Thermal bonding conjugate fiber, nonwoven fabric comprising same, and mattress and topper comprising same

Abstract

To provide a nonwoven fabric not only having excellent mechanical strength and impact resilience but also especially having remarkably low permanent compression shrinkage and exhibiting excellent recovery force, and to provide a mattress and a topper including the nonwoven fabric.SOLUTION: A thermal bonding conjugate fiber comprising a ThermoplasticPolyether-esterElastomer (TPEE), the thermal bonding conjugate fiber comprising an acid component and a diol component as a result of component analysis using nuclear magnetic resonance (NMR) spectroscopy, wherein the acid component comprises 27 to 33 mol% of isophthalic acid based on the total mol% of the acid component, and the diol component comprises 6 to 9 mol% of diethylene glycol, 20 to 23 mol% of 1, 4-butanediol, and 6 to 9 mol% of poly (tetramethylene glycol) based on the total mol% of the diol component. The present invention relates to a heat-bondable conjugate fiber and a nonwoven fabric produced by heat-treating a nonwoven web containing the heat-bondable conjugate fiber at a temperature of 150 to 180 °C.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a nonwoven fabric, and a mattress and topper containing the same, and more particularly to a nonwoven fabric that has a significantly low permanent compression shrinkage rate and exhibits excellent recovery, and a mattress and topper containing the same. [Background technology]

[0002] Generally, polyurethane foam is a foam produced by mixing isocyanate and polyol with a blowing agent, catalyst, etc., and simultaneously carrying out a foaming reaction and a polymerization reaction. Polyurethane foam is lightweight and has excellent heat retention, electrical insulation, chemical resistance, impact resilience, and durability, and is therefore widely used as an elastic material in the field of cushioning. However, polyurethane foam has problems such as discomfort in use (e.g., yellowing and odor), environmental hazards, and deterioration of physical properties.

[0003] In addition to polyurethane foam, fiber assemblies fused with thermal adhesive fibers, which are harmless to the human body and environmentally friendly, are also used as elastic materials. Elastomers, which are used as fiber assembly materials, have a wide range of applications, including packaging containers, automobile interior materials, and elastic fibers, due to their unique elasticity.

[0004] Unlike rubber materials, which cannot be recycled, elastomers are easy to recycle, which is why their demand is increasing. In particular, thermoplastic polyester copolymers are used as fiber aggregate materials due to their excellent elasticity.

[0005] Thermoplastic elastomers (TPEs) are polymers that possess two distinct properties: thermoplasticity, which allows them to be reshaped when heated, and the elasticity of elastomers, which are rubber-like polymers. Thermoplastic elastomers are a type of block copolymer, and are generally composed of hard segment blocks that exhibit thermoplastic properties and soft segment blocks that exhibit elasticity, allowing them to exhibit two distinct properties simultaneously.

[0006] Such thermoplastic elastomers are produced by copolymerizing acid components such as terephthalic acid, dimethyl terephthalate, isophthalic acid, and dimethyl isophthalate with diol components such as poly(tetramethylene ether) glycol, butanediol, polyethylene glycol, and ethylene glycol. However, producing low-melting-point thermoplastic elastomers using this polymerization method requires facilities for storing and charging butanediol and for recovering by-products such as tetrahydrofuran. In particular, tetrahydrofuran is a highly hazardous substance that is toxic and explosive, making safety management difficult.

[0007] In addition, although the demand for such thermoplastic elastomers is increasing, the market size is relatively small, which has the disadvantage of increasing fixed costs when producing polymers by polymerization, leading to increased costs. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Korean Patent Publication No. 10-2016-0014627 Summary of the Invention [Problem to be solved by the invention]

[0009] The present invention has been devised to solve the above problems, and an object of the present invention is to provide a nonwoven fabric that not only has excellent mechanical strength and rebound resilience, but also has a significantly low permanent compression shrinkage rate and excellent recovery power, and a mattress and topper containing the same. [Means for solving the problem]

[0010] In order to solve the above-mentioned problems, the thermally bondable conjugate fiber of the present invention can contain TPEE (Thermoplastic Polyether-ester Elastomer).

[0011] In a preferred embodiment of the present invention, the thermally bondable composite fiber of the present invention can contain an acid component and a diol component as a result of component analysis using nuclear magnetic resonance (NMR) spectroscopy, and the acid component can contain 27 to 33 mol% of isophthalic acid relative to the total mol% of the acid component, and the diol component can contain 6 to 9 mol% of diethylene glycol, 20 to 23 mol% of 1,4-butanediol, and 6 to 9 mol% of poly(tetramethylene glycol) relative to the total mol% of the diol component.

[0012] In a preferred embodiment of the present invention, the poly(tetramethylene glycol) may have a weight average molecular weight of 900 to 1,100.

[0013] In a preferred embodiment of the present invention, the TPEE may have a melting point of 130 to 140°C.

[0014] In a preferred embodiment of the present invention, the TPEE may have an MI (melt index) of 30 to 70 g / min.

[0015] In a preferred embodiment of the present invention, the TPEE may have a crystallization temperature of 45 to 55°C.

