JP2007146321A - Polyamide spun-dyed yarn and carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a polyamide spun-dyed yarn having excellent soiling prevention and weather resistance without impairing a texture and a carpet. <P>SOLUTION: The polyamide spun-dyed yarn contains a sulfone group-containing compound and/or a polyhydric phenol-based compound on the surface of the yarn. The carpet is constituted by using the polyamide spun-dyed yarn. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a polyamide original yarn and a carpet. More particularly, the present invention relates to a polyamide original yarn excellent in antifouling property, weather resistance and texture, and a carpet made from this polyamide original yarn and particularly preferably applied to uses such as door mats and foot wipe mats. .

  Conventionally, nylon bulky crimped yarn has been used as various interior materials represented by carpets, taking advantage of its excellent weather resistance, abrasion resistance and the like. In recent years, with the diversification of carpet applications, technology for developing carpets into entrance mats and foot wipe mats for stores and offices is also progressing.

  Traditionally, doormats and foot-wiping mats have mainly been used to remove mud, and are usually made of wire mesh or plastic sheets. However, metal mesh and plastic sheets have a luxurious atmosphere. There was a limit to providing this, and it was particularly unsuitable for directing the entrance of a store or office. Moreover, entrance mats and foot cleaning mats made of wire mesh or plastic sheets are excellent in removing mud in terms of removing relatively large mud, but they have poor performance in capturing relatively small mud, dust, and dust. There was an unsuitable aspect.

  In addition, as can be seen from the construction of the doormat and foot-wiping mat made of a wire net or a plastic sheet, the cushioning property is clearly inferior to that of a so-called carpet. Furthermore, since doormats and edge cleaning mats are exposed to sunlight because they are installed at the entrance of a building, weather resistance to ultraviolet rays is required, and many people are covered with their feet from the installation environment, Since it is repeatedly washed and used to remove dirt, excellent durability is required.

On the other hand, some proposals have already been made on the method of crimped polyamide crimped yarn for the purpose of improving the weather resistance performance of carpets. For example, an original polyamide having excellent weather resistance performance by adding specific pigments and copper. A method for producing a crimped yarn has been proposed (Patent Document 1).
However, although this method is excellent in weather resistance, it does not have anti-contamination performance, which is one of the important functions as a carpet, and once it becomes attached to coffee stains or oil stains, the stain does not easily fall off. was there.

  On the other hand, a method for treating a dyed polyamide yarn with a sulfone group-containing compound or a polyhydric phenol compound is known for the purpose of improving the fastness of dyeing. It was unsuitable for use.

As described above, the conventional technology has not proposed a polyamide yarn for carpets, particularly a polyamide original yarn, which has both weather resistance and antifouling properties.
Japanese Patent Laid-Open No. 2-169736

  In view of the background of the prior art described above, the present invention is intended to provide a polyamide original yarn and a carpet excellent in contamination prevention and weather resistance without impairing the texture.

  The present invention employs the following means in order to solve such problems.

  That is, the polyamide original yarn of the present invention is characterized in that the fiber surface contains a sulfone group-containing compound and / or a polyhydric phenol compound.

  In addition, the carpet of the present invention is characterized by using such a polyamide original yarn.

  According to the present invention, the polyamide original yarn can be prevented from being contaminated by coffee or oil stains, and also has excellent weather resistance, that is, polyamide having excellent antifouling properties and weather resistance. Original yarn can be provided. That is, according to the present invention, it is possible to provide a material that is suitably used for carpets having excellent antifouling properties, weather resistance, and texture, in particular, entrance mats and foot wipe mats.

  The present invention has been intensively studied on the above-mentioned problem, that is, a polyamide original yarn excellent in antifouling property and weather resistance without impairing the texture, and a specific compound that has not been used in the conventional polyamide original yarn technology is applied to polyamide. As a result of inclusion in the surface of the original yarn, the inventors have found that the above problems can be solved at once and that an excellent carpet material can be provided, and the present invention has been achieved.

  The polyamide yarn in the present invention needs to be an original yarn. Conventionally, various studies have been made on ordinary polyamide dyed yarns for improving weather resistance, such as examination of dyes and treatment after dyeing. Polyamide dyed yarns obtained by these prior art methods are used to produce polyamide raw materials with pigments. It has not been used in carpet applications because it is significantly discolored after weathering treatment compared to yarn setting.

