JPH09273025A - Crimped polyester yarn, plushed fabric and production of plushed fabric - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain a crimped non-torque polyester multifilament yarn having a specific crimping characteristic, exhibiting excellent loosening feeling, impact resilience and gloss and improved polisher processability and useful for the production of a plushed fabric, etc. SOLUTION: This crimped yarn is a mass-colored yarn having a flat cross-section and a crimping characteristic satisfying formula I and formula II at the same time [TC130 is a percentage crimp (%) after heating at 130 deg.C in dry state; TC180 is a percentage crimp (%) after heating at 180 deg.C in dry state]. A conjugate crimped yarn having improved polisher processability and impact resilience can be produced by blending 20-90wt.% of the crimped yarn and 80-10wt.% of a crimped yarn having a thermal durability of the crimp higher than that of the former crimped yarn.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a polyester crimped yarn which gives a napped fabric having improved napping feeling and gloss, a napped fabric having an improved napping feeling, and a method for producing the same.

[0002]

2. Description of the Related Art In recent years, there has been an increasing demand for a cut pile raised fabric which is excellent in fluffiness and gloss in rugs and the like, and a filament crimped yarn suitable for polisher property for improving the fluffiness and gloss is desired. ing. However, when creating a raised fabric such as a cut carpet (velor carpet) using a polyester-based multifilament crimped yarn, which has been proposed so far, a feeling of looseness when trying to obtain good resilience, On the contrary, the gloss becomes poor, and conversely, when it is attempted to obtain a loose feeling and gloss, the resilience becomes poor, and it is extremely difficult to satisfy both of them at the same time.

What is important in the process of manufacturing a napped fabric is, for example, in the case of cut carpet (velor carpet),
After tufting the yarn, the crimp is developed by heat of dyeing or primary backing, and then the crimp is stretched to 1/5 to 1/2 from the upper end of the cut pile yarn by polisher processing, and 4 / It is necessary to leave the crimp of 5 to 1/2 part.

However, it has been proposed so far that, for example, "a yarn bundle of two or more kinds of continuous fibers has a thread difference of 1 to 25% and a stuffing type crimp. Characteristic fiber for carpet "
No. 207335), "Consisting of continuous fibers of polyester that have been sown in two or more colors to form a blade, and the content of the component having the largest content of carboxyl end groups in the polyester is based on all the end groups. 30-85%, the difference between the maximum and the minimum content of carboxyl end groups with respect to the total end groups contained in each polyester of continuous fibers dyed in different colors is 0.5-25%, and the stuffing formula is used. "Fiber for carpet characterized by having crimps" (Japanese Patent Laid-Open No. 6-207336), "Recycled resin is at least 20% by weight of the raw material, and has bulkiness having 3 to 15 crimps per 25 mm. A continuous fiber for carpet, which is a continuous yarn having a carboxyl group in the terminal groups contained therein of 30 to 85% (Japanese Patent Laid-Open No. 6- No. 220716) is disclosed. Using polyester multifilament crimped yarn makes it difficult to stretch the crimp by polishing, and if the temperature and pressure during crimping pusher and polishing are increased, the crimp is stretched to the root of the cut pile. Repulsive elasticity is completely lost. It is speculated that the reason for this is that the processing temperatures in the above-mentioned prior art documents are all biased toward the high temperature range.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to solve the drawback of polyester crimped yarns, which has poor polisher processability, and to provide a napped fabric having improved fluffiness and rebound resilience at the same time. Providing crimped yarn.

[0006]

DISCLOSURE OF THE INVENTION The inventors of the present invention have explained the cause of poor polisher processability of a polyester multifilament crimped yarn prepared by conventional methods and conditions.
As a result of detailed examination, it was clarified that the relationship between the expression of crimp and the polisher processability in the production process of the cut pile fabric has not been considered in the past, and as a result, the polyester multifilament crimped yarn has a special property. The present invention has been achieved by knowing that good polisher workability can be inherently imparted by imparting crimp-developing characteristics.

