Carpet and method for manufacturing same

Abstract

The present invention relates to a carpet and a method for manufacturing same. According to the present invention, provided are a carpet having excellent mechanical properties while containing no latex material, thereby being easily recyclable and minimizing emission of volatile organic compounds, and a method for manufacturing same.

Description

Carpet and method of manufacturing the same

[0001] The present invention relates to a carpet and a method for manufacturing 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 aforementioned 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 causes several significant problems.

[0005] First, due to their 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 adhesion can release volatile organic compounds (VOCs) during the manufacturing and use of carpets. Excessive exposure to VOCs is not only harmful to human health but can also cause environmental pollution, potentially leading to even greater problems.

[0006] Therefore, developing carpets that ensure basic performance while facilitating the reuse and recycling of expired carpets and are not harmful to the human body or the environment is one of the urgent tasks that must be addressed in this technology field.

[0007]

[0008] The present invention aims to provide a carpet that has excellent mechanical properties, is easy to recycle, and minimizes the release of volatile organic compounds.

[0009] And, the present invention is intended to provide a method for manufacturing the said carpet.

[0010]

[0011] According to one embodiment of the invention,

[0012] A laminate comprising sequentially laminated foam sheets for carpets and a backing layer, and

[0013] It includes a plurality of carpet yarns implanted on the carpet base paper penetrating the laminate;

[0014] The backing layer comprises a long-fiber nonwoven fabric made of filaments with a fineness of 1.0 to 4.5 denier, including polyester with a melting point of 115 to 175 ℃, and

[0015] The carpet yarn is fixed onto the laminate by the fusion of the long fiber nonwoven fabric,

[0016] Carpets are provided.

[0017]

[0018] According to one embodiment, the long fiber nonwoven fabric is 30 g / m 2 Up to 70 g / m² 2 It can have a weight per unit area.

[0019]

[0020] According to one embodiment, the carpet may have a tensile strength of 20 N or more according to the standard test method specified in KS K ISO 4919 (2015).

[0021]

[0022] According to one embodiment, the carpet may have a volatile organic compound (VOC) emission amount of 3.0 ppm or less according to the standard test method specified in VDA 278.

[0023]

[0024] According to one embodiment, the foam sheet for the carpet may be a spunbond nonwoven fabric containing polyester filaments.

[0025]

[0026] According to one embodiment, the foam sheet for the carpet may be a spunbond nonwoven fabric comprising polyester filaments having a melting point of 250°C or higher.

[0027]

[0028] 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.

[0029]

[0030] According to another embodiment of the invention,

[0031] A backing layer providing step of preparing a backing layer comprising a long fiber nonwoven fabric composed of filaments having a fineness of 1.0 to 4.5 denier and including a polyester having a melting point of 115 to 175 ℃,

[0032] A step of providing a laminate to form a laminate by laminating the above backing layer with a foam sheet for carpets,

[0033] A tufting step of penetrating carpet yarns onto the laminate and implanting them onto the carpet base paper, and

[0034] A fusion step of fixing the carpet yarn onto the laminate by heat-treating the long-fiber nonwoven fabric of the backing layer.

[0035] A method for manufacturing a carpet, comprising

[0036]

[0037] According to one embodiment, in the tufting step, the carpet yarn can be implanted as a single loop pile type.

[0038]

[0039] According to one embodiment, the heat treatment for the long fiber nonwoven fabric can be performed at a temperature of 120°C to 180°C.

[0040]

[0041] According to the present invention, a carpet having excellent mechanical properties, which is easy to recycle and minimizes the release of volatile organic compounds by not including latex material, and a method for manufacturing the same are provided.

[0042]

[0043] Hereinafter, a carpet and a method for manufacturing the same according to embodiments of the present invention will be described in more detail.

[0044]

[0045] 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.

[0046] The singular forms used in this specification include plural forms unless the phrases clearly indicate otherwise.

[0047] 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.

[0048] 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.

[0049]

[0050] According to one embodiment of the invention,

[0051] A laminate including sequentially laminated foam sheets for carpets and a backing layer, and

[0052] It includes a plurality of carpet yarns implanted on the carpet base paper penetrating the laminate;

[0053] The backing layer comprises a long-fiber nonwoven fabric made of filaments with a fineness of 1.0 to 4.5 denier, including polyester with a melting point of 115 to 175 ℃, and

[0054] The carpet yarn is fixed onto the laminate by the fusion of the long fiber nonwoven fabric,

[0055] Carpets are provided.

