KR102037496B1

KR102037496B1 - Improved Plasticity Spunbonded Nonwoven for Primary Carpet Backing, and Method for Manufacturing the Same

Info

Publication number: KR102037496B1
Application number: KR1020130074482A
Authority: KR
Inventors: 최진환; 김진일; 이민호; 조희정
Original assignee: 코오롱인더스트리 주식회사
Priority date: 2013-06-27
Filing date: 2013-06-27
Publication date: 2019-10-28
Also published as: KR20150001364A

Abstract

The present invention relates to a spunbond nonwoven fabric for polyester-based carpet bubble paper, which is excellent in strength properties and elongation at high temperature, and which can be used for carpet bubble paper requiring high temperature formability, and a method of manufacturing the same.
The spunbonded nonwoven fabric for carpet foam according to the present invention has excellent strength properties, suppresses deterioration in physical properties even after tufting fixing, and has excellent flexibility in formability because it has a high elongation at the time of heat treatment and a moderately stretched flexibility. By mixing a terephthalate resin with a polybutylene terephthalate resin, which is a homogeneous resin, to produce a filament, the filament can be suppressed to produce high-speed spinning filaments with high spinning ability.

Description

Spunbonded nonwoven fabric for carpet foam having excellent moldability and manufacturing method therefor {Improved Plasticity Spunbonded Nonwoven for Primary Carpet Backing, and Method for Manufacturing the Same}

The present invention relates to a spunbond nonwoven fabric for polyester-based carpet bubble paper, which is excellent in strength properties and elongation at high temperature, and which can be used for carpet bubble paper requiring high temperature formability, and a method of manufacturing the same.

Spunbond nonwoven fabrics are used in many industrial fields because of their high productivity, high strength and low thickness. They are used for civil and construction applications because of their high strength and drainage, and they have excellent durability for the price. It is also widely used for automobiles.

In particular, the spunbonded nonwoven fabric has been found to have excellent form stability and dust particle collection ability in recent years, and is widely used as a filter material, and has excellent uniformity and high temperature form stability. It is also widely used for Primary Tufting Carpet Backing.

Generally, the filament constituting the spunbond nonwoven fabric uses one or more polyester chips. Generally, the melting point is obtained by adding adipic acid or isophthalic acid to a polyester having a melting point of 255 ° C. It is made using low melting polyesters polymerized lower than ordinary polyesters.

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

In addition, the nonwoven fabric in which the carpet yarn is implanted by the needle is 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.

A method for obtaining such a spunbond nonwoven fabric is disclosed in Korean Patent Application Publication No. 10-1079804 filed by the present applicant, and the present invention has a low melting point through a mixed fiber spinning of a low melting point copolyester and a general polyester. After forming a web in which copolyester fibers and general polyester fibers are mixed, physical properties such as tensile strength of the nonwoven fabric to be applied to the carpet bubble paper by melting the low-melting copolyester fiber through the heat bonding process of the web. To improve.

However, the nonwoven fabric lacks elongation as a carpet bubble, and thus, a problem arises in that the nonwoven fabric bursts in a process of forming into a molding machine at room temperature after heat treatment.

In order to solve this drawback, the present applicant manufactures a vinegar filament by applying an olefin polymer to the first part (Sheath part) through the Korean Patent Publication No. 10-2012-0033771 and using it to produce a non-woven fabric for carpet foam By establishing a plan, the elongation could be improved.

However, the present invention is due to the low melting temperature of the olefin polymer due to the temperature when drying the ethyl vinyl acetate, styrene butadiene rubber components used in the back coating process occurs a non-woven form deformation, which is the soft properties of the olefin polymer In addition, the shape of the molded product is a cause of somewhat poor.

As described above, various measures have been proposed to solve the problems occurring in the bubble nonwoven fabric of the carpet, and although some improvements have been made in general physical properties such as strength and elongation, it is possible to prevent physical property degradation during the heat treatment process. In terms of technology, there is still a need for improvement both technically and commercially.

The present invention is to solve the problems as described above, to improve the strength and elongation at high temperature, spunbond non-woven fabric and a method for manufacturing a spunbonded nonwoven fabric that can implement a carpet foam excellent in heat treatment and high temperature coating process of the carpet manufacturing process To provide.

