KR102027425B1 - manufacturing method of nonwoven for carpet backing with improved forming property - Google Patents

Abstract

The present invention relates to a method for producing a nonwoven fabric for carpet bubble paper which improves the molding workability when the carpet is molded by improving flexibility and elasticity.
The nonwoven fabric for carpet bubble fabric produced by blending, stretching and heat bonding polyester elastomer with polyethylene terephthalate has excellent mechanical properties, and has a high elongation at processing and non-woven fabrics. The occurrence of tearing can be suppressed.

Description

Manufacture method of nonwoven for carpet backing with improved forming property

The present invention relates to a method for producing a nonwoven fabric for carpet bubble paper which improves the molding workability when the carpet is molded by improving flexibility and elasticity.

Automotive carpet is generally a tufting process for transplanting a carpet company on a nonwoven fabric, and a bag that hardens after applying a crude liquid such as polyvinyl chloride (PVC) or styrene butadiene rubber (SBR) to the back side of the tufted nonwoven fabric. After the coating process, the carpet is pre-heated according to the shape of the floor of the car and pressed to form the mold.

In general, the filaments constituting the polyethylene terephthalate nonwoven fabric used as the foam of automobile carpets use one or more polyethylene terephthalate chips. acid) to use low melting point co-polyesters with lower melting points.

In addition, by spinning each polyester filament, mixed spinning (Matrix & Binder), which is a form in which they are mixed, and a composite spinning (Sheath & Core / Side by Side) using two polyester resins for the same filament production Form is dominant.

In forming a web from the filament to produce a nonwoven fabric for carpet bubble paper and applying the same to a carpet, a tufting process of implanting a carpet yarn (BCF) into a carpet bubble paper by a needle is required.

In addition, the nonwoven fabric in which the carpet company was implanted by the needle was coated with ethyl vinyl acetate (EVA) and styrene butadiene rubber (SBR) -based components on the back through back coating. In the form of a certain shape.

This method is disclosed in Korean Patent Publication No. 10-1079804. The present invention relates to a low melting point copolyester fiber and a low melting point copolyester with a general polyester such as polyethylene terephthalate. After forming a web in which polyester fibers are mixed, the low-melting copolyester fiber was melted through the heat bonding process of the web to be applied as a carpet bubble paper to improve physical properties such as tensile strength of the nonwoven fabric. .

However, the low melting point co-polyester, which serves as an adhesive in the nonwoven fabric, has a low elongation, so that tearing occurs frequently in the finished product after the molding process, and the nonwoven fabric has a lack of hot elongation as a carpet bubble paper and thus is 170 to 200 ° C. In the forming process of molding with a room temperature molding machine in a state of being preheated to a temperature of 占 폚, a problem occurs that the nonwoven fabric bursts.

The present invention is to solve the above problems, to provide a method for producing a non-woven fabric for carpet bubble paper to improve the moldability by improving the stretch properties of the nonwoven fabric in a high temperature environment when carpet molding.

In order to solve the above problems, the present invention, the step of producing a first filament by spinning a polyethylene terephthalate resin having a melting point of 255 ℃ or more; Spinning a polyester elastomer having a melting point of 180 to 200 ° C. to produce a second filament; A blending spinning step of mixing the first filament and the second filament; It provides a method for producing a non-woven fabric for the foamability improved carpet form comprising the;

In addition, the present invention is the form of the first filament made of polyethylene terephthalate having a melting point of more than 255 ℃ and the second filament made of a polyester elastomer having a melting point of 180 ~ 200 ℃ mixed with the web laminated and heat-bonded form Provides nonwoven fabric for carpet bubble paper.

According to the present invention by using a non-woven fabric using a polyester elastomer as the second filament in the blended yarn spinning is easy to stretch due to the improved elongation and flexibility at high temperature during carpet molding to suppress the occurrence of tearing, thereby improving the carpet molding processability and production yield It becomes possible.

Carpet bubble nonwoven fabric of the present invention comprises a polyethylene terephthalate (PET) resin having a melting point of more than 255 ℃ 70 ~ 95% by weight and a polyester elastomer (PEL) 5 ~ 30% by weight of 180 ~ 200 ℃ melting, carpet production When the elongation is high in a high temperature environment, flexibility and elasticity are improved, thereby preventing tearing and improving carpet molding processability.