[0007]

Thus, according to the present invention, a non-torque polyester multifilament crimped yarn having improved polisher workability, characterized in that crimping properties simultaneously satisfy the following expressions (1) and (2): . 20 ≧ TC ₁₃₀ ≧ 3 (%) ・ ・ ・ (1) TC ₁₈₀ / TC ₁₃₀ ≦ 0.5 ・ ・ ・ (2) TC ₁₃₀ : Dry heat Crimping rate at 130 ° C (%) TC ₁₈₀ : Dry heat Crimp ratio (%) at 180 ℃

The present invention will be described in more detail. Taking as an example a polyester cut pile carpet as the napped fabric, its production goes through the following steps. Crimped yarn → Dyeing, drying → Pile yarn → Tuft (cut) → 1
Next backing → Sharing → (Polisher processing) →
Secondary backing → cutting (product)

Here, it is important to carry out a polishing process for stretching the crimps at the tips of the piles in order to make the product more fluffy and glossy. Polyester usually does not have sufficient dyeing fastness under normal pressure, so it is common to use pile yarn for cheese dyeing or dyeing at high pressure before tufting, so-called yarn dyeing. In this series of steps, an attempt was made to produce a cut pile carpet excellent in fluffiness, luster, and rebound resilience, but none was satisfactory.

Therefore, as a result of paying attention to heat, crimp development of yarn and crimp fastness in the above manufacturing process, the crystal structure of the fiber is strengthened because it is exposed to high temperature for a long time by high-pressure dyeing, and it is wound by polishing. It was found that it was difficult to stretch the shrinkage. As a result of further study, the crimps are stretched by the polishing process because the heat of the working rollers eliminates the crimps rather than the force of stretching the piles by the frictional force between the working rollers and the piles. He found that the set was more important.

Still further, the following (1) and (2) are available as yarns that can be manufactured by a polisher process to make a napped fabric in which the crimp at the tip of the pile yarn is easily set and the crimp at the bottom of the pile yarn is sufficiently present. ) When the formulas are simultaneously satisfied, 20 ≧ TC ₁₃₀ ≧ 3 (%) ・ ・ ・ (1) TC ₁₈₀ / TC ₁₃₀ ≦ 0.5 ・ ・ ・ (2) TC ₁₃₀ : Crimping rate at 130 ° C. dry heat (%) TC ₁₈₀ : crimping ratio at dry heat 180 ° C. (%) It has been found that a non-torque polyester malt filament crimped yarn having improved polisher processability can be obtained.

From the above, the yarn of the present invention maintains high crimping at a temperature of 130 ° C. or lower until the step before polishing in the production of polyester napped fabric, or heat roller temperature in polishing. That is, the crimp can be easily reduced by heat of 170 to 200 ° C. Therefore, the degree of crimp stretching at the tip of the pile yarn can be easily adjusted by the temperature and the pressing pressure of the polishing process. Have.

Therefore, the ranges represented by the above formulas (1) and (2) in the present invention are extremely critical, and if they deviate from these ranges, the following disadvantages occur and The object of the invention cannot be achieved.

When the upper limit of the formula (1) is exceeded: When the crimp is developed by heat such as primary backing, the tip of the cut pile tends to face downward because the crimp is too high.
Also, the pile becomes felt-like, and even if the expression (2) is satisfied, crimp stretching of the pile tip by polishing is not successful, and the feeling of fluffing and gloss are poor. Further, the thickness of the cloth, that is, the so-called ground feeling is also impaired.

When the lower limit of the formula (1) is not satisfied: When the crimp is developed by heat such as primary backing, the desired rebound resilience of the cloth cannot be obtained because the crimp is too low.

When the upper limit of expression (2) is exceeded: expression (2)
The value of TC ₁₈₀ / TC ₁₃₀ of 1 means the heat fastness of crimps, and represents the ease of crimp stretching (heat crimping of crimps) of the pile by polishing. Therefore, the lower the TC ₁₈₀ , the better in terms of the ease with which the crimp is thermally set.
The value of ₁₈₀ is not the only decision.

