JPH11279877A - Yarn suitable for carpet pile yarn - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain fiber yarn for carpet pile yarn having both of high fatigue resistance and fast high color development which are characteristics necessary for tile carpet pile yarns. SOLUTION: This multifilament yarn comprises >=30% multifilament yarn comprising a polybutylene terephthalate in which a compound represented by the following general formula I (D is a trivalent aromatic group or a trivalent aliphatic group; X1 and X2 are each an ester-forming functional group or hydrogen atom and may be same or different and M exhibits a metal atom or an alkylphosphonium group) is copolymerized in a range of 0.5-5.0 mol.% based on total dicarboxylic acid component. In the multifilament yarn, the fiber physical properties satisfy the formulas II: DT=2.0 (g/d), the formula III: DE>=15 (%) and the formula IV: KI>=2.0 (%) and thickness decreasing ratio by caster chair measured based on DIN 54324 is <20% after 3,000 times.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention is excellent in sag resistance,
The present invention relates to a polybutylene terephthalate fiber excellent in color developability, and particularly to providing a fiber yarn suitable for use as a pile yarn of a carpet.

[0002]

2. Description of the Related Art Conventionally, polypropylene and nylon-6 have been used as carpet pile yarns. Polypropylene is widely used in terms of ease of processing and cost performance, and nylon-6 is particularly advantageous in hetability, which is also widely used. Also, due to the importance of recycling in recent years, PET (polyethylene terephthalate) as a raw material has been used for the purpose of reusing PET bottles. further,
Recently, a carpet made of PPT (polypropylene terephthalate) having excellent elastic recovery has been put on the market. In addition, high color developability is required for materials for post-dyeing, for example, printing. For this purpose, acid dyes for nylon-6 and cationic dyes for polyesters having acrylic or sulfonic acid groups have been used.

[0003]

SUMMARY OF THE INVENTION The present invention provides a fiber yarn for carpet pile yarn which has both high set resistance and robust high color development, which are characteristics required especially for tile carpet pile yarn. It is in the thing.

[0004]

According to the present invention, the above object has been achieved in that the compound represented by the following general formula (1) is contained in an amount of 0.5 to 5.0 mol% based on all dicarboxylic acid components. This is achieved by a multifilament yarn containing 30% or more of the total number of multifilament yarns composed of copolymerized polybutylene terephthalate.

[0005]

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Further, in obtaining the yarn of the present invention, the yarn is stretched at an appropriate stretching temperature and stretching ratio as it is through a usual melt-spinning process, or after being once wound up, and then is subjected to false twisting or a pushing method using a heated fluid. The dry strength, dry elongation, and crimp elongation of the yarn obtained by crimping by the following method or obtained through a false twisting step after winding once after melt spinning are represented by formulas (2) and ( 3) and (4), and the thickness reduction rate by the caster chair measured according to DIN 54324 is 20% after 3000 times.
Is achieved by being less than.

[0007]

BEST MODE FOR CARRYING OUT THE INVENTION The polybutylene terephthalate according to the yarn of the present invention is a polymer mainly composed of 1,4-butanediol and terephthalic acid, some of which may be replaced by other components. Good. As other components, for example, isophthalic acid, naphthalene dicarboxylic acid,
To dicarboxylic acids such as diphenyldicarboxylic acid, diphenoxyethanedicarboxylic acid, β-hydroxyethoxybenzoic acid, p-oxybenzoic acid, adipic acid, sebacic acid, 1,4-cyclohexanedicarboxylic acid, and ethylene glycol and trimethylene glycol; Diols such as xamethylene glycol, diethylene glycol, neopentyl glycol, cyclohexane-1,4-diethanol, polyethylene glycol, polytetramethylene glycol, bisphenol A, bisphenol S, bisphenol A, and ethylene oxide adduct of bisphenol S are mentioned. it can.

As the compound represented by the general formula (1), which is a copolymer component of polybutylene terephthalate according to the present invention, a compound in which D is a trivalent aromatic group from the viewpoint of heat resistance during polymerization is used. Things are preferred. For example, 1,
Benzenetriyl group such as 3,5-benzenetriyl group, 1,2,4-benzenetriyl group, 1,3,6-naphthalenetriyl group, 1,3,7-naphthalenetriyl group,
Examples include naphthalenetriyl groups such as 1,4,5-naphthalenetriyl group and 1,4,6-naphthalenetriyl group. M is an alkali metal atom such as sodium, potassium and lithium; an alkaline earth metal atom such as calcium and magnesium; or an alkylphosphonium group such as a tetra-n-butylphosphonium group, a butyltriphenylphosphonium group and an ethylbutylphosphonium group. .

