JPH06207335A - Fiber for carpet and its production - Google Patents

Abstract

PURPOSE:To decrease stripe-patterned unevenness frequently occurring in tufted carpet produced by using continuous synthetic fiber yarn as tussel yarn. CONSTITUTION:Two or more kinds of fibers are used in a continuous synthetic fiber yarn and at least two kinds of the constituent fibers are made to have different yarn lengths to make the stripe unevenness to be inconspicuous.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber yarn made of continuous fibers and a method for producing the same, which forms a carpet having a highly uniform appearance when it is used as a tuft of a carpet. The carpet fiber of the present invention can be used for all types of carpet using a carpet fiber composed of continuous fibers, and particularly exhibits excellent performance as a tuft of tufted carpet.

[0002] The carpet fiber of the present invention has an advantage that streak-like gloss unevenness and hue unevenness, which often occur in continuous fiber carpet fibers, hardly occur.

[0003]

2. Description of the Related Art With the development of synthetic fibers, the mainstay of carpet fibers has shifted from wool to synthetic fibers. It is considered that the cause of this tendency is that synthetic fibers are suitable for carpets in terms of performance, but rather it is more advantageous in terms of cost over wool.

Synthetic fiber carpet fiber forms have long been used in staple form, similar to wool. This is thought to be due to the advantage that there is little difference from wool in terms of product form, but it is not always rational from the viewpoint of manufacturing synthetic fibers. Synthetic fibers are originally produced as continuous fibers, but staples are naturally disadvantageous in terms of cost because they require extra steps such as cutting and spinning. Further, in the case of a carpet made of spun yarn, since the single fiber is cut short, there is a problem that a large amount of fiber comes off due to friction. In the case of wool, this problem has been solved to some extent by felting, but synthetic fibers cannot be entangled by felting.

When making carpet fibers from continuous synthetic fibers, crimping the fibers is an essential condition. This is because when a fiber having no crimp is processed into a carpet, the tuft yarn has a low bulk, so that a large amount of fiber is required and the cushioning property and the resilience are poor. Conventionally, the development of a technique for providing crimps to synthetic continuous fibers has been actively promoted, and several types of high-speed techniques capable of being directly connected to the spinning and drawing process to be processed have been developed. Since these techniques are high-speed and highly efficient, they all have a low production cost, but it has been found that there are frequent problems that are not found in spun yarn carpets. This defect is often seen especially in tufted carpets, and streaks of different gloss and different hues appear parallel to the running direction of the tufted needles.

Mottling similar to this is not known for crimped yarns that have been widely used in the past. The reason for this is thought to be that the conventional crimped yarns are relatively thin yarns and are mostly false twisted yarns, whereas the crimping of carpet fibers is stuffing or shaping. Since it is extremely difficult to perform false twisting on a thick yarn such as carpet fiber, it is unlikely to use the false twisted yarn for carpet in the future.

[0007]

SUMMARY OF THE INVENTION It is an object of the present invention to solve the problem of conventional continuous fiber yarns for carpets, in which streaks having different gloss and different hues appear.

[0008]

The present invention is characterized by comprising two or more kinds of continuous fibers, the yarn bundle of the continuous fibers having a yarn length difference of 1 to 25%, and having a stuffing crimp. It is a fiber for carpet. The two or more continuous fibers of the present invention may be any combination of fibers as long as they have a yarn length difference of 1 to 25%. To measure the difference in yarn length, take a sample as long as possible, divide this into single fibers, and measure the fiber length. Next, the top 10% excluding the maximum and minimum values
And the lower 10% of the measured values are averaged, the lower average is expressed as a percentage with the upper average being 100, and the difference between the upper and lower is taken as the yarn length difference. The length of the sample is preferably 30 to 50 cm, but it is not possible to take a long sample because the continuous fiber for carpet is often interlaced. In this case, a sample having a length of 50 cm or more is applied with tension enough to extend most of the crimps, and the sample is cut out including one interlace node.

Carpet fibers composed of continuous fibers include
Usually, stuffing or crimping is applied. The method of the present invention is effective for providing a stuffing crimp. The stuffing crimping method includes a method using an air flow and a method using a nip roller, but the method of the present invention is effective in any case. The crimping is preferably performed continuously with the stretching step. It is most preferable to apply the crimps continuously after the spinning and drawing steps because the cost is low.