When it is used as a napped fabric, from the viewpoint of visual sense and tactile sensation, the resilience and elasticity of the lower part of the pile influence the degree of diffused reflection, and the crisper is stretched by polishing to improve the feeling of looseness and gloss. This is because the product value is determined by the balance with the upper part of the pile. Therefore, the value of TC ₁₈₀ / TC ₁₃₀ should be designed to be 0.5 or less, preferably about 0.4 to 0.1. In this case, TC ₁₃₀ is preferably in the range of 5 to 15%. If the value of TC ₁₈₀ / TC ₁₃₀ exceeds 0.5, the preferable balance from the visual and tactile aspects cannot be maintained. For example, when TC ₁₃₀ is low, TC ₁₈₀ / TC ₁₃₀
When the value exceeds 0.5, the tactile sense of repulsive elasticity is impaired, and as a means to maintain the repulsive elasticity, the pile amount (pile weight) can be increased, but this method loses the economic effect. When TC ₁₈₀ is a high value and is 0.5 or more, the tactile sensation of looseness and the visual lustre are lost.

The lower limit of TC ₁₈₀ / TC ₁₃₀ is not particularly limited from the point of the present invention. However, it is not possible to provide an endlessly low TC ₁₈₀ / TC ₁₃₀ value. The value of TC ₁₃₀ is high in the range of the present invention even with the current manufacturing technology, for example, 1
For 5 to 20%, it is difficult to reduce the TC ₁₈₀ value to 2% or less, and the TC ₁₈₀ / TC ₁₃₀ value at this time is 0.1 or more.

The crimp rate in the present invention is measured by the following method. As a measuring instrument, LAWSON-HEM with the mechanism shown in Fig. 1
TYT (TEXTURED YARN TEST SYSTEM) manufactured by PHILL was used. The measurement mechanism will be described with reference to the drawings. The multifilament crimped yarn (Y) is adjusted to a predetermined yarn supply tension by the tenser (1), and then fed to the dry heat heating bath (4) by the first supply roller (2) through the first sensor (3). After being supplied, crimped and contracted, it is taken up by the intermediate roller (5), and then taken by the take-up roller (8) from the second supply roller (6) through the second sensor (7). After that, it is sucked up by the yarn suction (9). This time,
The first supply roller (2) rotates at a predetermined constant speed,
The intermediate roller (5) is automatically adjusted and changed by the first sensor (3) so that the yarn tension is maintained at a predetermined crimp development tension. Then, the second supply roller (6) is adjusted to a speed at which the crimp does not fully extend or sagging with the developed intermediate roller (5), and the speed of the take-up roller (8) is set to a predetermined crimp. It is automatically adjusted by the second sensor (7) adjusted to the measured tension.

The crimp rate is calculated by the following method. Crimping rate = (intermediate roller speed)-(take-off roller speed)
/ (1st supply roller speed) x 100 (%) Crimping rate measurement conditions are as follows: 1st supply roller speed = 40 m / min Yarn supply tension = 100 mg / de Crimping development tension = 1 mg / de Crimping measurement tension: 100m
g / de Crimp development treatment temperature: TC ₁₃₀ = 130 ° C, TC ₁₈₀ = 18
0 ° C

The non-torque polyester multifilament crimped yarn of the present invention can be easily prepared by using an ordinary heating fluid jet processing device. For example, a device in which spinning, drawing, and crimping processes are directly connected as shown in FIG.
Alternatively, an apparatus or the like may be used in which the material is spun, wound once, and then stretched and crimped.

A method for producing the non-torque polyester multifilament crimped yarn of the present invention in the apparatus shown in FIG. 2 will be described. Spinneret (1) of melt extruder (10)
The polyester yarn discharged from 1) is cooled by the cooling device (1
Cooling with 2), oiling with an oiling roller (13), supply roller (14) and stretching heating roller (15)
Preheating for stretching and indenting is performed between. Subsequently, the well-known heating fluid pushing nozzle (16) is pushed by the heating fluid to cause buckling crimping and at the same time cooled, and then taken up by the take-up roller (17), and further the intersection roller (1
Wind up through winder (19) via 8).

