DE1654135A1 - Tufted carpet and method of making it - Google Patents

Description

f- 1> _i 54 135.8-16 February 17, 1

hanegafuchi niosekl Kabushiki Kaisha in Tokyo / Japan and on ic 7iscosu 3ocietu Nazionale Industria Applicazioni Viscosa -S.p.A.

in Kai land / Italian

Shrubbery and method of making it

The present invention relates to tufted carpets with unique. Structure in which multiple fibers consisting of composite fibers with latent crimp ability are used, whereby the composite fibers consist of two different components.These fibers are tufted with conventional single-component fibers and then a post-treatment with heat, water, solvents etc. subject. The invention also relates to a method for setting up such carpets.

-2-

109887/0036

BATH

Since non-crimpable fibers have poor covering properties, raw fibers cannot be used for carpets, so that yarn spun or crimped for such corners is generally used because of its good curling properties. However, crimped yarn has the property of giving the hair blanket an irregular, three-dimensional shape, because the tension during the curling is inconsistent, so that it is difficult to obtain a carpet with a uniform surface. The above-mentioned disadvantages are avoided by tufting composite fibers with latent curling properties and then subjecting them to an aftertreatment and puffing them up and curling them to develop the curling properties.

In this case the covering properties are proportional to the loop formation, that is, the greater the loop formation of the ciarns, the better the looping properties. However, the tendency to matting increases considerably and the surface of a carpet is not always satisfactory. On the other hand, a (3arn with little loop formation forms loops on the upper side of the hair corner, but is inadequate in its coverage properties.

It is the goal of the present invention is to avoid the above disadvantages and to create a carpet with special tufting una a unique surface that has improved coverage properties, which are based on the difference in crimpability the carpet fibers used.

This goal is achieved by tufting one untwisted or little twisted multiple fiber is made up of composite fibers with latent crimp ability and consists of single-component fibers, the composite Fibers consist of two thermoplastic, synthetic, linear polymers. The proportion of composite fibers in the multiple fiber nerve Is given by the following formula (A) and is between 30% and 90% on the entire base cloth for the hair cover of the carpet, on which the The carpet is then subjected to heat treatment or padding, in order to fully develop the latent frizziness of the bicomponent fibers.

109887/0036

BATH ORSGINAL

1 € 54.T35

ir au ■■ - ■ ■

L χ 1> öÜ (te}

In our l ~ orr, el 1st ir. Oier number; dor connected fibers * π the number of per- ^ runakoroponenten-v c ·. The number of these were found: fibers and; ei the number ¹ -ueni'-sr * ü & r- individual-

In Qer vo-rl tcrremo'sn- i £ rfirrdung vyerden VGrzugsvtefeae not verdrfl |: te f-.ehr- fochfqsörn ac'sr werrlig verdHIÜte Niehrfachfasern with few 'as TSSO TP i-v preferably less than 50 TP-IM used ^ · ^ those made of two- triponents with latent crook ability and usually i'chsn £ _irikorripon "entenfGöern order ^" -. If the number; who are not able to curl up; Fosern, sa da-3 it is for the ^ nic = ~ t bruucnbur «

Ok -i- '· -OiKor ponentisnfiber tr.lt latent k.rcutel -fahrgkeit ,, which forms the te ί ^ν Ehrfechfosor ,. characterized by the separation of two thorn, ο— ρ Laotian, synthetic Ifhearer Polyrr: ere with different chi edHehatr Krause I— capabilities hK-roestöU-tv / virüerr, if you have a V ^ arrrebelnranidtung aaer ^: Quel-lunr ; untarzogen and then ^ gleiiehzeltifg "from © i FTWR gerneiriHcitanen; Qffriung," are injected 'This btldervsle · ejnB einheltliGhe Faserv Ict ^W.el-1 rather the two polymeric adjoin each other and: eccentric side by side * run or sheath unu core of entlano Axis cer fiber-hitderr «.Dfe thönriopla- stiäChen, synthetic, linear polymers can be selected from the large range of EnzoM solcfner i-osern oi tdender PgIyn.ere, as: do sina ·, Polyur.iiae ,, Polyertor, Poly & crylinitril: ©, polyplefine, PalywinylheiliOgeniaa ,, Palyvinyl iaenha I oceni as, depending on the goal.. - ■ -. -.-..---