In order to solve the above problems, the present invention is a first filament made of a resin mixed with a polyethylene terephthalate having a melting point of at least 255 ℃ and a polybutylene terephthalate having a melting point of at least 225 ℃; and a polyethylene terephthalate of the first filament A second filament made of a polyester resin having a melting point of 40 ° C. or lower; mixed and web laminated and heat bonded, and having a tensile strength of 23 to 30 kgf / 5cm and a tear strength of 9 to 10 kgf. A spunbonded nonwoven fabric for carpet foam having excellent moldability, having an elongation of at least 75% at 170 ° C.

In addition, the present invention comprises the steps of blending a resin mixed with polyethylene terephthalate having a melting point of at least 255 ℃ and polybutylene terephthalate having a melting point of at least 225 ℃ to prepare a first filament; Preparing a second filament by spinning a polyester resin having a melting point of 40 ° C. or more lower than that of the polyethylene terephthalate of the first filament; Intermixing the first filament and the second filament; It provides a method of producing a spunbonded nonwoven fabric for carpet foam, including;

In this case, the first filament is preferably 80 to 95% by weight polyethylene terephthalate and 5 to 20% by weight polybutylene terephthalate, the first filament and the second filament is 85 to 95: 5 to 15% by weight It is preferred to be mixed with.

In addition, the intrinsic viscosity of the polyethylene terephthalate of the first filament is preferably 0.6 to 0.7 and the intrinsic viscosity of the polybutylene terephthalate is 0.7 to 0.8.

In addition, it is preferable to stretch the mixed island spun yarn at a spinning speed of 4500 to 5000 m / min, and more preferably, the drawn mixed island yarn has a fineness of 4 to 10 denier.

In addition, the temperature for thermal bonding is preferably the same as the melting temperature of the polyester resin of the second filament, it is preferable that the basis weight of the nonwoven fabric is 100 ~ 140 g / ㎡.

The spunbonded nonwoven fabric for carpet foam according to the present invention has excellent strength properties, suppresses deterioration in physical properties even after tufting fixing, and has excellent flexibility in formability because it has a flexibility to increase moderately under a given tensile strength during heat treatment.

In addition, by mixing a polyethylene terephthalate resin with a polybutylene terephthalate resin of the same type of resin to produce a filament, it is possible to suppress the orientation of the filament to produce a filament excellent in spinning properties while being capable of high-speed spinning.

Hereinafter, a method of manufacturing a spunbonded nonwoven fabric for carpet bubble paper and a nonwoven fabric produced by such a method, which are excellent in various physical properties such as strength and elongation at high temperature and which can improve moldability and durability of the carpet, will be described in detail.

The spunbonded nonwoven fabric for carpet foam of the present invention is a first filament made of a resin in which a polyethylene terephthalate (PET) having a melting point of 255 ° C. or more and a polybutylene terephthalate (PBT) having a melting point of 225 ° C. or more serving as an orientation inhibitor are mixed. And a second filament made of a polyester resin having a melting point of 40 ° C. or more lower than the polyethylene terephthalate of the first filament is interspun and manufactured by laminating and thermally bonding a web.

The first filament is prepared by blending spinning 80 to 95% by weight of polyethylene terephthalate and 5 to 20% by weight of polybutylene terephthalate to an extruder and simultaneously melting through a feeder.

In this case, it is preferable that the intrinsic viscosity (IV) of the polyethylene terephthalate in the first filament is 0.6 to 0.7 and the intrinsic viscosity of the polybutylene terephthalate is 0.7 to 0.8.

When the content of the polybutylene terephthalate of the first filament exceeds 20% by weight due to the rapid cooling rate of polybutylene terephthalate unstable radioactivity due to cutting during filament manufacturing, if less than 5% by weight of the orientation inhibitor Since it is not able to play a sufficient role as a filament density decrease is not large, and the molding improvement effect is not large because of this.

Table 1 shows the density of the first filament according to the content ratio of the polyethylene terephthalate and polybutylene terephthalate of the first filament, the ratio of PET: PBT in the range of 80 ~ 95: 5 ~ 20% by weight It can be seen that represents 1.360 to 1.369 g / cm 3.

division PET: PBT content ratio (% by weight) 100: 0 95: 5 90:10 80:20 Density (g / cm 3) 1.372 1.369 1.365 1.360

The second filament is prepared by spinning a low melting point copolyester, and the low melting point copolyester is mixed with an additive such as adipic acid or isophthalic acid during the polymerization of the polyester and thus the melting point of the first filament It is adjusted so that it is 40 degreeC or more lower than the polyethylene terephthalate of.

