JP2005211111A - Carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bulky carpet with soft texture using polyolefin-based crimped yarn. <P>SOLUTION: The carpet contains the polyolefin-based crimped yarn composed of a single yarn of a trilobal cross section or a quadrilobal cross section of which the modification degree of a cross section is 2-5, whose single yarn fineness is 2-6 dtex and percentage crimp is 5-20%, preferably polyproylene crimped yarn, as pile, and the thickness reduction rate of the carpet is ≤35%. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a soft and bulky carpet made of polyolefin-based crimped yarn.

  Conventionally, crimped yarns obtained by hot-air crimping of thermoplastic fibers such as polyamide fibers and polyolefin fibers have been widely used as carpet pile yarns. In particular, polyolefin-based crimped yarns are used in vehicles. Since there are many carpet applications that are used while wearing shoes such as mats and office carpets, crimped yarn with a single yarn fineness of about 15 to 30 dtex is generally used. There is a demand for carpets that have a soft texture and high bulk.

  In order to give a soft texture to the carpet, it is already known to use a crimped yarn having a fine single yarn fineness (see Patent Document 1, Patent Document 2 and Patent Document 3). Patent Document 1 proposes a bulky crimped yarn having a flat cross-section with a single yarn fineness of 4d or more and less than 7d and a flatness ratio of 2 to 6, but the flat cross-sectional yarn gains bulkiness from its cross-sectional shape. For this reason, there is a problem that not only a sufficient gap between the single fibers cannot be obtained, but also the air entanglement treatment applied after the crimping process cannot be sufficiently performed in order to stabilize the passability of the tufting process.

  In Patent Document 2 and Patent Document 3, an S-shaped cross-section fiber having a single yarn fineness of 1.5 to 6 denier and an 8-shaped cross-section fiber having a single yarn fineness of 1.5 to 6 denier are proposed. In these proposals, it is necessary to keep the cross-sectional shape round in order to prevent white blurring and to suppress fibrillation of single fibers, and there is a problem in stabilizing production including quality control due to the narrow range of yarn production conditions. .

JP-A-9-49135 Japanese Patent Laid-Open No. 11-117145 JP-A-11-200179

  An object of the present invention is to solve such a conventional problem, and to provide a carpet having a soft texture and high bulkiness using a polyolefin-based crimped yarn.

  The gist of the present invention is a polyolefin-type crimping process comprising a single-filament having a three-leaf cross section or a four-leaf cross-section having a cross-section irregularity of 2 to 5, a single-filament fineness of 2 to 6 dtex, and a crimp rate of 5 to 20%. A carpet comprising a yarn as a pile and having a carpet thickness reduction rate of 35% or less.

  A carpet made of the polyolefin-based crimped yarn of the present invention, particularly a polypropylene crimped yarn, has a sufficient soft feel and bulkiness for a home use carpet. In addition, the carpet of the present invention also has an advantage unique to polyolefin fibers that no harmful substances are generated when the carpet is discarded or incinerated.

  The polyolefin-type crimped yarn included as a pile in the carpet of the present invention is composed of a single yarn having a three-leaf cross section or a four-leaf cross section having an irregularity of 2 to 5, and a single yarn fineness of 2 to 6 dtex, a crimping rate. Needs to be 5 to 20%.

  In the present invention, as shown in FIG. 1 (a) or (b), the profile irregularity refers to the diameter R of a circle that circumscribes the maximum length of the leaf portion in the single yarn cross section and contacts the other leaf tip. The ratio R / r of the diameter r of the circle of the trunk part excluding the leaf part is defined as the deformity. Moreover, as shown to (a) of FIG. 1, a 3 leaf cross section has three leaf parts which protruded radially in the single yarn cross section, and the 4 leaf cross section is the one shown in FIG. As shown to (b), it has four leaf parts which protruded radially in the single yarn section.