[0016] In a preferred embodiment of the present invention, the TPEE can satisfy both of the following conditions (1) and (2): (1) 2.0≦A / B≦2.4 In the above condition (1), A represents the weight average molecular weight (Mw) of the TPEE, and B represents the number average molecular weight (Mn) of the TPEE. (2) 1.5≦C / A≦1.8 In the condition (2), A represents the weight-average molecular weight (Mw) of the TPEE, and C represents the Z-average molecular weight (Mz) of the TPEE.

[0017] In a preferred embodiment of the present invention, the weight average molecular weight (Mw) of the TPEE may be 70,000 to 75,000.

[0018] In a preferred embodiment of the present invention, the number average molecular weight (Mn) of the TPEE may be 30,000 to 35,000.

[0019] In a preferred embodiment of the present invention, the Z-average molecular weight (Mz) of the TPEE may be 100,000 to 130,000.

[0020] Meanwhile, the thermally bondable composite fiber of the present invention is produced by conjugating and spinning a first component and a second component, wherein the first component comprises a first polyester resin, and the second component comprises a second polyester resin and TPEE (Thermoplastic Polyether-ester Elastomer). As a result of component analysis using nuclear magnetic resonance (NMR) spectroscopy, the thermally bondable composite fiber of the present invention comprises an acid component and a diol component, and the acid component comprises 27 to 33 mol% of isophthalic acid relative to the total mol% of the acid component, and the diol component comprises 6 to 9 mol% of diethylene glycol, 20 to 23 mol% of 1,4-butanediol, and 6 to 9 mol% of poly(tetramethylene glycol) relative to the total mol% of the diol component.

[0021] In a preferred embodiment of the present invention, the second component may contain 45 to 65 wt % of the second polyester resin and 35 to 55 wt % of the TPEE based on the total weight %.

[0022] In a preferred embodiment of the present invention, the first polyester resin may be a PET (polyethylene terephthalate) resin having an intrinsic viscosity (IV) of 0.55 to 0.75 dL / g.

[0023] In a preferred embodiment of the present invention, the second polyester resin may be a copolyester resin having an intrinsic viscosity (IV) of 0.51 to 0.71 dL / g.

[0024] In a preferred embodiment of the present invention, the copolyester resin is prepared by subjecting a copolyester resin composition to a polymerization and condensation reaction. The copolyester resin composition includes an ester compound prepared by subjecting an acid component including terephthalic acid and isophthalic acid to an esterification reaction with a diol component including ethylene glycol and diethylene glycol, and poly(tetramethylene glycol), and the copolyester resin composition may contain 1 to 10 parts by weight of poly(tetramethylene glycol) per 100 parts by weight of the ester compound.

[0025] In a preferred embodiment of the present invention, the cross-sectional shape of the thermally bondable bicomponent fiber of the present invention may be a core-sheath type, a peanut-shaped side-by-side or a circular side-by-side.

[0026] Furthermore, the thermally adhesive core-sheath type composite fiber of the present invention can include a core containing a first polyester resin, and a sheath that is arranged to surround the core and contains a second polyester resin and a TPEE (Thermoplastic Polyether-ester Elastomer).

[0027] In a preferred embodiment of the present invention, the thermally bondable sheath-core composite fiber of the present invention contains an acid component and a diol component as a result of component analysis using nuclear magnetic resonance (NMR) spectroscopy, and the acid component contains 27 to 33 mol% of isophthalic acid relative to the total mol% of the acid component, and the diol component can contain 6 to 9 mol% of diethylene glycol, 20 to 23 mol% of 1,4-butanediol, and 6 to 9 mol% of poly(tetramethylene glycol) relative to the total mol%.

[0028] In a preferred embodiment of the present invention, the cross-sectional area ratio of the core portion to the sheath portion may be 1-2:1.

[0029] In a preferred embodiment of the present invention, the thermal adhesive sheath-core conjugate fiber of the present invention may have a fineness of 2.0 to 10.0 denier and a fiber length of 44 to 84 mm.

[0030] On the other hand, the nonwoven fabric of the present invention may be produced by heat treating the thermal adhesive conjugate fiber of the present invention or a nonwoven web containing the thermal adhesive conjugate fiber of the present invention at a temperature of 150 to 180°C.

[0031] In one preferred embodiment of the present invention, the nonwoven fabric of the present invention may be formed into a TPEE matrix.

[0032] In a preferred embodiment of the present invention, the nonwoven fabric of the present invention may have a permanent compression shrinkage of 22 to 33% as measured by the ASTM D3574 TEST D method.

[0033] In a preferred embodiment of the present invention, the nonwoven fabric of the present invention may have a rebound resilience of 40 to 65% as measured by the ASTM D3574 TEST H method.

[0034] In a preferred embodiment of the present invention, the nonwoven fabric of the present invention may have a basis weight of 850 to 1250 gsm and a thickness of 30 to 70 mm.

[0035] Additionally, the mattress of the present invention comprises the nonwoven fabric of the present invention.

[0036] On the other hand, the topper of the present invention comprises the nonwoven fabric of the present invention.

[0037] The terms used in the present invention will be explained below.

[0038] In the present invention, the term "fiber" as used herein means "yarn" or "thread" and includes various common types of yarns and fibers.

[0039] The term "composite fiber" used in the present invention is used to mean a raw yarn itself produced by conjugate spinning, or a fiber obtained by drawing and / or partially drawing the raw yarn. [Effects of the Invention]

[0040] The thermally adhesive conjugate fiber of the present invention, the nonwoven fabric containing the same, and the mattress and topper containing the same not only have excellent impact resilience but also excellent mechanical strength.

