KR102710326B1 - Nonwoven fabric and manufacturing method thereof - Google Patents

Abstract

The present invention relates to a nonwoven fabric and a manufacturing method thereof, comprising: a step of melting polypropylene pellets (S10); a step of cooling, stretching, and spinning the molten polypropylene to form web layer filaments (S20); a step of cooling, stretching, and spinning the molten polypropylene to form surface layer filaments (S30); and a step of bonding the web layer filaments and the surface layer filaments with the heat and pressure of an embossing roll to manufacture a nonwoven fabric having an embossing pattern (S40). The present invention has the advantages of being attached to a hook Velcro to prevent lateral pushing, having excellent water resistance due to the characteristics of polypropylene and thus having strong resistance to moisture, being easy to process, and being capable of mass production.

Description

Nonwoven fabric and manufacturing method thereof {Nonwoven fabric and manufacturing method thereof}

The present invention relates to a nonwoven fabric and a method for manufacturing the same, and more specifically, to a nonwoven fabric for use in disposable mattress covers and the like and a method for manufacturing the same.

A mattress cover is a cover that is placed over a mattress to protect the mattress and keep it clean. If you put a mattress cover over your mattress, it blocks sweat and dirt that comes out while you sleep, and it also blocks unpleasant substances such as dust and mold from entering the mattress, providing a good sleeping environment.

Mattress covers are often made of cotton, but waterproof covers are sometimes used to prevent contamination.

However, since the mattress cover is a part that touches the skin, it is easily contaminated, and in the case of cotton, it is inconvenient to frequently disinfect and wash it. Since the waterproof cover is made of a waterproof material, it does not absorb sweat when sweat is released, so if you use the mattress with only the waterproof cover, skin trouble may occur. Therefore, if you use a waterproof cover, there is the inconvenient of having to additionally place a cotton pad on top of the waterproof cover.

On the other hand, in the case of hotels, accommodations, hospitals, etc., mattress covers are easily contaminated and are more vulnerable to contamination because they are used by multiple people, so disposable mattress covers are used. Also, due to the recent bed bug issue, most accommodations prefer disposable mattress covers. Disposable mattress covers are made of non-woven fabric.

However, the disposable mattresses currently on the market have the problem of being easily pushed, damaged, and torn when lying down, sitting, or tossing and turning in your sleep, and are also prone to generating static electricity.

Accordingly, the problem of the mattress cover being pushed or torn easily is solved by making the mattress cover thicker, but there is a problem that the mattress cover is stiff and does not feel good against the skin, which interferes with a good night's sleep, and the thick thickness makes it difficult to handle and transport.

Korean Patent No. 2522833 "Flame-retardant nonwoven fabric for mattress and its manufacturing method" (announced on April 19, 2023)

The technical problem to be solved by the present invention is to provide a nonwoven fabric which is resistant to moisture, has excellent water resistance, is easy to process, and can be mass-produced, and a method for manufacturing the same.

Another technical problem to be solved by the present invention is to provide a nonwoven fabric and a method for manufacturing the same, which is lightweight, has high strength, elasticity, excellent durability, and breathability so that it is easy to handle and transport when manufactured as a mattress cover.

To solve the above technical problems, the present invention provides a nonwoven fabric and a method for manufacturing the same.

According to one embodiment, the method for manufacturing a nonwoven fabric of the present invention includes the steps of melting polypropylene pellets, cooling and stretching the molten polypropylene and spinning it to form web layer filaments, cooling and stretching the molten polypropylene and spinning it to form surface layer filaments, and bonding the web layer filaments and the surface layer filaments with the heat and pressure of an embossing roll to manufacture a nonwoven fabric having an embossing pattern.

The step of melting the polypropylene pellets is performed by heating the polypropylene pellets in an extruder to a temperature between 190°C and 250°C to melt them.

The step of cooling, stretching and spinning the molten polypropylene to form web layer filaments includes the step of continuously discharging the molten polypropylene through a slit die, cooling and stretching it in a rotating drum, and then spinning it through a first spinneret to form web layer filaments having a spinning diameter in the range of 10 to 30 microns, and the step of passing the web layer filaments through a heated press roller to form a first nonwoven fabric.