Here, the crimp level is set by the temperature of the stretching heating roller (15) and the processing overfeed rate [(stretching roller speed)-(take-up roller speed) / (take-up roller speed) × 100 (%)]. Adjust with. In the case of polyester filament yarn, the processing preheating temperature is 180-
230 ℃, 170-200 ℃ for nylon 6
The conventional method is to set a high value of 15 to 30% in order to impart crimp fastness with a sufficient degree of processing overfeed rate, but the polyester multifilament prepared under such conditions The cut pile napped fabric made of crimped yarn is poor in polisher processing, the crimp at the tip of the pile is not stretched, and although it has resilience and resilience, it does not have a feeling of looseness and gloss at all.

In this respect, what is essential in the production of the polyester crimped yarn of the present invention is that the heat treatment is not excessive, and it is necessary to make the temperature much lower than the temperature condition used in the conventional crimping process. . The processing preheating temperature varies depending on the processing speed and the preheating time, but it is desirable that the crystallization of the fibers at 90 to 150 ° C. can be suppressed as much as possible, and the processing overfeed rate is also lower than usual conditions.

In the non-torque multifilament crimped yarn according to the present invention, "non-torque" is a yarn having no torque as a crimping function. That is, it means a method in which twisting-untwisting processing such as false twisting is not performed as a crimping method, and twisting or entanglement processing is added to improve the handleability of the yarn. May be. The polyester is not particularly limited as long as it is a linear polymer, and general-purpose polymers such as general polyethylene terephthalate and polybutylene terephthalate can be used, and these polymers contain a small amount of other components and improvers. Alternatively, a colorant may be added.

The cross-sectional shape of the fiber obtained from such a polymer may be either circular or non-circular, but it is possible to further improve the fluffing feeling and gloss by making it flat. The flat shape referred to in the present invention means a substantially flat shape, and may have a W _L / W _S of 1.5 or more and 10 or less as shown in FIG.

The yarn of the present invention can be dyed in a temperature range which does not impair the crimping property described in claim 1 in a state before tufting, and there is no problem, and of course, it is a so-called white yarn which is not colored. Can also be used. In addition, not only the yarn dyeing process can be omitted by using a so-called spun-dyed yarn to which a coloring agent is added in the spinning process, but also the yarn dyeing process, for example, the occurrence of crimping due to long-term heat treatment in cheese dyeing can be prevented. And can maintain good polisher processing.
Of course, there is no problem even with a mixed yarn of the spun yarn and the white yarn.

This yarn can be used for fabric production by using 100%, but it can also be used in combination with conventionally proposed polyester fibers or with other materials such as nylon crimped yarn. In this case, it is preferable that the material for composite use a crimp having higher heat fastness than the fiber of the present invention so as to occupy 10 to 80% by weight in the composite yarn.

That is, the high crimp heat fastness of the crimps of the materials to be mixed and used, which is intended by the present invention, improves the fluffing feeling and luster of the pile tip of the napped fabric by improving the polisher workability of the crimped yarn. It is possible to further improve the resilience by arranging the mixed material at the bottom of the fabric pile when the crimp is developed by utilizing the above. In this case, if the cross-sectional shape of the mixed material is made flat, the resilience is further improved.

In such a composite yarn, the yarn of the present invention preferably accounts for 20 to 90% by weight. If it is less than 20% by weight, the loosening feeling and gloss of the pile tip of the napped fabric are deteriorated, and the preferable lower limit is 30% by weight. Also,
If the ratio exceeds 90% by weight, further improvement in resilience, which is the purpose of mixed use, cannot be expected. However, when other materials are mixed and used for the purpose other than improving the resilience, for example, when non-crimped yarns having different hues are used in a point color, the content of the other materials may be 10% by weight or less.

The yarn of the present invention does not cause any trouble even if crimps are sufficiently developed before tufting. However, after tufting, the napped hair is processed, then the napped hair is subjected to crimp expression treatment, and then the napped tip is polished. The method is more preferable from the viewpoint of handleability of the yarn during tufting. Furthermore, the heat of the primary backing heated with hot air of about 130 ° C. can be used for the crimp development treatment of the napped pile, and it is not necessary to specially provide the crimp development treatment. The raising process after tufting also includes forming a pile loop on the base fabric with a tuft needle and subsequently cutting the loop to form a cut pile.

