JP4053829B2 - Bulky crimped yarn - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a bulky crimped yarn obtained by crimping a polyamide multifilament made of a single fiber having a flat cross-sectional shape, and particularly to a bulky crimped yarn suitable for household carpets.
[0002]
[Prior art]
Polyamide, acrylic, polyester, polypropylene, wool, etc. are mainly used as carpet materials. In carpets used at home, acrylic, polyester, polypropylene, and the like are often used because of their excellent touch and design. However, these fibers are characterized by a soft texture and good touch, but they are poor in durability and quickly become stale and deteriorate in quality. In particular, acrylic and polyester are often used with short fibers, so that there is a problem that loose hair is generated, the volume feeling and the design are lowered, and the maintenance is inferior.
[0003]
Therefore, as a means to solve these problems, compared with other fiber materials, polyamide fibers with superior mechanical properties such as elastic recovery (hardness to wear) and abrasion resistance (hard to wear) are used for household carpets. A method used as a material is conceivable.
Because of these characteristics, it is widely used for business purposes, and the commonly used cross-sections are mainly four-hole hollow fibers and tri-lobe yarns, and each has excellent antifouling properties and bulkiness. However, it is unsuitable for home use because it feels softer than acrylics.
[0004]
Therefore, in order to soften the texture of the polyamide fiber, those having a flat cross section of the polyamide fiber are proposed in Japanese Patent Application Laid-Open Nos. 62-117505 and 2000-222005. Although these fibers are superior in terms of softness, the ground part may be seen through the gaps of the piles that are raised when carpeted, that is, the covering property is inferior, and the glossy direction is also preferred. Therefore, there is a problem in that the shine is generated and the quality is lowered.
[0005]
[Problems to be solved by the invention]
The present invention solves the above-mentioned problems, has a good texture, durability, excellent covering properties, and has a high-grade gentle gloss, and is suitable for household carpets. It is a technical challenge to provide
[0006]
[Means for Solving the Problems]
The inventors of the present invention have arrived at the present invention as a result of studies to solve the above problems.
That is, the present invention is based on a polyamide multifilament having a flatness of a single fiber of 2.5 to 7.0 and having a plurality of convex portions on both surfaces perpendicular to the major axis direction of the flat cross section of the single fiber. It is a bulky crimped yarn that is configured, wherein a plurality of convex portions are provided symmetrically on both sides in a direction perpendicular to the major axis direction of the flat cross section, and the total number of convex portions is six or more, The gist of the bulky crimped yarn is characterized in that the ratio of the height of the convex portions in the flat cross section is 1.0 to 3.0 .
[0007]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail.
As the polyamide multifilament yarn constituting the processed yarn of the present invention, a polyamide polymer represented by nylon 4, nylon 6, nylon 12, nylon 46, nylon 66 can be mainly used, but is not necessarily limited thereto. Alternatively, other polyamides may be used. Moreover, what co-polymerized or mixed these some polyamide polymers may be used. Of these, nylon 6 and nylon 66 are preferable.
[0008]
In addition, various additives such as a matting agent, a flame retardant, a weathering agent, an antifouling agent, and a pigment may be added to the polyamide polymer within a range not impairing the effects of the present invention.
[0009]
The crimped yarn of the present invention is a polyamide multifilament subjected to crimping as described later, but the single fiber constituting the crimped yarn has a specific flatness and a plurality of convex portions. It has a flat cross-sectional shape.
[0010]
First, the flatness needs to be 2.5 to 7.0. As shown in FIG. 1, the flatness referred to in the present invention is a value (L / W) obtained by dividing the length (L) in the major axis direction by the distance (W) between the recesses in the minor axis direction in the cross-sectional shape. is there. If the flatness is less than 2.5, the flatness is insufficient, and the resulting carpet is inferior in softness. On the other hand, if it exceeds 7.0, the pile tends to bend, resulting in a carpet with poor elasticity.
[0011]
And as shown in FIG. 1, it is necessary for the some convex part to be provided in both surfaces of the orthogonal | vertical direction with respect to the major axis direction of the flat cross section of a single fiber. By providing a plurality of convex portions on both surfaces without being biased to one surface in this way, a bulky processed yarn can be obtained, and the covering property when carpeted is excellent. Further, irregular reflection of light can be suppressed, and an effect of preventing shine is produced.