The carpet fiber comprising two or more continuous fibers is preferably two or more polyester fibers having different intrinsic viscosities, or two or more nylon fibers having different relative viscosities, or two or more having different melt flow rates. Of polypropylene fiber. Here, as the intrinsic viscosity of the polyester fiber, a value measured at 30 ° C. using an equal mixture of tetrachloroethane and phenol or orthochlorophenol as a solvent is used. As the relative viscosity of nylon fiber, a value measured with a 1 g / 100 ml solution using 96% sulfuric acid as a solvent is used. The melt flow rate of the polypropylene fiber is measured using a melt index measuring device at a measurement temperature of 230 ° C. and a load of 2160 g. For each fiber, the difference in viscosity of each component is that the viscosity of the lowest viscosity component is 1 with respect to the viscosity of the highest viscosity component.
It is preferably ˜35% lower. If the difference in viscosity is too small, the effect of the present invention cannot be sufficiently exerted, and if it is too large, unstretched portions tend to remain during stretching, which is not preferable. The difference in viscosity is most preferably 2.5 to 17.5%.

Another preferred embodiment of carpet fibers consisting of two or more continuous fibers is a mixture of fibers differing in melting point by 2 ° C. or more. Since fibers having a low melting point in the same series of polymers generally have a low elastic modulus, when they are drawn in parallel with the fibers having a high melting point, they shrink a little when the tension is removed, causing a slight dimensional difference. Fibers with a low melting point have a large shrinkage ratio inside the stuffing box, so
If both effects are combined, there will be a considerable dimensional difference, and if the melting points differ by about 2 ° C., the homogenizing effect of the present invention will occur. Fibers with a low melting point generally have a high dye absorption rate,
Shows a tendency to be dyed in a dark color. In the carpet fiber of the present invention, the fiber having a low melting point easily enters the inside of the fiber bundle due to the dimensional difference of the constituent fibers. The fact that the dark-colored fibers are present inside the fiber bundle at a high density has the advantage of making it difficult to sense the hue unevenness of the fibers and making it difficult to see stains, but reduces the coloring efficiency of the dye,
There is a drawback that the dyeing cost increases. From this viewpoint, the difference in melting point is most preferably 5 to 20 ° C.

As yet another embodiment of the carpet fiber comprising two or more kinds of continuous fibers of the present invention, a recycled resin is used as a raw material, and the mixing ratio of the recycled resin is different. The blending of the recycled resin may be performed on all the continuous fibers or a part of the continuous fibers. Since the recycled resin is repeatedly melted, the degree of polymerization is lowered in the case of polyester fiber and polypropylene fiber, and the depolymerization and the formation of cross-linkage are occurred in the case of nylon fiber. In the case of either fiber, the blending of the recycled resin is low cost and easy to carry out in order to generate a dimensional difference. It is considered that the present invention has a very high spinnability, has less thread breakage even in the case of a recycled resin, and is particularly easy to carry out with a polyester fiber in which a large amount of the recycled resin can be obtained relatively easily, and is considered to be valuable.

A preferred embodiment of the method for producing a carpet fiber consisting of two or more continuous fibers of the present invention is such that the drawing is carried out continuously in the melt spinning step, and the boiling water shrinkage obtained at that time is 0. The fibers are mixed by 8 to 20%, treated, and then crimped by being pressed into the stuffing box with heated gas. Mixing different fibers can be done by spinning different types of resin from different spinning holes in the same spinneret, spinning different types of resin from different spinnerets and aligning them in the cooling process or lubrication process, or different spinning processes. A method of aligning fibers obtained by spinning a different type of resin from a die in a drawing step is used. The boiling water shrinkage of the fiber obtained in the drawing step is 0.8 to 20%, but the dimensional difference after crimping is 1
Corresponds to ~ 25%. Pressurized air or superheated steam can be used as the heating gas used to apply the crimps, but the superheated steam is suitable for high-speed processing because it has a higher heat conduction and a higher sonic velocity.

[0014]

The streak-like unevenness, which appears relatively frequently in the carpet fiber made of continuous fibers, is presumed to be due to the fact that this fiber has a fairly long-period nonuniformity. Introducing a yarn length difference between the single fibers constituting the continuous fiber is considered to give a non-uniformity of a short cycle, but it is considered that the non-uniformity of the long cycle becomes inconspicuous due to this non-uniformity. .

[0015]

EXAMPLES The present invention will be described in more detail with reference to the following examples.

Example 1 48 super bright polyester filaments of triangular cross section having an intrinsic viscosity of 0.55 measured with a mixed solution of tetrachloroethane and phenol, and 96 semi-dallar polyester filaments of triangular cross section having an intrinsic viscosity of 0.58. And 48 semicircular polyester filaments having a circular cross section with an intrinsic viscosity of 0.63 (both filaments have the same single fiber denier) were spun and aligned, and immediately oiled, continuously drawn, and then continuously. ,
It was sucked by steam heated to 200 ° C. and having a pressure of 4.5 kg · G / cm ² , sent to a stuffing box to be crimped, further interlaced and wound up. The obtained fiber was 1986 denier and had a yarn length difference of 5.5%.

Using this fiber as a tuft, it was processed into a tufted carpet by a conventional method. Row spacing of tufts 4.2m
No unevenness due to gloss or crimp was observed in the loop carpet having a pitch of 4.5 mm and a pitch of 4.5 mm.

