TWI829062B - Spunbond non-woven, carpet comprising the same and manufacturing method thereof - Google Patents
Spunbond non-woven, carpet comprising the same and manufacturing method thereof Download PDFInfo
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- nonwoven fabric
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 28
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 124
- 239000000463 material Substances 0.000 claims abstract description 33
- 238000000034 method Methods 0.000 claims description 47
- 239000000835 fiber Substances 0.000 claims description 45
- 239000002131 composite material Substances 0.000 claims description 34
- 238000009987 spinning Methods 0.000 claims description 33
- 238000002844 melting Methods 0.000 claims description 29
- 230000008018 melting Effects 0.000 claims description 29
- 229920000728 polyester Polymers 0.000 claims description 27
- 229920001577 copolymer Polymers 0.000 claims description 24
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 21
- 229920000642 polymer Polymers 0.000 claims description 11
- 238000007655 standard test method Methods 0.000 claims description 11
- -1 polyethylene terephthalate Polymers 0.000 claims description 10
- 238000010030 laminating Methods 0.000 claims description 6
- 239000000155 melt Substances 0.000 claims description 6
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 4
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 4
- 239000002994 raw material Substances 0.000 claims description 4
- 229920000098 polyolefin Polymers 0.000 claims description 3
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 2
- KKEYFWRCBNTPAC-UHFFFAOYSA-L terephthalate(2-) Chemical compound [O-]C(=O)C1=CC=C(C([O-])=O)C=C1 KKEYFWRCBNTPAC-UHFFFAOYSA-L 0.000 claims description 2
- 239000004816 latex Substances 0.000 abstract description 29
- 229920000126 latex Polymers 0.000 abstract description 29
- 239000000126 substance Substances 0.000 abstract description 4
- 239000011230 binding agent Substances 0.000 description 34
- 239000011159 matrix material Substances 0.000 description 17
- 230000000052 comparative effect Effects 0.000 description 14
- 238000009732 tufting Methods 0.000 description 14
- 239000004800 polyvinyl chloride Substances 0.000 description 12
- 229920000915 polyvinyl chloride Polymers 0.000 description 11
- 239000000047 product Substances 0.000 description 9
- 238000005520 cutting process Methods 0.000 description 8
- 238000000576 coating method Methods 0.000 description 6
- 239000004744 fabric Substances 0.000 description 6
- 238000010438 heat treatment Methods 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
- 238000000465 moulding Methods 0.000 description 5
- 231100000331 toxic Toxicity 0.000 description 5
- 230000002588 toxic effect Effects 0.000 description 5
- 229920001410 Microfiber Polymers 0.000 description 4
- 239000003517 fume Substances 0.000 description 4
- 238000002347 injection Methods 0.000 description 4
- 239000007924 injection Substances 0.000 description 4
- 206010033307 Overweight Diseases 0.000 description 3
- 239000004743 Polypropylene Substances 0.000 description 3
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 238000003490 calendering Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 239000012855 volatile organic compound Substances 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000010276 construction Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000007730 finishing process Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 1
- 229920002292 Nylon 6 Polymers 0.000 description 1
- 238000012356 Product development Methods 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 239000005038 ethylene vinyl acetate Substances 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 238000000691 measurement method Methods 0.000 description 1
- 238000002074 melt spinning Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000003658 microfiber Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000010899 nucleation Methods 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 231100000614 poison Toxicity 0.000 description 1
- 238000004080 punching Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 229920005989 resin Polymers 0.000 description 1
- 239000011347 resin Substances 0.000 description 1
- 239000000779 smoke Substances 0.000 description 1
- 239000003440 toxic substance Substances 0.000 description 1
- 238000003911 water pollution Methods 0.000 description 1
Classifications
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- 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
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)
Abstract
Description
本申請案主張於2020年12月30日提出申請的韓國專利申請案第10-2020-0187594號及於2021年12月28日提出申請的韓國專利申請案第10-2021-0189932號的權益，所述韓國專利申請案的揭露內容全文併入本案供參考。 This application claims the rights and interests of Korean Patent Application No. 10-2020-0187594, which was filed on December 30, 2020, and Korean Patent Application No. 10-2021-0189932, which was filed on December 28, 2021. The full text of the disclosures in the Korean patent application is incorporated into this case for reference.
本揭露是有關於一種用於適合於用作車地板材料的地毯的紡絲黏合不織布以及一種所述紡絲黏合不織布的製造方法。 The present disclosure relates to a spun-bonded nonwoven fabric for a carpet suitable for use as a car floor material and a method of manufacturing the spun-bonded non-woven fabric.
地毯是用於家庭、公共機構、酒店、餐館、汽車等的地板內飾產品，且被用於裝飾、用於達成舒適性、用於達成聲音吸收及用於達成行走方便性(緩衝(cushion))。 Carpets are floor interior products used in homes, public institutions, hotels, restaurants, automobiles, etc., and are used for decoration, comfort, sound absorption, and walking convenience (cushion). ).
現有的地毯結構由地毯紗線(膨鬆連續細絲(Bulky Continuous Filament，BCF)紗線(絨頭(pile)))、底布(不織布)、 乳膠及聚氯乙烯(polyvinyl chloride，PVC)(橡膠、乙烯乙酸乙烯酯(ethylene-vinyl acetate，EVA)等)構成。 The existing carpet structure consists of carpet yarn (Bulky Continuous Filament (BCF) yarn (pile)), base fabric (non-woven fabric), Made of latex and polyvinyl chloride (PVC) (rubber, ethylene-vinyl acetate (EVA), etc.).
其中，乳膠及PVC材料在於經簇絨底布(tufted base fabric)(不織布)上塗佈及整理地毯紗線的製程中產生有毒煙霧，且在成品中，其屬於車地板內飾產品組且會產生污染室內空氣品質的揮發性有毒煙霧。 Among them, latex and PVC materials produce toxic fumes during the process of coating and finishing carpet yarns on tufted base fabric (non-woven fabric), and in the finished product, they belong to the car floor interior product group and will Produces volatile toxic fumes that pollute indoor air quality.
即，在地毯構造中，乳膠塗佈製程及PVC層是最經常釋放出揮發性有害物質的層。此外，在用於製造地毯的後整理步驟(post-finishing step)中，存在一個問題，即在塗佈PVC層並對其進行固化的製程中會釋放大量有害物質。 That is, in carpet construction, the latex coating process and the PVC layer are the layers that most often release volatile harmful substances. Furthermore, in the post-finishing step used to manufacture carpets, there is a problem that a large amount of harmful substances are released during the process of applying the PVC layer and curing it.
因此，世界各地已加強對空氣品質的規定，且產品開發正在朝著不使用乳膠及PVC材料的方向進行。 As a result, air quality regulations have been tightened around the world, and product development is moving toward eliminating the use of latex and PVC materials.
然而，尚未開發出在滿足對空氣品質的嚴格規定的同時具有優異的功能性(例如不織布的拔出強度(pullout strength))的產品。 However, products that have excellent functionality (such as pullout strength of nonwoven fabrics) while meeting strict regulations on air quality have not yet been developed.
本揭露的一個目的是提供一種用於地毯的紡絲黏合不織布以及一種所述紡絲黏合不織布的製造方法，所述紡絲黏合不織布可不使用乳膠及PVC材料、而是使用具有優異功能性的用作乳膠層的不織布將地毯紗線穩定地固定至不織布。 An object of the present disclosure is to provide a spun-bonded non-woven fabric for carpets and a manufacturing method of the spun-bonded non-woven fabric. The spun-bonded non-woven fabric may not use latex and PVC materials, but use materials with excellent functionality. The non-woven fabric used as the latex layer stably fixes the carpet yarns to the non-woven fabric.
本揭露的另一目的是提供一種用於地毯的紡絲黏合不織布以及一種所述紡絲黏合不織布的製造方法，由於藉由消除乳膠及PVC材料而不產生揮發性有毒煙霧，因此所述紡絲黏合不織布是環境友好的。 Another object of the present disclosure is to provide a spun-bonded non-woven fabric for carpets and a manufacturing method of the spun-bonded non-woven fabric. Since no volatile toxic fumes are produced by eliminating latex and PVC materials, the spun-bonded non-woven fabric Bonded nonwovens are environmentally friendly.
