Non-woven fabric laminate for carpet base fabric and carpet comprising same

Abstract

The present invention relates to a non-woven fabric laminate for carpet base fabric and a carpet comprising same. According to the present invention, provided are a non-woven fabric laminate for carpet base fabric and a carpet comprising same, in which the non-woven fabric laminate for carpet base fabric provides good workability in a tufting process for manufacturing carpets, exhibits excellent mechanical properties, and is easily recyclable.

Description

Nonwoven fabric laminate for carpet backing and carpet including the same

[0001] The present invention relates to a nonwoven fabric laminate for carpet foam and a carpet including the same.

[0002]

[0003] Carpets are widely used products to enhance the aesthetic elements of indoor spaces and provide comfort. Such carpets generally comprise a carpet base, carpet yarns implanted in the base, and a backing layer to secure the carpet yarns. The carpet yarns are also referred to as BCF (bulked continuous filament).

[0004] In currently commercialized carpets, latex is widely used to reinforce the fixation of the backing layer. Latex possesses strong adhesive properties and is considered a suitable material for firmly securing carpet yarns onto a backing sheet. However, the use of latex raises several significant issues. First, due to its chemical properties, latex makes it difficult to reuse or recycle carpets that have reached the end of their lifespan. This characteristic hinders the circular economy and acts as a factor that increases the burden of waste management. Second, adhesives applied to the backing layer to replace latex or enhance fixation can release volatile organic compounds (VOCs) during the manufacturing and use of the carpet. Excessive exposure to VOCs is not only harmful to human health but can also cause environmental pollution, potentially leading to even greater problems.

[0005] Meanwhile, manufacturing a carpet requires a tufting process in which carpet yarns are implanted into a non-woven carpet backing using needles. However, during this tufting process, the filaments constituting the carpet backing are damaged by the needles penetrating at high speed, causing a deterioration in the mechanical properties of the carpet backing.

[0006] Therefore, developing carpets that secure the mechanical properties of foam sheets for carpets, facilitate the reuse and recycling of carpets at the end of their lifespan, and are not harmful to the human body or the environment is one of the urgent tasks that must be solved in this technical field.

[0007]

[0008] The present invention is intended to provide a nonwoven laminate for carpet base paper that exhibits excellent mechanical properties and is easy to recycle while providing good workability in the tufting process for carpet manufacturing.

[0009] And, the present invention is to provide a carpet comprising a nonwoven fabric laminate for carpet foam sheeting.

[0010]

[0011] According to one embodiment of the invention,

[0012] It includes a surface nonwoven fabric and a back nonwoven fabric stacked sequentially, and

[0013] The above surface nonwoven fabric comprises a fiber web in which polyester filaments with a melting point of 250°C or higher and polyester filaments with a melting point of 120 to 170°C are blended, and

[0014] The above-mentioned backing nonwoven fabric comprises a fiber web comprising a core-in-sheath type filament having a core portion comprising polyester with a melting point of 250°C or higher and a sheath portion comprising polyester with a melting point of 120 to 170°C,

[0015] A nonwoven laminate for carpet base paper is provided.

[0016]

[0017] According to one embodiment, the fiber web of the surface nonwoven fabric may comprise 70 to 95 weight percent of polyester filaments having a melting point of 250°C or higher and 5 to 30 weight percent of polyester filaments having a melting point of 120 to 170°C.

[0018]

[0019] According to one embodiment, in the fiber web of the surface nonwoven fabric, the polyester filament having a melting point of 250°C or higher has a fineness of 4 to 10 denier, and the polyester filament having a melting point of 120 to 170°C may have a fineness of 1 to 5 denier.

[0020]

[0021] According to one embodiment, in the fiber web of the back nonwoven fabric, the core-in-sheath type long fiber may include the core portion and the sheath portion in a weight ratio of 65:35 to 95:5.

[0022]

[0023] According to one embodiment, in the fiber web of the back nonwoven fabric, the core-in-sheath type long fibers may have a fineness of 4 to 10 denier.

[0024]

[0025] According to one embodiment, the surface nonwoven fabric and the back nonwoven fabric each have a g / m² of 30 to 200 g / m² 2 It can have a weight per unit area.

[0026]

[0027] According to one embodiment, the nonwoven fabric laminate has a weight of 60 to 400 g / m² 2 It can have a weight per unit area and a thickness of 0.2 to 2.0 mm.

[0028]

[0029] According to another embodiment of the invention,

[0030] It includes a nonwoven laminate for carpet base paper and a plurality of carpet yarns implanted on the surface nonwoven fabric of the nonwoven laminate for carpet base paper,

[0031] The carpet yarn penetrates the nonwoven laminate and is fixed by the fusion of the back nonwoven fabric,

[0032] A carpet is provided.

[0033]

[0034] According to one embodiment, the carpet yarn may be one or more selected from the group consisting of nylon yarn, polypropylene yarn, acrylic yarn, wool yarn, and cotton yarn.

