi-split spinneret can be used by adjusting the number of capillaries to have 8 to 64 divided yarns or 16 to 32 divided yarns.

In addition, during the composite melt spinning, the number of pores in the spinneret can be adjusted so that the ratio of the matrix (polyester) and the binder (copolymer) is 60 to 80% by weight: 20 to 40% by weight through the spinneret. .

Here, the detailed content of the polyester filament as the matrix material and the copolymer filament as the binder material is substituted for the above-described spunbond nonwoven fabric.

In addition, the spunbond may be provided using a continuous extruder.

In addition, the step of preparing the composite filaments, before the step of multi-segmenting the filaments in the heat-bonded web, adjusting the fineness so that the composite filaments have an average diameter of 22 to 31 μm and a fineness of 5.0 to 9.0 denier may include

The composite filament spun in the composite spinning form can be sufficiently stretched by adjusting the spinning speed using a high-pressure air stretching device to adjust the discharge amount and the number of capillaries of the nozzle to be 5.0 to 9.0 denier level.

For example, the stretching may be performed at a spinning speed condition of 3,000 m/min to 5,000 m/min. More specifically, for more sufficient stretching, the spinning speed may be 4,500 m/min to 5,000 m/min. If the spinning speed is 3,000 m/min or less, the lack of filament elongation causes shrinkage of the nonwoven fabric in the thermal bonding step and also affects the cooling efficiency, resulting in insufficient cooling. And there is a problem of poor opening. In addition, if the spinning speed is 5,000 m / min or more, there is a problem in that the filament is cut in the stretching process to form a non-woven fabric surface shape.

The step of forming the web and the step of thermal bonding may be performed by a fiber opener by a method well known in the art.

In addition, the step of splitting the filaments in the heat-bonded web may be performed using a water jet. That is, after the composite fiber is spun with the split yarn having a multi-split cross-section, the web is formed, and then water jet (spun lace) treatment is performed, the split yarn cross-section can be split as it is.

Specifically, after the prepared filament fiber is positioned in the form of a web on the conveyor, the apparent density of the web may be adjusted to 225 to 310 g/cm 3 .

The fiber web of which the apparent density is controlled is subjected to a step of thermal bonding using a calender roll or hot air, and then passes through a water jet to divide the filament into a multi-divided cross-sectional form. In this case, a spunbond nonwoven fabric having a thickness of 0.31 mm to 0.40 mm can be manufactured through step-by-step hydraulic pressure control of a water jet.

For example, if a physical external force is applied to the nonwoven fabric that has undergone the thermal bonding process through a high-pressure water jet, the filament may be split as it is in the form of split yarn. That is, in this process, the two types of polymers forming the split yarn may eventually break the physical bond between the polymers due to insufficient compatibility (affinity) with each other and may be split into microfibers. Although the pressure of the high-pressure water jet is not significantly limited, dividing the pressure in multiple stages at a level of 50 to 280 bar makes the structure of the web more complicated as the divided yarn is divided into microfibers to increase the strength of the nonwoven fabric. can be further improved.

In addition, the high-pressure water jet may have a different pressure range in two or more steps within the pressure range. According to one embodiment of the invention, the high-pressure water jet is a pressure intensity of the first stage of 50 to 80 bar, the pressure strength of the second stage of 150 to 280 bar, and the pressure strength of the third stage of 50 to 80 bar can be given in order. According to the pressure as described above, the water pressure is adjusted step by step, so that not only can the thickness of the nonwoven fabric be adjusted, but also the cross section of the divided yarn divided to a desired level can be maintained as it is.

At this time, when pressure is applied with the high-pressure water jet, when only one pressure is applied without multi-step pressure being applied, a trace remains in the form of a stripe in the mechanical direction when a single step of the high-pressure water jet is applied. , there is a problem that thickness and division rate non-uniformity occur. In addition, the fewer water jet treatment steps, the more affected by the water jet nozzle and water pollution level.

Therefore, in the present invention, by treating the water jet in multiple steps for the nonwoven fabric, it is possible to increase the split rate by dividing the nonwoven fabric several times through the steps, and to give the function of uniformly rearranging the filaments as mentioned above.

