JP4351893B2 - Polypropylene mixed fiber crimped yarn, method for producing the same, and carpet - Google Patents

Description

The present invention relates to a polypropylene mixed fiber crimped yarn excellent in bulkiness and suitable for carpet use, a method for producing the same, and a carpet.

Conventionally, as described in Patent Document 1 and Patent Document 2, a crimped yarn in which two types of polypropylene fibers having different shrinkage rates are mixed has been used as a carpet yarn.
JP-A-8-113837 JP 2003-201623 A

However, in these techniques, dry heat shrinkage factor is larger and 25% or more of high shrinkage component, the difference between the high shrinkage component and a low shrinkage component is large, the yarn length difference increases during hot air process, between two components yarn There was a problem that yarn breakage easily occurred. Further, in the method of performing post-processing such as stretching and heat setting without winding once, when the take-up speed is increased, the spinning stability is lowered and the productivity is insufficient.

Further, when a carpet is used, a technique such as increasing the single fiber fineness in order to reduce the thickness reduction rate (sagging property) has no soft feeling and the texture is insufficient.

The first gist of the present invention consists of a multifilament yarn containing an ethylene-propylene random copolymer and having a dry heat shrinkage of 5 to 15% at 130 ° C. and a multifilament yarn made of polypropylene homopolymer. The polypropylene-based mixed crimped yarn is characterized in that the bulk increase rate upon dry heat treatment is 50 to 140%.

The second gist of the present invention is that a polymer containing an ethylene-propylene random copolymer polymerized with a metallocene catalyst and a polypropylene homopolymer are melt-spun simultaneously from different spinnerets, and taken up at a take-up speed of 500 to 900 m / min. It is in the manufacturing method of the polypropylene-type mixed fiber crimped yarn which draws 1.5 to 4 times at 100-130 degreeC without taking, heat-sets at 70-130 degreeC, and performs hot air processing.

Furthermore, the third gist of the present invention resides in a carpet in which a pile is formed with the mixed crimped yarn of the present invention and the thickness reduction rate is 20% or less.

INDUSTRIAL APPLICABILITY According to the present invention, a polypropylene mixed fiber crimped yarn excellent in bulkiness and suitable for carpet use, and a carpet excellent in bulkiness and soft feeling can be obtained.

The polypropylene blended crimped yarn of the present invention needs to be composed of a multifilament yarn containing an ethylene propylene random copolymer and having a dry heat shrinkage of 5 to 15% at 130 ° C. and a multifilament yarn made of a polypropylene homopolymer. is there.

If the multifilament yarn containing the ethylene-propylene random copolymer has a dry heat shrinkage of less than 5% at 130 ° C., the shrinkage difference from the multifilament yarn made of polypropylene homopolymer is small, and sufficient bulkiness cannot be obtained. When the dry heat shrinkage rate exceeds 15%, the shrinkage difference between the high shrinkage component and the low shrinkage component is large, the yarn length difference is large during hot air processing, and the yarn cracking occurs between the two component yarns. Cannot get mixed yarn.

Furthermore, in the present invention, it is necessary that the bulk increase rate when dry heat treatment at 130 ° C. for 10 minutes is 50 to 140%. If the bulk increase rate is less than 50%, the volume feeling is insufficient in the heat treatment after the carpet is produced, and the fibers are liable to fall down, resulting in poor texture on the carpet surface. When the bulk increase rate exceeds 140%, the yarn-forming property at the time of drawing simultaneous hot air processing is deteriorated.

Moreover, the multifilament yarn containing an ethylene propylene random copolymer, which is one component constituting the mixed fiber crimped yarn of the present invention, preferably contains an ethylene propylene random copolymer containing 3% by weight or less of ethylene. When the ethylene content exceeds 3% by weight, the melting point becomes low, and the stability at the time of drawing hot air processing tends to deteriorate.

Further, in the multifilament yarn constituting the present invention, each single fiber may have an arbitrary fineness, and the fiber cross section may be either circular or triangular. Moreover, the cross section of the high shrinkage component yarn and the low shrinkage component yarn fiber may be different, and each fineness and each single fineness may be different.