The step of cooling, stretching and spinning the molten polypropylene to form surface layer filaments includes the step of continuously discharging the molten polypropylene through a slit die, cooling and stretching it in a rotating drum, and then spinning it through a second spinneret to form surface layer filaments having a spinning diameter in the range of 10 to 30 microns, and the step of passing the surface layer filaments through a heated press roller to form a second nonwoven fabric.

In the step of manufacturing a nonwoven fabric having an embossed pattern by bonding the above web layer filaments and the above surface layer filaments with the heat and pressure of an emboss roll, the fabric is bonded by passing through an emboss roll having a pressure of 39 MPa to 41 MPa, an upper emboss temperature in the range of 125°C to 132°C, and a lower emboss temperature in the range of 130°C to 140°C, and the bonded nonwoven fabric is cooled by passing through a cooling roller.

A nonwoven fabric manufactured by the method for manufacturing a nonwoven fabric of the present invention has an embossed pattern in which embossed portions and non-embossed portions are repeated, wherein the non-embossed portion is a single layer or multilayer in which web layer filaments and surface layer filaments are bonded by heat compression, and the embossed portion has a web structure in which web layer filaments and surface layer filaments are entangled with each other and has a polygonal or circular shape.

The above non-woven fabric is made of polypropylene.

The above non-woven fabric has a weight of 3g to 4g ^per 100mm2.

The thickness of the above embossed portion is in the range of 0.3 mm to 0.6 mm, and the thickness of the above non-embossed portion is in the range of 0.01 mm to 0.06 mm.

The above non-woven fabric is made into a mattress cover and is attached to and fixed to a hook Velcro fixed to the mattress cover, thereby preventing lateral pushing.

The nonwoven fabric of the present invention is attached to a hook Velcro, so that it is easy to separate the upper and lower parts, but prevents lateral pushing, and due to the characteristics of polypropylene, it has excellent water resistance and strong resistance to moisture, and is easy to process and enables mass production.

In addition, the nonwoven fabric of the present invention is lightweight, so it is easy to handle and transport when produced as a mattress cover, and by applying an embossed pattern, it has the effects of improved breathability and moisture absorption, as well as high-strength elasticity and excellent durability.

Figure 1 is a block diagram for explaining a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.
Figure 2 is a schematic diagram for explaining a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.
Figure 3 is a plan view showing a nonwoven fabric manufactured by a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.
Figure 4 is a side cross-sectional view showing the AA section of Figure 3.
Figure 5 is a block diagram for explaining a method for manufacturing a nonwoven fabric according to another embodiment of the present invention.
Figure 6 is a cross-sectional side view showing a nonwoven fabric manufactured by a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.
FIG. 7 is a drawing for explaining the principle of attaching a nonwoven fabric to a hook Velcro and preventing it from slipping according to an embodiment of the present invention.
FIGS. 8 and 9 are drawings showing a mattress cover manufactured from a nonwoven fabric according to an embodiment of the present invention, which is fixed to a bed mattress using a hook Velcro.
Figure 10 is a block diagram illustrating a method for manufacturing a nonwoven fabric according to another embodiment of the present invention.

Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the attached drawings. However, the technical idea of the present invention is not limited to the embodiments described herein and may be embodied in other forms. Rather, the embodiments introduced herein are provided so that the disclosed content can be thorough and complete and so that the idea of the present invention can be sufficiently conveyed to those skilled in the art.

FIG. 1 is a block diagram for explaining a method for manufacturing a nonwoven fabric according to an embodiment of the present invention, and FIG. 2 is a configuration diagram for explaining a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.

As illustrated in FIG. 1, a method for manufacturing a nonwoven fabric according to an embodiment of the present invention includes a step of melting polypropylene pellets (S10), a step of cooling, stretching, and spinning the molten polypropylene to form web layer filaments (S20), a step of cooling, stretching, and spinning the molten polypropylene to form surface layer filaments (S30), and a step of bonding the web layer filaments and the surface layer filaments with the heat and pressure of an embossing roll to manufacture a nonwoven fabric having an embossing pattern (S40).

As shown in Fig. 2, the step (S10) of melting polypropylene pellets is to melt the polypropylene pellets by heating them to between 190°C and 250°C in an extruder (10). The non-woven fabric is made of 1000% polypropylene (PP) material.

