# US 2014/0154943 A1 · Polyester nonwoven fabric and method for manufacturing the same

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- Number: US 2014/0154943 A1
- Document ID: US20140154943A1
- Status: Published application
- Kind: A1
- Application number: 14/232,058
- Filed: 2012-09-25
- Published: 2014-06-05
- Earliest claimed: 2011-09-30
- Assignees: Kolon Industries, Inc.
- Applicants: Kolon Industries, Inc.
- Inventors: Jin Whan Choi; Jin Il Kim; Min Ho Lee
- Web page: https://patentgrep.com/patent/US20140154943A1

## CPC

- D04H 1/56: in association with fibre formation, e.g. immediately following extrusion of staple fibres
- D01D 5/34: Core-skin structure; Spinnerette packs therefor
- D01F 6/62: from polyesters
- D01F 8/14: with at least one polyester as constituent
- D04H 1/425: Cellulose series
- D04H 1/435: Polyesters
- D04H 1/58: by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives (in combination with needling D04H1/488)
- D04H 3/011: Polyesters
- D04H 3/147: Composite yarns or filaments
- Y10T 442/609: Cross-sectional configuration of strand or fiber material is specified
- D04H: MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL (weaving D03; knitting D04B; braiding D04C; net-making D04G; sewing D05B; tufting D05C; finishing non-woven fabrics D06); FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING {; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION}(non-woven fabrics having an intermediate or external layer of a different kind, e.g. of woven fabric, B32B)
- D01D: MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
- D01F: CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## 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.

## Claims

### Claim 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.

### Claim 2 (depends on 1)

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.

### Claim 3 (depends on 1)

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.

### Claim 4 (depends on 1)

The polyester nonwoven fabric of claim 1, wherein the first polyester polymer is polyethylene terephthalate or polynaphthalene terephthalate.

### Claim 5 (depends on 4)

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.

### Claim 6 (depends on 1)

The polyester nonwoven fabric of claim 1, further comprising an oil.

### Claim 7 (depends on 6)

The polyester nonwoven fabric of claim 6, wherein the oil comprises a silicon compound.

### Claim 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.

### Claim 9 (depends on 8)

The method of claim 8, wherein the spinning and the conjugate spinning are performed simultaneously.

### Claim 10 (depends on 8)

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.

### Claim 11 (depends on 8)

The method of claim 8, wherein the web is heated with hot air.

### Claim 12 (depends on 8)

The method of claim 8, further comprising coating an oil on the heated web.