[0035]

[0036] According to one embodiment, the carpet may have a tensile strength of 1.8 to 3.0 kgf according to the standard test method specified in KS K ISO 4919 (2015).

[0037]

[0038] According to another embodiment of the invention,

[0039] The step of providing the above nonwoven fabric laminate for carpet foam,

[0040] A tufting step of implanting carpet yarns onto the surface nonwoven fabric by penetrating the nonwoven fabric laminate, and

[0041] A fusion step of heat-treating the back nonwoven fabric of the nonwoven laminate to fix the carpet yarn onto the nonwoven laminate.

[0042] A method for manufacturing a carpet, comprising

[0043]

[0044] According to one embodiment, in the tufting step, the carpet yarn can be implanted as a single loop pile type.

[0045]

[0046] According to one embodiment, the heat treatment for the back nonwoven fabric can be performed at a temperature of 120°C to 170°C.

[0047]

[0048] According to the present invention, a nonwoven fabric laminate for carpet base paper that provides good workability in a tufting process for carpet manufacturing, exhibits excellent mechanical properties, and is easy to recycle, and a carpet including the same are provided.

[0049]

[0050] Hereinafter, a nonwoven fabric laminate for carpet foam and a carpet including the same, according to embodiments of the present invention, will be described in more detail.

[0051]

[0052] 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.

[0053] The singular forms used in this specification include plural forms unless the phrases clearly indicate otherwise.

[0054] 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.

[0055] 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.

[0056] As used herein, "denier" is a unit of fineness based on the mass (gram) per 9,000 meters of length of a single fiber strand. For example, 1 denier can be expressed as 1 g / 9,000 m, or 0.11 mg / m, or 0.11 tex.

[0057]

[0058] According to one embodiment of the invention,

[0059] It includes a surface nonwoven fabric and a back nonwoven fabric stacked sequentially, and

[0060] The above surface nonwoven fabric comprises a fiber web in which polyester filaments with a melting point of 250°C or higher and polyester filaments with a melting point of 120 to 170°C are blended, and

[0061] The above-mentioned backing nonwoven fabric comprises a fiber web comprising a core-in-sheath type filament having a core portion comprising polyester with a melting point of 250°C or higher and a sheath portion comprising polyester with a melting point of 120 to 170°C,

[0062] A nonwoven laminate for carpet base paper is provided.

[0063]

[0064] As a result of the inventors' research, it has been confirmed that a nonwoven laminate for carpet base paper satisfying the above composition can provide good workability in the tufting process for carpet manufacturing, exhibit excellent mechanical properties, and offer easy recyclability.

[0065] In the above nonwoven laminate for carpet base paper, the surface nonwoven fabric has relatively few bonding points between filaments constituting the fiber web and is flexible, so needles can easily pass through it during the tufting process. That is, the surface nonwoven fabric has less entanglement between filaments caused by needles during the tufting process and low frictional resistance, providing good workability and enabling uniform tufting.

[0066] In the above nonwoven laminate for carpet base paper, the back nonwoven fabric to which core-in-sheath type long fibers are applied can exhibit excellent mechanical strength and durability, and can increase the structural stability of the nonwoven laminate by providing excellent heat fusion.

[0067] In particular, since polyester with a melting point of 120 to 170°C is applied to the surface nonwoven fabric and the back nonwoven fabric of the above nonwoven fabric laminate, not only is the adhesion performance with other materials excellent, but the carpet yarn implanted in the above nonwoven fabric laminate for carpet base paper can also be firmly fixed.

[0068] In addition, the nonwoven laminate for carpet backing paper can fix the carpet yarns onto the nonwoven laminate by fusing the backing nonwoven fabric without using latex materials or adhesives typically applied to the backing layer. Accordingly, when a carpet reaches the end of its lifespan and is discarded, it is easy to separate the polyester material from other materials, thereby activating the circular economy and reducing the burden of waste management.

[0069]

[0070] The above nonwoven laminate for carpet foam includes a surface nonwoven fabric and a back nonwoven fabric that are sequentially laminated.

[0071] The above surface nonwoven fabric is a nonwoven fabric located on the side facing the needle during the tufting process in which the above nonwoven fabric laminate is used as a base material when manufacturing a carpet. And, the above back nonwoven fabric is a nonwoven fabric located on the side opposite to the side facing the needle during the tufting process. The above surface nonwoven fabric and the above back nonwoven fabric are bonded and laminated by heat bonding to form the above nonwoven fabric laminate.

[0072]

[0073] The above surface nonwoven fabric includes a fiber web in which a polyester filament with a melting point of 250°C or higher (hereinafter referred to as 'first polyester filament') and a polyester filament with a melting point of 120 to 170°C (hereinafter referred to as 'second polyester filament') are blended.

[0074]

[0075] 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.

[0076] According to one embodiment, the first polyester filament may comprise one or more polyesters selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, polytetrafluoroethylene, and copolymers thereof, which satisfy the melting point range.

