JPH0470413B2 - - Google Patents

Description

[Detailed description of the invention]

<Industrial Application Field> The present invention relates to a method for producing a mixed fiber yarn for carpet. More specifically, the present invention relates to a method for producing a mixed fiber yarn for nylon BCF carpets that can be dyed in a wide range of hues with strong contrast. <Prior art> Conventionally, nylon BCF mixed yarns made of two or more fibers that have been differently dyed and/or have different dyeability, or dyed polyester BCF yarns or polypropylene BCF yarns and undyed nylon BCF yarns. The mixed fiber yarn is used as a mixed fiber yarn for carpet,
The manufacturing method thereof is known (Japanese Patent Application Laid-Open No. 52-31152 or 1987-148932). By the way, mixed fiber yarns that are different dyed require a yarn dyeing process, making the production process complicated and requiring a long time to process. There is a problem with degree or heterochromatic contrast. For blended yarns made of polyester BCT dyed yarns or polypropylene BCF dyed yarns and nylon BCF yarns, the ratio of mixed fibers such as polyester yarns is usually high, and the hue of the blended yarns is dominated by the hue of polyester yarns, so dyeing is fast. It is difficult to obtain a blended fiber yarn for carpets that has a wide range of multicolor discoloration effects with high strength and strong contrast, and does not satisfy the recent diversification of demand and demands for high functionality. <Purpose of the Invention> In view of the above circumstances, the present inventors have developed the present invention for the purpose of providing a mixed fiber yarn for carpets that is anti-dyed, has strong contrast, and can obtain a wide range of hues, and a method for producing the same. It has arrived. <Structure of the Invention> That is, the present invention provides “dyed polyester filament fiber (A)
and a crimped polyacid filament fiber (B) are guided into a mixing treatment nozzle to produce a mixed fiber yarn having a mixed fiber portion and a non-mixed fiber portion.
A fluid with a pressure of 3 to 7 kg/cm ² is injected perpendicularly to the fiber axis direction in a fiber mixing nozzle so that the following conditions are satisfied, and the fiber (A) is directly supplied to the nozzle. A method for producing a mixed fiber yarn for carpeting, which has a spread mixed fiber portion and a knotted non-mixed fiber portion. (B) Ratio of constituent numbers: Fiber (B)/Fiber (A) 0.5 to 2.0 (B) Fiber length: Fiber (A)/Fiber (B) 1.0 to 1.1 (C) Mixing ratio: Fiber (B)/ [Fiber (A) + Fiber (B)] 0.8 to 0.95 (d) Degree of entanglement between fiber (A) and fiber (B) 35 to 55 strands/m. First, the outline of the steps of the manufacturing method of the present invention will be explained with reference to the drawings. FIG. 1 is a schematic diagram of the process. The crimped polyacid filament fiber (B) 6 is fed to a fiber mixing nozzle 2 via a feed roller 1. Unwinding tension is applied between feed roller 1 and creel, and overfeed rate -0.45% is applied between feed roller 1 and delivery roller 3.
The fibers are mixed under the tension of On the other hand, the dyed polyester filament fiber (A) 7 is directly supplied to the mixed fiber processing nozzle 2 without passing through the feed roller 1. Its supply tension is 0.03 g/d or less. Also, inside the nozzle, the compressed air 5 enters in a direction perpendicular to the yarn guide, and since the entrance hole diameter is larger than the exit hole diameter of the yarn, the compressed air 5 is exhausted from the yarn entrance in a backflow manner with respect to the fibers, so it follows this. The fiber (A) 7 is also supplied in an amount necessary and sufficient for the fiber blending process. Therefore, the fibers (A) 7 are not supplied in excess of what is necessary and no loop fluff is produced. Thus fiber (A)7
