Spunbond non-woven fabric, method for manufacturing spunbond non-woven fabric, and tile carpet using same

Abstract

The present invention relates to a spunbond nonwoven fabric having improved toughening performance and sound absorption performance and implementing excellent antibacterial properties, a method for manufacturing the spunbond nonwoven fabric, and a carpet comprising same.

Description

Spunbond nonwoven fabric, method for manufacturing spunbond nonwoven fabric, and tile carpet using the same

[0001] Cross-citation with related application(s)

[0002] This application claims the benefit of priority based on Korean Patent Application No. 10-2024-0186115 filed on December 13, 2024, and all contents disclosed in the document of said Korean patent application are incorporated herein as part of this specification.

[0003] The present invention relates to a spunbond nonwoven fabric, a method for manufacturing a spunbond nonwoven fabric, and a tile carpet using the same.

[0004]

[0005] Nonwoven fabrics are products made by arranging filaments in a cotton-like form, and are broadly classified into short-fiber nonwoven fabrics and long-fiber nonwoven fabrics depending on the length of the filaments. Short-fiber nonwoven fabrics are products made by arranging short fibers of 5 mm or less in a cotton-like form through inter-fiber entanglement or resin bonding, and are characterized by high elongation. Long-fiber nonwoven fabrics are products made by arranging unbroken fibers in a cotton-like form through inter-fiber entanglement or resin bonding, and are characterized by high strength.

[0006] Long-fiber nonwoven fabrics, which possess the advantage of excellent strength, have primarily been used for construction and civil engineering purposes; however, following the recent trend toward lightweight automotive materials, their application is expanding to automotive interior and exterior materials. Furthermore, long-fiber nonwoven fabrics are being utilized because they offer lower weight while maintaining the same strength as conventional woven or short-fiber interior materials. Major product categories in which they are applied include tile carpets, automotive floor carpets, undercovers, and head linear products.

[0007] Recently, there has been a demand for the development of nonwoven fabrics for carpet bases that have excellent sound absorption and sound absorption properties.

[0008]

[0009] The present invention is intended to provide a spunbond nonwoven fabric that has improved toughening and sound absorption performance and excellent antibacterial properties.

[0010] In addition, the present invention is intended to provide a method for manufacturing the spunbond nonwoven fabric.

[0011] And, the present invention is to provide a carpet comprising the spunbond nonwoven fabric.

[0012]

[0013] According to one embodiment of the invention, a spunbond nonwoven fabric is provided, comprising a fiber web in which a first polyester filament with a hollow cross section and a second polyester filament with a different cross section are blended, wherein the first polyester filament comprises a polyester having a melting point of 250°C or higher, and the second polyester filament comprises a polyester having a melting point of 250°C or higher and a polyester having a melting point of 150°C or higher and 220°C or lower.

[0014]

[0015] According to another embodiment of the invention, a method for manufacturing a spunbond nonwoven fabric is provided, comprising the steps of: forming a first polyester filament by melt-spinning a polyester having a melting point of 250°C or higher; forming a second polyester filament by melt-spinning a polyester having a melting point of 250°C or higher and a polyester having a melting point of 150°C or higher and 220°C or lower; forming a fiber web in which the first filament and the second filament are blended; and forming a spunbond nonwoven fabric by heat-treating the fiber web under pressure; wherein the first polyester filament comprises a hollow cross-section filament and the second polyester filament comprises a heterogeneous cross-section filament.

[0016]

[0017] According to another embodiment of the invention, a carpet comprising the spunbond nonwoven fabric as a base is provided.

[0018]

[0019] Hereinafter, a spunbond nonwoven fabric, a method for manufacturing a spunbond nonwoven fabric, and a carpet including the same according to embodiments of the present invention will be described in more detail.

[0020]

[0021] Unless explicitly stated otherwise in this specification, technical terms are used merely to refer to specific embodiments and are not intended to limit the invention.

[0022] The singular forms used in this specification include plural forms unless the phrases clearly indicate otherwise.

[0023] As used in this specification, the meaning of “includes” specifies certain characteristics, regions, integers, steps, actions, elements, and / or components, and does not exclude the existence or addition of other specific characteristics, regions, integers, steps, actions, elements, components, and / or groups.

[0024] In this specification, terms including ordinal numbers, such as "first" and "second," are used for the purpose of distinguishing one component from another and are not limited by said ordinal numbers. For example, within the scope of the present invention, the first component may also be named the second component, and similarly, the second component may be named the first component.

[0025]

[0026] According to one embodiment of the invention, a spunbond nonwoven fabric is provided, comprising a fiber web in which a first polyester filament with a hollow cross section and a second polyester filament with a different cross section are blended, wherein the first polyester filament comprises a polyester having a melting point of 250°C or higher, and the second polyester filament comprises a polyester having a melting point of 250°C or higher and a polyester having a melting point of 150°C or higher and 220°C or lower.