[0012]
Especially, it is preferable that the convex part is provided symmetrically on both surfaces in the direction perpendicular to the major axis direction of the flat cross section, and there are three or more on one side, and a total of six or more. By adopting the number and arrangement of such convex portions, the above-described effects, that is, the covering property and the anti-shine effect are further improved. More preferably, the number of convex portions is four on one side as shown in FIG.
[0013]
And as a parameter | index which shows the height of a convex part, it is preferable that the ratio of the height of the convex part in a flat cross section is 1.0-3.0. As shown in FIG. 1, the height ratio of the convex portion in the present invention is a value obtained by dividing the height (H) of the flat yarn convex portion by the distance (W) between the concave portions in the minor axis direction of the flat yarn. / W). By setting the height ratio of the projections to 1.0 to 3.0, the bulkiness is excellent, the covering property is improved, and the anti-shine effect is further improved.
When the height ratio of the convex portion is less than 1.0, the height of the convex portion becomes low, the bulkiness becomes insufficient, and the covering property tends to be inferior. In addition, the anti-shine effect is likely to decrease. On the other hand, if it exceeds 3.0, the height of the convex portion becomes high, so that the elasticity is lowered and it becomes easy to get loose.
[0014]
The single fiber fineness of the polyamide multifilament constituting the processed yarn of the present invention is not particularly limited, but 5.0 to 10.0 decitex is preferable because it provides a soft texture as a household carpet. The total fineness of the polyamide multifilament is not particularly limited, and it is preferably 600 to 3000 dtex as a range usually used for carpets.
[0015]
Examples of means for crimping polyamide multifilament include false twisting, indentation, abrasion, shaping, air injection, etc. For carpet applications, indentation is preferred. As a result, a three-dimensional bulky crimp can be obtained.
[0016]
The crimp rate of the crimped yarn of the present invention is preferably 5.0 to 10.0%. By setting the crimp rate within this range, the balance between bulkiness and soft feeling due to crimp is particularly good.
[0017]
The crimp rate is measured and calculated as follows.
Create a sample with a 50 cm loop of crimped yarn, heat-treat this sample for 30 minutes in boiling water, remove it from the boiling water, wipe off the moisture, hang it on the hook without applying a load, It was air-dried in a 60% humidity room for 24 hours. With the air-dried sample suspended on the hook, apply a load of 0.09 CN / dtex, measure the yarn length (L1) 1 minute after applying the load, remove the post-measurement load and leave for 3 minutes Then, after applying a load of 0.0018 CN / dtex to the sample, the yarn length (L2) after 1 minute was measured and calculated by the following formula.
Crimp rate (%) = {(L1-L2) / L1} × 100
[0018]
Next, the method for producing the bulky crimped yarn of the present invention will be described using an example.
First, a flat single fiber having a cross-sectional shape having a convex portion can be obtained by adjusting the shape and discharge amount of the spinneret discharge hole or changing the viscosity of the polymer. After obtaining a polyamide multifilament through steps such as spinning, cooling, and drawing, the crimped yarn of the present invention can be obtained by performing the crimping as described above. The cross-sectional shape of the single fiber can also be adjusted by the take-up speed during spinning, the draw ratio, the crimping processing conditions, and the like.
[0019]
The crimped yarn of the present invention is suitable for carpets. When the crimped yarn of the present invention is used as a carpet, if it is used without being twisted, it is a velor tone that maximizes the soft texture. A carpet is obtained. Moreover, if a crimped yarn of the present invention is twisted and used as a pile to form a cut pile, a cut pile carpet excellent in elasticity can be obtained. Further, in this case, if a plurality of crimped yarns are single-twisted or twisted and further heat-fixed with a steam set, a saxony-like carpet with higher stiffness and superior durability can be obtained.
[0020]
And when using it as a carpet using the crimped yarn of this invention, it is preferable that 50 mass% or more is used as a pile yarn. When it is less than 50% by mass, it is difficult to obtain an effect of improving bulkiness and covering property and an anti-shine effect.
[0021]
【Example】
Next, the present invention will be described more specifically with reference to examples. In addition, each evaluation in an Example was performed as follows.
(1) Crimp rate Measured by the above method.
(2) Texture (soft feeling)
The texture of the obtained carpet was evaluated according to the following criteria based on tactile sensation.