After the step of multi-segmenting the filaments in the heat-bonded web, the split ratio according to Equation 1 may be 50% or more.

[Equation 1]

Split ratio (%) = (number of split filaments) / (number of split filaments + number of unsegmented filaments) × 100

(In Equation 1,

The number of divided filaments and the number of undivided filaments are the number of divided and undivided filaments observed in a photograph taken with a microscope (SEM) of a magnification × 200 of a cross section of the nonwoven fabric, and the division rate is 10 of the photographs. represents the average value)

According to the above method, the spunbond nonwoven fabric formed from filaments having a split yarn shape having a specified matrix and binder ratio can be used as a base paper for carpet manufacturing.

Accordingly, according to another embodiment of the present invention, a carpet including the spunbond nonwoven fabric and a method for manufacturing the same may be provided.

The carpet may be provided including a tufting process and a cutting process using a carpet yarn and a spunbond nonwoven fabric.

In particular, since the manufacturing method of the carpet does not proceed with the coating process of the latex and PVC layers as in the prior art, it is possible to shorten the process and provide an environmentally friendly product because harmful substances are not generated.

Therefore, the carpet yarn is fixed to one surface of the nonwoven fabric, and the latex layer is not included.

In addition, the carpet comprising the steps of fixing the carpet yarn to the nonwoven fabric through a tufting and heat treatment process on one surface of the spunbond nonwoven; and cutting the nonwoven fabric fixed to the carpet yarn.

In addition, between the step of fixing the carpet yarn and the cutting process, the step of laminating a backing layer on the nonwoven fabric fixed to the carpet yarn may be further included.

Specifically, the step of planting the carpet yarn in the nonwoven fabric by a tufting process on one surface of the spunbond nonwoven fabric provided in the above method and fixing the nonwoven fabric to the carpet yarn by heat treatment may be performed.

In this case, the step of fixing the carpet yarn to the nonwoven fabric may include heat-treating the back surface of the tufted nonwoven fabric after the tufting process.

The tufting process, the heat treatment process and the cutting process may be performed so that the carpet yarn is fixed to one surface of the nonwoven fabric using a needle using a known method and equipment. In this case, the tufting may be performed under a condition of a predetermined gauge (eg, 64/5 gauge) in the form of a loop.

In addition, the carpet yarn used in the tufting process may include BCF yarn well known in the art. The carpet yarn may have an aesthetic function and a cushioning function, and may have a predetermined fineness (eg, 500 to 3000 denier) and a height (eg, 3.0 to 7 mm). Through the tufting process, the carpet yarn is planted so that it can be recognized from one side of the nonwoven fabric.

The lamination process of the backing layer may also be performed by a method well known in the art. Specifically, a high weight web may be laminated on the backing layer, and a web of a short fiber or long fiber nonwoven fabric may be used as the high weight web.

By a method including a lamination process of the backing layer, the carpet is planted in the nonwoven fabric through a tufting process on one surface of the spunbond nonwoven fabric yarn; fixing the carpet yarn through heat treatment of the tufted nonwoven; Laminating a backing (Backing) layer; And it may be provided including the step of cutting the laminated carpet.

Accordingly, the carpet according to the present specification may be configured to include a spunbond nonwoven fabric, a carpet yarn and a backing layer without a latex layer.

According to a preferred example, the nonwoven fabric has a loop type polypropylene BCF (Bulky Continuous Filament) Yarn of about 3000De'/150 Fila. and the density in the width direction of the TUFTED CARPET is determined by the gauge) About 64/5 gauge, Stitch (density in the length direction of the tufted carpet) tufting (the process of planting threads in the nonwoven fabric) with about 13/1 go through Then, by heat-treating the rear surface of the tufted product using a heat chamber at about 180° C., and proceeding with the process after the cutting process (standard: 50 cm×50 cm), a carpet can be provided. Before the cutting process for the heat-treated carpet in the above method, the method may further include a step of laminating a high-weight long fiber or short fiber as a backing layer.

The carpet provided in this way has high performance with a pull-out strength (strength to pull the loop after tufting of the loop type) according to the standard test method of KS K ISO 4919 of about 2.0kgf, so it can be applied in various fields, Specifically, it may be used as an interior material of a flooring material of a vehicle.