  When the cross-section is less than 2, it is not preferable because a sufficient bulky property cannot be obtained when a crimped yarn is used, and a volume feeling is poor when a carpet or a material string is used. On the other hand, if the degree of deformity exceeds 5, the volume feeling is good, but each leaf portion becomes thin and wear resistance is lowered, which is not preferable. Furthermore, when the cross-sectional shape of the single yarn is a two-leaf cross-section (flat cross-section), as described above, the single-fiber gap cannot be obtained from the cross-sectional shape, and sufficient bulkiness cannot be obtained. There is a problem that the air entanglement treatment given after crimping processing cannot be sufficiently performed to stabilize the passage of the material, and in the case of a multi-leaf cross section of 5 or more leaves, it is difficult to obtain the range of the above-mentioned deformity It is not preferable.

  Moreover, it is preferable that each leaf part of the single yarn of a 3 leaf cross section or a 4 leaf cross section has the same shape, but if the irregularity degree is the range of 2-5, it may differ, and each If the leaves protrude radially, it is preferable that the leaves are evenly distributed, but they are not necessarily equal.

  When the crimp rate of the polyolefin-based crimped yarn is less than 5%, a sufficient volume feeling cannot be obtained. On the other hand, when the crimp rate exceeds 20%, a volume feeling can be obtained, but the range of the yarn forming conditions becomes narrow, and there are problems in quality control and productivity.

Furthermore, the polyolefin-based crimped yarn included as a pile in the carpet of the present invention has a high bulkiness because its constituent single yarn has an irregular cross section with crests and valleys, is fine, and is crimped. The bulk height is 5.0 cm ³ / g or more, and if it is less than 5.0 cm ³ / g, satisfactory bulkiness cannot be obtained.

  The carpet of the present invention needs to have a thickness reduction rate of 35% or less. When the thickness reduction rate of the carpet exceeds 35%, the hair tends to fall down and the appearance is not good.

  The polyolefin-based crimped yarn in the present invention is not particularly limited as long as it is made of polyolefin such as polypropylene and polyethylene, but for cost reduction and functional addition in the crimped yarn manufacturing process and carpet manufacturing process. In view of the ease of adding the third component, a polypropylene, more preferably a polypropylene containing a colorant is particularly preferred. The content of the colorant in the polymer varies depending on the required hue and single yarn fineness, but is preferably about 0.1 to 3% by weight in consideration of the uniformity of the hue and the stability of the spinning process. In order to further increase the added value, stabilizers such as UV absorbers and various functional agents may be added together with the colorant in order to add weather resistance, deodorant performance, tick-proof performance, and antibacterial performance.

  Examples of colorants that can be used in the present invention include carbon black, titanium oxide, anthraquinone colorants, phthalocyanine colorants, azo colorants, and iron oxide colorants. It can be used as appropriate.

Next, a method for producing a polypropylene crimped yarn that is particularly preferably used as a pile in the carpet of the present invention will be described. That is, the polypropylene crimped yarn according to the present invention has a spinneret in which three or four slits having a length / width ratio of each slit of 2.5 to 5 are radially arranged to form a multileaf discharge hole. , And the ratio of the total discharge hole area S (mm ² ) in the spinneret to the discharge rate Q (g / min) of the polymer Q / S satisfies 3 <Q / S <15. After discharging and applying the oil agent as a unit to a single yarn group of 150 or less single yarns at a position of 1 to 3 m along the fiber running direction from the spinneret, heating drawing and heat setting were performed, and a plurality of units were It can be manufactured by performing hot air crimping as a single yarn with a collected single yarn number of 200 to 400, and then winding it by air entanglement.

  Furthermore, a specific method suitable for producing a polypropylene crimped yarn will be described. As a polypropylene polymer used for producing a fiber used as a raw yarn of the crimped yarn, a polypropylene polymer having a known fiber forming property is used. Although a melt flow rate (MFR) of about 5 to 80 g / min is suitable. The MFR is a value measured under conditions of a temperature of 230 ° C. and a load of 2.16 kg in accordance with JIS K-7210.

  Further, as a polypropylene polymer to be used, for the purpose of improving crimp performance, a polypropylene copolymer and a copolymer such as an ethylene propylene random copolymer having different shrinkage properties can be used for side-by-side composite spinning.