The first filament and the second filament are blended and spun at 85 to 95: 5 to 15% by weight to form a blended yarn. When the content ratio of the second filament is less than 5% by weight, the second filament component acts as an adhesive. Due to the small amount of non-woven fabric, the strength and elongation of the nonwoven fabric is lowered, and if it exceeds 15% by weight, the adhesive component is excessive, so filament breakage occurs in the tufting process due to excessive adhesion between the filaments. This makes it difficult to use as a carpet bubble paper.

The filament spun in the form of mixed fiber spinning is stretched sufficiently to have a spinning speed of 4500 to 5000 m / min using a high-pressure air drawing device to produce a filament having a fineness of 4 to 10 denier, and the fineness of the filament When less than 4 denier, the filament is too thin and the number of filaments per unit area increases the breakage of the filament in the tufting process is a cause of deterioration of physical properties, if it exceeds 10 denier it becomes difficult to manufacture nonwoven uniformly.

The filament fibers produced by the mixed fiber spinning are laminated in the form of a web and thermally bonded using two hot / high pressure calender rolls or emboss rolls used in conventional nonwoven fabrics, or nonwoven fabrics using an adhesive method using hot air. To prepare.

In the case of using a heat setting device that injects hot air as a tenter as the hot air bonding method, the temperature of the hot air device is preferably the same as the low melting point copolyester melting point of the second filament, and the nonwoven fabric prepared as described above. The basis weight of is preferably 100 ~ 140 g / ㎡.

As described above, the first filament and the second filament are made of the same material, so that the low fusing copolyester of the second filament is melted in the heat bonding step, thereby bonding 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 raw material, to act more effectively to improve the strength of the nonwoven fabric.

Since the spunbond 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, thereby simplifying the manufacturing process of the nonwoven fabric and preventing breakage of the filament fibers in the needle punching process. In addition, since the adhesion of the fibers is made by heat rather than external force, the spunbond nonwoven fabric having a bulky structure may be obtained since the thickness change is not accompanied.

Finally, a small amount of emulsion may be evenly applied to the nonwoven fabric prepared above.

Spunbonded nonwoven fabric for carpet foam of the present invention prepared as described above has a tensile strength of 23 ~ 30 kgf / 5㎝ and a tear strength of 9 ~ 10 kgf, elongation at 170 ℃ 75% or more, specifically 75 It has physical properties of ~ 90% and has excellent moldability and durability at high temperatures.

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

1) Preparation of Filament Fiber

90 wt% of polyethylene terephthalate resin having intrinsic viscosity of 0.655 and melting point of 255 ° C as the first filament and 10 wt% of polybutylene terephthalate resin having intrinsic viscosity of 0.741 and melting point of 225 ° C are used and continuous extruder Melt spinning at a spinning temperature of 288 ° C.

Further, 22 mol / wt% of adipic acid was added as the second filament, and a low melting point copolyester resin having an intrinsic viscosity of 0.760 and a melting point of 190 ° C was melt spun at a spinning temperature of 288 ° C using a continuous extruder.

At this time, the spinning was intertwined spinning so that the first filament and the second filament were 90:10 wt%, and the discharge amount and the number of capillary pores 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 with a cooling air at 25 ° C., and then the filament fiber was sufficiently prepared by using a high-pressure air drawing device to draw a spinning speed of 5000 m / min.

2) Manufacture of Spunbond Nonwoven Fabric

Next, the filament fibers thus prepared were laminated in the form of a web on a metal net continuously moving by a conventional opening method.

The laminated filament was thermally bonded at the melting point of the second filament component using a hot air device to prepare a spunbond nonwoven fabric having a weight per unit area of 120 g / m 2 and then applying a small amount of an emulsion.

In Example 1, a spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that 95 wt% of polyethylene terephthalate resin and 5 wt% of polybutylene terephthalate resin were melt-spun as the first filament. It was.

In Example 1, a spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that 80 wt% of polyethylene terephthalate resin and 20 wt% of polybutylene terephthalate resin were melt-spun as the first filament. It was.

In Example 1, a spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that the first filament and the second filament were intertwined so as to be 95: 5 wt%.

Example 5

In Example 1, a spunbond nonwoven fabric was prepared in the same manner as in Example 1, except that the first filament and the second filament were interweaved so as to be 85: 15% by weight.

Comparative Example 1

In Example 1, a spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that 96 wt% of polyethylene terephthalate resin and 4 wt% of polybutylene terephthalate resin were melt-spun as the first filament. It was.

Comparative Example 2

In Example 1, a spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that 79 wt% of polyethylene terephthalate resin and 21 wt% of polybutylene terephthalate resin were melt-spun as the first filament. It was.

