Spunbonded nonwoven and tile carpet using the same

Patent metadata

Field	Value
Publication number	US-12188162-B2
Application number	US-202217715985-A
Country	US
Kind code	B2
Filing date	Apr 8, 2022
Priority date	Nov 8, 2019
Publication date	Jan 7, 2025
Grant date	Jan 7, 2025

Abstract

The present disclosure relates to a spunbond nonwoven fabric for a tile carpet base fabric which can manufacture tile carpets with excellent sound absorption performance and tuft withdraw force, including high-thickness nonwoven fabrics made of hollow fibers to which recycled polyester raw materials are applied, and a tile carpet using the same.

First claim

The invention claimed is:

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, 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.

2. The spunbonded nonwoven fabric according to claim 1 , 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 μm, of 3 to 10.

3. The spunbonded nonwoven fabric according to claim 2 , 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.

4. The spunbonded nonwoven fabric according to claim 1 , wherein
in the first filament, the content ratio of the polyester and the recycled polyester is x:50 wt % (x being a number larger than 0 and equal to or smaller than 25).

5. 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 %.

6. The spunbonded nonwoven fabric according to claim 1 , wherein
the first filament is a filament having an average fineness of 5 to 10 denier, and the second filament is a filament having an average fineness of 2 to 5 denier or less.

7. The spunbonded nonwoven fabric according to claim 1 , wherein
the spunbond nonwoven fabric has a thickness of 0.35 mm to 0.40 mm when the weight per unit area is 90 g/m 2 .

8. A tile carpet comprising the spunbonded nonwoven fabric according to claim 1 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.

Assignees

• Kolon Inc

Inventors

• Choi Woo-Seok
• Lee Min Ho
• Cho Hee-Jung
• Park Young-Shin
• Jang Jung-Soon

Classifications

• D10B2503/041

  Carpet backings · CPC title

• D10B2331/04

  polyesters, e.g. polyethylene terephthalate [PET] · CPC title

• D04H3/073

  Hollow cylinder shaped · CPC title

• A47G27/02

  Carpets; Stair runners; Bedside rugs; Foot mats (mat-like foot scrapers A47L23/22 {; doormats A47L23/26}) · CPC title

• D04H3/011 Primary

  Polyesters · CPC title