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EP-4053319-B1 - SPUNBONDED NON-WOVEN FABRIC, AND TILE CARPET USING SAME

EP4053319B1EP 4053319 B1EP4053319 B1EP 4053319B1EP-4053319-B1

Inventors

  • CHOI, WOO-SEOK
  • LEE, MIN HO
  • CHO, Hee-jung
  • PARK, YOUNG-SHIN
  • JANG, Jung-soon

Dates

Publication Date
20260506
Application Date
20201030

Claims (6)

  1. A spunbonded nonwoven fabric comprising a fiber web of mixed filament yarns of a first filament prepared from a polyester and a recycled polyester each having a melting point of 255 °C or more and a second filament prepared from a copolyester having a lower melting point than that of the first filament by 30 °C or more, wherein the first filament is a filament having a hollow fiber cross-section having a hollow ratio of 10 to 20 %, wherein a raw material of the recycled polyester has an average number of foreign matters with a size of 1.0 to 10.0 µm of 10 or less, wherein the recycled polyester contained in the first filament uses a recycled polyester that has a melting point of 255 °C or more, an intrinsic viscosity (IV) of 0.60 to 0.80 dl/g, and an average number of foreign matters with a size of 1.0 to 10.0 µ m of 3 to 10, wherein the content ratio of the polyester and the recycled polyester of the first filament is 0:50 to 50:100 wt% and wherein the spunbonded nonwoven fabric has tensile strength of 20 kgf/5 cm or more and tensile elongation of 20 % or more as measured according to the KS K 0521 test method, and is used as a base fabric for tile carpets, wherein the hollow ratio is measured as defined in the description.
  2. The spunbonded nonwoven fabric according to claim 1, wherein the recycled polyester contained in the first filament uses a polyethylene terephthalate chip that has a melting point of 255 °C or more, an intrinsic viscosity (IV) of 0.60 to 0.80 dl/g, and an average number of foreign matters with a size of 1.0 to 10.0 µm of 3 to 10.
  3. The spunbonded nonwoven fabric according to claim 1, wherein the combined filament yarn contains the first filament and the second filament in a content ratio of 30:70 to 95:5 wt%.
  4. The spunbonded nonwoven fabric according to claim 1, wherein the first filament is a filament having an average fineness of less than 5 to 10 denier, and the second filament is a filament having an average fineness of 2 to 5 denier or less.
  5. The spunbonded nonwoven fabric according to claim 1, wherein the spunbonded nonwoven fabric has a thickness of 0.35 mm to 0.40 mm when the weight per unit area is 90 g/m 2 .
  6. A tile carpet comprising a spunbonded nonwoven fabric according to any one of claims 1 to 5 as a base fabric, and having a sound absorption coefficient (at 500 Hz) of 0.2 or more, and a tuft withdraw force of carpets of 2.0 kgf or more, wherein the sound absorption coefficient and tuft withdraw force of carpets are measured as defined in the description.

Description

[TECHNICAL FIELD] This application claims the benefit of Korean Patent Application No. 10-2020-0186037 filed on December 29, 2020 in the Korean Intellectual Property Office. The present disclosure relates to a spunbond nonwoven fabric that can be applied as a tile carpet base fabric exhibiting high functionality. [BACKGROUND ART] Nonwoven fabric is a product made by arranging filaments in a planar form, and is largely divided into a staple fiber nonwoven fabric and a long fiber nonwoven fabric according to the length of the filament. The staple fiber nonwoven fabric is a product made by arranging staple fibers of 5 mm or less in a planar form, and subjecting it to entanglement between fibers or resin adhesion, and has a feature of high elongation. The long fiber nonwoven fabric is a product made by arranging unbroken fibers in a planar shape and subjecting it to entanglement between fibers or resin adhesion, and has a feature of high strength. Long-fiber nonwoven fabric, which has advantages such as excellent strength, is mainly used for construction and civil engineering purposes. In recent years, nonwoven fabrics have been expanded to be applied as interior/exterior materials for automobiles in accordance with the trend toward weight reduction in automobile materials. Further, a long fiber nonwoven fabric having a low weight while having the same strength as the interior material in the form of a conventionally used woven fabric or short-fiber nonwoven fabric is applied. The product groups that are mainly applied include tile carpets, automobile flooring carpets, under covers, head linear products, and the like. Double tile carpets are used as flooring materials for homes or offices, and their main purpose is heat insulation and decoration. Further, since the carpet has better sound absorption than other flooring materials and has relatively little sound resonance, it plays a role in creating a quiet living environment. Such a tile carpet is subjected to a tufting process (a process of planting threads in a nonwoven fabric) and a back-coating process (a process of immersing a PVC solution into a back surface of the tufted nonwoven fabric, and then heat-curing it through a chamber) for the nonwoven fabric, and then finally to a cutting process (standard: 50 cm x 50 cm) to manufacture a tile carpet. For tile carpet products that are currently being used, waste such as renewable polyester plastics is recycled, and thus tile carpet products containing recycled polyester raw materials, which have excellent basic physical properties of nonwoven fabrics such as tensile strength while contributing to resource recycling and prevention of environmental pollution, are being developed. Further, in such a case, the use is expanding to nonwoven fabrics for landscaping, filters, etc. in addition to carpet products. KR 101 976 119 relates to a method for manufacturing a spunbonded non-woven fabric for a tufted carpet backing fabric having a simple manufacturing process by not using a binder resin but using a long fiber needle punching method. In particular, the spunbonded non-woven fabric is manufactured by the heat-adhering method using the hot air. WO 2019/009539 relates to a non-woven fabric, that forms a web with filaments made of hollow yarns. WO 2019/059573 relates to a nonwoven fabric 50-90 wt% of polyester filaments having a melting point of 250°C or higher and 10-50 wt% of low-melting point copolyester filaments having a melting point of 200°C or lower. The nonwoven fabric comprising low-melting point polyester fibers is used as a backing fabric and the thickness of the backing fabric is controlled, so that the pull-out strength of the carpet is enhanced, thereby suppressing the falling out of BCF yarns from the carpet. However, the use of recycled polyester raw materials may cause deterioration of product characteristics (e.g., chip agglomeration, poor spinnability, and poor nonwoven fabric physical properties) due to the differences in the chemical composition of additives and adhesives contained in nonwoven waste, and the inclusion of a large amount of foreign matter. [DETAILED DESCRIPTION OF THE INVENTION] [Technical Problem] It is one object of the present disclosure to provide a spunbond nonwoven fabric that can be used as a tile carpet base fabric having excellent sound absorption performance and tuft withdraw force while having excellent basic physical properties of nonwoven fabric by applying recycled polyester raw materials with low foreign matter content and improved physical properties, and a method for manufacturing the same. It is another object of the present disclosure to provide a tile carpet base fabric having excellent physical properties such as sound absorption and tuft withdraw force using the above-mentioned spunbond nonwoven fabric. [Technical Solution] According to one aspect of the present disclosure, there is a spunbonded nonwoven fabric including: a fiber web of mixed filament yarns o