[0041] In particular, the thermally adhesive conjugate fiber of the present invention, the nonwoven fabric containing the same, and the mattress and topper containing the same have a significantly low permanent compression shrinkage rate and exhibit excellent recovery power. [Brief explanation of the drawings]

[0042] [Figure 1] 1 is a diagram illustrating a TPEE matrix formed in a nonwoven fabric according to a preferred embodiment of the present invention. FIG. [Figure 2] 1 is an SEM image of the thermal adhesive sheath-core composite fiber produced in Example 1 taken using a scanning electron microscope. DETAILED DESCRIPTION OF THE INVENTION

[0043] Hereinafter, with reference to the accompanying drawings, embodiments of the present invention will be described in detail so that those skilled in the art can easily carry out the present invention. The present invention may be embodied in various different forms and is not limited to the embodiments described herein. In the drawings, parts that are not relevant to the description will be omitted in order to clearly explain the present invention, and the same reference numerals will be used throughout the specification to refer to the same or similar components.

[0044] The thermally bondable conjugate fiber of the present invention may contain TPEE (Thermoplastic Polyether-ester Elastomer).

[0045] Specifically, TPEE may have a melting point of 130 to 140°C, preferably 131 to 139°C, and more preferably 132 to 136°C. If the melting point is less than 130°C, there may be a problem of poor spinnability when producing a thermally bondable conjugate fiber, and if it exceeds 140°C, there may be a problem that the desired nonwoven fabric cannot be produced.

[0046] Furthermore, the TPEE may have an MI (melt index) of 30 to 70 g / min, preferably 31 to 50 g / min, and more preferably 35 to 45 g / min. If the MI is less than 30 g / min, there may be a problem that a TPEE matrix is ​​not formed when a nonwoven fabric is produced using the thermal adhesive conjugate fiber of the present invention, and if it exceeds 50 g / min, there may be a problem that the physical properties of the nonwoven fabric are reduced.

[0047] Furthermore, the crystallization temperature of TPEE may be 45 to 55°C, preferably 46 to 54°C, and more preferably 48 to 52°C. If the crystallization temperature is less than 45°C, there may be a problem of interfiber bonding occurring at room temperature (approximately 25°C), and if it exceeds 55°C, there may be a problem of reduced elasticity.

[0048] Furthermore, TPEE can satisfy both of the following conditions (1) and (2). (1) 2.0≦A / B≦2.4, preferably 2.05≦A / B≦2.35, and more preferably 2.2≦A / B≦2.3 (2) 1.5≦C / A≦1.8, preferably 1.55≦C / A≦1.75, and more preferably 1.55≦C / A≦1.65

[0049] In the above conditions (1) and (2), A represents the weight-average molecular weight (Mw) of TPEE, B represents the number-average molecular weight (Mn) of TPEE, and C represents the Z-average molecular weight (Mz) of TPEE.

[0050] In the condition (1), if A / B is less than 2.0, there may be a problem of reduced stretchability, and if it exceeds 2.4, there may be a problem of poor spinnability when producing the thermally bondable conjugate fiber of the present invention.

[0051] In condition (2), if C / A is less than 1.5, there may be a problem of reduced stretchability, and if it exceeds 1.8, there may be a problem of poor spinnability when producing the thermally bondable conjugate fiber of the present invention.

[0052] The weight average molecular weight (Mw) of the TPEE may be 70,000 to 75,000, preferably 70,500 to 74,500, and more preferably 71,500 to 73,500. If the weight average molecular weight (Mw) is less than 70,000, the viscosity may be low, making it impossible to spin the thermoadhesive conjugate fiber of the present invention, whereas if it exceeds 75,000, the spinnability may be poor when producing the thermoadhesive conjugate fiber of the present invention.

[0053] The number average molecular weight (Mn) of the TPEE may be 30,000 to 35,000, preferably 30,500 to 34,500, and more preferably 31,500 to 33,500. If the number average molecular weight (Mn) is less than 30,000, the viscosity may be low, which may make it impossible to spin the thermoadhesive conjugate fiber of the present invention, whereas if it exceeds 35,000, there may be a problem of poor spinnability when producing the thermoadhesive conjugate fiber of the present invention.

[0054] The Z-average molecular weight (Mz) of the TPEE may be 100,000 to 130,000, preferably 110,000 to 125,000, and more preferably 113,000 to 120,000. If the Z-average molecular weight (Mz) is less than 100,000, the viscosity may be low, making it impossible to spin the thermobondable conjugate fiber of the present invention, whereas if it exceeds 130,000, it may result in poor spinnability when producing the thermobondable conjugate fiber of the present invention.

[0055] On the other hand, component analysis using nuclear magnetic resonance (NMR) spectroscopy has revealed that the thermally bondable composite fiber of the present invention can contain an acid component and a diol component. Specifically, the acid component can contain 27 to 33 mol%, preferably 28 to 32 mol%, and more preferably 29 to 31 mol% of isophthalic acid relative to the total mol% of the acid component. The acid component can contain 67 to 73 mol%, preferably 68 to 72 mol%, and more preferably 69 to 71 mol% of terephthalic acid relative to the total mol% of the acid component. The diol component can contain 6 to 9 mol%, preferably 7 to 8.9 mol%, and more preferably 8.0 to 8.8 mol% of diethylene glycol relative to the total mol% of the diol component. The diol component can contain 20 to 23 mol%, preferably 20.5 to 22 mol%, and more preferably 20.8 to 21.5 mol% of 1,4-butanediol relative to the total mol% of the diol component. The diol component may contain 6 to 9 mol%, preferably 6 to 8 mol%, and more preferably 6 to 7 mol% of poly(tetramethylene glycol) relative to the total mol% of the diol component, and 54 to 74 mol%, preferably 59 to 69 mol%, and more preferably 62 to 66 mol% of ethylene glycol relative to the total mol% of the diol component.