In addition, the nonwoven fabric for carpet foam of the present invention has a first filament component made of polyethylene terephthalate (PET) resin having a melting point of 255 ° C. or higher and a second filament component made of polyester elastomer (PEL) having a melting point of 180 to 200 ° C. A mixed fiber spinning step of spinning and mixing in a ratio of 95: 5 to 70:30 by weight; Forming a web from the filaments formed by the interwoven spinning; And thermally bonding the web.

The polyethylene terephthalate resin, which is the first filament component of the present invention, may be used without limitation as long as it has a melting point of 255 ° C. or more and is used for fiber produced by a conventional manufacturing method.

Polyethylene terephthalate, the first filament component in a nonwoven fabric, when tensile strength is given under high temperature conditions during nonwoven fabric processing and carpet molding, can be properly stretched at a similar ratio as a bag coating material with a low heat shrinkage rate to maintain a desired manufacturing width. Play a role.

In the second filament of the present invention, when a tensile force is given under a high temperature environment by using a polyester elastomer having a melting point of 180 ° C. to 200 ° C., the adhesive part of the fiber filaments constituting the nonwoven fabric may be softened to improve moldability.

Polyester elastomers are terephthalic acid (TPA), isophthalic acid (IPA), dimethyl terephthalate having -COOH or -COOR (wherein R is a C ₁ to C ₁₀ alkyl group or arylalkyl group) at the end of the polymerization monomer. (DMT), at least one acid component selected from the group consisting of dimethylisophthalate (DMI), poly (tetramethylene ether) glycol (PTMG), 1,4-butanediol (1,4-BD), ethylene glycol (EG It may be prepared by polymerizing at least one diol component selected from the group consisting of).

Conventionally, in order to improve moldability in a high temperature environment, a low melting point (less than 200 ° C.) copolymerized polyethylene terephthalate (Co-PET) having a melting point below a molding or preheating temperature should be used as the second filament.

However, in order to polymerize low melting point Co-PET, it is necessary to increase the content of additives such as AA or IPA. In this case, even though the melting performance of the Co-PET chip is lowered and the melting point is low, PET has a higher elongation than polyester elastomer. Low molding may tear the nonwoven fabric.

Therefore, in the present invention, tearing of the nonwoven fabric can be suppressed by using a polyester elastomer having a low melting point and excellent emissivity and high elongation.

The polyester elastomer of the present invention can be molded by various methods such as extrusion, injection, blow molding by melting with thermoplastic, and is excellent as an elastic recovery rate returned to the original even though it is soft as an elastic body and deformed by external force, and mechanical strength It has excellent elongation and heat fusion property by heating and pressing. In the present invention, the first filament and the entanglement are formed by acting as an adhesive for thermal bonding of fibers in nonwoven fabric, and the elongation is high in high temperature environment. Tear can be suppressed at the time.

Polyester elastomer in the present invention has an intrinsic viscosity (IV, measured by dissolving in solvent O-Chrophenol (OCP) at 100 ℃) is 0.6 ~ 0.8 dl / g, melt viscosity (MV, Piston diameter: 12mm, detention standard: 20 600 ~ 1000 Poise (measured at 1,000 Shear rate at 280 ° C using mm × 1 mm (L × D)) has better radioactivity and hot (180 ° C) elongation at nonwoven fabric is 50 ~ 80% It is preferable because a phosphorous nonwoven fabric can be manufactured.

Since the hot elongation of the nonwoven fabric is high, and the adhesive part by the second filament shows flexibility in a high temperature environment (molding or preheating), deformation of the nonwoven fabric by external force is easy, and tearing of the nonwoven fabric can be suppressed during molding.

The polyester elastomer of the present invention has a tensile elongation (by ASTM D638 method) of 300 to 600% and a melt index (by ASTM D1238 method) of 5 to 20 g / 10 min. The excellent elastic recovery rate characteristics of polyester elastomers make it easy to shrink after stretching and prevent uneven stretching, thus facilitating interweaving spinning, and improving mechanical strength in nonwoven fabrics and carpet forming processes. It is more preferable because it is possible to maintain and to prevent the occurrence of tearing while being flexible and elongated without dropping of the entanglement point.

If the polyester elastomer of the present invention has a tensile elongation (by ASTM D638 method) of less than 300%, the flexibility and elasticity of the nonwoven fabric may not be improved at the time of carpet molding, and tearing may occur. At this time, stretching is excessive or uneven stretching occurs, which may result in unevenness of fineness, which is undesirable.

