Non-woven fabric and manufacturing method therefor

Abstract

The present invention relates to a non-woven fabric and a manufacturing method therefor, and the method comprises the steps of: (S10) melting polypropylene pellets; (S20) cold-stretching and spinning molten polypropylene so as to form a web layer filament; (S30) cold-stretching and spinning the molten polypropylene so as to form a surface layer filament; and (S40) laminating the web layer filament and the surface layer filament by means of the heat and pressure of embossing rolls so as to manufacture a non-woven fabric with an embossed pattern. The present invention is attached to the hooked side of Velcro so as to be prevented from side slipping, has excellent water resistance due to the characteristics of polypropylene, thereby having strong moisture resistance, is easily processed and can be mass-produced.

Description

Nonwoven fabric and its manufacturing method

[0001] The present invention relates to a nonwoven fabric and a method for manufacturing the same, and more particularly, to a nonwoven fabric for use in disposable mattress covers and the like and a method for manufacturing the same.

[0002] A mattress cover is a covering placed over a mattress to protect it and maintain its cleanliness. Placing a mattress cover over a mattress protects it from sweat and dirt while you sleep, and keeps unpleasant substances like dust and mold out, providing a good sleeping environment.

[0003] Mattress covers are often made of cotton, but waterproof covers are sometimes used to prevent contamination.

[0004] However, mattress covers, because they come into contact with the skin, are easily contaminated, and cotton covers require frequent disinfection and washing, which is a hassle. Waterproof covers, while waterproof, don't absorb sweat, so using a mattress with just a waterproof cover can lead to skin irritation. Therefore, using a waterproof cover also requires the hassle of placing an additional cotton pad on top of the waterproof cover.

[0005] Meanwhile, hotels, lodging facilities, and hospitals often use disposable mattress covers, as mattress covers are easily contaminated and are used by multiple people, making them more susceptible to contamination. Furthermore, due to recent concerns about bedbugs, most lodging facilities are now preferring disposable mattress covers. Disposable mattress covers are made of non-woven fabric.

[0006] However, the disposable mattresses currently on the market have the problem of being easily pushed, ripped, and torn when lying down, sitting, or tossing and turning in sleep, and are also prone to generating static electricity.

[0007] Therefore, the problem of the mattress cover being pushed or torn easily is being solved by making the mattress cover thicker, but there is a problem that the texture is stiff, which does not feel good against the skin and interferes with a good night's sleep, and the thick thickness makes it difficult to handle and transport.

[0008] The technical problem to be solved by the present invention is to provide a nonwoven fabric and a method for manufacturing the same, which is resistant to moisture, has excellent water resistance, is easy to process, and can be mass-produced.

[0009] Another technical problem to be solved by the present invention is to provide a nonwoven fabric and a method for manufacturing the same, which is lightweight, has high strength, elasticity, excellent durability, and breathability so that it is easy to handle and transport when manufactured as a mattress cover.

[0010] To solve the above technical problem, the present invention provides a nonwoven fabric and a method for manufacturing the same.

[0011] According to one embodiment, the method for manufacturing a nonwoven fabric of the present invention includes the steps of melting polypropylene pellets, cooling and stretching the molten polypropylene and spinning it to form a web layer filament, cooling and stretching the molten polypropylene and spinning it to form a surface layer filament, and laminating the web layer filament and the surface layer filament with heat and pressure of an embossing roll to manufacture a nonwoven fabric having an embossing pattern.

[0012] The step of melting the polypropylene pellets is to melt the polypropylene pellets by heating them to between 190°C and 250°C in an extruder.

[0013] The step of cooling, stretching, and spinning the molten polypropylene to form a web layer filament includes the step of continuously discharging the molten polypropylene through a slit die, cooling and stretching it in a rotating drum, and then spinning it through a first spinneret to form a web layer filament having a spinning diameter in the range of 10 to 30 microns, and the step of passing the web layer filament through a heated press roller to form a first nonwoven fabric.

[0014] The step of cooling, stretching, and spinning the molten polypropylene to form surface layer filaments includes the step of continuously discharging the molten polypropylene through a slit die, cooling and stretching it in a rotating drum, and then spinning it through a second spinneret to form surface layer filaments having a spinning diameter in the range of 10 to 30 microns, and the step of passing the surface layer filaments through a heated press roller to form a second nonwoven fabric.