Melting of the polypropylene pellets takes place in an extruder (10) connected to a hopper.

Polypropylene has a melting point of 165°C to 170°C. In an embodiment, polypropylene is heated to between 190°C and 250°C, which is higher than the melting point, so as to produce thin filaments. If the melting temperature of polypropylene is lower than 190°C, filaments of the desired thin shape cannot be formed, and if it exceeds 250°C, the viscosity changes rapidly, oxidation occurs, and spinning does not occur.

The step (S20) of cooling, stretching and spinning molten polypropylene to form web layer filaments (P1) includes the step (S21) of continuously discharging molten polypropylene through a slit die (20a), cooling and stretching it in a rotating drum (30a), and then spinning it through a first spinneret (31a) to form web layer filaments (P1) having a spinning diameter in the range of 10 µm to 30 µm, and the step (S22) of making the web layer filaments (P1) into a first nonwoven fabric form (B1) by passing them through a heated press roller (40a).

The step (S30) of cooling, stretching and spinning molten polypropylene to form surface layer filaments (P2) includes the step (S31) of continuously discharging molten polypropylene through a slit die (20b), cooling and stretching it in a rotating drum (30b), and then spinning it through a second spinneret (31b) to form surface layer filaments (P2) having a spinning diameter in the range of 10 µm to 30 µm, and the step (S32) of making the surface layer filaments (P2) into a second nonwoven fabric form (B2) by passing them through a heated press roller (40b).

The processes of steps (S20) and (S30) are the same, but they are performed separately.

If the filaments are not sufficiently elongated in steps (S20) and (S30), the strength decreases and the shrinkage rate increases, so that the strength of the nonwoven fabric is ultimately decreased and a product with many wrinkles on the surface is obtained. Cooling can be performed by cooling air using air whose humidity is controlled to a constant temperature near room temperature. Cooling air at a constant speed affects the formation of the filament structure, thereby improving the properties of the final nonwoven fabric.

The processes of steps (S20) and (S30) form the filament into a nonwoven form and maintain a strength that can withstand a specific pressure. In steps (S20) and (S30), the heating temperature of the press rollers (40a, 40b) is 100°C to 130°C, and the rotation speed of the press rollers (40a, 40b) is 145 to 150 m/min.

Press rollers (40a, 40b) self-adhere ultrafine fiber web layer filaments (P1) and surface layer filaments (P2) by heat to form nonwoven fabrics, respectively. If the heating temperature of the press rollers (40a, 40b) is less than 100°C, it is difficult to secure strength, and if it exceeds 130°C, the filaments may melt and the web layer shape may be destroyed. If the rotation speed of the press rollers (40a, 40b) is less than 145 m/min, it is inefficient in terms of productivity, and if it exceeds 150 m/min, the effect of self-adhesion of each filament (P1, P2) by heat is insufficient.

In the step of manufacturing a nonwoven fabric (B) having an embossed pattern by bonding web layer filaments (P1) and surface layer filaments (P2) with the heat and pressure of an embossing roller (50), the web layer filaments (P1) and surface layer filaments (P2) are bonded by passing through an embossing roller (50) having a pressure of 39 MPa to 41 MPa, an upper embossing roller (51) having a temperature in the range of 125°C to 132°C, and a lower embossing roller (52) having a temperature in the range of 130°C to 140°C, and the bonded nonwoven fabric (B) is cooled by passing through a cooling roller (60). The cooled nonwoven fabric (B) is wound up on a winding roller (70).

When the web layer filament (P1) and the surface layer filament (P2) are combined by the heat and pressure of the embossing roll (50), the web layer filament (P1) is placed at the bottom and the surface layer filament (P2) is placed at the top.

