JPH0823093B2 - Polyamide pile yarn for mat - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a pile yarn for mat which has a significantly improved curling resistance.

[0002]

2. Description of the Related Art As one of mats, there is known a mat which uses bulky continuous filament yarn (hereinafter referred to as BCF) of synthetic fiber, especially polyamide. This mat has the advantage that, in addition to the soft feel inherent to polyamide fibers and the durable bulkiness due to BCF, it exhibits excellent washing durability as well as favorable texture and appearance. On the other hand, the only drawback of this type of mat was the problem of curling when the mat was wet. This is a phenomenon in which the mat warps in a concave shape when viewed from the side of the mat when wet (Fig. 1). Not only does the appearance of the mat deteriorate significantly when the mat is used, but also the part where the user curls up further. An unforeseen situation such as being caught in a leg and falling will occur, and the functionality of the rug will be significantly impaired. In FIG. 1, 1 is a pile yarn, 2 is a base cloth, and 3 is a backing agent.

However, in the past, attempts to prevent curling of the mat have been made only slightly from the viewpoint of improving the backing agent. For example, in JP-A-59-15465,
An aqueous dispersion prepared by blending a styrene-butadiene copolymer rubber latex with an epoxy compound and a compound having an aziridine ring is described. Further, JP-A-63-12764 describes that a blocked isocyanate is contained in an aqueous dispersion of a high molecular polymer.

[0004]

However, since the backing agent itself is a dispersion liquid, it is necessary to ensure its stability, which requires a great deal of labor. In addition, according to the study of the present inventors, with this backing agent, sufficient curling prevention effect is not obtained and the improvement of the backing agent is just a coping therapy, and it is essential improvement based on the fundamental principle of curling occurrence. I also knew that I didn't care. If a pile yarn having an anti-curling function is realized regardless of the kind of the dispersion liquid, its commercial significance will be extremely great.

Therefore, an object of the present invention is to provide a polyamide pile yarn capable of preventing the curling phenomenon of a mat as much as possible without relying only on a backing agent .
It is possible to manufacture a mat that is well balanced in terms of performance.
It is to turn into Noh.

[0006]

DISCLOSURE OF THE INVENTION As a result of intensive studies conducted by the present inventors in order to achieve the above-mentioned object, the above-mentioned curling phenomenon shows that the base cloth and the pile yarn are bonded by a backing agent as shown in FIG. The present invention has been achieved by investigating the fact that it is caused by the difference in shrinkage due to water absorption of the two-layer structure (a kind of bimetal structure).

Thus, according to the invention, of polyamide
Processing continuous filament yarn Preheating temperature 100
Heating fluid under heat shrinkage of 5% to 15% at ℃ to 170 ° C
Bulky continuous filament obtained by processing
In a state in which the yarn is twisted, under moist heat of 100 ° C to 110 ° C,
Is a twist-set yarn that is heat-set under dry heat of 120 ° C to 180 ° C, and has a yarn elongation rate of 6% or less due to water application, a polyamide pile yarn for mat,
However, the elongation rate (L) complies with the following definition. The length of the polyamide pile yarn is fixed (1 m), and the sample length when a load of 0.01 g / de is applied is L ₀ . This sample at 20 ℃
After dipping in water for 1 minute, excess water on the surface was removed with a filter paper, a load of 0.01 g / de was applied, and the sample length after 1 minute was L ₁ , which is a value determined by the following formula.

L = (L ₁ −L ₀ ) / L ₀ × 100% In the present invention, the pile yarn is a yarn tufted (implanted) on the primary base cloth, and is made of polyamide, especially nylon-6, 6.
Composed of nylon 66. Needless to say, not only homopolymers of nylon-6 to 66 itself, but also copolymers or blends may be used as long as the physical properties of nylon-6 to 66 are not impaired. The combination and blend may contain additives, pigments and the like which are commonly used in this field. It is already known that a continuous filament yarn of polyamide is made into BCF by heating and fluid processing, and then twisted and twist set (twist set) to obtain a pile yarn for mat.

As an example of such fluid processing, in (A) the nozzle, the yarn plasticized by the heating fluid is padded (p).
a method of applying crimps while accumulating in the form of ad) or wad (US Pat. No. 4,188,691 and 4,26)
No. 8,940), (B) A method in which the yarn plasticized by the heating fluid in the nozzle is taken out as a loop yarn, cooled, and then drafted to open (US Pat. No. 3,185,15).
No. 5, No. 3,543,353), (C) The yarn plasticized by the heating fluid in the nozzle is buckled and deposited on the air-permeable collision surface, cooled in this state, and then taken out. Method (US Pat. No. 3,255,508, British Patent No.
1,273,797) is adopted.