[0015] In the step of manufacturing a nonwoven fabric having an embossed pattern by bonding the above web layer filament and the above surface layer filament with the heat and pressure of an embossing roll, the fabric is bonded by passing through an embossing roll having a pressure of 39 MPa to 41 MPa, an upper embossing roll temperature in the range of 125°C to 132°C, and a lower embossing roll temperature in the range of 130°C to 140°C, and the bonded nonwoven fabric is cooled by passing through a cooling roller.

[0016] A nonwoven fabric manufactured by the method for manufacturing a nonwoven fabric of the present invention has an embossed pattern in which embossed portions and non-embossed portions are repeated, wherein the non-embossed portion is a single layer or multi-layer in which web layer filaments and surface layer filaments are bonded by heat compression, and the embossed portion is a web structure in which web layer filaments and surface layer filaments are entangled with each other and has a polygonal or circular shape.

[0017] The above non-woven fabric is made of polypropylene.

[0018] The above non-woven fabric is 100mm 2 The weight per area is 3g to 4g.

[0019] The thickness of the above embossed portion is in the range of 0.3 mm to 0.6 mm, and the thickness of the above non-embossed portion is in the range of 0.01 mm to 0.06 mm.

[0020] The above non-woven fabric is made into a mattress cover and is attached to a hook Velcro fixed to the mattress cover to prevent lateral movement.

[0021] The nonwoven fabric of the present invention is attached to a hook Velcro, so that it is easy to separate the upper and lower parts, but prevents sideways sliding, and due to the characteristics of polypropylene, it has excellent water resistance and strong resistance to moisture, and is easy to process and can be mass-produced.

[0022] In addition, the nonwoven fabric of the present invention is lightweight, so it is easy to handle and transport when produced as a mattress cover, and by applying an embossed pattern, it has the effect of improving breathability and moisture absorption, as well as high-strength elasticity and excellent durability.

[0023] Figure 1 is a block diagram for explaining a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.

[0024] Figure 2 is a schematic diagram for explaining a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.

[0025] Figure 3 is a plan view showing a nonwoven fabric manufactured by a nonwoven fabric manufacturing method according to an embodiment of the present invention.

[0026] Figure 4 is a side cross-sectional view showing the AA section of Figure 3.

[0027] Figure 5 is a block diagram for explaining a method for manufacturing a nonwoven fabric according to another embodiment of the present invention.

[0028] Figure 6 is a side cross-sectional view showing a nonwoven fabric manufactured by a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.

[0029] FIG. 7 is a drawing for explaining the principle of attaching a nonwoven fabric according to an embodiment of the present invention to a hook Velcro and preventing it from slipping.

[0030] FIG. 8 and FIG. 9 are drawings showing a mattress cover manufactured from a nonwoven fabric according to an embodiment of the present invention fixed to a bed mattress using a hook Velcro.

[0031] Figure 10 is a block diagram illustrating a method for manufacturing a nonwoven fabric according to another embodiment of the present invention.

[0032] * Explanation of symbols *

[0033] 10: Extruder 20a, 20b: Slit die

[0034] 30a, 30b: Rotating drum 40: Press roller

[0035] 50: Embossing roller 60: Cooling roller

[0036] 70: Winding roller P1: Web layer filament

[0037] P2: Surface layer filament

[0038] B1: Nonwoven web layer filament (first nonwoven form)

[0039] B2: Nonwoven type surface layer filament (second nonwoven type)

[0040] B: Non-woven fabric B-1: Laminated non-woven fabric

[0041] a: Embossed B: Non-embossed

[0042] 1: Mattress 100: Hook Velcro

[0043] 110: Hook ring

[0044] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the attached drawings. However, the technical concept of the present invention is not limited to the embodiments described herein and may be embodied in other forms. Rather, the embodiments introduced herein are provided to ensure that the disclosure is thorough and complete and to sufficiently convey the spirit of the present invention to those skilled in the art.

[0045] FIG. 1 is a block diagram for explaining a method for manufacturing a nonwoven fabric according to an embodiment of the present invention, and FIG. 2 is a configuration diagram for explaining a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.