  When adding a colorant to the polymer, add it at the polymer production stage, add a colorant directly during spinning, melt a master chip containing a high concentration of colorant and blend it with a separately melted base polymer for spinning. A known additive technique such as a method (so-called melt blending method), a method of blending a master chip containing a high concentration and a base chip and melt spinning, or a so-called chip blending method can be applied.

  In the production of a fiber to be a base yarn of a polyolefin-based crimped yarn, a spinneret having a multileaf discharge hole formed by gathering three or four slits at one end of each slit and arranging them radially is used. use. As for the discharge holes in the spinneret, the number of holes that is the number of single yarns required for one spinneret may be drilled, or the number of holes may be smaller than that and the single yarn group is appropriately collected after spinning to obtain the required number of single yarns. However, it is preferable to secure a necessary number of single yarns of 200 to 400 by connecting a plurality of spinnerets having ejection holes with 150 or less holes.

  In order to set the irregularity of the single yarn of the three-leaf or four-leaf cross section to 2 to 5, the length / width ratio of the slit of the discharge hole is set to 2.5 to 5. Each slit is preferably a combination having the same shape, but may have a different combination as long as the length / width ratio is in the range of 2.5 to 5. In addition, even when the slits are arranged radially, it is preferable to make the angle uniform, but it is not always necessary to make the angle uniform. In addition, in order to stabilize the shape of the three-leaf section or the four-leaf section, it is preferable to perform a round hole machining with a diameter not exceeding twice the slit width at the tip of each slit.

  For the production of the fiber that will be the raw yarn of the crimped yarn, a common method such as oiling roller method, oiling guide method, spraying method such as spraying can be adopted, but the oiling guide method is applied after oiling. The yarn convergence is easy and preferable. Further, the oil agent adhesion amount is preferably 0.3 to 1.5% by weight. The yarn provided with the oil agent was wound up with a take-up roller, then preheated with a heating roller at 80 to 150 ° C., then stretched 1.5 to 5 times with a stretching roller, and heat-set at 80 to 150 ° C. Thereafter, hot air crimping at 100 to 200 ° C. with a relaxation rate of 10 to 30% is performed, air entanglement treatment is further performed, and the resultant is wound as a crimped yarn.

  A heat roller system, a hot plate system, or the like is used for the heat setting, and there is no particular limitation. The crimping method includes a gear method and an air stuffer method. However, it is difficult to cope with the production rate of the direct spinning drawing crimp method by using these methods. Crimping with a push nozzle using air), so-called hot air crimping is preferred. Although the degree of entanglement by the air entanglement process varies depending on the application, it is preferably 10 to 40 units / m from the viewpoint of stabilizing the post-process passability. In addition, the obtained crimped yarn can be heat set depending on the application. The heat setting method can be performed by a general method such as steam.

  In the carpet of the present invention, as long as the above-described specific polyolefin-type crimped yarn is used as a pile yarn, there is no particular limitation on the method for producing the carpet. The polyolefin-type crimped yarn is used as a pile yarn. When used, loop pile carpets, cut pile carpets and the like can be easily manufactured on a tufting machine.

  Hereinafter, the present invention will be described specifically by way of examples. In addition, the irregularity degree of the crimped yarn of the present invention, the discharge amount of the colored polypropylene polymer in the production of the crimped yarn, the variation of the single fiber fineness (CV value%), and various performance evaluations of the carpet are evaluated by the following methods. did.

Deformation degree of single yarn cross section:
A cross-sectional photograph of the crimped yarn was taken with a scanning electron microscope, and the irregularity of the cross-section of each single yarn was measured for 50 arbitrary single yarns. The degree of profile was determined by the average value of 50 pieces.

Colored polypropylene polymer discharge rate Q:
The following formula was used to calculate the crimped yarn fineness D (dtex) and the crimped yarn winding speed Vsp (m / min).
Q (g / min) = [D / 10000] × Vsp
Q / S was calculated from the obtained Q value.

Single yarn fineness variation (CV value%):
The single yarn fineness of the crimped yarn is evaluated by DENIER COMPUTER (DC-11A) manufactured by Search Co., Ltd., and the CV value% measures the fineness of 50 arbitrary single yarns, and the obtained value is changed from denier to dtex. Obtained by conversion.