[0027]

[0028] As a result of the inventors' research, it was confirmed that a spunbond nonwoven fabric satisfying the configurations of the above embodiment has improved toughening performance and sound absorption performance, and can achieve excellent antibacterial properties.

[0029] Specifically, the inventors confirmed through experiments that by including a fiber web in which a first polyester filament with a hollow cross section and a second polyester filament with a different cross section are blended, the tufting performance can be improved by reducing the frictional force between the filament and the needle during tufting due to the increase in nonwoven fabric thickness caused by the pores between the hollow fiber and the different fiber, and the sound absorption performance can also be maximized by increasing the amount of sound absorbed as the pore size increases.

[0030]

[0031] According to one embodiment, the spunbond nonwoven fabric comprises a fiber web in which a first polyester filament with a hollow cross section and a second polyester filament with a different cross section are blended.

[0032] As described above, in one embodiment, the spunbond nonwoven fabric comprises a fiber web in which a first polyester filament with a hollow cross section and a second polyester filament with a different cross section are blended. Consequently, the pores between the hollow fiber and the different fiber increase the thickness of the nonwoven fabric, thereby reducing the frictional force between the filament and the needle during tufting, which can improve the tufting performance. Additionally, the sound absorption performance can be maximized by increasing the amount of sound absorbed as the pore size increases.

[0033] Specifically, the first polyester filament may include a polyester having a melting point of 250°C or higher.

[0034] More specifically, the first polyester filament has a melting point of 250°C or higher, or 250°C to 265°C, or 250°C to 260°C, or 255°C to 260°C.

[0035] For example, the first polyester filament may include one or more first polyesters selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, polytetrafluoroethylene, and copolymers thereof, which satisfy the melting point range.

[0036]

[0037] In the above embodiment, the fiber web may comprise 51 to 95 weight percent of the first polyester filament and 5 to 49 weight percent of the second polyester filament.

[0038] For example, the first polyester filament may be included in an amount of 51 to 95 weight percent with respect to the total weight of the fiber web, and the second polyester filament may be included in an amount of 5 to 49 weight percent. That is, the first polyester filament may be included in excess of the second polyester filament.

[0039] In order to secure the bonding strength of the filaments in the fiber web above, it is preferable that the second polyester filament be included in an amount of 5 wt% or more, 8 wt% or more, or 49 wt% or less, 40 wt% or less, 25 wt% or less, 10 wt% or less, 5 wt% or more and 49 wt% or less, 5 wt% or more and 40 wt% or less, 5 wt% or more and 25 wt% or less, 5 wt% or more and 10 wt% or less, 8 wt% or more and 49 wt% or less, 8 wt% or more and 40 wt% or less, 8 wt% or more and 25 wt% or less, or 8 wt% or more and 10 wt% or less.

[0040] If the above second polyester filament is included in an excessively small amount, the mechanical strength of the nonwoven fabric may be reduced due to a lack of bonding strength between filaments, and if it is included in an excessively large amount, filament clumping may occur due to insufficient cooling of the filaments, which may reduce spinning workability, and problems with operation such as roll curling of the nonwoven fabric may occur due to increased stickiness of the calender roll.

[0041]

[0042] In addition, the fiber web may contain 5 parts by weight or more and 99 parts by weight or less of the second polyester filament with respect to 100 parts by weight of the first polyester filament.

[0043] Specifically, the fiber web may contain the second polyester filament in an amount of 5 parts by weight or more, 10 parts by weight or more, 99 parts by weight or less, 50 parts by weight or less, 25 parts by weight or less, 20 parts by weight or less, 15 parts by weight or less, 5 parts by weight or more and 99 parts by weight or less, 5 parts by weight or more and 50 parts by weight or less, 5 parts by weight or more and 25 parts by weight or less, 5 parts by weight or more and 20 parts by weight or less, 5 parts by weight or more and 15 parts by weight or less, 10 parts by weight or more and 99 parts by weight or less, 10 parts by weight or more and 50 parts by weight or less, 10 parts by weight or more and 25 parts by weight or less, 10 parts by weight or more and 20 parts by weight or less, and 10 parts by weight or more and 15 parts by weight or less, based on 100 parts by weight of the first polyester filament.

[0044] If the above second polyester filament is included in an excessively small amount, the mechanical strength of the nonwoven fabric may be reduced due to insufficient bonding strength between filaments, and if it is included in an excessively large amount, filament clumping may occur due to insufficient cooling of the filaments, which may reduce spinning workability, and problems with operation such as roll curling of the nonwoven fabric may occur due to increased stickiness of the calender roll.