Further, it may be an original fiber containing a dye or a pigment. The original fibers may be different from the high shrinkage component yarn and the low shrinkage component yarn.

The crimp rate is preferably 7% or more, and more preferably 10% or more. When the crimp rate is less than 7%, the obtained carpet becomes a carpet without a volume feeling.

Furthermore, in the present invention, the mixing ratio of the multifilament yarn containing the ethylene propylene random copolymer and the multifilament yarn made of polypropylene homopolymer is such that the high shrinkage component yarn is in the range of 33% to 66% with respect to all the fibers. It is preferable. Multifilament yarn containing high-shrinkage ethylene propylene random copolymer has a fiber mixing ratio of 33%
If it is less than 1, the carpet after weaving does not have the characteristics of different shrinkage mixed crimped yarn. On the other hand, when the blend ratio of the high shrinkage component yarn exceeds 66%, the carpet after weaving becomes hard and soft feeling is lost.

  Next, the manufacturing method of the polypropylene type different shrinkage mixed fiber of this invention is demonstrated below.

In the present invention, a polymer containing an ethylene propylene random copolymer polymerized with a metallocene catalyst and a polypropylene homopolymer are melt-spun simultaneously from different spinnerets, taken up at a take-up speed of 500 to 900 m / min, 1
Stretching at 1.5 to 4 times at 30 ° C, heat setting at 70 to 130 ° C, and hot air processing.

The ethylene propylene random copolymer of the present invention needs to be an ethylene propylene random copolymer polymerized with a metallocene catalyst. Since the ethylene propylene random copolymer polymerized with a conventional Ziegler-Natta catalyst contains many low molecular components, if the take-up speed is increased to 500 m / min or more, fluff, yarn breakage, etc. occur and stable spinning cannot be performed.
Further, the take-up speed needs to be 500 to 900 m / min, and when the take-up speed is less than 500 m / min, the productivity is lowered. On the other hand, if it exceeds 900 m / min, fluff and yarn breakage occur and spinning stability is lowered.

Furthermore, in the present invention, productivity is improved by performing post-processing without unwinding the undrawn yarn melt-spun at the same time from the spinneret.

If the draw ratio is less than 1.5 times, the strength of the obtained mixed yarn is lowered and the elongation is increased. When it exceeds 4 times, the spinning stability is lowered. When the drawing temperature is less than 80 ° C., problems such as single fiber breakage during drawing occur, and the spinning stability is lowered. When the drawing temperature exceeds 130 ° C., the spinning stability is also lowered.

Arbitrary methods such as a hot plate method and a roller method are used for the heat setting, and the heat setting temperature is 70 ° C.
If it is less than the range, the heat shrinkage rate of the high shrinkage component yarn becomes large and a loop is generated at the time of simultaneous drawing hot air processing, and the yarn forming property is lowered. In addition, the mixed yarn causes shrinkage with time even at room temperature, and the weather resistance also decreases. When the temperature exceeds 130 ° C., the yarn-forming stability decreases.

Further, the hot air processing may be performed after stretching and heat setting, or may be performed simultaneously with stretching hot air processing. The simultaneous stretching hot air processing is a processing in which hot air is blown simultaneously with stretching, and can be made into a bulky crimped yarn having a lash-like tone by the simultaneous stretching hot air processing.
In this simultaneous stretching air processing, heat setting is also performed simultaneously with hot air.

The polypropylene-based different shrinkage mixed crimped yarn according to the present invention has high bulkiness while having the same strength and elongation as a normal polypropylene filament yarn, and is further highly shrunk by heat treatment in a subsequent process. The drawn filament yarn containing the component ethylene propylene random copolymer is further shrunk, and the polypropylene drawn filament yarn becomes a loop, resulting in higher bulk. The bulkiness can be expressed even in the state of a yarn, but the bulkiness can be expressed by weaving or knitting and forming a woven fabric or knitted fabric, followed by heat treatment. For example, if heat treatment is performed after weaving the carpet, the highly shrinkable component yarns sink, the root fibers become high density, the fibers are less likely to fall, and the carpet surface becomes low density, resulting in a good texture. Further, since the fibers are less likely to fall down, a clear pattern is obtained when a patterned carpet is used.