◎: Very soft touch ○: Soft touch △: Slightly soft touch ×: Hard touch (3) Bare feel The hand-pressed surface of the carpet was judged to determine the feeling of bottoming.
A: The pile yarn has a strong repulsive force and has excellent point feeling.
○: The pile yarn has an appropriate repulsive force.
Δ: There is a sense of repulsion that is practically usable.
X: There is a feeling of bottoming of the base fabric through the pile yarn.
(4) Covering property The surface of the obtained carpet was observed from directly above, and the visibility of the base fabric was visually evaluated according to the following criteria.
A: Bulkiness is particularly excellent, and the base fabric cannot be seen.
○: Bulkiness is good and the base fabric cannot be seen.
Δ: The fabric is slightly visible.
X: Bulkiness is poor and the base fabric is easily visible between pile yarns.
(5) The glossy carpet surface was observed from directly above, and the shine was evaluated according to the following criteria.
A: There is no shine, and the glossiness is particularly excellent.
○: No glossiness and excellent gloss.
Δ: Somewhat shining.
X: There is shine.
[0022]
Example 1
Nylon 6 pellets having a relative viscosity (measured at a concentration of 1 g / dl and a temperature of 25 ° C. using 96% sulfuric acid as a solvent) were fed to an extruder and melt-spun at a spinning temperature of 275 ° C. Then, an oil agent is applied to the yarn that has been cooled and solidified continuously after spinning, and heat drawing is performed between rollers at 160 ° C. and a draw ratio of 3.0 times, and then yarn is used using air at 255 ° C. and 0.59 MPa. The strips are crimped by the air stuffer method, wound at a speed of 2100 m / min, and each single yarn has a flatness of 5.5 as shown in FIG. A crimped yarn (1100 dtex / 120f) having a four-sided flat cross-sectional shape having eight convex portion height ratios was obtained. The crimp rate of the crimped yarn was 7.5%.
The crimped yarn thus obtained was used without twisting and tufted into a polypropylene woven base fabric according to the specifications of 1/8 gauge, cut pile, pile length 6.5 mm, and pile basis weight 400 g / m ² . Thereafter, dyeing and backing were performed by a conventional method to obtain a cut pile carpet.
[0023]
Example 2
Two crimped yarns obtained in Example 1 were aligned, subjected to a single twist at 80 t / m, and heat-set by heat treatment with steam. Next, it was tufted into a polypropylene woven base fabric according to the specifications of 1/8 gauge, cut pile, pile length 6.5 mm, and pile weight 600 g / m ² . Thereafter, dyeing and backing were performed by a conventional method to obtain a cut pile carpet.
[0024]
Example 3
Two crimped yarns obtained in Example 1 were used, both the upper twist and the lower twist were subjected to various twists of 210 t / m, and heat setting was performed by heat treatment with steam. Next, it was tufted into a polypropylene woven base fabric according to the specifications of 1/8 gauge, cut pile, pile length 6.5 mm, and pile basis weight 600 g / m ² . Thereafter, dyeing and backing were performed by a conventional method to obtain a cut pile carpet.