根據一個實施例，提供一種紡絲黏合不織布，所述紡絲黏合不織布包括自***型複合細絲(split-type conjugate filament)形成的纖維網，***型複合細絲包含60重量%至80重量%的聚酯細絲及20重量%至40重量%的共聚物細絲，聚酯細絲具有為250℃或大於250℃的熔點，共聚物細絲具有為170℃或小於170℃的熔點，其中所述紡絲黏合不織布具有根據以下方程式1的為50%或大於50%的***率(splitting rate)，且如根據KS K 0521的標準測試方法量測，具有為18千克力/5公分或大於18千克力/5公分的室溫強度(room-temperature strength)、為4.0千克力/3公分或小於4.0千克力/3公分的熱強度(hot strength)以及為80%或大於80%的熱伸長率(hot elongation)。 According to one embodiment, a spun-bonded non-woven fabric is provided. The spun-bonded non-woven fabric includes a fiber web formed from split-type conjugate filament, and the split-type conjugate filament contains 60% to 80% by weight. Polyester filaments and 20% to 40% by weight of copolymer filaments, the polyester filaments have a melting point of 250°C or greater than 250°C, and the copolymer filaments have a melting point of 170°C or less, wherein The spunbond nonwoven fabric has a splitting rate (splitting rate) of 50% or greater according to Equation 1 below, and has a splitting rate of 18 kgf/5 cm or greater as measured according to the standard test method of KS K 0521 Room-temperature strength of 18 kgf/5cm, hot strength of 4.0kgf/3cm or less, and thermal elongation of 80% or more Rate (hot elongation).
[方程式1]***率(%)=(***細絲數目)/(***細絲數目+未***細絲數目)×100 [Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100
(在方程式1中，***細絲數目及未***細絲數目是在利用 顯微鏡(掃描電子顯微鏡(Scanning Electron Microscope，SEM))以x200的放大率拍攝的所述不織布的橫截面的相片中觀察到的***細絲數目及未***細絲數目，且***率代表10張相片的平均值)。 (In Equation 1, the number of split filaments and the number of unsplit filaments are calculated using The number of split filaments and the number of unsplit filaments observed in photos of the cross-section of the nonwoven fabric taken with a microscope (Scanning Electron Microscope, SEM) at a magnification of x200, and the splitting rate represents 10 photos average of).
根據另一實施例，提供一種用於製造紡絲黏合不織布的方法，所述方法包括以下步驟：藉由多重***型(multi-split type)紡絲噴嘴對60重量%至80重量%的聚酯細絲及20重量%至40重量%的共聚物細絲進行紡絲及拉伸，以製備***型複合細絲，聚酯細絲具有為250℃或大於250℃的熔點，共聚物細絲具有為170℃或小於170℃的熔點以及為15克/10分鐘~25克/10分鐘的熔體指數(melt index，MI)(ASTM 1238，190℃)；對複合細絲進行層疊以形成纖維網；對纖維網進行熱黏合；以及對經熱黏合網中的細絲進行多重***，其中在對經熱黏合網中的細絲進行多重***的步驟之後，根據以下方程式1的***率為50%或大於50%。 According to another embodiment, a method for manufacturing a spunbonded nonwoven fabric is provided, the method comprising the following steps: spinning 60% to 80% by weight of polyester through a multi-split type spinning nozzle. The filaments and 20% to 40% by weight of the copolymer filaments are spun and stretched to prepare split type composite filaments, the polyester filaments have a melting point of 250°C or greater than 250°C, and the copolymer filaments have A melting point of 170°C or less and a melt index (MI) of 15 g/10 minutes to 25 g/10 minutes (ASTM 1238, 190°C); the composite filaments are laminated to form a fiber web ; thermally bonding the fiber web; and performing multiple splitting of the filaments in the thermally bonded web, wherein after the step of multiplely splitting the filaments in the thermally bonded web, the splitting rate is 50% according to Equation 1 below or greater than 50%.
[方程式1]***率(%)=(***細絲數目)/(***細絲數目+未***細絲數目)×100 [Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100
(在方程式1中，***細絲數目及未***細絲數目是在利用顯微鏡(SEM)以x200放大率拍攝的所述不織布的橫截面的相片 中觀察到的***細絲數目及未***細絲數目，且***率代表10張相片的平均值)。 (In Equation 1, the number of split filaments and the number of unsplit filaments are photographs of the cross-section of the nonwoven fabric taken using a microscope (SEM) at x200 magnification The number of split filaments and the number of unsplit filaments observed in , and the splitting rate represents the average of 10 photos).
根據又一實施例，提供一種包括所述紡絲黏合不織布的地毯。 According to yet another embodiment, a carpet including the spunbonded nonwoven fabric is provided.
在下文中，將詳細闡述根據本揭露實施例的一種地毯以及一種所述地毯的製造方法。 In the following, a carpet and a manufacturing method of the carpet according to embodiments of the present disclosure will be explained in detail.
在說明之前，除非在本說明書通篇中另有指定，否則本文中所使用的技術用語僅用於提及具體實施例，且不旨在限制本揭露。 Prior to description, unless otherwise specified throughout this specification, technical terms used herein are only used to refer to specific embodiments and are not intended to limit the disclosure.
除非上下文另有清楚規定，否則本文中所使用的單數形式「一(a、an)」及「所述(the)」包括複數引用。 As used herein, the singular forms "a," "an," and "the" include plural references unless the context clearly dictates otherwise.
本文中所使用的用語「包含(including)」或包括「(comprising)」指定特定特徵、區、整數、步驟、動作、元件及/或組件，但不排除不同的特定特徵、區、整數、步驟、動作、元件、組件及/或群組的存在或添加。 As used herein, the terms "including" or "comprising" designate specific features, regions, integers, steps, actions, elements and/or components, but do not exclude different specific features, regions, integers, steps. , actions, elements, components and/or groups.
此外，包括例如「第一(first)」、「第二(second)」等序數的用語僅用於將一個組件與另一組件區分開的目的，而不受序數的限制。舉例而言，在不背離本揭露的範圍的情況下，第一組件可被稱為第二組件，或者相似地，第二組件可被稱為第一組件。 In addition, terms including ordinal numbers such as "first", "second", etc. are used only for the purpose of distinguishing one component from another component and are not limited by ordinal numbers. For example, a first component could be termed a second component, or, similarly, a second component could be termed a first component, without departing from the scope of the present disclosure.
現在，將詳細闡述本揭露。 Now, this disclosure will be elaborated in detail.
根據本揭露的一個實施例，可提供一種紡絲黏合不織布， 所述紡絲黏合不織布包括：自***型複合細絲形成的纖維網，***型複合細絲包含60重量%至80重量%的聚酯細絲及20重量%至40重量%的共聚物細絲，聚酯細絲具有為250℃或大於250℃的熔點，共聚物細絲具有為170℃或小於170℃的熔點，其中如根據KS K 0521的標準測試方法量測，所述紡絲黏合不織布具有為18千克力/5公分或大於18千克力/5公分的室溫強度、為4.0千克力/3公分或小於4.0千克力/3公分的熱強度以及為80%或大於80%的熱伸長率。 According to an embodiment of the present disclosure, a spunbonded nonwoven fabric can be provided, The spin-bonded nonwoven fabric includes: a fiber web formed from self-splitting composite filaments. The splitting composite filaments include 60% to 80% by weight of polyester filaments and 20% to 40% by weight of copolymer filaments. , the polyester filaments have a melting point of 250°C or greater, and the copolymer filaments have a melting point of 170°C or less, wherein the spin-bonded nonwoven fabric is as measured according to the standard test method of KS K 0521 Having a room temperature strength of 18 kgf/5cm or greater, a thermal strength of 4.0kgf/3cm or less, and a thermal elongation of 80% or greater Rate.
基於由本發明者進行的持續研究的結果，證實了當使用由基質(matrix)的***纖維以及具有特定含量比及不同熔點的黏結劑材料構成的複合纖維時，即使在不經過乳膠及PVC材料的塗佈製程的情況下，亦可使用能夠表現出乳膠及PVC層功能的不織布來連續地製造地毯。 Based on the results of continuous research conducted by the present inventors, it was confirmed that when composite fibers composed of split fibers of a matrix and binder materials with specific content ratios and different melting points are used, even without passing through latex and PVC materials In the case of coating processes, non-woven fabrics that can exhibit the functions of latex and PVC layers can also be used to continuously manufacture carpets.
因此，本揭露具有以下特徵：製造一種包括現有的地毯構造中的乳膠材料的功能的不織布，藉此提供一種不具有乳膠層的地毯。 Therefore, the present disclosure has the following features: producing a nonwoven fabric that includes the function of latex material in existing carpet construction, thereby providing a carpet without a latex layer.