A dry heat treatment at a temperature of 120 to 140 ° C. is preferably applied to the bulky heat treatment. When the temperature is less than 120 ° C., the difference in shrinkage ratio becomes small and the bulkiness becomes low. When the temperature exceeds 140 ° C., the woven or knitted fabric or the carpet becomes hard, and the texture becomes inferior.

Moreover, the thickness reduction rate of the carpet in which the pile is formed with the mixed fiber crimped yarn of the present invention needs to be 20% or less. If the thickness reduction rate exceeds 20%, the carpet will be droopy and the bulkiness will be insufficient.

In addition, the mixed fiber crimped yarn used in the present invention preferably includes those in which the cross-sectional shape of the single fiber is an atypical cross section, and includes a hollow cross section, a multi-core hollow cross section, a Y-shaped cross section, a cross-shaped cross section, A cross section of the leaf is mentioned, and it is desirable that the cross-sectional shape forms a sufficient inter-fiber gap and has a high bending stress in the fiber axis direction.

  Hereinafter, the present invention will be specifically described by way of examples. Evaluation was performed by the following method.

(Crimp rate)
・ Batch a sample to create a crumpled sample. ・ Heat-treat the sample for 10 minutes at 80 ° C. ・ Leave it for 10 minutes or more after the heat treatment. Measuring load to be measured A = dtex × (1/10) × (2 × number of windings)
・ Leave for 2 minutes excluding measurement load A ・ Apply measurement load B to one end of sample yarn and measure yarn length (L2) after 1 minute Measurement load B = dtex × (1/10) × (2 × number of windings)
Calculation formula: Crimp rate (%) = [(L1−L2) / L1] × 100 The numerical value calculated as crimp rate is (shrink rate)
・ Batch a sample to create a crumpled sample ・ Hang the sample on a suspension stand ・ Apply a measurement load gently and measure the thread length [L1] in a vertical state Measurement load = dtex × (2/11) × ( 2 x number of windings)
・ Remove the load and pass through a stainless steel rod and dry heat-treat at 130 ° C. for 10 minutes. ・ After heat treatment, cool at room temperature for 15 minutes.

・ Hang the sample on the suspension base ・ Apply the measurement load gently and measure the thread length [L2] in a vertical state Measurement load = dtex × (2/11) × (2 × number of windings)
Calculation formula: Shrinkage rate (%) = [(L1−L2) / L1] × 100 The value calculated as shrinkage rate was used as the shrinkage rate. The separated yarns were wound up as undrawn yarns, and then drawn yarns heat-set at a draw ratio of 2.0 times, a drawing temperature of 105 ° C., and a heat setting temperature of 90 ° C. were used as samples.

(Bulk increase rate)
・ Bundled specimens to create a sample.

• Place the casserole sample on the measuring table and place the initial measurement load A (20 g). The measurement table is shown in FIG.

-Place the measurement positive load B (200 g) on the initial measurement load A after 1 minute.

・ After 1 minute, read the height (H) of the sample.

-Cut off the sample protruding from the sample stage and measure the weight (Xg) of the remaining sample.

Bulkiness (cm ³ / g) = 4H / X was used as the bulkiness, and the bulkiness before and after heat treatment (heat treatment conditions 130 ° C. × 10 minutes) was measured, and the rate of increase was determined by the following formula.

Rate of increase (%) = (bulkness after heat treatment−bulkness before heat treatment) / bulkness before heat treatment × 100
(Thickness reduction rate)
A sample yarn was used as a pile yarn, a carpet was prepared according to the following standards, and measurement was performed based on JIS L1022.