The temperature of the lower embossing roll (50) is relatively higher than that of the upper embossing roll (50). This is because a pattern for forming an emboss is formed on the lower embossing roll (50). The embossing roll (50) has an engraved polygonal pattern formed around the outer periphery of the lower embossing roll (50), so that a polygonal embossing pattern can be formed on the lower surface when the web layer filament (P1) and the surface layer filament (P2) are laminated. Since the embossing roll (50) has no pattern on the outer periphery of the upper embossing roll (50), a smooth surface layer without a protrusion is formed on the upper surface when the web layer filament (P1) and the surface layer filament (P2) are laminated. Of course, a non-woven fabric may have a polygonal embossing pattern formed on the upper surface. In addition, even when a polygonal embossing pattern is formed on only the lower surface of the non-woven fabric, it appears that the polygonal embossing pattern is formed on the upper surface because the thickness is thin. Of course, the embossed pattern on the non-woven fabric can also be circular in shape.

Embossing roll (50) is preferably a Kalander. The Kalander causes web layer filaments (P1) and surface layer filaments (P2) to advance in the direction of travel between two heavy rolls and to be combined under strong pressure and temperature. By applying strong pressure to the two rolls, an embossed portion is formed on the nonwoven fabric (B) in which the web layer filaments (P1) and surface layer filaments (P2) are combined and made soft. When pressure from the heavy rolls is applied, the nonwoven fabric (B) becomes extremely soft and glossy.

If the temperature of the embossing roll (50) is lower than 125℃, the web layer filament (P1) and the surface layer filament (P2) do not stick together, and if it exceeds 140℃, the properties of the nonwoven fabric (B) change and problems such as tearing or width distortion occur. In order for the embossing portion (a) to be formed on the lower surface of the nonwoven fabric (B), the temperature of the lower embossing roll (52) must be higher than 130℃.

The web layer filaments (B1) and the surface layer filaments (B2) in the form of nonwoven fabric are combined through the heat and pressure of the embossing roller (50) and manufactured into a durable nonwoven fabric through the cooling roller (60). The cooling temperature of the cooling roller (60) is 12°C to 17°C. The nonwoven fabric (B) that has passed through the embossing roller (50) is quickly cooled to impart a heat-setting effect to the filaments and facilitate winding. If the cooling temperature of the cooling roller (60) is less than 12°C, the shape stability of the web layer may deteriorate due to rapid cooling, and if it exceeds 17°C, it may be difficult to secure the desired level of durability. The manufactured nonwoven fabric (B) may be stored in a constant temperature and humidity room for a certain period of time while being wound around the winding roller (70) to stabilize its physical properties.

The manufactured non-woven fabric (B) has a flat upper surface and a protruding embossed pattern formed on the lower surface.

FIG. 3 is a plan view showing a nonwoven fabric manufactured by a method for manufacturing a nonwoven fabric according to an embodiment of the present invention, and FIG. 4 is a side cross-sectional view showing the A-A section of FIG. 3.

As shown in FIGS. 3 and 4, the nonwoven fabric (B) according to the embodiment of the present invention has an embossed pattern in which an embossed portion (a) and an unembossed portion (b) are repeated. The embossed portion (a) has a polygonal shape. Preferably, the embossed portion (a) has a hexagonal shape.

The embossed portion (b) may be a single-layer or multi-layer in which the web layer filaments (B1) and the surface layer filaments (B2) in the form of nonwoven fabric are bonded by thermal compression. Here, the web layer filaments (B1) and the surface layer filaments (B2) are each meant to be produced in the form of nonwoven fabric by passing through press rollers (40a, 40b). The embossed portion (a) is a web structure in which the web layer filaments (P1) and the surface layer filaments (P2) are entangled with each other, and has a polygonal shape. For example, the embossed portion (a) has a regular hexagonal shape, and the regular hexagonal shape may have a side length of 2 mm to 3 mm.

Nonwoven fabric (B) is made of 100% polypropylene. When polypropylene is melt spun, the cross-sectional shape varies depending on the shape of the spinneret, but the side is spun into filaments with protrusions on the surface. The side protrusions of the filaments cause the filaments to become entangled and bonded together.

Polypropylene has a regular molecular structure, so crystals develop, resulting in high strength, and it has the ability to quickly absorb moisture through capillary action and release it to the outside within a short period of time, and it has a good feel. In addition, polypropylene has good antimicrobial properties, so it is not attacked by pests or bacteria, and it has excellent water resistance, so its strength is not reduced by water. The above-mentioned properties of polypropylene provide water resistance and antibacterial properties to nonwoven fabric (B).