The fibers (B) 6 are mixed and entangled in a turbulent region within the nozzle, and then passed through a roll 3 and wound into cheese at 4. In addition, FIG. 3 is a side view of the pile yarn obtained by the manufacturing method of the present invention. Fiber (A) 7 and Fiber (B) 6
The fiber (A) 7 and the fiber (B) 6 are each bundled together and intertwined and knotted with a small amount of single yarn mixed fibers. It consists of a section 7 (knotted non-mixed fiber section). FIG. 4 is a side view of a carpet using this as pile yarn.
The pile yarn tufted into the base fabric is mixed and opened to create a deep colored pile part, and fibers (A) 7 and fibers (B) 6 are each focused, intertwined and knotted, resulting in a strong color contrast. It consists of floating nodular pile parts. FIG. 5 is a side view of a comparative pile yarn obtained by processing fiber (A) 7 and fiber (B) 6 in one feed. The opening and entangling of the fibers (A) 7 with respect to the fibers (B) 6 is insufficient, and the fibers (A) 7 are not sufficiently intertwined at the fiber breaking section, resulting in poor intertwining of the fibers (A) 7, resulting in loops and fuzz. Even in the side view of the carpet pile yarn (Figure 6), there are many loops and fuzz in the fibers (A), which causes problems when walking. Durability and abrasion resistance are also low. FIG. 7 is a side view of the pile yarn when the tension at which the fiber (A) is fed to the nozzle is increased. Compared to fiber (B) 6, fiber (A) 7 is less likely to open.
Therefore, the fibers (A) 7 are poorly mixed and entangled, and the fibers (A) 7 are located at the core of the fibers (B) 6, so that a sufficient color mixing effect cannot be obtained. FIG. 8 is a side view of a carpet using this pile yarn. The dyed polyester filament fibers (A) used in the present invention are polyester filament yarns (including crimped polyester filament yarns) that have been solution colored or dyed in thread form. Factors related to the degree of fiber mixing include the feeding direction of the yarn air turbulence nozzle, the number of feeds, overfeed rate (OF rate), and air pressure. On the other hand, undyed nylon BCF yarn is made of polyamides such as nylon 6,
It is a polyamide crimped yarn that is a multifilament yarn made of nylon 66 or a copolymer thereof, and has three-dimensional non-helical crimps with random crimps. The filament cross-sectional shape of each single yarn may be triangular, round, triangular hollow, etc., the single yarn fineness is 10 to 40 deniers, and the total fineness is 500 to 40 deniers.
2000 denier is preferable. This undyed nylon
BCF yarn is a deep dyed type (DR) for acid dyes,
There are standard types (SH), light dyed types (P), and types dyeable with cationic dyes (CZ), and these are used singly or in combination.
Here D: Deep dyeable.Semi Bright R: Deep dyedble.Semi Pull S: Acidic Standard dyeable.Semi Bright H: Acidic Standard dyeable.Semi Dull P: Pale dyeable.Semi Bright C: Cation dyeable.Semi Bright Z: Cation dyeable .Semi Dull Next, the method of mixing polyester filament dyed yarn and undyed nylon BCF yarn depends on the elongation of the polyester dyed yarn or undyed nylon BCF yarn,
Since each crimp rate is different, it is preferable to use a 2-feed system in which each is treated individually.