[0056] Furthermore, the weight-average molecular weight of poly(tetramethylene glycol) may be 900 to 1,100, preferably 950 to 1,050. If the weight-average molecular weight is less than 900, problems with the degree of polymerization and hardness may occur, while if it exceeds 1,100, not only problems with the degree of polymerization may arise, but also problems with reduced economic efficiency may occur.

[0057] Furthermore, the thermally adhesive conjugate fiber of the present invention may be produced by conjugate spinning the first component and the second component.

[0058] In this case, the first component may include a first polyester resin, and the second component may include a second polyester resin and a TPEE (Thermoplastic Polyether-ester Elastomer), the TPEE being as described above.

[0059] The first polyester resin may be a PET (polyethylene terephthalate) resin having an intrinsic viscosity (IV) of 0.55 to 0.75 dL / g, preferably 0.60 to 0.70 dL / g.

[0060] The second polyester resin may be a copolyester resin having an intrinsic viscosity (IV) of 0.51 to 0.71 dL / g, preferably 0.56 to 0.66 dL / g.

[0061] Meanwhile, the copolyester resin may be produced by subjecting a copolyester resin composition to a polymerization / condensation reaction. Specifically, the copolyester resin composition contains an ester compound and poly(tetramethylene glycol), and may contain 1 to 10 parts by weight, preferably 3 to 7 parts by weight, of poly(tetramethylene glycol) having a weight-average molecular weight of 900 to 1,100, preferably 950 to 1,050, per 100 parts by weight of the ester compound. In addition, the ester compound may be produced by subjecting an acid component containing terephthalic acid and isophthalic acid to an esterification reaction with a diol component containing ethylene glycol and diethylene glycol. Specifically, the acid component may contain, relative to the total mole % of the acid component, 65 to 85 mole %, preferably 70 to 80 mole %, of terephthalic acid, and 25 to 45 mole %, preferably 30 to 40 mole %, of isophthalic acid, and the diol component may contain, relative to the total mole % of the diol component, 85 to 95 mole %, preferably 88 to 92 mole %, of ethylene glycol, and 5 to 15 mole %, preferably 8 to 12 mole %, of diethylene glycol.

[0062] Furthermore, the second component may contain, relative to the total weight percent, 45 to 65% by weight, preferably 50 to 60% by weight, of a second polyester resin, and 35 to 55% by weight, preferably 40 to 50% by weight, of TPEE. If the TPEE content is less than 35% by weight, the adhesiveness of the thermally bondable conjugate fiber of the present invention will be low, and there may be a problem that it cannot be used to produce the desired nonwoven fabric, while if it exceeds 55% by weight, there may be an economic problem.

[0063] On the other hand, the cross-sectional shape of the thermally adhesive conjugate fiber of the present invention may be a core-sheath type, a peanut-shaped side-by-side or a circular side-by-side.

[0064] Furthermore, the thermally adhesive sheath-core composite fiber of the present invention can include a core containing a first polyester resin, and a sheath surrounding the core and containing a second polyester resin and a thermoplastic polyester-ester elastomer (TPEE). The first polyester resin, second polyester resin, and TPEE are as described above. The sheath can contain 45 to 65 wt %, preferably 50 to 60 wt %, of the second polyester resin and 35 to 55 wt %, preferably 40 to 50 wt %, of the TPEE, based on the total weight.

[0065] Furthermore, component analysis using nuclear magnetic resonance (NMR) spectroscopy has revealed that the thermally bondable sheath-core composite fiber of the present invention can contain an acid component and a diol component. Specifically, the acid component can contain 27 to 33 mol%, preferably 28 to 32 mol%, and more preferably 29 to 31 mol% of isophthalic acid relative to the total mol% of the acid component. The acid component can contain 67 to 73 mol%, preferably 68 to 72 mol%, and more preferably 69 to 71 mol% of terephthalic acid relative to the total mol% of the acid component. The diol component can contain 6 to 9 mol%, preferably 7 to 8.9 mol%, and more preferably 8.0 to 8.8 mol% of diethylene glycol relative to the total mol% of the diol component. The diol component can contain 20 to 23 mol%, preferably 20.5 to 22 mol%, and more preferably 20.8 to 21.5 mol% of 1,4-butanediol relative to the total mol% of the diol component. The diol component may contain 6 to 9 mol%, preferably 6 to 8 mol%, and more preferably 6 to 7 mol% of poly(tetramethylene glycol) relative to the total mol% of the diol component. The diol component may contain 54 to 74 mol%, preferably 59 to 69 mol%, and more preferably 62 to 66 mol% of ethylene glycol relative to the total mol% of the diol component. The poly(tetramethylene glycol) may have a weight-average molecular weight of 900 to 1,100, preferably 950 to 1,050. If the weight-average molecular weight is less than 900, problems with the degree of polymerization and hardness may occur, while if it exceeds 1,100, not only problems with the degree of polymerization may occur but also problems with reduced economic efficiency may occur.