具體而言，在現有的地毯層中，乳膠材料用於固定地毯紗線(BCF紗線)。然而，由於乳膠材料會引起環境問題，因此本揭露試圖製造一種包括乳膠層的作用的用於地毯的不織布，所述不織布是藉由在不使用單獨的乳膠材料的情況下增加具有所述不織布的地毯紗線的功能(拔出強度)而製造。 Specifically, in existing carpet layers, latex materials are used to secure carpet yarns (BCF yarns). However, since latex materials can cause environmental problems, the present disclosure attempts to create a non-woven fabric for carpets that includes the function of a latex layer by adding the non-woven fabric with the non-woven fabric without using a separate latex material. Manufactured for the performance of carpet yarns (pull-out strength).
因此，由於在地毯的生產期間消除乳膠塗佈製程，因此 不會產生有毒煙霧，且可減少成品的揮發性有機化合物(Volatile Organic Compound，VOC)(揮發性有毒物質)，以使得當用作車地板內飾材料時，其可在環境友好的同時進行使用。 Therefore, since the latex coating process is eliminated during the production of carpets, It does not produce toxic fumes and can reduce Volatile Organic Compound (VOC) (volatile toxic substances) in the finished product, so that it can be used while being environmentally friendly when used as car floor interior materials. .
根據本揭露的不織布具有以下特徵：所述不織布是一種紡絲黏合不織布，所述紡絲黏合不織布包括：自***型複合細絲形成的纖維網，所述***型複合細絲含有60重量%至80重量%的聚酯細絲及20重量%至40重量%的共聚物細絲，聚酯細絲具有為250℃或大於250℃的熔點，共聚物細絲具有為170℃或小於170℃的熔點。 The non-woven fabric according to the present disclosure has the following characteristics: the non-woven fabric is a spun-bonded non-woven fabric, the spun-bonded non-woven fabric includes: a fiber web formed from self-splitting composite filaments, the split-type composite filaments contain 60% by weight to 80% by weight of polyester filaments and 20% to 40% by weight of copolymer filaments, the polyester filaments having a melting point of 250°C or greater, and the copolymer filaments having a melting point of 170°C or less melting point.
具體而言，使用具有為250℃或大於250℃的熔點的聚酯細絲作為基質材料且使用具有為170℃或小於170℃的熔點的共聚物細絲作為黏結劑材料，所述不織布可被形成為可***型(splittable type)。 Specifically, using polyester filaments having a melting point of 250° C. or more as the matrix material and using copolymer filaments having a melting point of 170° C. or less as the binder material, the nonwoven fabric may be Formed into a splittable type.
如本文中所使用的***纖維具有多重***橫截面形狀，且意味著端視用於生產超細纖維(ultrafine fiber)的方法而定，所述兩種類型的聚合物及多重***型紡絲噴嘴被用於將所述兩種類型的聚合物製作成超細纖維，且單一纖維的內部橫截面包括多重***型(multiple splitting type)。因此，***纖維不具有僅由圓形形狀組成的橫截面。舉例而言，多重***橫截面形狀可在單一組分纖維內部包括8至64個***纖維、或16至32個***纖維或者32個***纖維。 Split fiber as used herein has a multiple split cross-sectional shape and means that depending on the method used to produce ultrafine fibers, the two types of polymers and multiple split spinning nozzles The two types of polymers are used to make ultrafine fibers, and the internal cross-section of a single fiber includes multiple splitting types. Therefore, split fibers do not have a cross-section consisting solely of circular shapes. For example, a multi-split cross-sectional shape may include 8 to 64 split fibers, or 16 to 32 split fibers, or 32 split fibers within a single component fiber.
因此，由於不織布指定基質與黏結劑材料的混合比，且 使用包括8至64個***纖維的複合細絲，因此可在無乳膠材料的情況下賦予乳膠層的功能性。 Therefore, since nonwovens specify the mixing ratio of matrix and binder materials, and Composite filaments consisting of 8 to 64 split fibers are used, thus imparting the functionality of the latex layer without the latex material.
具體而言，黏結劑材料在用於製造地毯的後整理(簇絨、熱處理、背襯(backing)及模製(molding))步驟中熔融，且用於表現出高的黏接劑伸長率及模製效能，以使得其可起到乳膠層的作用。 Specifically, the binder material is melted during the finishing (tufting, heat treatment, backing and molding) steps used to manufacture carpets and is used to exhibit high binder elongation and Molding efficiency so that it can act as a latex layer.
即，用作黏結劑材料的聚合物的作用是在簇絨製程之後在對簇絨的背表面的熱處理期間熔融，且用作地毯紗線(BCF紗線)與底布(不織布)之間的黏接劑。此外，在用於製造成車地毯的最終模製製程中，黏結劑聚合物在180℃~200℃的高溫環境中處於即將熔融的狀態，且其起到表現出高伸長率的作用，藉此使得能夠進行模製。 That is, the polymer used as the binder material functions to be melted during the heat treatment of the back surface of the tufts after the tufting process and serves as a bond between the carpet yarns (BCF yarns) and the base fabric (nonwoven fabric) Adhesive. In addition, in the final molding process for manufacturing finished car carpets, the binder polymer is in a state of melting in a high temperature environment of 180°C to 200°C, and it plays a role in exhibiting high elongation, thereby Enables molding.
此時，當黏結劑的含量為19重量%或小於19重量%時，難以形成***纖維形狀(黏結劑聚合物可能無法被擠出，或者其可能由於不均勻的紡絲壓力而向一側移位)，且形成所述不織布的細絲之間的黏合力不足，因此在後整理製程中容易被破壞。若***纖維形狀不均勻，則所述不織布的物理性質可能會根據位置而發生偏差，此可能會在後整理及模製製程中導致撕裂(tearing)及低拔出強度值。 At this time, when the binder content is 19% by weight or less, it is difficult to form a split fiber shape (the binder polymer may not be extruded, or it may move to one side due to uneven spinning pressure position), and the adhesion between the filaments forming the non-woven fabric is insufficient, so it is easily damaged during the finishing process. If the shape of the split fibers is uneven, the physical properties of the nonwoven fabric may vary depending on their location, which may lead to tearing and low pull-out strength values during finishing and molding processes.
此外，當黏結劑的含量為41重量%或大於41重量%時，在用於在180℃或大於180℃的溫度下製造地毯的後整理製程中用作支撐件的基質組分不足，此會增加在高溫下熔融的黏結劑材料 的量，且因此由於外力導致形狀變形(收縮率、伸長率)，且最終，不可能進行後整理。 In addition, when the content of the binder is 41% by weight or more, the matrix component used as a support member in the finishing process for manufacturing carpets at a temperature of 180°C or more is insufficient, which may cause Increased binder material that melts at high temperatures amount, and therefore shape deformation (shrinkage, elongation) due to external forces, and ultimately, post-finishing is impossible.
此外，當黏結劑原料的熔點為170℃或大於170℃時，黏結劑原料在所述不織布必須表現出賦予強度、黏接性及高伸長率的作用的加工溫度下不熔融，且因此其無法用作黏結劑細絲。 In addition, when the melting point of the binder raw material is 170°C or greater, the binder raw material does not melt at the processing temperature at which the nonwoven fabric must exhibit the effect of imparting strength, adhesion and high elongation, and therefore it cannot Used as adhesive filament.
此外，所述細絲可包括具有在進行***之前為22微米至31微米的平均直徑以及為5.0丹尼至9.0丹尼的細度的***纖維。更具體而言，***纖維可具有在進行***之前為22微米至31微米的平均直徑以及為5.0丹尼至9.0丹尼的細度。另外，在進行***之前的複合細絲的橫截面可為被劃分成8份至64份的圓形形狀或球形形狀。 Furthermore, the filaments may include split fibers having an average diameter before splitting of 22 to 31 microns and a fineness of 5.0 to 9.0 denier. More specifically, the split fibers may have an average diameter before splitting of 22 to 31 microns and a fineness of 5.0 to 9.0 denier. In addition, the cross section of the composite filament before being split may be a circular shape or a spherical shape divided into 8 to 64 parts.
當複合細絲的橫截面形狀是圓形橫截面而非可***形狀時，必須另外對黏結劑細絲進行紡絲，且必須對基質細絲與所述黏結劑細絲進行混合以形成網。此時，當所述細絲被混合時，均勻性受到限制，且因此會產生無黏結劑細絲的部分。黏結劑細絲是用於表達所述不織布的抗拉強度(tensile strength)的一個因素，且抗拉強度可根據黏結劑細絲的黏合的存在/不存在來確定。然而，在圓形橫截面形式中，如上所述產生了無黏結劑細絲的部分，此可能會降低強度及伸長率，且亦會降低拔出強度。 When the cross-sectional shape of the composite filaments is a circular cross-section rather than a splittable shape, the binder filaments must be additionally spun, and the matrix filaments and the binder filaments must be mixed to form a mesh. At this time, when the filaments are mixed, the uniformity is limited, and thus portions without binder filaments are produced. Binder filaments are one factor used to express the tensile strength of the nonwoven fabric, and the tensile strength can be determined based on the presence/absence of bonding of the binder filaments. However, in the circular cross-section form, as described above, a portion without adhesive filaments is created, which may reduce strength and elongation, and also reduce pullout strength.
