SPUNBONDED NONWOVEN FABRIC AND TILE CARPET USING THE SAME

Abstract

The present disclosure relates to a spunbond nonwoven fabric for a base fabric for tile carpet which not only has excellent spinnability during the production of nonwoven fabric and improves tensile strength and tensile elongation, and has the effect of recycling waste such as polyester plastic, by using recycled polyester with optimized intrinsic viscosity, crystallization temperature, and number of foreign matters as a raw material, 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 composed of a recycled polyester having a melting point of 255° C. or more, and a second filament prepared from a copolyester having a melting point that is lower by 30° C. or more than that of the first filament, wherein the recycled polyester contains a recycled material of a waste polyester polymer obtained by using a monomer composition in which the ratio of diethylene glycol to ethylene glycol is 1.30 or less, and has an intrinsic viscosity (IV) of 0.60 to 0.80 dl/g, and a crystallization temperature of 175° C. or more and lower than 185° C.

2. The spunbonded nonwoven fabric according to claim 1, wherein the recycled polyester comprises a recycled material of the waste polyester polymer of the monomer composition that contains 45 to 75 parts by weight of isophthalic acid (IPA), 47 to 58 parts by weight of ethylene glycol (EG), and 69 to 74 parts by weight of diethylene glycol based on 100 parts by weight of terephthalic acid (TPA).

3. The spunbonded nonwoven fabric according to claim 1, wherein the recycled polyester has an average number of foreign matters of 10 or fewer having a size of 1.0 to 10.0 μm based on the total weight.

4. The spunbonded nonwoven fabric according to claim 3, wherein the recycled polyester contained in the first filament includes 2 to 9 average foreign matters having a size of 1.0 to 10.0 μm based on the total weight of the recycled polyester.

5. The spunbonded nonwoven fabric according to claim 1, wherein the recycled polyester is a recycled material of waste polyethylene terephthalate obtained by using a monomer composition having a ratio of diethylene glycol to ethylene glycol of 1.30 or less, and includes a recycled polyethylene terephthalate having an intrinsic viscosity (IV) of 0.60 to 0.80 dl/g, a crystallization temperature of 175° C. or more and less than 185° C., and an average number of foreign matters of 10 or fewer having a size of 1.0 to 10.0 μm based on the total weight of the recycled polyethylene terephthalate.

6. The spunbonded nonwoven fabric according to claim 1, wherein the mixed filament yarn contains 50 to 95% by weight of the first filament and 5 to 50% by weight of the second filament.

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

8. The spunbonded nonwoven fabric according to claim 1, wherein the spunbonded 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.

9. The spunbonded nonwoven fabric according to claim 1, which is obtained under spinning conditions where a pressure range of a spinning pack is 1600 to 2500 psi.

10. The spunbonded nonwoven fabric according to claim 1, wherein the spunbonded nonwoven fabric has a tensile strength of 15 kg.f/5 cm or more, and a tensile elongation of 15% or more, as measured according to the KS K ISO-9073-3 test method.

11. A tile carpet comprising the spunbonded nonwoven fabric according to claim 1.

Description

BRIEF DESCRIPTION OF THE STRETCHING

[0072] FIG. 1 shows the state (a) of a calender roll at the time of manufacturing a nonwoven fabric according to Comparative Example 3 and the result of a nonwoven fabric sheet surface (b).

DETAILED DESCRIPTION OF THE EMBODIMENTS

[0073] 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.

Preparation of Materials

[0074] As the recycled polyester used as the first filament in the following examples, a recycled raw material in the form of chips (hereafter, recycled PET) recycled from waste of polyethylene terephthalate (PET) that was produced through esterification at a temperature of about 220 to 240° C. using a monomer composition containing 45 to 75 parts by weight of isophthalic acid (IPA), 47 to 58 parts by weight of ethylene glycol (EG), and 69 to 74 parts by weight of diethylene glycol based on 100 parts by weight of terephthalic acid (TPA) was used. The recycled chips of the recycled polyester were produced in the form of chips by pulverizing the polyethylene terephthalate waste, putting it in a twin-screw extruder, and melt-extruding it.

[0075] At this time, the recycled PET used the one in which the monomer content range was adjusted so as to satisfy the condition of a ratio of diethylene glycol to ethylene glycol (i.e., a ratio of diethylene glycol/ethylene glycol) in the range of 1.21:1 to 1.30:1, and an intrinsic viscosity 0.61 to 0.80 as shown in Table 1, and the average number of foreign matters having a size of 1.0 to 10.0 μm based on the total weight of the recycled PET was adjusted to 10 or fewer.