[0046] As illustrated in FIG. 1, a method for manufacturing a nonwoven fabric according to an embodiment of the present invention includes a step of melting polypropylene pellets (S10), a step of cooling and stretching the molten polypropylene and spinning it to form a web layer filament (S20), a step of cooling and stretching the molten polypropylene and spinning it to form a surface layer filament (S30), and a step of combining the web layer filament and the surface layer filament with heat and pressure of an embossing roll to manufacture a nonwoven fabric having an embossing pattern (S40).

[0047] As illustrated in Fig. 2, the step (S10) of melting polypropylene pellets is to melt the polypropylene pellets by heating them to between 190°C and 250°C in an extruder (10). The non-woven fabric is made of 1000% polypropylene (PP) material.

[0048] Melting of polypropylene pellets takes place in an extruder (10) connected to a hopper.

[0049] Polypropylene has a melting point of 165°C to 170°C. In an embodiment, polypropylene is heated to a temperature higher than its melting point, between 190°C and 250°C, to produce thin filaments. If the melting temperature of polypropylene is lower than 190°C, the desired thin filament shape cannot be formed. If it exceeds 250°C, the viscosity changes rapidly, causing oxidation and preventing spinning.

[0050] The step (S20) of cooling, stretching, and spinning molten polypropylene to form web layer filaments (P1) includes a step (S21) of continuously discharging molten polypropylene through a slit die (20a), cooling and stretching it in a rotating drum (30a), and then spinning it through a first spinneret (31a) to form web layer filaments (P1) having a spinning diameter in the range of 10 µm to 30 µm, and a step (S22) of passing the web layer filaments (P1) through a heated press roller (40a) to form them into a first nonwoven fabric form (B1).

[0051] The step (S30) of cooling, stretching, and spinning molten polypropylene to form surface layer filaments (P2) includes a step (S31) of continuously discharging molten polypropylene through a slit die (20b), cooling and stretching it in a rotating drum (30b), and then spinning it through a second spinneret (31b) to form surface layer filaments (P2) having a spinning diameter in the range of 10 µm to 30 µm, and a step (S32) of passing the surface layer filaments (P2) through a heated press roller (40b) to form a second nonwoven fabric form (B2).

[0052] The processes of steps (S20) and (S30) are the same, but are performed separately.

[0053] If the filaments are not sufficiently elongated in steps (S20) and (S30), the strength will decrease and the shrinkage rate will increase, ultimately resulting in a nonwoven fabric with reduced strength and a wrinkled surface. Cooling can be performed by cooling air using air with a constant humidity and a temperature near room temperature. This constant cooling air velocity influences the filament structure formation, thereby improving the properties of the final nonwoven fabric.

[0054] The processes of steps (S20) and (S30) form the filament into a nonwoven fabric and maintain a strength that can withstand a certain pressure. In steps (S20) and (S30), the heating temperature of the press rollers (40a, 40b) is 100°C to 130°C, and the rotation speed of the press rollers (40a, 40b) is 145 to 150 m / min.

[0055] The press rollers (40a, 40b) self-adhere the ultra-fine fiber web layer filaments (P1) and the surface layer filaments (P2) by heat to form a non-woven fabric, respectively. If the heating temperature of the press rollers (40a, 40b) is less than 100°C, it is difficult to secure strength, and if it exceeds 130°C, the filaments may melt and the web layer shape may be destroyed. If the rotation speed of the press rollers (40a, 40b) is less than 145 m / min, it is not efficient in terms of productivity, and if it exceeds 150 m / min, the effect of self-adhesion of each filament (P1, P2) by heat is minimal.

[0056] In the step of manufacturing a non-woven fabric (B) having an embossed pattern by bonding a web layer filament (P1) and a surface layer filament (P2) with the heat and pressure of an embossing roll (50), the web layer filament (P1) and the surface layer filament (P2) are bonded by passing through an embossing roll (50) having a pressure of 39 MPa to 41 MPa, an upper embossing roll (51) having a temperature in the range of 125°C to 132°C, and a lower embossing roll (52) having a temperature in the range of 130°C to 140°C, and the bonded non-woven fabric (B) is cooled by passing through a cooling roller (60). The cooled non-woven fabric (B) is wound on a winding roller (70).

