JP2007092206A - Crimped yarn for flame-retardant polyamide carpet and the resultant polyamide carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide crimped yarn for inexpensive flame-retardant polyamide carpets excellent in both flame retardancy and yarn manufacturability with no problems even in case only pile yarn has been flame-retarded, and to provide such a flame-retardant polyamide carpet using the crimped yarn. <P>SOLUTION: The crimped yarn comprises 0.5-25 wt.% of a melamine polyphosphate-based flame retardant 0.1-5.0μm in particle size and 75-99.5 wt.% of polycapramide. The crimped yarn is modified cross-section and/or hollow cross-section yarn and 15-40% in percent crimp. The flame-retardant polyamide carpet produced from the crimped yarn is also provided. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a flame-retardant polyamide carpet crimped yarn and a carpet using the same. More specifically, the present invention relates to an aircraft excellent in flame retardancy and a carpet fiber and carpet suitable for marine applications.

  Polyamide carpets are widely used in offices, hotels, etc. taking advantage of their excellent durability and bulkiness. However, it has been considered difficult to apply to aircraft and ships that have high flame retardancy characteristics because flame retardance cannot be achieved.

  At present, many products using wool are used. However, in order to satisfy the quality and durability of wool, it is necessary to increase the amount of yarn, and replacement with other materials is required from the viewpoint of weight reduction and price.

  As means for solving the conventional flame retardancy, one obtained by treating the surface of the yarn with a flame retardant has been proposed (for example, Patent Document 1). However, in the surface treatment, the flame retardant cannot be sustained because the surface treatment agent falls off when used in shoes such as airplanes and ships.

  Moreover, although the flame retarding of the carpet base fabric and the backing agent has been studied (Patent Document 2.3), since the flame retardance of the yarn itself on the surface has not been solved, the effect is small. .

  Solutions for carpet piles are also disclosed. One is a carpet using a thermoplastic fluorine-containing polymer (Patent Document 4). However, in this case, the processability is difficult compared to nylon, and unless the processing speed is slowed down, a carpet with high bulkiness cannot be obtained, and the material cost is high, making it difficult to apply widely. It was.

  In addition, a flame-retardant carpet yarn using polyamide has also been proposed. As this method, a carpet using a yarn obtained by adding an inorganic flame retardant to a mixture of nylon 6 and nylon 66 has been proposed (Patent Document 5). However, it is not at a level that can be applied to highly demanding aircraft and marine applications so that flame retardancy is optimal for automotive applications. Further, by mixing nylon 6 and nylon 66, the texture and the like are improved as compared with nylon 66 alone, but it is not as good as nylon 6 alone.

  Moreover, although the thread | yarn which incorporated zinc, molybdenum, and chlorine in the polyamide is proposed (patent document 6), since it contained chlorine, the point which generate | occur | produces chlorine gas at the time of combustion became a problem.

As another method, the use of a triazine flame retardant is disclosed as a crimped yarn that does not generate halogen or the like and a carpet using the crimped yarn (Patent Document 7). However, since the triazine flame retardant is a drip-type flame retardant, the surface of the carpet drip during combustion, exposing the backing of the base fabric and NRB rubber that have not been subjected to flame retardant formulation, and continue to burn as a core. Therefore, the flame retardant effect as expected could not be obtained.
Japanese Patent Laid-Open No. 5-33270 JP 58-70714 A JP 59-71483 A JP-A 61-55229 JP 58-104218 A JP-A-60-259621 JP 2002-309443 A

  The present invention has been achieved as a result of studying the solution of the problems in the prior art described above as an issue.

  Therefore, the object of the present invention is rich in light weight compared with conventional wool products, no toxicity at the time of combustion, no problem even if it is a flame retardant prescription only with pile yarn, inexpensive and excellent in both flame retardancy and yarn production Another object of the present invention is to provide a crimped yarn for flame retardant polyamide carpet and a flame retardant polyamide carpet using the same. In addition, the above-mentioned problems were solved only with polycaproamide, which is superior in texture but slightly inferior in flame retardancy as compared with conventional polyhexamethylene adipamide.

  In order to achieve the above object, according to the present invention, melamine polyphosphate flame retardant having a particle size of 0.1 to 5.0 μm is composed of 0.5 to 25% by weight and 75 to 99.5% by weight of polycaproamide. Provided is a crimped yarn for flame-retardant polyamide carpet, characterized in that the crimped yarn has an irregular cross section and / or a hollow cross section, and the crimp rate is 15 to 40%. Is done.