[0077]

[0078] The second polyester filament has a melting point of 120 to 170 ℃.

[0079] Specifically, the second polyester filament has a melting point of 120°C or higher, or 130°C or higher, or 140°C or higher, or 150°C or higher; and 170°C or lower, or 169°C or lower, or 168°C or lower, or 167°C or lower.

[0080] If the melting point of the second polyester filament is less than 120°C, the degree of crystallization decreases due to the increased proportion of copolymerizing compounds applied to lower the melting point, making it difficult to form the filament and potentially weakening the mechanical strength and durability of the nonwoven fabric. Additionally, due to the low melting point, it may be difficult to maintain the shape and strength of the nonwoven fabric during the heat treatment process, and the desired physical properties may not be secured. Therefore, it is preferable that the melting point of the second polyester filament be 120°C or higher, or 130°C or higher, or 140°C or higher, or 150°C or higher.

[0081] However, if the melting point of the second polyester filament exceeds 170°C, the heat treatment temperature required to fix the fiber web during the formation of the surface nonwoven fabric needs to be increased, but the surface nonwoven fabric may undergo thermal deformation during the heat treatment process. Furthermore, the bonding strength between filaments and the interlayer bonding strength within the nonwoven fabric may decrease due to a reduction in thermal fusibility. Additionally, due to the high melting point, the sheath portion of the back nonwoven fabric may not melt sufficiently, raising concerns that the bonding strength between the carpet yarn and the nonwoven fabric laminate may be weakened. Consequently, a phenomenon known as 'yarn pull' may occur, where the carpet yarn is not embedded or comes out after the tufting process, and the tensile strength may decrease. Therefore, it is preferable that the melting point of the second polyester filament be 170°C or lower, or 169°C or lower, or 168°C or lower, or 167°C or lower.

[0082] Preferably, the second polyester filament may have a melting point of 120 to 170 ℃, or 130 to 170 ℃, or 130 to 169 ℃, or 140 to 169 ℃, or 140 to 168 ℃, or 150 to 168 ℃, or 150 to 167 ℃.

[0083] According to one embodiment, the second polyester filament may be formed using a copolyester that satisfies the melting point range.

[0084] The composition of the above copolyester is not particularly limited as long as it satisfies the melting point range. For example, the above copolyester may be obtained by using a dicarboxylic acid compound such as terephthalic acid and a diol compound such as ethylene glycol as main raw materials, and adding a comonomer such as isophthalic acid, adipic acid, and 1,4-cyclohydroxydimethylethanol, or by adding a low molecular weight monomer such as butylene glycol, neopentyl glycol, and butadiene. Preferably, the compound added in addition to the main raw materials to obtain the above copolyester may be included in an amount of 30 mol% or more of the total reactants.

[0085]

[0086] According to one embodiment, the fiber web of the surface nonwoven fabric comprises 70 to 95 weight% of the first polyester filament and 5 to 30 weight% of the second polyester filament.

[0087] For example, the fiber web may comprise 75 to 95 weight% of the first polyester filament and 5 to 25 weight% of the second polyester filament. For another example, the fiber web may comprise 75 to 90 weight% of the first polyester filament and 10 to 25 weight% of the second polyester filament. For yet another example, the fiber web may comprise 75 to 85 weight% of the first polyester filament and 15 to 25 weight% of the second polyester filament.

[0088] In order to secure the bonding strength of the filaments in the fiber web of the surface nonwoven fabric, it is preferable that the second polyester filament be included in an amount of 5 weight% or more, 10 weight% or more, or 15 weight% or more.

[0089] However, if the fiber web of the surface nonwoven fabric contains an excessive amount of the second polyester filament, the mechanical properties of the fiber web may be reduced due to a decrease in the content of the first polyester filament, and the workability of the spinning process and subsequent processes may be reduced. Therefore, it is preferable that the second polyester filament be included in an amount of 30 weight% or less or 25 weight% or less.

[0090]

[0091] According to one embodiment, the first and second polyester filaments may each have a cross-section that is circular, Y-shaped, W-shaped, triangular, star-shaped, cross-shaped, flat, or multilobed.

[0092]

[0093] According to one embodiment, in the fiber web of the surface nonwoven fabric, the first polyester filament has a fineness of 4 to 10 denier or 5 to 9 denier, and the second polyester filament has a fineness of 1 to 5 denier or 2 to 4 denier.

[0094] In order to secure the mechanical properties, flexibility, and tufting workability of the surface nonwoven fabric, it is preferable that the first polyester filament has a fineness within the range described above. Additionally, in order to secure the bonding strength of the filaments in the fiber web, it is preferable that the second polyester filament has a fineness within the range described above.

[0095]

[0096] Meanwhile, the above-mentioned back nonwoven fabric comprises a fiber web comprising a core-in-sheath type filament having a core portion containing polyester with a melting point of 250°C or higher and a sheath portion containing polyester with a melting point of 120°C to 170°C.

