JP2719338B2 - Carpet making - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION 1. Field of the Invention The present invention relates to a method of making carpet that includes the use of a specific synthetic yarn, wherein the synthetic yarn is a first synthetic base fiber, and a first synthetic base fiber. Consisting of a blend of fibers including a second heat activated adhesive fiber having a substantially lower melting point than that of By subjecting this yarn to normal processing conditions for twisting the yarn during the carpet manufacturing process, the heat-activated adhesive fiber substantially completely melts and loses its distinctiveness as a base fiber. At the intersections of, and upon subsequent cooling, adhesion occurs, thereby altering the properties and performance of the resulting product. 2. Description of the Related Art Non-adhesive fibers are blended with potential adhesive fibers to form a thread or other fibrous structure, and then the latent adhesive fibers are activated to bond them to the contacting fibers. It is known that this changes the end use properties of the yarn. U.S. Pat. No. 2,252,999 (Wallach, issued Aug. 19, 1941) forms a yarn comprising a mixture of non-adhesive fibers and potentially adhesive fibers, activates the latent adhesive fibers, and removes the fibers. A method has been proposed which consists in compressing under adhesive conditions, thereby adhering them at the point of contact. U.S. Pat. No. 3,877,214 (Vandelweg, published Apr. 15, 1975) shows a non-twisted yarn containing a polyamide fiber that melts at a relatively low temperature as an adhesive component. U.S. Pat. No. 3,494,819 (McAlister, issued Feb. 10, 1970) shows a blend of fusible and non-fusible polyethylene terephthalate fibers incorporated into a fabric, in which case the final fabric is Heat to melting temperature to obtain improved anti-pill properties. U.S. Pat. No. 3,978,267 (Celwood, issued Aug. 31, 1976) discloses a substantially twist-free compression comprising a percentage of potentially adhesive fibers adhered to activated and contacting fibers. A thread is shown. It is known to produce self-adhesive nonwoven fabrics using thermoplastic binder fibers in combination with structural fibers. U.S. Patent No.
No. 2,880,112 (Dorrich, published March 31, 1959) discloses the use of nylon-6 to bond viscose rayon and other cellulosic materials to form a washable nonwoven fabric. Cut pile carpets are currently manufactured from staple yarn or bulk processed continuous filament yarn. For example, staple fiber is continuously carded,
Pinned and spun or wrap spun into a single yarn, which is generally twisted and twisted with a similar yarn,
Book or three-ply yarns are formed. The yarn is twisted using any of several commercially available twisting methods. In a general method, the yarn is conducted to the heating chamber in a relaxed state. The temperature of this processing step is important for proper twisting of the base fibers to obtain the desired properties of the final carpet product. For nylon-6 based fibers, the conditions for this step are generally 195-200 ° C. for a residence time of about 60 seconds for the Suessen method and about 135-140 ° C. for a residence time of about 60 seconds for the Superba method. It is. Similarly, bulk continuous filament nylon yarn is produced by various conventional methods. Twisting, entanglement (entanglin
g) or direct cabling is used in various ways. For example, a two-ply twisted yarn produced by combining two 1185 denier 70 filament yarns is produced, and under ordinary twist-preventing conditions, for example, for the above-mentioned staple yarn, or a residence time of about 60 seconds in an autoclave at 132 ° C. in saturated steam. Put. A number of twisted yarns are tufted into cut pile carpet, which is finished by a conventional method to obtain a desired carpet product. SUMMARY OF THE INVENTION Synthetic yarns are polyester, nylon-6 and nylon
Base fiber selected from the group consisting of 6, 6 and melting point 1
It consists of a blend of 1-12% by weight, preferably 1-8% by weight of heat-activated binder fibers at 10-170 ° C, preferably 130-160 ° C. Preferred binder fibers are copolyamide fibers having the above melting point range. 6/66/12 type ternary copolyamides are examples of preferred binder fibers. If the yarn is twisted, twisted and twisted in a conventional manner, for example at 195 ° C. with a residence time of about 60 seconds, and the treated yarn is tufted into cut pile carpet, the resulting carpet is enhanced. 9 shows a carpet tufted appearance, improved resilience, and reduced appearance changes with use. DESCRIPTION OF THE PREFERRED EMBODIMENTS The inventor has determined that by including in the yarn structure a small percentage of heat-activated binder fibers having a substantially lower melting point than the base fibers, the binder is subjected to standard conditions for twisting the yarn. It has been found that the fiber melts and substantially loses its distinctiveness as a fiber. It flows to the intersection of the base fibers and, during subsequent cooling, surrounds and bonds the fibers and yarns to one another, thereby maintaining the twist in the cut pile carpet. Carpets made with the yarns of the present invention have improved surface, aesthetics, hand, durability and abrasion resistance. Due to the judicious choice of the fibers of the binder fiber, the desired improvement is "built-in" into the yarn, which gives the spinner, carpet manufacturer or additional processing steps in dyeing and finishing. Is unnecessary. The base fiber is selected from known synthetic fibers suitable for carpet use. Preferred base fibers are polyamide,