[0057] When the web layer filament (P1) and the surface layer filament (P2) are combined by the heat and pressure of the embossing roll (50), the web layer filament (P1) is placed at the bottom and the surface layer filament (P2) is placed at the top.

[0058] The temperature of the lower embossing roll (50) is relatively higher than that of the upper embossing roll (50). This is because a pattern for forming an embossed portion is formed on the lower embossing roll (50). The embossing roll (50) has an engraved polygonal pattern formed around the outer periphery of the lower embossing roll (50), so that when the web layer filament (P1) and the surface layer filament (P2) are laminated, a protruding polygonal embossing pattern can be formed on the lower surface. Since the embossing roll (50) has no pattern on the outer periphery of the upper embossing roll (50), when the web layer filament (P1) and the surface layer filament (P2) are laminated, a smooth surface layer without protrusions is formed on the upper surface. Of course, a non-woven fabric may also have a protruding polygonal embossing pattern formed on the upper surface. In addition, even when a protruding polygonal embossing pattern is formed only on the lower surface of the non-woven fabric, the thickness is thin, so that it appears that a polygonal embossing pattern is formed on the upper surface. Of course, the embossed pattern on the non-woven fabric can also be circular in shape.

[0059] The embossing roll (50) is preferably a calender. The calender applies strong pressure and temperature to the web layer filaments (P1) and the surface layer filaments (P2) while moving in the direction between two heavy rolls, thereby causing them to be combined. By applying strong pressure to the two rolls, an embossed portion is formed on the nonwoven fabric (B) in which the web layer filaments (P1) and the surface layer filaments (P2) are combined, and the embossed portion becomes soft. When subjected to the pressure of the heavy rolls, the nonwoven fabric (B) becomes extremely soft and glossy.

[0060] If the temperature of the embossing roll (50) is lower than 125°C, the web layer filament (P1) and the surface layer filament (P2) do not stick together, and if it exceeds 140°C, the properties of the nonwoven fabric (B) change and problems such as tearing or width distortion occur. In order for the embossing portion (a) to be formed on the lower surface of the nonwoven fabric (B), the temperature of the lower embossing roll (52) must be higher than 130°C.

[0061] The web layer filaments (B1) and the surface layer filaments (B2) in the form of nonwoven fabric are combined through the heat and pressure of the embossing roller (50) and manufactured into a durable nonwoven fabric through the cooling roller (60). The cooling temperature of the cooling roller (60) is 12°C to 17°C. The nonwoven fabric (B) that has passed through the embossing roller (50) is quickly cooled to impart a heat-setting effect to the filaments and facilitate winding. If the cooling temperature of the cooling roller (60) is less than 12°C, the shape stability of the web layer may be reduced due to rapid cooling, and if it exceeds 17°C, it may be difficult to secure the desired level of durability. The manufactured nonwoven fabric (B) may be stored in a constant temperature and humidity room for a certain period of time in a state in which it is wound around the winding roller (70) to stabilize its physical properties.

[0062] The manufactured non-woven fabric (B) has a flat upper surface and a protruding embossed pattern formed on the lower surface.

[0063] FIG. 3 is a plan view showing a nonwoven fabric manufactured by a method for manufacturing a nonwoven fabric according to an embodiment of the present invention, and FIG. 4 is a side cross-sectional view showing the AA section of FIG. 3.

[0064] As illustrated in FIGS. 3 and 4, the nonwoven fabric (B) according to an embodiment of the present invention has an embossed pattern in which embossed portions (a) and non-embossed portions (b) are repeated. The embossed portions (a) have a polygonal shape. Preferably, the embossed portions (a) have a hexagonal shape.

[0065] The non-embossed portion (b) may be a single-layer or multi-layer in which web layer filaments (B1) and surface layer filaments (B2) in the form of non-woven fabric are bonded by heat compression. Here, the web layer filaments (B1) and the surface layer filaments (B2) are each meant to be produced in the form of non-woven fabric by passing through press rollers (40a, 40b). The embossed portion (a) has a web structure in which the web layer filaments (P1) and the surface layer filaments (P2) are entangled with each other, and has a polygonal shape. For example, the embossed portion (a) has a regular hexagonal shape, and the regular hexagonal shape may have a side length of 2 mm to 3 mm.