此外，根據本揭露的所述不織布具有根據以下方程式1的為50%或大於50%、54%或大於54%或者56%或大於56%的***率。 Furthermore, the nonwoven fabric according to the present disclosure has a splitting rate of 50% or more, 54% or more, or 56% or more according to the following Equation 1.
[方程式1]***率(%)=(***細絲數目)/(***細絲數目+未***細絲數目)×100 [Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100
(在方程式1中，***細絲數目及未***細絲數目是在利用顯微鏡(SEM)以x200放大率拍攝的所述不織布的橫截面的相片中觀察到的***細絲數目及未***細絲數目，且***率代表10張相片的平均值)。 (In Equation 1, the number of split filaments and the number of unsplit filaments are the number of split filaments and the number of unsplit filaments observed in a photograph of the cross-section of the nonwoven fabric taken with a microscope (SEM) at x200 magnification number, and the split rate represents the average of 10 photos).
可以各種方式調節用於量測所述***率的具有所述不織橫截面的測試件。舉例而言，可使用具有為3毫米×3毫米的尺寸的不織測試件。 The test piece with the nonwoven cross-section used to measure the splitting rate can be adjusted in various ways. For example, a nonwoven test piece with dimensions of 3 mm x 3 mm may be used.
當***率小於50%時，黏結劑聚合物的黏接面積低，且因此黏結劑不足，此可能導致所述不織布的機械性質及拔出強度劣化。 When the splitting rate is less than 50%, the bonding area of the binder polymer is low, and therefore the binder is insufficient, which may cause the mechanical properties and pull-out strength of the nonwoven fabric to deteriorate.
用作基質材料的聚酯細絲可包含選自由聚對苯二甲酸乙二醇酯、聚對苯二甲酸丁二醇酯、聚對苯二甲酸萘酯及其回收原料組成的群組的至少一種聚酯聚合物。 The polyester filaments used as the matrix material may include at least one selected from the group consisting of polyethylene terephthalate, polybutylene terephthalate, polynaphthyl terephthalate and recycled raw materials. A polyester polymer.
所述聚酯細絲可包含具有為0.60分升/克(dl/g)至0.90分升/克的固有黏度(intrinsic viscosity，IV)以及為250℃或大於250℃的熔點的聚酯聚合物。 The polyester filaments may include a polyester polymer having an intrinsic viscosity (IV) of 0.60 deciliter/gram (dl/g) to 0.90 dl/g and a melting point of 250°C or greater. .
作為黏結劑材料，使用具有為170℃或小於170℃的熔點以及為15克/10分鐘至25克/10分鐘的熔體指數(MI)(ASTM 1238，190℃)的共聚物細絲。 As the binder material, a copolymer filament having a melting point of 170°C or less and a melt index (MI) (ASTM 1238, 190°C) of 15 to 25 g/10 min is used.
具體而言，所述共聚物細絲可為選自由具有為170℃或小於170℃的熔點以及為15克/10分鐘至25克/10分鐘的熔體指數(MI)(ASTM 1238，190℃)的聚烯烴組成的群組的至少一者。所述聚烯烴可為聚乙烯或聚丙烯。 Specifically, the copolymer filaments may be selected from the group consisting of having a melting point of 170°C or less and a melt index (MI) of 15 g/10 min to 25 g/10 min (ASTM 1238, 190°C ) at least one of the group consisting of polyolefins. The polyolefin may be polyethylene or polypropylene.
如本文中所使用的MI(熔體指數)意指根據ASTM 1238在190℃下量測的值。 MI (Melt Index) as used herein means the value measured at 190°C according to ASTM 1238.
根據此種方法提供的所述不織布具有優異的細絲間黏接性、優異的地毯紗線的可固定性，且亦可相較於常規情形而言改善伸長率。此外，由於所述不織布用作用於地毯的底布，因此其可改善最終產品的拔出強度，且此外，其不使用對人體有害的乳膠及PVC材料，藉此能夠提供環境友好的材料。 The nonwoven fabric provided by this method has excellent adhesion between filaments, excellent fixability of carpet yarns, and can also improve elongation compared to conventional situations. In addition, since the non-woven fabric is used as a base fabric for carpets, it can improve the pull-out strength of the final product, and in addition, it does not use latex and PVC materials that are harmful to the human body, thereby providing an environmentally friendly material.
根據本揭露的實施例，如根據KS K 0521的標準測試方法量測，所述不織布可同時滿足具有為18千克力/5公分或大於18千克力/5公分的室溫強度、為4.0千克力/3公分或小於4.0千克力/3公分的熱強度以及為80%或大於80%的熱伸長率的物理性質。更具體而言，由於所述不織布被構造成使得上述***率為54%或大於54%，因此強度及伸長率可被進一步最佳化。因此，如根據KS K 0521的標準測試方法量測，所述不織布可具有為19千克力/5公分或大於19千克力/5公分的室溫強度、為3.0千克力/3公分或小於3.0千克力/3公分的熱強度以及為81%或大於81%的熱伸長率。 According to embodiments of the present disclosure, as measured according to the standard test method of KS K 0521, the non-woven fabric can simultaneously meet the requirements of having a room temperature strength of 18 kgf/5 cm or greater than 18 kgf/5 cm and a room temperature strength of 4.0 kgf /3 cm or less than 4.0 kgf/3 cm of thermal strength and thermal elongation of 80% or greater than 80% of the physical properties. More specifically, since the nonwoven fabric is configured such that the above-mentioned splitting rate is 54% or greater, the strength and elongation can be further optimized. Therefore, as measured according to the standard test method of KS K 0521, the nonwoven fabric may have a room temperature strength of 19 kgf/5cm or greater, and a room temperature strength of 3.0kgf/3cm or less than 3.0kg force/3cm and a thermal elongation of 81% or greater.
當每單位面積重量為90克/平方米時，所述不織布可為 具有為225克/立方公分至310克/立方公分的表觀密度(apparent density)的紡絲黏合不織布。 When the weight per unit area is 90 grams/square meter, the non-woven fabric can be Spun bonded nonwoven fabric having an apparent density of 225 g/cm3 to 310 g/cm3.
此外，根據本揭露的紡絲黏合不織布可改善地毯的拔出強度。因此，基於KS K ISO 4919的標準測試方法，根據本揭露的地毯具有為2.0(千克力)或大於2.0(千克力)的拔出強度，且可用作車地板材料。 In addition, the spunbonded nonwoven fabric according to the present disclosure can improve the pull-out strength of the carpet. Therefore, based on the standard test method of KS K ISO 4919, the carpet according to the present disclosure has a pull-out strength of 2.0 (kilogram force) or greater than 2.0 (kilogram force), and can be used as a car floor material.
另一方面，根據本揭露的另一實施例，可提供一種用於製造紡絲黏合不織布的方法，所述方法包括以下步驟：藉由多重***型紡絲噴嘴對60重量%至80重量%的聚酯細絲及20重量%至40重量%的共聚物細絲進行紡絲及拉伸，以製備***型複合細絲，聚酯細絲具有為250℃或大於250℃的熔點，共聚物細絲具有為170℃或小於170℃的熔點以及為15克/10分鐘~25克/10分鐘的MI(熔體指數)(ASTM 1238，190℃)；對複合細絲進行層疊以形成纖維網；對纖維網進行熱黏合；以及對經熱黏合網中的細絲進行多重***。 On the other hand, according to another embodiment of the present disclosure, a method for manufacturing a spun-bonded nonwoven fabric may be provided, the method including the following steps: spinning 60% to 80% by weight of Polyester filaments and 20% to 40% by weight of copolymer filaments are spun and stretched to prepare split composite filaments. The polyester filaments have a melting point of 250°C or greater than 250°C, and the copolymer filaments are fine The filaments have a melting point of 170°C or less and an MI (melt index) of 15 g/10 minutes to 25 g/10 minutes (ASTM 1238, 190°C); the composite filaments are laminated to form a fiber web; Thermal bonding of the fiber web; and the multiple splitting of the filaments in the thermally bonded web.
