JP5264599B2 - carpet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a carpet with an improved plant-derivation degree by using spin-dyeing polytrimethylene terephthalate crimped yarns for a major part of pile yarns of the carpet. <P>SOLUTION: The spin-dyeing polytrimethylene terephthalate crimped yarn for use in the pile yarn simultaneously satisfies the following (1)-(7) characteristics, so that this carpet having excellent abrasion resistance, bulkiness and the like and having the improved plant-derivation degree is provided. (1) The cross-section of monofilament is a modified cross-section and the deformation degree expressed by the ratio (B/A) of the diameter (B) of a circumscribed circle to the diameter (A) of an inscribed circle of the fiber cross section is 1.8-4.5, (2) the limiting viscosity (IV) is 0.7-1.3, (3) the strength is 1.5-2.5 cN/dtex, (4) the degree of elongation is 25-60%, (5) the single yarn fineness is 10-25 dtex, (6) the hot water shrinkage rate is 1-5%, and (7) the dry heat crimp percentage is 5-25%. <P>COPYRIGHT: (C)2011,JPO&amp;INPIT

Description

  The present invention relates to a carpet using an original polytrimethylene terephthalate crimped yarn made of a plant-derived raw material as a pile yarn, and is excellent in abrasion resistance, bulkiness and the like that could not be achieved by the prior art. It provides carpets with improved degree of conversion.

  Polytrimethylene terephthalate is a polyester-based resin made from a glycol component obtained from starch such as corn and sugarcane. Because it uses plants as a raw material, it is effective in reducing carbon dioxide, which is considered to be a cause of global warming, and is attracting attention as a material that is compatible with the natural circulation cycle and is friendly to the global environment. Vehicle floor carpets and option mats, and household carpets and rugs using polytrimethylene terephthalate fibers made of such plant-derived materials are being made and put into practical use.

  However, carpets using conventional polytrimethylene terephthalate fibers have the disadvantages of being easily worn and inferior in bulkiness, and have been put to practical use only for limited applications. This is because the properties and crimping properties of polytrimethylene terephthalate crimped yarn are inferior to those of nylon and polyester fiber crimped yarns. If the same physical properties can be obtained, it can be widely used as a material for interiors as well as carpets.

  As prior art, Patent Document 1, Patent Document 2, and Patent Document 3 are disclosed regarding polytrimethylene terephthalate crimped yarn and carpet using the same.

  Patent Document 1 states that “poly (trimethylene terephthalate) polyester carpet having excellent antifouling property, texture retention and crush resistance, bulky continuous filament yarn used for producing the carpet, and yarn of the yarn It is disclosed as “a manufacturing method of poly (trimethylene terephthalate) bulky continuous filament yarn, the filament, and a carpet manufactured therefrom” as a solution. Methylene terephthalate) describes a carpet using bulky continuous filament yarn.

Patent Document 2 has an object of "providing a dust control mat excellent in dirt removal property, compression recovery property, and contamination property", and as a means for solving the problem, "a crimped yarn having polytrimethylene terephthalate as a main component in a pile yarn". And a fineness of the single yarn constituting the crimped yarn is 10 to 100 dtex, and the basis weight of the pile yarn is 500 to 5000 g / m ^2. A dust control mat is described in which trimethylene terephthalate crimped yarn is used as a pile yarn, and the fineness of the single yarn constituting the crimped yarn and the basis weight of the pile yarn are limited.

  Patent Document 3 states, “Crimped yarn for dust control mat that has improved pencil point property while utilizing the antifouling property peculiar to polytrimethylene terephthalate and has excellent surface aesthetic maintenance of carpet after long-term use, and dust control mat comprising the same As a means for solving the problem, “after applying various twists of 150 to 220 T / m to the original multifilament crimped yarn made of polytrimethylene terephthalate, steam at 100 to 130 ° C. A method for producing a crimped yarn for dust control mats, characterized by being heat-set with a polytrimethylene terephthalate original multifilament crimped yarn as a crimped yarn for dust control mats, and twisting thereof. Describes processing conditions and heat setting conditions.

  The technology of Patent Document 1 described above is a method for producing a bulky continuous filament yarn of poly (trimethylene terephthalate) and its yarn characteristics, such as intrinsic viscosity of filament yarn, total denier, denier per filament, boiling water treatment BCE, shrinkage, References are made to strength, elongation at break, etc., as well as carpet standards made with the yarn, such as the number of turns per inch of yarn, carpet weight, carpet pile height, and the like. However, no mention is made of the wear characteristics which are important for carpet use.

  The technique of the above-mentioned patent document 2 is that, for polytrimethylene terephthalate crimped yarn, the fineness of single yarn, crimp elongation after boiling water treatment, etc., and for dust control mat, pile yarn weight, compression recovery, etc. To mention. However, it does not describe any wear characteristics that are important for carpet use.

  The technology of Patent Document 3 mentioned above refers to a dust control mat manufactured from an original multifilament crimped yarn made of polytrimethylene terephthalate. However, no mention is made regarding the durability of the carpet, such as wear resistance and sag resistance.

  Since the contents of the above Patent Documents 1 to 3 do not refer to the wear resistance and bulkiness of the carpet, the level of satisfaction with respect to the wear resistance and bulkiness of the carpet obtained by the technique is satisfactory. It cannot be said that it has become.