[0066] Nonwoven fabric (B) is made of 100% polypropylene. When melt-spun, polypropylene has a cross-sectional shape that varies depending on the shape of the spinneret. However, the side surfaces are spun into filaments with protrusions on their surfaces. The protrusions on the side surfaces of the filaments cause them to intertwine and bond.

[0067] Polypropylene has a regular molecular structure, resulting in crystal development and high strength. It rapidly absorbs moisture through capillary action and rapidly dissipates it, providing a pleasant texture. Furthermore, polypropylene possesses excellent antimicrobial properties, making it resistant to insect or fungal attack. Furthermore, its water resistance ensures its strength is not diminished by water. These properties of polypropylene impart water resistance and antibacterial properties to the nonwoven fabric (B).

[0068] Non-woven fabric (B) manufactured by melt spinning polypropylene into filaments and heating and pressing is 100 mm 2 It is low-weight, weighing 3g to 4g per area. The thickness of the embossed part of the non-woven fabric (B) ranges from 0.3mm to 0.6mm, and the thickness of the non-embossed part ranges from 0.01mm to 0.06mm. The low-weight characteristic of the non-woven fabric makes it easy to handle and transport.

[0069] Meanwhile, the aforementioned nonwoven fabric can be laminated in multiple layers to form a web of a predetermined thickness with random filament orientation. For example, two layers of the aforementioned nonwoven fabric can be laminated and bonded using heat and pressure. By bonding two low-weight nonwoven fabrics, the resulting lightweight nonwoven fabric can possess high strength and elasticity, as well as superior durability and breathability.

[0070] Nonwoven fabric (B) maintains its web structure due to its embossed pattern, enhancing breathability and moisture absorption, and adding a sense of luxury. If a nonwoven fabric lacks an embossed pattern, the entire surface area is compressed and formed into a thin layer, which can reduce breathability and moisture absorption.

[0071] FIG. 5 is a block diagram for explaining a method for manufacturing a nonwoven fabric according to another embodiment of the present invention, and FIG. 6 is a side cross-sectional view showing a nonwoven fabric manufactured by a method for manufacturing a nonwoven fabric according to an embodiment of the present invention.

[0072] As illustrated in FIG. 5, a method for manufacturing a nonwoven fabric according to another embodiment includes a step of melting polypropylene pellets (S10), a step of cooling and stretching the molten polypropylene and spinning it to form a web layer filament (S20), a step of cooling and stretching the molten polypropylene and spinning it to form a surface layer filament (S30), a step of manufacturing a nonwoven fabric having an embossed pattern by combining the web layer filament and the surface layer filament with heat and pressure of an embossing roll (S40), and a step of combining two nonwoven fabrics by applying heat and pressure (S50).

[0073] The step (S50) of combining two pieces of nonwoven fabric (B) by applying heat and pressure can use an embossing roll (drawing symbol 50 in FIG. 2).

[0074] As shown in Fig. 6, by laminating two nonwoven fabrics (B) and applying heat and pressure to combine them, a laminated nonwoven fabric (B-1) having an embossed pattern with repeated embossed portions (a) and non-embossed portions (b) and having high strength and excellent durability can be manufactured.

[0075] The non-embossed portion (b) of the laminated non-woven fabric (B-1) may be a single layer, and may be formed by integrating multiple layers through heat compression. For example, the non-embossed portion (b) may be formed by integrating four layers through heat compression. The embossed portion (a) of the laminated non-woven fabric (B-2) may have a higher volume than the non-woven fabric (B) of the embodiment, which may further enhance the adhesive strength with the hook Velcro described below.

[0076] The nonwoven fabric (B) and the laminated nonwoven fabric (B-1) described above are lightweight, making them easy to handle and transport, which facilitates processing and improves work efficiency when manufacturing mattress covers. In addition, the nonwoven fabric (B) and the laminated nonwoven fabric (B-1) described above have high-strength elasticity, excellent durability, and breathability despite their lightweight nature. The breathability of the nonwoven fabric (B) and the laminated nonwoven fabric (B-1) is due to the web layer filament structure and the inherent properties of polypropylene. In addition, the nonwoven fabric (B) and the laminated nonwoven fabric (B-1) described above are made of 100% polypropylene, which makes them excellent in water resistance and moisture resistance. In addition, the nonwoven fabric (B) and the laminated nonwoven fabric (B-1) described above are thin, easy to process, and can be produced in a continuous roll-to-roll process, making mass production possible.