[0097] The above-mentioned core-in-sheath type long fiber has a form consisting of a core portion and a sheath portion that surrounds the outer surface of the core portion.

[0098] Preferably, in order to secure the mechanical properties of the core-in-sheath type long fiber, the core portion is made of a polyester with a relatively high melting point. In addition, in order to provide sufficient bonding and fixation to the fiber web including the core-in-sheath type long fiber, the sheath portion is made of a polyester with a relatively low melting point.

[0099] Specifically, the core-in-sheath type long fiber comprises a core portion containing a polyester with a melting point of 250°C or higher (hereinafter referred to as 'third polyester') and a sheath portion containing a polyester with a melting point of 120 to 170°C (hereinafter referred to as 'fourth polyester').

[0100] In the above core-in-sheath type long fiber, the third polyester may have 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. According to one embodiment, the third polyester may be one or more polyesters selected from the group consisting of polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, polytetrafluoroethylene, and copolymers thereof that satisfy the above melting point range.

[0101] In the above core-in-sheath type long fiber, the fourth polyester has a melting point of 120°C or higher, or 130°C or higher, or 140°C or higher, or 150°C or higher; and 170°C or lower, or 169°C or lower, or 168°C or lower, or 167°C or lower.

[0102] If the melting point of the fourth polyester is less than 120°C, the degree of crystallinity may be lowered due to an increase in the ratio of copolymer compounds applied to lower the melting point, making it difficult to form filaments. Therefore, it is preferable that the melting point of the fourth polyester be 120°C or higher, or 130°C or higher, or 140°C or higher, or 150°C or higher.

[0103] However, if the melting point of the fourth polyester exceeds 170°C, the heat treatment temperature required to fix the fiber web during the formation of the back nonwoven fabric needs to be increased, and the back nonwoven fabric may be thermally deformed during the heat treatment process. Therefore, it is preferable that the melting point of the fourth polyester filament be 170°C or lower, or 169°C or lower, or 168°C or lower, or 167°C or lower.

[0104] Preferably, the fourth polyester may have a melting point of 120 to 170 ℃, or 130 to 170 ℃, or 130 to 169 ℃, or 140 to 169 ℃, or 140 to 168 ℃, or 150 to 168 ℃, or 150 to 167 ℃.

[0105] According to one embodiment, the fourth polyester may be formed using a copolyester that satisfies the melting point range. The composition of the copolyester is not particularly limited as long as it satisfies the melting point range. For example, the copolyester may be obtained by using a dicarboxylic acid compound such as terephthalic acid and a diol compound such as ethylene glycol as main raw materials, and adding a comonomer such as isophthalic acid, adipic acid, and 1,4-cyclohydroxydimethylethanol, or by adding a low molecular weight monomer such as butylene glycol, neopentyl glycol, and butadiene. Preferably, the compound added in addition to the main raw materials to obtain the copolyester may be included in an amount of 30 mol% or more of the total reactants.

[0106]

[0107] According to one embodiment, in the fiber web of the back nonwoven fabric, the core-in-sheath type long fiber comprises the core portion and the sheath portion in a weight ratio of 65:35 to 95:5.

[0108] In order to impart sufficient bonding strength to the fiber web including the core-in-sheath type long fiber and to enable the effect according to the above embodiment to be manifested, it is preferable that the sheath portion be 5% by weight or more, or 10% by weight or more, or 15% by weight or more, based on the weight of the core portion and the sheath portion. However, if the content of the sheath portion is too high, the spinnability of the long fiber may deteriorate, and the mechanical properties of the long fiber may deteriorate as the content of the core portion is relatively reduced. Therefore, it is preferable that the sheath portion be 35% by weight or less, or 30% by weight or less, or 25% by weight or less, based on the weight of the core portion and the sheath portion.

[0109] Specifically, in the core-in-sheath type long fiber, the weight ratio of the core portion to the sheath portion may be 65:35 to 95:5, or 70:30 to 95:5, or 70:30 to 90:10, or 75:25 to 90:10, or 75:25 to 85:15.

[0110]

[0111] According to one embodiment, in the fiber web of the back nonwoven fabric, the core-in-sheath type long fibers have a fineness of 4 to 10 denier.

[0112] In order to maintain the core-in-sheath form during the filament spinning process and to ensure an appropriate level of tufting workability, it is preferable that the core-in-sheath type long fiber has a fineness of 4 denier or more, or 5 denier or more, or 6 denier or more, or 6.5 denier or more, or 7.0 denier or more. However, to prevent a decrease in spinnability and operability due to problems such as pack leakage and insufficient cooling of the filament, it is preferable that the core-in-sheath type long fiber has a fineness of 10 denier or less, or 9.5 denier or less, or 9.0 denier or less, or 8.5 denier or less.

[0113] Specifically, the core-in-sheath type long fiber may have a fineness of 4.0 to 10.0 denier, or 5.0 to 10.0 denier, or 6.0 to 9.5 denier, or 6.5 to 9.0 denier, or 7.0 to 8.5 denier.