Japanese National Patent Publication No. 10-502139 JP 2007-169868 A JP 2007-197886 A

  The object of the present invention is to overcome the above-mentioned problems and to improve the degree of planting by using an original polytrimethylene terephthalate crimped yarn, which could not be achieved by the prior art, as a main part of carpet pile yarn. It is to provide a carpet excellent in wear resistance and bulkiness.

  The present invention can be achieved by the following means in order to solve the above problems.

[1] In a carpet using an original polytrimethylene terephthalate crimped yarn made of a plant-derived material as a pile yarn, the pile yarn according to a Taber type abrasion test (wear ring: H-18, number of wears of 300 times) of the carpet skin A carpet having a wear amount of 2 to 15% by mass.

[2] Pile by carpet taber type abrasion test (wear ring: H-18, wear count 1,000 times) for carpets using original polytrimethylene terephthalate crimped yarns made from plant-derived materials as pile yarns A carpet characterized in that the wear amount of the yarn is 3 to 30% by mass.

[3] The carpet according to item 1 or 2, wherein the original polytrimethylene terephthalate crimped yarn made of the plant-derived material satisfies the following characteristics (1) to (7).
(1) The cross-sectional shape of the single fiber is an irregular cross-sectional shape, and the degree of irregularity expressed by the ratio (B / A) of the circumscribed circle diameter (B) to the inscribed circle diameter (A) of the fiber cross section is 1. 8-4.5
(2) Intrinsic viscosity (IV) 0.7-1.3
(3) Strength is 1.5 to 2.5 cN / dtex
(4) Elongation is 25-60%
(5) Single yarn fineness of 10 to 25 dtex
(6) Hot water shrinkage is 1-5%
(7) Dry heat crimp rate is 5-25%

[4] The carpet has an average pile length of 5 to 15 mm and a pile basis weight of 300 to 3,000 g / m ² using the pile yarn of the original polytrimethylene terephthalate made of the plant-derived material. The carpet according to any one of the preceding items 1 to 3.

  In the invention of [1], the wear amount of the pile yarn is 2 by the Taber type abrasion test (wear ring: H-18, wear number of 300 times) of the carpet skin using the original polytrimethylene terephthalate crimped yarn as the pile yarn. Since it is -15 mass%, it can be set as the carpet excellent in abrasion resistance. In addition, since the yarn is an original yarn, it is not necessary to provide a dyeing step in the carpet manufacturing process, and a carpet using a plant-derived raw material having excellent wear resistance can be obtained.

  In the invention of [2], the amount of wear of the pile yarn by the Taber type abrasion test (wear ring: H-18, number of wear 1,000 times) of the carpet skin using the original polytrimethylene terephthalate crimped yarn as the pile yarn. Is 3 to 30% by mass, the carpet can be more excellent in abrasion resistance. In addition, since the yarn is an original yarn, it is not necessary to provide a dyeing step in the carpet manufacturing process, and a carpet using a plant-derived raw material having excellent wear resistance can be obtained.

  In the invention of [3], the cross-sectional shape and irregularity of the single fiber constituting the original polytrimethylene terephthalate crimped yarn are limited to a specific configuration, the limiting viscosity is limited to a specific range, and the strength, elongation, Since the single yarn fineness, hot water shrinkage rate, and dry heat crimp rate are limited to specific ranges, respectively, a carpet having excellent wear resistance and bulkiness can be obtained.

In the invention of [4], the average pile length of the carpet skin using the pile yarn of the original polytrimethylene terephthalate crimped yarn made of the plant-derived material is 5 to 15 mm, and the pile basis weight is 300 to 3,000 g / m. ^Since it is ² , it can be set as the carpet which is excellent in abrasion resistance, is bulky, and does not have a bottom feeling.

  The present invention has been intensively studied on improvement of poor wear resistance and lack of bulkiness of carpets using an original polytrimethylene terephthalate crimped yarn made of plant-derived materials as a pile yarn, and is used for a pile yarn. Specific cross-sectional shape, intrinsic viscosity (IV), strength, elongation, single yarn fineness, hot water shrinkage rate, dry heat crimp rate, etc. of the single fiber itself of the polytrimethylene terephthalate crimped yarn Further, when the average pile length and pile basis weight of the carpet skin were specified, the carpet could solve the above-mentioned problems all at once.

  The carpet of the present invention uses a pile yarn of an original polytrimethylene terephthalate crimped yarn made of a plant-derived raw material, and a pile yarn obtained by a Taber type abrasion test (wear wheel: H-18, number of wears of 300 times) of the carpet skin. It is a carpet satisfying an abrasion amount of 2 to 15% by mass.

  Abrasion resistance when the abrasion amount of the pile yarn is 2 to 15% by mass according to the Taber type abrasion test (300 times) of the carpet skin using the pile yarn of the original polytrimethylene terephthalate crimped yarn made of plant-derived materials. It can be made an excellent carpet. It is most preferable if the wear amount of the pile yarn is 2% by mass or less, but it is a number that is difficult to achieve in practice. When the wear amount of the pile yarn is 15% by mass or more, the fibers fall off over time while the carpet is used, and the carpet base fabric can be seen and the appearance changes greatly. The wear amount of the pile yarn according to the Taber type abrasion test (300 times) of the carpet skin is preferably 2 to 12% by mass, and particularly preferably 2 to 10% by mass.

  The carpet of the present invention uses a pile yarn of an original polytrimethylene terephthalate crimped yarn made of a plant-derived raw material, and a pile by a Taber type abrasion test (wear wheel: H-18, number of wear 1,000 times) of the carpet skin. This is a carpet satisfying a yarn wear amount of 3 to 30% by mass.