[0045]

[0046] According to one embodiment, the first polyester filament comprises a hollow cross-section filament.

[0047]

[0048] The above-mentioned hollow cross-section filament is a filament in which the center of its cross section is hollow. The above-mentioned hollow cross-section filament may have a hollow circular cross section or a hollow irregular cross section.

[0049] Preferably, the hollow cross-section filament may have a hollow ratio of 10% to 30% (percentage of the inscribed circle area based on the circumscribed circle area of ​​the hollow cross-section).

[0050] In order to maintain a hollow shape during the spinning process of the filament, it is preferable that the hollowness of the hollow cross-section filament be 10% or more. However, if the hollowness is excessive, the mechanical properties of the filament may deteriorate and it may be difficult to maintain the hollow shape. Therefore, it is preferable that the hollowness of the hollow cross-section filament be 30% or less. Specifically, the hollowness of the hollow cross-section filament may be 10% to 30%, or 10% to 25%, or 10% to 20%.

[0051] If the hollowness of the above hollow cross-section filament becomes excessively small, the pressure on the die increases excessively during spinning, which may cause deformation and damage to the die; if it becomes excessively large, the spinnability of the filament decreases, and at the same time, a problem may arise where it becomes impossible to manufacture a filament of the appropriate fineness.

[0052]

[0053] In addition, the cross-sectional area of ​​the first polyester filament may be 0.12 mm² or more and 0.2 mm² or less. Specifically, the cross-sectional area of ​​the first polyester filament is 0.12 mm² or more, 0.13 mm² or more, 0.135 mm² or more, 0.2 mm² or less, 0.18 mm² or less, 0.15 mm² or less, 0.12 mm² or more and 0.2 mm² or less, 0.12 mm² or more and 0.18 mm² or less, 0.12 mm² or more and 0.15 mm² or less, 0.13 mm² or more and 0.2 mm² or less, 0.13 mm² or more and 0.18 mm² or less, 0.13 mm² or more and 0.15 mm² or less, 0.135 mm² or more and 0.2 mm² or less, and 0.135 mm² or more and 0.18 mm². It may be less than or equal to 0.135 mm² or greater and less than or equal to 0.15 mm².

[0054] If the cross-sectional area of ​​the first polyester filament becomes excessively small, the pressure on the die increases excessively during spinning, which may cause deformation and damage to the die; if it becomes excessively large, the spinnability of the filament decreases, and at the same time, a problem may arise in which it becomes impossible to manufacture a suitable fineness.

[0055]

[0056] In addition, the first polyester filament may include a metal-containing masterbatch.

[0057] As the first polyester filament above includes a metal-containing masterbatch, it is possible to eliminate odors caused by the proliferation and fermentation of microorganisms and inhibit the proliferation of bacteria, thereby enabling excellent antibacterial properties.

[0058] Specifically, the type of the above metal is not significantly limited, but may include, for example, silver.

[0059]

[0060] The first polyester filament may contain 0.5 parts by weight or more and 3.0 parts by weight or less of the metal-containing masterbatch per 100 parts by weight of the polyester having a melting point of 250°C or higher.

[0061] Specifically, the first polyester filament may contain the metal-containing masterbatch in an amount of 0.5 parts by weight or more, 0.6 parts by weight or more, 3.0 parts by weight or less, 2.8 parts by weight or less, or 2.0 parts by weight or less, or 0.5 parts by weight or more and 3.0 parts by weight or less, 0.5 parts by weight or more and 2.8 parts by weight or less, 0.5 parts by weight or more and 2.0 parts by weight or less, 0.6 parts by weight or more and 3.0 parts by weight or less, 0.6 parts by weight or more and 2.8 parts by weight or less, or 0.6 parts by weight or more and 2.0 parts by weight or less, based on 100 parts by weight of the polyester having a melting point of 250°C or higher.

[0062] If the first polyester filament contains an excessively small amount of the metal-containing masterbatch with respect to 100 parts by weight of polyester having a melting point of 250°C or higher, the antibacterial properties may not be sufficiently realized, and if it contains an excessively large amount, the spinnability is inferior, and a problem arises in that it cannot be manufactured into a nonwoven fabric.

[0063]

[0064] The first polyester filament may have a fineness of 3 denier or more and 10 denier or less. Specifically, the first polyester filament may have a fineness of 3 denier or more, 6 denier or more, 10 denier or less, 9 denier or less, or 3 denier or more and 10 denier or less, 3 denier or more and 9 denier or less, 6 denier or more and 10 denier or less, or 6 denier or more and 9 denier or less.

[0065] If the fineness of the first polyester filament is less than 3 denier, technical problems such as shaking and cutting of the filament due to cooling air speed may occur, and if it exceeds 10 denier, technical problems such as leakage due to excessive increase in pack pressure may occur.