根據本揭露的用於地毯的紡絲黏合不織布包括藉由在特定條件下對作為基質的聚酯細絲與作為黏結劑的具有特定熔點及MI的共聚物細絲進行複合紡絲而具有可***形狀的纖維網，且是藉由紡絲黏合方法來生產。 The spun-bonded nonwoven fabric for carpets according to the present disclosure includes splitting properties by composite spinning polyester filaments as a matrix and copolymer filaments with a specific melting point and MI as a binder under specific conditions. Shape fiber web, and is produced by spinning bonding method.
在所述紡絲黏合方法中，聚酯及共聚物各自獨立地藉由一個複合紡絲噴嘴來進行熔融、紡絲及拉伸，所述一個複合紡絲噴嘴可調節不同種類的樹脂的排出孔的數目且以多重***橫截面 形狀進行紡絲，藉此能夠獲得複合細絲。 In the spin bonding method, polyester and copolymer are each independently melted, spun and stretched through a composite spinning nozzle that can adjust the discharge holes of different types of resins number and split cross-sections in multiple By spinning into a shape, composite filaments can be obtained.
此外，所述紡絲黏合不織布的製造方法可使用連續擠出機來進行，且因此機械性質及***率優異，此使得可連續地製造有效地改善地毯的拔出強度的不織布。 In addition, the manufacturing method of the spunbonded nonwoven fabric can be performed using a continuous extruder, and therefore has excellent mechanical properties and splitting rate, which enables continuous manufacturing of a nonwoven fabric that effectively improves the pull-out strength of carpets.
具體而言，製備聚酯(基質)及共聚物(黏結劑)，然後將其裝入至連續擠出機中，對其進行加熱及熔融，且然後藉由多重***型紡絲噴嘴對其進行紡絲。藉由此種製程，所述細絲可包括呈其中單一紗線的內部被***的多重***橫截面形式的***紗線。可藉由調節毛細管數目來使用多重***型紡絲噴嘴，以便具有8至64個***纖維或16至32個***纖維。 Specifically, polyester (matrix) and copolymer (binder) are prepared, then loaded into a continuous extruder, heated and melted, and then processed through multiple split spinning nozzles Spinning. With such a process, the filaments may include split yarns in the form of multiple split cross-sections in which the interior of a single yarn is split. A multi-split spinning nozzle can be used by adjusting the number of capillaries so as to have 8 to 64 split fibers or 16 to 32 split fibers.
此外，在複合熔體紡絲期間，可調節每一紡絲噴嘴上的毛細管數目，以使得經由紡絲噴嘴的基質(聚酯)與黏結劑(共聚物)之間的比率為60重量%至80重量%或20重量%至40重量%。 Furthermore, during composite melt spinning, the number of capillaries on each spinning nozzle can be adjusted so that the ratio between the matrix (polyester) and the binder (copolymer) passing through the spinning nozzle is from 60% by weight to 80% by weight or 20% to 40% by weight.
此處，利用以上針對所述紡絲黏合不織布闡述的內容來取代關於作為基質材料的聚酯細絲及作為黏結劑材料的共聚物細絲的構造的詳細內容。 Here, the details regarding the structures of the polyester filaments as the matrix material and the copolymer filaments as the binder material are replaced by what has been explained above for the spunbonded nonwoven fabric.
此外，可使用連續擠出機提供所述紡絲黏合不織布。 Furthermore, a continuous extruder can be used to provide the spunbond nonwoven fabric.
此外，製備所述複合細絲的步驟可包括調節細度，以使得所述複合細絲在對經熱黏合網中的細絲進行多重***之前具有為22微米至31微米的平均直徑以及為5.0丹尼至9.0丹尼的細度。 Additionally, the step of preparing the composite filaments may include adjusting the fineness such that the composite filaments have an average diameter of 22 to 31 microns and an average diameter of 5.0 before multiple splitting of the filaments in the thermally bonded web. Denier to 9.0 denier fineness.
藉由使用高壓空氣拉伸裝置來調節紡絲速度，以複合紡絲形式紡出的複合細絲被充分拉伸，以使得排出量及紡絲噴嘴毛細管數目可被調節為5.0丹尼至9.0丹尼的水準。 By using a high-pressure air drawing device to adjust the spinning speed, the composite filaments spun in the form of composite spinning are fully stretched so that the discharge volume and the number of spinning nozzle capillaries can be adjusted from 5.0 denier to 9.0 denier. Ni's level.
所述拉伸可在3000米/分鐘至5000米/分鐘的紡絲速度條件下執行。更具體而言，為達成更充分地拉伸，紡絲速度可為4500米/分鐘至5000米/分鐘。當紡絲速度小於3000米/分鐘時，存在的問題是：由於對細絲的拉伸不足，所述不織布在熱黏合步驟中收縮，此亦會影響冷卻效率，且會發生冷卻不足，從而在拉伸製程中導致細絲之間的黏接，從而導致拉伸及開鬆(opening)不良。此外，當紡絲速度為5000米/分鐘或大於5000米/分鐘時，存在的問題是：細絲在拉伸製程中被切割而不形成所述不織布的平面形狀。 The drawing may be performed at a spinning speed of 3000 m/min to 5000 m/min. More specifically, in order to achieve more sufficient drawing, the spinning speed may be 4500 m/min to 5000 m/min. When the spinning speed is less than 3000 meters/minute, the problem is that due to insufficient stretching of the filaments, the non-woven fabric shrinks during the thermal bonding step, which will also affect the cooling efficiency, and insufficient cooling will occur, resulting in The drawing process causes adhesion between filaments, resulting in poor drawing and opening. Furthermore, when the spinning speed is 5000 m/min or greater, there is a problem that the filaments are cut during the drawing process without forming the planar shape of the nonwoven fabric.
形成所述網的步驟以及熱黏合步驟可藉由此項技術中眾所習知的方法藉由所述開鬆來執行。 The step of forming the web and the step of thermal bonding can be performed by the opening by methods well known in the art.
此外，對經熱黏合網中的細絲進行***的步驟可使用射水(water jet)來執行。即，當複合纖維被紡絲成具有多重***橫截面的***纖維且形成為網形式時，其隨後經歷射水(水刺(spun lace))，且***纖維橫截面可被原樣***。 Additionally, the step of splitting the filaments in the thermally bonded web can be performed using a water jet. That is, when the composite fiber is spun into split fibers having multiple split cross-sections and formed into a web form, it is subsequently subjected to water jet (spun lace), and the split fiber cross-sections can be split as they are.
具體而言，將所製備的細絲纖維以網的形式放置於傳送機上，且然後可將所述網的表觀密度調節至225克/立方公分至310克/立方公分。 Specifically, the prepared filament fibers are placed on a conveyor in the form of a web, and the apparent density of the web can then be adjusted to 225 to 310 g/cm3.
在使用壓延輥(calender roll)或熱空氣執行熱黏合步驟 之後，表觀密度已被調節的纖維網通過射水，以將所述細絲***成多重***橫截面形狀。此時，可藉由逐步地調節所述射水的水壓來生產具有為0.31毫米至0.40毫米的厚度的紡絲黏合不織布。 Perform the thermal bonding step using a calender roll or hot air Thereafter, the fiber web whose apparent density has been adjusted is passed through water injection to split the filaments into multiple split cross-sectional shapes. At this time, a spun-bonded nonwoven fabric having a thickness of 0.31 mm to 0.40 mm can be produced by gradually adjusting the water pressure of the water jet.
舉例而言，若藉由高壓射水向已經歷熱黏合製程的不織布施加物理外力，則所述細絲可呈***纖維的形式。即，在此種製程中，形成***纖維的所述兩種類型的聚合物彼此缺乏相容性(親和力)，且最終，聚合物之間的物理黏合可能被破壞且***成微纖維(microfiber)。儘管高壓射水的壓力並無特別限制，然而由於***纖維被***成超細纖維，因此進行水準為50巴至280巴的多級***(multi-stage splitting)以及施加壓力可使所述網的結構更複雜，藉此進一步改善所述不織布的強度。 For example, if physical external force is applied to a nonwoven fabric that has undergone a thermal bonding process by high-pressure water jets, the filaments may take the form of split fibers. That is, in such a process, the two types of polymers that form split fibers lack compatibility (affinity) with each other, and eventually, the physical bond between the polymers may be broken and split into microfibers. . Although the pressure of the high-pressure water jet is not particularly limited, since the split fibers are split into ultrafine fibers, performing multi-stage splitting at a level of 50 bar to 280 bar and applying pressure can change the structure of the mesh. More complex, thereby further improving the strength of the nonwoven fabric.