~10% overfeed (OF) is required. That is, a polyester filament dyed yarn with low elongation requires an OF of 8 to 10%, but an OF of 2 to 3% is sufficient for a spun-dyed polyester woolly yarn. In other words, the OF ratio has a strong relationship with elongation. In addition, if there are large fluctuations in the amount of yarn fed due to fluctuations in the unwinding tension, the fibers will be mixed poorly and the polyester filament yarn will easily separate into large loops, so it is necessary to minimize the fluctuation in the amount of yarn fed as much as possible. . One method is to uniformly adjust the yarn feeding tension and overfeed rate to the fiber mixing nozzle. Another method is to feed nylon BCF yarn from a creel through a feed roller as usual, while feeding polyester dyed yarn directly to the nozzle. At this time, the yarn feeding tension is kept as low as possible, and excessive supply of polyester dyed yarn is controlled by backflow of compressed air in the fiber mixing nozzle. In the case of this method, the degree of blending is increased and the nylon BCF
Even if the yarn feeding amount fluctuates, the polyester dyed yarn will not be supplied in excess, and the polyester dyed yarn will not separate into loops. Also,
The strength of entanglement is maximum when the air is injected perpendicularly to the direction of the yarn axis, that is, the direction of the yarn axis, and as the air injection angle with the yarn axis decreases, the entanglement becomes weaker. As mentioned earlier, if the intertwining of the mixed fiber yarn is weak, it will easily separate due to external forces such as tension and temperature applied to the mixed fiber yarn in processes after tufting, resulting in loss of efficiency, grace, and quality. The nylon ratio of the blended yarn thus obtained is 80.
~95% is desirable; if the polyester ratio exceeds 20%, the hue of polyester becomes dominant, resulting in a narrow hue density range of the resulting carpet and a decrease in physical properties of nylon (abrasion resistance, elastic properties, etc.) . In other words, polyester/black dope-dyed yarn
When mixed at 30%, even if a light hue is added to the nylon color, it will remain in the charcoal gray range, leaving only a dark color scheme. On the other hand, if it is less than 5%, it cannot sufficiently fulfill its role as an effect yarn. When the number of mixed fiber yarns is approximately the same for nylon and polyester, the color difference between the mixed fiber portion and the non-mixed fiber portion becomes large, and a span-like color mixing effect is obtained. That is, although it depends on the size of the single filament fineness of the nylon BCF yarn, it is usually preferably about 0.5 times to twice the number of polyester yarns. In other words, the single yarn fineness of polyester filament yarn is 2 to 5 deniers, but the single yarn fineness of nylon BCF yarn is
10-40 deniers are used. In addition, it is desirable that the yarn length of polyester filament yarn is equal to or less than 10% of that of nylon BCF. That is, high elongation spun-dyed polyester crimped yarns have approximately the same length, low elongation polyester filament yarns are nearly 10% longer, and cheese-dyed polyester crimped yarns are 6 to 7% longer. That is, it depends on the elongation of the polyester thread. In other words, the dyed yarn with lower elongation,
It is necessary to increase the OF ratio compared to nylon BCF yarn. In addition, the air pressure during mixed fiber processing is 5 to 6 kg/cm ²
is desirable; outside this range, the degree of entanglement will decrease or it will be difficult to form a uniform mixed fiber yarn. The thus obtained mixed yarn of colored polyester yarn and nylon BCF yarn can be used alone or as a double yarn. When used as a double yarn, it is used for carpet pile yarn as a single-twisted yarn or a plied yarn with other nylon BCF double yarns. It is possible to obtain a wide range of hues economically in a short period of time. <Effects of the Invention> Anti-dyed loop carpet using a pile yarn as a carpet blend yarn made of dyed polyester filament fibers (A) and crimped polyacid filament fibers (B) produced by the method of the present invention. is fiber