[0066]

[0067] In the above embodiment, the second polyester filament may include a polyester having a melting point of 250°C or higher and a polyester having a melting point of 150°C or higher and 220°C or lower.

[0068] Specifically, the second polyester filament may include two types of polyester having a melting point of 250°C or higher, or 250°C to 265°C, or 250°C to 260°C, or 255°C to 260°C, and a melting point of 150°C to 220°C, or 160°C to 220°C, or 160°C to 210°C, or 170°C to 210°C.

[0069] As the above second polyester filament includes a polyester with a melting point of 250°C or higher and a polyester with a melting point of 150°C or higher and 220°C or lower, the effect of the physical properties of the nonwoven fabric produced by the adhesion effect with the first filament can be realized.

[0070]

[0071] That is, in the above embodiment, the second polyester filament may include two types of polyester having a melting point difference of 30°C or more.

[0072] Specifically, in the above embodiment, the second polyester filament may include two types of polyester having a melting point difference of 30°C or more, 50°C or more, 80°C or more, 85°C or more, or 30°C or more, 50°C or more and 100°C or less, 80°C or more and 100°C or less, 85°C or more and 100°C or less, 50°C or more and 90°C or less, 80°C or more and 90°C or less, or 85°C or more and 9°C or less.

[0073] As the above second polyester filament includes two types of polyester with a melting point difference of 30°C or more, the effect of the physical properties of the nonwoven fabric produced by the adhesion effect with the first filament can be realized.

[0074]

[0075] For example, the second polyester filament may include one or more second polyesters selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, polytetrafluoroethylene, and copolymers thereof, which satisfy the melting point range.

[0076]

[0077] Specifically, the second polyester filament may contain 5 parts by weight or more and 99 parts by weight or less of a polyester having a melting point of 150°C or more and 220°C or less, for every 100 parts by weight of a polyester having a melting point of 250°C or more.

[0078] More specifically, the second polyester filament comprises, for every 100 parts by weight of the polyester having a melting point of 250°C or higher, 5 parts by weight or more, 10 parts by weight or more, 15 parts by weight or more, 99 parts by weight or less, 50 parts by weight or less, 25 parts by weight or less, 20 parts by weight or less, 5 parts by weight or more and 99 parts by weight or less, 5 parts by weight or more and 50 parts by weight or less, 5 parts by weight or more and 25 parts by weight or less, 5 parts by weight or more and 20 parts by weight or less, 10 parts by weight or more and 99 parts by weight or less, 10 parts by weight or more and 50 parts by weight or less, 10 parts by weight or more and 25 parts by weight or less, 10 parts by weight or more and 20 parts by weight or less, 15 parts by weight or more and 99 parts by weight or less, 15 parts by weight or more and 50 parts by weight or less, 15 parts by weight or more and 25 parts by weight or less. It may contain 15 parts by weight or more and 20 parts by weight or less.

[0079] If the second polyester filament contains an excessively small amount of polyester with a melting point of 150°C or higher and 220°C or lower relative to 100 parts by weight of polyester with a melting point of 250°C or higher, the adhesion effect with the first filament is reduced, which may result in a technical problem of delamination of the nonwoven fabric being manufactured. If it contains an excessively large amount, technical problems such as unoriented surface and poor fiber opening on the surface of the nonwoven fabric may occur due to insufficient cooling performance.

[0080] The second polyester filament may have a different cross-section. That is, the second polyester filament may be a filament with a different cross-section.

[0081] The above-described irregular cross-section filament is a filament having a cross-section other than a circular one. For example, the above-described irregular cross-section filament may have a Y-shaped, W-shaped, triangular, star-shaped, cross-shaped, flat, or multi-lobed cross-section.

[0082]

[0083] The second polyester filament may have a fineness of 1 denier or more and 5 denier or less. Specifically, the second polyester filament may have a fineness of 1 denier or more and 5 denier or less, or 1 denier or more and 4 denier or less.

[0084] Technical problems such as shaking and cutting of the filament may occur due to cooling wind speed, etc., when the fineness of the second polyester filament is less than 1 denier, and technical problems such as leakage problems due to excessive increase in Pack pressure may occur when the fineness exceeds 5 denier.

[0085]

[0086] The first polyester filament and the second polyester filament may have a fineness difference of 2 denier or more and 8 denier or less. Specifically, the fineness difference may be 2 denier or more and 8 denier or less, or 3 denier or more and 8 denier or less.

[0087]

[0088] The weight and thickness of the above spunbond nonwoven fabric are not particularly limited and can be adjusted within an appropriate range depending on the application field.