[0056]

[0057] Generally, latex is used as the backing layer of carpets to enhance the fixation of the carpet yarns. Additionally, adhesives are sometimes used to reinforce the fixation of the backing layer or to replace latex.

[0058] However, carpets made of latex have limitations in that recycling them after they reach the end of their lifespan is difficult. Additionally, if adhesives are used to secure the carpet yarns, volatile organic compounds may be released during the manufacturing and use processes, requiring quality control in accordance with relevant regulations.

[0059]

[0060] As a result of the inventors' research, it was confirmed that by applying a long-fiber nonwoven fabric consisting of filaments with a fineness of 1.0 to 4.5 denier containing polyester with a melting point of 115 to 175 °C instead of a latex material in the backing layer of the carpet, and fusing it to the carpet base paper to fix the carpet yarn, it is possible to provide a carpet that has excellent mechanical properties, is easy to recycle, and minimizes the release of volatile organic compounds.

[0061] In particular, since the long-fiber nonwoven fabric included in the backing layer is manufactured using the same polyester-based material as the carpet backing paper, it can be recycled without the need to separate the carpet backing paper and the long-fiber nonwoven fabric during the carpet recycling process. This characteristic serves as an advantage that can revitalize the circular economy and reduce the burden of waste management.

[0062]

[0063] The carpet comprises a laminate including sequentially laminated carpet foam sheets and a backing layer, and a plurality of carpet yarns implanted on the carpet foam sheets through the laminate.

[0064]

[0065] As for the above-mentioned foam sheet for carpets, a sheet with a composition conventional in the technical field to which the present invention belongs may be applied without special limitations.

[0066] It is preferable that the above-mentioned foam sheet for the carpet be applied in a manner that can maintain an appropriate level of mechanical properties during the tufting process for implanting the carpet yarn.

[0067] According to one embodiment, the carpet base may be a spunbond nonwoven fabric containing polyester filaments. For example, the carpet base may be a spunbond nonwoven fabric formed from a fiber web containing polyester filaments having a melting point of 250°C or higher. The polyester filaments may include 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.

[0068]

[0069] The above carpet yarn is implanted by penetrating the above carpet foam sheet.

[0070] 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.

[0071] 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 may be one or more selected from the group consisting of nylon yarn, polypropylene yarn, acrylic yarn, wool yarn, and cotton yarn.

[0072]

[0073] The backing layer is laminated to one side of the foam paper for the carpet and serves to fix the carpet yarn onto the laminate.

[0074] According to one embodiment, in the manufacturing process of a carpet, the backing layer is laminated with a foam sheet for the carpet to form a laminate, the carpet yarn is implanted by penetrating it onto the laminate, and the carpet yarn is fixed onto the laminate by heat-treating and fusing the backing layer.

[0075]

[0076] According to one embodiment, the backing layer comprises a long fiber nonwoven fabric made of filaments with a fineness of 1.0 to 4.5 denier, including polyester with a melting point of 115 to 175 °C.

[0077] That is, the long fiber nonwoven fabric included in the backing layer comprises a fiber web made of filaments with a denier of 1.0 to 4.5, and the filaments comprise polyester with a melting point of 115 to 175°C.

[0078]

[0079] Specifically, in the long fiber nonwoven fabric, the filament comprises a polyester having a melting point of 115°C or higher or 120°C or higher, and 175°C or lower or 170°C or lower.

[0080] If the melting point of the above polyester is less than 115°C, the degree of crystallinity may be lowered due to an increase in the ratio of copolymer monomers applied to lower the melting point, making it difficult to form filaments. Therefore, it is preferable that the above filaments include a polyester having a melting point of 115°C or higher or 120°C or higher.

[0081] However, if the melting point of the polyester exceeds 175°C, the heat treatment temperature required to fuse the long fiber nonwoven fabric and fix the carpet yarn onto the laminate needs to be increased, but the carpet base may be deformed due to the high temperature during the heat treatment process. If the heat treatment temperature is insufficient, the tensile strength value, which is the force fixing the carpet yarn, decreases, and a defect may occur in which the carpet yarn easily comes out. Therefore, it is preferable that the filament includes a polyester having a melting point of 175°C or lower or 170°C or lower.

[0082] Preferably, the filament may include a polyester having a melting point of 115°C to 175°C, or 120°C to 175°C, or 120°C to 170°C.