The mixing ratio of (A) is kept low at 5-20%, and the number of fibers (A) is almost the same as that of fibers (B), so the blended fiber part (spread part) has a spun-like and mild depth. Shows a certain color effect. On the other hand, since the fibers are bundled together in the non-mixed fiber part (knot part), a strong color contrast is expressed. This effect is caused by a specific effect on fiber (A) and fiber (B).
(a) Ratio of constituent numbers, (b) Fiber length, (c) Fiber ratio, (d) Fiber
Under the conditions of the degree of entanglement between (A) and fiber (B), a fluid with a pressure of 3 to 7 kg/cm ² is injected perpendicularly to the fiber axis direction in a fiber mixing nozzle, and the fiber (A) is This is due to the special two-feed mixed fiber treatment in which the fibers are directly supplied to the nozzle. Furthermore, the obtained carpet yarn has high durability and abrasion resistance. Furthermore, by adjusting the color density and blending ratio of the fibers (A), carpets with a wide range of hues and contrasts can be manufactured. <Examples> Examples of the present invention will be described below, but the present invention is not particularly limited to these Examples. Example 1 Regular type nylon 6 multifilament crimped yarn (S type; 1300 denier/68 filaments) and dark dyed nylon 6 multifilament crimped yarn with circular cross section (D type; 1300 denier/68 filaments) Supply speed by aligning
Three black threads of polyester filament crimped thread (semi-dull 75 denier/36 filament) were fed to a 450 m/min feed roller, then passed through a blending nozzle, and dyed in black and light brown using a cheese dyeing machine. , pull together three light brown threads
The nylon 6 multifilament crimped yarn and the polyester filament crimped yarn were passed directly through the mixing treatment nozzle with a supply tension of 0.013 g/d, and the overfeed rate was -0.45% and the air pressure was 6.
The mixed fiber treatment was carried out under the condition of Kg/cm ² . First, the obtained mixed fiber yarn was used as it was as a pile yarn (Table 1, Prototype No. 1). On the other hand, this mixed fiber yarn subjected to S twist processing with a twist count of 40 times/m was used as a pile yarn (Table 1, Prototype No. 2). Also, for comparison, two nylon 6 multifilament crimped yarns same as above, three black yarns of polyester filament crimped yarn same as above, and three light brown yarns.
The supply tension of the polyester filament crimped yarn to be supplied to the mixed fiber processing nozzle was set to 0.044 g/d.
A mixed fiber yarn was obtained by carrying out the blending treatment under the same conditions as above (Table 1, Prototype No. 3). Furthermore, a total of 8 crimped yarns, 2 nylon 6 multifilament crimped yarns as above, 3 black yarns and 3 light brown yarns of the same polyester filament crimped yarns as above, were arranged at a feeding speed of 450 m/min. The yarn was fed to a feed roller, and then passed through a mixing nozzle, and subjected to mixing treatment under the conditions of an overfeed rate of -0.45% and a compressed air pressure of 6 kg/cm ² to obtain a mixed fiber yarn (see Table 1).
No. 4). Each of the four types of pile yarns obtained was tufted using a loop pile tufting machine under the following conditions: gauge 1/10 inch, stitches 6.3/inch, pile height 5 mm, pile weight 550 g/m ² . Dyeing in two colors was carried out using a continuous dyeing machine under the conditions of a steamer temperature of 100°C and a steam time of 5 minutes. 1 batch is acid dye Tectilon
It was dyed using Yellow 4R (manufactured by CIBA-GEIGY) at a dye concentration of 0.1 g/l to emphasize the contrast with the black thread of the polyester filament crimped thread. The other batch is gold-containing dye Isolan Gray.
Using PGL (manufactured by BAYER), dye concentration 2.0g/
1 to emphasize the contrast between the polyester filament crimped yarn and the light brown yarn. The obtained loop pile carpet had the properties shown in Table 1.