[0089] Preferably, the spunbond nonwoven fabric is 80 g / m² 2 150 g / m² or more 2 Below, 80 g / m² 2 125 g / m² or more 2 Below, 100 g / m² 2 150 g / m² or more 2 Below, 100 g / m² 2 125 g / m² or more 2 It can have a weight per unit area of ​​less than or equal to

[0090] In addition, the spunbond nonwoven fabric may have a thickness of 0.40 mm or more and 0.65 mm or less, 0.50 mm or more and 0.65 mm or less, and 0.60 mm or more and 0.65 mm or less.

[0091] The method for measuring the thickness of the above is not significantly limited, but, for example, it can be measured using the KS K ISO 9073-2 method.

[0092]

[0093] According to another embodiment of the invention, a method for manufacturing a spunbond nonwoven fabric is provided, comprising the steps of: forming a first polyester filament by melt-spinning a polyester having a melting point of 250°C or higher; forming a second polyester filament by melt-spinning a polyester having a melting point of 250°C or higher and a polyester having a melting point of 150°C or higher and 220°C or lower; forming a fiber web in which the first filament and the second filament are blended; and forming a spunbond nonwoven fabric by heat-treating the fiber web under pressure; wherein the first polyester filament comprises a hollow cross-section filament and the second polyester filament comprises a heterogeneous cross-section filament.

[0094]

[0095] According to one embodiment, the spunbond nonwoven fabric can be manufactured by melt-spinning a first polyester and a second polyester to form a fiber web in which the first polyester filament and the second polyester filament are blended, and then heat-treating the web under pressure.

[0096]

[0097]

[0098] In the above manufacturing method, the characteristics of the first polyester, the first polyester filament, the second polyester, and the second polyester filament are as described above.

[0099]

[0100] According to one embodiment, the first polyester and the second polyester may be formed by independently melting each and spinning through separate die-cutting tubes. Alternatively, the first polyester and the second polyester may be formed by melting each and spinning through a single die-cutting tube capable of controlling the number and shape of the extrusion holes of the heterogeneous resin.

[0101]

[0102] In the above melt spinning, the spinning speed and tension can be controlled by taking into account the fineness of the first and second polyester filaments.

[0103] In addition, the step of forming the first and second polyester filaments is preferably performed under a spinning speed of 4,000 m / min to 6,000 m / min, 4,500 m / min to 6,000 m / min, or 4,500 m / min to 5,500 m / min, respectively. In order to form filaments having an appropriate degree of crystallinity, the spinning speed is preferably 4,000 m / min or 4,500 m / min or higher. However, if the spinning speed is excessive, entanglement of the filaments may occur during the spinning process, which may reduce the uniformity of the nonwoven fabric. Therefore, the spinning speed is preferably 6,000 m / min or lower, or 5,500 m / min or lower.

[0104]

[0105] The first and second polyester filaments are blended to form the fiber web. The blended first and second polyester filaments are laminated onto a net conveyor that moves continuously by conventional fiber opening methods such as electrostatic charging, impact plate method, and airflow diffusion method to form the fiber web. Here, it is preferable that the fiber web comprises 50 to 95 weight percent of the first polyester filament and 5 to 50 weight percent of the second polyester filament.

[0106]

[0107] Next, a step is performed to form a spunbond nonwoven fabric by heat-treating the fiber web under pressure.

[0108] The above step is to obtain a spunbond nonwoven fabric by heat-bonding the filaments contained in the fiber web. For example, a spunbond nonwoven fabric with appropriate smoothness and thickness is obtained by passing the fiber web through a heated roll. Conventional devices such as a calender roll and an emboss roll may be used in the above step. The roll is heated to a temperature capable of melting the second polyester filament to a bondable degree.

[0109]

[0110] According to another embodiment of the invention, a carpet comprising the spunbond nonwoven fabric as a base layer can be provided. By using the spunbond nonwoven fabric as a base layer of the carpet, a carpet having excellent sound absorption and antibacterial properties can be provided.

[0111]

[0112] In the present invention, a carpet can be provided by using a nonwoven fabric provided according to the method described above and performing a tufting process, a back coating process, and a cutting process according to a well-known method.

[0113]

[0114] According to the present invention, a spunbond nonwoven fabric having improved toughening performance and sound absorption performance and excellent antibacterial properties, a method for manufacturing the spunbond nonwoven fabric, and a carpet including the same are provided.

[0115]

[0116] Preferred embodiments are presented below to aid in understanding the invention. However, the following embodiments are merely illustrative of the invention and do not limit the invention to these embodiments.

[0117]

[0118] Example 1

[0119] Polyethylene terephthalate (PET; first polyester) having a melting point of 255 °C and a copolymer polyester (PET + Co-PET; second polyester, weight ratio 85:15) having a melting point of 170 °C and a melting point of 255 °C were each melted using a continuous extruder at 280 °C.