[0114]

[0115] According to one embodiment, the surface nonwoven fabric and the back nonwoven fabric each have a g / m² of 30 to 200 g / m² 2 It has a weight per unit area.

[0116] In order to ensure appropriate mechanical properties, the weight per unit area of ​​the surface nonwoven fabric and the back nonwoven fabric is 30 g / m² each. 2 Above, or 40 g / m² 2 Above, or 50 g / m² 2 It is desirable that the above be the case. Although the stiffness of the nonwoven fabric increases as the weight per unit area and thickness increase, this not only raises the production cost of the nonwoven fabric but also means that a weight exceeding what is necessary for the application of the carpet backing paper may not be suitable. Therefore, the weight per unit area of ​​the surface nonwoven fabric and the back nonwoven fabric is 200 g / m² each. 2 Less than, or 150 g / m² 2 Less than, or 100 g / m² 2 It is desirable that it be less than or equal to this.

[0117] Preferably, the surface nonwoven fabric and the back nonwoven fabric each have a g / m² of 30 to 200 g / m² 2 , or 40 to 200 g / m² 2 , or 40 to 150 g / m² 2 , or 50 to 150 g / m² 2 , or 50 to 100 g / m² 2 It can have a weight per unit area.

[0118]

[0119] According to one embodiment, the surface nonwoven fabric and the back nonwoven fabric may each have a thickness of 0.1 to 1.0 mm. In order to achieve appropriate mechanical properties and fixing strength for carpet yarns, it is preferable that the thickness of the surface nonwoven fabric and the back nonwoven fabric be 0.1 mm or more or 0.2 mm or more, respectively. However, if the thickness of the nonwoven fabric becomes excessively thick, the workability of the tufting process may decrease. Therefore, it is preferable that the thickness of the surface nonwoven fabric and the back nonwoven fabric be 1.0 mm or less or 0.8 mm or less, respectively. Preferably, the surface nonwoven fabric and the back nonwoven fabric may each have a thickness of 0.1 to 1.0 mm, or 0.2 to 1.0 mm, or 0.2 to 0.8 mm.

[0120] In addition, the thickness of the surface nonwoven fabric and the back nonwoven fabric may have a ratio of 1:0.8 to 1:1.2, or 1:0.9 to 1:1.2, or 1:0.9 to 1:1.1, which may be advantageous for the manifestation of the aforementioned effects.

[0121]

[0122] According to one embodiment, the nonwoven laminate formed by sequentially laminating the surface nonwoven fabric and the back nonwoven fabric has a weight of 60 to 400 g / m² 2 , or 80 to 400 g / m² 2 , or 80 to 300 g / m² 2 , or 100 to 300 g / m² 2 , or 100 to 200 g / m² 2 It may have a weight per unit area; and a thickness of 0.2 to 2.0 mm, or 0.4 to 2.0 mm, or 0.4 to 1.5 mm.

[0123]

[0124] The above surface nonwoven fabric and the above back nonwoven fabric can be obtained by a conventional nonwoven fabric manufacturing method in the technical field to which the present invention belongs.

[0125] For example, the surface nonwoven fabric can be manufactured by a method comprising the steps of: obtaining a polyester filament with a melting point of 250°C or higher and a polyester filament with a melting point of 120 to 170°C; laminating the filaments on a net conveyor to form a fiber web; and heat-treating the fiber web under pressure to form the surface nonwoven fabric.

[0126] As another example, the above-mentioned back nonwoven fabric may be manufactured by a method comprising the steps of: obtaining a core-in-sheath type long fiber with the composition described above by composite spinning of a polyester with a melting point of 250°C or higher and a polyester with a melting point of 120°C to 170°C; laminating the core-in-sheath type long fiber onto a net conveyor to form a fiber web; and heat-treating the fiber web under pressure to form the back nonwoven fabric.

[0127] When manufacturing the above surface nonwoven fabric, the above back nonwoven fabric, and a nonwoven laminate in which they are sequentially laminated, a device configured with various types of spinnerets in an appropriate arrangement can be used in consideration of process efficiency.

[0128]

[0129] According to another embodiment of the invention,

[0130] It includes a nonwoven laminate for carpet base paper and a plurality of carpet yarns implanted on the surface nonwoven fabric of the nonwoven laminate for carpet base paper,

[0131] The carpet yarn penetrates the nonwoven laminate and is fixed by the fusion of the back nonwoven fabric,

[0132] A carpet is provided.

[0133]

[0134] Regarding the nonwoven fabric laminate for the carpet base in the above carpet, the previously described details shall apply.

[0135]

[0136] The carpet comprises a plurality of carpet yarns implanted on the surface nonwoven fabric of the nonwoven laminate for the carpet base.

[0137] According to one embodiment, the carpet yarn penetrates the nonwoven laminate for the carpet base and is implanted onto the surface nonwoven fabric. Additionally, the carpet yarn penetrates the nonwoven laminate and is fixed by the fusion of the back nonwoven fabric.