[0083]

[0084] In the above long fiber nonwoven fabric, the polyester included in the filament may be a copolyester that satisfies the melting point range.

[0085] 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.

[0086]

[0087] According to one embodiment, the filaments in the long fiber nonwoven fabric have a fineness of 1.0 denier to 4.5 denier.

[0088] Specifically, the filament may have a fineness of 1.0 denier or more, and 4.5 denier or less, or 4.0 denier or less.

[0089] If the fineness of the above filament is less than 1.0 denier, the filament may break during the stretching process for manufacturing it, making it difficult to manufacture the nonwoven fabric. Therefore, it is desirable for the above filament to have a fineness of 1.0 denier or more.

[0090] However, if the fineness of the above filament exceeds 4.5 denier, the filament may not be sufficiently cooled during the cooling process after melt spinning to manufacture it, making it difficult to manufacture the nonwoven fabric. Therefore, it is preferable that the above filament have a fineness of 4.5 denier or less or 4.0 denier or less.

[0091] Preferably, the filament may have a fineness of 1.0 to 4.5 denier or 1.0 to 4.0 denier.

[0092]

[0093] According to one embodiment, the long fiber nonwoven fabric included in the backing layer is 30 g / m² 2 Up to 70 g / m² 2 It has a weight per unit area.

[0094] In order to ensure appropriate mechanical properties, the weight per unit area of ​​the long fiber nonwoven fabric is 30 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 can lead to higher tufting resistance during carpet manufacturing, potentially resulting in a higher defect rate. Therefore, the weight per unit area of ​​the above long-fiber nonwoven fabric is 70 g / m² 2 It is preferable that it be less than or equal to 30 g / m². Specifically, the long fiber nonwoven fabric is 30 g / m² 2 Up to 70 g / m² 2 , or 40 g / m² 2 Up to 70 g / m² 2 , or 40 g / m² 2 Up to 60 g / m² 2 It can have a weight per unit area.

[0095]

[0096] According to one embodiment, layers typically applied to maintain the shape stability of the carpet may be additionally applied to the backing layer without special limitations.

[0097] For example, a so-called 'heavy layer' may be applied to the backing layer to maintain the shape stability of the carpet. The heavy layer comprises a resin such as PVC and SBR at a concentration of 1800 to 3500 g / m² 2 A layer formed by applying, which can be additionally applied to the back surface of the long fiber nonwoven fabric included in the backing layer.

[0098]

[0099] According to one embodiment, the carpet can minimize the release of volatile organic compounds while having excellent mechanical properties as it satisfies the above-described composition.

[0100] For example, the carpet may have a tensile strength of 20 N or more according to the standard test method specified in KS K ISO 4919 (2015). Specifically, the carpet may have a tensile strength of 20 N or more or 22 N or more; and 30 N or less or 28 N or less. Preferably, the carpet may have a tensile strength of 20 N to 30 N, or 22 N to 30 N, or 22 N to 28 N.

[0101] As another example, the carpet may have a volatile organic compound (VOC) emission amount of 3.0 ppm or less according to the standard test method specified in VDA 278. Specifically, the carpet may have a VOC emission amount of 3.0 ppm or less, or 2.9 ppm or less, or 2.8 ppm or less; and 1.0 ppm or more, or 1.2 ppm or more, or 1.5 ppm or more. Preferably, the carpet may have a VOC emission amount of 1.0 ppm to 3.0 ppm, or 1.0 ppm to 2.9 ppm, or 1.2 ppm to 2.9 ppm, or 1.2 ppm to 2.8 ppm, or 1.5 ppm to 2.8 ppm.

[0102]

[0103]

[0104] According to another embodiment of the invention,

[0105] A backing layer providing step of preparing a backing layer comprising a long fiber nonwoven fabric composed of filaments having a fineness of 1.0 to 4.5 denier and including a polyester having a melting point of 115 to 175 ℃,

[0106] A step of providing a laminate to form a laminate by laminating the above backing layer with a foam sheet for carpets,

[0107] A tufting step of penetrating carpet yarns onto the laminate and implanting them onto the carpet base paper, and

[0108] A fusion step of fixing the carpet yarn onto the laminate by heat-treating the long-fiber nonwoven fabric of the backing layer.

[0109] A method for manufacturing a carpet, comprising

[0110]

[0111] According to one embodiment, a backing layer providing step is performed to prepare a backing layer comprising a long fiber nonwoven fabric made of filaments having a fineness of 1.0 to 4.5 denier, which includes a polyester having a melting point of 115 to 175 °C.