In the polyester elastomer of the present invention, if the melt index (by ASTM D1238 method) is less than 5 g / 10 min, the ratio of the crystal structure region in the polyester elastomer is high, and thus the improvement of flexibility may not appear in the nonwoven fabric, and 20 g / 10 min. When the filament is exceeded, the flow rate of the filament formed during the spun spinning is so good that the first filament and the blended filament become uneven, uneven stretching frequently occurs, and mechanical strength including tensile strength may be degraded, causing tearing.

The resin used in the conventional non-woven fabric for carpet bubble paper is designed to melt at a high temperature of 200 ° C or higher or 180 ° C or lower and to contain 10 wt% or more of the nonwoven fabric, but it is not satisfactory in that deformation occurs due to heat shrinkage. In the polyester elastomer while maintaining the melting temperature of 180 ~ 200 ℃ to be contained in 5 ~ 30 wt% in the nonwoven fabric to maintain a stable shape even when the high temperature heat treatment in the carpet manufacturing process.

In general, since the coating, heat treatment, and drying temperature of the carpet used for durability is less than about 180 ° C., in order to manufacture the carpet nonwoven fabric according to the present invention, the melting temperature of the polyester elastomer contained in the nonwoven fabric should be maintained at 180 to 200 ° C. do.

When the melting temperature of the polyester elastomer is less than 180 ℃, the ratio of the crystal structure region in the polyester elastomer is low, when stretching in intertwine spinning, the stretching is made more than the first filament or non-uniform and shrinkage occurs after stretching It is difficult to obtain the desired draw ratio, which may result in unevenness of the fineness.The polyester elastomer melts during the carpet manufacturing process, causing breakage of the bubble sheet and increasing the heat shrinkage rate, resulting in insufficient width and length of the finished carpet product and nonwoven fabric and coating. Due to the difference in heat shrinkage of the material, warpage may occur in carpet products.

In addition, if the melt temperature of the polyester elastomer is 200 ℃ or more, the heat shrinkage rate of the nonwoven fabric is stable, so that the cutting of the sheet and the shortage of the width and length of the finished product do not occur, but the high temperature coating, heat treatment, In the drying process and the carpet forming process, the flexibility of the nonwoven fabric becomes low, so that the tearing may occur.

The nonwoven fabric for carpet foam of the present invention has a polyethylene terephthalate resin (first filament) having a melting point of 255 ° C. or more and a polyester elastomer (second filament) having a melting point of 180 to 200 ° C. at a weight ratio of 95: 5 to 70:30. Each is fed to an extruder through a feeder to melt and intermix spinning, and the intermixed filaments are stretched sufficiently to have a spinning speed of 4500 to 5000 m / min using a high-pressure air stretching apparatus, and 4 to 10 deniers. It can be produced from filaments having a fineness of.

In this case, when the filament has a fineness of less than 4 denier, the filament is too thin and the number of filaments per unit area increases, causing a lot of breakage of the filament in the tufting process, which causes a decrease in physical properties. It becomes difficult to manufacture.

The filament fibers prepared by the mixed fiber spinning are laminated in the form of a web to adjust the thickness of the nonwoven fabric using two high-temperature / high pressure calender rolls used in the conventional nonwoven fabric manufacture, and then, the nonwoven fabric is manufactured by using an adhesive method using hot air. do.

In the case of using a heat setting apparatus that injects hot air, such as a tenter, as the hot air bonding method, the temperature of the hot air apparatus is preferably equal to the melting point of the second filament.

The nonwoven fabric for the carpet bubble paper is composed of 70 to 95% by weight of the first filament and 5 to 30% by weight of the second filament. When the content ratio of the second filament is less than 5% by weight, the amount of the component that improves elasticity is high due to the high elongation. Because of the loss, tearing may occur during processing and carpet molding of the nonwoven fabric, and if the content of the second filament is more than 30% by weight, the filament breakage during the tufting process is increased due to excessive adhesion between the filaments due to the excessive adhesive component. After the tufting occurs, the strength and elongation of the nonwoven fabric is lowered and the nonwoven fabric becomes hard, which may adversely affect the molding of the carpet.

Finally, a small amount of oil (0.4 to 1.0% by weight) may be uniformly applied to the prepared nonwoven fabric, and the basis weight of the nonwoven fabric thus prepared is suitably 100 to 140 g / m 2.