[0138] The carpet yarn mentioned above is also referred to as BCF (bulked continuous filament), and any composition conventional in the technical field to which the present invention belongs may be applied without special limitations. The material of the carpet yarn mentioned above may be selected considering the purpose of use and the environment of use of the carpet. As a non-limiting example, the carpet yarn mentioned above may be one or more selected from the group consisting of nylon yarn, polypropylene yarn, acrylic yarn, wool yarn, and cotton yarn.

[0139]

[0140] The carpet described above can have excellent mechanical properties as it has the above-described composition. In particular, the carpet yarn is strongly fixed by the fusion of the back nonwoven fabric, so the number of yarns detaching from the carpet is small, and it can exhibit high tensile strength.

[0141] For example, the carpet may have a tensile strength of 1.8 to 3.0 kgf according to the standard test method specified in KS K ISO 4919 (2015). Specifically, the carpet may have a tensile strength of 1.8 kgf or more or 2.0 kgf or more; and 3.0 kgf or less or 2.8 kgf or less. Preferably, the carpet may have a tensile strength of 1.8 to 3.0 kgf, or 2.0 to 3.0 kgf, or 2.0 to 2.8 kgf.

[0142]

[0143] According to another embodiment of the invention,

[0144] The step of providing the above-described nonwoven fabric laminate for carpet foam,

[0145] A tufting step of implanting carpet yarns onto the surface nonwoven fabric by penetrating the nonwoven fabric laminate, and

[0146] A fusion step of heat-treating the back nonwoven fabric of the nonwoven laminate to fix the carpet yarn onto the nonwoven laminate.

[0147] A method for manufacturing a carpet, comprising

[0148]

[0149] The carpet yarn mentioned above may be selected considering the purpose of use and environment of use of the carpet. As a non-limiting example, the carpet yarn may be one or more selected from the group consisting of nylon yarn, polypropylene yarn, acrylic yarn, wool yarn, and cotton yarn.

[0150] The carpet yarn can be implanted by penetrating the laminate using a conventional tufting machine. The carpet yarn is implanted from the surface nonwoven fabric side of the nonwoven fabric laminate toward the back nonwoven fabric side. For example, in the tufting step, the carpet yarn can be implanted in a single loop pile type.

[0151]

[0152] After the carpet yarn is implanted onto the nonwoven laminate through the above tufting step, if the back nonwoven surface of the nonwoven laminate is heat-treated, the long fiber nonwoven fabric is fused and the carpet yarn is fixed onto the laminate.

[0153] In the above fusion step, the heat treatment for the back nonwoven fabric may be performed within the melting point range of the sheath portion of the long fibers constituting the back nonwoven fabric. Preferably, the heat treatment may be performed at a temperature of 120 to 170 ℃.

[0154]

[0155] 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.

[0156]

[0157] Example 1

[0158] Polyethylene terephthalate (PET) with a melting point of 255 °C and copolyester (co-PET) with a melting point of 165 °C were each melted using a continuous extruder and melt-spun at a spinning speed of 5000 m / min through a plurality of spinnerets. In the melt-spun process, a filament made of the PET (fineness 8.5 denier), a filament made of the co-PET (fineness 3.5 denier), and a core-in-sheath type filament (fineness 8.5 denier) having a core part made of the PET and a sheath part made of the co-PET were each obtained. The core-in-sheath type filament was prepared so that the weight ratio of the core part to the sheath part was 85:15 (weight%).

[0159] The above filaments were laminated on a continuously moving net conveyor to form a fiber web laminate. At this time, a fiber web for a back nonwoven fabric containing the core-in-sheath type filament was first formed on the net conveyor, and a fiber web for a surface nonwoven fabric was formed thereon, in which the filament made of PET and the filament made of co-PET were blended. The fiber web for the surface nonwoven fabric was blended such that the weight ratio of the filament made of PET and the filament made of co-PET was 85:15 (weight%).

[0160] The above fiber web laminate is passed through a smooth roller maintained at 200 ℃ and 35 N / mm and hot-air dried to produce a nonwoven laminate (weight per unit area 120 g / m² 2 , thickness 0.5 mm) was formed. The nonwoven laminate is a surface nonwoven fabric (weight per unit area 60 g / m²) formed from the fiber web for the surface nonwoven fabric. 2 ) and a back nonwoven fabric formed from the fiber web for the back nonwoven fabric (weight per unit area 60 g / m²) 2 It has a structure in which ) are sequentially laminated. In the above nonwoven laminate, the thickness ratio of the surface nonwoven fabric to the back nonwoven fabric is approximately 1:1.

[0161] Using a pilot tufting machine with a width of 1.0 m, carpet yarn (Nylon 6 material, triangular cross-section yarn with a fineness of 1200 denier and 96 filaments; manufactured by Hyosung Corp.) was tufted vertically toward the surface nonwoven fabric of the nonwoven laminate. The tufting was performed as a single loop pile type under conditions of 1 / 1 gage per inch, 1 / 1 stitch per inch, and a pile height of 5 mm.