According to the present invention, by including a spunbond nonwoven fabric that can act as a latex material while having excellent mechanical properties as a base paper, the latex and PVC coating processes are omitted, so fumes, which are harmful substances, are not generated, and VOCs ( Provided are a carpet that can be used as a floor interior product for automobiles because it is possible to reduce volatile harmful substances) and a method for manufacturing the same.

Hereinafter, through specific examples of the invention, the operation and effect of the invention will be described in more detail. However, these embodiments are merely presented as an example of the invention, and the scope of the invention is not defined thereby.

[Example 1]

After preparing a matrix made of a polyethylene terephthalate (PET) material having a melting point of 255°C and a binder made of a polyethylene material (MI: 20) having a melting point of 137°C, a continuous extruder is put in to melt it by heating, and then the orange divided into 32 Composite spinning was carried out through one spinneret to obtain a filament having a cross-sectional shape. At this time, the number of pores of the spinneret was adjusted so that the ratio of the matrix (polyester) and the binder (copolymer) was 70 wt%: 30 wt% through the spinneret for the composite.

Then, the 32-split composite filaments discharged through the spinneret are solidified with cooling air at 15°C, and then sufficiently stretched so that the spinning speed is 5,000 m/min using a high-pressure air stretching device to obtain 5.0 to 9.0 denier A composite filament fiber having a fineness and an orange cross-sectional shape was prepared.

Next, the composite filament fibers prepared above are laminated in the form of a web on a continuously moving metal conveyor net by a conventional fiber opening method, and then subjected to a calendering process using a flat roll having a flat surface to obtain an apparent density of 270 g/cm 3 was given.

Thereafter, by passing a water jet through the nonwoven fabric that has completed the calendering process and applying pressure to the nonwoven fabric in the order of the pressure intensity of low (70 bar)-up (250 bar)-low (50 bar) pressure, through step-by-step water pressure control The final spunbond nonwoven fabric was prepared by controlling the thickness of the nonwoven fabric (weight per unit area of 90 g/m 2 , thickness: 0.33 mm).

After tufting (Cut type, 64/5 gage in inch, 13/1 Stitch in inch, polypropylene carpet yarn (BCF) 1200 De', pile yarn height 4mm) on the manufactured nonwoven fabric, the back of the tufting is 235 The carpet was manufactured by fixing the carpet yarn (BCF yarn) by heat treatment at ℃, and the tufted sample was used to measure the pull-out strength.

[Example 2]

In Example 1, a spunbond nonwoven fabric and a carpet were prepared in the same manner as in Example 1, except that the matrix:binder composite ratio was changed to be 80wt%:20wt%.

[Comparative Example 1]

In Example 1, a spunbond nonwoven fabric and carpet were prepared in the same manner as in Example 1, except that the filament cross-sectional shape was changed to a circular shape instead of an orange shape and split yarn.

[Comparative Example 2]

In Example 1, a spunbond nonwoven fabric and a carpet were prepared in the same manner as in Example 1, except that the binder material was changed to nylon 6.

[Comparative Example 3]

In Example 1, a spunbond nonwoven fabric and a carpet were prepared in the same manner as in Example 1, except that the composite ratio of the matrix:binder was changed to be 50wt%:50wt%.

[Comparative Example 4]

In Example 1, a spunbond nonwoven fabric and a carpet were prepared in the same manner as in Example 1, except that the composite ratio of the matrix:binder was changed to be 90wt%:10wt%.

[Comparative Example 5]

A spunbond nonwoven fabric and a carpet were prepared in the same manner as in Example 1, except that the spinning speed was set to 6,000 m/min.

[Comparative Example 6]

A spunbond nonwoven fabric and a carpet were prepared in the same manner as in Example 1, except that the spinning speed was 2,500 m/min.

[Comparative Example 7]

For the prepared nonwoven fabric, a spunbond nonwoven fabric and a carpet were prepared in the same manner as in Example 1, except that only water punching was performed at a water pressure of 294 bar without applying pressure in the third step.