üie geir.aS uer lirfinaung benutzte'Kehrfachfaser can.. by the Verdoppeln- · ZweiKOfi ponentenfaaern with Jatenter Kräuselfdhigkeit rnit gewohni cozy I £ | .nkoa - i 7onentenfas "rn hergestelItwerden OAER oie.ser by gieichzeitiQes spinning Fasorn, n a speci oil spinning device, - whereby, the existing fibers - are wound up on a bobbin, - Furthermore, bushes;

165 * 135

piche obtained by changing the mixing ratio between the composite fibers and Einkompanentenfasern or by changing the nature of the titers of both fibers different fineness and ünterschledllche properties * However, should the ratio of the composite fibers in the Mehrfaehfaser, which is represented by the formula (A) _r between 30% does not reach satisfactory Qeekungselgenschaften: and 90%, preferably between 40% and HQ% _t are * is the value of the Formet (A) less ats 30% *, the composite fibers dominated by the single component, the said composite fibers produce no crimp and be "If on the other hand the value of the Farmei (a) is too Grooe _r may indeed sufficient funds are erzfeit, but the tendency of entanglement increases, and moreover, the loop formation decreases on the Tepptchaberflache by the Einkamponentenfasern, so that £ ai & features aer before! sweeping Erfindun g get lost.

It is necessary that the bicomponent fibers used according to the invention have a latent curl ability, but it is not necessary that these fibers assume a completely uncrimped state; rather, part of the latent curl ability becomes a small curl Developed * In the final state of the product, the entire latent frizzy ability must be developed, but before a bushiness of 3% to 50% is required, preferably 50% to 30% of the latent frizziness is developed. However, 1st ^ as already remarked above difficult to achieve in a highly crimped fiber ^ a Busche Lung so that die.vor d ^ r © öjjschelung ntwlckette crimp only a preliminary 1st and d tr Betr'aa of crimp is less than 50% Hegt. May be a temporary crimp gives the Vorteilj.daß full curling after Busche averaging slightly durchgeHihrt _t and excessive strengthening of the carpet can be avoided "

This means that the fibers are strong in the main development of the crimp crumple so that the carpet is slightly hard. The fibers crumple only a little if they are only temporarily ruffled, so dad-the carpet becomes voluminous and elastic.

10 9887/0036 ~ ⁵ ""

BAD LOCAL NAL

The percentage of crimp d r bicomponent fiber can be determined in the following catfish: was the two-component fiber of 30QO denier * developed in which no crimp still for 10 minutes, treated for unencumbered with hot water is gurgled of 100 C and air-dried. Then the length of the crimped fiber L _{n is} measured unloaded * · The crimped fiber is then loaded with a weight of ΐ kg and the length is determined again after 1 minute »

The percentage of complete crimp is given by the following formula: - - ·

((L ^ - L ₀ VL ₁ ) XiOO (^ o) (B) ■■■ ": '.

Oer percentage of provisional Ripple Zwelkomponentenfaser is determined in the same manner as above provided! that the treatment with hot water was not carried out, whereupon the value of this percentage is divided by the percentage of total curling indicated above and multiplied by 100 to calculate the percentage of preliminary curling. .

The preliminary crimp can be achieved by not crimping composite fibers or composed of composite »fibers Multiple fibers and monocomponent fibers at constant speed be drawn through a warm zone, whereupon locally a partial ripple from the influence of dry heat, steam heat or wet heat setting * The partially crimped fibers are cut with a speed that is less than the feed speed, withdrawn and wound on a spool. ■

The height of the temperature is determined by the type of polymer used Movement speed of the fibers, the heating tent, etc. »determined * The upper Zlehrjeschwindlgkelt is usually determined by the percentage of preliminary curling determined.

109887 / 003S

The process of creating the hair cover through bushes development of the multiple fibers on the basic cloth is known catfish in known machines executed. If the tufted carpet is cleaned with heat, water or hot water is treated before the main development of the crimp of the bicomponent fibers has been completed, a carpet is obtained of luxurious appearance in which the monocomponent fibers are loops form on the surface of the carpet.

For a better understanding of the invention, reference is now made to the drawing taken showing a cross section through a tufted carpet according to of the invention shows. The number 1 denotes the assembled fiber with latent frizziness, the numeral 2 is a non-frizzy income ™ component fiber and the number 3 is the base fabric for the tufts. At the

The subject of the invention appears the non-crimpable fiber 2 on the Surface of the carpet In loop shape and gives the carpet a luxurious look Appearance and luxurious feel that have never been achieved with known carpets. The fibers 1 with latent curling property are In after treatment to achieve good coverage properties.