Particularly included are nylon-6 and nylon-6,6, and polyesters, especially polyethylene terephthalate. The binder fibers are chosen to adhere well to the base fibers. The melting point of the binder fiber is 110-17 under ambient humidity conditions
It is important that the temperature is 0 ° C, preferably 130-160 ° C. This range ensures that the binder fibers will melt during the normal twisting process and still provide adequate adhesion during any subsequent dyeing steps and end use. In a saturated steam environment, such as in an autoclave, the melting point of the fibers is significantly reduced. A preferred type of binder fiber for use with a polyamide base fiber is a copolyamide within the above melting point range. Suitable copolyamides of the type 6/66/12 and their preparation are described in GB 1,168,404 (October 22, 1969
Published by Inventa, Inc.), which is incorporated herein by reference. Melt-bonded copolyamide-based adhesive fiber is EMS to GRILON (registered trademark) type K140
(Melting range 130-140 ° C) and type K115 (melting range 110
(-117 ° C). The binder fibers are blended with the base staple fibers, and the resulting staple fiber blend can then be processed in a known manner. Thorough blending is important to avoid the possibility of clamping in the final carpet. The staple fiber blend contains 1-12% by weight of binder fiber, preferably 1-8%.
Should contain% by weight. Above this level, undesired rough texture is produced due to the untwisting conditions that substantially completely melt the binder fibers. Heat activated spun yarns made from the staple fiber blends of the present invention have strength properties approaching those of bulk continuous filament (BCF) yarns. The properties of BCF yarn are also enhanced. Selection of heat activated binder fibers within the above weight and melting point ranges improves abrasion resistance, resilience, reduces appearance changes over time and with use,
The end use properties of the final carpet can be modified to increase hand, gloss and apparent value. Denier per filament, cut length, fiber cross section, type and frequency of crimp, display finish, melt viscosity, softening point,
Melting point, dye affinity and other properties are important to achieve ideal properties of the final product. To get the desired or optimal results from the final carpet product,
Binder fibers must be properly selected. This will depend on a number of factors, including the denier, length, crimp, and other properties of the finish of the base textile. Utilizing the present invention, the commonly used anti-twisting conditions are sufficient to activate the binder fibers and to form bond points that increase the strength of the final product, thereby imparting other properties of interest. For the Sassen process, the yarn is treated at a temperature of 190-205 ° C and a residence time of 50-60 seconds under relatively low humidity conditions. In the Sassen process, fiber movement caused by vibrations or airflow in a relaxed state causes the molten binder fibers to flow to the intersection "point of contact" of the base fibers as a function of the melt flow and surface properties of the binder fibers. Exercise to a sufficient degree. As the fibers move away from the elevated temperature conditions, the binder solidifies and surrounds the two or more base fibers in a durable bond at the intersection or adheres to each other. Subsequent treatments, including dyeing, finishing and back coating by commercial processing methods, will not soften sufficiently to weaken the bond points, but rather will reinforce them. The resulting carpet may be of various shapes, but the general style is a cut pile carpet with a backing attached to about 40 oz / square yard (1.4 kg / m ² ) containing binder. The carpet construction is typically 5/32 "(4mm) gauge, 3/4" (20mm) pile height and the carpet will be dyed, dried, back coated and cut by conventional processing methods. The yarns of the present invention will also provide important property improvements in the manufacture of loop pile carpets. Example 1 Staple containing 3% by weight of Grilon type K140 copolyamide fiber having a melting point range of 130-140 ° C and 97% by weight of base staple fiber (Allied type 521 nylon-6 fiber having a melting point range of 215-225 ° C). A fiber blend was prepared. The blended fibers were carded, pinned and spun by conventional processing to obtain single yarns. This yarn, a 3'S cotton count yarn containing 4.7 "Z" twists / inch (185 tpm), is twisted with a similar yarn to form a two-ply twisted 3'S / 2 cotton count 4.7Z x 4.0S (185Z x 160S) Yarn was obtained. The two twisted yarns were twisted by a usual Sassen twisting method. In a state of relaxation in a heating room at about 195 ° C,
