SPUNBONDED NONWOVEN AND TILE CARPET USING THE SAME

Abstract

The present disclosure relates to a spunbond nonwoven fabric for a tile carpet base fabric which can manufacture tile carpets with excellent sound absorption performance and tuft withdraw force, including high-thickness nonwoven fabrics made of hollow fibers to which recycled polyester raw materials are applied, and a tile carpet using the same.

Claims

1. A spunbonded nonwoven fabric comprising a fiber web of mixed filament yarns of a first filament prepared from a polyester and a recycled polyester each having a melting point of 255° C. or more and a second filament prepared from a copolyester having a lower melting point than that of the first filament by 30° C. or more, wherein the first filament is a filament having a hollow fiber cross-section having a hollow ratio of 10 to 20%, wherein a raw material of the recycled polyester has an average number of foreign matters with a size of 1.0 to 10.0 μm, of 10 or less, and wherein the spunbonded nonwoven fabric has tensile strength of 20 kgf/5 cm or more and tensile elongation of 20% or more as measured according to the KS K 0521 test method, and is used as a base fabric for tile carpets.

2. The spunbonded nonwoven fabric according to claim 1, wherein the recycled polyester contained in the first filament uses a recycled polyester that has a melting point of 255° C. or more, an intrinsic viscosity (IV) of 0.60 to 0.80 dl/g, and an average number of foreign matters with a size of 1.0 to 10.0 μm, of 3 to 10.

3. The spunbonded nonwoven fabric according to claim 2, wherein the recycled polyester contained in the first filament uses a polyethylene terephthalate chip that has a melting point of 255° C. or more, an intrinsic viscosity (IV) of 0.60 to 0.80 dl/g, and an average number of foreign matters with a size of 1.0 to 10.0 μm, of 3 to 10.

4. The spunbonded nonwoven fabric according to claim 1, wherein the content ratio of the polyester and the recycled polyester of the first filament is 0:50 to 50:100 wt %.

5. The spunbonded nonwoven fabric according to claim 1, wherein the combined filament yarn contains the first filament and the second filament in a content ratio of 30:70 to 95:5 wt %.

6. The spunbonded nonwoven fabric according to claim 1, wherein the first filament is a filament having an average fineness of less than 5 to 10 denier, and the second filament is a filament having an average fineness of 2 to 5 denier or less.

7. The spunbonded nonwoven fabric according to claim 1, wherein the spunbond nonwoven fabric has a thickness of 0.35 mm to 0.40 mm when the weight per unit area is 90 g/m.sup.2.

8. A tile carpet comprising the spunbonded nonwoven fabric according to claim 1 as a base fabric, and having a sound absorption coefficient (at 500 Hz) of 0.2 or more, and a tuft withdraw force of carpets of 2.0 kgf or more.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0064] FIG. 1 is a cross-sectional view of a first filament in the form of a hollow fiber according to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0065] Hereinafter, the action and effect of the invention will be described in more detail with reference to specific examples of the invention. However, these examples are presented for illustrative purposes only and the scope of the invention is not limited thereby in any way.

Example 1

[0066] The first filament (recycled polyester having an IV of 0.65 dl/g, a content of 70 wt % relative to pure polyester of 30 wt %, and a melting point of 255° C., i.e., the content of recycled PET is 70 wt %) and the second filament (copolyester with a melting point of about 220° C.) each having a filament hollow ratio of 10% were melted using a continuous extruder at a spinning temperature of about 280° C., then subjected to conjugate spinning so that the content ratio of the first filament and the second filament became 30:70 wt %, and stretched, whereby the discharge amount and the number of spinneret capillaries were adjusted so that the average fineness of the first filament produced was 8.5 denier. Further, as the pure polyester, PET having a melting point of 255° C. and an intrinsic viscosity of 0.65 dl/g was used.

[0067] Then, the continuous filaments discharged from the capillaries were solidified with cooling air, and then stretched so that the spinning speed was 5000 m/min using a high-pressure air stretching device to produce filament fibers.

[0068] Next, the filament fibers produced above were laminated in the form of a web on a conveyor net by a conventional fiber opening method. The laminated web was subjected to a calendering process by a heated smooth roll to impart smoothness and appropriate thickness.

[0069] The laminated filaments were heat-bonded at a hot air temperature of about 220° C. to produce a spunbond nonwoven fabric having a weight per unit area of 90 g/m.sup.2 and a thickness of 0.35 mm.