Comparative Example 1 All the polyester of Example 1 was changed to one having an intrinsic viscosity of 0.63, and spinning, drawing, crimping and entanglement were performed under the other conditions in the same manner to produce a fiber. The resulting 1994 denier fibers had a yarn length difference of 0.4% between the single fibers. When this fiber was processed into a tufted carpet in the same manner as in Example 1, a streak-like defect having a large gloss was found to be 1 m ^2.
There were 23 per hit.

Example 2 Instead of superbright polyester having an intrinsic viscosity of 0.55 in Example 1, recycled pigment-free polyester resin (mixture of approximately equal amounts of film ear waste and bottle waste), an intrinsic viscosity of Instead of 0.58 semidal polyester, an equal mixture of recycled polyester resin and regular polyester resin was used. The intrinsic viscosities after spinning were 0.55 and 0.58, respectively. The difference in yarn length between the single fibers was 6.3%. When the obtained fiber was processed into a tufted carpet, a fiber having few defects was obtained as in Example 1.

Example 3 36 super bright nylon 6 filaments with a triangular cross section having a relative viscosity of 2.31 measured with a 96% sulfuric acid aqueous solution, and 72 semi-dal nylon 6 filaments with a triangular cross section having a relative viscosity of 2.57. , And 36 semicircular nylon 6 filaments with a circular cross section having an intrinsic viscosity of 2.64 (both filaments have the same monofilament denier) were spun, aligned, and immediately fed, immediately and continuously drawn, and then continuously. , 3.5k overheated to 165 ℃
It was sucked with water vapor of g · G / cm ² , sent to a stuffing box to be crimped, further interlaced and wound up. The obtained fiber was 1986 denier and had a yarn length difference of 4.7%. Using this fiber as a tuft, it was processed into a tufted carpet by a conventional method.
No loop unevenness due to glossiness or crimp abnormality was found in the loop carpet having a tuft row interval of 4.2 mm and a pitch of 4.6 mm.

Comparative Example 2 Instead of the nylon 6 filament of Example 3, a continuous fiber yarn was prepared with a relative viscosity of all 2.3. The obtained fibers had a yarn length difference of 0.3%. A tufted carpet obtained by using this fiber in the same manner as in Example 3 had 17 streaks per 1 m ² .

Example 4 60 super bright polypropylene filaments having a triangular cross section with a melt flow rate of 22.3, 120 semi-hollow polypropylene filaments with a hollow square cross section having a melt flow rate of 15.7, and a melt flow rate of 12 60 semi-dal polypropylene filaments with a circular cross-section of 6 (all filaments have the same single fiber denier) were spun and aligned for oiling, immediately and continuously drawn, and then continuously heated to 145 ° C. It was sucked with 2.8 kg · G / cm ² of water vapor, sent to a stuffing box to be crimped, further interlaced and wound up. The obtained fiber was 2861 denier and had a yarn length difference of 8.7%. Using this fiber as a tuft, it was processed into a tufted carpet by a conventional method. No streaks due to gloss or crimp abnormalities were found in the loop carpet having a tuft row interval of 5.2 mm and a pitch of 6.1 mm.

Example 5 Various combinations of polyester fibers were used to examine the occurrence of streak unevenness in a tufted carpet while varying the yarn length difference. The results are shown in Table 1.

[0024]

[Table 1]

[0025]

INDUSTRIAL APPLICABILITY The carpet fiber of the present invention can be used for all types of carpets that use a carpet fiber composed of continuous fibers, but particularly exhibits excellent performance as a tuft of tufted carpet. INDUSTRIAL APPLICABILITY The carpet fiber of the present invention has an advantage that streak-like uneven gloss and uneven hue, which often occur in carpet fibers made of continuous fibers, hardly occur.

Claims (7)

[Claims] 1. A carpet fiber comprising two or more kinds of continuous fibers, a yarn bundle of the continuous fibers having a yarn length difference of 1 to 25%, and a stuffing crimp. 2. The two or more continuous fibers according to claim 1,
A carpet fiber characterized by being polyester fibers having different intrinsic viscosities. 3. The two or more continuous fibers according to claim 1,
A carpet fiber characterized by being nylon fibers having different relative viscosities. 4. The two or more continuous fibers according to claim 1,
A carpet fiber characterized by being polypropylene fibers having different melt flow rates. 5. The two or more continuous fibers according to claim 1,
A carpet fiber having a melting point different by 2 ° C. or more. 6. A carpet fiber, wherein the two or more kinds of continuous fibers according to claims 1 to 5 have different blending ratios of recycled resin. 7. A stretching process is carried out continuously in the melt-spinning step, and fibers having different shrinkages of boiling water obtained at that time are mixed and treated, and then stuffing box is heated with heated gas. A method for producing a carpet fiber comprising continuous fibers, which comprises press-fitting the inside to impart crimps.