Carpet texture:
A cut pile carpet was created and evaluated by tactile sensation.
Bulkiness (volume):
A crimped yarn is stored horizontally in a groove of a sample stand having a concave shape of 4 cm in length and having a square groove having a groove width of 1 cm, and the yarns protruding from both ends of the sample stand are cut. A load of 200 g matched to the groove width is applied to the cut crimped yarn, and the amount per weight of crimped yarn in the groove is determined from the amount (weight) of the crimped yarn and the volume of the groove formed by the load. The occupied volume (cm ³ ) was calculated and indicated by the bulk height (cm ³ / g).

Thickness reduction rate (koshi):
It was measured in accordance with a test method for thickness reduction (JIS L 1022.1992 6) due to a short-time / medium static load. (The values in Table 2 are measured values after 2 hours in the pressurized state)

(Example 1)
Three raw materials obtained by chip blending a black polypropylene master chip mainly composed of carbon black and a polypropylene homopolymer with MFR of 30 g / 10 min (SA03 manufactured by Nippon Polychem Co., Ltd.) at a weight ratio of 1:20 as a base chip. From a melt spinning machine adjusted to an extruder temperature of 240 ° C. and a spinning head temperature of 230 ° C., three slits are arranged in a Y-shape, and a round hole is processed at the end of each slit. A spinneret having 80 discharge holes with one discharge hole area of 0.097 mm ² with a rounded tip was discharged using a triple spinneret.

  After applying an oil agent to the yarn composed of 80 single yarns discharged from the spinneret with a triple oiling guide attached 1.7 m below from the spinneret along the fiber running direction, the draw ratio is doubled. After stretching at a stretching temperature of 125 ° C. and heat setting at 130 ° C., the three yarns were combined into one and subjected to hot air crimping at 170 ° C. with a relaxation rate of 18.0%. Air entangled with an air pressure of 3 MPa, wound at a speed of 980 m / min, and obtained a black crimped yarn of 1370 dtex / 240 filament.

Table 1 shows the production stability of the obtained black crimped yarn, the irregularity of the cross section of the single yarn, the single yarn fineness, and the texture evaluation results of the carpet obtained using this black crimped yarn. The production stability of the black crimped yarn was good because no single fiber was wound around the winding roller and the drawing roller in a 2-hour running study. The irregularity of the single yarn cross section was 2.8, a sharp three-leaf cross-sectional shape, and the single yarn fineness CV value was 13.8%. The obtained black crimped yarn was used as a pile raw yarn to prepare a cut pile carpet having a gauge of 5/32 G, a pile height of 15 mm, and a basis weight of 800 g / m ² . As shown in Table 2, the obtained carpet was bulky and sufficiently soft in texture, and was a very good carpet.

(Example 2)
A black crimped yarn of 1370 dtex / 240 filament was obtained under the same conditions as in Example 1. The obtained black crimped yarn was used as a pile raw yarn to prepare a cut pile carpet having a gauge of 5/32 G, a pile height of 15 mm, and a basis weight of 700 g / m ² . As shown in Table 2, the obtained carpet was compared with the carpets obtained in Comparative Examples 1 and 2, and the bulkiness was almost the same volume feeling although the basis weight was 12.5% less. Was obtained, the texture was sufficiently soft, and the carpet was very good.

(Comparative Example 1)
As the spinneret, the same conditions as in Example 1 were used except that a spinneret having 80 discharge holes having a normal Y-shape and each slit tip portion not round was 1 discharge hole area 1.029 mm ² . A black crimped yarn of 1370 dtex / 240 filament was obtained. Table 1 shows the production stability, irregularity, single fiber fineness, and texture evaluation of the carpet obtained using the black crimped yarn obtained. As for the production stability of the black crimped yarn, the single yarn was wound around the winding roller by 7 degrees in the running examination for 2 hours, and the stability was poor. The deformity of the single yarn cross section was 1.9, and the trilobal shape was not sharp compared to the black crimped yarn obtained in Example 1. The single yarn fineness CV value was 32.6%, and the variation was very large. The obtained black crimped yarn was used as a pile raw yarn to prepare a cut pile carpet having a gauge of 5/32 G, a pile height of 15 mm, and a basis weight of 800 g / m ² . As shown in Table 2, the obtained carpet had a soft texture, but its deformity was low, so that a sufficient volume feeling could not be obtained.