[0112] The above long fiber nonwoven fabric can be obtained by melt-spinning a polyester having a melting point of 115°C to 175°C to form a fiber web containing polyester filaments and heat-treating it under pressure.

[0113] In the above step, the characteristics of the polyester filament and the long-fiber nonwoven fabric containing it are the same as those previously described. Preferably, in the long-fiber nonwoven fabric, the filament comprises a polyester having a melting point of 115°C to 175°C. The filament has a fineness of 1.0 denier to 4.5 denier. Furthermore, the long-fiber nonwoven fabric has a thickness of 30 g / m² 2 Up to 70 g / m² 2 It has a weight per unit area.

[0114] The above 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 a fiber web. The fiber web is heat-treated under pressure to form a spunbond nonwoven fabric. For example, by passing the fiber web through a roller heated to about 115°C to 175°C, a spunbond nonwoven fabric with appropriate smoothness and thickness is obtained.

[0115]

[0116] According to one embodiment, a step of providing a laminate is performed to form a laminate by laminating the backing layer with a foam sheet for carpets.

[0117] As for the above carpet foam, a foam with a composition conventional in the technical field to which the present invention belongs may be applied without special limitations. According to one embodiment, the carpet foam may be a spunbond nonwoven fabric formed from a fiber web comprising polyester filaments having a melting point of 250°C or higher.

[0118] The above laminate can be provided by a method of laminating the backing layer and the carpet foam sheet by applying hot air or passing them through a heated roller.

[0119]

[0120] According to one embodiment, a tufting step is performed in which carpet yarn is implanted by penetrating the laminate.

[0121] 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.

[0122] The carpet yarn can be implanted by penetrating the laminate using a conventional tufting machine. For example, in the tufting step, the carpet yarn can be implanted as a single loop pile type.

[0123]

[0124] Next, a fusion step is performed in which the long fiber nonwoven fabric of the backing layer is heat-treated to fix the carpet yarn onto the laminate.

[0125] For example, after the carpet yarn is implanted onto the laminate through the above tufting step, if the long fiber nonwoven fabric surface of the backing layer on the laminate is heat-treated, the long fiber nonwoven fabric is fused and the carpet yarn is fixed onto the laminate.

[0126] Preferably, the heat treatment can be performed at a temperature of 120°C to 180°C, which is slightly higher than the melting point of the filaments constituting the long fiber nonwoven fabric.

[0127]

[0128] According to one embodiment, a step of applying layers to maintain the shape stability of the carpet may be further performed after the fusion step. For example, these layers may be the heavy layers described above. A resin such as PVC and SBR may be applied to the back surface of the long-fiber nonwoven fabric at a rate of 1800 to 3500 g / m² using a conventional coating method such as knife coating. 2 The heavy layer can be formed by coating and curing in a heating chamber.

[0129]

[0130] Process conditions other than those specified for each step described above may be carried out in accordance with the customary practices applied in the technical field to which the present invention belongs.

[0131]

[0132] 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.

[0133]

[0134] Example 1

[0135] A copolyester raw material with a melting point of 150 °C was melt-spun using a continuous extruder at a spinning speed of 5,000 m / min to obtain a filament with a fineness of 3.0 denier. The obtained filament was laminated onto a continuously moving net conveyor to form a fiber web. The fiber web was passed through a smooth roller and an embossed roller maintaining a temperature of 200 °C and 35 N / mm to produce a fiber with a weight per unit area of ​​50 g / m² 2 A long fiber nonwoven fabric with a thickness of 0.23 mm was manufactured.

[0136] A laminate was formed by laminating the above long fiber nonwoven fabric onto a carpet base paper (polyester-based spunbond nonwoven fabric, manufactured by Kolon Industries) with a thickness of 0.40 mm and then passing it through a heated roller.

[0137] Using a tufting machine, carpet yarn (Nylon 6 pre-dyed yarn with a fineness of 1200 denier, manufactured by Hyosung Corp.) was tufted to penetrate and implant onto the 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. The carpet yarn was implanted from the base paper side of the laminate toward the long-fiber nonwoven fabric, which is the backing layer.

[0138] After the above tufting step, the long fiber nonwoven fabric surface of the laminate was heat-treated at a temperature of 155°C to fuse, thereby fixing the carpet yarn onto the laminate to manufacture the carpet.