  The term “primary yarn” as used herein refers to a yarn obtained by spinning a pigment previously contained in a chip before the polyamide spinning step, and the pigment concentration is usually 5% by weight in the yarn. %, And more preferably 3% by weight or less. When the pigment concentration in the yarn is within such a preferable range, the action as a spherulite nucleus does not manifest, and no single fiber breakage occurs during drawing. As the pigment used in the present invention, either an organic pigment or an inorganic pigment can be used, and there is no particular limitation.

  The single fiber fineness of the polyamide original yarn in the present invention is not particularly limited, but is preferably in the range of 10 to 30 dtex, more preferably 13 to 25 dtex. That is, if the single fiber fineness is less than 10 dtex, sufficient crimping is not obtained in the fluid crimping process, the texture of the carpet is too soft, and it is easy to wear, and further, pilling occurs during use of the carpet. Yarn ball called is likely to occur. On the other hand, if the single fiber fineness exceeds 30 dtex, cooling during spinning is insufficient, and spherulite growth increases, causing single fiber breakage during stretching, and the texture as a carpet becomes hard.

  In the polyamide original yarn of the present invention, the degree of cross-section of the single fiber is not particularly limited, but is in the range of 2.8 to 3.8, and more preferably in the range of 3.0 to 3.6. Are preferably used from above. The cross-sectional shape of these polyamide original yarns may be any of a round cross-section, a trilobe cross-section, a four-lobe cross-section, or a hollow cross-section, and is not particularly limited.

  The polyamide primary yarn used in the present invention is not particularly limited as long as it is a polyamide-based fiber made of nylon 6, nylon 66, nylon 610, nylon 46, or a copolymer of these polyamides. Nylon 66 having good weather resistance and wear resistance is more preferable.

  In the present invention, the fiber surface of the above-mentioned polyamide original yarn is treated with a treatment liquid containing such a compound in order to contain the sulfone group-containing compound and / or the polyhydric phenol compound, Here, as the sulfone group-containing compound, any compound having affinity for the amino group of the polyamide original yarn having a sulfone group in the molecular structure may be used. Sulfonated products, acid dyes, metal-containing acid dyes and the like can be used. Among these compounds, an α-olefin sulfonate salt having an average carbon number of 12 to 30 is more preferable from the above effect. Such a sulfone group-containing compound adsorbs to the amino group and moisture-absorbing component of the polyamide original yarn, and exhibits a function of preventing the adsorption of the soil component by such adsorption.

  Moreover, as a polyhydric phenol type compound, the synthetic tannin represented by the sulfonated thing of phenol formalin resin, such as a natural tannin, a novolak type, a resol type, can be used, for example. In addition, when using the said natural tannin, it is good from the top of the following effect to use together with tartar. When such a polyhydric phenol compound is used, the polyhydric phenol compound forms a film on the surface of the polyamide fiber, and this film formation functions to prevent the adsorption of dirt components.

  The sulfone group-containing compound and / or polyhydric phenol compound of the present invention is characterized by containing 0.05 to 10.0% by mass with respect to the polyamide original yarn. When the adhesion amount of the sulfone group-containing compound and / or the polyhydric phenol compound is lower than 0.05% by mass, the antifouling property, which is one of the effects of the present invention, is impaired. Moreover, when 10.0 mass% or more is made to adhere, a texture will become rough and the quality of a carpet will fall.

  The present inventors discovered that such a specific compound exerts the above-mentioned special function, and when it was first adopted in a polyamide original yarn, it was excellent in antifouling properties and weather resistance, and had a texture. The present invention has succeeded in providing an excellent polyamide original yarn which does not impair the yarn.

  Below, the manufacturing method of this invention is demonstrated.

  The polyamide original yarn of the present invention is produced by a conventional melt spinning method basically comprising known melt spinning, cooling, oiling, drawing, and crimping steps. As the melt spinning apparatus used in the present invention, both an extruder-type spinning machine and a pressure-type spinning machine can be used, but the former is preferable in terms of product uniformity and yield in the spinning process. In particular, when using an original polymer, an extruder type spinning machine is advantageous.

  The polyamide original yarn of the present invention is an original yarn in which a pigment is mixed with a chip in advance and then spun. Therefore, the master chip containing the pigment can be the same as the blend component. Specifically, the use of a polycapramide as the master chip for mixing the pigment is a good example applied in the present invention. Even when a copper compound or the like is present as a weathering agent in the yarn, the addition is performed before spinning, but the addition method may be determined according to the type and characteristics of the compound to be added.