[0032]

EFFECTS OF THE INVENTION A napped fabric using a multifilament crimped yarn made of polyester, having a feeling of looseness, gloss,
It has become possible to provide a napped fabric that satisfies both the resilience and elasticity at the same time. In particular, as a napped fabric using the yarn of the present invention, it is more effective in a cut pile rug. Since the raised fabric of the present invention has a good feeling of looseness and gloss on the surface and is excellent in resilience,
This is because the feeling of stepping and sitting are greatly improved.

[0033]

EXAMPLES Examples of the effects of the present invention will be shown. Example 1 A polyethylene terephthalate polymer having an intrinsic viscosity of 0.65 and a pigment master chip added thereto so as to be light beige was spun from a 120-hole flat spinneret at a melting temperature of 285 ° C. in the apparatus shown in FIG. Then, after cooling with cooling air, a spinning oil is applied, and the spun oil is drawn at 600 m / min, and subsequently drawn at a draw ratio of 4.5 times, and at the same time, it is subjected to indentation crimping to obtain various non-torque polyester multi-ply. A filament crimped yarn was created. At this time, the polymer discharge amount was adjusted to be 800 denier with the processed yarn. The crimping rate was adjusted by changing the preheating temperature during indentation processing and the processing overfeed rate as shown in Table 1.

[0034]

[Table 1]

Three non-torque polyester multifilament crimped yarns obtained were combined and added with Z twist of 50 times / m to form a pile yarn, and a cut pile tufted carpet raw machine was prepared. At this time, the tuft standard is pile length = 13
mm, gauge = 5/32 G, stitches 7, 9 and pile weight = 650 g / m ² . Next, this raw machine 13
A cut pile carpet was prepared by performing SBR latex backing in the hot air tank at 0 ° C. and simultaneously performing crimp expression treatment, and further performing polisher processing using the polisher processing machine shown in FIG. The conditions for polishing are: processing speed 3 m / min, heat roller temperature = (Fig. 3
22a) 190 ° C./(22b in FIG. 3) 170 ° C. Polisher number of times = two passes. The cut pile carpet thus obtained was evaluated by a skilled person for the feeling of looseness, gloss, and resilience. Table 2 shows the results.

[0036]

[Table 2]

<Flipping Feeling, Gloss> ◎: Crimping is extended and fluffing feeling, gloss is very good ○: Crimping is extended and fluffing feeling, good gloss Δ: Crimping remains and fluffing, gloss Slightly poor ×: Crimped and loose, poor gloss <Rebound resilience> ◎: Crimp at pile lower end, bulky and very good ○: Pile lower end is crimped, bulky and elastic Δ: Unsatisfactory texture between ○ and × ×: Poor texture with few crimps and no bulkiness

NO 3, 4, 5, 7, which are examples of the present invention,
Nos. 8, 11, and 12 have good fluffiness, gloss, and rebound resilience
It is. No. 1 and No. 2 which are outside the present invention have a feeling of looseness and gloss.
Good, but crimped (TC₁₃₀) Is low, so repulsive elasticity
Poor, and crimped (NO6, 9, 10, 13) (TC
₁₃₀) Is satisfactory and the resilience is good, but TC₁₈₀
/ TC₁₃₀Value is high, polisher is bad, and a feeling of looseness,
The gloss is poor. NO14 is because the crimp is too high
Then the tufting machine was made felt by crimping on the backing.
Not only does it have poor polisher properties
The resilience was also unsatisfactory.

Example 2 A polyester multi-filament crimped yarn having a crimping characteristic of NO7 produced in Example 1, one flat yarn of 800 denier / 120 filaments, and a yarn 14 of NO14, which is also the same as the untwisted yarn. A cut pile carpet was obtained through the same steps and conditions as in Example 1 using a yarn of 2400 denier / 360 filament twisted together with the book at 50 times / m. The obtained cut pile carpet was evaluated for fluffiness, gloss, and repulsion resilience, and a pile in which the crimp at the tip was extended and a pile thread in which the tip was not extended and the crimp was high and sank below were mixed, It had good fluffiness and gloss, and was very excellent in resilience.