In the crimped yarn for carpet of the present invention, the following (a) or (b) can be mentioned as a preferred embodiment.
(A) Y-shaped and Y-shaped hollow with a modified cross section of three leaves, or a rice-shaped hollow having four hollows.
(B) The single yarn fineness of the crimped yarn is 10 to 30 dtex.

  According to the present invention, as described below, a crimped yarn for polyamide carpet excellent in flame retardancy, durability, bulkiness, and yarn forming property and a carpet using the same are provided.

  The present invention is described in detail below.

  The crimped yarn for flame retardant polyamide carpet of the present invention is a variant comprising 0.5 to 25% by weight of a melamine polyphosphate flame retardant having a particle size of 0.1 to 5.0 μm and a polyamide of 75 to 99.5% by weight. It is characterized by having a cross section and / or a hollow.

  The polyamide of the present invention needs to be polycaproamide. Polycaproamide is most suitable for carpet application because of its excellent texture, color developability and low cost.

  The crimped yarn for flame-retardant polyamide carpet of the present invention preferably contains 0.5 to 25% by weight of melamine polyphosphate as a flame retardant. The flame retardant mechanism of the melamine polyphosphate flame retardant added to the flame retardant polyamide fiber of the present invention is such that melamine and the like generate nitrogen during combustion, forms a carbonized foam film, improves heat insulation, Form an intumescent). In addition, phosphorus is effective as a dehydrating agent, and the produced polyphosphoric acid film is sticky. Therefore, it is considered to stop in the solid phase for a long time to promote the dehydration reaction and prevent the diffusion of oxygen. . Therefore, since the carbonized layer is formed on the carpet surface, the flame retardancy of the carpet is maintained without flame-retarding the base fabric and the backing layer which are the constituent elements of the carpet.

  The melamine polyphosphate flame retardant used in the present invention is an equimolar reaction mixture of polyphosphoric acid and melamine, and is, for example, a white powder obtained by mixing and heating an aqueous solution of polyphosphoric acid and an aqueous solution of melamine. The melamine polyphosphate flame retardant may be melamine polyphosphate alone or may form a condensed salt such as melamine, melam, melem.

  When the content of the melamine polyphosphate flame retardant is less than 0.5% by weight, flame retardancy in aircraft applications cannot be achieved. Flame retardancy in aircraft applications is self-extinguishing in a vertical test, the average burning length must not exceed 20 cm, and the average burning time after removing the fire source exceeds 15 seconds It is stipulated that it should not. On the other hand, when the amount exceeds 25% by weight, the amount added is too large, so that yarn breakage and fluff are generated and the yarn-making property is deteriorated. In particular, when a modified cross-section yarn is used, particles are clogged by a narrow slit with a modified cross section due to long-term use, and a defective cross-section and fluff are generated, making it difficult to produce the yarn.

  The same applies to the particle size. The melamine polyphosphate flame retardant added to the flame retardant polyamide fiber of the present invention uses fine particles having a particle size of 0.1 to 5 μm. More preferably, it is 0.1-4 micrometers. When the thickness exceeds 5 μm, particles are clogged in a narrow base slit having a deformed cross section due to long-term use, and a defective cross section and fluff are generated, making it difficult to produce a yarn. Also in a spin pack, the filtration pressure increases due to clogging with a filter, and the fineness and the spinning performance are affected by variations in fineness. In addition, even when a melamine polyphosphate flame retardant having a particle size of less than 0.1 μm is added to a polyamide polymer, it becomes aggregated particles of 0.1 μm or more due to secondary aggregation in the polyamide fiber, and more than 5 μm. As a result, the yarn-making property and the quality deteriorate.

  The particle size of the melamine polyphosphate flame retardant in the flame retardant polyamide fiber is a value measured by observation under a transmission optical microscope.

  Moreover, the melamine polyphosphate flame retardant added to the flame retardant polyamide fiber of the present invention can further improve the flame retardancy by using various flame retardants in combination. Preferred flame retardants used in combination are alkali metal hypophosphites or earth metal hypophosphites such as sodium hypophosphite, potassium hypophosphite, calcium hypophosphite, barium hypophosphite, hypophosphorous acid. Magnesium oxide, aluminum hypophosphite, aluminum hydroxide and magnesium hydroxide, and the like. The flame retardant used in combination is usually 0.1 to 10% by weight, preferably 0.5 to 3% by weight.