  When the abrasion amount of the pile yarn by the Taber type abrasion test (1,000 times) of the carpet skin using the pile yarn of the original polytrimethylene terephthalate crimped yarn made of plant-derived material is 3 to 30% by mass, The carpet can be more excellent in abrasion. The wear amount of the pile yarn is most preferably 3% by mass or less, but it is a number that is difficult to achieve in practice. If the wear amount of the pile yarn is 30% by mass or more, the fibers fall off over time while the carpet is used, and the carpet base fabric can be seen and the appearance changes greatly. It is preferable that the abrasion amount of the pile yarn by the Taber type abrasion test (1,000 times) of the carpet skin is 3 to 25% by mass, more preferably 3 to 20% by mass of the pile yarn. A wear amount of 3 to 15% by mass is particularly preferable.

  In the present invention, the method for producing the carpet is not particularly limited, and examples thereof include methods for producing a woven carpet, an embroidery carpet, an adhesive carpet, a knitted carpet, and the like. The form of the pile is not particularly limited, and any form of a cut pile, a loop pile, and a cut and loop can be selected.

  The polytrimethylene terephthalate polymer constituting the polytrimethylene terephthalate composition, which is the raw material of the original polytrimethylene terephthalate crimped yarn, has terephthalic acid as the acid component and 1,3-propanediol as the glycol component, especially from plants The polytrimethylene terephthalate obtained by polymerization using 1,3-propanediol as a glycol component. The polytrimethylene terephthalate is composed of 95 mol% or more of trimethylene terephthalate repeating units and 5 mol% or less of other ester repeating units. Moreover, as long as the effect of the present invention is not impaired, a copolymer obtained by copolymerizing components other than trimethylene terephthalate may be used. When a component other than trimethylene terephthalate is copolymerized, 80% by mass or more, preferably 90% by mass or more, of all repeating units of the polymer molecular chain constituting the trimer terephthalate unit.

  The intrinsic viscosity (IV) of the original polytrimethylene terephthalate crimped yarn needs to be 0.7 to 1.3. Here, the intrinsic viscosity is a value measured with a mixed solution of 30 ° C. and phenol / tetrachloroethane = 50/50 (mass ratio). When the intrinsic viscosity is less than 0.7, the strength and elongation of the polylactic acid crimped yarn and abrasion resistance suitable for carpet use cannot be imparted. On the other hand, if the intrinsic viscosity is higher than 1.3, the melt viscosity becomes too high, so that it is necessary to raise the spinning temperature. As a result, acrolein that is not good for the working environment is generated, and it is difficult to produce the yarn. The problem of becoming. Among them, the relative viscosity (IV) of the original polytrimethylene terephthalate crimped yarn is preferably 0.9 to 1.1.

  Moreover, the polytrimethylene terephthalate composition used as a raw material for the original polytrimethylene terephthalate crimped yarn has a composition containing 0.01 to 3.0% by mass of a colorant. By setting to such a density | concentration, the color of a suitable density | concentration can be provided to a crimped yarn and the design property can be improved. Further, when the content is 0.01% by mass or more, the occurrence of uneven color due to pigment unevenness can be prevented, and when the content is 3.0% by mass or less, the occurrence of thread breakage can be sufficiently prevented. Among them, the content of the colorant is preferably 0.05 to 1.0% by mass.

  As long as the effects of the present invention are not impaired, the polytrimethylene terephthalate composition includes a polymer (including polymer particles) other than polytrimethylene terephthalate, a matting agent, a plasticizer, Various additives such as a flame retardant, an antistatic agent, a deodorant, an antibacterial agent, an antioxidant, a heat resistance agent, a light resistance agent, and an ultraviolet absorber may be included as necessary.

For carpets using the original polytrimethylene terephthalate crimped yarn as the pile yarn, the original polytrimethylene terephthalate crimped yarn used for the pile yarn satisfies the following characteristics (1) to (7) at the same time: It is a characteristic carpet.
(1) The cross-sectional shape of the constituent single fiber is an irregular cross-sectional shape. By making such a cross-sectional shape, the pile yarn does not easily fall down, and the fiber surface does not easily rub due to friction or the like from the outside. The degree of irregularity represented by the ratio (B / A) of the diameter (B) of the circumscribed circle and the diameter (A) of the inscribed circle of the fiber cross section is an irregular sectional shape of 1.8 to 4.5. Preferably, it is 2.0-4.0, More preferably, it is 2.2-3.8. If the degree of profile is less than 1.8, the bulkiness of the polytrimethylene terephthalate crimped yarn will be insufficient, and the covering properties of the yarn will deteriorate, such being undesirable. Polytrimethylene terephthalate crimped yarns with a degree of profile exceeding 4.5 are difficult to manufacture.
(2) The intrinsic viscosity (IV) is 0.7 to 1.3.
(3) Strength is 1.5 to 2.5 cN / dtex
(4) Elongation is 25-60%
(5) Single yarn fineness of 10 to 25 dtex
(6) Hot water shrinkage is 1-5%
(7) Dry heat crimp rate is 5-25%

  The strength of the original polytrimethylene terephthalate crimped yarn is 1.5 to 2.5 cN / dtex. When the strength of the crimped yarn is less than 1.5 cN / dtex, the wear resistance is inferior when the carpet is used, and a portion of the crimped yarn may be worn out during use. Among them, the strength of the original polytrimethylene terephthalate crimped yarn is preferably 1.75 to 2.25 cN / dtex. Further, the elongation of the original polytrimethylene terephthalate crimped yarn is 25 to 60%. When the elongation of the crimped yarn is less than 25%, the wear resistance is inferior when the carpet is used, and a portion of the crimped yarn may be worn out during use. Among them, the elongation of the original polytrimethylene terephthalate crimped yarn is preferably 30 to 55%, particularly preferably 35 to 50%.