In the meantime, in the mat in which the twist set yarn made of the polyamide obtained as described above is used for the pile yarn, a remarkable warp phenomenon occurs as shown in FIG. Speaking as a model, if a test piece obtained by sampling the mat in the tuft direction by 10 cm (width is a single row of tuft width) is immersed in water and left to stand, it will warp into a semi-arc shape (concave shape) in about 40 minutes. It will be easily understood that such a phenomenon causes not only the quality of the product but also a serious problem of falling as a product originally provided in a place around a slippery water.

However, according to the present invention, such a fatal problem is to adjust the elongation rate of the twist set yarn to be used as the pile yarn by applying water to 6% or less, preferably 4% or less based on the above principle. Will be solved all at once.

According to the results of examination by the present inventors, the above-mentioned elongation rate of the conventional twist set yarn is 6.5 to 14.0, and the object of the present invention is not achieved at all with such a high level of elongation rate. is there.

Due to the above, special twist setting conditions are adopted to obtain the pile yarn of the present invention. In other words, when twisting and setting the BCF after twisting it, usually 11
A temperature of about 5 to 135 ° C. is used, while in the present invention 100 to
A low temperature of 110 ° C is used. Alternatively, if a dry heat set that is not normally used is used, a temperature condition of 120 to 180 ° C is used. Regarding the set time, BCF
Depending on the thickness of the mat, it is usually used as pile yarn for mats in the range of 1,000 to 10,000 de
Minutes, 30 seconds to 60 minutes is suitable for dry heat.

Bulky continuous filament yarns made of polyamide are generally obtained by hot fluid processing. That is, the drawn continuous filament yarn is sufficiently preheated at a temperature of 170 to 200 ° C. and then heat-contracted by a heating fluid jet nozzle for about 15 to 30% to heat-fix the crimp.

That is, a normal BC by heating fluid processing
For F, it is common knowledge that the preheating temperature is 170 ° C or higher, and at the same time, the heat shrinkage during processing is 15% or more and the crimps are sufficiently heat-fixed. If set under the set conditions, the twisting effect may not be obtained sufficiently. As a result of various studies on this, the present inventors have found that there are special conditions for heating fluid processing in which post-twisting setting is easy and curling does not easily occur.

That is, in the above-mentioned heated fluid processing,
Preheat roller temperature of filament yarn before crimping to 100
℃ ~ 170 ℃, preferably 110 ℃ ~ 160 ℃, when adjusting the heat shrinkage of the filament yarn in the range of 5% ~ 15%,
A BCF that most closely meets the twist setting conditions described above is obtained.
In other words, curling is controlled by suppressing crystallization and heat shrinkage during hot fluid processing, enabling low-temperature twist-setting and preventing the amorphous part from having a loose structure.

In the present invention, when hollow fibers are used as BCF, the low temperature heat setting effect is further promoted,
It has also been found that a more preferred twist set yarn with less curl is obtained. In this case, the hollow ratio is 5% to 30%,
It is preferably 10% to 25%. The monofilament cross section may be any of a Y-shape, a triangle, a quadrangle, a cross, etc. in addition to a round cross section. Further, the hollow shape is not particularly limited as long as the hollow ratio in the above range is satisfied. The reason why the setting effect is improved is not clear at present, but it is presumed that the setting effect is probably promoted even at low temperature because the hollow part is slightly crushed and plastically deformed.

The twist set yarn of the present invention thus obtained is planted on the primary base fabric. A known tufting machine may be used for the planting itself, and the tufting density at that time may be arbitrarily set according to the intended use and intended use of the final product. As the primary base cloth, for example, a woven cloth made of polyester filament threads (thread denier; 100 to 1000 de, basis weight; 100
~ 400 g / m ² ), nylon woven fabric (thread denier; 100 ~
1000 de, basis weight: 100-400 g / m ² ) or non-woven fabric consisting of polyester short fibers (short fiber denier; 1 de-10
de, basis weight; 50 to 300 g / m ² ). The elongation behavior of this base cloth also indirectly influences the curling phenomenon. In this sense, the constituent material (fiber) of the base cloth is the same as the pile yarn, that is, if the pile yarn is nylon-6, the material is nylon-6, and the heat setting conditions are the same. Are preferably substantially the same. Here, “substantially” means that the difference in elongation is in the range of ± 1.0%.