  Next, the obtained polyamide original yarn is treated with a treatment liquid containing a sulfone group-containing compound and / or a polyhydric phenol compound. When this treatment is performed simultaneously with the dyeing, for example, such a compound is 0.1 to 10% o. w. Treat with a treatment solution that contains f. In this case, the dye used at the same time is not particularly limited, and a dyeing aid such as a leveling agent and an acid can be used in combination. When this treatment is performed after dyeing, it is preferable to use a treatment liquid containing, for example, water, methanol, ethanol or other organic solvent as a solvent and the above compound in an amount of 0.1 to 100 g / l. This treatment liquid may be a solution, an emulsification or a dispersion. At this time, a surfactant such as a dispersant or a scouring agent, a chelating agent, or the like may be used in combination as long as the action of the compound used in the treatment liquid is not inhibited.

  As such a treatment method, an appropriate method may be selected depending on the type of compound and the type of solvent after applying the treatment liquid to the fiber product by the pad cure method, the gravure method, or the spray method. It is preferable to perform the heat treatment. Moreover, it can also process from room temperature to about 140 degreeC by a dipping method using a cassette dyeing machine, a beam dyeing machine, a liquid dyeing machine, an airflow dyeing machine, a jigger, a wins, a rotary washer, etc.

  The polyamide original yarn thus obtained is tufted by a known method. When tufting, it is possible to mix anti-static yarns, monofilaments and other yarns, blended fibers, blended yarns, and even blended fabrics. Next, backing is performed by a known method. In this case, it is recommended as a more preferable method to perform shearing as necessary. Moreover, in order to improve pollution prevention property, it is safe to apply a pollution inhibitor.

  The polyamide original yarn of the present invention and a cut pile carpet using the same are utilized as an entrance mat and a foot cleaning mat for stores and offices, taking advantage of excellent weather resistance, abrasion resistance, and point properties at the tip of the pile. Although it is suitable, if it is necessary to utilize the effect, it can also be used for applications such as vehicle mats and home mats.

  Hereinafter, the present invention will be described in more detail with reference to examples. The performance shown in the examples was measured by the following method.

[Discoloration after weathering]
Using a sunshine weather meter, black panel temperature 83 ° C ± 5 ° C, carbon arc treatment 100 hours, and after treatment with water sprayed at a frequency of 18 minutes for 120 minutes, JIS gray color for fading The grade was judged on the scale.
[Evaluation of pollution prevention]
(1) Contamination prevention property against coffee stains As a sample, 3 cm × 3 cm of tufted carpet or pile yarn knitted fabric is prepared. 100 ml of instant coffee (Maxim (R) manufactured by Ajinomoto General Foods Co., Ltd.) dissolved in hot water at a rate of 14 g / liter was prepared as a contaminated liquid, and the sample was immersed in the contaminated liquid at 80 ° C. for 5 minutes and then dried. Dry at 80 ° C. for 1 hour. Further, the contaminated sample is dehydrated in a household washing machine for 30 seconds and left in a dryer at 80 ° C. for 1 hour. After that, the sample was washed in a household washing machine at a rate of 5 g / liter in hot water (25 liters) at 40 ° C. at a rate of 5 g / liter, and then rinsed for 4 minutes. After carrying out for 1 minute, it is left again at 80 degreeC with a dryer for 1 hour. The contamination status of the sample was judged on the JIS contamination gray scale.

(2) Oil stain As a sample, 3 cm x 3 cm of tufted carpet or pile yarn knitted fabric is prepared. As a contaminated liquid, a mixture of 100 g of an automatic transmission oil liquid (“DEXRON-III (R)” manufactured by ESSO) and 1 g of tar (JIS K 2439) was prepared, and the sample was further contaminated after being immersed for 5 minutes at room temperature. The sample is dehydrated in a home washing machine for 30 seconds and left in a dryer at 80 ° C. for 1 hour. Then, the sample was washed in a household washing machine at a rate of 5 g / liter in hot water (25 liters) at 40 ° C. at a rate of 5 g / liter, and then washed for 5 minutes. After rinsing for 4 minutes, the sample is again left in a dryer at 80 ° C. for 1 hour. The contamination status of the sample was judged on the JIS contamination gray scale.