  When the strength of the original polytrimethylene terephthalate crimped yarn is 1.5 to 2.5 cN / dtex and the elongation of the original polytrimethylene terephthalate crimped yarn is 25 to 60%, Since it is excellent in abrasion, it is preferable. However, as the strength is increased, the normal elongation decreases. When the elongation is 25% or more, the strength is 2.5 cN / dtex at most, and when the elongation exceeds 60%, the strength is decreased. It cannot be 1.5 cN / dtex or more.

  The single yarn fineness of the original polytrimethylene terephthalate crimped yarn is in the range of 10 to 25 dtex. When the single yarn fineness is less than 10 dtex, the carpet formed using the crimped yarn has insufficient bulkiness. On the other hand, when the single yarn fineness exceeds 25 dtex, it is difficult to obtain the yarn physical properties of the original polytrimethylene terephthalate crimped yarn. Among them, the single yarn fineness of the original polytrimethylene terephthalate crimped yarn is in the range of 15 to 25 dtex.

  The total fineness of the original polytrimethylene terephthalate crimped yarn is preferably in the range of 800 to 3,000 dtex. If it is such a range, it will become the optimal original crimped yarn for a tufted carpet use, However, It is not limited to the use for such a use in particular. Among them, the total fineness of the original polytrimethylene terephthalate crimped yarn is preferably in the range of 1,000 to 2,500 dtex, and more preferably in the range of 1,000 to 2,000 dtex.

  Moreover, the hot water shrinkage rate of the original polytrimethylene terephthalate crimped yarn is in the range of 1 to 5%. If the hot water shrinkage is less than 1%, the crystallinity of the polytrimethylene terephthalate crimped yarn becomes high, and the strength and elongation are not well-balanced. On the other hand, when the hot water shrinkage rate exceeds 5%, there is a problem that yarn shrinkage occurs during the heat setting treatment of the polytrimethylene terephthalate crimped yarn, and it becomes difficult to manage in each process in carpet production. Especially, it is preferable that the hot water shrinkage rate of the said original polytrimethylene terephthalate crimped yarn is in the range of 1 to 3%.

  Further, the dry heat crimp rate of the original polytrimethylene terephthalate crimped yarn is in the range of 5 to 25%. This dry heat crimp rate is a parameter indicating the volume feeling of the original polytrimethylene terephthalate crimped yarn, and the original polytrimethylene terephthalate crimped yarn is treated with hot air at 120 ° C. to develop the crimp, This value indicates the degree of crimp. When the dry heat crimp rate is less than 5%, the crimp is insufficient, the volume feeling as a carpet is insufficient, and the yarn covering property is inferior. On the other hand, a carpet constructed using polytrimethylene terephthalate crimped yarn having a dry heat crimp rate of more than 25% is felt-like, and a preferred carpet cannot be obtained. Especially, it is preferable that the dry heat crimp rate of the said original polytrimethylene terephthalate crimped yarn is in the range of 8 to 20%, and the particularly preferable range is 8 to 15%.

  Examples of the colorant used for the original polytrimethylene terephthalate crimped yarn include inorganic pigments and organic pigments, and are not particularly limited as long as they can give color to the crimped yarn. Examples of the colorant include carbon black, oxidized inorganic pigments, ferrocyanide inorganic pigments, silicate inorganic pigments, carbonate inorganic pigments, phosphate inorganic pigments, and the like, phthalocyanine organic pigments, perylene organic pigments, At least one pigment selected from the group consisting of isoindolinone-based organic pigments is used.

  The pile yarn used for the carpet of the present invention is a non-twisted yarn and / or twisted yarn of an original polytrimethylene terephthalate crimped yarn made of a plant-derived material, and these are used as a single yarn and / or two or more twisted yarns. It can also be used.

Specifically, an original polytrimethylene terephthalate crimped yarn made of a plant-derived material can be used as a pile yarn such as the following (1) to (6).
(1) Use untwisted yarn (raw yarn) as pile yarn (2) Use air yarn entangle the untwisted yarn and use pile yarn (3) Use twisted yarn as pile yarn (4) Twist number is 50 to 250 T / m Twisted yarn and used for pile yarn (5) Two or more twisted yarns and used for pile yarn (6) Wet heat treatment or dry heat treatment of pile yarn heat set Original polytrimethylene terephthalate made of the above plant-derived materials By appropriately selecting and using the reduced yarn as a pile yarn, a carpet with improved wear resistance can be produced.

And the carpet of this invention uses the pile yarn of the original polytrimethylene terephthalate crimped yarn made from a plant-derived raw material, the average pile length of the carpet skin is 5 to 15 mm, and the pile basis weight is 300 to 3,000 g / m. ² is a feature.

  When an original polytrimethylene terephthalate crimped yarn made of a plant-derived material is used as a pile yarn, the average pile length is 5 to 15 mm. Preferably, it is 6.5-15 mm. More preferably, it is 7.5-12 mm. Especially preferably, it is 8-12 mm. If the average pile length is 5 mm or less, the base fabric can be seen through the gaps in the pile skin, resulting in poor covering characteristics and a feeling of bottoming when using the carpet. When the average pile length is 15 mm or more, the volume feeling and bulkiness are excellent and there is a high-class feeling, but the cost is increased, the pile yarn becomes weak, and the pile is easy to sleep while using the carpet.