[0076] Further, the recycled PET used in comparative examples is a recycled raw material of PET waste produced by a method outside the above-mentioned monomer usage range, and as disclosed in Table 1, is a case where an intrinsic viscosity, a crystallization temperature, a ratio of diethylene glycol/ethylene glycol of waste, and the average number of foreign matters were deviated from the present configuration.

EXAMPLE 1

[0077] A recycled polyester (recycled PET) having an intrinsic viscosity (IV) of 0.61 dl/g, a crystallization temperature of 176.5° C., a diethylene glycol/ethylene glycol ratio of 1.27, an average number of foreign matters of 5.6, and a melting point of 255° C. as the first filament, and a copolyester having a melting point of about 220° C. as a second filament were respectively melted using a continuous extruder at a spinning temperature of about 280° C., and then the discharge amount and the number of pores in the nozzle were adjusted so that the average fineness of the first filament prepared by conjugate-spinning and drawing the first filament and the second filament at the content ratio of 90:10 wt. % was 8.5 denier.

[0078] Then, the continuous filaments discharged from the capillaries were solidified with cooling air, and then drawn so that the spinning speed was 5000 m/min using a high-pressure air drawing device, thereby producing filament fibers. At this time, the pressure range of the spinning pack was the same as the conditions disclosed in Table 2.

[0079] Next, the produced filament fibers 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 using a heated smooth roll to impart smoothness and an appropriate thickness.

[0080] The laminated filaments were thermally 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 degree (thickness) of 0.33 mm.

EXAMPLE 2

[0081] A spunbond nonwoven fabric was produced in the same manner as in Example 1, except that a recycled polyester raw material (recycled PET) having an IV of 0.65 dl/g, a crystallization temperature of 175.8° C., a diethylene glycol/ethylene glycol ratio of 1.24, and an average number of foreign matters of 3.1 was applied as the first filament, and it was adjusted to the same thickness and weight per unit area.

EXAMPLE 3

[0082] A spunbond nonwoven fabric was produced in the same manner as in Example 1, except that a recycled polyester raw material (recycled PET) having an IV of 0.73 dl/g, a crystallization temperature of 176.0° C., a diethylene glycol/ethylene glycol ratio of 1.21, and an average number of foreign matters of 2.7 was applied as the first filament, and it was adjusted at the same thickness and weight per unit area.

EXAMPLE 4

[0083] A spunbond nonwoven fabric was produced in the same manner as in Example 1, except that a recycled polyester raw material (recycled PET) having an IV of 0.80 dl/g, a crystallization temperature of 176.3° C., a diethylene glycol/ethylene glycol ratio of 1.30, and an average number of foreign matters of 8.4 was applied as the first filament, and it was adjusted at the same thickness and weight per unit area.

COMPARATIVE EXAMPLE 1

[0084] A spunbond nonwoven fabric was produced in the same manner as in Example 1, except that a recycled polyester raw material (recycled PET) having an IV of 0.55 dl/g, a crystallization temperature of 176.3° C., a diethylene glycol/ethylene glycol ratio of 1.27, and an average number of foreign matters of 5.1 was applied as the first filament, and it was adjusted at the same thickness and weight per unit area.

COMPARATIVE EXAMPLE 2

[0085] A spunbond nonwoven fabric was produced in the same manner as in Example 1, except that a recycled polyester raw material (recycled PET) having an IV of 1.00 dl/g, a crystallization temperature of 175.9° C., a diethylene glycol/ethylene glycol ratio of 1.21, and an average number of foreign matters of 1.1 was applied as the first filament, and it was adjusted at the same thickness and weight per unit area.

COMPARATIVE EXAMPLE 4

[0086] A spunbond nonwoven fabric was produced in the same manner as in Example 1, except that a recycled polyester raw material (recycled PET) having an IV of 0.68 dl/g, a crystallization temperature of 166.4° C., a diethylene glycol/ethylene glycol ratio of 1.22, and an average number of foreign matters of 2.9 was applied as the first filament, and it was adjusted at the same thickness and weight per unit area.

REFERENCE EXAMPLE 1

[0087] A spunbond nonwoven fabric was produced in the same manner as in Example 1, except that a recycled polyester raw material (recycled PET) having an IV of 0.75 dl/g, a crystallization temperature of 176.2° C., a diethylene glycol/ethylene glycol ratio of 1.37, and an average number of foreign matters of 12.4 was applied as the first filament, and it was adjusted at the same thickness and weight per unit area.