Next, a backing agent is applied to the back surface of the tufting machine. In this case, considering the ease of washing the mat, the thickness of the coating film is 0.1 to 2.0 mm, preferably 0.2 to 1.0 mm.
mm is suitable. As the backing agent, a cross-linking agent as described in the above-mentioned Japanese Patent Laid-Open Publication is useful. According to the present invention, when the hardness of the backing agent after curing is set to 0.9 to 2, even if curling occurs between the pile yarn and the base cloth, the bending resistance is increased and the curling resistance is further improved. It was also found to be improved.

The above hardness shall be measured by the following method.

Using a Gurley type flexibility tester (manufactured by Toyo Tester Industry Co., Ltd.), a sample having a length of 3 cm and a width of 1.
It is a maximum load scale with a test piece of 5 m / m and a thickness of 0.7 m / m, and a weight of 25 g attached to the pendulum at a position of 1 inch.

[0022]

According to the research conducted by the present inventors, it was confirmed that the curling phenomenon does not occur in the following cases. When there is no backing (tufting machine) When there is no pile thread When the pile thread on the back side of the base cloth is cut However, when the mat structure in which the base cloth and pile thread are bonded with latex is wetted with water, as shown in Fig. 1. Curling occurs. The curl amount can be displayed as the curl height H (mm) as shown in FIG. From the above findings, the occurrence of this curling is caused by the base fabric (usually polyester fiber is used from the viewpoint of dimensional stability) and the pile yarn (usually twisted set yarn made of polyamide is used from the viewpoint of durability),
As shown in FIG. 2, a two-layer structure bonded by a backing agent is formed (in other words, this is a kind of bimetal structure), and the pile yarn stretches due to water absorption and a difference in expansion and contraction occurs with the base fabric. It was presumed that it caused curl. From this point of view, as a result of various analyses, the base fabric made of polyester fiber does not expand or contract much due to water, whereas the pile yarn made of polyamide twist set yarn is surprisingly wetted with water. It turned out that the thread stretches considerably. Then, it was discovered that the conventional measure for improving the dimensional stability of the pile yarn (to suppress the elongation of the yarn), that is, the conventional means of raising the twisting set temperature, works exactly opposite to curling. is there. In other words, it has been clarified that, in such a structure, the result of stretching of the twist-set polyamide yarn which is a pile yarn due to water absorption causes a curling phenomenon, which has never been recognized until now.

The conventional twist setting has been carried out in the range of over 125 ° C. under moist heat. This is based on the recognition that if a more severe heat treatment is applied, the fiber structure will be stable and the dimensional change due to water will be less, and thus the twisting effect will be improved accordingly. Is. But this has the opposite effect on the mat,
That is, the dimensional stability based on the anisotropy of the fiber assembly called mat was caused.

Further detailed examination revealed that when the saturated steam temperature during twisting was changed, the elongation of the polyamide yarn due to water adhesion depended on the saturated steam temperature as shown in the table below.

[0025]

[Table 1] (The pile yarn was a nylon-6 1300 de / 68 fil. Original yarn twisted with an upper twist of 230 T / m and a lower twist of 230 T / m set by a continuous saturated wet heat setting machine of Superva Co.) Although not clear, it is estimated as follows. That is, in the case of the polyamide yarn, crystallization proceeds by raising the temperature of the wet heat setting, and the crystal size increases, whereby the strain of the tie molecule is promoted and the amorphous portion has a looser structure. It is presumed that, when the wet heat set yarn is wetted with water, the water enters the loose amorphous part, activates the molecular motion, and lifts the crystal part, which appears as elongation in the fiber axis direction of the yarn. Therefore, the dimensional stability against water becomes worse as the wet heat setting temperature is increased.

Based on this consideration, the present inventors have for the first time used a dry heat setting method for mats as a twist stopping method that does not promote the crystal size as much as the wet heat setting and does not make the amorphous part have a loose structure. It was applied as a heat setting means. The dry heat set has a lower setting efficiency than the wet heat set, and the nylon thread is apt to yellow, so that it has not been conventionally used as a setting means for a mat. According to the examination, as shown in the table below, the elongation when the pile yarn is wetted with water is significantly smaller than that of the wet heat set, although the set temperature is high.

[0027] Therefore, it has been found that the combination of the dry heat set for the dust control mat is very effective as a curling countermeasure although the heat set time is somewhat longer.

Based on the above findings, mats were made from the above various heat-set yarns, and curling tests were carried out.
It has been found that, as a physical property of a pile yarn in which curling is practically acceptable, an elongation upon application of water is 6% or less, preferably 4% or less.

