NON-WOVEN FABRIC FOR PRIMARY CARPET BACKING AND MANUFACTURING METHOD THEREOF

Abstract

The present disclosure relates to a nonwoven fabric for primary carpet backing and a method for manufacturing same, the non-woven fabric having different colors on the two sides thereof and improved mechanical property. More specifically, the present disclosure relates to a non-woven fabric for primary carpet backing and a method for manufacturing same, wherein any one surface of the two surfaces of appears in a range of white to grey and the opposite surface thereof appears in a range of dark grey to black, so that the separate manufacture of non-woven fabrics having various colors according to carpet colors is not required, which facilitates the inventory management of the non-woven fabric, achieves color matching between a carpet pile yarn and a nonwoven fabric for primary carpet backing, and improve the efficiency of the carpet manufacturing process.

Claims

1. A nonwoven fabric for primary carpet backing, comprising: a first surface layer and a second surface layer, wherein the first surface layer and the second surface layer comprises a mixed filament yarn having a content ratio of a first filament including a first polyester having a melting point of 250° C. or more and a carbon black, and a second filament including a second polyester having a melting point of 190° C. or less of 95:5 to 85:15%, and wherein the total content of the carbon black in the first surface layer is 0.06 to 0.15% by weight, and the total content of the carbon black in the second surface layer is 0.3 to 0.5% by weight.

2. The nonwoven fabric for primary carpet backing according to claim 1, wherein the first filament constituting the first surface layer contains 0.07 to 0.15% by weight of the carbon black, and the first filament constituting the second surface layer contains 0.37 to 0.5% by weight of the carbon black.

3. The nonwoven fabric for primary carpet backing according to claim 1, wherein a white index is 5.3 to 17.0 for the first surface layer, and 4.0 to 5.2 for the second surface layer.

4. The nonwoven fabric for primary carpet backing according to claim 1, wherein in the case of tufting to manufacture a carpet, a reduction rate of tensile strength before and after tufting is 70% or less.

5. A method for manufacturing a nonwoven fabric for primary carpet backing, the method comprising the steps of: melting a first polyester having a melting point of 250° C. or more containing carbon black for the first filament and a second polyester having a melting point of 190° C. or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, thereby preparing a mixed filament yarn for web of the first row; melting a first polyester having a melting point of 250° C. or more containing carbon black for the first filament and a second polyester having a melting point of 190° C. or less for the second filament, respectively, discharging the molten polyester through a spinning nozzle, and bicomponent-spinning so that a content ratio of the first filament to the second filament is 95:5 to 85:15% by weight, thereby preparing a mixed filament yarn for web of the second row; laminating the mixed filament yarns for web of the first row to form a web of the first row, and laminating a web of the second row with the mixed filament yarn for web of the second row thereon to form a web in which the first row and the second row are laminated; and subjecting the laminated web to calendering process using a smooth roll, and then thermally bonding the web with hot aft to manufacture the nonwoven fabric, wherein the web of the first row contains 0.06 to 0.15% by weight of the carbon black, and the web of the second row contains 0.3 to 0.5% by weight of the carbon black.

Description

EXAMPLE 1

[0049] An extruded melt of polyethylene terephthalate having a melting point of 255° C. which was obtained by side-feeding carbon black so that the content of carbon black was 0.07 wt % to form the first filament, and an extruded melt of polyethylene terephthalate having a melting point of 180° C. which was obtained by copolymerizing adipic acid and isophthalic acid to form a second filament, were respectively discharged through a spinning nozzle at the bottom of the continuous extruder, and bicomponent-spun to produce a mixed filament yarn for web of the first row.

[0050] An extruded melt of polyester having a melting point of 255° C. which is obtained by side-feeding carbon black so that the content of carbon black was 0.5wt % to form the first filament, and an extruded melt of polyester having a melting point of 180° C. which was obtained by copolymerizing adipic acid and isophthalic acid to form a second filament, were respectively discharged through a spinning nozzle at the bottom of the continuous extruder, and bicomponent-spun to produce a mixed filament yarn for web of the second row.

[0051] At this time, the bicomponent spinning was made such that the content ratio of the first filament and the second filament was 90:10 wt %, and the discharge amount and the number of spinning nozzles were adjusted so that the fineness of the mixed filament produced by drawing was 8 denier.

[0052] Further, the continuous filaments discharged from the spinning nozzle were solidified with a cooling aft, and then drawn so that the spinning speed was 5,000 m/min using a high-pressure aft drawing device.

[0053] Subsequently, the mixed filament yarn for web of the first row was laminated on a conveyor net by a conventional opening method to form a web of the first row such that the content of the carbon black of the first row was 0.063 wt %, and a web of the second row was laminated with the mixed filament yarn for web of the second row thereon so that the content of carbon black of the second row was 0.45wt %, to thereby form a web in which the first surface layer by the first row and the second surface layer by the second row were laminated.