[0139]

[0140] Example 2

[0141] A carpet was manufactured in the same manner as in Example 1, except that in the step of manufacturing the long fiber nonwoven fabric, a copolyester raw material with a melting point of 150°C was melt-spun to obtain a filament with a fineness of 1.0 denier and the long fiber nonwoven fabric was manufactured using the same.

[0142]

[0143] Example 3

[0144] A carpet was manufactured in the same manner as in Example 1, except that in the step of manufacturing the long fiber nonwoven fabric, a copolyester raw material with a melting point of 150°C was melt-spun to obtain a filament with a fineness of 4.0 denier and used to manufacture the long fiber nonwoven fabric.

[0145]

[0146] Example 4

[0147] A carpet was manufactured in the same manner as in Example 1, except that in the step of manufacturing the long fiber nonwoven fabric, a copolyester raw material with a melting point of 120°C was melt-spun to obtain a filament with a fineness of 3.0 denier and used to manufacture the long fiber nonwoven fabric.

[0148]

[0149] Example 5

[0150] A carpet was manufactured in the same manner as in Example 1, except that in the step of manufacturing the long fiber nonwoven fabric, a copolyester raw material with a melting point of 170°C was melt-spun to obtain a filament with a fineness of 3.0 denier and the long fiber nonwoven fabric was manufactured using the same.

[0151]

[0152] Comparative Example 1

[0153] In the step of manufacturing the above long fiber nonwoven fabric, an attempt was made to manufacture a filament with a fineness of 5.0 denier by melt-spinning a copolyester raw material with a melting point of 150 ℃.

[0154] However, due to the excessive fineness of the above filament, the filament was not sufficiently cooled during the cooling process after melt spinning, so the shape of the filament could not be formed and the long fiber nonwoven fabric could not be manufactured.

[0155]

[0156] Comparative Example 2

[0157] A carpet was manufactured in the same manner as in Example 1, except that in the step of manufacturing the long fiber nonwoven fabric, a copolyester raw material with a melting point of 180°C was melt-spun to obtain a filament with a fineness of 3.0 denier and used to manufacture the long fiber nonwoven fabric.

[0158]

[0159] Comparative Example 3

[0160] In the step of manufacturing the above long fiber nonwoven fabric, an attempt was made to manufacture a filament with a fineness of 3.0 denier by melt-spinning a copolyester raw material with a melting point of 110 ℃.

[0161] However, the crystallinity of the aforementioned copolyester raw material was too low, so it was extruded from the extrusion hole of the melt spinning process in a form that flowed like water rather than in the form of a filament, making it impossible to form filaments and thus impossible to manufacture long-fiber nonwoven fabric.

[0162]

[0163] Comparative Example 4

[0164] Carpet yarn (Nylon 6 pre-dyed yarn with a fineness of 1200 denier, manufactured by Hyosung Corp.) was tufted onto a carpet backing sheet (polyester-based spunbond nonwoven fabric, manufactured by Kolon Industries) with a thickness of 0.40 mm using a tufting machine to penetrate and implant the yarn. 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. After the tufting step, a latex solution (manufacturer: HapSong YangHaeng Co., Ltd.) at 30 g / m² was applied to the back surface of the carpet backing sheet implanted with the carpet yarn using a knife coating method. 2 A carpet was manufactured by coating it and curing it in a heating chamber at 140°C.

[0165]

[0166] Comparative Example 5

[0167] Carpet yarn (Nylon 6 pre-dyed yarn with a fineness of 1200 denier, manufactured by Hyosung Corp.) was tufted onto a carpet backing sheet (polyester-based spunbond nonwoven fabric, manufactured by Kolon Industries) with a thickness of 0.40 mm using a tufting machine to penetrate and implant the yarn. 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. After the tufting step, an acrylic coating solution (Manufacturer: DIC Corporation) at 20 g / m² was applied to the back surface of the carpet backing sheet implanted with the carpet yarn using a knife coating method. 2 A carpet was manufactured by coating it and curing it in a heating chamber at 120°C.

[0168]

[0169] Test example

[0170] (1) Measurement of tensile strength

[0171] The tensile strength of the carpets according to the above examples and comparative examples was measured according to the standard test method specified in KS K ISO 4919 (2015).

[0172] After fixing the manufactured carpet to the floor surface, a single carpet yarn is fixed to the clamp of a tensile testing machine in the vertical direction of the carpet, and the peak value of the load that appears when the carpet yarn is pulled in the vertical direction of the carpet is measured.