此外，高壓射水可在所述壓力範圍內分二或更多步施加不同的壓力範圍。根據本揭露的一個實施例，高壓射水可依次被賦予為50巴至80巴的第一級壓力強度、為150巴至280巴的第二級壓力強度及為50巴至80巴的第三級壓力強度。根據如上所述的壓力，調節每一級中的水壓，以使得不僅可調節所述不織布的厚度，而且可使被劃分成所期望水準的***纖維橫截面維持原樣。 In addition, high-pressure water injection can apply different pressure ranges in two or more steps within the pressure range. According to an embodiment of the present disclosure, the high-pressure water jet may be sequentially given a first-stage pressure intensity of 50 bar to 80 bar, a second-stage pressure intensity of 150 bar to 280 bar, and a third stage of 50 bar to 80 bar. Pressure intensity. The water pressure in each stage is adjusted according to the pressure as described above, so that not only the thickness of the nonwoven fabric can be adjusted, but also the split fiber cross-section divided into the desired level can be maintained as it is.
此時，當利用高壓射水施加壓力時，若僅施加一種壓力而不施加多級壓力，則在應用單一高壓射水步驟時，痕跡在機械方向上以條紋(stripe)的形式保留，此可能導致出現重量、厚度及***率不均勻的問題。此外，射水處理步驟越少，則射水噴嘴 及水污染水準受影響越大。 At this time, when applying pressure using high-pressure water jetting, if only one pressure is applied instead of multiple levels of pressure, when a single high-pressure water jetting step is applied, traces will remain in the form of stripes in the machine direction, which may cause Problems with uneven weight, thickness and splitting rate. In addition, the fewer water jet processing steps, the water jet nozzle and water pollution levels will be more affected.
因此，根據本揭露，所述不織布經歷多級射水，由此所述不織布經過多級而被***數次以增加***率，且其可給予如上所述均勻地對細絲進行重新排列的能力。 Therefore, according to the present disclosure, the non-woven fabric undergoes multi-stage water injection, whereby the non-woven fabric is split several times through multiple stages to increase the splitting rate, and it can give the ability to rearrange the filaments uniformly as described above.
在對經熱黏合網中的細絲進行多重***的步驟之後，根據以下方程式1的***率可為50%或大於50%。 After multiple steps of splitting the filaments in the thermally bonded web, the splitting rate according to Equation 1 below may be 50% or greater.
[方程式1]***率(%)=(***細絲數目)/(***細絲數目+未***細絲數目)×100 [Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100
(在方程式1中，***細絲數目及未***細絲數目是在利用顯微鏡(SEM)以x200放大率拍攝的所述不織布的橫截面的相片中觀察到的***細絲數目及未***細絲數目，且***率代表10張相片的平均值)。 (In Equation 1, the number of split filaments and the number of unsplit filaments are the number of split filaments and the number of unsplit filaments observed in a photograph of the cross-section of the nonwoven fabric taken with a microscope (SEM) at x200 magnification number, and the split rate represents the average of 10 photos).
根據以上方法，自具有***纖維形狀的細絲形成的所述紡絲黏合不織布可用作用於生產地毯的底布，在所述***纖維形狀中指定了基質與黏結劑的比率。 According to the above method, the spunbond nonwoven fabric formed from filaments having a split fiber shape in which the ratio of matrix to binder is specified can be used as a backing fabric for the production of carpets.
因此，根據本揭露的另一實施例，可提供一種包括所述紡絲黏合不織布的地毯以及一種用於製造所述地毯的方法。 Therefore, according to another embodiment of the present disclosure, a carpet including the spun-bonded nonwoven fabric and a method for manufacturing the carpet may be provided.
所述地毯可藉由包括簇絨製程及切割製程、使用地毯紗線及紡絲黏合不織布來提供。 The carpet may be provided by including tufting processes and cutting processes, using carpet yarns and spun bonded non-woven fabrics.
具體而言，由於所述地毯的製造方法不像常規方法中一樣進行乳膠及PVC層的塗佈製程，因此不僅可縮短製程，而且不 會產生有害物質，且因此可提供環境友好的產品。 Specifically, since the manufacturing method of the carpet does not involve the coating process of latex and PVC layers as in conventional methods, it can not only shorten the manufacturing process, but also eliminate the need for Harmful substances are produced and therefore environmentally friendly products can be provided.
因此，所述地毯具有固定至所述不織布的一個表面的地毯紗線，且不包含乳膠層。 Thus, the carpet has carpet yarns secured to one surface of the nonwoven fabric and does not include a latex layer.
此外，所述地毯是藉由包括在所述紡絲黏合不織布的一個表面上透過簇絨製程及熱處理製程將地毯紗線固定至不織布的步驟以及對固定至地毯紗線的不織布進行切割的步驟來獲得。 In addition, the carpet is produced by including the steps of fixing the carpet yarn to the non-woven fabric through a tufting process and a heat treatment process on one surface of the spun-bonded non-woven fabric and the step of cutting the non-woven fabric fixed to the carpet yarn. obtain.
此外，在固定地毯紗線的步驟與切割步驟之間可更包括將背襯層層疊於固定至地毯原紗線的不織布上的步驟。 In addition, between the step of fixing the carpet yarns and the cutting step, a step of laminating the backing layer on the non-woven fabric fixed to the original carpet yarns may be further included.
具體而言，可執行藉由簇絨製程在由以上方法提供的所述紡絲黏合不織布的一個表面上將地毯紗線種植於不織布中以及藉由熱處理將所述不織布固定至所述地毯紗線的步驟。 Specifically, planting carpet yarns in the nonwoven fabric by a tufting process on one surface of the spunbonded nonwoven fabric provided by the above method and fixing the nonwoven fabric to the carpet yarns by heat treatment can be performed steps.
此時，將地毯紗線固定至不織布的步驟可包括在簇絨製程之後對經簇絨不織布的背表面進行熱處理。 At this time, the step of fixing the carpet yarns to the nonwoven fabric may include heat treating the back surface of the tufted nonwoven fabric after the tufting process.
可執行簇絨製程、熱處理製程及切割製程，以使得利用已知的方法及設備、使用針將地毯紗線固定至所述不織布的一個表面。此時，可以環(loop)形式在預定隔距(gauge)(例如，64/5隔距)的條件下執行所述簇絨。 The tufting process, the heat treatment process and the cutting process may be performed such that the carpet yarns are secured to a surface of the nonwoven fabric using needles using known methods and equipment. At this time, the tufting may be performed in a loop form under a predetermined gauge (eg, 64/5 gauge).
此外，在簇絨製程中使用的地毯紗線可包括此項技術中眾所習知的BCF紗線。地毯紗線可具有美學功能及緩衝功能，且可具有預定的細度(例如，500丹尼至3000丹尼)及高度(例如，3.0毫米至7毫米)。藉由簇絨製程，地毯紗線被種植成使得其可自所述不織布的一側進行視覺辨別。 Additionally, carpet yarns used in the tufting process may include BCF yarns as are well known in the art. Carpet yarns may have aesthetic and cushioning functions, and may have predetermined fineness (eg, 500 to 3000 denier) and height (eg, 3.0 to 7 mm). Through the tufting process, the carpet yarns are planted so that they are visually discernible from one side of the nonwoven.
對背襯層進行層疊的步驟亦可藉由本領域中眾所習知的方法來執行。具體而言，可將高重量網層疊於背襯層上，且對於所述高重量網，可使用短纖維(staple fiber)或長纖維(long fiber)不織布形式的網。 The step of laminating the backing layer can also be performed by methods well known in the art. Specifically, a high weight web may be laminated on the backing layer, and for the high weight web, a web in the form of staple fiber or long fiber nonwoven fabric may be used.
藉由包括對背襯層進行層疊的步驟的方法，可藉由包括以下步驟來提供所述地毯：藉由簇絨製程在紡絲黏合不織布的一個表面上將地毯紗線種植於不織布中的步驟；藉由對經簇絨不織布的熱處理來對地毯紗線進行固定的步驟；以及對背襯層進行層疊的步驟；以及對經層疊地毯進行切割的步驟。 The carpet may be provided by a method including the step of laminating a backing layer, by seeding the carpet yarns into the nonwoven fabric by a tufting process on one surface of the spun bonded nonwoven fabric. ; The step of fixing the carpet yarns by heat treatment of the tufted nonwoven fabric; the step of laminating the backing layer; and the step of cutting the laminated carpet.