X ₁ and X ₂ represent an ester-forming functional group or a hydrogen atom, which may be the same or different. An ester-forming functional group is more preferable in that it is copolymerized in the main chain of the polymer. The following are specific examples of the ester-forming functional group.

[0010]

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Specific examples of the compound include 5-sodium sulfoisophthalic acid, 2-sodium sulfoterephthalic acid, 5-potassium sulfoisophthalic acid, 5-tetrabutylphosphonium sulfoisophthalic acid, and 2,6-dicarboxynaphthalene-4-. Examples thereof include sulfonic acid tetrabutylphosphonium salt and α-tetrabutylphosphonium sulfosuccinic acid, and among them, 5-sodium sulfoisophthalic acid is preferred from the viewpoint of cost performance.

[0012] The copolymerization amount of the compound is in the range of 0.5 to 5.0 mol% based on all acid components forming the polymer. If the amount is less than 0.5 mol%, clear color developability is insufficient. On the other hand, if it exceeds 5.0 mol%, it has a vivid color development, but the fiberization step, especially spinnability and stretchability, is poor, and the physical properties of the above formulas (2), (3) and (4) And the thickness reduction rate by the caster chair measured according to DIN 54324 is 2 after 3000 times.
In some cases, it is not possible to achieve less than 0%. The preferred copolymerization amount is in the range of 1.0 to 3.0 mol%.

The yarn of the present invention using the modified polybutylene terephthalate is characterized by its color-forming properties, and is usually a so-called bright polymer having no matting agent. Depending on the application, titanium dioxide or barium sulfate may be used. A polymer having fine particles such as calcium carbonate and calcium carbonate according to the purpose may be used.

Further, the yarn of the present invention is characterized by containing a yarn using the above-mentioned modified polybutylene terephthalate, and its mixing ratio must be 30% or more. 30%
When it is less than the above, although it depends on the type of the yarn to be mixed, when using ordinary PBT, Ny-6, PET, PPT, etc., the coloring property, which is a feature of the present invention, is insufficient, which is not preferable. . Further, when the settling resistance of the mixed yarn is lower than the yarn using only the modified polybutylene terephthalate, which is the main component of the present invention, the settling resistance of the mixed yarn as a whole is also reduced. It is low and is not preferred.

The dry strength, dry elongation and crimp elongation of the yarn are expressed by the following formulas (2), (3) and (4). Dry strength DT ≧ 2.0 (g / d) (2) Dry elongation Degree DE ≧ 15 (%) (3) Crimp elongation KI ≧ 2.0 (%) (4) If the dry strength is less than 2.0 g / d, or if the dry elongation is less than 15%, the yarn is not properly stretched and heat-set in the process of spinning, and the yarn has a settling resistance. In addition, since the wear resistance is low, the commercial value is low. On the other hand, if the dry strength and the dry elongation are low, fuzzing occurs in the spinning process and in the tufting process, which is not preferable because the production efficiency or product quality is reduced. Further, the crimp elongation (KI) needs to be 2.0% or more as shown in equation (4). If the content is less than 2.0%, the feeling of swelling of the yarn is insufficient, and the covering property of the surface of a carpet is insufficient.

Further, the thickness reduction rate by a caster chair measured based on DIN 54324 as an index of set resistance, which is a main feature of the yarn of the present invention, needs to be less than 20% after 3000 times. . This is a yarn having various physical properties of the above formulas (2), (3) and (4), using a modified polybutylene terephthalate, which is a main component of the present invention, and through appropriate spinning, drawing and crimping steps. And nylon-6, unmodified P
It cannot be obtained using BT or PET. Here, there is an advantage over other materials of the present invention.

In addition, pile yarns for carpets, which are generally required to have gloss or rebound against bending,
Although a triangular cross section or a Y-shaped cross section is adopted, the yarn of the present invention is not limited to these, and in addition to a round cross section, a square cross section, a pentagon cross section, a flat cross section, a U-shaped cross section, a V-shaped cross section, and a W-shaped cross section. Cross section,
Irregular cross sections such as a cross-shaped cross section and a hollow cross section can also be adopted.

The yarn of the present invention is melt-spun at a low speed, in the middle, stretched after being wound once, and then the drawn yarn is false-twisted or subjected to indentation crimping with a heating fluid to obtain a crimped yarn. A method, a method of false-twisting a wound raw yarn melt-spun at high speed to obtain a crimped yarn, and a method of stretching a rolled raw yarn melt-spun at high speed and subsequently applying indentation crimping with a heated fluid. Method of obtaining a crimped yarn by spinning directly after spinning, or false twisting of a wound yarn obtained by applying a pressurized crimp with a heating fluid to obtain a crimped yarn Alternatively, it can be manufactured by any method such as a method of directly connecting and stretching after spinning, stretching, and then directly connecting to obtain a crimped yarn by applying indentation crimping with a heating fluid.