Gauge: 1 / 10G (Pile density in the horizontal direction)
Stitch: 14 (pile density in the weft direction, number of shots per inch)
Pile height: 3mm
Tester: Rotary type dynamic loading tester rotary impactor (rubber roll Hs60)
Load 1 kg / number of rotations of one-arm test bench: 10,000 times Thickness reduction rate / thickness reduction rate (%) = [H1-H2] / H1 × 100 (H1: thickness before test. H2: thickness after test. Measurement results Table 1)

Ethylene Prolene Random Copolymer (Wintech XK118 manufactured by Nippon Polychem Co., Ltd.)
3 (MFR = 25 g / 10 min, melting point = 125 ° C., ethylene 2.5 wt%)) and polypropylene polymer (SA03 manufactured by Nippon Polychem Co., Ltd. (MFR = 31 g / 10 min, melting point = 1)
64 ° C.)) is blended at a ratio of 3: 7 as a polymer for a high shrinkage component, and as a polymer for a low shrinkage component, a polypropylene polymer (SA03 manufactured by Nippon Polychem Co., Ltd.)
MFR = 31 g / 10 min, melting point = 164 ° C.)).

In the melt extruder, the extrusion temperature for the high shrinkage component is set to the first zone 200 ° C. and the second to fourth zones 21.
Spinneret (60 holes) with 5 ° C, extrusion temperature for low shrinkage component at first zone 200 ° C, second to fourth zone 215 ° C, spinning temperature at 200 ° C, and high shrinkage component yarn with Y shape. Using low-shrinkage component yarns with a spinneret having a triangular shape (number of holes 60), each was supplied, discharged, and spun at a spinning speed of 600 m / min.

Without being wound once, the obtained undrawn yarn was subsequently heat set at a draw ratio of 2.0 times, a draw temperature of 105 ° C. and a heat set temperature of 90 ° C., and then a relaxation rate of 17.9% at a hot air temperature of 135 ° C.
Were simultaneously drawn hot air processing to obtain a crimped yarn of 1780 dtex / 120 filaments.

The obtained crimped yarn was in a state in which a high shrinkage component and a low shrinkage component were well mixed, and there was no loop and the yarn production stability was good.

The high-shrinkage component yarn of the obtained mixed crimped yarn had a dry heat shrinkage rate of 10%, and the bulky crimped yarn had an increase rate of 124%, which was excellent in bulkiness.

Further, the thickness reduction rate of the carpet on which the pile was formed with the obtained mixed crimped yarn was 15%, which was excellent in bulkiness and had a soft texture.

Ethylene Prolene Random Copolymer (Wintech XK119 manufactured by Nippon Polychem Co., Ltd.)
5 (MFR = 7 g / 10 min, melting point = 135 ° C., ethylene 2.0 wt%)) and polypropylene polymer (SA01 manufactured by Nippon Polychem Co., Ltd. (MFR = 9 g / 10 min, melting point = 164 ° C.))
) In a ratio of 5: 5 was used as a polymer for a high shrinkage component, and a polypropylene polymer (SA01 manufactured by Nippon Polychem Co., Ltd.) was used as a polymer for a low shrinkage component.

In the melt extruder, the extrusion temperature for the high shrinkage component is set to the first zone 245 ° C. and the second to fourth zones 24.
Spinneret with 8 ° C, extrusion temperature for low shrinkage component 1st zone 245 ° C, 2nd-4th zone 248 ° C, spinning temperature 240 ° C, high shrinkage component yarn with Y shape hole shape (: 60 holes) , And using a spinneret having a triangular shape of the low shrinkage component yarn (number of holes: 60), each of which was supplied and discharged to spin at a spinning speed of 600 m / min.

Without being wound once, the obtained undrawn yarn was subsequently heat set at a draw ratio of 2.4 times, a draw temperature of 105 ° C. and a heat set temperature of 90 ° C., and then a relaxation rate of 18.0% at a hot air temperature of 130 ° C.
Were simultaneously drawn hot air processing to obtain a crimped yarn of 1780 dtex / 120 filaments.

The obtained crimped yarn was in a state in which a high shrinkage component and a low shrinkage component were well mixed, and there was no loop and the yarn production stability was good.

The high shrinkage component yarn of the obtained mixed crimped yarn had a dry heat shrinkage rate of 11.9%, and the bulky crimped yarn had an increase rate of 90%, which was excellent in bulkiness.

Moreover, the thickness reduction rate of the carpet in which the pile was formed with the obtained mixed fiber crimped yarn was 11%, which was excellent in bulkiness and had a soft texture.