[0120] The above first polyester melt and silver-containing antimicrobial masterbatch (0.6 wt% relative to the total weight of polyethylene terephthalate having a melting point of 255 °C) were spun through a spinning pack equipped with a die having a hollow cross-section discharge hole to form a hollow cross-section filament (hollow ratio 20%) having the fineness listed in Table 1 below. After solidifying the continuous filament spun through the spinning pack with cooling air, the first polyester filament was obtained by stretching it using a high-pressure air stretching device to a spinning speed of 5000 m / min.

[0121] The above second polyester melt was extruded through a die having a shaped cross-section discharge hole (Y-shaped), and the continuous filament extruded through the spinning pack was solidified with cooling air, and then stretched to a spinning speed of 5000 m / min using a high-pressure air stretching device to form a second polyester filament.

[0122] The first polyester filament and the second polyester filament were blended so that their weight ratio was 90:10 (weight%), and the blended fibers were laminated on a continuously moving net conveyor to form a fiber web.

[0123]

[0124] The above fiber web is passed through a smooth roller maintaining 150°C and 30 N / mm and hot-air dried at 180°C to produce a spunbond nonwoven fabric (weight per unit area 120 g / m² 2 , thickness 0.54 mm) was manufactured.

[0125]

[0126] Examples 2~4

[0127] A spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that the masterbatch content in the first polyester filament and the fineness of the first polyester filament and the second polyester filament were each adjusted as shown in Table 1 below.

[0128]

[0129] Comparative Example 1

[0130] Polyethylene terephthalate (PET; first polyester) having a melting point of 255 ℃ and copolymer polyester (PET + Co-PET; second polyester, weight ratio 85:15) having a melting point of 170 ℃ were each melted using a continuous extruder at 280 ℃.

[0131]

[0132] The above first polyester melt and silver-containing antimicrobial masterbatch (0.6 wt% relative to the total weight of polyethylene terephthalate having a melting point of 255 °C) were spun through a spinning pack equipped with a die having a hollow cross-section discharge hole and a shaped cross-section discharge hole to form a hollow cross-section filament (hollow ratio 10%) and a shaped cross-section filament (Y-shaped cross-section) having the fineness listed in Table 1 below. After solidifying the continuous filament spun through the spinning pack with cooling air, the filament was stretched using a high-pressure air stretching device to achieve a spinning speed of 5000 m / min to obtain the first polyester filament. At this time, the first polyester filament was prepared to include 50 wt% of the hollow cross-section filament and 50 wt% of the shaped cross-section filament.

[0133] The above second polyester melt was extruded through a die having a circular cross-section discharge hole to form a second polyester filament having a fineness of 5 denier.

[0134] The first polyester filament and the second polyester filament were blended so that their weight ratio was 90:10 (weight%), and the blended fibers were laminated on a continuously moving net conveyor to form a fiber web.

[0135] A spunbond nonwoven fabric was manufactured by passing the above fiber web through a calender roll and an emboss roll maintained at 200°C and 35 N / mm.

[0136]

[0137] Comparative Example 2

[0138] A spunbond nonwoven fabric was prepared in the same manner as in Example 1, except that one type of copolymer polyester (Co-PET) having a melting point of 170°C was used as the second polyester.

[0139]

[0140] Comparative Example 3

[0141] A spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that a masterbatch was not added when manufacturing the first polyester filament.

[0142]

[0143] Comparative Example 4-5

[0144] A spunbond nonwoven fabric was manufactured in the same manner as Example 1, except that the amount of masterbatch added during the manufacture of the first polyester filament was adjusted as shown in Table 1 below.

[0145]

[0146] Comparative Example 6

[0147] A spunbond nonwoven fabric was prepared in the same manner as in Example 1, except that the weight ratio between the second polyester, which has a melting point of 255 °C and a copolymer polyester, which has a melting point of 170 °C, was adjusted to 50:50.

[0148]

[0149] Comparative Examples 7~10

[0150] A spunbond nonwoven fabric was manufactured in the same manner as in Example 1, except that the masterbatch content in the first polyester filament and the fineness of the first polyester filament and the second polyester filament were each adjusted as shown in Table 1 below.