Example 2

[0070] A spunbond nonwoven fabric was produced in the same manner as in Example 1, except that a recycled PET raw material having an IV of 0.72 dl/g and a melting point of 255° C. with a content of 100 wt % relative to pure polyester was applied as a first filament having a filament hollow ratio of 15%, and the thickness was adjusted to 0.35 mm at the same weight per unit area.

Example 3

[0071] A nonwoven fabric was produced in the same manner as in Example 1, except that a recycled PET raw material having an IV of 0.72 dl/g and a melting point of 255° C. with a content of 100 wt % relative to pure polyester was applied as a first filament having a filament hollow ratio of 15%, and the thickness was adjusted to 0.38 mm at the same weight per unit area.

Example 4

[0072] A nonwoven fabric was produced in the same manner as in Example 1, except that a recycled PET raw material having an IV of 0.72 dl/g and a melting point of 255° C. with a content ratio of 50:50 wt % relative to pure polyester was applied as a first filament having a filament hollow ratio of 17%, and the thickness was adjusted to 0.40 mm at the same weight per unit area.

Example 5

[0073] A nonwoven fabric was produced in the same manner as in Example 1, except that a recycled PET raw material having an IV of 0.72 dl/g and a melting point of 255° C. with a content of 100 wt % relative to pure polyester was applied as a first filament having a filament hollow ratio of 17%, and the thickness was adjusted to 0.40 mm at the same weight per unit area.

Comparative Example 1

[0074] A nonwoven fabric was produced in the same manner as in Example 1, except that pure polyester of 100 wt % was applied as a first filament having a filament hollow ratio of 0%, and the thickness was adjusted to 0.30 mm at the same weight per unit area.

Comparative Example 2

[0075] A nonwoven fabric was produced in the same manner as in Example 1, except that a recycled PET raw material having an IV of 0.65 dl/g and a melting point of 255° C. with a content of 100 wt % relative to pure polyester was applied as a first filament having a filament hollow ratio of 5%, and the thickness was adjusted to 0.33 mm at the same weight per unit area.

Comparative Example 3

[0076] A nonwoven fabric was produced in the same manner as in Example 1, except that a recycled PET raw material having an IV of 0.60 dl/g and a melting point of 255° C. with a content of 70 wt % relative to pure polyester of 30 wt % was applied as a first filament having a filament hollow ratio of 5%, and the thickness was adjusted to 0.33 mm at the same weight per unit area.

Comparative Example 4

[0077] A nonwoven fabric was produced in the same manner as in Example 1, except that a recycled PET raw material having an IV of 0.72 dl/g and a melting point of 255° C. with a content of 100 wt % relative to pure polyester was applied as a first filament having a filament hollow ratio of 15%, and the thickness was adjusted to 0.38 mm at the same weight per unit area.

Reference Example 1

[0078] A nonwoven fabric was produced in the same manner as in Example 1, except that recycled PET raw material having an IV of 1.00 dl/g and a melting point of 255° C. with a content of 100 wt % relative to pure polyester was applied as a first filament having a filament hollow ratio of 15%, and the thickness was adjusted to 0.38 mm at the same weight per unit area.

Comparative Example 5

[0079] A nonwoven fabric was produced in the same manner as in Example 1, except that recycled PET raw material having an IV of 0.72 dl/g and a melting point of 255° C. with a content of 100 wt % relative to pure polyester was applied as a first filament having a filament hollow ratio of 30%, and the thickness was adjusted to 0.45 mm at the same weight per unit area.

TABLE-US-00001 TABLE 1 Recycled polyester raw material Average number First filament of foreign matters Pure/recycled (1.0~10.0 μm) polyester content Hollow ratio Thickness Category IV (dl/g) (number) ratio (wt %) (%) (mm) Example 1 0.65 5.8 30/70  10 0.35 Example 2 0.72 6.8  0/100 10 0.35 Example 3 0.72 5.1  0/100 15 0.38 Example 4 0.72 6.1 50/50  10 0.38 Example 5 0.72 7.1  0/100 17 0.40 Comparative 0.65 4.9 100/0    0 0.30 Example 1 Comparative 0.65 7.1  0/100 5 0.33 Example 2 Comparative 0.55 5.8 30/70  5 0.33 Example 3 Comparative 0.72 10.7  0/100 15 0.38 Example 4 Reference 1.00 8.8  0/100 15 0.38 Example 1 Comparative 0.72 7.0  0/100 22 0.45 Example 5

Experimental Example

[0080] The physical properties of the examples, comparative examples, and reference example were measured according to the following measurement methods for each evaluation item, and the results are shown in Table 2 below.

