Polyester nonwoven fabric and method for manufacturing the same

Abstract

Disclosed are a polyester nonwoven fabric which can be used as an useful primary backing substrate for a carpet since it exhibits good physical properties even after tufting process, and a method for manufacturing the same. The polyester nonwoven fabric of the present invention comprises an one-component filament and a sheath-core type filament both of which have a fineness of 4 to 10 denier. The one-component filament comprises a first polyester polymer having a melting point of 250° C. or higher, the sheath-core type filament comprises the first polyester polymer of 70 to 95 wt % as a core component and a second polyester polymer of 5 to 30 wt % as a sheath component, and a melting point of the second polyester polymer is lower than the melting point of the first polyester polymer by 20° C. or more.

1 . A polyester nonwoven fabric comprising:
 an one-component filament having a fineness of 4 to 10 denier; and   a sheath-core type filament having a fineness of 4 to 10 denier,   wherein the one-component filament comprises a first polyester polymer having a melting point of 250° C. or higher,   wherein the sheath-core type filament comprises the first polyester polymer of 70 to 95 wt % as a core component and a second polyester polymer of 5 to 30 wt % as a sheath component, and   wherein a melting point of the second polyester polymer is lower than the melting point of the first polyester polymer by 20° C. or more.   
     
     
         2 . The polyester nonwoven fabric of  claim 1 , wherein a ratio of a number of the one-component filament to a number of the sheath-core type filament in the polyester nonwoven fabric is 9:1 to 1:9. 
     
     
         3 . The polyester nonwoven fabric of  claim 1 , wherein the melting point of the first polyester polymer is 250 to 280° C. and the melting point of the second polyester polymer is 180 to 230° C. 
     
     
         4 . The polyester nonwoven fabric of  claim 1 , wherein the first polyester polymer is polyethylene terephthalate or polynaphthalene terephthalate. 
     
     
         5 . The polyester nonwoven fabric of  claim 4 , wherein the second polyester polymer is polybutylene terephthalate, polytrimethylene terephthalate, or a copolymer of one of polyethylene terephthalate and polynaphthalene terephthalate and one of adipic acid and isophthalic acid. 
     
     
         6 . The polyester nonwoven fabric of  claim 1 , further comprising an oil. 
     
     
         7 . The polyester nonwoven fabric of  claim 6 , wherein the oil comprises a silicon compound. 
     
     
         8 . A method for manufacturing a polyester nonwoven fabric, the method comprising:
 spinning a first polyester polymer to form an one-component filament;   conjugate spinning the first polyester polymer and a second polyester polymer to form a sheath-core type filament, the first polyester polymer being a core component and the second polyester polymer being a sheath component;   forming a web with the one-component filament and the sheath-core type filament; and   heating the web so that the one-component filament and the sheath-core type filament can be bonded to each other.   
     
     
         9 . The method of  claim 8 , wherein the spinning and the conjugate spinning are performed simultaneously. 
     
     
         10 . The method of  claim 8 , further comprising elongating the one-component filament and the sheath-core type filament before forming the web so that the one-component filament and the sheath-core type filament can have a fineness of 4 to 10 denier. 
     
     
         11 . The method of  claim 8 , wherein the web is heated with hot air. 
     
     
         12 . The method of  claim 8 , further comprising coating an oil on the heated web.