[0019]

EXAMPLES The present invention will be described below in detail with reference to examples, but the present invention is not limited to these examples. The measured values in the examples are measured by the following method.

(1) Intrinsic viscosity ([η] dl / g) In an equal weight mixed solvent of phenol / tetrachloroethane,
It measured at 30 degreeC using the Ubbelohde viscometer.

(2) Dry strength and dry elongation Measured according to JIS L 1013.

(3) Crimp elongation rate (KI value) After winding the sample with a skein winding machine to a skein of 5000 denier, a load of 10 g is suspended at the center of the lower end of the skein and the skein at the upper center. Is fixed and subjected to a hot water treatment at 90 ° C. for 30 minutes under a load of 0.001 g / d. Then, after drying at room temperature in a non-weighted state, a weight of 10 g was again applied, and the yarn length after standing for 5 minutes was measured.
This is referred to as L _1. Next, a 1 kg weight is applied, and the yarn length after being left for 30 seconds is measured, and this is defined as L ₂ . The value of the crimp elongation (KI) is determined by the following equation. KI (%) = {(L ₁ −L ₂ ) / L ₂ } × 100

(4) Thickness reduction rate by caster chair Measured according to JIS DIN54324.

Example 1 Polybutylene terephthalate obtained by copolymerizing 2.5 mol of 5-sodium sulfoisophthalic acid with respect to all the acid components was polymerized by a conventional method using tetraisopropyl titanate to obtain an intrinsic viscosity [η]. = 0.7
8 polymer pellets were obtained. This chip is Y
It is melt-spun using a cross-section nozzle, directly connected, stretched and heat-set, and crimped by a fluid indentation crimping device using steam, and has various physical properties as shown in Table 1.
A 2,000 denier-120 filament yarn was obtained. A circular knitted fabric was prepared from the yarn, dyed with a cationic dyeable dye by a conventional method, and its color development was evaluated.

Further, the corresponding yarn is a polyester spunbond nonwoven fabric as a primary base fabric. The pile height was adjusted to 4 mm and 11 stitches using a 1/10 gauge tufted machine to obtain a level loop greige having a basis weight of 660 g / m ² . Using this, a tile carpet having a side of 50 cm was obtained by a conventional method, and the surface covering property was evaluated.

For the evaluation of the settling property, the tile carpet thus prepared was spread evenly, and the result of walking by 100,000 people was visually evaluated, and the degree of deformation of the pile yarn was compared with the initial product to evaluate the series.

Example 2 The polymer chips obtained in Example 1 and polybutylene terephthalate having an intrinsic viscosity [η] = 0.83 are separately melt-extruded, and both yarns are spun in a spinning step using a Y-section nozzle. The strips were mixed at a ratio of modified PBT / PBT = 1/1, directly connected, stretched and heat-set, and crimped with a fluid-indented crimping device using steam, as shown in Table 1. 2000 denier-120 filament yarn having the following physical properties was obtained. Using the yarn,
A carpet was prepared and evaluated in the same manner as in Example 1.

Example 3; The polymer chip obtained in Example 1 and Ny-6 having an intrinsic viscosity [η] = 1.13 are separately melt-extruded, and both yarns are spun at a spinning step using a Y-section nozzle. The strips were mixed at a ratio of modified PBT / Ny-6 = 1/3, directly connected, stretched and heat-set, and crimped with a fluid press-in crimping device using steam. A yarn of 2000 denier-120 filaments having the physical properties as shown was obtained. A carpet was prepared using the corresponding yarn in the same manner as in Example 1 and evaluated.

Example 4; The polymer chips obtained in Example 1 and PET having an intrinsic viscosity [η] = 0.66 were separately melt-extruded, and both yarns were spun at a spinning step using a Y-section nozzle. , Modified PBT / PET = 1/1, directly bonded, stretched and heat-set, and crimped by a fluid indentation crimping device using steam. A yarn of 2000 denier-120 filaments having physical properties was obtained. A carpet was prepared using the corresponding yarn in the same manner as in Example 1 and evaluated.

Comparative Example 1 Polybutylene terephthalate obtained by copolymerizing 0.3 mol of 5-sodium sulfoisophthalic acid with respect to all the acid components was polymerized by a conventional method using tetraisopropyl titanate, and the intrinsic viscosity [η] was obtained. = 0.8
1 polymer pellet was obtained. This chip is Y
It is melt-spun using a cross-section nozzle, directly connected, stretched and heat-set, and crimped by a fluid indentation crimping device using steam, and has various physical properties as shown in Table 1.
A 2,000 denier-120 filament yarn was obtained. A carpet was prepared using the corresponding yarn in the same manner as in Example 1 and evaluated. As shown in Table 2, the results were poor color development and slightly poor settling resistance.