If the latent curling ability of the fibers used is high, the Thickness of the hair cover will be decreased because of the coverage properties grow, so that the manufacturing cost can be reduced. Hereinafter Some examples of execution according to the invention are given. The parts given in the examples are parts by weight.

example 1

Nylon-6 with an average degree of polymerization of 162 is said to be polymer A designated. A mixed polymer of 90 parts nylon-6 and 10 parts polyhexamethylene-isophthafamide with an average polymerisation rate of 194 is referred to as polymer B. Polymers A and B are melted separately and fed to a common spinning device and so with the same Speed and equal weight in pairs verbutvdeh with each other. This connection takes place just before the spinneret, whereupon it passes through the

109887/0036

ORIGINAL

opening, which has a Y-shaped cross-section, so that a so-called trilobate: fiber is created in which polymer A has two tips of the cross-section and polymer B the other tip and. occupies the greater part of the center · Then the extruded fiber is cooled while it is oiled and continues at room temperature to the 2,9-fashe of its origin! It is pulled out to a small length, with which a non-twisted multi-ply fiber G with a high latent crimp ability and a total titer of 15QQ denier / 100 fibers is achieved. The percentage of complete crimp of the fiber is 60.7 %. On the other hand, a trilobate fiber is drawn from 15QQ Denler / IQQ fibers, which consists only of Nylah-6, "referred to as fiber D". Each of the fibers G and D are from the tufted carpet is generated * In this case, a Büsche- is averaging of the thickness dimension of £> / inch, a mesh count of by a Verart Settin g of 30 TPM doubled * whereby the fiber E is obtained, Tj inch and a ^ j

High hair covering of 18 mm is reached * Then immersed wira the carpet in hot water of Ueq O without cutting OCE loops and the temperature was raised within 30 minutes to 1Q0 G, wherein * this- temperature is maintained for 30 minutes. The carpet is then cooled and immersed in a single-color bath at -30 ° C * whereby the temperature is increased to 70 ° C within €> Q minutes. After that, the carpet is washed ,, getrock' net and ^ provided with a lamination such aa the TepptGhpradykt F with a very complicated surface "is obtained That is * the crimped conjugate fiber is close down _to% while ^see: the non-crimped EinkoTipanentenfaser establishes and falls into a loop-like state, so that the surface has a double structure and a luxurious appearance "

EXAMPLE 2 . '"

The fiber G according to Example 1 is transported through a metal tube which has been lightened to a height of 8 cm and an inner diameter of 4 mm, the input speed being 60 m / min and the output speed being 40 m / mln is «This results in a preliminary curled fiber <3. The fiber Q is rolled up on a reel and stored for 24 hours in a chamber with 65% relative humidity at 2S ^{Q G.} There*-

0 (130

1854135

after, the percentage of crimp is determined to be 5.4%. After that, will taking into account the latent frizziness the percentage of preliminary crimp

(5.4 / 63) χ 100 β 8.57%

The fiber Θ and the fiber D ₁ described in Example 1 are doubled in order to achieve a multiple fiber with the same properties and the same twist as in the example "T". Then the multiple fiber obtained is tufted under the same conditions as described above, curled, dyed, dried and laminated, with which the carpet product H is obtained. the product obtained has very soft touch and high capacity of elasticity W '. In addition, the crimped bicomponent fibers are densely

held on the carpet and distributed over the entire surface. This owns according to its ripple a deep sheen. The one-component fiber, however, stands up and forms loops on the surface of the carpet without Curling, which gives an excellent shine. Hence the carpet a unique, diverse and luxurious look,

Example 3

The bicomponent fiber made of polymer A and described in Example 1 B and a one-component fiber from polymer A are simultaneously made from one common spinneret pressed and wound on a spool.

^w - '. The openings of the spinnerets have a Y-shaped cross section. The resulting undrawn fibers are stretched 2.6 times their original length and then applied to the machine without twisting, so that a substantially untwisted fiber J is obtained from 120 parts of bicomponent fibers of 15 denier and 80 parts of monocomponent fibers of 15 denier. The fiber J was subjected to a preliminary crimping treatment as described in Example 2. In this case, the introduction speed is 50 m / min and the exit speed is 35 m / m In. The bicomponent fiber is removed from the obtained multiple fiber and the percentage of the preliminary crimp due to the latent crimp factor

109887/0036 "^"