[0077] The above-described non-woven fabric (B) and composite non-woven fabric (B-1) are attached to a bed mattress using a hook Velcro when manufactured as a mattress cover, thereby preventing lateral sliding. In addition, the non-woven fabric (B) and composite non-woven fabric (B-1) are attached by the micro hook loop (110) of the hook Velcro (100) hooking onto the filament entanglement structure when attached and detached to the hook Velcro (100), so that they are attached and detached smoothly without making a sound.

[0078] FIG. 7 is a drawing for explaining the principle of attaching a nonwoven fabric according to an embodiment of the present invention to a hook Velcro and preventing it from slipping, and FIGS. 8 and 9 are drawings showing a mattress cover manufactured from a nonwoven fabric according to an embodiment of the present invention being fixed to a bed mattress using a hook Velcro.

[0079] As illustrated in FIG. 7, the hook Velcro (100) is manufactured by melting polypropylene pellets in an extruder and then passing them through a roll-shaped mold to include a plurality of hook loops (110) on the upper surface. Alternatively, the hook Velcro (100) is made of nylon and can be produced by a plastic injection molding method. The thickness (m) of the hook Velcro (100) is in the range of 0.3 mm to 2.5 mm, preferably in the range of 0.3 mm to 0.6 mm, which is thinner than or equal to the thickness of the non-woven fabric (B). The hook Velcro (100) is a soft Velcro like fiber.

[0080] The hook rings (110) of the hook Velcro (100) are arranged in pairs, but are arranged so as to face each other and the rings are positioned so as to cross each other, so that they can be easily hooked and fixed to the filament entanglement structure of the non-woven fabric (B).

[0081] The hook Velcro (100) described above can be integrally fixed to a bed mattress at a certain location. The hook Velcro (100) has a snapping function, but is very thin, smooth, and soft, so it does not cause any discomfort to the user.

[0082] Accordingly, as illustrated in FIG. 8, a non-woven fabric (B) is manufactured into a mattress cover to cover the mattress (1). The hook Velcro (100) can be attached to the upper surface of the mattress (1). When the mattress cover covers the mattress (1), the mattress cover is gently attached to the hook Velcro (100) fixed to the mattress (1) and prevents lateral sliding. When the mattress cover is lifted upwards for replacement, etc. while covering the mattress (1), it is easily separated from the hook Velcro (100). The hook Velcro (100) and the non-woven fabric (B) can be easily separated vertically, but it is difficult to separate them laterally due to the entangled structure of the web and the micro-hooks and the resulting friction. Unlike general Velcro, the hook Velcro (100) does not make a sound when removed, is easy to separate, and has a function of preventing lateral sliding while attached.

[0083] Meanwhile, as illustrated in Fig. 9, a plurality of hook Velcros (100) can be attached to the side of the mattress (1). When the mattress cover covers the mattress (1), the mattress cover is attached to the hook Velcros (100) attached to the side of the mattress (1) in a soft snap-like manner, preventing lateral sliding, so that the mattress cover stably maintains the state of covering the upper surface of the mattress.

[0084] As mentioned above, the above matrix cover is made of non-woven fabric manufactured by melt spinning polypropylene, so it has a soft feel and no rustling noise, which can help you get a good night's sleep.

[0085] In addition, the above-mentioned non-woven fabric is used with hook Velcro to ensure a clean and close fit with the mattress, and provides a soft feel, excellent breathability, and antibacterial properties.

[0086] The nonwoven fabric described above can be used as hospital bed covers and bed covers for lodging facilities. Furthermore, the nonwoven fabric is lightweight and thin enough to be carried, yet maintains high strength to prevent bed bugs from penetrating. Furthermore, the polypropylene's antibacterial properties prevent access by bed bugs and other insects.

[0087] Figure 10 is a block diagram illustrating a method for manufacturing a nonwoven fabric according to another embodiment of the present invention.