[0066] Furthermore, the cross-sectional area ratio of the core to the sheath of the thermally adhesive core-sheath type composite fiber of the present invention may be 1 to 2:1, preferably 1.3 to 1.7:1. If the ratio is less than 1:1, problems with elasticity may arise, and if it exceeds 2:1, problems with the production of fibers may arise.

[0067] The thermal adhesive sheath-core type composite fiber of the present invention may have a fineness of 2.0 to 10.0 denier, preferably 4.0 to 8.0 denier.

[0068] The thermally adhesive core-sheath type conjugate fiber of the present invention may have a fiber length of 44 to 84 mm, preferably 54 to 74 mm.

[0069] On the other hand, the thermally adhesive sheath-core type composite fiber of the present invention can be produced by a melt spinning method.

[0070] Specifically, the method for producing the thermal adhesive sheath-core composite fiber of the present invention can include the first to fifth steps.

[0071] First, as a first step in the method for producing a thermally adhesive sheath-core composite fiber of the present invention, a core-forming resin and a sheath-forming resin are charged into a composite spinneret and composite spun to produce an undrawn sub-tow.

[0072] The composite spinning can be performed using various types of spinnerets, and the subtow produced by the spinneret type can be a sheath-core monofilament, preferably a sheath-core spinneret. In the sheath-core monofilament, the core can include a core-forming resin, and the sheath can include a sheath-forming resin. The core-forming resin can include a first polyester resin, and the sheath-forming resin can include a second polyester resin and TPEE (Thermoplastic Polyether-ester Elastomer).

[0073] Next, in the second step of the method for producing the thermally adhesive sheath-core conjugate fiber of the present invention, the undrawn subtow can be drawn, dried and heat-set.

[0074] In this case, the undrawn subtow can be drawn 2.0 to 6.0 times, preferably 3.0 to 5.0 times, at a temperature of 20° C. to 90° C. If the draw ratio is less than 2.0 times, the elongation increases, which may reduce the physical properties of the applied product using the thermal adhesive sheath-core composite fiber of the present invention, while if the draw ratio exceeds 6.0 times, there may be a problem of yarn breakage.

[0075] The drying and heat setting may be carried out at a temperature of 50 to 120° C., preferably 70 to 115° C. The drying and heat setting time may be 1 to 60 minutes, preferably 3 to 50 minutes, and various crimp forms may be achieved by the heat setting.

[0076] Next, in the third step of the method for producing the thermally adhesive sheath-core composite fiber of the present invention, the drawn and dried subtow can be immersed in a hydrophilic oil to coat the surface.

[0077] In this case, the hydrophilic oil may be any hydrophilic oil that is commonly used in the art, and preferably contains one or more selected from ionic surfactants, nonionic surfactants, anionic surfactants, and amphoteric surfactants.

[0078] Next, as the fourth step of the method for producing the thermally bondable core-sheath composite fiber of the present invention, the surface-coated sub-tow can be crimped by a common crimping method available in the art.

[0079] Finally, as the fifth step of the method for producing a thermally bondable sheath-core composite fiber of the present invention, the crimped subtow is cut to produce a thermally bondable composite fiber.

[0080] In this case, cutting is a process of cutting the heat-set subtow so that the heat-bondable sheath-core composite fiber of the present invention has an appropriate fiber length depending on the processed product in which the heat-bondable sheath-core composite fiber of the present invention is to be used, and can be performed by a general cutting method available in the art.

[0081] On the other hand, the nonwoven fabric of the present invention may be a nonwoven fabric produced by heat treating the thermally adhesive conjugate fiber of the present invention or a nonwoven web containing the thermally adhesive sheath-core conjugate fiber of the present invention at a temperature of 150 to 180° C., preferably 160 to 170° C., and more preferably 160 to 165° C. If the heat treatment temperature is less than 150° C., the adhesiveness of the nonwoven web may decrease, and the desired nonwoven fabric may not be produced, whereas if the heat treatment temperature exceeds 180° C., the physical properties of the produced nonwoven fabric may decrease.

[0082] The nonwoven web may be produced by carding the thermally adhesive conjugate fiber of the present invention or the thermally adhesive sheath-core conjugate fiber of the present invention.

[0083] Furthermore, the nonwoven fabric of the present invention may have a TPEE matrix. Specifically, referring to Figure 1, the nonwoven fabric of the present invention is formed by mixing polyester resin 10 and TPEE 20. When two materials of different components are mixed, one component has a domain structure and the other component has a matrix structure. The nonwoven fabric of the present invention has a structure in which polyester resin 10 forms domains and TPEE 20 forms a matrix. As the nonwoven fabric of the present invention has a TPEE matrix, the nonwoven fabric of the present invention has physical properties similar to those of TPEE.

[0084] Furthermore, the nonwoven fabric of the present invention may have a Shore D hardness of 55 HS or less, preferably 30 to 70 HS, and more preferably 31 to 60 HS.