The nonwoven fabric (B) manufactured by melting and spinning polypropylene into filaments and heating and pressurizing has a low weight of 3 to 4 g per 100 mm ² . The thickness of the embossed portion of the nonwoven fabric (B) is in the range of 0.3 to 0.6 mm, and the thickness of the unembossed portion is in the range of 0.01 to 0.06 mm. The low weight characteristic of the nonwoven fabric makes it easy to handle and transport.

Meanwhile, the above-described nonwoven fabric can be laminated in multiple layers to form a web of a predetermined thickness with random filament orientation. For example, two sheets of the above-described nonwoven fabric can be laminated and bonded by applying heat and pressure. When two low-weight nonwoven fabrics are bonded, the nonwoven fabric can have high strength and elasticity, superior durability, and breathability even though it is a lightweight nonwoven fabric.

Nonwoven fabric (B) can maintain the web structure due to the embossing pattern, improve breathability and moisture absorption, and add a sense of luxury. If there is no embossing pattern in the nonwoven fabric, the entire area is pressed and formed thinly, so breathability and moisture absorption may be reduced.

FIG. 5 is a block diagram for explaining a method for manufacturing a nonwoven fabric according to another embodiment of the present invention, and FIG. 6 is a side cross-sectional view showing a nonwoven fabric manufactured by a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.

As illustrated in FIG. 5, a method for manufacturing a nonwoven fabric according to another embodiment includes a step of melting polypropylene pellets (S10), a step of cooling, stretching, and spinning the molten polypropylene to form web layer filaments (S20), a step of cooling, stretching, and spinning the molten polypropylene to form surface layer filaments (S30), a step of manufacturing a nonwoven fabric having an embossed pattern by combining the web layer filaments and the surface layer filaments with heat and pressure of an embossing roll (S40), and a step of combining two nonwoven fabrics by applying heat and pressure (S50).

The step (S50) of combining two pieces of nonwoven fabric (B) by applying heat and pressure can use an embossing roll (drawing symbol 50 of FIG. 2).

As shown in Fig. 6, by laminating two nonwoven fabrics (B) and applying heat and pressure to combine them, a laminated nonwoven fabric (B-1) having an embossed pattern with repeated embossed portions (a) and non-embossed portions (b) and having high strength and excellent durability can be manufactured.

The non-woven fabric (B-1) may have a single-layer unembossed portion (b), which may be a multi-layer integral part formed by thermal compression. For example, the unembossed portion (b) may have four layers integrally formed by thermal compression. The embossed portion (a) of the non-woven fabric (B-2) may have a higher volume than the non-woven fabric (B) of the embodiment, which may further enhance the adhesive strength with the hook Velcro described below.

The nonwoven fabric (B) and the laminated nonwoven fabric (B-1) described above are lightweight, so they are easy to handle and transport, and thus, they are easy to process and improve work efficiency when manufacturing mattress covers. In addition, the nonwoven fabric (B) and the laminated nonwoven fabric (B-1) described above have high-strength elasticity, excellent durability, and breathability despite their lightweight nature. The breathability of the nonwoven fabric (B) and the laminated nonwoven fabric (B-1) is due to the web layer filament structure and the characteristics of polypropylene itself. In addition, the nonwoven fabric (B) and the laminated nonwoven fabric (B-1) described above are made of 100% polypropylene, so they have excellent water resistance and are strong against moisture. In addition, the nonwoven fabric (B) and the laminated nonwoven fabric (B-1) described above have high-strength elasticity and excellent durability, but are also thin, so they are easy to process, and since they can be produced in a continuous process using roll-to-roll, mass production is possible.

The above-described nonwoven fabric (B) and the composite nonwoven fabric (B-1) are attached to the bed mattress using a hook Velcro when manufactured as a mattress cover, and side sliding is prevented. In addition, the nonwoven fabric (B) and the composite nonwoven fabric (B-1) are structured so that the micro hook loop (110) of the hook Velcro (100) is hooked to the filament entanglement structure when attached or detached to the hook Velcro (100), so that they are attached and detached smoothly without making a sound.

FIG. 7 is a drawing for explaining the principle of attaching a nonwoven fabric according to an embodiment of the present invention to a hook Velcro and preventing slipping, and FIGS. 8 and 9 are drawings showing a mattress cover manufactured from a nonwoven fabric according to an embodiment of the present invention being fixed to a bed mattress using a hook Velcro.