[0162] Next, the back nonwoven fabric of the above nonwoven laminate was heat-treated at a temperature of 200°C to obtain a carpet. The carpet yarn penetrated the above nonwoven laminate and was implanted onto the surface nonwoven fabric, and was fixed by the fusion of the back nonwoven fabric.

[0163]

[0164] Example 2

[0165] A nonwoven laminate and a carpet containing the same were manufactured in the same manner as in Example 1, except that a copolyester with a melting point of 159°C was used instead of the copolyester (co-PET) with a melting point of 165°C.

[0166]

[0167] Example 3

[0168] A nonwoven laminate and a carpet containing the same were manufactured in the same manner as in Example 1, except that a copolyester with a melting point of 152°C was used instead of the copolyester (co-PET) with a melting point of 165°C.

[0169]

[0170] Example 4

[0171] A nonwoven laminate and a carpet containing the same were manufactured in the same manner as in Example 1, except that the core-in-sheath type filament was manufactured and used such that the weight ratio of the core part and the sheath part was 80:20 (weight%).

[0172]

[0173] Example 5

[0174] A nonwoven laminate and a carpet containing the same were manufactured in the same manner as in Example 1, except that the core-in-sheath type filament was manufactured and used such that the weight ratio of the core part and the sheath part was 90:10 (weight%).

[0175]

[0176] Example 6

[0177] A nonwoven laminate and a carpet containing the same were manufactured in the same manner as in Example 1, except that when manufacturing the fiber web for the surface nonwoven fabric, the filament made of PET and the filament made of co-PET were blended so that the weight ratio of the two filaments was 80:20 (weight%).

[0178]

[0179] Example 7

[0180] A nonwoven laminate and a carpet containing the same were manufactured in the same manner as in Example 1, except that when manufacturing the fiber web for the surface nonwoven fabric, the filament made of PET and the filament made of co-PET were blended so that the weight ratio of the two filaments was 90:10 (weight%).

[0181]

[0182] Comparative Example 1

[0183] A nonwoven laminate and a carpet containing the same were manufactured in the same manner as in Example 1, except that a copolyester with a melting point of 175°C was used instead of the copolyester (co-PET) with a melting point of 165°C.

[0184]

[0185] Comparative Example 2

[0186] Instead of a nonwoven laminate in which the above-mentioned surface nonwoven fabric and the above-mentioned back nonwoven fabric are sequentially laminated, a nonwoven fabric comprising a fiber web blended such that the weight ratio of the PET filament and the co-PET filament is 85:15 (weight%) (weight per unit area 120 g / m²) 2 A nonwoven fabric (thickness 0.5 mm) was manufactured. Then, a carpet was manufactured in the same manner as in Example 1, except that the nonwoven fabric was used as a base material for the carpet.

[0187]

[0188] Comparative Example 3

[0189] Instead of a nonwoven laminate in which the above-mentioned surface nonwoven fabric and the above-mentioned back nonwoven fabric are sequentially laminated, a nonwoven fabric comprising a fiber web made of the above-mentioned core-in-sheath type filament (weight per unit area 120 g / m²) 2 A nonwoven fabric (thickness 0.5 mm) was manufactured. Then, a carpet was manufactured in the same manner as in Example 1, except that the nonwoven fabric was used as a base material for the carpet.

[0190]

[0191] Test example

[0192] (1) Measurement of carpet pull strength

[0193] The tensile strength of the carpet was measured according to the standard test method specified in KS K ISO 4919 (measurement of carpet-tuft tensile strength).

[0194] A single pile from the manufactured carpet was fixed to the clamp of a tensile testing machine, and the loops on both sides adjacent to the loop to be measured were cut. The peak value of the load that appeared when the fixed pile was pulled in the vertical direction of the carpet was measured. This measurement was repeated 5 times per sample, and the average value was taken.

[0195]

[0196] (2) Number of carpet yarn strays

[0197] After the tufting process for manufacturing a carpet, the number of carpet yarns detached from the foam sheet was counted when the carpet yarns implanted in a carpet specimen with a width of 1 m and a length of 1 m were pulled with a constant force.

[0198]

[0199] (3) Measurement of tensile strength and tensile elongation of bubbles

[0200] Tensile strength and tensile elongation were measured for a foam (non-woven fabric or non-woven laminate) applied to a carpet according to the standard test method specified in KS K 0521 (2017).

[0201] A bubble specimen measuring 5 cm in width and 20 cm in length was clamped onto a jig measuring 5 cm x 5 cm using INSTRON's measuring equipment and subjected to a tensile test at a speed of 200 mm / min. At this time, the tensile test performed parallel to the direction of movement of the production line during bubble manufacturing was designated as MD (machine direction), and the tensile test performed perpendicular to the above direction was designated as CD (cross direction).