Example 1
Nylon 66 base polymer chip containing 2.0 wt% of nylon 66 master chip A containing 5% by weight of a pigment mixed with a blue petal and carbon black, cyanine blue pigment and titanium oxide white Nylon 66 master chip B and nylon 66 master chip C containing 1.5% by weight of a pigment obtained by appropriately mixing red petals and carbon black are mixed in a ratio of 95: 3.5: 1.0: 0.5, respectively. After mechanical blending at a weight ratio, it was melted with an extruder-type spinning machine and spun from a known trilobal die.

  First, an oil agent is attached to the yarn obtained from the spinning section, then taken up by a take-up roll, drawn at 3.0 times by a heated drawing roll at 180 ° C. or higher, and continuously applied to a heated fluid crimping apparatus. A heat steam treatment at 230 ° C. or higher was performed to impart crimp.

  Next, it was stretched to such an extent that the crimps were not loosened, and finally wound with a winding tension of about 0.08 g / d to obtain a polyamide original yarn of 1300 dtex 68 filaments. The strength after the weathering treatment of the polyamide original yarn obtained at this time was measured.

  The obtained polyamide original yarn is subjected to a lower twist (180 T / m), twisted together using an upper twist (180 T / m), and subjected to a twisting treatment at a dry heat of 130 ° C., and then subjected to scouring. Nylon Fix (R) SZ-2 (Senka Co., Ltd.), which is a drug mainly composed of a polyhydric phenol derivative, was prepared with a cheese dyeing machine at 6% o. w. f, Anti-contamination treatment was performed at 90 ° C. × 30 minutes and a bath ratio of 1:20. The obtained yarn was washed with water and dried, and tufted as a cut pile carpet. The resulting carpet was evaluated for contamination prevention and discoloration after weathering treatment. As a result of evaluating the carpet stain resistance, the stain resistance and discoloration after weathering were good. The results are shown in Table 1.

(Example 2)
After scouring the same polyamide original yarn as in Example 1, the chemical Sun Life (R) (manufactured by Nikka Chemical Co., Ltd.) mainly composed of a sulfonic acid condensate was used in a cheese dyeing machine at 6% o. w. f, Anti-contamination treatment was performed at 90 ° C. × 30 minutes and a bath ratio of 1:20.
The obtained yarn is washed and dried, tufted as a cut-pile carpet, the obtained yarn is washed and dried, tufted as a cut-pile carpet, anti-contamination of the resulting carpet, and discoloration after weathering treatment evaluated.

  As a result of evaluating the carpet stain resistance, the stain resistance and discoloration after weathering were good. The results are shown in Table 1.

(Comparative Example 1)
After scouring the same polyamide original yarn as in Example 1, antifouling treatment as in the Example was not performed, and antifouling property and discoloration after weathering treatment were evaluated.

  As a result, the discoloration after the weathering treatment was good, but the anti-contamination property was poor. The results are shown in Table 1.

(Comparative Example 2)
Nylon 66 base polymer chips were melted with an extruder type spinning machine and spun from a known trilobal die.

  First, an oil agent is attached to the yarn obtained from the spinning section, then taken up by a take-up roll, drawn at 3.0 times with a heated drawing roll at 180 ° C. or higher, and continuously with a heated fluid crimping apparatus. Heat steaming at 230 ° C. or higher was performed to impart crimp.

Subsequently, the yarn was stretched to such an extent that the crimp was not loosened, and finally wound with a winding tension of about 0.08 g / d to obtain a polyamide yarn of 1300 dtex 68 filaments.
The strength after the weathering treatment of the polyamide original yarn obtained at this time was measured.

  The obtained polyamide crimped yarn is twisted under the first twist (180 T / m), twisted together with the upper twist (180 T / m) using the two, and subjected to a twisting treatment at a dry heat of 130 ° C. And dyed with a gold-containing dye so as to have the same color as in Example 1.

  The obtained yarn was washed with water and dried, and tufted as a cut pile carpet. The resulting carpet was evaluated for contamination prevention and discoloration after weathering treatment. As a result of evaluating the carpet stain resistance, the stain resistance and discoloration after weathering were poor.

Claims (3)

  A polyamide original yarn characterized by containing a sulfone group-containing compound and / or a polyhydric phenol compound on the fiber surface.   The polyamide original yarn according to claim 1, wherein the content of the sulfone group-containing compound and / or the polyhydric phenol compound is 0.05 to 10.0% by mass with respect to the polyamide original yarn.   A carpet comprising the polyamide original yarn according to claim 1 or 2.