因此，根據本揭露的地毯可被構造成包括紡絲黏合不織布、地毯紗線及背襯層，而不具有乳膠層。 Therefore, carpets in accordance with the present disclosure may be constructed to include a spunbond nonwoven, carpet yarns, and a backing layer without a latex layer.
根據較佳實例，所述不織布在表面上利用為約3000丹尼'/150細絲的環型聚丙烯BCF(膨鬆連續細絲)紗線、以為約64/5隔距的隔距(在簇絨機中，針間距以英吋指示，作為指示針的密度的單位，且經簇絨地毯在寬度方向上的密度由所述隔距決定)及為約13/1的針跡(經簇絨地毯在縱向方向上的密度)經歷簇絨處理(將紗線種植至不織布中的製程)。然後，使用處於約180℃的熱腔室對經簇絨產品的背表面進行熱處理，且最終執行切割製程(標準：50公分×50公分)，以使得可提供地毯。在用於藉由以上方法進行熱處理的地毯的切割步驟之前，可更包括將高重量長纖維或短纖維作為背襯層進行層疊的步驟。 According to a preferred embodiment, the nonwoven fabric utilizes endless polypropylene BCF (bulky continuous filament) yarns of approximately 3000 denier/150 filament on the surface at a gauge of approximately 64/5 (at In tufting machines, the needle spacing is indicated in inches as a unit of needle density, and the density of a tufted carpet in the width direction is determined by the gauge) and is about 13/1 stitch (tufted The density of pile carpet in the longitudinal direction) undergoes tufting (the process of planting yarn into a nonwoven fabric). Then, the back surface of the tufted product is heat treated using a heat chamber at about 180° C., and finally a cutting process (standard: 50 cm × 50 cm) is performed so that a carpet can be provided. Before the cutting step for the carpet heat-treated by the above method, a step of laminating high-weight long fibers or short fibers as a backing layer may be further included.
以此種方式提供的所述地毯具有高效能以及如根據KS K ISO 4919的標準測試方法量測的為約2.0千克力的拔出強度(在環型簇絨之後拔出所述環的強度)，且因此可應用於各種領域中，且具體而言，其可用作車地板內飾材料。 The carpet provided in this way has high performance and as per KS The standard test method of K ISO 4919 measures the pull-out strength (strength of pulling out the ring after ring tufting) of about 2.0 kgf, and can therefore be used in various fields and, in particular, its Can be used as car floor interior material.
根據本揭露，包括能夠在具有優異機械性質的同時用作乳膠材料的紡絲黏合不織布作為底布，且因此消除了乳膠及PVC塗佈製程，由此不會產生有毒煙霧，可減少成品的VOC(揮發性危險性物質)，以使得提供一種能夠用作車地板內飾產品的地毯以及一種所述地毯的製造方法。 According to the present disclosure, a spun-bonded non-woven fabric that can be used as a latex material while having excellent mechanical properties is included as the base fabric, and therefore the latex and PVC coating processes are eliminated, thereby no toxic smoke is generated, and the VOC of the finished product can be reduced (volatile hazardous substances), so as to provide a carpet that can be used as a vehicle floor interior product and a manufacturing method of the carpet.
在下文中，將參照本發明的具體實例更詳細地闡述本發明的作用及效果。然而，該些實例僅是出於例示性目的而呈現，且本發明的範圍不以任何方式受其限制。 Hereinafter, the functions and effects of the present invention will be explained in more detail with reference to specific examples of the present invention. However, these examples are presented for illustrative purposes only, and the scope of the invention is not limited thereto in any way.
製備出了由具有為255℃的熔點的聚對苯二甲酸乙二醇酯(PET)材料製成的基質及由具有為137℃的熔點的聚乙烯材料(MI：20)製成的黏結劑，且然後將其裝入至連續擠出機中，對其進行加熱及熔融，且然後藉由一個紡絲噴嘴對其進行複合紡絲，以使得其成為被劃分成32份的橙狀橫截面(orange cross-section)形式的細絲。此時，調節紡絲噴嘴毛細管數目，以使得經由複合 紡絲噴嘴的基質(聚酯)與黏結劑(共聚物)之間的比率為70重量%：30重量%。 A matrix made of a polyethylene terephthalate (PET) material with a melting point of 255° C. and a binder made of a polyethylene material (MI: 20) with a melting point of 137° C. were prepared. , and then put it into a continuous extruder, heat and melt it, and then perform composite spinning on it through a spinning nozzle, so that it becomes an orange-shaped cross-section divided into 32 parts (orange cross-section) form of filaments. At this time, adjust the number of capillaries in the spinning nozzle so that the The ratio between matrix (polyester) and binder (copolymer) of the spinning nozzle is 70% by weight: 30% by weight.
然後，利用處於15℃的冷卻空氣對經由紡絲噴嘴排出的所述32個***紡絲複合細絲進行了固化，且然後使用高壓空氣拉伸裝置進行了充分拉伸，以使得紡絲速度為5000米/分鐘。由此，製備出了具有為5.0丹尼至9.0丹尼的細度及橙狀橫截面形狀的複合細絲纖維。 Then, the 32 split-spun composite filaments discharged through the spinning nozzle were solidified using cooling air at 15° C., and then fully stretched using a high-pressure air stretching device such that the spinning speed was 5000 meters/minute. Thus, composite filament fibers having a fineness of 5.0 denier to 9.0 denier and an orange cross-sectional shape were prepared.
接下來，藉由常規纖維開鬆方法將所製備的複合細絲纖維以網的形式層疊於連續移動的金屬傳送網上，且然後使用具有平的表面的平輥(flat roll)使其經歷壓延製程(calendering process)，藉此賦予為270克/立方公分的表觀密度。 Next, the prepared composite filament fibers are laminated in the form of a mesh on a continuously moving metal conveyor mesh by a conventional fiber opening method, and then subjected to calendering using a flat roll with a flat surface. The calendering process gives it an apparent density of 270 g/cm3.
在此之後，使已完成壓延製程的不織布通過射水，且壓力以為下(70巴)-上(250巴)-下(50巴)壓力的壓力強度依次施加至所述不織布，由此藉由逐步地調節水壓，不織布的厚度得到了調節，且生產出了最終的紡絲黏合不織布(每單位面積重量：90克/平方米，厚度：0.33毫米)。 After that, the non-woven fabric that has completed the calendering process is passed through the water jet, and the pressure is sequentially applied to the non-woven fabric with a pressure intensity of lower (70 bar) - upper (250 bar) - lower (50 bar) pressure, thereby gradually By carefully adjusting the water pressure, the thickness of the nonwoven fabric was adjusted, and a final spun-bonded nonwoven fabric was produced (weight per unit area: 90 g/m2, thickness: 0.33 mm).
對所生產的不織布進行了簇絨(切割型，64/5英吋隔距，13/1英吋針跡，聚丙烯地毯紗線(BCF)1200丹尼'，絨頭紗線高度4毫米)，且然後在235℃下對簇絨的背表面進行了熱處理以對地毯紗線(BCF紗線)進行固定，藉此製造所述地毯。經簇絨樣品被用於量測拔出強度。 The nonwoven fabric produced was tufted (cut type, 64/5 inch gauge, 13/1 inch stitch, polypropylene carpet yarn (BCF) 1200 denier', pile yarn height 4 mm) , and then heat-treated the back surface of the tufts at 235°C to fix the carpet yarns (BCF yarns), thereby manufacturing the carpet. Tufted samples were used to measure pullout strength.
除在實例1中將基質：黏結劑的複合比(conjugate ratio)改變為80重量%：20重量%以外，以與實例1中相同的方式生產出了紡絲黏合不織布以及地毯。 A spunbonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the conjugate ratio of matrix:binder was changed to 80% by weight:20% by weight.
除在實例1中將細絲的橫截面形狀改變為圓形形狀而非橙狀形狀及***纖維以外，以與實例1中相同的方式生產出了紡絲黏合不織布以及地毯。 A spunbond nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the cross-sectional shape of the filaments was changed to a circular shape instead of an orange shape and the fibers were split.
除在實例1中將黏結劑材料改變為耐綸6以外，以與實例1中相同的方式生產出了紡絲黏合不織布以及地毯。 A spun-bonded nonwoven fabric and carpet were produced in the same manner as in Example 1, except that the binder material was changed to nylon 6.
除在實例1中將基質：黏結劑的複合比改變為50重量%：50重量%以外，以與實例1中相同的方式生產出了紡絲黏合不織布以及地毯。 A spun-bonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the compound ratio of matrix:binder was changed to 50% by weight:50% by weight.