[Test Example]

For each Example, Reference Example, and Comparative Example, physical properties were measured according to the measurement method for each evaluation item below, and the results are shown in Table 1.

1. Split rate (%)

The division ratio was calculated by Equation 1 below through 10 photos of the nonwoven fabric cross section taken with a magnification × 200 microscope.

[Equation 1]

Split ratio (%) = (number of split filaments) / (number of split filaments + number of unsegmented filaments) × 100

(In Equation 1,

The number of divided filaments and the number of undivided filaments are the number of divided and undivided filaments observed in a photograph taken with a microscope of a magnification × 200 of a cross section of a nonwoven fabric having a size of 3 mm × 3 mm, and the division rate is 10 photos represents the average value of )

2. Room temperature strength (kgf/5cm)

The strength at room temperature was measured using a standard test method according to KS K 0521.

Specifically, a specimen having a size of width × length = 5 cm × 20 cm was bitten with a jig of size 5 cm × 5 cm at the top/bottom using INSTRON's measuring equipment, and then measured under the condition of a tensile speed of 200 mm/min.

3. Hot strength (kgf/3cm), hot elongation (%)

Hot strength and hot elongation were measured using a standard test method according to KS K 0521.

Specifically, after biting a specimen with a size of width × length = 3 cm × 10 cm with an upper/lower 5 cm × 5 cm jig using INSTRON’s measuring equipment, preheated at 180° C. for 3 minutes using a hot chamber, and then tensioned. It was measured under the condition of speed 200mm/min.

4. Pull-out strength (%)

As described above, after tufting (Cut type, 64/5 gage in inch, 13/1 Stitch in inch, pile height 4mm) to the nonwoven fabric, the back side of the tufting is heat treated to fix the carpet yarn (BCF yarn) and the tufted sample was prepared.

According to the KS K ISO 4919 (carpet-tuft pull-out force measurement) standard for the sample thus made, one pile to be measured in the tufted sample was fixed to the measuring device. The loop to be measured and the adjacent loops on both sides were cut. Then, the strength (Peak) value that appears when the pile to be measured is pulled in the vertical direction to the sample using an Instron measuring device was taken. This method was repeated 5 times and the average value was taken. Three samples to be used for the test were prepared and evaluated repeatedly.

division Measurement example split rate room temperature strength hot strength hot elongation pulling strength % kgf/5cm kgf/3cm % kgf Example 1 56 22 2.7 84 2.6 Example 2 58 19 2.6 81 2.3 Comparative Example 1 0 23 4.2 75 1.2 Comparative Example 2 53 21 9.5 38 1.6 Comparative Example 3 error 29 Cannot be evaluated due to high temperature shrinkage Comparative Example 4 Unable to manufacture sheet because the division is not formed Comparative Example 5 Unable to manufacture sheet due to filament cutting in the stretching stage Comparative Example 6 After stretching, it is impossible to produce a uniform sheet due to shrinkage in the thermal bonding step. Comparative Example 7 36 24 3.8 69 1.3

As seen from the results of Table 1, Examples 1 and 2, as compared to Comparative Examples 1 to 7, include a spunbond nonwoven fabric serving as a latex, so the split rate is high, and the room temperature strength, hot strength and annual elongation are excellent. Confirmed. In addition, the Examples had excellent pull-out strength of 2.0 (kgf) or more. On the other hand, Comparative Example 1 showed a circular cross-sectional shape and used an undivided nonwoven fabric, and had low mechanical properties. did

In addition, in Comparative Example 2, as nylon was used as a binder, latex function could not be performed, and both mechanical properties and drawing strength were poor.

In Comparative Examples 3 and 4, as the content of the matrix and binder material was out of the scope of the present specification, the division rate was poor or finely divided, and the nonwoven fabric was not well formed, making it difficult to manufacture the carpet.

In addition, as shown in Table 1, in Comparative Examples 5 and 6, the spinning speed was out of the range of the present invention, and the nonwoven fabric could not be prepared due to shrinkage during filament cutting or thermal bonding in the stretching step. In Comparative Example 7, the high-pressure water jet was applied only in a single step, and as the split ratio was lowered compared to Examples 1 and 2, the strength, elongation, and pulling strength were all lowered.