[0085] Furthermore, the nonwoven fabric of the present invention may have a compression hardness of 2.1 to 3.3 N, preferably 2.7 to 3.1 N, as measured by the ASTM D3574 TEST D method. If the compression hardness is less than 2.1 N, there may be a problem of a lack of elasticity, and if it exceeds 3.3 N, there may be a problem of stiffness.

[0086] Furthermore, the nonwoven fabric of the present invention may have a permanent compression shrinkage of 22 to 33%, preferably 24 to 32%, and more preferably 27 to 31%, as measured by ASTM D3574 TEST D. If the permanent compression shrinkage is less than 22%, the elasticity may be good and the nonwoven fabric may feel stiff, whereas if it exceeds 33%, the elasticity may be poor and the nonwoven fabric may dent.

[0087] Furthermore, the nonwoven fabric of the present invention may have a rebound resilience of 40 to 65%, preferably 50 to 60%, as measured by ASTM D3574 TEST H. If the rebound resilience is less than 40%, the nonwoven fabric may be too soft, whereas if it exceeds 65%, the nonwoven fabric may be too hard.

[0088] The nonwoven fabric of the present invention may have a basis weight of 850 to 1250 gsm, preferably 950 to 1150 gsm.

[0089] The nonwoven fabric of the present invention may have a thickness of 30 to 70 mm, preferably 40 to 60 mm.

[0090] Meanwhile, the nonwoven fabric of the present invention can be produced by subjecting the thermal adhesive composite fiber of the present invention or the thermal adhesive core-sheath composite fiber of the present invention to an air-through bonding method or a calendaring method.

[0091] As an example, the method for producing a nonwoven fabric of the present invention includes a first step of carding the thermal adhesive conjugate fiber of the present invention or the thermal adhesive core-sheath type conjugate fiber of the present invention to produce a nonwoven web, and a second step of heat-treating the nonwoven web to produce a nonwoven fabric.

[0092] In this case, the heat treatment can be carried out using a hot air blower, and can be carried out for 1 second to 10 minutes, preferably 2 seconds to 5 minutes, at a temperature of 150 to 180°C, preferably 160 to 170°C, and more preferably 160 to 165°C. If the heat treatment temperature is less than 150°C, the physical properties of the nonwoven fabric may deteriorate, and if the heat treatment temperature exceeds 180°C, it may be difficult to bond the nonwoven fabric.

[0093] On the other hand, the mattress of the present invention can include the nonwoven fabric of the present invention.

[0094] The topper of the present invention can also include the nonwoven fabric of the present invention.

[0095] While the present invention has been described above with reference to exemplary embodiments, these are merely illustrative and are not intended to limit the scope of the present invention. Those skilled in the art will recognize that various modifications and applications, not exemplified above, are possible without departing from the essential characteristics of the present invention. For example, the components specifically illustrated in the exemplary embodiments of the present invention may be modified and implemented. Differences related to such modifications and applications should be construed as being included within the scope of the present invention as defined in the appended claims.

[0096] Preparation example 1: Preparation of TPEE (Thermoplastic Polyether-ester Elastomer) chip TPEE chips having the physical properties shown in Table 1 below were prepared. [Table 1]

[0097] Preparation Example 2: Production of copolyester resin chips (1) An acid component and a diol component were charged in a molar ratio of 1:1.6, and mixed and esterified at a temperature of 250°C and a pressure of 1140 torr to produce an ester compound, with a production rate of 97.5%.

[0098] In this case, 75 mol % of terephthalic acid and 35 mol % of isophthalic acid were used as the acid component relative to the total mol % of the acid component, and 90 mol % of ethylene glycol and 10 mol % of diethylene glycol were used as the diol component relative to the total mol % of the diol component.

[0099] (2) To 100 parts by weight of the prepared ester compound, 5 parts by weight of poly(tetramethylene glycol) having a weight average molecular weight of 1,000 and 0.03 parts by weight of antimony trioxide (polymerization / condensation catalyst) were added, and the mixture was gradually reduced in pressure to a final pressure of 0.5 torr while the temperature was raised to 280°C, resulting in mixing and a polymer / condensation reaction. A copolyester resin having an intrinsic viscosity (IV) of 0.61 dL / g was prepared, and the copolyester resin chips were prepared by chipping the resin.

[0100] Preparation Example 3: Production of TPEE mixed resin The TPEE chips prepared in Preparation Example 1 and the copolyester resin chips prepared in Preparation Example 2 were melted and mixed at 180°C to prepare a molten mixture, and a compatibilizer was added to the molten mixture to prepare a TPEE mixed resin. The molten mixture was prepared by mixing 45 wt% of the TPEE chips prepared in Preparation Example 1 and 55 wt% of the copolyester resin chips prepared in Preparation Example 2 based on the total weight percent, and the TPEE mixed resin was prepared by mixing 95 wt% of the molten mixture and 5 wt% of the compatibilizer based on the total weight percent. An epoxy-based compatibilizer was used as the compatibilizer.

[0101] Example 1: Production of heat-bondable core-sheath composite fiber (1) A PET (polyethylene terephthalate) resin having an intrinsic viscosity (IV) of 0.65 dL / g was used as the resin for forming the core portion, and the TPEE mixed resin produced in Preparation Example 3 was used as the resin for forming the sheath portion. These resins were then fed into a core-sheath composite spinneret and composite spun to produce a core-sheath undrawn subtow having circular cross sections for the core and sheath portions.