As shown in Fig. 7, the hook Velcro (100) is manufactured by melting polypropylene pellets in an extruder and then passing them through a roll-shaped mold to include a plurality of hook rings (110) on the upper surface. Alternatively, the hook Velcro (100) is made of nylon and can be produced by a plastic injection molding method. The thickness (m) of the hook Velcro (100) is in the range of 0.3 mm to 2.5 mm, preferably in the range of 0.3 mm to 0.6 mm, which is thinner than or equal to the thickness of the non-woven fabric (B). The hook Velcro (100) is a soft Velcro like fiber.

The hook rings (110) of the hook Velcro (100) are arranged in pairs, but are arranged so as to face each other and the rings are positioned so as to intersect each other, so that they can be easily hooked onto and fixed to the filament entanglement structure of the nonwoven fabric (B).

The above-described hook Velcro (100) can be fixed integrally to a bed mattress at a certain location. The hook Velcro (100) has a snapping function, but is very thin, smooth, and soft, so it does not cause discomfort to the user.

Therefore, as shown in Fig. 8, a non-woven fabric (B) is manufactured as a mattress cover to cover the mattress (1). The hook Velcro (100) can be attached to the upper surface of the mattress (1). When the mattress cover covers the mattress (1), the mattress cover is smoothly attached to the hook Velcro (100) fixed to the mattress (1) and sideways sliding is prevented. When the mattress cover is lifted upward for replacement, etc. while covering the mattress (1), it is easily separated from the hook Velcro (100). The hook Velcro (100) and the non-woven fabric (B) can be easily separated upward and downward, but sideways separation is difficult due to the entanglement structure of the web and the micro-hook and the frictional force caused by this. Unlike general Velcro, the hook Velcro (100) does not make a sound when removed, is easy to separate, and has a function of preventing sideways sliding while attached.

Meanwhile, as shown in Fig. 9, a plurality of hook Velcros (100) can be attached to the side of the mattress (1). When the mattress cover covers the mattress (1), the mattress cover is attached to the hook Velcro (100) attached to the side of the mattress (1) in a soft snapping manner, and the mattress cover is prevented from sliding sideways, so that the mattress cover stably covers the upper surface of the mattress.

As mentioned above, the above matrix cover is made of non-woven fabric manufactured by melt spinning polypropylene, so it has a soft feel and no rustling noise, which can help you get a good night's sleep.

In addition, the above-mentioned non-woven fabric is used with hook Velcro to ensure a clean and close fit with the mattress, and provides a soft feel, excellent breathability, and antibacterial properties.

The above-mentioned non-woven fabric can be applied as a hospital bed cover and a bed cover for accommodation facilities. In addition, the non-woven fabric is light and thin enough to carry, but maintains high strength to prevent bed bugs from penetrating. In addition, due to the nature of polypropylene, it has antibacterial properties, so it can prevent bugs such as bed bugs from approaching.

Figure 10 is a block diagram illustrating a method for manufacturing a nonwoven fabric according to another embodiment of the present invention.

As illustrated in FIG. 10, the method for manufacturing a nonwoven fabric includes a step of melting polypropylene pellets (S10), a step of cooling, stretching, and spinning the molten polypropylene to form web layer filaments (S20), a step of cooling, stretching, and spinning the molten polypropylene to form surface layer filaments (S30), a step of manufacturing a nonwoven fabric having an embossed pattern by combining the web layer filaments and the surface layer filaments with heat and pressure of an embossing roll (S40), a step of combining two nonwoven fabrics by applying heat and pressure (S50), and, prior to performing the step (S50), a step of infiltrating a functional masterbatch (S60).

The functional masterbatch penetration step (S60) is to penetrate the nonwoven fabric (B) with dyes for coloring, flame retardants to prevent it from burning, antibacterial agents, antistatic agents, etc. in the form of foam absorbents (pigments). By penetrating the nonwoven fabric (B) with the functional masterbatch, a desired color or additional function can be imparted to provide a customized product.