Comparative Example 2 Polybutylene terephthalate obtained by copolymerizing 6.0 mol of 5-sodium sulfoisophthalic acid with respect to all acid components was polymerized by a conventional method using tetraisopropyl titanate, and the intrinsic viscosity [η] was obtained. = 0.6
9 polymer pellets were obtained. This chip is Y
Melt spinning was performed using a cross-section nozzle, and direct connection was attempted for stretching and heat setting. However, the process condition was poor due to frequent fluff. It was crimped by a fluid indentation crimping device using steam to obtain a yarn of 2000 denier-120 filaments having various physical properties as shown in Table 1. In particular, the strength was poor, the appearance of the yarn was frequent, and the product quality was low. A carpet was prepared using the corresponding yarn in the same manner as in Example 1 and evaluated. As shown in Table 2, the results were poor in settling resistance and covering property.

Comparative Example 3 The polymer chips obtained in Example 1 and polybutylene terephthalate having an intrinsic viscosity [η] = 0.83 were separately melt-extruded, and both yarns were spun at the spinning stage using a Y-section nozzle. Are mixed at a ratio of modified PBT / PBT = 1/4, directly connected, stretched and heat-set, and crimped by a fluid-indented crimping device using steam,
2000 denier-1 having various physical properties as shown in Table 1.
Twenty filaments were obtained. A carpet was prepared using the corresponding yarn in the same manner as in Example 1 and evaluated. As shown in Table 2, since the content of the modified PBT was low, the coloring property was poor and the set resistance was poor.

Comparative Example 4 The polymer chips obtained in Example 1 and PET having an intrinsic viscosity [η] = 0.66 were separately melt-extruded, and both yarns were spun in a spinning step using a Y-section nozzle. , Modified PBT / PET = 1/4, mixed directly, stretched and heat-set, and crimped with a fluid-indented crimping device using steam. A yarn of 2000 denier-120 filaments having physical properties was obtained. A carpet was prepared using the corresponding yarn in the same manner as in Example 1 and evaluated. The results are as shown in Table 2.
The coloring was poor and the settling resistance was poor.

Comparative Example 5: Polyethylene terephthalate having an intrinsic viscosity [η] of 0.54 obtained by copolymerizing 2.5 mol of 5-sodium sulfoisophthalic acid with respect to all the acid components was melted using a Y-section nozzle. It is spun, directly connected, stretched and heat-set, and subjected to crimping by a fluid-indentation crimping device using steam to obtain a yarn of 2000 denier-120 filament having various physical properties as shown in Table 1. Was. A carpet was prepared using the corresponding yarn in the same manner as in Example 1 and evaluated.

[0035]

[Table 1]

[0036]

[Table 2]

(Note 1) Criteria for judging color development Good: Comparative example 5 Poor: inferior to Comparative Example 5. (Note 2) Criteria for judging the surface covering property Good: The piled pile yarns are sufficiently in contact with each other due to crimping of the yarn. Bad: A gap is seen between the piled pile yarns.

(Note 3) Criterion for judging settability 5th grade: The height and shape of the pile yarn hardly changed. Grade 4: The pile yarn is slightly deformed and low. Class 3: Deformation of the pile yarn can be determined, but the pile yarn has elasticity. Level 2: Deformation of the pile yarn can be determined and is low. Grade 1: The pile yarn is significantly deformed, and the pile yarn has no elasticity.

[0039]

The multifilament yarn using polybutylene terephthalate obtained by copolymerizing a specific compound having a sulfonic acid group defined in the present application is not available in conventional nylon-6, PP, PET, and PPT. It has the characteristics of simultaneously having high color developability and high set resistance, especially yarns with dry strength, dry elongation, and crimp elongation ratio exceeding a certain value are remarkable, and carpet piles Useful for yarn.

Claims (2)

[Claims] 1. A compound represented by the following general formula (1):
A multifilament yarn comprising a multifilament yarn composed of polybutylene terephthalate copolymerized in a range of 0.5 to 5.0 mol% based on the total dicarboxylic acid component, in an amount of 30% or more of the total yarn. Article. Embedded image 2. The yarn according to claim 1, wherein the fiber properties satisfy the following formulas (2), (3) and (4), and DIN5432.
A multifilament yarn characterized in that the caster chair has a thickness reduction rate of less than 20% after 3000 cycles, as measured based on No. 4. DT = 2.0 (g / d) (2) DE ≧ 15 (%) (3) KI ≧ 2.0 (%) (4)