[0102] (2) The prepared core-sheath type undrawn subtow was drawn 4.0 times at a temperature of 80°C, and then dried and heat-set at a temperature of 90°C for 10 minutes.

[0103] (3) The stretched and dried subtow was immersed in a hydrophilic oil to coat the surface.

[0104] (4) The surface-coated subtow was crimped using a crimper.

[0105] (5) The crimped subtow was cut to produce a heat-bondable core-sheath composite fiber having a fineness of 6.0 denier and a fiber length of 64 mm. The cross-sectional area ratio of the core to the sheath was 3:2, and the core was made of PET resin, while the sheath was made of the TPEE mixed resin produced in Preparation Example 3.

[0106] Comparative Example 1: Production of heat-bondable core-sheath composite fiber A thermally bondable sheath-core conjugate fiber was produced in the same manner as in Example 1. However, unlike Example 1, the copolyester resin produced in Preparative Example 2 was used as the resin for forming the sheath portion, rather than the TPEE mixed resin produced in Preparative Example 3, and a thermally bondable sheath-core conjugate fiber was finally produced.

[0107] Experimental Example 1: Component Analysis Nuclear magnetic resonance (NMR) spectroscopy was performed on each of the thermal adhesive sheath-core composite fibers prepared in Example 1 and Comparative Example 1 to analyze the components and contents of each of the thermal adhesive sheath-core composite fibers prepared in Example 1 and Comparative Example 1. The results are shown in Table 2 below. [Table 2]

[0108] Experimental Example 2: Measurement of thermal adhesive strength Nonwoven webs prepared by carding the thermal adhesive sheath-core composite fibers prepared in Example 1 and Comparative Example 1 were placed in a Teflon-coated frame measuring 30 cm x 30 cm x 1 cm in width x length x height, and heat-treated at 160°C for 10 minutes. The heat-treated nonwoven webs were cut into pieces measuring 10 cm x 2 cm in width x length, and the thermal adhesive strength of each of the thermal adhesive sheath-core composite fibers prepared in Example 1 and Comparative Example 1 was measured using an INSTRON instrument. The results are shown in Table 3 below. [Table 3]

[0109] As can be seen from Table 3, the thermal adhesive sheath / core conjugate fiber produced in Example 1 and the thermal adhesive sheath / core conjugate fiber produced in Comparative Example 1 were found to have comparable levels of thermal adhesive strength.

[0110] Experimental example 3: SEM photography The thermal adhesive core-sheath composite fiber prepared in Example 1 was photographed using a scanning electron microscope, and the SEM image is shown in Figure 2. As can be seen from Figure 2, it was confirmed that the TPEE mixed resin prepared in Preparation Example 3 for the sheath formed a TPEE matrix.

[0111] Manufacturing Example 1 and Comparative Manufacturing Example 1: Manufacturing of nonwoven fabric The thermal adhesive core-sheath composite fibers prepared in Example 1 and Comparative Example 1 were each carded to prepare a nonwoven web, and the prepared nonwoven web was heat-treated at a temperature of 160°C for 20 seconds using a circulating hot air blower to prepare a nonwoven fabric having a basis weight of 1050 gsm and a thickness of 50 mm.

[0112] Experimental Example 4: Measurement of compression hardness The compression hardness of each of the nonwoven fabrics produced in Production Example 1 and Comparative Production Example 1 was measured according to the method of KS M ISO 3386-1, and the results are shown in Table 4 below.

[0113] Experimental Example 5: Measurement of permanent compression shrinkage The permanent compression shrinkage of each of the nonwoven fabrics prepared in Preparation Example 1 and Comparative Preparation Example 1 was measured according to ASTM D3574 (Felxible cellular materials - Slab, Bonded, and Molded Unrethane Foams) TEST D method, and the results are shown in Table 4. The permanent compression shrinkage is the shrinkage that does not recover over time, and a higher permanent compression shrinkage indicates a lower recovery force.

[0114] Experimental Example 6: Measurement of rebound resilience The impact resilience of each of the nonwoven fabrics prepared in Preparation Example 1 and Comparative Preparation Example 1 was measured according to ASTM D3574 (Felxible cellular materials - Slab, Bonded, and Molded Unrethane Foams) TEST H method, and the results are shown in Table 4 below.

[0115] Experimental Example 7: Shore D Hardness Measurement The Shore D hardness of each of the nonwoven fabrics produced in Production Example 1 and Comparative Production Example 1 was measured using a Shore hardness tester, and the results are shown in Table 4 below. [Table 4]

[0116] As can be seen from Table 4, the nonwoven fabric produced in Preparation Example 1 has the same rebound resilience and mechanical strength (compression hardness, Shore D hardness, etc.) as the nonwoven fabric produced in Comparative Preparation Example 1, but has a significantly lower permanent compression shrinkage rate, demonstrating excellent recovery.

[0117] Simple variations and modifications of the present invention can be easily implemented by those having ordinary skill in the art, and all such variations and modifications are considered to be included within the scope of the present invention.

Claims

1. A thermally bondable composite fiber containing TPEE (Thermoplastic Polyether-ester Elastomer), The thermal adhesive composite fiber contains an acid component and a diol component as a result of component analysis using nuclear magnetic resonance (NMR) spectroscopy, the acid component comprises 27 to 33 mol % of isophthalic acid based on the total mol % of the acid component; The diol component contains, relative to the total mole percent of the diol component, 6 to 9 mole percent of diethylene glycol, 20 to 23 mole percent of 1,4-butanediol, and 6 to 9 mole percent of poly(tetramethylene glycol).