BATH ORIGINAL

wedge determined to be 14.5%. These multiple fibers and those with a twist of 50 TPM are treated in the same way as in Example 1
and give two carpet products K and L. Product K is similar to this
Product according to Example 2, the product L is similar to the product according to Example 1, but both have increased elasticity and a diverse and luxurious appearance,

0988 7/0036

Claims (17)

Claims 1. Shrubbery carpet with a double-sided structure and a unique one Appearance, characterized in that aie corner of the carpet is made of two thermoplastic, synthetic, linear polymers composite multiple fibers (i) and a single component fiber (2) Insists that the composite fiber is dense and dispersed the surface of the base cloth (3) rests in a puckered state, and that the single component fiber stands up on the surface and in loop form falls. 2. Gebüscheiter carpet according to claim 1, characterized in that the composite fiber in aer multiple fibers present in a ratio of 30% to 90% is according to the formula: md. br- xioo (%) rnd ,. + nd _? where m is the number of composite fibers, η a! e number of one-component fibers, d ,. the titre of the individual composite fibers and dp is the titer of the individual monocomponent fibers. 3. Gebüscheiter carpet according to claim 1, characterized g e k e η n - shows that the composite fiber in the iviehrfoch fiber in a ratio of 40% to 80% is represented. 4. Gebüscheiter carpet according to one of claims 1 to 3, aaaurch characterized in that the composite fiber and the one-component fibers made of fiber-forming thermoplastic, synthetic, linear: polymers such as polyamides, polyesters, polyacrylonitriles, Polyolefins, polyvinyl halides, and polyvinylidene halides confess. 5. GebUscheiter carpet according to one of claims 1 to 3, characterized characterized in that the composite fibers and the monocomponent fibers consist of polyamides. ■. ■ - ■■ ..- ■:. ' ν. -11- 109887/0036 Documents (Art. 7 % I Para. 2 Nn Τ Sate 3 of the Amendment 4.9- i9 & BATH ORIGINAL 6. Gebüsdnelter carpet according to one of claims 1 to 3, characterized geke nr \ characterized in that at least one of the composite fibers and the monocomponent fibers sJnd trilobate. 7. Method of making a tufted carpet with double Surface structure and unique appearance, characterized in that it consists of an untwisted or slightly twisted multiple fiber a composite fiber with latent crimpability, from two thermoplastic, synthetic, linear polymers and a one-component fiber bundled on the basic cloth of the carpet to form the hair blanket and that the carpet is subjected to a heat or smoldering treatment which causes the composite fiber to crimp completely. 8. The method according to claim 7, characterized in that Re η η ζ el chnet, dai3 the composite fiber in the multiple fiber in the ratio of 30% to 90% is available. 9. The method according to claim 7, characterized in that a'a, 3 the composite fiber in the multiple fiber in a ratio from 40% to 30% is present. 10. The method according to claim 7, characterized gekennzei chnet _t dad 3/0 to 50% of the latent crimpability of the composite fiber before cer tufting are developed. 11. The method according to any one of claims 7 to 9, characterized It assumes that 50% to 30% of the latent capacity of the compound Fiber to be developed before tufting. 12. The method according to any one of claims 7, 8 or 10, characterized in that it is identified η e t, da3 is the number of twists in the multiple fiber is between 0 and 100 TPM. · • -12- 109887/0036 13. The method according to any one of claims 7, 8 or 10, characterized in that g e - <· kennzelc h η e t, daö the number of twists of the multiple fiber between 0 and 50 TPN '; lies. Method according to one of Claims 7, 8 or 10, characterized in that the multiple fiber is produced by simultaneous spinning of a composite fiber consisting of two thermoplastic, synthetic, linear polymers with latent Krüuselfahlgkelt and a single-component fiber through a common opening, and that the end product is wound up on a reel. 15 »Method according to one of claims 7, 8 or 10, also characterized, aaB the composite fibers from fiber-forming fibers thermoplastic, synthetic, linear polymers consist and of the group of polyamides, polyesters, polyacrylonitriles, polyolefins, polyvinyl halides and polyvinyl idene halides can be selected. 16, A method according to any one of claims 7, 8 or 10, characterized GEK e η η ζ e I et η, da3 the composite fibers and the Einkomponentenfaserh consist of polyamides. 17. The method according to any one of claims 7, 8 or 10, characterized GEK e η η ζ e ί ch η et, da3 least one aer composite fibers and the fibers are Elnkomponentehfaser trlfobale. 109887/0036 BATH ORIGINAL