[0025]
Example 4
Except that the relative viscosity of nylon 6 pellets was 2.5, the same procedure as in Example 1 was performed, and the four-sided flat cross-sectional shape with a cross-sectional flatness of 3.0 and a convex portion height ratio of 1.3 A crimped yarn (1100 dtex / 120f) was obtained. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0026]
Example 5
Except for the relative viscosity of nylon 6 pellets being 3.5, the same procedure as in Example 1 was performed, and the four-sided flat cross-sectional shape with a cross-sectional flatness of 6.5 and a convex portion height ratio of 2.2 A crimped yarn (1100 dtex / 120f) was obtained. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0027]
Example 6
The same procedure as in Example 1 was performed except that the shape of the discharge hole of the spinneret was changed, and the crimping of the four-square flat cross-sectional shape with a cross-sectional flatness of 5.5 and a convex portion height ratio of 2.8 was performed. A yarn (1100 dtex / 120f) was obtained. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0029]
Comparative Example 1
Except for the relative viscosity of nylon 6 pellets being 2.1, the same procedure as in Example 1 was performed, and the four-sided flat cross-sectional shape with a cross-sectional flatness of 1.5 and a convex portion height ratio of 0.9 A crimped yarn (1100 dtex / 120f) was obtained. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0030]
Comparative Example 2
Except that the relative viscosity of the nylon 6 pellet was set to 3.9, it was carried out in the same manner as in Example 1, and the cross-sectional flatness was 8.0 and the height ratio of the convex part was 2.5. A crimped yarn (1100 dtex / 120f) was obtained. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0031]
Comparative Example 3
The cross-sectional shape was the same as in Example 1 except that the relative viscosity of the nylon 6 pellet was 2.5, the shape of the discharge hole of the spinneret was changed, and the cross-sectional shape of the single fiber was changed to a flat cross-sectional yarn having no projections. A crimped yarn (1100 dtex / 120 f) having a flatness of 3.0 was obtained. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0032]
Comparative Example 4
The same procedure as in Example 1 was performed except that the shape of the discharge hole of the spinneret was changed and the cross-sectional shape of the single fiber was changed to a trilobal cross-sectional yarn, to obtain a crimped yarn (1100 dtex / 120f) having an irregularity of 3.5. It was. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0033]
Comparative Example 5
The same procedure as in Example 1 was carried out except that the shape of the discharge hole of the spinneret was changed and the cross-sectional shape of the single fiber was changed to a four-hole hollow fiber (square shape). A yarn (1100 dtex / 120f) was obtained. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0034]
Comparative Example 6
The shape of the discharge hole of the spinneret is changed, and the cross-sectional shape of the single fiber has a flatness of 5.5, a convexity of only four on one side, and a convexity height ratio of 2.5. Of crimped yarn (1100 dtex / 120f) was obtained. The crimp rate of the crimped yarn was 7.5%. Next, a cut pile carpet was obtained from the crimped yarn obtained in the same manner as in Example 3.
[0035]
Tables 1 and 2 show the physical properties and evaluation results of the crimped yarns and cut pile carpets obtained in Examples 1 to 6 and Comparative Examples 1 to 6 .
[0036]
[Table 1]
[0037]
[Table 2]
As is clear from Tables 1 and 2, any of the carpets made from the crimped yarns of Examples 1 to 6 has a very soft feel, is excellent in bulkiness, has excellent covering properties, and has a feeling of shine. It had a controlled and calm luster, and was also sufficient as a carpet.
On the other hand, since the fiber of Comparative Example 1 has low flatness, the resulting carpet was inferior in texture (soft feeling). Since the fiber of Comparative Example 2 had an excessively high flatness, the pile was likely to fall down in a certain direction, and the resulting carpet had a poor harshness. Since the fibers of Comparative Example 3 were flat yarns having no convex portions, and the fibers of Comparative Example 6 were fibers having convex portions only on one side, the bulkiness was poor, and the resulting carpet was covered. The nature was insufficient, and the shine due to irregular reflection of light was also large. Since the fiber of Comparative Example 4 was a trilobal cross-sectional yarn, the obtained carpet was excellent in covering properties but was unsuitable for household use with a rough texture. Since the fiber of Comparative Example 5 was a square hollow fiber, the obtained carpet lacked the covering property and had a poor soft texture.
[0038]
【The invention's effect】
The bulky crimped yarn of the present invention has a flat cross-sectional shape in which each single fiber has a specific flatness, and has a plurality of convex portions on both sides in a direction perpendicular to the major axis direction of the flat cross-sectional shape. Therefore, it is possible to obtain a carpet suitable for home use, which is excellent in bulkiness, excellent in covering properties, has a gentle gloss with a high-class feeling, and has a soft feel and durability.
[Brief description of the drawings]
FIG. 1 is a schematic cross-sectional view showing one embodiment of a single fiber of a bulky crimped yarn of the present invention.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Flat yarn 2 Flat yarn convex part 3 Flat yarn concave part L Flat yarn long-axis direction length D Flat yarn short-axis direction length H Flat yarn convex part height W Flat-fiber short-axis direction distance between recessed parts

Claims (1)

A bulky ridge composed of a polyamide multifilament having a flatness of a single fiber of 2.5 to 7.0 and having a plurality of convex portions on both surfaces perpendicular to the major axis direction of the flat cross section of the single fiber A plurality of convex portions provided symmetrically on both sides perpendicular to the major axis direction of the flat cross section, the total number of convex portions being six or more, and the convex portions in the flat cross section A bulky crimped yarn having a height ratio of 1.0 to 3.0.