2. The thermal adhesive composite fiber according to claim 1, wherein the poly(tetramethylene glycol) has a weight average molecular weight of 900 to 1,100.

3. The thermally bondable composite fiber according to claim 1, wherein the TPEE has a melting point of 130 to 140°C.

4. The thermal adhesive composite fiber according to claim 1, wherein the TPEE has an MI (melt index) of 30 to 70 g / min.

5. The thermal adhesive composite fiber according to claim 1, wherein the TPEE has a crystallization temperature of 45 to 55°C.

6. The thermal adhesive conjugate fiber according to claim 1, characterized in that the TPEE satisfies both of the following conditions (1) and (2): (1) 2.0≦A / B≦2.4 (2) 1.5≦C / A≦1.8 In the above conditions (1) and (2), A represents the weight-average molecular weight (Mw) of TPEE, B represents the number-average molecular weight (Mn) of TPEE, and C represents the Z-average molecular weight (Mz) of TPEE.

7. The weight average molecular weight (Mw) of the TPEE is 70,000 to 75,000, The number average molecular weight (Mn) of the TPEE is 30,000 to 35,000, The thermal adhesive composite fiber according to claim 6, wherein the Z-average molecular weight (Mz) of the TPEE is 100,000 to 130,000.

8. A thermally bondable conjugate fiber produced by conjugation spinning a first component and a second component, the first component comprises a first polyester resin; the second component includes a second polyester resin and TPEE (Thermoplastic Polyether-ester Elastomer); The thermal adhesive composite fiber contains an acid component and a diol component as a result of component analysis using nuclear magnetic resonance (NMR) spectroscopy, the acid component comprises 27 to 33 mol % of isophthalic acid based on the total mol % of the acid component; The diol component contains, relative to the total mole percent of the diol component, 6 to 9 mole percent of diethylene glycol, 20 to 23 mole percent of 1,4-butanediol, and 6 to 9 mole percent of poly(tetramethylene glycol).

9. The thermal adhesive composite fiber according to claim 8, wherein the second component comprises 45 to 65 wt % of the second polyester resin and 35 to 55 wt % of the TPEE, based on the total weight percent.

10. The first polyester resin is a polyethylene terephthalate (PET) resin having an intrinsic viscosity (IV) of 0.55 to 0.75 dL / g; The thermal adhesive composite fiber according to claim 8, wherein the second polyester resin is a copolyester resin having an intrinsic viscosity (IV) of 0.51 to 0.71 dL / g.

11. The copolyester resin is produced by subjecting a copolyester resin composition to a polycondensation reaction, The copolyester resin composition comprises an ester compound produced by esterifying an acid component including terephthalic acid and isophthalic acid with a diol component including ethylene glycol and diethylene glycol; and poly(tetramethylene glycol); The thermal adhesive conjugate fiber according to claim 10, characterized in that it contains 1 to 10 parts by weight of poly(tetramethylene glycol) per 100 parts by weight of the ester compound.

12. The thermal adhesive conjugate fiber according to claim 8, wherein the cross-sectional shape of the thermal adhesive conjugate fiber is a core-sheath type, a peanut-shaped side-by-side type, or a circular side-by-side type.

13. a core comprising a first polyester resin; and a sheath portion disposed so as to surround the core portion and containing a second polyester resin and a TPEE (Thermoplastic Polyether-ester Elastomer); The thermal adhesive sheath-core composite fiber contains an acid component and a diol component as a result of component analysis using nuclear magnetic resonance (NMR) spectroscopy, the acid component comprises 27 to 33 mol % of isophthalic acid based on the total mol % of the acid component; The diol component contains, relative to the total mole percent of the diol component, 6 to 9 mole percent of diethylene glycol, 20 to 23 mole percent of 1,4-butanediol, and 6 to 9 mole percent of poly(tetramethylene glycol).

14. 14. The thermal adhesive core-sheath type conjugate fiber according to claim 13, wherein the cross-sectional area ratio of the core to the sheath is 1 to 2:

1.

15. The thermal adhesive sheath-core conjugate fiber according to claim 13, characterized in that the thermal adhesive sheath-core conjugate fiber has a fineness of 2.0 to 10.0 denier and a fiber length of 44 to 84 mm.

16. A nonwoven fabric produced by heat-treating a nonwoven web comprising the thermal adhesive conjugate fiber according to claim 1, the thermal adhesive conjugate fiber according to claim 8, or the thermal adhesive conjugate fiber according to claim 13 at a temperature of 150 to 180°C, The nonwoven fabric is characterized in that a TPEE matrix is ​​formed in the nonwoven fabric.

17. The nonwoven fabric is The permanent compression shrinkage measured by ASTM D3574 TEST D method is 22 to 33%; 17. The nonwoven fabric according to claim 16, wherein the rebound resilience measured by ASTM D3574 TEST H method is 40 to 65%.

18. The nonwoven fabric according to claim 16, characterized in that the nonwoven fabric has a basis weight of 850 to 1250 gsm and a thickness of 30 to 70 mm.

19. A mattress comprising the nonwoven fabric of claim 16.

20. A topper comprising the nonwoven fabric of claim 16.

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