Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B60—VEHICLES IN GENERAL
  • B60N—SEATS SPECIALLY ADAPTED FOR VEHICLES; VEHICLE PASSENGER ACCOMMODATION NOT OTHERWISE PROVIDED FOR
  • B60N3/00—Arrangements or adaptations of other passenger fittings, not otherwise provided for
  • B60N3/04—Arrangements or adaptations of other passenger fittings, not otherwise provided for of floor mats or carpets
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
  • D01D5/00—Formation of filaments, threads, or the like
  • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
  • D01D5/30—Conjugate filaments; Spinnerette packs therefor
  • D01D5/32—Side-by-side structure; Spinnerette packs therefor
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
  • D01F8/06—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyolefin as constituent
• • D—TEXTILES; PAPER
  • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
  • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
  • D01F8/00—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof
  • D01F8/04—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers
  • D01F8/14—Conjugated, i.e. bi- or multicomponent, artificial filaments or the like; Manufacture thereof from synthetic polymers with at least one polyester as constituent
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/005—Synthetic yarns or filaments
  • D04H3/007—Addition polymers
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/005—Synthetic yarns or filaments
  • D04H3/009—Condensation or reaction polymers
  • D04H3/011—Polyesters
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/018—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the shape
• • D—TEXTILES; PAPER
  • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
  • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
  • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
  • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
  • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
  • D04H3/147—Composite yarns or filaments

Definitions

• 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.).
• 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
• the latex coating process and PVC layer among the carpet components are the layers that emit the most volatile harmful substances.
• 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 division ratio according to the following formula 1 is 50% or more
• 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.
• 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 split ratio according to Equation 1 is 50% or more.
• 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)
• a carpet including the spunbond nonwoven fabric.
• first component may be referred to as a second component
• second component may be referred to as a first component
• a polyester filament having a melting point of 250° C. or higher 60 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.
• 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.
• the latex material in the existing carpet layer serves to fix the carpet yarn (BCF yarn).
• 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. .
• 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 this 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.
• 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.
• the split yarn has a multi-split cross-section
• 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.
• 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.
• 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.
• 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.
• 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).
• the binder polymer is in a state just before melting in a high temperature environment of 180 to 200 ° C.
• the binder polymer may not be extruded or may be driven to one side due to non-uniform spinning pressure
• the bonding force between the filaments constituting the nonwoven fabric is insufficient in the post-processing process.
• 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.
• 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).
• 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.
• the filament may include divided yarns having an average diameter of 22 to 31 ⁇ m 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 ⁇ m before division and a fineness of 5.0 to 9.0 denier.
• the cross-section before division of the composite filament may be 8 divided to 64 divided circular or spherical shape.
• 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• IV intrinsic viscosity
• 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.
• 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.
• MI melt index
• 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.
• 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.
• 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 .
• 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.
• 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 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.
• 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.
• 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.
• 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.
• 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. .
• polyester filament as the matrix material and the copolymer filament as the binder material is substituted for the above-described spunbond nonwoven fabric.
• the spunbond may be provided using a continuous extruder.
• 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 ⁇ m 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.
• 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.
• 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.
• 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.
• 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.
• 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.
• affinity compatibility
• 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.
• the high-pressure water jet may have a different pressure range in two or more steps within the pressure range.
• 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.
• 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.
• the split ratio according to Equation 1 may be 50% or more.
• 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 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.
• 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.
• the carpet yarn is fixed to one surface of the nonwoven fabric, and the latex layer is not included.
• 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.
• the step of laminating a backing layer on the nonwoven fabric fixed to the carpet yarn may be further included.
• 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.
• 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.
• the tufting may be performed under a condition of a predetermined gauge (eg, 64/5 gauge) in the form of a loop.
• 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).
• a predetermined fineness eg, 500 to 3000 denier
• a height eg, 3.0 to 7 mm.
• 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.
• 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.
• 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.
• the nonwoven fabric has a loop type polypropylene BCF (Bulky Continuous Filament) Yarn of about 3000 De'/150 Fila. and the density in the width direction of the TUFTED CARPET is determined by 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 back side 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 with respect to the heat-treated carpet in the 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.
• 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.
• 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.
• 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.
• the final spunbond nonwoven fabric was prepared by adjusting the thickness of the nonwoven fabric (weight per unit area of 90 g/m 2 , thickness: 0.33 mm).
• 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 80wt%:20wt%.
• 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.
• 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.
• 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%.
• 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%.
• 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.
• 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.
• 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.
• the division ratio was calculated by Equation 1 below through 10 photos of the nonwoven fabric cross section taken with a magnification ⁇ 200 microscope.
• 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 )
• the strength at room temperature was measured using a standard test method according to KS K 0521.
• 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.
• Hot strength and hot elongation were measured using a standard test method according to KS K 0521.
• the back side of the tufting is heat treated to fix the carpet yarn (BCF yarn) and the tufted sample was prepared.
• 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 were excellent in pulling strength of 2.0 (kgf) or more.
• Comparative Example 1 showed a circular cross-section and used a non-divided nonwoven fabric, and had low mechanical properties and, in particular, had a poor pull-out strength of 1.2 kfg.
• 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.
• 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.
• 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.

Landscapes

• Engineering & Computer Science (AREA)
• Textile Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Mechanical Engineering (AREA)
• General Chemical & Material Sciences (AREA)
• Transportation (AREA)
• Nonwoven Fabrics (AREA)
• Carpets (AREA)

Priority Applications (1)

Applications Claiming Priority (4)

Publications (1)

Family

ID=82260909

Family Applications (1)

Country Status (3)

Citations (5)

Family Cites Families (6)

• 2021
  • 2021-12-29 TW TW110149448A patent/TWI829062B/zh active
  • 2021-12-29 WO PCT/KR2021/020106 patent/WO2022146005A1/ko active Application Filing
  • 2021-12-29 JP JP2023537644A patent/JP7629996B2/ja active Active

Patent Citations (5)

Also Published As

Similar Documents

Legal Events