  The crimped yarn for carpet of the present invention is required to be a modified cross-section yarn or a hollow fiber from the viewpoint of bulkiness. Examples of the irregular cross-sectional yarn include a triangular cross-section other than a round cross-section, a flat cross-section, a Y-shaped cross-section, a polygonal cross-section, and a rice field hollow cross-section. The expression of high bulkiness as a carpet tends to increase as the number of leaves increases due to multiple leaves, but the durability tends to be inferior. Therefore, the Y-shaped cross section and the Y-shaped hollow fiber are preferable in that both are balanced. From the viewpoint of antifouling properties and resilience, a hollow paddy is preferred.

  In the present invention, the Y-shaped cross section has a convex portion in three directions in a cross section perpendicular to the longitudinal direction of the single fiber, and the three convex portions are connected by a smooth concave portion.

  The Y-shaped hollow has a convex portion in three directions in a cross section perpendicular to the longitudinal direction of the single fiber, and the three convex portions are connected by a smooth concave portion, and there are one or more hollow portions. It is a multifilament made of a single fiber having. When compared with the same fineness, the bulky property is created because the apparent occupied volume is larger because of the hollow portion.

  In the present invention, the term “hollow” is provided with four hollow portions in a rectangular cross section having no concave portion on the outer surface of the single fiber. The outer shape of the cross section has no recess to prevent dust and dirt from adhering to the surface, and light is diffusely reflected by a plurality of hollow portions to make the dirt visually inconspicuous. Moreover, a carpet with high resilience can be obtained by having a hollow.

  These cross sections can be properly used according to the required characteristics of the carpet.

  In addition, the crimped yarn for carpet of the present invention has a crimp rate of 15 to 40%, more preferably 17 to 30%, which indicates the rate of occurrence of crimp when treated in boiling water described below. The crimp rate is correlated with the density of the carpet pile. The higher the crimp, the more the pile will spread laterally and the porosity between pile rows will decrease. Therefore, it becomes difficult for the air in the gaps between the rows to pass through, and the amount of air passing through the carpet can be suppressed. If the crimping rate is less than 15%, the pile does not swell and a gap is generated between the pile rows, so that the amount of air passing is increased and the flameproofness is lowered. On the other hand, if the crimping rate exceeds 40%, excessive heat treatment is required at the time of crimping, and the strength of the yarn is lowered. Therefore, the durability of carpets for aircraft and ships used in shoes and the like is inferior.

  In the crimped yarn for carpet of the present invention having such characteristics, the single yarn fineness is preferably 10 to 30 dtex, and more preferably 14 dtex or more and 25 dtex or less. If it is less than 10 dtex, the carpet which can satisfy both in terms of durability and texture can be obtained within such a range.

  The carpet of the present invention is a carpet comprising a face yarn made of crimped yarn for carpet, a base fabric to which the face yarn is tufted, and a backing material attached to the back of the base fabric. Is characterized by including the above-mentioned crimped yarn for carpet. The face yarn can be used appropriately depending on the purpose and the pattern, regardless of whether the pile is cut or looped.

Moreover, it is preferable that the thread | yarn weight in a carpet, ie, a fabric weight, is 500-1500 g / m < ² >. If it is less than 500 g / m ² , the amount of yarn on the carpet surface is too small and the flameproofness is slightly inferior. On the other hand, if it exceeds 1500 g / m ² , the weight of the carpet increases and the lightness is inferior, so it is not suitable for aircraft use.

  Below, an example of the manufacturing method of the crimped yarn for polyamide carpets which is excellent in a flame retardance, durability, bulkiness, and the yarn-making property is shown.

  The melt spinning, spinning oil agent, drawing, crimping, entangled or twisted yarn, and tuft when producing the crimped yarn for carpet of the present invention can usually employ known methods.

  Mixing of the polyamide chip with the flame retardant, the copper compound and the pigment for raw use can be performed at any stage from immediately after completion of the polycondensation of the polyamide until the polyamide fiber is spun from the spinneret. For example, immediately after polycondensation is completed, in a polymerization can, flame retardant etc. is added to kneaded polyamide and kneaded, converted into chips by a conventional method, solid phase polymerization, then melt spinning with an extruder spinning machine, A method of stretching, a method of kneading a flame retardant or the like into a dried polyamide chip, melt spinning and stretching, or a master chip containing a high concentration of a flame retardant in advance, and producing the master chip and polyamide There are methods such as melt spinning and drawing while mixing chips. In order to finely disperse the flame retardant, it is preferable to mix a master chip having a flame retardant concentration in the range of 5 to 30% at a mixing ratio of 1 to 100 with respect to the polyamide chip 100. When the mixing ratio is out of the above range, the flame retardancy of the fiber is reduced, or secondary aggregation of the flame retardant particles is likely to occur, and a problem is likely to occur in the yarn forming property.