The pile basis weight is 300 to 3,000 g / m ² . Preferably, it is 350-2500 g / m < ² >. More preferably, it is 450-2,000 g / m < ² >. When the basis weight of the pile is 300 g / m ² or less, the base fabric can be seen through the gaps in the pile skin, resulting in inferior covering characteristics and a feeling of bottoming out. When the pile basis weight is 3,000 g / m ² or more, the volume feeling and the bulkiness are excellent and there is a high-class feeling, but it becomes heavy and the handling of the carpet becomes difficult.

  For example, when tufting a pile yarn of an original polytrimethylene terephthalate crimped yarn made of the plant-derived material using a tufting machine, the gauge is 1/16 to 1/4 (1 inch: 2.54 cm / The number of needles) is preferred. More preferably, it is 1/12 to 1/8. The stitches are 20 to 70 stitches / 10 cm, preferably 30 to 65 stitches / 10 cm. More preferably, it is 35-60 stitches / 10 cm.

  The carpet using the original polytrimethylene terephthalate crimped yarn made of the plant-derived material as a pile yarn is subjected to a backing treatment after the tuft to fix the pile yarn. At this time, it passes through a drying step and a heat setting step, and usually crimps latent in the original polytrimethylene terephthalate crimped yarn made of the plant-derived material are expressed by dry heat treatment and / or steam treatment. It is possible to make the carpet with excellent volume and no bottom.

  The tufted carpet using the original polytrimethylene terephthalate crimped yarn made of the plant-derived raw material of the present invention as a pile yarn is a carpet having greatly improved wear resistance and bulkiness. As a result, a high-quality carpet with excellent bulkiness and volume can be obtained.

  Carpets using the original polytrimethylene terephthalate crimped yarns made from plant-derived materials of the present invention as pile yarns are automotive floor carpets and option mats, roll carpets, piece carpets, tile carpets, household rugs and mats, etc. Yes, the characteristics of the carpet of the present invention can be utilized, and it can be used for many applications.

  The carpet of the present invention is obtained by using an original polytrimethylene terephthalate crimped yarn as a main part of a pile yarn. If 30 to 70% by weight of polytrimethylene terephthalate resin is contained in the base fabric or backing resin that constitutes the carpet, the degree of planting is further improved and the amount of carbon dioxide in the air is less increased. From the standpoint, it can be a carpet that is friendly to the global environment.

  Next, a specific method for producing the original polytrimethylene terephthalate crimped yarn necessary for the present invention will be described, but it is not limited to this production method. (See Figs. 1 and 2)

  The polytrimethylene terephthalate polymer used for producing the original polytrimethylene terephthalate crimped yarn has an intrinsic viscosity (IV) measured in a mixed solution of 30 ° C. and phenol / tetrachloroethane = 50/50 (mass ratio). 0.7-1.3 is used. In the carpet application of the present invention, the strength, elongation, crimp characteristics and abrasion resistance of the crimped yarn are required, and therefore the above-specified intrinsic viscosity polymer is required.

  As the inorganic pigment and the organic pigment used as the colorant for the original polytrimethylene terephthalate crimped yarn, at least one pigment selected from the above-mentioned specified compounds is used. Alternatively, the coloring agent can be added to the polytrimethylene terephthalate polymer to form a master batch, and then the yarn can be produced.

  The polytrimethylene terephthalate polymer and the colorant mixed in a certain ratio through a mixer are supplied to a vented (13) twin screw extruder (12) to be melted, and passed through a spinning pack. Spin from the die pores (15).

  The cross-section of the original polytrimethylene terephthalate crimped yarn has an irregular cross-sectional shape, and the ratio of the circumscribed circle diameter (B) to the inscribed circle diameter (A) (B / A) of the single yarn cross section. Is preferably 1.8 to 4.5.

  Next, the spun yarn is cooled and solidified by the cold air of the spray cooling device (16).

  An oil agent is applied to the cooled and solidified yarn by an oiling device (17), and then wound by a take-up roller (1) that rotates at a predetermined speed.

  The speed of the take-up roller (1) is 400 to 1,000 m / min.

  The method for producing a crimped yarn according to the present invention is characterized by a direct spinning drawing / crimping process in which the crimped yarn is produced in one step. Therefore, the take-up speed is preferable.

  The undrawn yarn filament taken up is continuously heat-drawn in a single stage or multiple stages of two or more stages using a roller group (1 to 4). The temperature of the stretching roller (3) is 70 to 100 ° C. Further, the draw ratio is in the range of 3.0 to 5.0. In particular, in order to obtain the excellent abrasion resistance and bulkiness of the original trimmed polytrimethylene terephthalate crimped yarn of the present invention, it is important to crimp the sufficiently stretched and oriented polytrimethylene terephthalate fiber.

  The sufficiently stretched and oriented polytrimethylene terephthalate fiber is heat set by a heat setting roller (4). The temperature of the heat setting roller (4) is 90 to 160 ° C. By optimizing the temperature range of the heat setting roller (4), the crystallization of the polytrimethylene terephthalate fiber is controlled, and the desired physical properties are obtained.

  The polytrimethylene terephthalate fiber yarn that has been drawn is continuously introduced into the heated fluid crimping device (5) to impart crimps. The yarn (6) crimped by the heated fluid crimp imparting device (5) is cooled on the cooling drum (20).