As described above, the first filament and the second filament are made of the same polyester material, so that the polyester elastomer of the second filament is melted in the heat bonding step to bond the polyester fibers of the first filament having a relatively high melting point to each other. It is easily combined with the polyester of the first filament, which is a material, and works more effectively to improve the strength of the nonwoven fabric.

Since the nonwoven fabric of the present invention is manufactured by thermal bonding, the filament fibers are manufactured by thermal bonding even if the processes such as needle punch are not carried out separately, so the manufacturing process of the nonwoven fabric is simple and can prevent the breakage of the filament fibers in the needle punching process. , Since the adhesion of the fiber is made by hot air, not emboss roll, there is no crimped portion of the nonwoven fabric such as paper, thereby reducing damage to the nonwoven fabric during the tufting process.

The present invention is to produce a nonwoven fabric using a polyester elastomer having a higher elongation than polyethylene terephthalate as a second filament in a high temperature environment, thereby improving flexibility and elasticity in high temperature coating, heat treatment, drying process and carpet forming process in carpet production. This can suppress the occurrence of tearing can improve the molding processability.

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

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

Example 1

Polyethylene terephthalate having an intrinsic viscosity (IV) of 0.655 dl / g and a melting point of 255 ° C. was melted at 288 ° C. to spin the first filament through the spinning nozzle.

Also, Polyester elastomers having a melting point of 180 ° C. (KP3355, Kolon Industries, IV = 0.806 dl / g, MV = 890 foams) were melted at 288 ° C. to spin the second filament through the spinning nozzle.

At this time, the spinning filament was spun so that the first filament and the second filament had a weight ratio of 95: 5, and the discharge amount and the number of capillary holes were adjusted so that the total filament fineness after the stretching step following the spinning step was 9 denier.

Subsequently, the continuous filament discharged from the capillary was solidified by a cooling air at 25 ° C., and then the filament fiber was prepared by sufficiently stretching the spinning filament to 5000 m / min using a high-pressure air stretching apparatus.

Thereafter, by laminating in a web form on the conveyor net by a conventional opening method, it is calendered by a heated calender roll to maintain smoothness and proper thickness, and then a nonwoven fabric is prepared by applying hot air at 180 ° C. A nonwoven fabric was prepared by applying 0.7 wt% emulsion by weight.

Example 2

In Example 1, the nonwoven fabric was manufactured in the same manner as in Example 1, except that the filament of the filaments was mixed so that the first filament and the second filament were in a 85:15 weight ratio.

Example 3

In Example 1, the non-woven fabric was prepared in the same manner as in Example 1, except that the filaments of the filaments were 70:30 weight ratio of the first filament and the second filament.

Comparative Example 1

A nonwoven fabric was prepared in the same manner as in Example 1, except that a copolymerized polyethylene terephthalate resin having a melting point of 180 ° C. was used as the second filament in Example 1.

Comparative Example 2

In Example 1, the nonwoven fabric was manufactured in the same manner as in Example 1, except that the filament of the filaments was such that the first filament and the second filament had a weight ratio of 96: 4.

Comparative Example 3

In Example 1, the nonwoven fabric was prepared in the same manner as in Example 1, except that the filament of the filaments was a 69:31 weight ratio of the first filament and the second filament.

The physical properties of the nonwoven fabrics prepared in Examples and Comparative Examples were measured by the following evaluation method, and the results are shown in Table 1 below.

(Assessment Methods)

1. Tensile strength (unit: kg.f / 5cm)

KS K 0521 method was used. Specifically, the width × length = 5cm × 20cm sized specimens are bitten by a 5cm × 5cm jig up / down using an INSTRON company's measuring equipment, and measured at a tensile rate of 200mm / min.

2. Room temperature elongation (unit:%)

KS K 0521 method was used. Specifically, the width × length = 5cm × 20cm sized specimens are bitten by a 5cm × 5cm jig up / down using an INSTRON company's measuring equipment, and measured at a tensile rate of 200mm / min.

3. Hot Elongation (Unit:%)

The specimen of width x length = 3 cm x 10 cm was bitten with a 3 cm x 2.5 cm jig using an INSTRON measuring instrument and then measured at a tensile rate of 200 mm / min. In the measurement, after preheating for 3 minutes in a temperature environment of 180 ℃ using a hot chamber, it is measured.