Example 3 Polyester multi-filament crimped yarn having a crimping characteristic of NO7 prepared in Example 1 before being compounded 800 denier / 120 filament flat yarn (oblateness 5.3) and nylon 6 830 denier / 56 colored gray
A tuft greige machine was prepared by using a filament of 1630 denier / 176 filament obtained by air-blending one air-pressed crimped yarn having a tri-lobal cross section with a filament. At this time, the tuft standard is pile length = 12 mm, gauge = 1/10 G,
The stitch was adjusted to 12.0 and the pile weight was adjusted to 900 g / m ² . Then, this raw machine is S for 5 minutes in a hot air bath at 125 ° C.
A BR pile backing was performed and a crimp development treatment was performed at the same time, and a polisher process was further performed to prepare a cut pile carpet. The conditions for polishing are: processing speed 3 m / min, heat roller temperature = (2 in FIG. 3
2a) 190 ° C./(22b in FIG. 3) 170 ° C. Polisher count = 1 time. The cut pile carpet obtained was evaluated for fluffing feeling, gloss, and rebound resilience.As a result, only the pile end of the polyester component was stretched out, and not only the fluffing feeling and gloss were very good, but the surface feeling of the feather touch was also felt. It was shown and very excellent in resilience. The crimping rate of the nylon 6 crimped yarn used at this time was TC ₁₃₀ = 12% and TC ₁₈₀ = 18%.

[Brief description of drawings]

FIG. 1 shows a crimp measuring machine according to the present invention.

FIG. 2 shows a spinning and stretch crimping machine.

FIG. 3 shows a polisher processing machine

FIG. 4 shows an example of a fiber cross section used in the present invention.

[Explanation of symbols]

 Y measurement yarn 1 tensor 2 1st supply roller 3 1st sensor 4 dry heat heating bath 5 intermediate roller 6 2nd supply roller 7 2nd sensor 8 take-up roller 9 yarn suction F filament 10 melt extruder 11 spinneret 12 cooling device 13 Oiling Roller 14 Supply Roller 15 Stretching Heat Roller 16 Heating Fluid Pushing Nozzle 17 Take-up Roller 18 Support Point Roller 19 Winder 20 Standing Fabric 21 Supply Roller 22a Heat Roller 22b Heat Roller 23 Take-up Roller

Claims (7)

[Claims] 1. A non-torque polyester multifilament crimped yarn having improved polisher processability, wherein crimping properties satisfy the following expressions (1) and (2) at the same time. 20 ≧ TC ₁₃₀ ≧ 3 (%) ・ ・ ・ (1) TC ₁₈₀ / TC ₁₃₀ ≦ 0.5 ・ ・ ・ (2) TC ₁₃₀ : Dry heat Crimping rate at 130 ° C (%) TC ₁₈₀ : Dry heat Crimp ratio (%) at 180 ℃ 2. The crimped yarn according to claim 1, which has a flat cross section. 3. The crimped yarn according to claim 1, wherein the crimped yarn is a spun yarn. 4. 20 to 90% by weight of the crimped yarn according to claim 1, and 8 crimped yarns having a higher crimp heat fastness than the crimped yarn.
A composite crimped yarn having improved polisher workability and rebound resilience, which is composed of 0 to 10% by weight. 5. The crimped yarn according to claim 1 or 4 is tufted on a base fabric at room temperature, napped and then crimped to the napped hair, and then the napped tip is polished. A napped fabric with an improved feeling of looseness. 6. The cloth is a cut pile rug according to claim 5.
The napped cloth described. 7. The crimped yarn according to claim 1 or 4 is tufted on a base fabric at room temperature, then napped, and then napped, and then the napped tip is polished. A method for producing a napped cloth having a characteristic feeling of looseness.