Comparative Example 3

In Example 1, a spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that the first filament and the second filament were intertwined so as to be 96: 4 wt%.

In Example 1, a spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that the first filament and the second filament were interweaved to be 84:16 wt%.

Comparative Example 5

In Example 1, a spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that only the polyethylene terephthalate resin was melt-spun without blending the polybutylene terephthalate resin as the first filament.

The preparation conditions of the Examples 1 to 5 and Comparative Examples 1 to 5 are summarized in Table 2 below.

PET: PBT content ratio of the first filament
(weight%) First filament: second filament content ratio
(weight%) Fineness of filament after stretching process
(Denier) Nonwoven Weight
(g / ㎡) Example 1 90:10 90:10 9 120 Example 2 95: 5 90:10 9 120 Example 3 80:20 90:10 9 120 Example 4 90:10 95: 5 9 120 Example 5 90:10 85:15 9 120 Comparative Example 1 96: 4 90:10 9 120 Comparative Example 2 79:21 90:10 9 120 Comparative Example 3 90:10 96: 4 9 120 Comparative Example 4 90:10 84:16 9 120 Comparative Example 5 100: 0 90:10 9 120

Tensile strength, tear strength and elongation (hot elongation) of the nonwoven fabric during heat treatment were measured for the nonwoven fabrics prepared in Examples and Comparative Examples, and the results are shown in Table 3 below.

Tensile strength before tufting was performed using the KS K 0521 method. Specifically, a specimen having a width × length = 5 × 20 cm was bitten with a jig of 5 × 5 cm up / down using an INSTRON measuring device and a tensile speed of 200 Measured at mm / min.

Tensile strength after tufting was measured by Lab. After tufting under conditions of GPI (Gage per Inch) 1/10 and SPI (Stroke per Inch) 1/10 using a tufting facility, the measurement was performed in the same manner as described above.

The tearing strength was measured using KS K 0536 (Single Tongue) method. Specifically, the center part of the specimen of 7 × 10 × 7.6 cm was cut in 7 cm and the tensile speed was 300 mm / min using INSTRON's measuring equipment. Measured.

The hot elongation was measured using the KS K 0521 method. Specifically, a specimen having a width × length = 3 × 10 cm was kept in the hot chamber for 1 minute at 170 ° C. using INSTRON measuring equipment, and the upper and lower 2.5 × 2.5 cm After being bitten by a jig, the tensile velocity was measured at 200 mm / min.

Before tufting
The tensile strength
(Kgf / 5cm) After tufting
The tensile strength
(Kgf / 5cm) Tear strength
(Kgf) Hot elongation
(%) Note ² ⁾ Example 1 26.0 / 26.2 ^{Note 1)} 15.8 / 16.2 9.8 / 9.8 77.1 / 83.2 ◎ Example 2 27.5 / 27.1 15.1 / 16.5 10.1 / 9.6 75.5 / 75.2 ◎ Example 3 25.8 / 25.7 16.8 / 15.6 10.3 / 9.1 82.1 / 88.9 ◎ Example 4 23.9 / 24.5 14.5 / 14.9 9.7 / 9.2 75.6 / 80.1 ○ Example 5 29.8 / 30.1 14.3 / 15.0 9.0 / 9.1 76.2 / 76.0 ○ Comparative Example 1 28.5 / 27.3 15.2 / 15.1 9.6 / 9.1 66.2 / 62.9 △ Comparative Example 2 24.8 / 25.2 15.2 / 16.0 9.5 / 9.6 83.2 / 82.5 X Comparative Example 3 20.7 / 21.2 12.2 / 11.0 8.9 / 9.1 75.1 / 80.2 △ Comparative Example 4 30.1 / 32.3 13.2 / 12.5 8.8 / 8.6 76.2 / 77.9 △ Comparative Example 5 28.7 / 28.6 16.7 / 15.9 9.9 / 10.2 65.2 / 63.8 △ Note 1) MD / CD (MD: mechanical direction, CD: cross direction)
Note 2) ◎: Excellent, ○: Good, △: Lack, X: Poor

In the results of Table 3, the nonwoven fabric of the example showed excellent tensile strength, tearing strength and hot elongation before and after tufting, when the content of the second filament was 5% by weight and 15% by weight during mixed spinning. After the tufting, the tensile strength and tearing strength are slightly decreased, so the physical properties of the nonwoven fabric are slightly decreased.