  The heating fluid is preferably heated air, and its operating temperature is 150 to 210 ° C. Appropriate conditions are selected according to the fineness, processing speed, etc. of the polytrimethylene terephthalate fiber.

The crimping rate of the polytrimethylene terephthalate crimped yarn is appropriately selected from the heat setting roller (4) temperature for setting the fibers in tension and heat and the heating fluid temperature condition of the heating fluid crimping device (5) for setting relaxation heat thereafter. Thus, it can be produced as a target dry heat crimp rate value.

  Next, the crimped yarn is entangled through the nozzle of the entanglement processing device (21). The entanglement nozzle usually has 2 to 6 holes, and entanglement treatment is performed by injecting high pressure air of 0.2 to 0.5 MPa from a direction substantially perpendicular to the traveling crimped yarn.

  Next, the polytrimethylene terephthalate crimped yarn is wound into a cheese shape (22). The winding tension is performed at a low tension of 0.10 cN / dtex or less.

  Next, the manufacturing method of the pile yarn used for the carpet of this invention is described. The pile yarn used for the carpet of the present invention is the original polytrimethylene terephthalate crimped yarn made of the plant-derived material in the state of non-twisted yarn and / or twisted yarn, or they are single yarn and / or two or more yarns. It can be used for pile yarn as a twisted yarn.

  The pile yarn is based on the manufacturing standard of tufted carpet, and the color of the pile yarn, the total fineness (dtex), the state of the crimped yarn (non-twisted yarn or twisted yarn), the number of combined yarns of the crimped yarn, the condition of the twisted yarn・ Determine the form.

  The crimped yarn may be used in the state of untwisted yarn, or the untwisted yarn and other untwisted yarns may be used as they are / or twisted as mixed fiber in an air entanglement facility.

  The crimped yarn may be used in the form of a twisted yarn (twisting number is preferably 150 to 250 T / m), and twisted into two or more after twisting (twisting number is preferably 50 to 200 T / m). It can also be used.

  For example, two or more original polytrimethylene terephthalate crimped yarns are used, and a lower twist (200 T / m) and an upper twist (200 T / m) are applied to obtain two or more twisted yarns. After that, twist setting is performed by hot air treatment at 120 to 150 ° C. or vacuum steam heat treatment at 90 to 120 ° C. to obtain pile yarn for carpet. If necessary, use two or more of the above-mentioned two or more twisted yarns, twist them (60 T / m), and then twist them with hot air treatment at 120 to 150 ° C or vacuum steam heat treatment at 90 to 120 ° C. And pile yarn for carpets.

  The physical property definitions and measurement methods described in the text and examples are as follows.

[Intrinsic viscosity: IV]
The sample was dissolved in a mixed solution of phenol / tetrachloroethane = 50/50 (mass ratio) to a concentration of 1 g / dl, and the intrinsic viscosity (IV) was measured at 30 ° C. using an Ubbelohde viscosity tube.

[Strong elongation]
Strength (cN) and elongation (%) were measured under the conditions of a sample length of 25 cm and a tensile speed of 30 cm / min using a tensile tester of TENSORAPID3 manufactured by USTER. The strength (cN / dtex) is a value obtained by dividing the strength of the multifilament by its fineness.

[Fineness]
Measured according to JIS L 1013.

[Deformation degree]
After cutting the single yarn, the diameter (B) of the circumscribed circle of the single yarn and the diameter (A) of the inscribed circle were measured using an optical microscope, and obtained by the following formula.
Deformity = (B) / (A)

[Hot water shrinkage]
The hot water shrinkage (%) is a measured value according to JIS L1013 Kase shrinkage (Method A).
A polytrimethylene terephthalate crimped yarn cut from a bobbin package is used as a sample. A load giving a tension of total fineness dtex × 0.882 mN (90 mg / dtex) is applied to the sample yarn, and after 10 seconds, the sample length (Ls1) is measured. After being immersed in hot water at 98 ° C. for 30 minutes in an unloaded state, it is naturally dried all day and night. This is the polytrimethylene terephthalate crimped yarn after the hot water treatment. A load giving the same total fineness dtex × 0.882 mN (90 mg / dtex) tension is applied to the sample yarn before the hot water treatment, and after 10 seconds, the sample length (Ls2) is measured. The hot water shrinkage rate (%) is obtained from the following formula.

  Hot water shrinkage (%) = [(Ls1-Ls2) / Ls1] × 100

[Dry heat crimp rate]
The polytrimethylene terephthalate crimped yarn cut from the bobbin package is treated with hot air at 120 ° C. for 10 minutes under no load, and then allowed to stand naturally for 10 minutes. This is a polytrimethylene terephthalate crimped yarn after dry heat treatment. A constant load that gives a tension of total fineness dtex × 0.882 mN (90 mg / dtex) is applied to the sample yarn, and after 10 seconds, the sample length (Lc1) is measured. Next, a constant load that gives a tension of a total fineness of dtex × 0.0176 mN (1.8 mg / dtex) is applied to the sample, and after 10 minutes, the sample length (Lc2) is measured. The dry heat crimp rate (%) is obtained from the following formula.