4. After molding evaluation, the width of the nonwoven fabric torn (unit: cm 2)

After applying and drying the PVC crude liquid on the back side of the nonwoven fabric, draw a grid pattern of 2cm intervals on the specimen of width × length = 30cm × 30cm. This was preheated at 180 ° C. for 3 minutes on a preheating plate, followed by molding evaluation. After the molding evaluation, the area of the torn portion is determined by counting the number of lattice patterns at the site where the nonwoven fabric is torn.

Ex) Number of squares of torn areas = 6 → Width of torn areas = 6 * 4 = 24㎠

division The tensile strength
MD / CD
(kg.f / 5cm) Room temperature elongation
MD / CD
(%) Hot elongation
MD / CD
(%) Non-woven fabric torn area (cm2) after molding evaluation Example 1 19.9 / 20.5 25.6 / 26.7 50.3 / 51.6 8 Example 2 25.0 / 25.5 33.5 / 32.6 65.7 / 66.9 0 Example 3 29.2 / 28.8 40.3 / 44.5 73.6 / 74.4 4 Comparative Example 1 26.7 / 25.4 32.6 / 31.8 32.1 / 33.6 16 Comparative Example 2 14.6 / 15.4 22.8 / 23.7 36.2 / 38.8 12 Comparative Example 3 33.2 / 32.8 41.4 / 40.5 74.8 / 73.1 8

When using the polyester elastomer according to the present invention from Table 1 it can be confirmed that the tearing of the nonwoven fabric due to the increase in hot elongation is reduced.

In the nonwoven fabric of Comparative Example 3, the increase in the content of the polyester elastomer increases the entanglement between the filaments and the tensile strength exceeds 30kg.f / 5cm, the nonwoven fabric becomes hard like paper. As a result, the filament is damaged by the needle in the tufting process, so that the nonwoven fabric is broken and damaged, making it difficult to maintain the shape.

Therefore, even if the hot elongation is high, the torn area is increased.

By limiting the maximum content of the polyester elastomer as in the present invention it can be seen that the nonwoven fabric can suppress the tearing of the nonwoven fabric during molding while maintaining the shape stability even after the tufting process.

Claims (7)

Preparing a first filament by spinning a polyethylene terephthalate resin having a melting point of at least 255 ° C;
Spinning a polyester elastomer having a melting point of 180 to 200 ° C. to produce a second filament;
A blending spinning step of mixing the first filament and the second filament; And
And heat-bonding the mixed fiber spun yarn mixed with the web.
The polyester elastomer has an intrinsic viscosity (measured by dissolving in solvent O-Chrophenol (OCP) at 100 ° C.) of 0.6 to 0.8 dl / g, melt viscosity (MV, piston diameter: 12 mm, detention standard: 20 mm × 1). measured at 1,000 Shear rate at 280 ° C using mm (L × D)) Method for producing a non-woven fabric for carpet foam paper, characterized in that the improved moldability. The method of claim 1,
The blend fiber spinning method for producing a non-woven fabric for foam, characterized in that the first filament and the second filament is 95: 5 ~ 70:30 weight ratio. The method of claim 1,
The thermal bonding temperature is the manufacturing method of the non-woven fabric for carpet foam paper with improved moldability, characterized in that the same as the melting temperature of the second filament. A first filament made of polyethylene terephthalate having a melting point of 255 ° C. or more and a second filament made of a polyester elastomer having a melting point of 180 ° C. to 200 ° C. are mixed and laminated to a web and thermally bonded.
The polyester elastomer has an intrinsic viscosity (measured by dissolving in solvent O-Chrophenol (OCP) at 100 ° C.) of 0.6 to 0.8 dl / g, melt viscosity (MV, piston diameter: 12 mm, detention standard: 20 mm × 1). measured at 1,000 Shear rate at 280 ° C using mm (L × D)) Carpet bubble paper nonwoven fabric with improved moldability. The method of claim 4, wherein
The nonwoven fabric has a tensile strength of 19 ~ 30kgf / 5㎝, room temperature elongation is 25 ~ 45%, hot (180 ℃) elongation is characterized in that the carpet foam paper improved nonwoven fabrics characterized in that 50 ~ 80%. delete The method of claim 4, wherein
The nonwoven fabric is a carpet foam paper nonwoven fabric with improved moldability, characterized in that consisting of 70 to 95% by weight of the first filament and 5 to 30% by weight of the second filament.