At the same time, if the principle of bimetal is applied, it is clear that it is even better if the base cloth is made of a material having the same elongation as the pile yarn, for example, a polyamide fiber is set.

Although the backing agent has an auxiliary role, in order to bend the hard backing layer even if curling occurs, for example, by increasing the crosslinking degree of the latex or increasing the adhesion amount to make it hard. Curling can be further reduced by controlling the hardness of the backing because it requires power.

The present invention will be described below with reference to examples, but of course the present invention is not limited thereto.

[0032]

[Example 1 and Comparative Examples 1 and 2] Japanese Patent Publication No. 56-37339 JP Using the method and apparatus for crimping a yarn described in Examples, a coil is preheated at a temperature of 190 ° C and a heat shrinkage rate during processing is 25% Shrinking,
BCF of polycaprolamide (conventional BCF) was obtained, and twisted at 230 T / m with 2 plies, and further 130 ° C. set (conventional example) and 110 ° C. set (invention) with saturated steam. These 2 types of set yarns, and the unset pile yarns are 5/32 gauge, 8.5 stitches / inch, and pile height 10 on polyester fiber base fabric.
Tufted at m / m and unit weight of 850 g / m ² . As the backing agent, the composition (A) described in Example 1 of JP-A-63-12764 was used, which was preheated (120 ° C. × 10 minutes) and then dried (13).
0 ℃ × 15 minutes), the backing thickness of the base cloth is about 0.7 m
/ M mat was obtained. Table 3 shows the curl amount of each mat, the bending hardness of the backing agent, the yarn elongation of the pile yarn, the heat setting property, the pencil point property, and the bulky property.

The method for measuring the curl amount (m / m) of the mat is as follows.

A length of 10 cm in the tuft direction from the mat, including one tuft thread (cut out as a sample with a width of 3.5 m / m, immersed in water for 1 minute, and after removing water on the surface with filter paper Then, it is allowed to stand on a horizontal plate, the time-dependent change of the dimension H (m / m) shown in the drawing is measured, and the maximum value is taken as the curl amount.

The pencil point property is good (5th grade) by visually observing the convergence property of the pile tip of the new pile cut surface.
-Normal (3rd grade) -Poor (1st grade) was applied.

Regarding the heat-setting property of the twist, the shape retention of the pencil point was similarly good (5th grade) to normal (3rd grade) to poor (1st grade) after the mat was stirred in boiling water for 30 minutes. I graded it.

The unset yarn (Comparative Example 1), which has almost no yarn elongation when wet, has a small curl amount but has no pencil point property because the pile is not twist-set.
High added value such as Saxony and Freeze cannot be obtained. When heat-moisture set at 130 ° C. (Comparative Example 2), the yarn elongation rate is large, the curl amount is large, and the function as a dust control mat is lacking. On the other hand, in the case of wet heat setting at 110 ° C. (Example 1), the yarn elongation rate is halved compared to 130 ° C., and the curl amount of the mat is correspondingly improved and the commercial value comes out. The twist setting of the pile is also at a reasonable level.

Overall, the dust control mat has a sufficient commercial value.

When the 130 ° C. set yarn by pressure steam was used, the curling amount could not be greatly improved even if the backing agent coating amount was changed and the base fabric backing thickness after drying was changed.

[0040]

[Table 3]

[0041]

Examples 2 to 5, Comparative Examples 3 and 4 In the same manner as in Example 1,
BCF with different crimping conditions of yarn (preheating hot roller temperature and process shrinkage) was twisted with 2 plies at 230 T / m, 110 ° C set by pressure steam, tufted and backed to obtain a mat. .

Table 4 shows the curl amount of each mat, the bending hardness of the backing agent, the yarn elongation rate of the pile yarn, the heat setting property of twist, the pencil point property, and the bulky property.

The preheating hot roller temperature is especially 100 to 16
BCF satisfying both 0 ° C and processing shrinkage of 5 to 15% has small yarn elongation and curl amount when wet, and pile heat setting property and pencil point property are 110 ° C even at low temperature setting. Without improvement (Examples 2 and 3).

When the preheating hot roller temperature is high or the work shrinkage is high and both conditions are not satisfied, the heat setting property of the pile twist remains at a reasonable level (Examples 4 and 5). On the other hand, when the temperature of the preheating hot roller is 100 ° C. or less and the work shrinkage is 5% or less, the bulkiness of the pile is deteriorated and the quality is lost and the product function is lost (Comparative Examples 3 and 4).