  Dry heat crimp rate (%) = [(Lc1-Lc2) / Lc1] × 100

[Bulky]
When the carpet was viewed from directly above, it was visually evaluated in a state where the base fabric could be seen from the gap between the pile skins. Invisible (◎), difficult to see (○), somewhat visible (△), well visible (×)

[Abrasion resistance]
The abrasion resistance of the carpet was in accordance with a Taber type abrasion tester (specified in JIS L 1096.17.3). Using an H-18 wear wheel, a load of 9.8 N is applied to each wear wheel, the test table is rotated 300 times or 1,000 times to wear the test piece, and the amount of wear of the pile yarn is measured.
The Taber wear amount (% by mass) is obtained from the following formula.
Taber wear amount (mass%) = pile drop-off mass of wear ring part after test / pile part mass of wear ring part before test x 100%

Hereinafter, the present invention will be described in detail using examples.

<Example 1>
[Manufacturing of an original polytrimethylene terephthalate crimped yarn made of plant-derived raw material: 1,170 dtex / 60 filament: 1,170T-60f]
An original polytrimethylene terephthalate crimped yarn was produced using a production apparatus having the configuration shown in FIG. 100 parts by mass of polytrimethylene terephthalate chip (Intrinsic viscosity: 1.02, melting point: Tm = 228 ° C.) is charged from the polytrimethylene terephthalate resin inlet (10), while carbon made of the same polytrimethylene terephthalate resin 4 parts by mass of a black 25% by mass kneading master batch was introduced from the additive inlet (11) and melt-kneaded at 253 ° C. while degassing with a twin screw extruder (12). The content of carbon black as a colorant was 1.0% by mass.

  The spinning temperature of the spinning head (14) was 255 ° C., a filter of 600 mesh was used for the spinning pack (15), and it was discharged from a nozzle having 20 holes with a Y-shaped cross section, and three packs were spun together.

  The spun yarn was cooled and solidified with cold air (20 ° C. × 70%) of a spray cooling device (16) to obtain a polytrimethylene terephthalate multifilament with 60 Y-shaped cross sections.

  The spinning yarn is cooled and solidified, and then a 15% by weight water emulsion type oil agent for polytrimethylene terephthalate yarn is applied by an oiling device (17), and an unheated take-up roller (1) rotating at a speed of 615 m / min. ) To take over. The yarn was then preheated with a preheating roller (2) continuously heated to 65 ° C. at a speed of 621 m / min and wound on a drawing roller (3) at a speed of 647 m / min heated to 94 ° C. Then, it extended | stretched between the heat setting rollers (4) heated at 100 degreeC rotated at a speed | rate of about 2,380 m / min. The draw ratio was 3.68 times.

  Next, the drawn yarn was introduced into a heated fluid crimping apparatus (5), crimped with 190 ° C. and 0.6 MPa heated air, and cooled on the cooling drum (20). Next, the polytrimethylene terephthalate crimped yarn was subjected to entanglement treatment of 12 pieces / m with an entanglement treatment device (21), and with a winding tension of 0.05 cN / dtex, cheese ( 22) It wound up in the shape.

  The obtained black original polytrimethylene terephthalate crimped yarn 1,170T-60f has a Y-shaped irregular cross-sectional shape with a total fineness of 1,172 dtex / 60 filaments (single yarn fineness of 19.5 dtex) and a deformity of 3.4. It has physical properties of viscosity (IV) of 1.00, strength of 1.78 cN / dtex, elongation of 31.7%, hot water shrinkage of 2.1%, and dry heat crimp of 11.2%. It was.

[Production of Tufted Carpet: Examples 1-1 to 1-3]
Using a tufting machine, a non-twisted yarn of the above-mentioned black original polytrimethylene terephthalate crimped yarn as a pile yarn was used as the primary base fabric for tufted carpet made of polyester long-fiber nonwoven fabric, and gauge (1 inch: 2.54 cm / 10 stitches), stitches (number of piles / 10 cm), average pile length (mm), pile weight per unit area (g / m ² ) were changed. Table 1: <Example 1-1 in each standard A tufted pile original fabric of ~ 1-3> was prepared.

  Next, pre-coating of SBR latex was performed on the back side of the tufted pile raw fabric obtained by tufting the above black original polytrimethylene terephthalate crimped yarn as a pile yarn, and a tufted carpet was produced using a polyethylene resin sheet as a backing agent.

Table 1 shows the results of Taber abrasion test and bulkiness of carpets using untwisted polytrimethylene terephthalate crimped yarns of <Example 1> as pile yarns as <Examples 1-1 to 1-3>. Shown in

<Example 2>
[Manufacturing of an original polytrimethylene terephthalate crimped yarn made of plant-derived materials: 1,450 dtex / 60 filament: 1,450T-60f]
A black-trimmed polytrimethylene terephthalate crimp made from a plant-derived material in the same manner as in Example 1 except that the polymer discharge amount is set to 1450T-60f and the heat setting roller (4) temperature is set to 120 ° C. Yarn was produced.

  The obtained black original polytrimethylene terephthalate crimped yarn 1,450T-60f has a Y-shaped irregular cross-sectional shape having a total fineness of 1,448 dtex / 60 filaments (single yarn fineness of 24.2 dtex) and a deformity of 3.1. Viscosity (IV) has physical properties of 1.00, strength 1.86 cN / dtex, elongation 35.6%, hot water shrinkage 1.8%, dry heat crimp 14.8% It was.

[Production of Tufted Carpet: Examples 2-1 to 2-5]
Using a tufting machine, a non-twisted yarn of the above-mentioned black original polytrimethylene terephthalate crimped yarn as a pile yarn was used as the primary base fabric for tufted carpet made of polyester long-fiber nonwoven fabric, and gauge (1 inch: 2.54 cm / 10 stitches), stitches (number of piles / 10 cm), average pile length (mm), and pile weight per unit area (g / m ² ) were changed. A tufted pile original fabric of ~ 2-5> was prepared.