[0151]

[0152] First polyester filament, second polyester filament, nonwoven fabric weight (g / m²) 2Nonwoven Fabric Thickness (mm) Fineness Masterbatch Content (wt%) Fineness Example 1 5 1.05 1200.55 Example 2 6 0.63 1200.54 Example 3 7 1.84 1200.58 Example 4 9 2.81 1200.61 Example 5 3 2.05 1200.51 Comparative Example 1 Hollow section: 7 Irregular section: 21.05 1200.72 Comparative Example 2 5 1.05 1200.60 Comparative Example 3 5 0.51 200.56 Comparative Example 4 5 0.25 1200.55 Comparative Example 5 5 5.05 1200.57 Comparative Example 6 5 1.05 1200.54 Comparative Example 7 2 2.02 1200.30 Comparative Example 880.231200.56 Comparative Example 9132.14 Sheet manufacturing impossible Comparative Example 1011.812 Sheet manufacturing impossible

[0153]

[0154] Test example

[0155] (1) Thickness of nonwoven fabric

[0156] The thickness of the nonwoven fabric was measured according to the Korean Standards Association KS K ISO 9073-2:2006.

[0157] The distance between the reference plate on which the nonwoven fabric specimen was placed and the pressure device parallel to the reference plate that applies a specified pressure to the nonwoven fabric was measured. Ten nonwoven fabric specimens (20 cm x 20 cm) were prepared for each example and comparative example, and the average thickness values ​​are shown in Table 2 below. A ProGage Thickness Tester from Thwing-Albert Instruments was used to measure the thickness.

[0158]

[0159] (2) Radioactive

[0160] The nonwoven fabrics according to the examples and comparative examples were evaluated based on the occurrence of filament detachment and breakage, and the uniformity of the fiber web, according to the following criteria.

[0161] - ◎ : Filament detachment and breakage are very minimal, and normal filaments are continuously laminated onto the net to form a very uniform nonwoven fabric.

[0162] - ○ : Filament detachment and breakage are minimal, and normal filaments are continuously laminated onto the net to form a relatively uniform nonwoven fabric.

[0163] - △ : Numerous filament breaks occur, and the filaments are abnormal, but nonwoven fabric formation is possible.

[0164] - X: Frequent filament breakage occurs, and the filaments are abnormal, making it difficult to form the nonwoven fabric.

[0165]

[0166] (3) Fudo

[0167] The thickness of the nonwoven fabric according to the examples and comparative examples was measured using the KS K ISO 9073-2 method.

[0168] Specifically, 10 specimens with an area of ​​20cm x 20cm were prepared, and the specimens were fixed on a measuring plate using the Progage Thickness Gauge equipment from Thwing-Albert Instrument. Then, pressure was applied uniformly to the specimens through a pressure needle, and the thickness was measured by moving a horizontal bar downward until it touched the surface of the measuring plate.

[0169]

[0170] (4) Toughening performance

[0171] It was evaluated using Le Clair & Meert's ID344 Grade equipment, and GPI (Gage

[0172] The experiment was conducted under conditions of Per Inch 1 / 10 and SPI (Stroke per Inch) 1 / 10, and evaluated as follows based on the arrangement uniformity of BCF (Bulky Continuous Filament) embedded on the surface of the nonwoven fabric.

[0173] - ○ : BCF (Bulky Continuous Filament) is arranged in a line.

[0174] - X : Cases where the BCF (Bulky Continuous Filament) is arranged in a zigzag pattern or where the nonwoven fabric is damaged during tufting, making the work impossible.

[0175]

[0176] (5) Antibacterial properties

[0177] The antimicrobial activity of the nonwoven fabrics according to the examples and comparative examples was evaluated against Staphylococcus aureus and Klebsiella pneumoniae according to the AATCC174 evaluation standard (Antimicrobial Activity, Assessment on New Carpets).

[0178] - ○ : The above antibacterial activity is 99% or higher

[0179] - X : The above antibacterial activity is less than 99%

[0180]

[0181] (6) Sound absorption (NRC: Noise Reduction Coefficient)

[0182] The sound absorption of the nonwoven fabric according to the examples and comparative examples was measured using the in-pipe method (KS F 2814).

[0183] Specifically, the evaluation was performed using the HM-02 I / O (Manufacturer: Scein, South Korea) equipment, and all results obtained by repeatedly measuring frequencies at 250Hz, 500Hz, 1,000Hz, and 2000Hz were divided by the average value to be expressed as a single index.

[0184] ※ NRC = (a250+a500+a1,000+a2,000) / 4 [aX : Sound absorption coefficient at X Hz (X is a number)]

[0185]

[0186] Nonwoven Fabric Thickness (mm) Toughening Performance Antibacterial Properties Sound Absorption (NRC) Example 10.55 0.43 Example 20.54 0.42 Example 30.60 0.50 Example 40.65 0.54 Example 50.59 0.47 Comparative Example 10.72 0.61 Comparative Example 2 Nonwoven fabric manufacturing impossible Comparative Example 30.56 0.43 Comparative Example 40.55 0.42 Comparative Example 5 Nonwoven fabric manufacturing impossible Comparative Example 6 Nonwoven fabric manufacturing impossible Comparative Example 70.38 0.23 Comparative Example 80.58 0.53 Comparative Example 9 Nonwoven fabric manufacturing impossible Comparative Example 10 Nonwoven fabric manufacturing impossible

[0187] Referring to Tables 1 and 2 above, it was confirmed that the spunbond nonwoven fabrics of the examples exhibited a thickness of 0.54 mm or more, indicating excellent toughening performance, as well as excellent sound absorption performance and antibacterial properties of 0.42 or more. Comparative Example 1 showed poor toughening performance, and Comparative Example 2 was found to be unable to manufacture a nonwoven fabric because only one type of copolymer polyester (Co-PET) with a melting point of 170 °C was used as the second polyester.