  In addition, when a flame retardant is added, the melt viscosity may be lowered, and the spinning performance may be difficult, so the polyamide resin used for the master chip may have a higher viscosity than the polyamide resin used for the base chip. preferable.

  In order to promote fine dispersion of the flame retardant, it is preferable to use an extruder type extruder as the extruder.

  The polymer formed into a filament shape by the melt spinning method is stretched and heat-set as necessary. In the stretching, a one-stage or two-stage multi-stage heat stretching method is adopted, and a steam processing apparatus or the like can be used in combination for the purpose of fixing the stretching point as an auxiliary. Since it is necessary to have a certain degree of orientation and crystallization, it is usually preferable to stretch 2 to 4 times. About extending | stretching temperature, 170-200 degreeC is employ | adopted.

  Next, crimp is imparted to the drawn yarn. Crimping can be applied by known heated fluid processing, and various crimping methods such as jet nozzle type, jet stuffer type and gear system can be adopted, but high crimping can be easily applied. From the above, the jet nozzle method and the jet stuffer method are more preferable. As described above, the temperature of the heating fluid applied to the yarn, that is, the crimping temperature, is preferably 200 to 250 ° C. In addition, for the purpose of fixing crimps, there is no limitation to a method of cooling with a cooling medium at the time of crimping stuffing, or to combining a rotary filter. In crimping, the drawn yarn may be continuously crimped without being wound as it is, or the unwound yarn or the one wound up at the drawn yarn stage is released and used for the crimping step. Also good.

  The yarn speed introduced into the crimp nozzle is usually preferably 700 to 3500 m / min. When the yarn speed is within this range, efficient production is possible, crimping after passing through the nozzle is easy to fix, and stable running is easy.

  Next, entanglement is given to this, but entanglement can be given by using a known entanglement nozzle using compressed air. In order to impart high entanglement to the crimped yarn having a high degree of crimp according to the present invention, the running yarn tension at the time of application and the pressure of compressed air are important. In order to sufficiently open the single fiber and impart high entanglement, it is preferable that the running tension is usually 0.2 g / dtex or less, particularly 0.1 g / dtex or less. Further, the air pressure may be appropriately set so that a predetermined number of entanglements is obtained in combination with the fineness and tension of the yarn. Usually, a range of 0.2 to 0.9 MPa is preferably used in order to impart high confounding and prevent the confounding node from becoming too stiff.

  Subsequently, the crimped yarn for carpet is wound around cheese, bobbins, corn, or the like using a winding device such as a winder.

By the above method, the crimped yarn for carpet according to the present invention can be obtained. Next, the crimped yarn for carpet is used as a face yarn, and a carpet is prepared using a known tufting machine. As described above, specific examples of carpets comprising the crimped yarn for carpets of the present invention thus obtained having a basis weight in the range of 500 to 1500 g / m ² include roll carpets and tile carpets. A form is mentioned. Further, the pile may be either a loop pile or a cut pile.

  In addition, it is also preferable to mix an anti-fouling agent to the carpet of the present invention to mix conductive fibers to suppress static electricity or to improve antifouling properties.

  EXAMPLES Hereinafter, although this invention is demonstrated in detail using an Example, this invention is not limited at all by these Examples. In addition, each measured value in an Example is as follows.

(1) Sulfuric acid relative viscosity A polymer sample was dissolved in 98% sulfuric acid at a concentration of 1% by weight and measured at 25 ° C using an Ostwald viscometer.

(2) Total fineness It measured by the method prescribed | regulated to JISL1090.

(3) Single yarn fineness The total fineness was converted per single yarn.

(4) Crimp elongation after boiling water treatment After winding the crimped yarn, it was left in an atmosphere of cheese shape at 20 ° C. and a relative humidity of 65% for 20 hours or more, and then stolen for 24 hours. The crimp elongation rate when immersed in boiling water is shown, specifically the value measured by the following method.

That is, the crimped yarn to be measured was immersed in boiling water for 20 minutes in an unloaded state and then dried to obtain an equilibrium moisture content. The initial load of 1.8 mg / dtex was applied to this sample for 30 seconds. After marking, the sample length 50 cm (L3) was marked, then a constant load of 91 mg / dtex was applied to the sample, and the elongation (L4) after 30 seconds was measured, and the (L3) and (L4) From the value of the formula [(L4-L3) / L3] × 100
The value obtained by calculating as.

(5) Weight per unit area Measured by the method defined in JIS L1021 8.2.