[0054] The web thus laminated was subjected to a calendering process using a heated smooth roll to impart smoothness and appropriate thickness, and thermally bonded through hot air. Thereby, a nonwoven fabric for primary carpet backing having a weight per unit area of 120 g/m2 was prepared by thermal bonding through hot air.

EXAMPLES 2 to 4 AND COMPARATIVE EXAMPLES 1 to 4

[0055] The nonwoven fabrics for primary carpet backing were manufactured in the same manner as in Example 1, except that in Example 1, the bicomponent-spinning ratio of the mixed filament yarn and the carbon black content in the first row and the second row are as shown in Table 1 below.

TABLE-US-00001 TABLE 1 Content of carbon black Content of carbon black Content Content of first row (wt %) of second row (wt %) of first of second First Second filament filament First laminated First laminated Category (wt %) (wt %) filament web filament web Example 1 90 10 0.07 0.063 0.5 0.45 Example 2 90 10 0.15 0.135 0.37 0.333 Example 3 86 14 0.15 0.129 0.37 0.318 Example 4 94 6 0.15 0.141 0.37 0.347 Comparative 90 10 0.05 0.045 0.5 0.45 Example 1 Comparative 90 10 0.07 0.063 0.6 0.54 Example 2 Comparative 96 4 0.07 0.067 0.5 0.48 Example 3 Comparative 80 20 0.07 0.056 0.4 0.4 Example 4

[0056] The properties of the spunbond nonwoven fabric for primary carpet backing and the nonwoven fabric after tufting in the Examples and Comparative Examples were measured according to the following test method, and the results are shown in Table 2 be low.

[0057] At this time, the tufting was performed under the conditions of a gauge (10 ea/inch) and a BCF yarn height (3 mm) in a loop form.

Testing Method

1. Tensile Strength (Unit: Kg.f/5 cm) and Tensile Elongation (%)

[0058] The method of KS K 0521 was used

[0059] A specimen having a size of width×length=5×20 cm is clamped with a jig with a size of top/bottom 5×5 cm using Instron's testing equipment, and then measured at a tensile speed of 200 mm/min.

2. White Index (WI)

[0060] Measured using X-rite's Color-Eye 7000A device.

[0061] For the evaluation specimen, a minimum diameter of 40 mm or more was used, and the average value was shown after measuring three times for each sample.

[0062] As the numeral value of the measured value WI is higher, it means white.

TABLE-US-00002 TABLE 2 Tensile strength Reduction rate of White Index Final color MD/CD (Kg .Math. f/5 cm) tensile strength Tensile (first surface (first surface Before After after tufting elongation layer/second layer/second Category tufting tufting MD/CD (%) MD/CD (%) surface layer) surface layer) Remark Example 1 27.2/28.4 11.4/13.1 58/54 56.6/58.1 16.4/4.2 Light gray/black Example 2 26.8/27.3 10.5/10.4 61/62 57.1/57.8  5.7/5.1 Gray/dark gray Example 3 29.5/30.1  9.4/10.2 68/66 51.3/52.8  5.8/5.2 Gray/dark gray Example 4 26.2/26.7 11.5/12.8 56/52 59.4/60.2  5.5/4.9 Gray/dark gray Comparative 27.6/28.4 13.2/13.1 52/54 57.4/58.3 18.3/4.4 White/black Example 1 Comparative — — — — — — Defective Example 2 spinning Comparative 17.5/19.5 8.6/9.9 51/49 56.9/58.2 16.4/4.3 Light Strength Example 3 gray/black failure Comparative 31.4/33.1 9.1/8.3 71/75 38.6/39.7 16.5/4.3 Light Tufting Example 4 gray/black failure

[0063] From the results of Table 2, it is confirmed that in the nonwoven fabric for primary carpet backing according to the present disclosure, the first surface layer appears in a range of white to gray, the second surface layer appears in a dark gray to black range, and the first and second surface layers show different colors of relatively light and dark colors which are clearly contrasting, and thus, it is possible to select and use a surface appearing light or dark color in compliance with the final color of the carpet.

[0064] On the other hand, when the content of the second filament in the mixed filament yarn decreases (see Comparative Example 3), the tensile strength of the nonwoven fabric is lowered, and when the content of the second filament is increased (see Comparative Example 4), the reduction rate of tensile strength after tufting is increased, so that the physical properties after tufting are deteriorated.

[0065] In addition, when the content of carbon black in the first filament is increased (see Comparative Example 2), it is confirmed that yarn breakage and clogging of the spinning nozzle occur and spinning is not performed properly, and thus, the nonwoven web is not formed.