(Comparative Example 2)
A black crimped yarn of 1370 dtex / 240 filament under the same conditions as in Example 1 except that a spinneret having a Δ shape and an area of 0.156 mm ² and having 80 discharge holes was used. Got. Table 1 shows the production stability of the obtained black crimped yarn, the irregularity of the cross section of the single yarn, the single yarn fineness, and the texture evaluation results of the carpet obtained using this black crimped yarn. The production stability of the black crimped yarn was good with no single yarn wound around the winding roller and the drawing roller in a 2-hour running study. The irregularity of the single yarn cross section was as small as 1.3 due to the Δ cross section, and the single yarn fineness CV value was 9.9% and the variation was small. The obtained black crimped yarn was used as a pile raw yarn to prepare a cut pile carpet having a gauge of 5/32 G, a pile height of 15 mm, and a basis weight of 800 g / m ² . As shown in Table 2, the obtained carpet had a soft texture similar to that in Comparative Example 1, but the degree of deformity was low, so that a sufficient volume feeling could not be obtained.

(Comparative Example 3)
A black crimped yarn of 1370 dtex / 80 filament was obtained under the same conditions as in Example 1 except that the number of filaments was 80. Table 1 shows the production stability of the obtained black crimped yarn, the irregularity of the cross section of the single yarn, the single yarn fineness, and the texture evaluation results of the carpet obtained using this black crimped yarn. As for the production stability of the obtained black crimped yarn, the single yarn was not wound around the winding roller in a 2-hour running study, and the stability was good. The irregularity of the single yarn cross section was 2.8, which was a sharp trilobal shape similar to that in Example 1. The single fiber fineness CV value was 12.3%. The obtained black crimped yarn was used as a pile raw yarn to prepare a cut pile carpet having a gauge of 5/32 G, a pile height of 15 mm, and a basis weight of 800 g / m ² . As shown in Table 2, the obtained carpet had a voluminous feel, but because the single yarn fineness was thick, a soft texture could not be obtained.

(Comparative Example 4)
1370 dtex / 240 filament under the same conditions as in Example 1, except that hot air crimping at 130 ° C. was performed at a relaxation rate of 8.0%, and then air entangled and wound at a speed of 1100 m / min. Of black crimped yarn was obtained. As for the production stability of the obtained black crimped yarn, the single yarn was not wound around the winding roller in a 2-hour running study, and the stability was good. The irregularity of the single yarn cross section was 2.8, which was a sharp trilobal shape similar to that obtained in Example 1. The single yarn fineness CV value was 13.2%. The obtained black crimped yarn was used as a pile raw yarn to prepare a cut pile carpet having a gauge of 5/32 G, a pile height of 15 mm, and a basis weight of 800 g / m ² . As shown in Table 2, the obtained carpet had a soft texture as described above, but could not obtain a sufficient volume feeling.

  The carpet of the present invention is extremely useful particularly for home use because it has a soft texture that cannot be obtained from conventional crimped yarns of thermoplastic fibers and has high bulkiness.

It is single yarn sectional drawing of the example of the polypropylene crimped yarn contained as a pile in the carpet of this invention.

Explanation of symbols

R Diameter of the circle that circumscribes the leaf portion of the maximum length in the single yarn section and touches the tip of the other leaf portion r Diameter of the trunk circle excluding the leaf portion in the single yarn section

Claims (3)

  It comprises a single-filament having a three-leaf cross-section or a four-leaf cross-section with a cross-section irregularity of 2-5, a single-filament fineness of 2-6 dtex, and a crimped polyolefin-based crimped yarn of 5-20% as a pile. A carpet having a thickness reduction rate of 35% or less.   The carpet according to claim 1, wherein the polyolefin crimped yarn is a polypropylene crimped yarn. The carpet according to claim 1 or 2, wherein the crimped yarn has a bulk height of 5.0 cm ³ / g or more.

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