  Next, the back surface of the tufted pile original fabric obtained by tufting the untwisted polytrimethylene terephthalate crimped yarn as a pile yarn is pre-coated with SBR latex, and a tufted carpet is used with a polyethylene resin sheet as a backing agent. Manufactured.

Table 2 shows the results of Taber abrasion test and bulkiness of tufted carpets using non-twisted polytrimethylene terephthalate crimped yarns of <Example 2> as <Examples 2-1 to 2-5>. .

Tables 1 and 2 show comparative examples 1-1 to 1-2: nylon 6BCF, comparative examples 2-1 to 2-3: taber abrasion test results and bulkiness of tufted carpets using PETBCF. 3 shows.

[Manufacturing pile yarn made by twisting original polytrimethylene terephthalate crimped yarn]
(Manufacture of double-ply yarn for pile yarn)
After using the black original polytrimethylene terephthalate crimped yarn 1,450-60f obtained in <Example 2> and applying a lower twist: S200 T / m, an upper twist: Z200 T / m to obtain a double twisted yarn The pile yarn for tufted carpet was manufactured by twisting with hot air treatment at 130 ° C. in the Sussen heat set equipment.
(Manufacture of pile yarn (2 stranded yarn) x 2 stranded yarn)
Using the two twisted yarns obtained in the above (manufacturing of the two twisted yarns), applying the number of twists: Z60T / m to make two twisted yarns, then twisting with hot air treatment at 130 ° C in the Sussen heat set equipment The pile yarn for tufted carpet was manufactured.

[Manufacture of carpets: Examples 3-1 to 3-6, Examples 4-1 to 4-4]
Using a tufting machine, the pile yarn described above was applied to a primary base fabric for tufted carpet made of polyester non-woven fabric, gauge (1 inch: 2.54 cm / 10 stitches), stitch (number of piles / 10 cm), average The conditions of pile length (mm) and pile unit weight (g / m ² ) were changed, and the tufted pile original fabric of Examples 3-1 to 3-6 of Table 4 and the implementation of Table 5 were changed according to the respective standards. Tufted pile original fabrics of Examples 4-1 to 4-4 were prepared.

  Next, the back surface of the tufted pile original fabric tufted with pile yarn was pre-coated with SBR latex, and a tufted carpet was produced using a polyethylene resin sheet as a backing agent.

  The results of the Taber abrasion test and bulkiness of these carpets are shown in Tables 4 and 5 as Examples 3-1 to 3-6 and Examples 4-1 to 4-4, respectively.

Table 5 shows the results of the Taber abrasion test and bulkiness of the carpets of Comparative Example 3: Nylon 6BCF and Comparative Example 4: PETBCF.

It is a schematic block diagram which shows an example of the manufacturing apparatus used with the manufacturing method of an original polytrimethylene terephthalate crimped yarn. It is explanatory drawing of the irregularity degree of a thread | yarn.

1: take-up roller 2: preheating roller 3: stretching roller 4: heat setting roller 5: heated fluid crimping device 10: polytrimethylene terephthalate resin inlet 11: additive inlet 12: twin screw extruder 14: spinning head 16: Spray cooling device 17: Oiling device 20: Cooling drum 21: Entangling device 22: Cheese

Claims (3)

Taber-type abrasion test of carpet skin using carpets made of plant-derived raw material polytrimethylene terephthalate crimped yarns that use the crimped yarns satisfying the following characteristics (1) to (7) at the same time as pile yarns The carpet characterized in that the wear amount of the pile yarn by (wear wheel: H-18, 300 times of wear) is 2 to 15% by mass.
(1) The cross-sectional shape of the single fiber is an irregular cross-sectional shape, and the degree of irregularity expressed by the ratio (B / A) of the circumscribed circle diameter (B) to the inscribed circle diameter (A) of the fiber cross section is 1. 8-4.5
(2) Intrinsic viscosity (IV) 0.7-1.3
(3) Strength is 1.5 to 2.5 cN / dtex
(4) Elongation is 25-60%
(5) Single yarn fineness of 10 to 25 dtex
(6) Hot water shrinkage is 1-5%
(7) Dry heat crimp rate is 5-25% Taber-type abrasion test of carpet skin using carpets made of plant-derived raw material polytrimethylene terephthalate crimped yarns that use the crimped yarns satisfying the following characteristics (1) to (7) at the same time as pile yarns The carpet characterized in that the wear amount of the pile yarn by (wear wheel: H-18, 1,000 times of wear) is 3 to 30% by mass.
(1) The cross-sectional shape of the single fiber is an irregular cross-sectional shape, and the degree of irregularity expressed by the ratio (B / A) of the circumscribed circle diameter (B) to the inscribed circle diameter (A) of the fiber cross section is 1. 8-4.5
(2) Intrinsic viscosity (IV) 0.7-1.3
(3) Strength is 1.5 to 2.5 cN / dtex
(4) Elongation is 25-60%
(5) Single yarn fineness of 10 to 25 dtex
(6) Hot water shrinkage is 1-5%
(7) Dry heat crimp rate is 5-25% The average pile length of the carpet skin using the pile yarn of the original polytrimethylene terephthalate crimped yarn made of the plant-derived material is 5 to 15 mm, and the pile basis weight is 300 to 3,000 g / m ^2. The carpet according to claim 1 or 2 .