[0173]

[0174] (2) Measurement of volatile organic compound emissions

[0175] Volatile organic compound emissions from carpets according to the above examples and comparative examples were measured according to the standard test method specified in VDA 278.

[0176] A sealed container containing 60 mg of carpet sample was heat-treated at 90°C for 30 minutes. The gas inside the sealed container was collected, and the amount of volatile organic compounds (VOCs) with 25 or fewer carbon atoms contained in the gas was measured using a gas chromatography-mass spectrometer (GC / MS).

[0177]

[0178] Drawing Strength (N) VOCs (ppm) Example 1 24.70 2.20 Example 2 24.10 2.70 Example 3 26.40 2.55 Example 4 25.80 1.96 Example 5 23.60 1.68 Comparative Example 1 -- Comparative Example 2 14.20 2.46 Comparative Example 3 -- Comparative Example 4 29.40 85.60 Comparative Example 5 28.40 112.40

[0179]

[0180] Referring to Table 1 above, it was confirmed that the carpets according to the examples have a high tensile strength of 20 N or more while exhibiting a low VOCs emission of 3.0 ppm or less.

[0181] In Comparative Examples 1 and 3, it was impossible to manufacture the long-fiber spunbond nonwoven fabric serving as the backing layer. In Comparative Example 1, the long fibers could not be sufficiently cooled during the cooling process after melt spinning due to the excessive fineness of the long fibers, making it impossible to manufacture the long-fiber nonwoven fabric. In Comparative Example 3, the crystallinity of the copolyester raw material was too low, making it impossible to form long fibers, and thus making it impossible to manufacture the long-fiber nonwoven fabric.

[0182] It was confirmed that the carpet according to Comparative Example 2 exhibited a level of VOCs emission equivalent to that of the carpets of the Examples, but had significantly lower tensile strength.

[0183] It was confirmed that the carpets according to Comparative Examples 4 and 5 exhibited slightly higher tensile strength than the carpets of the Examples, but showed significantly higher VOC emissions.

[0184]

[0185] 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 laminate including sequentially laminated foam sheets for carpets and a backing layer, and It includes a plurality of carpet yarns implanted on the carpet base paper penetrating the laminate; The backing layer comprises a long-fiber nonwoven fabric made of filaments with a fineness of 1.0 to 4.5 denier, including polyester with a melting point of 115 to 175 ℃, and The carpet yarn is fixed onto the laminate by the fusion of the long fiber nonwoven fabric, Carpet.

2. In Paragraph 1, The above long-fiber nonwoven fabric is 30 g / m 2 Up to 70 g / m² 2 A carpet having a weight per unit area.

3. In Paragraph 1, The above carpet is a carpet having a tensile strength of 20 N or more according to the standard test method specified in KS K ISO 4919 (2015).

4. In Paragraph 1, The said carpet is a carpet having a volatile organic compound (VOC) emission amount of 3.0 ppm or less according to the standard test method specified in VDA 278.

5. In Paragraph 1, The above carpet base is a spunbond nonwoven fabric containing polyester filaments.

6. In Paragraph 1, The above-mentioned foam sheet for the carpet is a carpet that is a spunbond nonwoven fabric containing polyester filaments with a melting point of 250°C or higher.

7. In Paragraph 1, 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.

8. A backing layer providing step of preparing a backing layer comprising a long fiber nonwoven fabric composed of filaments having a fineness of 1.0 to 4.5 denier and including a polyester having a melting point of 115 to 175 ℃, A step of providing a laminate to form a laminate by laminating the above backing layer with a foam sheet for carpets, A tufting step of penetrating carpet yarns onto the laminate and implanting them onto the carpet base paper, and A fusion step of fixing the carpet yarn onto the laminate by heat-treating the long-fiber nonwoven fabric of the backing layer. A method for manufacturing a carpet, comprising 9. In Paragraph 8, A method for manufacturing a carpet, wherein in the above tufting step, the carpet yarn is implanted as a single loop pile type.

10. In Paragraph 8, A method for manufacturing a carpet, wherein the carpet yarn is one or more selected from the group consisting of nylon yarn, polypropylene yarn, acrylic yarn, wool yarn, and cotton yarn.

11. In Paragraph 8, A method for manufacturing a carpet, wherein the heat treatment of the above-mentioned long fiber nonwoven fabric is performed at a temperature of 120 ℃ to 180 ℃.