[0202]

[0203] Pulling Strength (kgf) Number of Detachments (pieces) MD Tensile Strength (kgf / 5cm) CD Tensile Strength (kgf / 5cm) CD Tensile Elongation (%) Example 1 2.5 0 19.0 11.3 27.0 Example 2 2.2 0 18.5 10.9 26.5 Example 3 2.3 18.6 11.0 25.9 Example 4 2.4 0 18.8 11.2 26.8 Example 5 2.3 0 18.7 11.1 26.4 Example 6 2.4 11.8 9 11.3 27.0 Example 7 2.2 0 18.4 10.8 25.7 Comparative Example 11.7 117.0 8.0 24.3 Comparative Example 21.7 0 18.5 8.2 26.6 Comparative Example 32.9522.211.625.2

[0204] Referring to Table 1 above, the foam sheet (non-woven laminate) applied to the carpets of the above examples exhibited excellent mechanical properties, and the tufting process performed using it exhibited good workability. Furthermore, it was confirmed that the carpet with the non-woven laminate applied as the foam sheet had a high tensile strength of 2.2 kgf or more, while the carpet yarn hardly detached from the substrate.

[0205] In the case of Comparative Examples 1 and 2, it was confirmed that the mechanical properties of the foam paper applied to the carpet were generally inferior compared to the examples, and the tensile strength of the carpet was also low.

[0206] In the case of Comparative Example 3, the mechanical properties of the foam paper applied to the carpet and the tensile strength of the carpet were found to be similar to those of the examples, but it was confirmed that the number of carpet yarn escapes was significantly higher compared to the examples.

[0207]

[0208] 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. Includes a surface nonwoven fabric and a back nonwoven fabric stacked sequentially, and The above surface nonwoven fabric comprises a fiber web in which polyester filaments with a melting point of 250°C or higher and polyester filaments with a melting point of 120 to 170°C are blended, and The above-mentioned backing nonwoven fabric comprises a fiber web comprising a core-in-sheath type filament having a core portion comprising polyester with a melting point of 250°C or higher and a sheath portion comprising polyester with a melting point of 120 to 170°C, Nonwoven laminate for carpet backing.

2. In Paragraph 1, A nonwoven laminate for carpet base paper, wherein the fiber web of the surface nonwoven fabric comprises 70 to 95 weight% of polyester filaments having a melting point of 250°C or higher and 5 to 30 weight% of polyester filaments having a melting point of 120 to 170°C.

3. In Paragraph 1, A nonwoven laminate for carpet base paper, wherein in the fiber web of the surface nonwoven fabric, the polyester filament having a melting point of 250°C or higher has a fineness of 4 to 10 denier, and the polyester filament having a melting point of 120 to 170°C has a fineness of 1 to 5 denier.

4. In Paragraph 1, A nonwoven laminate for carpet base paper, wherein in the fiber web of the above-mentioned back-side nonwoven fabric, the core-in-sheath type long fiber comprises the core portion and the sheath portion in a weight ratio of 65:35 to 95:

5.

5. In Paragraph 1, A nonwoven laminate for carpet base paper, wherein in the fiber web of the above-mentioned back-side nonwoven fabric, the core-in-sheath type long fibers have a fineness of 4 to 10 denier.

6. In Paragraph 1, The surface nonwoven fabric and the back nonwoven fabric are each 30 to 200 g / m² 2 A nonwoven laminate for carpet base paper having a weight per unit area.

7. In Paragraph 1, The above nonwoven fabric laminate is 60 to 400 g / m 2 A nonwoven laminate for carpet foam having a weight per unit area and a thickness of 0.2 to 2.0 mm.

8. A nonwoven fabric laminate for carpet base paper according to claim 1 and a plurality of carpet yarns implanted on the surface nonwoven fabric of the nonwoven fabric laminate for carpet base paper, The carpet yarn penetrates the nonwoven laminate and is fixed by the fusion of the back nonwoven fabric, Carpet.

9. In Paragraph 8, The carpet is one or more of the above carpet yarns selected from the group consisting of nylon yarn, polypropylene yarn, acrylic yarn, wool yarn, and cotton yarn.

10. In Paragraph 8, The above carpet is a carpet having a tensile strength of 1.8 to 3.0 kgf according to the standard test method specified in KS K ISO 4919 (2015).

11. A step of providing a nonwoven fabric laminate for carpet foam according to claim 1, A tufting step of implanting carpet yarns onto the surface nonwoven fabric by penetrating the nonwoven fabric laminate, and A fusion step of heat-treating the back nonwoven fabric of the nonwoven laminate to fix the carpet yarn onto the nonwoven laminate. A method for manufacturing a carpet, comprising 12. In Paragraph 11, A method for manufacturing a carpet, wherein in the above tufting step, the carpet yarn is implanted as a single loop pile type.

13. In Paragraph 11, A method for manufacturing a carpet, wherein the heat treatment of the above-mentioned back nonwoven fabric is performed at a temperature of 120 ℃ to 170 ℃.