In Example 1, the high shrinkage component yarn hole shape was changed to a Y-shaped spinneret (: 40 holes), and the low shrinkage component yarn hole shape was a triangular spinneret (: 80 holes). Example 1 except for
In the same manner as above, a 1780 decitex / 120 filament different shrinkage mixed crimped yarn was obtained.

The high shrinkage component yarn of the obtained mixed crimped yarn had a dry heat shrinkage rate of 10.9%, and the bulky crimped yarn had an increase rate of 134%, which was excellent in bulkiness.

Further, the thickness reduction rate of the carpet on which the pile was formed with the obtained mixed crimped yarn was 15%, which was excellent in bulkiness and had a soft texture.

Except for changing the fineness, a 2440 dtex / 120 filament different shrinkage mixed crimped yarn was obtained under the same conditions as in Example 1.

The high shrinkage component yarn of the obtained mixed crimped yarn had a dry heat shrinkage of 10.2%, and the bulk increase rate of the mixed fiber crimped yarn was 108%, which was excellent in bulkiness.

Further, the thickness reduction rate of the carpet in which the pile was formed with the obtained mixed crimped yarn was 9%, which was excellent in bulkiness and had a soft texture.

(Comparative Example 1)
Polypropylene polymer (Nippon Polychem SA03 (MFR = 31 g / 10 min.,
Melting point = 164 ° C.) only, and the extrusion temperature is 200 ° C. in the first zone and the second to fourth zones 215.
Spinning speed using a spinneret (60 holes) with a spinneret with a spinneret with a Y shape (60 holes) and a spinneret with a triangle shape (60 holes) on the other side. 600m /
Spinned in minutes.

Subsequently, the obtained undrawn yarn was heat-set at a draw ratio of 2.0 times, a drawing temperature of 105 ° C., and a heat setting temperature of 90 ° C., and then simultaneously drawn hot air with a relaxation rate of 19.4% at a hot air temperature of 165 ° C. And 1780 dtex / 120 filament crimped yarn was obtained.

The dry shrinkage rate of the high shrinkage component yarn of the obtained mixed crimped yarn was 6.3%, and the bulk increase rate of the mixed fiber crimped yarn was 40%, which was inferior in bulkiness.

Moreover, the thickness reduction rate of the carpet in which the pile was formed with the mixed fiber crimped yarn was 22%, and the bulkiness was insufficient.

(Comparative Example 2)
Ethylene Prolene Random Copolymer (Wintech XK118 manufactured by Nippon Polychem Co., Ltd.)
3) Example except that 100% was used as a polymer for a high shrinkage component, and a polypropylene polymer (SA03 manufactured by Nippon Polychem Co., Ltd.) was used as a polymer for a low shrinkage component, and the relaxation rate was changed to 21.4%. Under the same conditions as in No. 1, a crimped yarn of 1815 dtex / 120 filaments was spun.

The dry shrinkage rate of the high shrinkage split yarn of the obtained mixed fiber crimped yarn is 32%, the processability of the undrawn yarn through the hot air processing part is poor, and the high shrinkage component yarn and the low shrinkage component yarn are separated. In addition, the mixed fiber state became poor.

Bulkiness increase measuring table

Explanation of symbols

A: Initial load for measurement B: Positive load for measurement C: Sample D: Measurement width (1 cm)
L: Measurement length (4cm)

Claims (3)

Contains ethylene propylene random copolymer and has a dry heat shrinkage of 5 to 15 at 130 ° C.
% Multifilament yarn and a multifilament yarn made of polypropylene homopolymer, and has a bulk increase rate of 50 to 140% when subjected to a dry heat treatment at 130 ° C. for 10 minutes. Crimped yarn. A polymer containing an ethylene-propylene random copolymer polymerized with a metallocene catalyst and a polypropylene homopolymer are melt-spun simultaneously from different spinnerets, and taken up at a take-up speed of 500 to 900 m / min. .
A method for producing a polypropylene-based mixed crimped yarn that is stretched 5 to 4 times, heat-set at 70 to 130 ° C., and hot-air processed. A carpet in which a pile is formed from the mixed crimped yarn according to claim 1 and the thickness reduction rate is 20% or less.

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