Conduction occurred at a residence time of about 60 seconds. A large number of these yarns were tufted into cut pile carpets and finished by a conventional method to obtain an improved product. Use the resulting carpet as a base staple fiber 10
0% was compared to a control carpet made in the same manner. Carpets containing the binder staple fiber blend exhibited improved carpet tuft appearance, higher resilience, and better abrasion resistance. Example 2 Carpet can also be made from bulk continuous filament (BCF) yarn, and the carpet thus made can be improved by the present invention in surface, aesthetics, texture, and in durability and abrasion resistance. it can. In the following examples, carpet manufacturers simply employ conventional treatments to achieve the desired effect. Filament nylon yarn is produced according to the procedures of various conventional fiber manufacturers. These methods are not particularly relevant to the present invention except that other, smaller filament yarns are associated with the base yarn throughout the subsequent processing steps. Often, this combination will provide the necessary two, three or other forms of plied yarn for the carpet style. In various methods, twisting, entanglement, or direct cabling is employed. As in this example, a 70 denier (78 dtex), 14 filament yarn and a 1185 denier (2000 dtex), 70 filament yarn are combined in a direct cable creel, and each single yarn has a 3.5 "S" twist / inch (140 tpm). ) And the resulting 2
3.5 "Z" (140tpm) for this twisted yarn (1185 x 2)
In order to obtain the yarn of the above, direct cabling is adopted. The final yarn contains a third component, a binder yarn, which has a lower melting point, loses its distinctiveness as it melts in subsequent processing steps, flows and adheres the fiber and yarn to each other. This will maintain the twist of the cut pile carpet. In this example, a binder fiber for combination is obtained from a copolyamide 70 denier nylon yarn having a melting point range of 130-140 ° C., and a combination of about 2.8% of the binder is obtained by combining with two of 1185 denier (2000 dtex). can get. This ratio may be doubled by using two strands, or may be changed by feeding other denier products to the yarn. When this product is subjected to the usual twisting treatment, the binder is activated and the final product with the desired properties of improved carpet tuft appearance, higher resilience, and better abrasion resistance than similar carpets without binder The product is obtained. Twisting conditions for this are generally 270 ° F (130 ° C) in saturated steam and a residence time of about 60 seconds. As the fibers move away from the elevated temperature conditions, the binder solidifies and surrounds the two or more base yarns and adheres to each other in a permanent or durable bond. A large number of these yarns are tufted to make a cut pile carpet, and finished by a conventional method to obtain an improved product.

   ────────────────────────────────────────────────── ─── Continuation of front page    (56) References Jiko 57-13912 (JP, Y2)                 United States Patent 3,948,482 (US, A)                 UK Patent 1168404 (GB, B)                 Published German Patent Application 2204119 (DE, A)

Claims (1)

(57) [Claims] Carpet surface fiber comprising (a) a base fiber selected from nylon 6, nylon 6,6 and polyester and (b) 1-12% by weight of a heat-activated binder fiber having a melting point range of 110-170 ° C under ambient humidity conditions. The synthetic yarn is twisted while heating to a degree sufficient to substantially melt the heat-activated binder fiber; and then the yarn is cooled to solidify the melt, thereby surrounding the intersection of the base fibers. And adhering; and then incorporating the heat-treated yarn into the carpet structure. 2. The binder fiber has a melting point range of 130-160 ° C.,
The method according to claim 1. 3. 3. The method according to claim 2, wherein the synthetic yarn comprises 1-8% by weight of binder fibers. 4. The method of claim 1, wherein the binder fiber is a copolyamide. 5. 5. The method according to claim 4, wherein the binder fiber is a 6/66/12 type ternary copolyamide. 6. The binder fiber has a melting point range of 110-150 ° C,
The method according to claim 5. 7. The method according to claim 6, wherein the synthetic yarn comprises 1-8% by weight of binder fibers. 8. The method of claim 7, wherein the base fiber is nylon 6. 9. The method of claim 1, wherein the base fiber is nylon 6.