【table】

[Table] **See Figures 7 and 8

***See Figures 5 and 6

That is, the loop pile carpets (prototype Nos. 1 and 2) using the mixed fiber yarn of the present invention are different from the conventional nylon yarn.
It is possible to express a mixed fiber color effect in a range that cannot be expressed with 100% BCF anti-dyed carpet, and it has a tweed-like color mixing effect, and is also excellent in terms of pile surface, texture, and abrasion resistance. The carpet was useful not only for general household use but also for contrast purposes. Example 2 Regular type nylon 6 with triangular hollow cross section
A multifilament crimped yarn (H type; 830 denier/46 filaments) and a nylon 6 multifilament crimped yarn (Z type; 830 denier/46 filaments), which has a triangular hollow cross section and is dyeable with cationic dyes, are prepared. It was fed to a feed roller with a feeding speed of 450 m/min, then passed through a mixing nozzle, and two black spun-dyed polyester filament yarns (75 denier/36 filament) were pulled together and mixed directly with a feeding tension of 0.013 g/d. Pass through a fiber processing nozzle to alternately intertwine nylon 6 multifilament crimped yarn and polyester filament yarn, overfeed rate -0.45%, air pressure 6
The mixed fiber treatment was carried out under the condition of Kg/cm ² . Two of the obtained mixed yarns were combined and subjected to a cape ring twisting process of first twist (Z direction) and second twist (S direction) at a twist rate of 60 times/m to make a pile yarn (Table 2, Prototype No. 5). On the other hand, for comparison, one black spun-dyed polyester filament yarn (75 denier/36 filament) and two nylon 6 multifilament crimped yarns mentioned above.
A mixed fiber yarn was obtained by performing a blending process under the same conditions as above, and then a twisting process was performed in the same manner (second
Table, prototype No. 6). Furthermore, for comparison, six black spun-dyed polyester filament yarns (75 denier/36 filaments) and two nylon 6 multifilament crimped yarns were used, and mixed fibers were treated under the same conditions as above. After obtaining the yarn, it was twisted in the same manner (Table 2, Prototype No. 7). Each of the three types of pile yarns obtained was tufted using a loop pile tufting machine under the conditions of a gauge of 1/10 inch, stitches of 6.3/inch, pile height of 4.5 mm, and pile weight of 600 g/ ^m2 . Next, using a continuous dyeing machine, acid dye Tectilon Yellow 4R (manufactured by CIBA-GEIGY) was applied.
and cationic dye Astrazon Biue 5GL (manufactured by BAYER) under the conditions of a steamer temperature of 100°C and a steam time of 5 minutes. The obtained loop pile carpet had the properties shown in Table 2.

【table】 [Brief explanation of the drawing]

FIG. 1 is a schematic diagram of the steps of the manufacturing method of the present invention. FIG. 2 is a cross-sectional view of the mixed fiber processing nozzle. FIG. 3 is a side view of the carpet blend yarn of the present invention. FIG. 4 is a sectional view of a carpet using the mixed fiber yarn of the present invention. FIG. 5 is a side view of a comparative pile yarn obtained by processing fiber (A) 7 and fiber (B) 6 in one feed. FIG. 6 is a sectional view of a carpet using the mixed yarn of FIG. 5. FIG. 7 is a side view of a comparative mixed yarn when the fiber (A) 7 was mixed at a feeding tension of 0.044 g/de. FIG. 8 is a sectional view of a carpet using the mixed yarn of FIG. 7. 1: feed roller, 2: nozzle, 3: draft roller, 4: winding cheese, 5: compressed air path,
6: crimped polyamide filament fiber (B), 7: polyester filament fiber (A), 8: mixed fiber portion of fiber (B) and fiber (A), 9: base fabric.

Claims (1)

[Claims] 1. Dyed polyester filament fiber (A)
and crimped polyamide filament fibers (B) are guided into a mixing fiber processing nozzle to produce a mixed fiber yarn having a mixed fiber portion and a non-mixed fiber portion.
A fluid with a pressure of 3 to 7 kg/cm ² is injected perpendicularly to the fiber axis direction in a fiber mixing nozzle so that the following conditions are satisfied, and the fiber (A) is directly supplied to the nozzle. A method for producing a mixed fiber yarn for carpeting, which has a spread mixed fiber portion and a knotted non-mixed fiber portion. (B) Ratio of constituent numbers: Fiber (B)/Fiber (A) 0.5 to 2.0 (B) Fiber length: Fiber (A)/Fiber (B) 1.0 to 1.1 (C) Mixing ratio: Fiber (B)/ [Fiber (A) + Fiber (B)] 0.8 to 0.95 (d) Degree of entanglement between fiber (A) and fiber (B) 35 to 55 pieces/m