[0045]

[Table 4]

[0046]

[Examples 6 to 8] Similar to Example 1, except that when the cross-sectional shape of the yarn to be treated is hollow fiber, crimping,
A mat was obtained by twisting, setting at 110 ° C. with pressure steam, tufting, and backing. Curl amount of each mat,
Table 5 shows the bending hardness of the backing agent, the yarn elongation rate of the pile yarn, the heat setting property, the pencil point property, and the bulky property.
In the tri-lobal yarn, the heat setting property of the twist of the pile yarn and the pencil point property were at a reasonable level due to the decrease in the set temperature to reduce the curl amount, whereas the hollow yarn made the heat setting property of the twist and the pencil point property. The point property was improved, sufficient pencil point property was obtained even at heat setting at a lower temperature, and because of the hollow shape, a mat with a curl amount excellent in pencil point property with bulky was obtained. When the hollow ratio was 4%, the effect of improving the pencil point property was not observed. When the hollow ratio was 31%, open mouth (adhesion failure) occurred frequently and the operability was very poor. Examples 6 and 7 show the results for the triangular hollow fiber and Example 8 for the trilobal hollow fiber. The hollow trilobal showed a more improved bulkiness.

[0047]

[Table 5]

[0048]

[Examples 9 to 11 and Comparative Example 5] BCF was twisted under the same conditions as in Example 1 and then saturated steam was used to obtain 11
After setting at 0 ° C., tufting was performed on a base fabric made of nylon-6, which was previously heat-set at 110 ° C. with saturated steam, and backed to obtain a mat. In this case, the curl amount of the mat, the bending hardness of the backing agent, the yarn elongation rate of the pile yarn, the twist setting property, and the pencil point property are shown in Table 6.
This is shown in (Example 9). Even when a twist set yarn having a yarn elongation of 6% when wet was used, a mat with almost no curl was obtained in the case of a base fabric made of nylon-6 heat set yarn with a curl amount of 1.0 mm.

The BCF obtained under the conditions shown in Example 1 or Example 8 was set at 110 ° C. or 105 ° C. by twisting pressure steam and then tufted onto a polyester base fabric.
Preheating (12) using the composition (B) described in Example 2 of Japanese Patent Publication No.
Mats having different bending hardness of the backing were obtained by changing the thickness of the backing by carrying out main drying (140 ° C. × 15 minutes) at 0 ° C. × 10 minutes) (Examples 10 and 11). The evaluation results of the curl amount of this mat are also shown in Table 6, and the curl is further improved.

However, if the backing agent is thickly preheated (120 ° C. × 10 minutes) and main drying (160 ° C. × 30 minutes) is carried out to further accelerate the crosslinking of the backing agent (Gurley scale 22), it becomes hard. It is too poor to be handled easily and is not practical.

[0051]

[Table 6]

[0052]

As shown in Tables 3, 4, 5 and 6, according to the present invention, when the yarn elongation rate of the pile yarn when wet is 6% or less, the curl amount becomes small, and a more special case is obtained. By using crimping conditions and using hollow cross-section yarns, a dust control mat with high commercial value, which has excellent twist setting properties, pencil point properties, bulky properties, and greatly improved curling resistance, can be obtained.

[Brief description of drawings]

FIG. 1 is a side view showing a curling state of a mat.

FIG. 2 is a side view illustrating a curling generation mechanism of a mat.

[Explanation of symbols]

 1 pile yarn 2 base fabric 3 backing agent H curling amount

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI technical display location D02J 13/00 N // D05C 17/02

Claims (3)

[Claims] 1. A continuous filament of polyamide
5% to 1 by setting the preheating temperature of the yarn to 100 ° C to 170 ° C
Bulky-con, obtained by heat-fluid processing under 5% heat shrinkage
100 ° C with twisted continuous filament yarn
~ 110 ℃ wet heat, or 120 ℃ -180 ℃ dry heat
A set yarn twist formed by heat setting under, mat polyamide pile yarn, wherein the yarn elongation by water application is not more than 6%. However, the elongation rate (L) complies with the following definition. The length of the sample when the polyamide pile yarn was fixed length (1 m) and a load of 0.01 g / de was applied was L ₀
And This sample was immersed in water at 20 ° C. for 1 minute, excess water on the surface was removed with a filter paper, a load of 0.01 g / de was applied, and the sample length after 1 minute was set to L ₁ , which was determined by the following formula. It is a value. L = (L ₁ −L ₀ ) / L ₀ × 100% 2. The polyamide pile yarn for mat according to claim 1, wherein the yarn elongation is 0 to 4%. 3. The polyamide pile yarn for mat according to claim 1, wherein the constituent single fibers of the pile yarn are hollow fibers.