In Comparative Example, for Comparative Example 1 in which the polybutylene terephthalate content of the first filament was less than 5% by weight (polyethylene terephthalate content was more than 95% by weight), the polybutylene terephthalate played a minor role as an orientation inhibitor, and thus the filament density The decrease in temperature was not large, and thus the hot elongation was lowered. On the contrary, in the case of Comparative Example 2, the polybutylene terephthalate content of the first filament was more than 20% by weight (polyethylene terephthalate content was less than 80% by weight). Due to the rapid cooling rate of phthalate, poor radioactivity due to cutting during spinning occurred.

In addition, in the case of Comparative Example 3 in which the content of the second filament is less than 5% by weight (the content of the first filament is more than 95% by weight), the amount of the second filament component serving as the adhesive is small, so that before the tufting of the nonwoven fabric / In the case of Comparative Example 4, after which the tensile strength and tearing strength were lowered and the content of the second filament was greater than 15% by weight (the content of the first filament was less than 85% by weight), Many filament breakages result in a decrease in tensile strength and tearing strength after tufting, making it unsuitable for use as a bubble paper for carpets.

In the case of Comparative Example 5 using only polyethylene terephthalate resin without mixing the polybutylene terephthalate resin in preparing the first filament, the density of the filament is lowered as the density of the filament is not lowered for the same reason as in Comparative Example 1 above. Results.

As described above, the spunbonded nonwoven fabric for carpet foam according to the present invention is excellent in formability because it has excellent strength properties and suppresses deterioration of physical properties even after tufting fixing, and has a high elongation during heat treatment, and has a moderately stretched flexibility under given tensile strength. There is an advantage.

Claims

A first filament made of a mixture of a polyethylene terephthalate having a melting point of at least 255 ° C. and a polybutylene terephthalate having a melting point of at least 225 ° C .; and a polyester resin having a melting point of 40 ° C. or more lower than a polyethylene terephthalate of the first filament. As the second filament to be manufactured is mixed and laminated web and heat-bonded,
The first filament comprises 80 to 95% by weight of polyethylene terephthalate and 5 to 20% by weight of polybutylene terephthalate,
Intrinsic viscosity of the polyethylene terephthalate of the first filament is 0.6 ~ 0.7 and inherent viscosity of the polybutylene terephthalate is 0.7 ~ 0.8,
The first filament and the second filament are mixed with 85 to 95: 5 to 15% by weight,
A spunbonded nonwoven fabric for carpet foam having excellent moldability, having a tensile strength of 23 to 30 kgf / 5 cm, a tear strength of 9 to 10 kgf, and an elongation of at least 75% at 170 ° C.

delete

The method according to claim 1,
The spunbonded nonwoven fabric for carpet foam having excellent moldability, characterized in that the blended yarn in which the first filament and the second filament are blended has a fineness of 4 to 10 denier.

The method according to claim 1,
Spunbonded nonwoven fabric for carpet foam having excellent moldability, characterized in that the basis weight of the nonwoven fabric is 100 ~ 140 g / ㎡.

Preparing a first filament by blending and spinning a resin containing a polyethylene terephthalate having a melting point of at least 255 ° C. and a polybutylene terephthalate having a melting point of at least 225 ° C .;
Preparing a second filament by spinning a polyester resin having a melting point of 40 ° C. or more lower than that of the polyethylene terephthalate of the first filament;
Intermixing the first filament and the second filament; And
And heat-bonding the mixed fiber spun yarn mixed with the web.
The first filament is prepared by blending 80 to 95% by weight of polyethylene terephthalate and 5 to 20% by weight of polybutylene terephthalate,
Intrinsic viscosity of the polyethylene terephthalate of the first filament is 0.6 ~ 0.7 and inherent viscosity of the polybutylene terephthalate is 0.7 ~ 0.8,
The intertwined spinning is the first filament and the second filament is blended and spun at 85 to 95: 5 to 15% by weight,
A method for producing a spunbonded nonwoven fabric for carpet foam having excellent moldability according to claim 1.

delete

The method according to claim 7,
The method for producing a spunbonded nonwoven fabric for carpet foam, characterized in that the blended yarn spun yarn spun at a spinning speed of 4500 ~ 5000 m / min.

The method according to claim 11,
The elongated blended yarn has a fineness of 4 ~ 10 denier, characterized in that the manufacturing method of the spunbonded nonwoven fabric for carpet foam excellent.

The method according to claim 7,
The heat-bonding temperature is the same as the melting temperature of the polyester resin of the second filament, characterized in that the manufacturing method of the spunbonded nonwoven fabric for carpet foam excellent.