[0088] As illustrated in FIG. 10, the method for manufacturing a nonwoven fabric includes a step of melting polypropylene pellets (S10), a step of cooling, stretching, and spinning the molten polypropylene to form web layer filaments (S20), a step of cooling, stretching, and spinning the molten polypropylene to form surface layer filaments (S30), a step of manufacturing a nonwoven fabric having an embossed pattern by combining the web layer filaments and the surface layer filaments with heat and pressure of an embossing roll (S40), a step of combining two nonwoven fabrics with heat and pressure (S50), and a step of infiltrating a functional masterbatch prior to performing the step (S50).

[0089] The functional masterbatch penetration step (S60) involves penetrating nonwoven fabric (B) with dyes for coloring, flame retardants for preventing fire, antibacterial agents, antistatic agents, etc. in the form of foam absorbents (pigments). By penetrating nonwoven fabric (B) with a functional masterbatch, a desired color or additional functionality can be imparted, allowing for the provision of customized products.

[0090]

[0091] While the present invention has been described in detail using preferred embodiments, the scope of the present invention is not limited to the specific embodiments described above, and should be interpreted in accordance with the appended claims. Furthermore, those skilled in the art will appreciate that numerous modifications and variations are possible without departing from the scope of the present invention.

Claims

1. Step of melting polypropylene pellets; A step of cooling and stretching the above molten polypropylene and spinning it to form a web layer filament; A step of cooling, stretching and spinning the above molten polypropylene to form a surface layer filament; A step of manufacturing a nonwoven fabric having an embossed pattern by combining the above web layer filament and the above surface layer filament with heat and pressure of an embossing roll; A method for manufacturing a nonwoven fabric comprising:

2. In paragraph 1, The step of melting the above polypropylene pellets is: A method for manufacturing a non-woven fabric, characterized in that the polypropylene pellets are melted by heating them in an extruder at a temperature between 190°C and 250°C.

3. In paragraph 1, The step of cooling, stretching and spinning the above molten polypropylene to form a web layer filament is as follows: A step of continuously discharging the above molten polypropylene through a slit die, cooling and stretching it in a rotating drum, and then spinning it through a first spinneret to form a web layer filament having a spinning diameter in the range of 10 to 30 microns; and A step of making the above web layer filament into a first nonwoven fabric form by passing it through a heated press roller; A method for manufacturing a nonwoven fabric, characterized in that it includes:

4. In paragraph 1, The step of cooling and stretching the above molten polypropylene and spinning it to form a surface layer filament is as follows: A step of continuously discharging the above molten polypropylene through a slit die, cooling and stretching it in a rotating drum, and then spinning it through a second spinneret to form a surface layer filament with a spinning diameter in the range of 10 to 30 microns; and A step of making the surface layer filament into a second nonwoven fabric by passing it through a heated press roller; A method for manufacturing a nonwoven fabric, characterized in that it includes:

5. In paragraph 1, In the step of manufacturing a non-woven fabric having an embossed pattern by combining the above web layer filament and the above surface layer filament with the heat and pressure of an embossing roll, A method for manufacturing a nonwoven fabric, characterized in that the nonwoven fabric is laminated by passing through an embossing roller having a pressure of 39 MPa to 41 MPa, an upper embossing roller temperature in the range of 125°C to 132°C, and a lower embossing roller temperature in the range of 130°C to 140°C, and the laminated nonwoven fabric is cooled by passing through a cooling roller.

6. It has an embossed pattern with repeated embossed and unembossed parts. The above-mentioned non-embossed portion is a single layer or multi-layer in which the web layer filament and the surface layer filament are bonded by thermal compression, A nonwoven fabric characterized in that the above embossed portion has a web structure in which web layer filaments and surface layer filaments are entangled with each other and has a polygonal shape.

7. In paragraph 6, The above nonwoven fabric is characterized in that it is made of polypropylene.

8. In paragraph 6, The above non-woven fabric is 100mm 2 A non-woven fabric characterized by a weight per area of 3g to 4g.

9. In paragraph 6, The thickness of the above embossed portion is in the range of 0.3 mm to 0.6 mm, A nonwoven fabric characterized in that the thickness of the above-mentioned non-embossed portion is in the range of 0.01 mm to 0.06 mm.

10. In paragraph 6, The above non-woven fabric Made with mattress covers, A non-woven fabric that is attached to and fixed to the hook Velcro fixed to the above mattress cover and prevents lateral movement.

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