除在實例1中將基質：黏結劑的複合比改變為90重量%：10重量%以外，以與實例1中相同的方式生產出了紡絲黏合不織布以及地毯。 A spun-bonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the compound ratio of matrix:binder was changed to 90% by weight:10% by weight.
除將紡絲速度設定為6000米/分鐘以外，以與實例1中相同的方式生產出了紡絲黏合不織布以及地毯。 A spun-bonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the spinning speed was set to 6000 meters/minute.
除將紡絲速度設定為2500米/分鐘以外，以與實例1中相同的方式生產出了紡絲黏合不織布以及地毯。 A spun-bonded nonwoven fabric and a carpet were produced in the same manner as in Example 1, except that the spinning speed was set to 2500 meters/minute.
除僅在為294巴的水壓下在所生產的不織布上進行水衝壓(water punching)而不施加三級壓力以外，以與實例1中相同的方式生產出了紡絲黏合不織布以及地毯。 A spunbonded nonwoven as well as a carpet was produced in the same manner as in Example 1, except that water punching was carried out on the produced nonwoven only at a water pressure of 294 bar without applying a tertiary pressure.
根據針對以下每一評價項的量測方法量測了實例、參照例及比較例的物理性質，且結果示出於表1中。 The physical properties of the examples, reference examples, and comparative examples were measured according to the measurement method for each evaluation item below, and the results are shown in Table 1.
1.***率(%) 1. Split rate (%)
根據以下方程式1藉由其中利用放大率×200的顯微鏡拍攝所述不織布的橫截面的10張相片計算出了***率。 The splitting rate was calculated according to the following Equation 1 by taking 10 photographs of the cross-section of the nonwoven fabric using a microscope with a magnification of ×200.
[方程式1]***率(%)=(***細絲數目)/(***細絲數目+未***細絲數目)×100 [Equation 1] Split rate (%) = (number of split filaments)/(number of split filaments + number of unsplit filaments) × 100
(在方程式1中，***細絲數目及未***細絲數目是在利用顯微鏡(SEM)以x200放大率拍攝的不織布的橫截面的相片中觀察到的***細絲數目及未***細絲數目，且***率代表10張相片的平均值)。 (In Equation 1, the number of split filaments and the number of unsplit filaments are the number of split filaments and the number of unsplit filaments observed in a photograph of the cross-section of the nonwoven fabric taken with a microscope (SEM) at x200 magnification, And the split rate represents the average of 10 photos).
2.室溫強度(千克力/5公分) 2. Room temperature strength (kilogram force/5 cm)
使用根據KS K 0521的標準測試方法量測了室溫強度。 Room temperature strength was measured using the standard test method according to KS K 0521.
具體而言，使用英斯特朗(INSTRON)量測設備、藉由 上/下具有為5公分×5公分的尺寸的夾具對具有為寬度×長度=5公分×20公分的尺寸的測試件進行固定，且然後在抗拉速度為200毫米/分鐘的條件下執行了所述量測。 Specifically, using INSTRON measuring equipment, by The test piece with the dimensions of width × length = 5 cm × 20 cm was fixed by a clamp with upper/lower dimensions of 5 cm × 5 cm, and then performed at a tensile speed of 200 mm/min. Said measurement.
3.熱強度(千克力/3公分)、熱伸長率(%) 3. Thermal strength (kilogram force/3 cm), thermal elongation (%)
使用根據KS K 0521的標準測試方法量測了熱強度及熱伸長率。 Thermal strength and thermal elongation were measured using standard test methods according to KS K 0521.
具體而言，使用英斯特朗量測設備、藉由上/下具有為5公分×5公分的尺寸的夾具對具有為寬度×長度=3公分×10公分的尺寸的測試件進行固定，且然後使用熱腔室在180℃下預熱達3分鐘，且在抗拉速率為200毫米/分鐘的條件下執行了所述量測。 Specifically, Instron measuring equipment is used to fix the test piece with dimensions of width × length = 3 cm × 10 cm by a clamp with upper/lower dimensions of 5 cm × 5 cm, and A thermal chamber was then preheated at 180°C for 3 minutes, and the measurements were performed at a tensile rate of 200 mm/min.
4.拔出強度(%) 4. Pull-out strength (%)
如上所述，對不織布進行了簇絨(切割型，64/5英吋隔距，13/1英吋針跡，絨頭高度4毫米)，且然後對簇絨的背表面進行了熱處理，且對地毯紗線(BCF紗線)進行了固定以製備經簇絨樣品。 The nonwoven fabric was tufted as described above (cut type, 64/5 inch gauge, 13/1 inch stitch, pile height 4 mm), and the back surface of the tufts was then heat treated, and Carpet yarns (BCF yarns) were fixed to prepare tufted samples.
在因此製備出的樣品中，根據KS K ISO 4919標準將欲在經簇絨樣品中量測的一個絨頭固定至所述量測裝置，且將欲在經簇絨樣品中量測的一個絨頭固定至所述量測裝置。對欲量測的環及位於兩側上的相鄰的環進行了切割。然後，取當使用英斯特朗量測裝置在與樣品的方向垂直的方向上拔出欲量測的絨頭時出現的強度(峰)值。將此種方法重複5次，並取平均值。為所述測試準備了三個樣品，並重複進行了評價。 In the sample thus prepared, one pile to be measured in the tufted sample is fixed to the measuring device according to the KS K ISO 4919 standard, and one pile to be measured in the tufted sample is The head is fixed to the measuring device. The ring to be measured and adjacent rings on both sides were cut. Then, take the intensity (peak) value that occurs when the pile to be measured is pulled out in a direction perpendicular to the direction of the sample using the Instron measuring device. Repeat this method 5 times and take the average value. Three samples were prepared for the test and evaluated in duplicate.
根據表1中的結果，證實了由於實例1及實例2包括用作乳膠的紡絲黏合不織布，因此相較於比較例1至比較例7的情形而言，***率高，且室溫強度、熱強度及熱伸長率優異。另外，所述實例表現出為2.0(千克力)或大於2.0(千克力)的優異拔出強度。 According to the results in Table 1, it was confirmed that since Examples 1 and 2 included the spun-bonded nonwoven fabric used as latex, compared with the cases of Comparative Examples 1 to 7, the splitting rate was higher, and the room temperature strength, Excellent thermal strength and thermal elongation. In addition, the examples exhibited excellent pull-out strength of 2.0 (kilogram force) or greater than 2.0 (kilogram force).
另一方面，比較例1顯示出圓形橫截面形狀，且使用未***不織布，且因此表現出低的機械性質，且具體而言，表現出為1.2千克力的不良拔出強度。 On the other hand, Comparative Example 1 showed a circular cross-sectional shape and used unsplit nonwoven fabric, and therefore showed low mechanical properties, and specifically, showed poor pull-out strength of 1.2 kgf.
此外，在比較例2中，由於使用耐綸作為黏結劑，因此無法執行乳膠功能，且機械性質與拔出強度二者均不良。 In addition, in Comparative Example 2, since nylon was used as the binder, the latex function could not be performed, and both the mechanical properties and pull-out strength were poor.
在比較例3及比較例4中，由於基質及黏結劑材料的含量在本揭露的範圍以外，因此***率不良或未***，且不織布成形不好，從而使得難以製造所述地毯。 In Comparative Examples 3 and 4, since the contents of the matrix and binder materials are outside the range of the present disclosure, the splitting rate is poor or not splitting, and the nonwoven fabric is poorly formed, making it difficult to manufacture the carpet.
另外，如表1中所示，在比較例5及比較例6中，紡絲 速度在本揭露的範圍以外，且由於在拉伸步驟中的細絲切割或熱黏合期間的收縮而無法生產所述不織布。在比較例7中，僅在單一步驟中應用高壓射水，且相較於實例1及實例2而言，***率降低，使得強度、伸長率及拔出強度皆降低。 In addition, as shown in Table 1, in Comparative Examples 5 and 6, spinning The speed is outside the scope of the present disclosure and the nonwoven cannot be produced due to filament cutting in the drawing step or shrinkage during thermal bonding. In Comparative Example 7, high-pressure water injection was only used in a single step, and compared with Examples 1 and 2, the splitting rate was reduced, resulting in reduced strength, elongation, and pull-out strength.
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| TW200914671A (en) * | 2007-02-12 | 2009-04-01 | Freudenberg Carl Kg | Method for manufacturing a tufted nonwoven fabric, tufted nonwoven fabric, and use thereof |
| KR20110001501A (en) * | 2009-06-30 | 2011-01-06 | 코오롱인더스트리 주식회사 | Polyester nonwoven fabrics, its preparation method and carpet primary backing substrate |
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