Experimental Example 1: Tensile Strength (kgf/5 cm) and Tensile Elongation (%)

[0081] The KS K 0521 Test Method was used. Specifically, a specimen having a size of width×length=5 cm×20 cm was clamped with an upper/lower 5 cm×5 cm jig using an Instron testing machine, and then it was measured at a tensile speed of 200 mm/min.

Experimental Example 2: Sound Absorption Coefficient (at 500 Hz)

[0082] The reverberation time in the state where the sample was not installed in the reverberation room according to the procedure stipulated in Measurement of Sound Absorption in a Reverberation Room (KS F 2805:2014), and the reverberation time after a sample was installed were determined, and then the sound absorption coefficient was calculated according to the following Equation 2.

Sound Absorption Coefficient (A)=55.3 V/cS(1/T1−1/T2)  [Equation 2]

[0083] In Equation 2,

[0084] A: sound absorption coefficient

[0085] T1: reverberation time (s) in a state where a sample was added

[0086] T2: reverberation time (s) in a state where a sample was not added

[0087] V: reverberation room volume (m.sup.3).fwdarw.200.0 m.sup.3

[0088] S: sample area (m.sup.2)

[0089] C: speed of sound in air (m/s).fwdarw.331.42+0.61t (t: temperature of air.fwdarw.17±1)

Experimental Example 3: Measurement Test of Tuft Withdraw Force

[0090] It was measured according to the standard KS K ISO 4919 (Carpet-Determination of Tuft Withdrawal Force). Specifically, one loop to be measured of the tufted sample was fixed to the measuring device. The loop to be measured and the adjacent loops on both sides were cut. The strength (peak) value appearing when the loop to be measured was pulled in the direction perpendicular to the sample using an Instron testing machine was determined as the tuft withdrawal force, which was repeated 5 times and the average value was taken.

TABLE-US-00002 TABLE 2 Sound Strength Elongation absorption Tuft (kgf/5 cm) (%) coefficient withdrawal Spinnability Final Category (MD/CD) (MD/CD) at 500 Hz force (kgf) evaluation evaluation Example 1 24.1/25.6 25.1/27.6 0.26 2.2 ∘ ∘ Example 2 23.8/23.4 23.8/25.6 0.28 2.3 ∘ ∘ Example 3 22.8/24.1 24.2/26.8 0.35 2.6 ∘ ∘ Example 4 23.1/22.8 23.4/24.7 0.34 2.8 ∘ ∘ Example 5 21.4/23.6 22.1/24.9 0.37 2.9 ∘ ∘ Comparative 22.8/23.7 23.3/23.2 0.15 1.8 ∘ x Example 1 Comparative 22.5/23.1 22.9/24.1 0.22 1.7 ∘ x Example 2 Comparative 20.8/21.2 21.4/22.8 0.21 1.9 Δ x Example 3 Comparative 23.1/25.8 24.1/25.4 0.25 2.3 Δ x Example 4 Reference Production of sheet was impossible x Example 1 Comparative Production of sheet was impossible x Example 5

[0091] Looking at the results of Table 2, in Examples 1 to 5, the recycled polyester raw material was applied to at least 50 wt % or more to 100 wt % and a hollow fiber having a certain hollow ratio was used as compared to the comparative examples and the reference example, thereby exhibiting the tensile strength and elongation equal to or higher than that of the method using only a pure polyester raw material. Also, Examples 1 to 5 can provide a spunbond nonwoven fabric with excellent spinnability and easy thickness adjustment even when recycled polyester raw materials are used, thereby providing a tile carpet with a high sound absorption coefficient and excellent tuft withdrawal force.

[0092] On the other hand, in Comparative Example 1 consisting only of a pure polyester raw material and with a low average foreign matter content, but with no hollow fiber, the sound absorption and tuft withdrawal force were inferior to those of the examples when applied as a tile carpet of the finished product. In addition, in Comparative Examples 2 to 4, as the first filament outside the average foreign matter range and/or hollow ratio of the present disclosure was used, the physical properties of the spunbond nonwoven fabric were deteriorated, or the spinnability was poor, and the sound absorption and tuft withdrawal force of the final tile carpet were inferior to those of the examples. Further, in Reference Example 1, a recycled polyester raw material was used, but a material having an excessively high intrinsic viscosity was used, whereby the sheet was not manufactured and thus the tile carpet could not be manufactured. In Comparative Example 4, an attempt was made to improve sound absorption by increasing the hollow ratio of the first filament, but the sheet was also not manufactured and thus the tile carpet could not be manufactured.