Above, although the present invention has been described in detail using preferred embodiments, the scope of the present invention is not limited to specific embodiments, and should be interpreted by the appended claims. In addition, those who have acquired common knowledge in this technical field should understand that many modifications and variations are possible without departing from the scope of the present invention.

10: Extruder 20a, 20b: Slit die
30a,30b: Rotating drum 40: Press roller
50: Emboroll 60: Cooling roller
70: Winding roller P1: Web layer filament
P2: Surface layer filament
B1: Nonwoven type web layer filament (first nonwoven type)
B2: Nonwoven type surface layer filament (second nonwoven type)
B: Non-woven fabric B-1: Laminated non-woven fabric
a: Embobu B: Muembobu
1: Mattress 100: Hook Velcro
110: Hook ring

Claims (10)

Step of melting polypropylene pellets;
A step of cooling and stretching the above molten polypropylene and spinning it to form a web layer filament;
A step of making the above web layer filaments into a first nonwoven fabric form by passing them through a heated press roller;
A step of cooling, stretching and spinning the above molten polypropylene to form surface layer filaments;
A step of making the above surface layer filament into a second non-woven fabric form by passing it through a heated press roller;
A step of manufacturing a low-weight nonwoven fabric having a flat upper surface and a protruding embossed pattern on the lower surface by bonding the first nonwoven-type web layer filament and the second nonwoven-type surface layer filament using heat and pressure of an embossing roll, the low-weight nonwoven fabric having a weight per 100 m2 of 3 g to 4 g, an embossed portion having a thickness of 0.3 mm to 0.6 mm, and an unembossed portion having a thickness of 0.01 mm to 0.06 mm;
Including,
In the step of manufacturing a non-woven fabric having an embossed pattern by bonding the above web layer filament and the above surface layer filament with the heat and pressure of an embossing roll,
A method for manufacturing a nonwoven fabric, characterized in that the nonwoven fabric is laminated by passing through an embossing roller having a pressure of 39 MPa to 41 MPa, an upper embossing roller temperature of 125°C to 132°C, and a lower embossing roller temperature of 130°C to 140°C, and the laminated nonwoven fabric is cooled by passing through a cooling roller having a cooling temperature of 12°C to 17°C. In the first paragraph,
The step of melting the above polypropylene pellets is:
A method for manufacturing a non-woven fabric, characterized in that the polypropylene pellets are melted by heating them at a temperature between 190°C and 250°C in an extruder. In the first paragraph,
The step of cooling, stretching and spinning the above molten polypropylene to form web layer filaments is as follows.
A step of continuously discharging the above molten polypropylene through a slit die, cooling and stretching it in a rotating drum, and then spinning it through a first spinneret to form a web layer filament having a spinning diameter in the range of 10 to 30 microns; and
A step of making the above web layer filaments into a first nonwoven fabric form by passing them through a heated press roller;
A method for manufacturing a nonwoven fabric, characterized by including a. In the first paragraph,
The step of cooling, stretching and spinning the above molten polypropylene to form surface layer filaments is as follows.
A step of continuously discharging the above molten polypropylene through a slit die, cooling and stretching it in a rotating drum, and then spinning it through a second spinneret to form a surface layer filament with a spinning diameter in the range of 10 to 30 microns; and
A step of making the above surface layer filament into a second non-woven fabric form by passing it through a heated press roller;
A method for manufacturing a nonwoven fabric, characterized by including a. delete It has an embossed pattern with repeated embossed and unembossed parts.
The above-mentioned non-embossed portion is a single layer or multilayer in which the web layer filament and the surface layer filament are bonded by thermal compression.
The above embossed portion is a web structure in which web layer filaments and surface layer filaments are entangled with each other and has a polygonal shape.
The above web layer filaments and the above surface layer filaments are made of polypropylene,
Non-woven fabrics weigh 3g to 4g per ^100mm2 area.
The thickness of the above embossed portion is in the range of 0.3 mm to 0.6 mm,
A nonwoven fabric characterized in that the above-mentioned nonwoven fabric has a low weight nonwoven fabric thickness ranging from 0.01 mm to 0.06 mm. delete delete delete In Article 6,
The above non-woven fabric
Made with mattress covers,
A non-woven fabric that is attached to and fixed to a hook velcro fixed to the above mattress cover and prevents lateral movement.