TABLE-US-00001 TABLE 1 Recycled polyester raw material Viscosity Crystallization Diethylene Average number of Intrinsic Melting point temperature glycol/ethylene foreign matters viscosity (at 280° C.) (Tc) glycol ratio (1.0~10.0 μm) Category dl/g Poise ° C. [DEG/EG] (   ) Example 1 0.61 984 176.1 1.27 5.6 Example 2 0.65 1122 176.3 1.24 3.1 Example 3 0.73 1478 176.5 1.21 2.7 Example 4 0.80 1681 175.8 1.30 8.4 Comparative 0.55 420 176.3 1.27 5.1 Example 1 Comparative 1.00 2410 175.9 1.21 1.1 Example 2 Comparative 0.68 1320 169.4 1.37 2.9 Example 3 Reference 0.75 1514 176.2 1.21 12.4 Example 1

EXPERIMENTAL EXAMPLE

[0088] The physical properties of the examples and comparative examples were measured according to the following measurement methods for each evaluation item, and the results are shown in Table 2 below.

Experimental Example 1: Spinnability (Pack Pressure)

[0089] A pressure measurement sensor (model name: TB422J-9/18-231) available from Dynisco was used.

[0090] Specifically, a sensor for measuring the spinning pack pressure was installed on the rear end side of the gear pump, and the pack pressure was confirmed when the polymer was inserted at the pack pressure and discharged. The normal pack pressure management range was 1600 to 2500 psi.

Experimental Example 2: Tensile Strength (kgf/5 cm) and Tensile Elongation (%)

[0091] KS K ISO-9073-3 (Cut Strip) test method was used.

[0092] 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 3: Measurement of Filament Detachment and Number of Times of Cutting Filaments

[0093] During 24-hour observation, the number of cutting filaments and the number of cop detachments were measured.

TABLE-US-00002 TABLE 2 Spinnability Tensile strength Tensile (Pack pressure) (kg .Math. f/5 cm) elongation Final Category (Psi) (MD/CD) (%) (MD/CD) evaluation Example 1 1678 17.2/18.6 20.1/20.8 ∘ Example 2 1823 19.8/20.4 21.8/22.6 ∘ Example 3 2209 23.4/23.6 22.1/24.9 ∘ Example 4 2461 25.8/26.1 24.2/26.8 ∘ Comparative 1011 Impossible to spin due to filament cutting x Example 1 Comparative 3084 Impossible to spin due to leakage caused by x Example 2 excessive pack pressure Comparative 1907 Calendar roll stick phenomenon and sheet quality x Example 3 failure caused by undrawn yarn (FIG. 1) Reference 2328 Filament detachment and multiple cutting x Example 1 filaments, impossible to spin due to cop detachment

[0094] Looking at the results of Table 2, it was confirmed that in Examples 1 to 4 of the present disclosure, as the intrinsic viscosity, crystallization temperature, diethylene glycol/ethylene glycol ratio, and average number of foreign matters are all specified for the first filament (recycled polyester raw material), the spinnability was excellent and both the tensile strength and tensile elongation were excellent as compared with Comparative Examples 1 to 3 and Reference Example 1.

[0095] On the other hand, in Comparative Example 1, the intrinsic viscosity of the first filament was lower than the range of the present disclosure, and thus, the spinnability was low, and spinning was impossible due to cutting filaments, whereby the tensile strength and tensile elongation could not be measured. In Comparative Example 2, the intrinsic viscosity of the first filament was too high compared to the range of the present disclosure, and thus the pressure of the spinning pack was excessively increased, whereby it was impossible to spin due to leakage.

[0096] In addition, Comparative Example 3 and Reference Example 1 were included in the normal spinning pack pressure management range, but the crystallization temperature of the first filament was too low or the content of foreign matters was high as compared with the present disclosure, whereby it was difficult to measure the physical properties. In particular, as shown in FIG. 1, Comparative Example 3 exhibited a severe sticky phenomenon of the calender roll during production of the nonwoven fabric (FIG. 1 (a)). Looking at the appearance of the nonwoven fabric surface resulting therefrom, sheet quality defects due to the undrawn yarn occurred (FIG. 1 (b)) occurred. In Comparative Example 4, a large number of filament detachments and filament cutting occurred, and spinning due to the cop detachment was impossible, whereby the tensile strength and tensile elongation could not be measured.