[0188] Comparative Examples 3 and 4 showed poor antibacterial properties compared to the Examples.

[0189] In addition, Comparative Examples 5 and 6 confirmed that nonwoven fabric could not be manufactured due to filament breakage.

[0190] In the case of Comparative Example 7, it was confirmed that the thickness was poor, resulting in poor toughening performance and poor sound absorption.

[0191] In the case of Comparative Example 8, it was confirmed that the antibacterial properties were poor.

[0192] In addition, it was confirmed that nonwoven fabric manufacturing was not possible in the case of Comparative Examples 9 and 10.

[0193]

[0194] Although the present invention has been described above by limited embodiments, the present invention is not limited thereto, and it is obvious that various modifications and variations are possible within the scope of the technical spirit of the present invention and the equivalent scope of the claims described below by those skilled in the art to which the present invention belongs.

Claims

1. A fiber web comprising a first polyester filament with a hollow cross section and a second polyester filament with a different cross section, and The first polyester filament comprises a polyester having a melting point of 250°C or higher, and The above second polyester filament is a spunbond nonwoven fabric comprising a polyester having a melting point of 250°C or higher and a polyester having a melting point of 150°C or higher and 220°C or lower.

2. In Paragraph 1, The first polyester filament is a spunbond nonwoven fabric comprising a metal-containing masterbatch.

3. In Paragraph 2, A spunbond nonwoven fabric comprising, for every 100 parts by weight of the first polyester filament having a melting point of 250°C or higher, 0.5 parts by weight or more and 3.0 parts by weight or less of the metal-containing masterbatch.

4. In Paragraph 1, The fiber web is a spunbond nonwoven fabric comprising 51 to 95 weight percent of the first polyester filament and 5 to 49 weight percent of the second polyester filament.

5. In Paragraph 1, The above fiber web is a spunbond nonwoven fabric comprising 5 parts by weight or more and 99 parts by weight or less of the second polyester filament per 100 parts by weight of the first polyester filament.

6. In Paragraph 1, The above second polyester filament is a spunbond nonwoven fabric comprising 5 parts by weight or more and 99 parts by weight or less of a polyester having a melting point of 150°C or more and 220°C or less, for every 100 parts by weight of a polyester having a melting point of 250°C or more.

7. In Paragraph 1, The first polyester filament is a spunbond nonwoven fabric having a fineness of 3 denier or more and 10 denier or less.

8. In Paragraph 1, The above second polyester filament is a spunbond nonwoven fabric having a fineness of 1 denier or more and 5 denier or less.

9. In Paragraph 1, The first polyester filament is a spunbond nonwoven fabric having a hollow ratio of 10% to 30% (percentage of the inscribed circle area based on the circumscribed circle area of ​​the hollow cross-section).

10. In Paragraph 1, The second polyester filament is a spunbond nonwoven fabric having a Y-shaped, W-shaped, triangular, star-shaped, cross-shaped, flat, or multi-lobed cross section.

11. In Paragraph 1, 80 g / m 2 150 g / m² or more 2 Spunbond nonwoven fabric having a weight per unit area of ​​less than or equal to 12. In Paragraph 1, Spunbond nonwoven fabric having a thickness of 0.40 mm or more and 0.65 mm or less.

13. A step of forming a first polyester filament by melt-spinning a polyester having a melting point of 250°C or higher; A step of forming a second polyester filament by melt-spinning a polyester having a melting point of 250 ℃ or higher and a polyester having a melting point of 150 ℃ or higher and 220 ℃ or lower; A step of forming a fiber web in which the first filament and the second filament are mixed; and The method includes the step of forming a spunbond nonwoven fabric by heat-treating the fiber web under pressure. The first polyester filament above includes a hollow cross-section filament, and A method for manufacturing a spunbond nonwoven fabric, wherein the second polyester filament comprises a filament with a different cross-section.

14. In Paragraph 13, A method for manufacturing a spunbond nonwoven fabric, wherein the step of forming the first polyester filament and the second polyester filament is performed at a spinning speed of 4000 m / min to 6000 m / min, respectively.

15. A carpet comprising the spunbond nonwoven fabric of claim 1 as a base.