Claims (14)

A fibrous web formed from composite filaments having a split yarn form comprising 60 to 80% by weight of a polyester filament having a melting point of 250° C. or higher, and 20 to 40% by weight of a copolymer filament having a melting point of 170° C. or lower,
The split ratio according to the following formula 1 is 50% or more,
A spunbond nonwoven fabric having a room temperature strength of 18 kgf/5cm or more, a hot strength of 4.0 kgf/3cm or less, and a hot elongation of 80% or more according to the standard test method of KS K 0521.
[Equation 1]
Split ratio (%) = (number of split filaments) / (number of split filaments + number of unsegmented filaments) × 100
(In Equation 1,
The number of divided filaments and the number of undivided filaments are the number of divided and undivided filaments observed in a photograph taken with a microscope (SEM) of a magnification × 200 of a cross section of the nonwoven fabric, and the division rate is 10 of the photographs. represents the average value)
According to claim 1,
The nonwoven fabric has a room temperature strength of 19 kgf / 5 cm or more, a hot strength of 3.0 kgf / 3 cm or less, and a hot elongation of 81% or more according to the standard test method of KS K 0521, a spunbonded nonwoven fabric.
According to claim 1,
A spunbond nonwoven fabric having the split ratio of 54% or more.
According to claim 1,
The cross-section of the composite filament before division is 8 to 64 divided circular or spherical, spunbond nonwoven fabric.
According to claim 1,
The composite filament has an average diameter of 22 to 31 μm before splitting and has a fineness of 5.0 to 9.0 denier, spunbond nonwoven fabric.
According to claim 1,
The polyester has an intrinsic viscosity (IV) of 0.60 to 0.90 dl/g and a melting point of 250 ° C. or higher A spunbond nonwoven comprising a polyester polymer.
According to claim 1,
The copolymer filament is a spunbond nonwoven fabric comprising at least one selected from the group consisting of polyolefins having a melting point of 170° C. or less and an MI (melt index) of 15 to 25 g/10 min (ASTM 1238, 190° C.).
60 to 80% by weight of a polyester filament having a melting point of 250° C. or higher, and 20 to 40% by weight of a copolymer filament having a melting point of 170° C. or less and a Melt index (MI) of 15-25 g/10 min (ASTM 1238, 190° C.) manufacturing a composite filament having a divided yarn shape by spinning and stretching through a multi-split composite spinneret;
forming a fibrous web by laminating the composite filaments;
bonding the fibrous web by thermal bonding; and
multi-segmenting the filaments in the heat-bonded web;
Method for producing a spunbond nonwoven fabric having a split ratio of 50% or more according to Equation 1 below after the step of dividing multiple filaments in the heat-bonded web.
[Equation 1]
Split ratio (%) = (number of split filaments) / (number of split filaments + number of unsegmented filaments) × 100
(In Equation 1,
The number of divided filaments and the number of undivided filaments are the number of divided and undivided filaments observed in a photograph taken with a microscope (SEM) of a magnification × 200 of a cross section of the nonwoven fabric, and the division rate is 10 of the photographs. represents the average value)
9. The method of claim 8,
The step of producing the composite filament,
Method for producing a spunbond nonwoven fabric comprising the step of adjusting the fineness so that the composite filaments have an average diameter of 22 to 31 μm and a fineness of 5.0 to 9.0 denier before the step of multiplying the filaments in the heat-bonded web.
9. The method of claim 8,
A method of manufacturing a spunbond nonwoven fabric having a circular or spherical cross-section divided into 8 to 64 divisions before division of the composite filament.
9. The method of claim 8,
The stretching is a method for producing a spunbond nonwoven fabric that is performed under the conditions of 3,000 m / min to 5,000 m / min.
9. The method of claim 8,
The multi-segmenting of the filaments is a method of manufacturing a spunbond nonwoven fabric that is performed using a water jet.
A carpet comprising the spunbond nonwoven fabric according to any one of claims 1 to 7.
14. The method of claim 13,
The pulling strength according to the standard test method of KS K ISO 4919 is 2.0 (kgf) or more,
Carpet used as a flooring material for automobiles.