Washable nonwoven fabric and manufacture method

Abstract

A washable nonwoven fabric for washable is provided in some embodiments of the present disclosure, including: a base layer and a washable anti-pilling layer. The base layer has a softness coefficient of from 40 to 140, in which the softness coefficient is tested according to method A in JIS L1096-2010 standard test. The washable anti-pilling layer is adhered to the base layer and comprises a composition including polyurethane. A covalent bond exists between the base layer and the washable anti-pilling layer, and the covalent bond is an amide functional group bond, a urethane functional group bond, a urea functional group bond, or a combination thereof. A weight percentage of isocyanate groups in the composition is not lower than 1.2%. A method of manufacturing a washable nonwoven fabric is also provided in some embodiments of the present disclosure.

What is claimed is: 
     
         1 . A washable nonwoven fabric, comprising:
 a base layer, having a softness coefficient of from 40 to 140, wherein the softness coefficient is tested according to method A of JIS L1096-2010 standard test; and   a washable anti-pilling layer, disposed on the base layer and comprising a composition including polyurethane,   wherein the washable anti-pilling layer is disposed on at least one surface layer or at least one inner layer of the base layer through a covalent bonding with the base layer;   wherein the covalent bond is an amide functional group bond, an urethane functional group bond, an urea functional group bond, or a combination thereof;   wherein the base layer has a plurality of hydroxyl groups, a plurality of carboxyl groups, a plurality of amine groups, or a combination thereof, and the polyurethane has a plurality of isocyanate groups, wherein a weight percentage of the plurality of isocyanate groups in the composition is not lower than 1.2% based on 100% by total weight of the composition;   wherein the amide functional group bond is formed by reacting the plurality of isocyanate groups of the washable anti-pilling layer with the plurality of hydroxyl groups of the base layer;   wherein the urethane functional group bond is formed by reacting the plurality of isocyanate groups of the washable anti-pilling layer and the plurality of carboxyl groups of the base layer;   wherein the urea functional group bond is formed by reacting the plurality of isocyanate groups of the washable anti-pilling layer with the plurality of amine groups of the base layer.   
     
     
         2 . The washable nonwoven fabric of  claim 1 , wherein the base layer comprises polyester fiber, polyamide fiber, or a combination thereof. 
     
     
         3 . The washable nonwoven fabric of  claim 1 , wherein fiber cross-section configuration of the base layer has configuration of hollow type, sea-island type, sheath-core type, side-by-side type or orange-petal type. 
     
     
         4 . The washable nonwoven fabric of  claim 1 , wherein fineness of fiber in the base layer is from 0.01 denier to 7 denier. 
     
     
         5 . The washable nonwoven fabric of  claim 1 , wherein volume density of the base layer is from 0.2 g/cm 3  to 0.5 g/cm 3 . 
     
     
         6 . The washable nonwoven fabric of  claim 1 , wherein a weight percentage of the washable anti-pilling layer is from 1% to 10% based on 100% by total weight of the washable nonwoven fabric. 
     
     
         7 . The washable nonwoven fabric of  claim 1 , wherein the composition comprises a polyester unit, a polyether unit, or a combination thereof. 
     
     
         8 . A method of manufacturing the washable nonwoven fabric of  claim 1 , comprising:
 providing a base layer, having a softness coefficient of from 40 to 140, wherein the softness coefficient is tested according to method A of JIS L1096-2010 standard test;   providing polyol and a cross-linking agent;   mixing the polyol and the cross-linking agent to make a hydroxyl group of the polyol bond to an isocyanate radical of the cross-linking agent to form prepolymer having an urethane unit; and   adhering the prepolymer to the base layer to make the prepolymer perform a cross-linking reaction with moisture to form a composition including polyurethane and simultaneously react with functional groups of the base layer to form a covalent bond, thereby obtaining a washable anti-pilling layer adhered to the base layer, wherein the covalent bond is an amide functional group bond, an urethane functional group bond, an urea functional group bond, or a combination thereof, the prepolymer has a plurality of isocyanate groups, and a weight percentage of the plurality of isocyanate groups in the prepolymer is not lower than 1.2% based on 100% by total weight of the prepolymer.   
     
     
         9 . The method of  claim 8 , wherein the moisture is water vapor in air. 
     
     
         10 . The method of  claim 8 , wherein the base layer is a nonwoven fabric prepared by a hydro-entanglement method or a needle punch method. 
     
     
         11 . The method of  claim 8 , wherein the polyol comprises polyester polyol, polyether polyol, trimethylolpropane, trihydroxymethylethane, cyclohexane dimethanol, neopentyl glycol, trimethylpentanediol, pentaerythritol, or a combination thereof. 
     
     
         12 . The method of  claim 11 , wherein the polyester polyol is obtained by a condensation reaction of polyhydric alcohol and polycarboxylic acid. 
     
     
         13 . The method of  claim 11 , wherein the polyether polyol comprises polyethylene glycol, poly(1,3-propanediol), poly(1,2-propanediol), Polytetramethylene Ether Glycol, poly(hexane-1,6-diol), poly(2-methyl-1,3-propanediol), poly(2-ethyl-1,2-hydroxymethyl)-1,3-propanediol, poly(2-2-methoxyethoxyethanol), copolymer of polyethylene glycol and polypropylene glycol, or a combination thereof. 
     
     
         14 . The method of  claim 11 , wherein the polyol comprises the polyester polyol and the polyether polyol, and a mixing weight ratio of the polyester polyol and the polyether polyol is from 0.5:1 to 10:1. 
     
     
         15 . The method of  claim 8 , wherein a weight ratio of the polyol and the cross-linking agent is from 2:1 to 9:1. 
     
     
         16 . The method of  claim 8 , wherein the cross-linking agent comprises isocyanate. 
     
     
         17 . The method of  claim 8 , wherein the amide functional group bond is formed by reacting the plurality of isocyanate groups of the prepolymer and a plurality of hydroxyl groups of the base layer; the urethane functional group bond is formed by reacting the plurality of isocyanate groups of the prepolymer and a plurality of carboxyl groups of the base layer; the urea functional group bond is formed by reacting the plurality of isocyanate groups of the prepolymer and a plurality of amine groups of the base layer. 
     
     
         18 . The method of  claim 8 , wherein the base layer has a plurality of hydroxyl groups, a plurality of carboxyl groups, a plurality of amine groups, or a combination thereof.