(6) Flame retardancy A sample was supported vertically and ignited using a Bunsen burner having a nominal inner diameter of 0.95 cm adjusted to obtain a flame having a height of 3.8 cm. The center temperature of the flame was 843 ± 10 ° C. The lower side of the sample was placed 1.9 cm above the upper end of the burner, and a flame was applied to the lower center line of the sample. The flame was applied for 12 seconds and then removed. The flame time and the combustion distance at that time were measured. Three samples were subjected to the above test and the average value was adopted.
A. Flame time ○ or more was accepted.
Less than 10 seconds ◎
10-15 seconds ○
15-20 seconds △
Over 20 seconds ×
B. Combustion distance ○ More than acceptable.
Less than 15cm ◎
Less than 15-20cm ○
Less than 20-25cm △
25 cm or more.

(7) Yarn-making property The number of yarn breaks per 1t production was judged according to the following criteria. ○ The above was accepted.
0.0-2.0 times / t ◎
2.1-4.0 times / t ○
4.1-6.0 times / t △
6.1-times / t ×.

(Examples 1-9, Comparative Examples 2-6)
Nylon 6 regular chip with a relative viscosity of 2.8 and melamine polyphosphate double salt with a relative viscosity of 3.5 (Nissan Chemical Industry “PHOSMEL-200”) 20% Nylon 6 master chip was weighed and measured at Micosuper before melting. Using a jet stuffer nozzle, which is a known heated fluid processing device, kneaded and melt-spun with an extruder-type spinning machine under the conditions and cross-sections shown in Table 1, cooled, lubricated, stretched and subsequently wound up Then, crimping was applied and cooling was performed, and entanglement was applied at an air pressure of 0.2 Mpa and the yarn tension just before the entanglement nozzle was 70 g, which was wound to obtain a flame-proof nylon crimp yarn of 1100 dtex / 54 fil. The number of entanglements was 8 / m.

  Next, the obtained crimped yarn was tufted at 1000 rpm using about 1600 crimped yarns with a known level loop tuft machine, and 10 pile rows per inch (1/10 gauge), pile height A 5 mm loop pile carpet was obtained. The spinning conditions, basis weight, flame retardancy evaluation results, and spinning characteristics are as shown in Table 1.

  In Examples 1 to 9, the flame retardancy and the spinning property were good. Since Comparative Example 1 was not added with a flame retardant, the flame retardancy was very poor and it was rejected. In Comparative Example 2, the flame retardance was good due to the large addition rate, but the yarn-making property was extremely deteriorated due to the occurrence of a defective cross-section due to filter clogging or die slit clogging. In Comparative Example 3, the flame retardancy was good, but the average particle size was too small, so the particles were secondary agglomerated, and defective cross-section was generated due to filter clogging and cap slit clogging. In Comparative Example 4, the flame retardancy was good, but the average particle size was too large, so that the defective cross-section was generated due to filter clogging or cap slit clogging, so that the yarn production was poor. In Comparative Example 5, since the crimping rate was low, a gap was generated between the rows of piles, and the air permeability was high, so the flame retardancy was unacceptable. In Comparative Example 6, the heat treatment was increased in order to increase the crimping rate, so that fusion occurred and the spinning property was poor.

  The carpet obtained by using the crimped yarn of the present invention can be applied to fields having high flame retardancy characteristics such as aircraft and ships, and further, the flame retardancy is sustained in comparison with a post-processed surface-treated product. High carpet.

Claims (7)

  A crimped yarn comprising 0.5 to 25% by weight and 75 to 99.5% by weight of polycaproamide of a melamine polyphosphate flame retardant having a particle size of 0.1 to 5.0 μm, A crimped yarn for flame-retardant polyamide carpet, characterized in that the cross section is an irregular cross section and / or a hollow cross section, and the crimp rate is 15 to 40%.   The crimped yarn for flame-retardant polyamide carpet according to claim 1, wherein the crimped yarn has a Y-type or Y-type hollow having a cross section of three leaves.   The crimped yarn for flame-retardant polyamide carpet according to claim 1, wherein the crimped yarn has a cross-sectional shape having four hollow sections.   The crimped yarn for flame-retardant polyamide carpet according to any one of claims 1 to 3, wherein a single yarn fineness of the crimped yarn is 10 to 30 dtex.   A flame-retardant polyamide carpet comprising the crimped yarn for carpet according to any one of claims 1 to 4. 6. The flame-retardant polyamide carpet according to claim 5, wherein the basis weight of the carpet is 500 to 1500 g / cm < ² >.   The flame retardant polyamide carpet according to claim 5 or 6, wherein the carpet base and / or the backing agent is subjected to a flame retardant treatment.